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Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 1 of 39
NX Safety Troubleshooting
Table of Contents Opening & Getting Started With Sysmac Studio .................................................................................................................... 3
Unable to open Program ..................................................................................................................................................... 3
Unable to use Program ....................................................................................................................................................... 4
Register Robot Option ........................................................................................................................................................ 5
Unregister Robot Option ..................................................................................................................................................... 6
Program Build Errors and Warnings........................................................................................................................................ 7
I030 PLCopen: Instance ‘instance name’ of single call FB “FB name” requires a call ......................................................... 9
I120 Mapped output (variable_name) cannot be assigned at two places ....................................................................... 10
I132 Unused variable is declared but never used ............................................................................................................. 12
I133 Useless variable: is assigned but never read ............................................................................................................ 13
I134 VAR_EXTERNAL ‘variable name” requires an assignment ........................................................................................ 14
I139 the value of VAR is never changed, it should be declared CONSTANT: .................................................................... 15
I392 Empty network .......................................................................................................................................................... 16
A048 Unused logical device in application ....................................................................................................................... 17
A052 Logical device contains no mapping ........................................................................................................................ 18
L511 Identifier “variable name” not defined. ................................................................................................................... 21
L520 Access to global variable ‘variable name” requires a VAR_External ........................................................................ 22
V140 No global definition found for VAR_EXTERNAL ‘variable_name’ ............................................................................ 23
V152 External declaration of I/O variables have no modifier ........................................................................................... 24
Connections and Transfer ..................................................................................................................................................... 25
Unable to Load Program into NX CPU ............................................................................................................................... 25
Not Able to go Online........................................................................................................................................................ 26
Not Able to Transfer any part of the NX Program ............................................................................................................ 28
Flashing LEDs ......................................................................................................................................................................... 29
Normal Operation ............................................................................................................................................................. 29
Normal Operation, FS on I/O Module Flashing Green ...................................................................................................... 29
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 2 of 39
Flashing Red on NJ, NX and select I/O Modules (Activate or replace safety I/O module) ............................................... 30
Flashing Red on Coupler and NJ ........................................................................................................................................ 33
Flashing Red on all I/O on Coupler .................................................................................................................................... 34
Flashing Green I/O LEDS and Red/Green CPU .................................................................................................................. 35
Function Block Diagnostic Codes .......................................................................................................................................... 36
Post Programming ................................................................................................................................................................. 37
Reset Only Works at Initial Start-up.................................................................................................................................. 37
LEDs Will Not Turn On, NJ & NX Are Running ................................................................................................................... 38
Maximum Number of Tabs ............................................................................................................................................... 38
Safe Motion Connection on G5 ............................................................................................................................................. 39
St on G5 Display ................................................................................................................................................................ 39
83 on G5 Display ............................................................................................................................................................... 39
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 3 of 39
Opening & Getting Started With Sysmac Studio
Unable to open Program This is for programs from another source that will not allow you to download any part of the program.
Cause: Program is corrupted.
Solution: Have creator built the program(s) before exporting
Cause: Sysmac Studio version programmer used is higher that your version. Therefore, some features
are not available.
Solution: Downloaded latest version of Sysmac Studios. (Caution: This can take several hours.)
An “Omron Automation Software Auto Update” icon may be available in the “Start” menu.
If not,
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 4 of 39
Unable to use Program This is a program using functionality for a special license.
Cause: Program does not have the correct license.
Solution: Add additional license
Note: Robot license may not be used with database versions.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 5 of 39
Register Robot Option 1. Install Sysmac Studio with Standard Edition.
Note: If Sysmac Studio is Trial Edition, you cannot register Robot Option.
2. Launch Sysmac Studio, press [License] button in left side of start window and press [Register License] button.
3. Enter the license number of Robot option and press [Register] button.
4. The following message is shown after succeeding to register the license.
5. Confirm that Robot Option is displayed like following window and restart Sysmac Studio.
6. Install patch “Smc1206_0102Setup”
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 6 of 39
Unregister Robot Option When you will move the license of Robot Option to another PC, Please unregister Robot Option with following
steps.
