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GSM machine stops randomly; "BM" bus master light out

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One of our GSM1 machines occasionally stops running in the m... - Sep 26, 2019 by Tom  

Hi there ... - Feb 01, 2021 by rubyjones  


Tom

#83469

GSM machine stops randomly; "BM" bus master light out | 26 September, 2019

One of our GSM1 machines occasionally stops running in the middle of a program and I haven't been able to figure out what is causing it.

When the issue occurs, the "BM" (bus master) light on the SYS68K card drops out (turns off, no activity) the board support drops down and board clamps release. The machine doesn't register e-stops or anything after that and it has to be rebooted to resume production. Unfortunately the job data is lost and the board has to be completed by hand if possible.

I have cloned and replaced the hard drive and swapped SYS68K cards. Has anyone else run into this before? Are there any logs I can look at to see some error messages?

Thanks!

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#83473

GSM machine stops randomly; "BM" bus master light out | 27 September, 2019

Did you try "Logicomm" debug procedure? It might give you a hint...

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Tom

#83476

GSM machine stops randomly; "BM" bus master light out | 27 September, 2019

Hi Deni- Thanks for the suggestion I will read up on Logicomm and see what it gets me.

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#83477

GSM machine stops randomly; "BM" bus master light out | 27 September, 2019

Just one more thought - we had an issue with +12V supply for VME rack. One tantalum cap in the DC/DC converter module for linear encoder interpolator shorted it out, but oddly enough - not always. We ended up hooking scope to all PSU voltages and when it triggered at least we knew where to start to look for faults. Took us a while until we nailed it down. Recently, one DC/DC converter on HP servo board failed in a strange way - +12V was ok but -12 was anywhere between -4 and -8, depending on the Moon phases, stars alignment and God knows what else. Bugged us for weeks until we found it. At the end, machine gave some clues that leaded us the right way. Good luck!

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Tom

#83478

GSM machine stops randomly; "BM" bus master light out | 27 September, 2019

Thanks for the suggestions!

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#83486

GSM machine stops randomly; "BM" bus master light out | 30 September, 2019

Please report here if (and how) you manage to solve the problem - it might be helpful for all of us in the future!

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Tom

#83487

GSM machine stops randomly; "BM" bus master light out | 30 September, 2019

Yes, if I figure it out I will report back.

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Tom

#83564

GSM machine stops randomly; "BM" bus master light out | 11 October, 2019

FYI I did try logicomm but the log files were empty. There must be something wrong with my connections from the force board to the EPC. I'll keep investigating. I also swapped the EPC to see if that makes any difference.

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#83744

GSM machine stops randomly; "BM" bus master light out | 13 November, 2019

Tom,

Did you put the machine in debug mode? Do you use RAMTF or PTF? Based on your problem, check PilZ box.

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Tom

#83824

GSM machine stops randomly; "BM" bus master light out | 27 November, 2019

Hi Tushar,

Thanks for the reply. I do believe I put it into debug mode but I will be sure to check next time I try logicomm. I am not using any RAMTF or PTF.

At the moment I have upgraded the machine from EPC-5 to EPC-5-66 which I found cheap. The switch from 33mhz to 66mhz makes loading screens and programs faster, and so far I have not had any problems with the BM light.

I will report back if the problem continues, but for now I will consider the issue likely with the EPC-5 unit.

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Tom

#86025

GSM machine stops randomly; "BM" bus master light out | 22 December, 2020

Well it seems you are onto something with the vme power supply. The issue has resurfaced and I did notice the LED's on the keyboard went out when the issue occurs. I looked at the power distribution board to the left of the vme and it shows the +12V supply is out. The power returns about 30sec later but the system needs to be rebooted to reinitialize everything.

How did you identify the encoder issue? What do you suggest I look at other than swapping the vme power supply? Thanks

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#86028

GSM machine stops randomly; "BM" bus master light out | 22 December, 2020

Tom, There are two power supply in the machine. One on top of VME box and other behind power distribution panel. The voltage that you see and check at PDP is not from VME.

