Troubleshooting Guide. All Vision Systems CIVCore 11 and CIVControl 11

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1 Troubleshooting Guide CIVCore 11 and CIVControl 11

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3 Table of Contents 1 Introduction Scope How to Use This Guide 3 2 Normal Operation Issues 4 3 Setup and Administration 11 4 CIVCore and Tracking Module s/faults Description of ID Numbers and s s and Faults for ID Numbers Under s and Faults for ID Numbers Over Table of Contents 1

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5 1 Introduction WARNING Before attempting any corrective action, be sure that the person doing the action has been trained on the Vision System and has read the entire operator manual. Failure to do so can result in injury or death and/or property damage. Corrective actions denoted with "MT Service Technician" should not be attempted by operators or in-house technicians. 1.1 Scope This Troubleshooting Guide is intended to be used by operators and in-house technicians that have been trained on a CI-Vision Vision System. It covers the basic symptoms and most usual fixes to failures that may occur on a vision system. This Guide can be applied to all CI-Vision systems with B&R controls that have been installed by a trained METTLER TOLEDO Service technician. 1.2 How to Use This Guide This guide is divided into 3 sections representing the different categories of failures: Normal Operation: These are failures observed when the system is being used normally for production. Setup and Administration: These are failures that usually occur when a part is being set up or when there are administration changes. CIVCore and Tracking Module s/faults: These are messages and faults which pertain to the CIVCore software or the B&R tracking module. These messages appear in the lower panel of the display. See "Handling Faults and Other s" in Part 4. Below are descriptions of the column headings that appear in the troubleshooting tables. Not all of the columns listed appear in all of the tables. Column Component/Category ID Number Text Symptom Cause Corrective Action System Reaction Meaning What component is affected or the type of issue encountered The number of the fault or message that appears in the ID column of the CIVCore s screen The relative importance or severity of the message or fault The text associated with the ID number of a fault or message How the failure is manifested What is causing the failure How to resolve the failure How the system behaves immediately following the cause of failure Some of the corrective action entries contain numbered items. The user should try each item sequentially until the issue is resolved. If the problem persists, contact the Service Line at or at service.civision@mt.com. Introduction 3

6 4 Normal Operation Issues 2 Normal Operation Issues Component/Category Symptom Cause Corrective Action Camera Height Adjuster After startup, the camera does not go to the right position Emergency stop pressed Camera height adjuster motor failure Motion axis did not reach the homing position Height defined for given part is not correct Lift emergency stop and press reset 1. Check power to the motor and drive 2. Check motor connectors and cabling 3. Replace defective motor (MT Service Technician) 1. Check to ensure motion assembly is free of obstructions 2. Check proximity sensor connectors and cable 3. Replace defective sensor Verify position setting for part. Reference user manual Part 4 for part training Conveyors and Side Grips All conveyors do not start Power is off Check power to the motor and drive One of the conveyors does not start Emergency stop pressed Conveyors not started Line stopped; external stop, prime, or backup sensor conditions supplied to system Debris in belt causing belt to jam Motion drives not functioning Lift emergency stop and press the reset button. On the display screen, touch [ENABLE] and then [AUTO] Wait until line is running again Clean belt thoroughly Contact CI-Vision service Motor failure 1. Check power to the motor and drive Conveyors have been stopped by too much pressure Drive failure 2. Check motor connectors and cabling 3. Replace defective motor (MT Service Technician) Remove weight from conveyor and restart Replace frequency converter (MT Service Technician)

7 Normal Operation Issues 5 Component/Category Symptom Cause Corrective Action Conveyors and Side Grips Belt damaged Belt damaged by an external source Belt edges frayed Noise during running Conveyor ends hitting each other Belt type incorrect Belt drift to the side - belts misaligned Belt drift to the side - belts misaligned Conveyor clogged with debris Roller damaged Tooth belt pulleys defective Motor and/or drive defective Motor mountings are loose 1. Replace belt 2. Conduct visual check to verify that the external source is no longer in contact with the belt. Replace belt Ensure conveyors are not touching each other Check belt material 1. Replace belt 2. Check and adjust the mechanical conveyor setup Check and adjust the mechanical conveyor setup Clean the conveyor Replace roller Replace tooth belt pulley Replace motor (MT Service Technician) Tighten motor and conveyor Display Black with power on Touch screen failure 1. Check touch screen connection PC failure 24V power supply failure 2. Replace defective connectors or cable 3. Replace defective touch screen (MT Service Technician) Replace PC (MT Service Technician) Replace system main fuse Screen color wrong Touch screen failure 1. Check touch screen connection Touch is not working Touch screen failure or not calibrated 2. Replace defective connectors or cable 3. Replace defective touch screen (MT Service Technician) 1. Recalibrate the touch screen 2. Check touch screen connection 3. Replace defective connectors or cable 4. Replace defective touch screen (MT Service Technician)

