January 17, 2019, 07:31:32 PM
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 Help! Communication works, but still SYS-X44 Ethercat Bus Error


Author Topic:  Help! Communication works, but still SYS-X44 Ethercat Bus Error  (Read 502 times)

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November 01, 2018, 04:45:32 PM
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SnakesNLadders


Hi Guys and Gals,

This is an existing, operating, kuka cell to which I need to add to. I have made an ethercat connection between the Kuka controller and my ipc, where the ipc has a Hilscher CIFX card. I have successfully made my code changes to the kuka, and deployed the hardware changes (eds, mapping), but now I get the posted error. The strange thing is, if, using the pendant,  I manually turn on the mapped output bit, my ipc receives the signal. And if, from my ipc, i turn on its output bit, the robot receives the signal. So why the error? The comms seem to be working, minus the error, which inhibits running any programs on the robot. All kuka has said is restart, re-install, re-configure, all to no success. If anyone has experienced a similar problem please help!

Specs:
KRC4 - 8.3.33
Hilscher CIFX RE/ECS v2.0



Linkback: https://www.robot-forum.com/robotforum/index.php?topic=29433.0
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Today at 07:31:32 PM
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November 02, 2018, 12:48:44 PM
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SkyeFire

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What's an IPC?  Industrial PC?  I'm assuming that's the CIFX RE/ECS shown in the hardware tree.

If your ECat communications to that branch are working, then the error lies elsewhere in the SYSX-44 branch.  Is the EK1100 bus coupler, and the EL 16ch modules in place?  Are they working?

The last time I had an error like this, someone had added the EK and EL modules to the hardware tree, but they were not actually physically present.  The robot ran perfectly, aside from showing that error message.  I had to delete the entire SYSX-44 branch to eliminate the message.

Obviously, that's not an option for you, since you're using SYSX-44 for you PLC(?) communications.  But if the EK and EL modules are not actually on the bus, you need to delete them from the hardware tree.

If the EK and EL modules are physically on the bus, then you need to start checking them for errors.  Could be power, could be a physical disconnection, could be a short on an output, any number of things.
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November 02, 2018, 01:46:37 PM
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panic mode

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What are the other messages?
What is the topology? Does it match connections EXACTLY? Is the mapping correct and matching image size?

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November 05, 2018, 12:27:46 AM
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SnakesNLadders


SkyeFire
 
Yes, an industrial PC with the Hilscher ethercat card. The EK and EL modules were already in place and working. All I've added was the ipc. After I made my hardware changes in work visual and deployed it, is when I get the error, but with seemingly functional comms. If I remove my hardware changes, and use the original config, the error disappears.


panic mode

I believe the other message was a 'reset failed'. It was clear-able however. As for the topology, the ipc is connected to wire "A20-X1" in the image. So I believe it does match. The mapping seems to be correct bc I can see the bits turning on and off from robot to ipc and vise versa. But I am not sure about matching image size. I used the signal editor to only map the first bit of the input and output bytes, as that's all i need. Would I need to map all IO bits from the CIFX?
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November 05, 2018, 12:37:35 AM
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SnakesNLadders


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November 07, 2018, 02:09:24 PM
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SnakesNLadders


**Update

Start up order seems to be important.  Power up ipc (slave) first, then Kuka controller, then reset IO Drive, and then I get flawless comms. But it only works sometimes. Further investigation is needed.
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November 07, 2018, 02:51:59 PM
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panic mode

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you can edit ECAT_SYS_X44.XML file and change reset from "manual" to "auto", then deploy project with changed file. after this X44 bus will reset automatically.
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Today at 07:31:32 PM
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November 10, 2018, 11:05:03 PM
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SnakesNLadders


**UPDATE

The comms work one out of every ~5 tries. The procedure is: power everything off, power up slave, power up kuka, restart IODrives (when I get it 100% i'll modify the xml to restart automatically.) All slave settings are the same in kuka and in slave; all IO's are mapped, with equal size. The frustrating thing is, during the kuka's power up, the comms are always functioning (as can be seen by monitoring the slave (via its own monitoring software)), and then the comms will break (1 out of ~5 it wont) right when the kuka is done its initialization. Truly frustrating...
 
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November 11, 2018, 06:53:26 PM
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panic mode

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i would check for different device description file...
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November 12, 2018, 01:22:29 AM
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SnakesNLadders


**UPDATE

The plot thickens. Found an older description file, and now the comms work routinely. However a strict (and peculiar) start up procedure must be followed:
Power up ipc.
Power up kuka.
Link is established.
Clear errors on kuka (SYS 44 Ethercat bus error persists).
Send a minimum of 1 bit from ipc to kuka.
Reset IODrives.
Error clears.
Everybody's happy.
I still need to figure out the root cause though. Cant leave this up to the client to do.

 
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