General Overview:
SimpleConnect consists of several layers of software that monitors the installation and operation of SimpleConnect devices. The following is intended to detail possible alarms and messages that can occur during installation and operation of SimpleConnect. Items that make-up SimpleConnect include:
- SimpleConnect Pendant Application: This is the user interface portion of SimpleConnect that a user launches and uses to add & remove devices to their network, enable/disable robot options, and monitor operation and communication status during daily operation. The pendant application provides on-screen troubleshooting and doesn’t generate any notable errors or messages.
- SimpleConnect Moto+ Application: This low-level application automatically starts when the robot controller is powered on and monitors the operation of the SimpleConnect devices from start-up. It monitors following:
- SimpleConnect USB installation & file contents
- Ethernet network connections & settings
- CIO/ladder program version
- Parameter settings
- Robot SRAM access
- CIO / Ladder: The robot’s ladder program has been modified to also monitor for a small number of events and alarm or message when they occur. These
- Turck Module Alarms & Messages: The Turck modules used in various SimpleConnect devices have a locally running program within them that allows them to self-monitor themselves. This lightens the burden on the robot & Moto+. When the Turck device identifies an issue, it transmits details of the issue to Moto+ which then raises the issue to the robot system and either sends an alarm or message to the robot pendant. Below we’ll detail the various alarms & messages raised by the various Turck blocks and provide a brief troubleshooting suggestion for resolving it.
Simple Connect Moto+ Generated alarms:
Moto+ generates the following 8990-series of alarms based off the status of the Moto+ application and its attempts at communication and file access. 8990-series of alarms are largely isolated to the robot controller and physical connections to external devices but not operation of the external device itself.
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Device On-line Alarms & Messages:
Moto+ generates the following 8992-series of alarms are based off the on-line connection status of the Moto+ monitored devices Some devices are deemed critical for system operation while others are less critical and can be allowed to go off-line without generating alarm and preventing whole system from operating the following is listing of various Simple Connect devices and if they will generate alarms or messages when they go off-line:
| Simple Connect Device Type: | Alarm Text: | Message Text: |
| YAI Reamer | RMR*: Device Offline | |
| YAI Reamer + ToolSight | RMR+TS*: Device Offline | |
| YAI Tip Change Interface | TCB*: Device Offline | |
| YAI Basic 7-Color Beacon | TWR*: Device Offline | |
| YAI Adv 7-Color Beacon | TWR*: Device Offline | |
| YAI MSR Table Interface | 8992[*] STA*: Device Offline | |
| YAI YDG Barrier Interface | 8992[*] STA*: Device Offline | |
| YAI Sta/Pos Safety Interface | 8992[*] S1&S2*: Device Offline | |
| YAI Op Station:No Thumbwheel | 8992[*] OPS*: Device Offline | |
| Rite-Hite Roll-up Barrier | 8992[*] STA*: Device Offline | |
| FEN20-16DXP | 8992[*] EIO*: Device Offline | |
| FEN20-4DIP-DXP | 8992[*] EIO*: Device Offline | |
| FEN20-4DIP-DXN | 8992[*] EIO*: Device Offline | |
| YAI Op Station:4-Digit TWS | 8992[*] OPS*: Device Offline | |
| YAI Op Station:3-Digit TWS | 8992[*] OPS*: Device Offline | |
| YAI Op Station:Dual 3-Digit TWS | 8992[*] OPS*: Device Offline | |
| YAI Carriage Interface | 8992[*] CRG*: Device Offline |
Turck Initiated Alarms & Messages:
Any 8991 alarm is originated by a Turck module on the Simple Connect network and Moto+ presents the alarm to the robot pendant. This means 8991 alarms should cause user to look at the indicated remote device and the wiring to the Turck module for possible causes. Except for some limited number of RiteHite roll-up doors all other Turck modules are remotely located outside of the robot cabinet.