8 6 Normal Operation Issues Component/Category Symptom Cause Corrective Action Image Display Picture in wrong place Guide rails on infeed conveyor misaligned Station delay not set appropriately Put guide rails back to the original position Adjust station delay so that the image is centered on the screen. Picture moves during production Encoder pulse erratic 1. Check encoder cable connections Color/brightness changes during operation Lines or specks on picture Defective or incorrectly mounted photo eye sensor Photo eye sensor multiple triggering Product movement has changed after initial trigger Light power failure or light defective Lens or glass of camera box dirty or damaged 2. Replace defective encoder or PLC (MT Service Technician) 1. Check position of sensor with reflector 2. Check sensor connectors and cabling 3. Replace defective photo eye sensor 1. Check surroundings around sensor that could cause triggering 2. Make sure products do not have features that could cause multiple triggering 3. Check connectors and cabling 4. Replace defective photo eye sensor Check speed and surface of feeding conveyors 1. Check/tighten light connectors and cabling 2. Replace defective light (MT Service Technician) 1. Clean glass of camera box or lens 2. Replace component if damaged (MT Service Technician)

9 Normal Operation Issues 7 Component/Category Symptom Cause Corrective Action Image Display Picture black Photo eye sensor blocked Unblock photo eye sensor Photo eye sensor multiple triggering Light power failure or light defective 1. Check surroundings around sensor that could cause triggering 2. Make sure products do not have hanging features that could cause multiple triggering 3. Check connectors and cabling 4. Replace defective photo eye sensor 1. Check/tighten light connectors and cables 2. Check replace fuse to light 3. Replace defective light (MT Service Technician) Photo eye sensor failure 1. Check position of sensor with reflector 2. Check sensor connectors and cabling 3. Replace defective photo eye sensor Camera issue 1. Check/tighten camera connections 2. Check that Ethernet connection light is on 3. Re-start the system 4. Replace defective camera (MT Service Technician or consult Part 3 of the Operator Manual) Picture does not update Not in inspecting mode Put CIVCore in inspecting mode by touching the [ON] button on the display screen Inspection light Does not come on Light power failure or light defective Photo eye sensor failure 1. Check position of sensor with reflector 2. Check sensor connectors and cabling 3. Replace defective photo eye sensor 1. Check/tighten light connectors and cables 2. Check/replace light fuse 3. Replace defective light (MT Service Technician) Photo eye sensor failure 1. Check position of sensor with reflector 2. Check sensor connectors and cabling 3. Replace defective photo eye sensor Light is always on (CLS only) Photo eye sensor blocked Unblock photo eye sensor

10 8 Normal Operation Issues Component/Category Symptom Cause Corrective Action Reject Excessive false rejects System not in Run Mode Put system in Run Mode. Wrong part was loaded Defects/measurements/prints outside of tolerances Defects/prints changed position Surface of the product or package shape has changed Photo eye sensor multiple triggering Defective or incorrectly mounted photo eye sensor Product movement has changed after initial trigger Check the loaded part against the presented part Ensure tolerances are within the system specifications Re-train part 1. Re-train the part 2. Adjust display control settings (brightness, contrast, etc.) 3. Contact MT for re-training of the product 1. Check surroundings around the sensor that could cause triggering 2. Make sure products do not have features that could cause multiple triggering 3. Check connectors and cabling 4. Replace defective photo eye sensor 1. Check connectors and cabling 2. Check mounting of photo eye sensor 3. Replace defective photo eye sensor Check speed and surface of feeding conveyors

11 Normal Operation Issues 9 Component/Category Symptom Cause Corrective Action Reject Excessive false rejects Lens or glass of camera box dirty or damaged Reject Bin Light power failure or light defective Clean glass of camera box or lens Replace component if damaged (MT Service Technician) 1. Check/tighten light connectors and cables 2. Check fuses for DC power supply 3. Replace defective light (MT Service Technician) No reject but should have System is set to bypass Turn Bypass switch to off position Air pressure too low Photo eye sensor blocked Check air supply Unblock photo eye sensor Photo eye sensor failure 1. Check position sensor with reflector 2. Check sensor connectors and cabling 3. Replace defective photo eye sensor Rejecter failure 1. Check rejecter cable connectors and cables 2. Replace defective rejecter (MT Service Technician) Air pressure valve failure 1. Check air pressure valve cable connectors and cables Reject did not verify Photo eye sensor blocked Unblock photo eye sensor Reject bin full, but no signal from system Air pressure too low 2. Replace defective air pressure valve (MT Service Technician) Check air supply Photo eye sensor failure 1. Clean sensor and reflector 2. Check position of sensor with reflector 3. Check sensor connectors and cabling 4. Replace defective photo eye sensor Rejecter failure 1. Check rejecter cable connectors and cables 2. Replace defective rejecter (MT Service Technician) Photo eye sensor failure 1. Check position of sensor with reflector 2. Check sensor connections and cabling 3. Replace defective photo eye sensor