1. Launch Sysmac Studio, press [License] button in left side of start window and press [Unregister License] button.
2. Enter the license number of Robot option and press [Unregister] button.
3. The following message is shown after succeeding to register the license.
4. Confirm that Robot Option is not displayed like following window and restart Sysmac Studio.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 7 of 39
Program Build Errors and Warnings
Overview
Sysmac Studio provides a list of warnings that allows the program to be built and downloaded for testing, but
may not be efficient in functionality or an optimized design. Most of these warnings appear when initially
setting up all of the hardware, by programming and testing in small sections, or after changes. They may
include topics such as:
1. Variables assigned but never used
2. Mapping
3. Constant declaration
4. Unused devices
5. Duplication
While most warnings can be ignored during the early stages of programming, they will serve as reminders of
items to be cleaned-up before final installation.
Setup
This example will use a dual channel emergency stop and dual force guided contacts.
List of warnings after the build
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 8 of 39
Hiding some warnings
It is practical to hide some of the warnings when programming and testing small sections since most of the
warning will be corrected as the program is completed.
Go to Tools -> option -> program check. As a default, all of the options are selected.
Unselect the ladder program warning display options and select OK.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 9 of 39
I030 PLCopen: Instance ‘instance name’ of single call FB “FB name” requires a call
Cause: Extra variables are declared in the program. Function blocks are deleted or the name was changed.
1. Right click on Estop_001, Estop_002 and Estop_003 names and select “delete”.
2. Menu -> Project -> Build Controller (F8).
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 10 of 39
I120 Mapped output (variable_name) cannot be assigned at two places
Cause: Same output variable is assigned in two places.
1. Double click on the error.
2. In this case, the output S_EnableSwitchOut is used in another program, and this is duplicated. 3. Open program with the output. 4. Add a new network. 5. Insert the enable switch.
6. Use “AND” Boolean operator to add it to your existing EDM FB.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 11 of 39
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 12 of 39
I132 Unused variable is declared but never used
Cause: Changes were made to the variable names or a function block was deleted.
1. Double click on the warning.
2. It will take you to the location where the warning is occurring.
3. It might be cleaner programming to delete the variable. If you use it later, it will be automatically added.
4. Do this for all of the I132 warnings. 5. Menu -> Project -> Build Controller (F8). 6. The warning is no longer there.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 13 of 39
I133 Useless variable: is assigned but never read
Cause: A variable assigned in the I/O map and/or global variables that is not used in the program.
1. Open up the global variables.
2. Delete the unused variables.
3. Menu -> Project -> Build Controller (F8).
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 14 of 39
I134 VAR_EXTERNAL ‘variable name” requires an assignment
Cause: Unknown (Future development).
Ignore. Note: This appears mostly in Sysmac Studio version before 1.10.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 15 of 39
I139 the value of VAR is never changed, it should be declared CONSTANT:
Cause: Occurs with a constant variable.
Anything using timers or set values, the value should remain the same.
1. Double click on the warning.
2. It will take you to the location where the warning is occurring.
3. Select the Constant
4. Do this for all of the I139 warnings. 5. Menu -> Project -> Build Controller (F8). 6. The warnings are no longer there.
Note: It is a best practice to activate the function block by using the Safety Connection Status, which would
verify the device is actually connected.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 16 of 39
I392 Empty network
Cause: Network exists with no programming.
1. Double click on the warning.
2. Here, the program was toggled to be a comment.
3. Right click on the pink area or any area away from the program.
4. Select Toggle network comment state. 5. Menu -> Project -> Build Controller (F8). 6. In this case error I711 occurs.
7. Only way to get rid of the warning and error is to delete it. 8. Right click on the pink area or any area away from the program.
9. Delete.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 17 of 39
A048 Unused logical device in application
Cause: Device is reference as an instance. Find it in the configurations and setup under the safety I/O.
Still working on a solution …..
Note: As of Jan. 22, 2014, the locations with IL and GVL designations are still in development.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 18 of 39
A052 Logical device contains no mapping
Cause: A device has not been assigned in the parameters and/or I/O map.
1. Open up the parameters to see what devices are not connected.
2. Connect the devices.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 19 of 39
3. Verify the devices are mapped in the I/O Map.
4. Map the devices if needed. Note: Since these are already defined in the global variable list and used in the program, use the drop down list to select the variable name.
5. Menu -> Project -> Build Controller (F8).
6. The warnings go away and two get replaced by errors. Double click on error.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 20 of 39
7. Deselect the constant.
8. Build controller and the error will go away.
Why did this happen? Since the devices’ wiring was not assigned prior to programming, setting the constant made the device always true. Once the devices assigned, Sysmac Studio knows it needs to do a check of the safety device before it can continue the rest of the programs logic.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 21 of 39
L511 Identifier “variable name” not defined.