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Alarm / Message Code: |
Alarm / Message Text: | Technical Issue: | Possible Solution#1: | Possible Solution#2: |
| 8991[1] | Output_overcurrent_0 | Turck module is reporting excessive current draw on Output#0 | Check wiring and physical device for wiring shorts or device failures that would causes excessive current draw. | Disconnect the wiring from the corresponding output and cycle power, if with nothing connected to the output the same alarm occurs, replace the Turck device |
| 8991[2] | Output_overcurrent_1 | Turck module is reporting excessive current draw on Output#1 | ||
| 8991[3] | Output_overcurrent_2 | Turck module is reporting excessive current draw on Output#2 | ||
| 8991[4] | Output_overcurrent_3 | Turck module is reporting excessive current draw on Output#3 | ||
| 8991[5] | Output_overcurrent_4 | Turck module is reporting excessive current draw on Output#4 | ||
| 8991[6] | Output_overcurrent_5 | Turck module is reporting excessive current draw on Output#5 | ||
| 8991[7] | Output_overcurrent_6 | Turck module is reporting excessive current draw on Output#6 | ||
| 8991[8] | Output_overcurrent_7 | Turck module is reporting excessive current draw on Output#7 | ||
| 8991[9] | Output_overcurrent_8 | Turck module is reporting excessive current draw on Output#8 | ||
| 8991[10] | Output_overcurrent_9 | Turck module is reporting excessive current draw on Output#9 | ||
| 8991[11] | Output_overcurrent_10 | Turck module is reporting excessive current draw on Output#10 | ||
| 8991[12] | Output_overcurrent_11 | Turck module is reporting excessive current draw on Output#11 | ||
| 8991[13] | Output_overcurrent_12 | Turck module is reporting excessive current draw on Output#12 | ||
| 8991[14] | Output_overcurrent_13 | Turck module is reporting excessive current draw on Output#13 | ||
| 8991[15] | Output_overcurrent_14 | Turck module is reporting excessive current draw on Output#14 | ||
| 8991[16] | Output_overcurrent_15 | Turck module is reporting excessive current draw on Output#15 | ||
| 8991[17] | Overvoltage_Supply_V1 | The V1 power rail is sensing voltage levels above 30VDC | Measure the voltage between V1+ and V1-. Attempt to correlate alarm occurrence to disabling of a particular output & disconnect that output. | A properly installed flyback diode may resolve the issue |
| 8991[18] | Undervoltage_Supply_V1 | The V1 power rail is sensing voltage levels below 12VDC | Note if alarm occurs when turning any particular output and troubleshoot the output | Possibly add electrolytic capacitor to help maintain voltages during drops or draws |
| 8991[19] | Modulebus_Comm_Lost | This is indication of a failure of an internal communication bus within the Turck module. | Cycle power to the Turck module | Replace module |
| 8991[20] | Modulebus_Config_Error | This is indication of a failure of an memory within the Turck module. | Cycle power to the Turck module | Replace module |
| Message | Force_Mode_Enabled | This message indicates that the HMI user interface is commanding an output on and should ideally be shutoff to allow regular programmatic operation to resume. | Using either the “Turck Service Tool” or the device’s IP-address+HMI.HMTL (192.168.1.***/hmi.html) disable any output that may be forced on | Cycling power to the Turck device will terminate any forced IO |
| Message | Module Diagnostic Avail | The Turck module is stating that an unexpected event has occurred and needs examined | Connect “Turck Service Tool” and review the status of the device reporting the issue. “Service Tool’ will report the specific issue | If “Turck Service Tool” isn’t available, power-off and reboot the device. |
| Message | Station_Config_Chng | This message indicates that some settings within the block have been updated and need to be confirmed | Connect “Turck Service Tool” and review the status of the device reporting the issue. “Service Tool’ will report the specific issue | If “Turck Service Tool” isn’t available, power-off and reboot the device. |
| Message | Overcurrent_Isys | The modules have a 700mA output for powering inputs. If inputs draw more than 700mA this message will occur | Attempt to isolate which input’s actuation triggers the message then focus on that input | It is possible to utilize an external 24VDC power source to power your devices. Consider this if needed! |
| Message | Overvoltage_Supply_V2 | The V2 power rail is sensing voltage levels above 30VDC | Measure the voltage between V1+ and V1-. Attempt to correlate alarm occurrence to disabling of a particular output & disconnect that output. | A properly installed flyback diode may resolve the issue |
| Message | Undervoltage_Supply_V2 | The V2 power rail is sensing voltage levels below 12VDC | Note if alarm occurs when turning any particular output and troubleshoot the output | Possibly add electrolytic capacitor to help maintain voltages during drops or draws |