12 10 Normal Operation Issues Component/Category Symptom Cause Corrective Action Startup System not inspecting at startup Light power or detect failure Check light and detect sensor Photo eye sensor blocked or failure System System does not start External power not available or power cable disconnected Fuse blown 1. Unblock sensor 2. Check position of sensor with reflector 3. Check sensor connectors and cabling 4. Replace defective photo eye sensor Check power and cable connection Replace fuse System turns off without warning UPS failure Replace UPS (MT Service Technician)

13 Setup and Administration 11 3 Setup and Administration Component Symptom Cause Corrective Action CIVCore Image Display [Train], [Test], [Live Video] button in SETUP screen is grayed out System is in inspecting mode Incorrect measurements reported Incorrect tool setup Check tool settings Color/brightness changes during initial testing Take system out of inspecting mode by touching the [OFF] button Poor image quality 1. Check and adjust contrast settings Surface of the product has changed (different product material or surface finish) Different heights or different distances of part to light and camera Camera brightness/contrast settings incorrect Picture does not update Acquire tool disabled Check tool setup Picture is too dark Incorrect part loaded Load correct part Product is moving in the picture during the production 2. Check the position and function of the lighting 1. Adjust the image settings (brightness and/or shutter speed) 2. Train the part with the new condition 3. Change mechanical position of light and camera to get a sufficient picture (MT Service Technician) Adjust position of cameras and lights Adjust settings in Live Video to get appropriate image Incorrect shutter speed 1. Check and adjust camera setting in CIVCore Improper setup of guides rails causing product to slip on the conveyor Poor transition between the conveyors Encoder slipping on conveyor Debounce time too short 2. Check and adjust camera setting on camera (MT Service technician) Check and adjust guide rail setup Check and adjust conveyor heights Check to make sure the encoder is properly secured to the conveyor shaft. Adjust the debounce time to be part specific (MT Service Technician)

14 12 Setup and Administration Component Symptom Cause Corrective Action Rejects Product moves incorrectly during reject Too many false rejects Wrong reject settings of position and/or reject length Incorrect contrast, brightness or shutter speed setting in CIV Core Check and change settings Adjust contrast, brightness or shutter speed settings Incorrect match code 1. Check registered match code Position and rotation in the picture is incorrect Too much product movement Improper camera position Poor image quality 2. Check printed code on the product 3. Check the code that the system reads Increase the search fields/areas of the inspections Check and adjust guide rails and conveyors Check and adjust camera (MT Service Technician) Change f-stop or focus setup of the camera (MT Service Technician)

15 4 CIVCore and Tracking Module s/faults 4.1 Description of ID Numbers and s The s and Faults are divided into two sections: ID Numbers under 100 pertain to tracking module messages and faults. ID Numbers over 1000 pertain to CIVCore messages and faults. The below table describes the relative importance of the messages and faults according to : Type Meaning 1 Info Reports general information The system is not halted. No operator action is required. [MESSAGES] flashes green until the message is cleared. 3 Alert Reports a minor event which does not impact the vision inspection process The system is not halted. Operator action may be required either with the vision system or with other components of the assembly line. [MESSAGES] flashes amber until the message is cleared. 4 Fault Reports an event which impacts the ability to inspect and pass good products as expected 5 Critical Fault The system is not halted, but it may be impaired. The red stack light indicator flashes red. User action is required to fix the cause of the event and clear the fault before the system can be restarted. [MESSAGES] flashes red until the message is cleared. Reports an event which prevents the reliable removal of defective products from the production line The system is halted The red stack light indicator flashes red. Immediate user action is required to fix the cause of the event and clear the fault before the system can be restarted. [MESSAGES] flashes red until the message is cleared. CIVCore and Tracking Module s/faults 13

16 14 CIVCore and Tracking Module s/faults 4.2 s and Faults for ID Numbers Under No message ID matches {0}: Contact CI-Vision 1 4 Vision communications fault on communication channel {0}: numbers do not match 2 3 Language error: text missing 3 4 Vision communication fault on communication channel {0}: General connection error Internal system error where a message was to be displayed but the language text could not be located. The communication became unsynchronized on the specified communications channel. The message text for the chosen language is missing The communication on the specified communications channel has failed. 4 4 Safety relay tripped The safety relay is configured and the input is currently off 5 5 Anti-Circumvention warning: Encoder is not moving while run input is on 6 5 Anti-Circumvention warning: Encoder is moving while run input is off Anti-Circumvention is enabled, the run input is on, but the encoder has not changed over the configurable amount of cycles Anti-Circumvention is enabled, the run input is off, but the encoder is still moving for more than the configured amount of cycles Contact CI-Vision service to report the issue Check Ethernet cables between tracking controller and vision system for lose connections or damage. Contact CI-Vision service to report the issue Check Ethernet cables between tracking controller and vision system for lose connections or damage. Reset the safety relay. Make sure the conveyor is running properly. If the conveyor is running then check the encoder for proper operation. Check to make sure run input is not turned off while conveyor is still moving. If conveyor is not moving then check encoder and cabling. The system will attempt to recover from the communications loss. During a communications failure, all products which are not inspected properly will be rejected. The system will not perform properly until this is corrected. The system will stop all motion so the machine is in a safe state.