Cause: Variable needs to be defined in the internal list in the program.
1. Right click on the internal variable list inside the program. 2. Select “create new”. 3. Select the variable name from the pull down list.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 22 of 39
L520 Access to global variable ‘variable name” requires a VAR_External
Cause: Variable need to be defined in the external variable list.
1. Right click on variable list inside the program. 2. Select “create new”.
3. Select the variable name from the pull-down list.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 23 of 39
V140 No global definition found for VAR_EXTERNAL ‘variable_name’
Cause: Variable is used in multiple programs but is not defined as a global variable.
Define in the global variable list.
Safety CPU -> Programming -> Data -> Global Variables -> Right click -> Create New -> type variable name.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 24 of 39
V152 External declaration of I/O variables have no modifier
Cause: Variable was declared a constant.
In the internal / external variable list, make sure “Constant” is not selected.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 25 of 39
Connections and Transfer
Unable to Load Program into NX CPU
Happened when an existing program in NJ and NX was loaded into an existing Sysmac Studio program.
There was a difference between the NX safety programs, and the coupler version.
Had to uncheck all of the NX modules.
Reconfigure the nodes and I/O map.
Re-enter the program.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 26 of 39
Not Able to go Online Cause: Bad cable, not connected, or port is locked
Solution: Replace cable, set dip switch 4 on the NJ so it is in safe mode, check port on computer.
This pops up when you go online.
In top menu bar -> Controller -> Communications Setup
Select the communication types
When you go online, this pop-up will appear. Select the connection type.
If you are still not able to go online, from the Start menu on your computer, go to “All Programs”.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 27 of 39
Select “Omron”
Select “Communications middleware utilities”
Select “DirectEthernetUtility”
In the popup, unselect “Disable the direct Ethernet connection function”
But, I was just online …..
Cause: Something is locked up.
Solution: Restart the system and the computer.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 28 of 39
Not Able to Transfer any part of the NX Program
Cause: EtherCAT network does not see devices
Solution: Merge and compare should give you a device(s) that are different or not connected. Check cable
connections. Verify the devices are securely attached to the DIN rail.
Go to NJ CPU
Configurations and Setup -> EtherCAT -> right click on NJ CPU -> Merge and compare with actual
configuration -> apply actual network configuration
Check for I/O modules, couplers and the NX CPU connection
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 29 of 39
Flashing LEDs
Normal Operation
NJ – Run and NET RUN – Green
NJ – LINK/ACC – Flashing orange if EtherCAT cable is connected and running
Coupler – RUN and TS – Green
Coupler – L/A in and L/A OUT – Flashing green if connected and running
NX – FS, TS, and RUN – Green
NX – Valid – Orange
I/O Module – FS and TS – Green
I/O Module – I/O connection – Orange if signal is high.
Normal Operation, FS on I/O Module Flashing Green
Cause: Module is not active
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 30 of 39
Flashing Red on NJ, NX and select I/O Modules (Activate or
replace safety I/O module)
NJ – Error – Flashing Red
NX – FS/Valid/Debug – Flashing red
FS of I/O modules on coupler with minor fault – flashing red (Note: TS is solid green)
Cause: NX does not recognize the safety I/O modules since the FSoE watchdog timers do not match. They
might have been added at a later time or were deactivated and then reactivated in a different program.
Solution: Reset memory
1.) In Sysmac Studio -> Configurations and Setup -> Communications -> Safety -> double click on Safety I/O 2.) In the “Active” column, make sure the I/O modules are all selected.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 31 of 39
3.) Connect the USB cable to the coupler with re-activated modules.
4.) In Sysmac Studio -> select NJ CPU -> Configuration and setup -> EtherCAT -> right click on the node (coupler) with the reactivated modules -> Coupler Connection (USB) -> Online
5.) Double click on the node (coupler)
6.) Right click on the re-activated module -> Clear All Memory -> Execute
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 32 of 39
7.) Confirm. This will appear while it is clearing.
8.) This will appear when the memory is cleared.
9.) Right click on the node (module) -> Coupler connection (USB) -> Offline
10.) Rebuild NJ and NX programs. 11.) Go online with NJ. 12.) Download NJ and NX programs. 13.) Power may need to be recycled.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 33 of 39
Flashing Red on Coupler and NJ
NJ – ERROR & NET ERR – flashing red NJ – Link/ACC - flashing orange
Coupler – ERR – flashing red Coupler – RUN – flashing green
Coupler – TS – red NX & I/O modules – FS & TS - flashing green
NX – VALID - orange
Cause: One of the devices listed may be a different version.
