Simple Connect Errors and Messages

  • Updated

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:

  1. 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.
  2. 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:
  3. SimpleConnect USB installation & file contents
  4. Ethernet network connections & settings
  5. CIO/ladder program version
  6. Parameter settings
  7. Robot SRAM access
  8. 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
  9. 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.

Alarm Code: Alarm Text: Technical Issue: Possible Solution#1: Possible Solution#2:
8990[0] Failed to create pendant socket Moto+ app is attempting UDP communications to the pendant & failing. Verify Ethernet-IP is abled and verify parameters Pendant is expected to be on IP-address 10.0.0.4
8990[1] Failed to bind pendant socket Moto+ app is expecting communication with the pendant but not receiving any when expected. Verify parameters Make sure matching versions of Moto+ and PP-app are installed!
8990[2] Failed to listen pendant socket Moto+ is not receiving socket communication from the pp-app when expected Ensure PP-app is installed Make sure matching versions of Moto+ and PP-app are installed!
8990[3] Failed to create pendant socket Moto+ app is attempting UDP communications to the pendant & failing. Verify parameters Pendant is expected to be on IP-address 10.0.0.4
8990[4] Failed to bind pendant socket Moto+ app is expecting communication with the pendant but not receiving any when expected. Verify parameters Make sure matching versions of Moto+ and PP-app are installed!
8990[5] Failed to listen pendant socket Moto+ is not receiving socket communication from the pp-app when expected Ensure PP-app is installed Make sure matching versions of Moto+ and PP-app are installed!
8990[6] Cannot broadcast to devices When searching for new devices, Moto+ issues a “Broadcast” message asking devices on the network to reply. The attempted broadcast failed to transmit to the network Check network connections external to the robot cabinet and ensure link lights and power to all external devices which are being communicated with  
8990[7] Failed to save options The Moto+ app is attempting to generate & save the “Robot Options” to a BIN file but failed. Verify parameters SRAM is corrupt and needs to be initialized in maintenance mode under “File à Initialize”
8990[8] Failed to save mappings Moto+ app is attempting to generate a BIN file containing Turck Device details (MAC,IP-add, DeviceType) but has filed. Turck Device is offline or improperly configured.  
8990[9] Failed to save options      
8990[10] Failed to save options      
8990[11] Simple Connect Needs CIO v* Simple Connect check ladder version via a register in the ladder. This alarms when the ladder contents don’t match the expected ladder contents Implement the ladder changes that correspond to the version Moto+ being used  
8990[12] Set Parameter S2C1402=3 Moto+ needs API access even during alarm or error states S2C1402=3 enables API access even during alarm and error states  
8990[13] Simple Connect missing USB drive At boot-up Moto+ checks for a USB stick within CN102 of YCP01 board. If no drive is detected, this alarm occurs Locate the provided USB and insert it into CN102 of the ACP01 board If installed & alarm occurs check contents of thumbdrive using PC/laptop and if files are missing or corrupt contact Yaskawa
8990[14] Simple Connect missing files At boot-up Moto+ checks for a USB stick with associated SimpleConnect files CN102 Locate the provided USB and insert it into CN102 of the ACP01 board If installed & alarm occurs check contents of thumbdrive using PC/laptop and if files are missing or corrupt contact Yaskawa
8990[15] SC: Could not move file to SRAM When updating setting, setting are stored to SRAM as part of the update process. Parameters or file corruption can prevent storage. Parameters S2C1102 needs to be set to a value of 2 SRAM is corrupt and needs to be initialized in maintenance mode under “File à Initialize”
8990[16] Timeout reading DAT files Moto+ is not able to access or extract needed data from the robot’s native ethernet/IO settings Software version conflicts or data file format changed due to new features or software version Revert to previously known good version of System software
8990[17] Open [Setup]>[SimpleConnect] A configuration change has occurred outside of Simple Connect (Maintenance Mode) so Simple Connect needs to process the changes and possibly update it’s associated files. In “Management Mode” open the Simple Connect application and upon start-up the application should automatically begin checking and updating files or prompt the user for input If following the Simple Connect app instructions does not resolve the issue, restore a backup or contact Yaskawa

 

 

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.

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.
  1. If this message occurs a first step to resolving it is to cycle power to whole system and it will often recover on reboot
  2. Using Turck Service Tool scan the network you should see the following IP addresses for each Op-Station:

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
  1. If earlier solutions don’t resolve the issue, Open the Simple Connect app and delete the Op-Station from the network.
  2. Using “Turck Service Tool” perform a “Factory Reset” both FEN20 modules.
  3. Reboot the whole system after having done the “factory reset” in step#2
  4. Open “Simple Connect” and re-add the Op-Station to the network paying close attention to the MAC-IDs of the various devices as you add them.

 

YAI Reamer Specific Alarms & Messages:

  • NONE!