17 CIVCore and Tracking Module s/faults Anti-Circumvention warning: Channel is bypassed while run input is on 8 5 Anti-Circumvention warning: Product detect was triggered while run input is off 9 3 Tracking parameters have been changed. Resynchronizing tracking Anti-Circumvention is enabled, the run input is on, but we have not detected a product within the configurable amount of time Anti-Circumvention is enabled, the run input is off, but we received more than the configured amount of allowable detections The user has changed parameters while the system was running Custom Signal {0}:{1} Depends on the configured custom signals. The actual fault will be generated by the configured description of the custom signal 11 4 C{0} Vision inspecting too slowly for product {1}: Resetting inspection system 12 3 C{0} Rejecter bypass timeout: System no longer in bypass - toggle switch to re-enter bypass mode Waiting for more images than the configured allowable amount The bypass switch has been turned on for the configured amount of time Correct the blockage which is stopping product from reaching the vision system. Correct the situation which is allowing product to pass the system while the run input is off None required. Corrective action will depend on user configuration of the custom signals. Verify the vision system is properly inspecting and has not been configured for too many inspection tools which could take too long. Verify that the product flow rate has not exceeded the maximum rate. If bypass mode is still desired, then the bypass switch needs to be turned off and back on. The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected. The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected. The system exits bypass mode and returns to normal operational mode.

18 16 CIVCore and Tracking Module s/faults 13 4 C{0}R{1} Vision inspection took too long for product {2}: Product rejected without receiving vision results 14 5 C{0} Detection sensor warning: Sensor blocked too long 15 4 C{0}S{1} Vision result could not be applied to product {2}: Resetting inspection system C{0} Detection sensor warning: Second detection occurred without encoder movement 17 4 C{0} Product width exceeded configured setting 18 4 C{0} Product spacing less than configured setting 19 4 C{0} Simple sensor high failure rate detected: Has failed {1} times consecutively 20 4 C{0} Simple sensor failure: Sensor did not toggle as expected The specified product has reached the reject location without receiving a vision result. The detect sensor has been blocked longer than the configurable amount of time A vision result was received without ever sending a trigger. A new product was detected but the encoder has not moved since the last one The configured product width has been exceeded The configured minimum gap between products has been surpassed Products passing the simple sensor have failed more than the configured allowable amount of times Simple sensor has not changed state during a full cycle. Verify the vision system is properly inspecting and has not been configured for too many inspection tools which could take too long. Verify that the product flow rate has not exceeded the maximum rate. Check the detect sensor to verify it is not blocked and is operating properly. Contact CI-Vision service to report the issue Verify proper operation of the detect sensor. Check that the product is not damaged. Check settings to verify they are correct. Check that the product is not damaged. Check settings to verify they are correct. Correct product defect which is causing multiple failures. Verify adjustment of simple sensor. Verify wiring and operation of simple sensor The product will be rejected. The system is unable to inspect products or function properly until this is corrected. The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected.

19 CIVCore and Tracking Module s/faults C{0} Countercheck error: Sensor blocked for too long 22 5 C{0} Countercheck error: Rejected product {1} still present - rejecter failed to operate properly 23 5 C{0} Countercheck error: Unexpected product detected - tracking not working properly 24 5 C{0} Countercheck error: Product {1} missing - tracking not working properly 25 4 C{0} Tracking failure: Too many products being tracked. Resynchronizing tracking 26 5 C{0}Q{1} exit FIFO warning: Sensor blocked for too long 27 4 C{0}Q{1} exit FIFO failure: Unexpected product at sensor. All products must be removed from system. Resynchronizing tracking The countercheck sensor has been blocked for longer than the configured maximum amount of time The countercheck sensor has detected a product that should have been previously rejected The countercheck sensor has detected an unexpected product. A product that should not have been rejected did not arrive at the countercheck sensor The system has attempted to track too many products at the same time. The FIFO sensor has been blocked longer than the configured amount of time A product has been detected but it was not expected Clear blockage at countercheck location. Verify wiring and operation of countercheck sensor. Verify proper operation of tracking and rejection system. Correct defect which allows rejected products past the reject location. Remove extra product from conveyor. Verify that products are not slipping on the conveyor. Verify tracking settings for proper distances. Verify that products are not slipping on the conveyor. Verify tracking settings for proper distances. This fault will often happen with other faults which should be addressed first and probably caused this fault. Verify the vision system is operating properly. Verify the system settings to make sure queue lengths are not too long. Clear blockage at FIFO location. Verify wiring and operation of FIFO sensor. Verify that products are not slipping on conveyor. Verify proper operation and wiring of FIFO sensor. The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected. FIFO operation will not work properly. Products may not be tracked properly. The system will resume proper operation after blockage is cleared The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected.