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Tom

#86034

GSM machine stops randomly; "BM" bus master light out | 22 December, 2020

Ok; is this the 5a box located under and behind the pdp? I see now in the diagram it is labeled pdp1.ps1.

Any suggestion for what to check to determine if the problem is the power supply or something connected to it?

I noticed that when the 12v power returns to the pdp that the 12v switch led does not turn back on with the other 12v led's.

There seems to be no repeatable process at this point to replicate the condition reliably.

Thanks for your help!

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Tom

#86035

GSM machine stops randomly; "BM" bus master light out | 23 December, 2020

I believe I found the power supply you refer to on the back side of the pdp mounting panel. I will have a look at it.

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#86041

GSM machine stops randomly; "BM" bus master light out | 23 December, 2020

1. Palm down the GSM and open the safety cover to check input voltage +12VDC (at KDC2 3PL pins 2 to 3) and output voltage +5VDC (at KDC2 2PL pin 4 to 3) at the DC/DC converter. The DC/DC converter is located inside the control panel assembly ("Nose cone"). 2. If there is no 12 volt input at the DC/DC converter, check it as it comes out of the Power distribution panel (PDP1 PC1 P10 pin 2 to 3)

There are two more DC/DC converters that supply power to the X and Y interpolation boxes and the board handling encoders. If either of the other two converters are bad, there will be no encoder feedback for that particular axis and the machine will report a position-following error. These converters are all the same and can be swapped for troubleshooting purposes. Bypass the DC/DC converter by swapping it with one of the other converters to verify if this is the cause of the problem. If you do not have 12 volts coming into the converter, then the DC/DC converter is not the problem. Check the 12 volt source; on older machines this would be the VME power supply and on newer machines (H block and higher) the 12 volts is supplied by the power distribution panel.

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Tom

#86042

GSM machine stops randomly; "BM" bus master li | 23 December, 2020

Thanks for the detailed information. I have a spare dc/dc converter on order to try swapping them.

Another note is all dc power is cut out by the pdp.ps1, not just 12vdc. 24vac power remains.

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#86043

GSM machine stops randomly; "BM" bus m | 23 December, 2020

Check Power Distribution Panel Power Supply. No output or output too low for 24V, 15V, and 12V. Also, LED's on PDP LT6, LT7, LT8 , LT9, LT10, LT11 don't turn on at all, even though all fuses test OK for continuity.

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Tom

#86045

GSM machine stops randomly; "BM&quo | 23 December, 2020

Thanks; I have a spare power supply coming as well. I will start by swapping dc-dc converters first and if the problem persists swap the pdp power supply. I'll report back what I find.

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Tom

#86191

GSM machine stops randomly; "BM&amp | 29 January, 2021

Update: I have replaced both dc-dc converters without any improvement.

Observing the issue again yesterday I was able to see more of the problem. Logicomm reported a bus error at fcff1043 running "butt" (photo attached.)

The DC power lights on pdp would begin to dim/flicker then all went out for a minute or so then would come back up, with the process repeating randomly. I decided it is probably the pdp power supply and changed it out. So far so good, I will report if any further problems develop on this issue.

Attachments:

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#86194

GSM machine stops randomly; "BM&amp | 29 January, 2021

The error in the attached picture(FCFF1043) is for 16 I/O card located in CIO slot one for board transfer. May be thats when your PDP supply drop voltage. If problem comes back, look at that card and/or connection and/or cable.

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Tom

#86196

GSM machine stops randomly; "BM&amp | 29 January, 2021

Thanks for the heads up. I suspect it is due to power dropping out to the IO chassis and other devices connected to the pdp. This is the first logicomm capture I have for it so I don't have other messages to compare it to. Machine has been running all day without incident so far, fingers crossed it was just a failing pdp psu.

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#86197

GSM machine stops randomly; "BM" bus master light out | 1 February, 2021

Hi there

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Tom

#86323

GSM machine stops randomly; "BM&amp | 26 February, 2021

We have been running the machine for about a month after replacing the pdp power supply. We have not had a repeat of the problems since. I believe we can consider this issue resolved. Failing pdp supply was a known issue in the uic kb.

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