Cause/Solution |
|
A momentary error (glitch) occurred while the fetcher was moving, causing the fetcher
to stop. The glitch clears before the firmware has a chance to report it. The fetcher reports Fetcher: ‘Move’ Complete,
but an automatic firmware check determines that it is at the wrong position. The firmware will retry twice and it will report
error #45833 if the second retry fails. The glitch that stops the fetcher can be:
- Cause: Over current error on the carriage driver. If an over current error occurs, the red Over current LED on the carriage
board will be on. The over current LED is latched so it will stay illuminated until the machine is reset or initialized.
Solution: If the over current LED is on, initialize the device so that the LED switches off. Use the loop
test in Service Shell and set up a loop as follows:
- Fetcher move 300 (wait for either Command Complete or set it to 10 seconds)
- Fetcher move 3000 (wait for either Command Complete or set it to 10 seconds)
- Check the stepper driver board and see if the Over current LED comes on. Also, watch the Device Monitor window to
see if the line Fetcher move failed… retrying appears. That message indicates that the momentary fault occurred.
- If the over current LED lights and the Fetcher move failed… message appears, the problem is intermittent
over current faults. Check the mhauto fetchergain parameter. The default is 5. You can reduce it to 4.6
to lower the current to the stepper motor. Do not reduce it any more than that or it can cause the motor to stall.
- Check for mechanical problems obstructing fetcher movement, replace the fetcher stepper motor, the driver, or the GENINE board.
Since you can reproduce the problem with the test loop, replace the parts one at a time, starting with the stepper motor.
- Inspect the cables to the fetcher motor from the driver and make sure that the insulation is not damaged.
Cause: The home, safe home, safe away, or away sensor has an intermittent fault. This can occur if the
wires to the sensor are pinched to the frame by a panel, resulting in a short circuit to the frame. It can also occur if the
sensor connector is loose. A broken/intermittent wire to the sensor can also cause this because vibration can cause the wire
to break contact momentarily. The sensors connect to J2 and J14 on GENINE 0 in the power box. A loose cable can also cause this fault.
Solution: Run the loop test (1a and 1b above). If the Fetcher move failed… message appears
and the over current LED does not illuminate, then the problem is an intermittent sensor. Check the home, safe home, away,
and safe away sensors for the fetcher. If one of the wires breaks or shorts to the frame, the fetcher will stop momentarily
and report Fetcher move failed… retrying.
- Hint 1: Search the device logs using service shell and look for the string “Fetcher stepper motor unexpectedly”.
If you see that message and it appears at about the same time as “fetcher move failed…”, then you’ve found the problem.
For example, if the message is: Fetcher stepper motor unexpectedly hit the home sensor, then the home sensor
is bad, the wires to the home sensor are broken, the insulation is damaged, GENINE 0 has a loose connector (J2 or J14), or
GENINE 0 is faulty.
Note that the message “Fetcher motor unexpectedly hit the sensor” may not always appear. This depends on how long
the sensor fault condition lasts. If the fault clears before the firmware can read the status, then the only message will
be Fetcher move failed….
- Hint 2: The over current LED is latched so it could have been on for a long time. It is only cleared when the device is
reset or initialized. If you are troubleshooting the problem and you see that the LED is illuminated, initialize the device
and run the loop test in steps 1a and 1b above. An intermittent faulty sensor can disrupt the fetcher movement and cause the
over current LED to illuminate sometimes, and sometimes not. Be careful because you may end up replacing the motor, driver, and
GENINE when the problem is actually just a bad sensor.
- Hint 3: The 4 LEDs on the carriage driver are not labeled. Their function is as follows:
i. GREEN: DS4: Power and Safety loop are OK
ii. RED: DS3: Fault. This LED will illuminate only as long as the fault condition lasts. It is not latched.
iii. RED: DS2: Over current. This condition is latched and you must reset or initialize to clear it. This indicates that an overcurrent condition was detected. (> 12A)
iv. RED: DS1: Over temperature. The board temperature exceeded the limits. This condition is latched.
v. BOTH Over current and Over temperature are on – power supply voltage is out of range.
|