20 18 CIVCore and Tracking Module s/faults 28 5 C{0}Q{1} exit FIFO failure: Expected product {2} did not arrive at sensor 29 5 C{0}R{1} failure: Unable to verify product {2} was removed 30 5 C{0}R{1} verify sensor warning: Sensor blocked for too long 31 5 C{0}R{1} Reject now sensor warning: Sensor blocked for too long 32 4 C{0}R{1} Reject now error: Rejected unexpected product 33 4 C{0}S{1} Resync configuration error: Location not configured before inspection station 34 4 C{0}S{1} Resync configuration error: Inspection station configured too close to reject or end of queue for resync functionality An expected product never arrived at the exit FIFO sensor The rejected product was not detected by the configured reject verify sensor The reject verify sensor has been blocked longer than the configured amount of time The reject now sensor has been blocked longer than the configured amount of time An untracked product was rejected by the reject now sensor. The resync sensor is configured to be past or at the inspection station The station is configured too close to the reject or to the end of the queue for resync functionality to work Verify that products are not slipping on conveyor. Verify proper operation and wiring of FIFO sensor. Verify that the rejecter is working properly and no jam is present. Verify proper operation and wiring of reject verify sensor. Clear the blockage at the reject verify sensor. Verify proper operation and wiring of reject verify sensor. Clear the blockage at the reject now sensor. Verify proper operation and wiring of reject now sensor. Verify that products are not slipping on conveyor. Correct the configuration of the resync sensor so it is located before the inspection station. Correct the configuration, or alter machine layout to allow proper distances between station and reject or end of queue. System will attempt reject all products while sensor is blocked. The rejecter will repeatedly toggle possibly causing a jam. After blockage is cleared the system will resume normal operation. The resync sensor will not function. The resync sensor will not function.

21 CIVCore and Tracking Module s/faults C{0}S{1} Resync configuration error: Tolerance configured is too large for product spacing 36 4 C{0}S{1} Resync failure: Expected product {2} did not arrive at sensor before tolerance expired 37 4 C{0}S{1} Tracking failure: Vision result number:{2} does not match expected result:{3}. Resetting inspeciton system 38 4 C{0}S{1} Resync error: Sensor blocked for too long 39 5 Tracking controller hardware fault: IO Bus Voltage Warning 40 5 Tracking controller hardware fault: IO Supply Voltage Warning 41 3 Tracking controller hardware fault: Battery Low Voltage The resync tolerance is configured to be longer than the detect debounce setting. The resync sensor was expecting a product, but one was not detected. The product number of the vision result returned by CIVCore does not match the expected product number that was sent to the vision system for this product. The resync sensor has been blocked longer than the configured amount of time The voltage on the I/O bus has dropped below the acceptable amount The voltage from the I/O supply has dropped below the acceptable amount The PC battery voltage level has dropped to 0. Verify proper settings and correct the setting which does not match the product being run. Verify product is not slipping on the conveyor. Verify proper operation and wiring of resync sensor. Contact CI-Vision service to report the issue. Check Ethernet cables between tracking controller and vision system for lose connections or damage. Clear the blockage at the resync sensor. Verify proper operation and wiring of resync sensor. Contact CI-Vision service to report the issue. Check power supplies and incoming power. Contact CI-Vision service to report the issue. Check power supplies and incoming power. Replace the battery function normally but without resync sensor inspections may fail. The resync sensor will not function. The system will trigger a vision inspection where it expected the product to be, possibly resulting in a blank image and a reject. The system will resynchronize the tracking and resume normal operation. During the resynchronization all products will be rejected. function normally but without resync sensor inspections may fail. The resync sensor will not function. function normally if possible. function normally if possible