Solution: Match the version without affecting the configuration.
Online -> Select “NJ controller” -> Configurations and Setup -> double click on EtherCAT -> right click on
“Master” – select ”Compare and merge with actual network configuration.”
See if any of the devices are different and close the window.
Note: you do not want to merge and compare since it will delete
your node and I/O map settings.
Go offline.
Right click on the coupler with the device -> “Edit slave terminal
configuration” -> Right click on the device -> “Change device” ->
select the correct version. (Note: if only 2 versions are available, it
automatically gives you only the other version to select.)
Rebuild NJ and NX programs and transfer them to the CPUs.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 34 of 39
Flashing Red on all I/O on Coupler
NJ – ERROR and NET ERR – Flashing red
NJ – LINK/ACC – Flashing orange
Coupler – TS and ERR – flashing red (with Run flashing green in between them)
NX – FS – Flashing red NX – TS – Flashing green
I/O modules on the coupler- FS and connected inputs / outputs – flashing red
Cause: Lost EtherCAT connection
Solution: Check EtherCAT cables for loose connection.
If online with a computer and Sysmac Studio, open up troubleshooting and select “reset all”.
OR Recycle power to the system.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 35 of 39
Flashing Green I/O LEDS and Red/Green CPU
NJ – RUN - Solid Green NJ – ERROR and NET ERR - Flashing Red
NJ – LINK/ACC – Flashing orange Coupler – RUN – red
Coupler – L/AIN and L/A OUT – Flashing green (super fast)
I/O module – FS and TS – Flashing green
Cause: Issue during transfer of the program
Solution: Open new project
Open up new project
Configurations and Setup -> EtherCAT -> right click on NJ CPU -> Merge and compare with actual
configuration -> apply actual network configuration
Transfer from Controller
Make sure the options are not selected.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 36 of 39
Function Block Diagnostic Codes
Decimal Hexadecimal
0 0000 FB is disabled FB is not operating or Safety CPU has stopped
32768 8000 FB is operating and there are no errors
32769 8001 FB is already started
Solution: See if S_StartReset is required
32770 8002 FB is waiting for device input signal to change to true
Solution: make sure reset is false before input signal goes to true
32771 8003 Waiting for reset to turn to true after the input is true
32772 8004 A safety request was detected
Solution: Need device input to change to true
32773 8005 Waiting for reset
Check S_AutoReset or Reset since they are not changing to true
32785 8011 Waiting for operator to request unlocking the guard
32786 8012 Guard is unlocked and open
32787 8013 Guard is unlocked and closed
32788 8014 S_SafetyActive was restored but need reset signal
49152 FB is operating and an error exists
49153 C001 Undetected change to true for the reset input
49154 C002 Undetected change to true for the reset input
49155 C003 Undetected change to true (during safety lost state)
49156 C004 Safety device was activated (guard opened or unlocked)
49169 C011 Equivalent signals for reset and EDM1 device input
49185 C021 Equivalent signals for reset and EDM2 device input
49201 C031 Equivalent signals for reset, EDM1 and EDM2 device input
49217 C041 Equivalent signals for reset and EDM1 device input
Thru 49297 Reset error
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 37 of 39
Post Programming
Reset Only Works at Initial Start-up
Solution: Check reset functions and see if reset signal remains high
G5 servo drive saw high signal for reset button once it was initially pressed. Add SF_TOF and SF_F_TRIG
to turn reset signal off for the NJ.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 38 of 39
LEDs Will Not Turn On, NJ & NX Are Running
Cause: Unknown
Solution: Recycle power,
If that does not work, rebuild NJ and NX programs, transfer programs to CPUs, recycle power.
Maximum Number of Tabs Cause: Too many windows are opened.
Solution: Click on “X” in the tab to close several tabs.
Note: Maximum number of tabs allowed is 10.
Document: NX Safety Troubleshooting - Version 2.0 Sept. 19, 2014 Page 39 of 39
Safe Motion Connection on G5
St on G5 Display Cause: G5 is waiting for the safety
Solution: Press reset button.
If using multiple reset pushbuttons, make sure they are OR instead of AND.
83 on G5 Display Cause: G5 does not see the safety
Solution: Check the cable connections. Check the program.
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