Tip Change Box Specific Alarms & Messages:
| Alarm / Message Code: | Alarm / Message Text: | Technical Issue: | Possible Solution#1: | Possible Solution#2: |
| Message | TCB*: Enclosure Door Open | Message will occur anytime the TCB’s door is open. Will clear when door is closed | If this message occurs with the door closed switch actuation or wiring is likely the cause | If door closed input is on and message still occurs, power down the system and reboot to clear the message |
| Message | TCB*: E-Stop Button Pressed | Message will occur anytime the TCB’s E-Stop button is pressed. Will clear when the E-Stop is cleared | If this message occurs with the E-Stop released, wiring is likely the cause | If E-Stop pressed input is on and message still occurs, power down the system and reboot to clear the message |
Barrier Door Specific Alarms & Messages:
| Alarm / Message Code: | Alarm / Message Text: | Technical Issue: | Possible Solution#1: | Possible Solution#2: |
| Message | STA*: Op-Station E-Stop Pressed! | Message will occur anytime the Op-Station’s E-Stop button is pressed. Will clear when the E-Stop is cleared | If this message occurs with the E-Stop released, wiring is likely the cause | If E-Stop pressed input is on and message still occurs, power down the system and reboot to clear the message |
| 8991[*] | STA*: J1000 Drive Fault | When the VFD housed within the barrier door assembly is faulted this alarm will occur | Open the cover to the barrier door and examine the error code reported on the display. Consult the manual for the VFD to resolve the issue | Cycling system power will reset the error on the VFD and pendant but has potential to reoccur on the next cycling of the barrier |
Basic Light Beacon Specific Alarms & Messages:
- NONE!
Advanced Light Beacon Specific Alarms & Messages:
- NONE!
MSR Table Specific Alarms/messages:
| Alarm / Message Code: | Alarm / Message Text: | Technical Issue: | Possible Solution#1: | Possible Solution#2: |
| Message | STA*: Light Curtain Fault! | The connected light curtain has an output that is on indicating that the curtain is in an error state | Review curtain manual for possible causes and solutions. Causes often include: alignment, configuration, EDM wiring, dirty lenses | If the input is NOT on but the message exists, reboot the message to clear the message |
| Message | STA*: Safety Gate#1 Open! | Message will occur anytime Safety Gate#1 is open. Message will clear when the gate is closed | If the message is on with the safety gate closed, confirm wiring and operation of the gate switch. Replace if needed | If the input is NOT on but the message exists, reboot the message to clear the message |
| Message | STA*: Safety Gate#2 Open! | Message will occur anytime Safety Gate#2 is open. Message will clear when the gate is closed | If the message is on with the safety gate closed, confirm wiring and operation of the gate switch. Replace if needed | If the input is NOT on but the message exists, reboot the message to clear the message |
| Message | STA*: Safety Gates (#1+2) Open! | Message will occur anytime both Safety Gate#1 & Safety Gate#2 are open. Message will clear when both gates are closed | If both gates are closed and message appears, make sure the right cables are plugged into the right ports on the table interface. | If the input is NOT on but the message exists, reboot the message to clear the message |
Op-Station Specific Alarms & Messages:
| Alarm / Message Code: | Alarm / Message Text: | Technical Issue: | Possible Solution#1: | Possible Solution#2: |
| Message | OPS*: Op-Station E-Stop Pressed | Message will occur anytime the Op-Station’s E-Stop button is pressed. Will clear when the E-Stop is cleared | If this message occurs with the E-Stop released, wiring is likely the cause | If E-Stop pressed input is on and message still occurs, power down the system and reboot to clear the message |
| Message | OPS*: Modbus Comm to Slave Lost | Op-Stations with thumbwheel switches have two Turck devices in them and they operate as a single “device”. The FEN20-16 reads all of the pushbuttons & joysticks while the FEN20-4 reads the thumbwheel switch settings and passes the thumbwheel switch settings back to the robot on predetermined I-variable. The two modules communicate to each other across Modbus and this message will occur when the Modbus link between the two Turck blocks is not operational. |
OPS#1: FEN20-4à .76 FEN20-16 à80 OPS#2: FEN20-4à .77 FEN20-16 à81 OPS#3: FEN20-4à .78 FEN20-16 à82 OPS#4: FEN20-4à .79 FEN20-16 à83 The FEN20-4 modules should contain the Turck ARGEE programs while the FEN20-16’s have NO ARGREE programs |
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YAI Reamer Specific Alarms & Messages:
- NONE!
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