22 20 CIVCore and Tracking Module s/faults 42 3 Tracking controller file system error: Network connection to configuration files unavailable. Files not saved 43 3 Tracking controller hardware warning: Debug I/O is active 44 3 Backup sensor warning: Product backup occurred 45 4 Motion warning: Unable to enable axis while in motion 46 4 Motion warning: Conveyor external stop activated 47 4 Motion warning: Conveyor emergency stop activated 48 3 Motion warning: Vision cannot inspect while axis are in motion. Product(s) will be rejected 49 4 Ax{0} Motion error: Sidegrip motion command failed: {1} 50 4 Ax{0} Motion error: Conveyor motion command failed: {1} The file sharing function is not able to access the network where files are stored. The debug I/O option has been set Product is blocking the configured backup sensor Not all of the drives are yet in a standstill state The configured external stop button has been pressed The configured external e- stop has been pressed CIVCore is running while the axis are not yet in position A fault has occurred in the sidegrip motion commands A fault has occurred in the conveyor motion commands 51 4 Motion error: {0} A fault has occurred in the drive mapping Check Ethernet cables between tracking controller and vision system for lose connections or damage. Make sure to turn off the debug I/O option after troubleshooting is completed. No corrective action required If the sensor is not blocked and the fault occurs verify proper operation and wiring of backup sensor. Wait for drives to stop moving before attempting the operation again. Reset the external stop. Reset the E-stop. Wait for motion to complete before sending product through the machine. Contact CI-Vision service to report the issue. Provide copy of text in this fault. Contact CI-Vision service to report the issue. Provide copy of text in this fault. Contact CI-Vision service to report the issue. Provide copy of text in this fault. The file will not be saved or loaded, but the controller will continue with local data. The drives configured to stop on backup will stop until the backup has been cleared by the system. Conveyors will not move. Conveyors will not move. Products will be rejected while the axis are moving, then the system will resume normal operation. Motion may not function until the issue is resolved. Motion may not function until the issue is resolved. Motion may not function until the issue is resolved.

23 CIVCore and Tracking Module s/faults Hardware failure: Main I/O Failure 53 5 Hardware failure: Remote I/O{0} Failure 54 4 Backup sensor warning: Sensor blocked for too long 55 4 Prime sensor warning: Sensor blocked for too long 56 4 Reject Bin Full Warning: Sensor Blocked 57 1 Channel {0} is in bypass mode Hardware has failed on the main I/O rack. Hardware has failed on the remote I/O rack. The backup sensor has been blocked longer than the configured amount of time. The prime sensor has been blocked longer than the configured amount of time. Configured reject bin is full The specified channel has been placed into bypass mode System is in bypass mode All configured channels on this system have been placed into bypass mode C{0} Product width less than configured setting 60 4 C{0}S{1} Resync failure: Expected product {2} arrived at sensor before configured tolerance The product is below the configured product width A product arrived at the specified sensor before the expected window. Contact CI-Vision service to report the issue. Check power, wiring, Contact CI-Vision service to report the issue. Check power, wiring, Clear the blockage at the backup sensor. Verify proper operation and wiring of the backup sensor. Clear the blockage at the prime sensor. Verify proper operation and wiring of the prime sensor. Empty the reject bin. If the sensor is not blocked and the fault occurs verify proper operation and wiring of the reject bin full sensor. None required. None required. Check that the product is not damaged. Check settings to verify they are correct. Check settings to verify they are correct. System will not function until the issue is resolved. System will not function until the issue is resolved. The drives that have been configured to stop on backup will be stopped. The drives that have been configured to need the prime sensor will be stopped. The specified channel will not reject products until taken back out of bypass mode. All configured channels on this system will not reject products until taken back out of bypass mode.

24 22 CIVCore and Tracking Module s/faults 61 4 CIVCore communications were online, but have now been lost 62 5 C{0}Q{1} FIFO configuration error: FIFO too close to start of queue 63 5 C{0}S{1} FIFO configuration error: Station within FIFO tolerance 64 5 C{0}S{1} FIFO configuration error: Resync sensor within FIFO tolerance 65 5 C{0}R{1} FIFO configuration error: Reject within FIFO tolerance 66 5 C{0}R{1} FIFO configuration error: Reject Now sensor within FIFO tolerance 67 5 C{0}R{1} FIFO configuration error: Counter Check sensor within FIFO tolerance 68 4 C{0}S{1} Received unexpected vision result: Resetting inspection system The communications to CIVCore have been lost. The start of the queue falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The station falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The resync sensor falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The reject falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The reject now sensor falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The counter check sensor falls between the start of the Virtual FIFO Tolerance and the Physical FIFO offset. The tracking module received an unrequested result from the inspection system. Check Ethernet cables between tracking controller and vision system for lose connections or damage. Adjust the configured settings to limit the tolerance to not include the start of the queue. Adjust the configured settings to limit the tolerance to not include the station position. Adjust the configured settings to limit the tolerance to not include the resync sensor position. Adjust the configured settings to limit the tolerance to not include the reject position. Adjust the configured settings to limit the tolerance to not include the reject now position. Adjust the configured settings to limit the tolerance to not include the counter check position. Contact CI-Vision service to report the issue. Check tracking settings to verify they are correct. The system will function normally once the connection has been restored. The system will not function until this issue is resolved. The system will not function until this issue is resolved. The system will not function until this issue is resolved. The system will not function until this issue is resolved. The system will not function until this issue is resolved. The system will not function until this issue is resolved.

25 69 3 C{0} Tracking compromised, remove all products between detect and last reject The tracking module has reset tracking data without a way to remove untracked products. Check other messages for details on the tracking reset. Remove all product from between the detect sensor and last reject. After the removal or products, clear the messages. After the removal of products, clear the messages and the system will continue to function normally. CIVCore and Tracking Module s/faults 23

26 24 CIVCore and Tracking Module s/faults 4.3 s and Faults for ID Numbers Over Timeout waiting for {0} to launch CI-Vision key error: Key replaced CI-Vision key error: Clock has been set back ({0}) CI-Vision key error: Authorization key date expired CIVCore was configured to start an external application but was unable to start the application properly. After the software was started, the authorization key was switched to a different key. The PC clock was set backwards on a time locked WIBU key, indicating system tampering. A time locked WIBU key is being accessed on a date past what is stored on the key. There are several configuration settings for external applications such as Statistics, Image Viewer, and Customer specified programs which can be launched. Often the application which did not start can be determined by the action previously taken by the user. Working with the CI-Vision service group may be necessary. If key was changed, then no action required. If key was not changed, then key may be loose or defective, or the port on the PC may not be functioning properly. The CI-Vision license key has the ability to time lock software. If the clock on a PC is set to a time earlier than it has been, this message indicates that shift. The software will not work until the time has shifted back to a point after what was stored in the license key. Check PC Clock functionality. If PC clock was changed, then system will not work until "new" time catches up with what the time was before. If waiting is not an option, then set clock back to original time, or contact CI-Vision for a WIBU key update to reset the system WIBU key clock. The CI-Vision license key has the ability to time lock software. When the time on the key has expired the software will no longer function. Contact CI-Vision service for a WIBU key update to extend the time. The system will continue to function, but the external application may not have started. System will use authorization licensing from new key found. System will not function until issue is corrected. System will not function until issue is corrected.

27 CIVCore and Tracking Module s/faults CI-Vision key error: Authorization key internal error ({0}) CI-Vision key warning: Authorization key will expire in {0} days CI-Vision key warning: Authorization key will expire in {0} hours CI-Vision key warning: Authorization key connected CI-Vision key error: Authorization key time expired CI-Vision key error: Authorization key missing CI-Vision key error: Unauthorized usage, Tool '{0}' {1} available, {2} used Stitch calibration appears to be from a different system, or this system has significantly changed. The saved calibration is no longer valid. Internal error from the Authorization key software. Time locked WIBU key is approaching it's expiration date. Time locked WIBU key is approaching it's expiration date. The CI-Vision authorization key was found on the system after being found to be missing. Time locked WIBU key has reached it's expiration date. WIBU authorization key not found on start-up of CIVCore. WIBU key tool authorization has limited the number of specific tools on the system which can be used at one time. Hardware configuration or setup has changed since last time CIVCore was run. Check presence and connection of green WIBU key. Possible causes are a damaged authorization key, or improperly functioning USB port. This warning of the expiration date in the key gives the customer ample time to get the key updated for more runtime. Contact CI-Vision service to get a WIBU key update to extend the expiration date. This warning of the expiration date in the key gives the customer ample time to get the key updated for more runtime. Contact CI-Vision service to get a WIBU key update to extend the expiration date. Check connection and functioning of the WIBU key on the system. Something is causing it to disconnect and reconnect. Contact CI-Vision Service department for updated WIBU key file. Check for presence of green WIBU licensing key. Check connections and PC port for proper functioning. Remove extra tools which are above the authorized amount. Contact CI-Vision service to increase the number of authorized tools. Calibrate the 360 system and make sure shapes are setup properly if hardware has changed. System will not function until issue is corrected. Information only. System will function normally until WIBU key has expired. Information only. System will function normally until WIBU key has expired. System will function normally using the authorizations on the found key. System will not function until issue is corrected. System will not function until issue is corrected. Tools above the authorized amount will not inspect. 360 system will not inspect until the stitch calibration is completed and all shapes are properly trained.

28 26 CIVCore and Tracking Module s/faults Camera {0} has been disconnected from the system. System will no longer function Camera configuration checks failed. There is a logical or physical configuration issue that must be addressed before CIVCore will function properly Database error: Found version {0} is newer than the expected version {1} Inspecting mode entry check failed: Camera(s) {0} did not respond to hardware triggers. Inspecting mode not entered Tracking controller communications fault: Failed to receive exit hardware trigger mode message Database error: The database has been temporarily disabled due to errors. Please see log files for more information. Low level camera drivers have indicated to CIVCore that the camera is no longer connected to the system. When starting up CIVCore, if the camera and triggering system have not tested out properly this message is displayed. Different versions of CIVCore have been run on this database and a newer version of CIVCore has upgraded the database layout. When attempting to enter inspecting mode, the cameras are given hardware triggers. Cameras did not respond properly. CIVCore requested the Tracking controller exit hardware mode (Inspecting mode would be an example) and the Tracking controller did not respond in time. System recorded too many database errors, so is disabling database writing. Check camera network connections and configuration. Verify camera power and functionality. Look at other messages which happened with this message and address them. The system will probably not enter into inspecting mode, but may be able to enter live video and other menus to troubleshoot the issues. Either switch back to a newer version of CIVCore, or run the batch files to remove the database and rebuild the database for the current version of CIVCore. Check cameras and network for proper operation. This message generally happens during system start-up when cameras or hardware is not wired or configured properly. On a functioning system indicates a hardware failure, or configuration change. This is an internal event which could be caused by other events such as communication issues or the PC being overloaded. Contact CI-Vision service for assistance. Verify database has been properly installed and configured. Check configuration of connection in "Database.txt" configuration file. System will not function until issue is corrected. System will not function properly until camera configuration issues are addressed. The database will not function properly to store historical data. System will not enter inspecting mode. System may will attempt to clear data and may not function properly next time the user attempts to use hardware mode (such as setting the system to Inspecting mode) System will inspect properly but the inspection data will not be written to the database.

29 CIVCore and Tracking Module s/faults Automatic bandwidth disabled: Camera {0} is manually set to a frame rate of {1} Automatic bandwidth disabled: Could not automatically calculate bandwidth for adapter {0} Part file error: CIVCore restored part from backup. The old part has been saved as {0} Memory low: Buffer pool has reached max size of {0}. Occurs only on the start-up of CIVCore. Indicates that a "Machine Camera XX.txt" file has the automatic bandwidth calculation for the camera network turned off. Occurs only on the start-up of CIVCore. Indicates the automatic bandwidth calculation failed. The currently selected part was found to have a backup directory, the software has used this directory to load the part. The number of acquisition buffers specified in the "Machine General.txt" file has been exhausted so the system has automatically allocated extra buffers so it can stay running. Contact CI-Vision Service. Re enable the automatic bandwidth calculations in the camera files, or disable this message in the "Acquisition.txt" configuration file. The text of the message gives you information on which camera has been manually set. Contact CI-Vision Service. This message should not occur on a functioning system unless a hardware change has been made. Increasing the automatic bandwidth iteration setting may correct the issue by allowing the bandwidth calculation to complete. Verify that the part is properly loaded and functioning as expected. This could have been caused by a system crash or unexpected shutdown of the system. The software has recovered as expected. Contact CI-Vision Service. Check setting in "Machine General.txt" file to verify enough buffers are allocated. Check if system is falling behind in inspections (check inspection timing vs line rate). If unable to resolve, then server debug logs of the event occurring can be used to help track down root cause. None. Information only. System may not be running at optimal bandwidth, as it is not being automatically calculated. None. Information only. System may not be running at optimal bandwidth, as it is not being automatically calculated. It is possible that the system will not function properly as the camera bandwidth may not work. This message should not happen again, the system has used the backup and moved the possibly corrupted part out of the way. More buffers are allocated, system continues to inspect normally. System likely to run out of buffers again, and eventually fall behind and run out of RAM.

30 28 CIVCore and Tracking Module s/faults Matrox key error: Color tool license missing File system error: Copy Failed : {0} : {1} Tool high fail rate: {0} of last {1} Failed - {2} Debug version of Server Running - not for production use File system error: Delete Failed : {0} Tool setting error: Invalid fixture for tool {0} on camera {1}. Values have been reset to default Tool setting error: Camera {0} : Stored image not found Matrox licensing for color tools was not found, but is required for loaded part. A file copy on the hard drive failed. Serious internal error, data may have been lost. Products are failing at a high rate. CIVCore detected that the current version of software is not code released for production. A file delete operation on the hard drive failed. Serious internal error, data may have been lost. Tool settings have changed and a tool is no longer fixtured to a valid tool. The acquire tool is configured to load an image from disk, but that image could not be loaded. Get correct license, check to verify license is working properly, or remove tools if they are not required. Check hard drive operation. Verify CI-Vision directory is not read only. Verify system is logged in as administrator and has write permission to CI-Vision directory. Correct manufacturing issues to properly make products. Correct vision system to properly inspect products. Install released version of CIVCore. Check hard drive operation. Verify CI-Vision directory is not read only. Verify system is logged in as administrator and has write permission to CI-Vision directory. Correct fixturing of the listed tool so it is properly located when inspecting. The fixture can be set in the tool parameter screen using the "Expert" screen. Check location of file in acquire parameter tools, verify file called out is loaded in the proper location on the hard drive. The color tools will not inspect on the system until the licensing is corrected and the CIVCore software is restarted. System will attempt to continue operations. s may continue to occur and system stability will be compromised. System continues to inspect normally. System will inspect normally. System will attempt to continue operations. s may continue to occur and system stability will be compromised. System will function normally but the tool may not perform as intended as the fixturing has been cleared. System could possibly fail good products, or pass failed products due to the vision inspection being set up improperly. Grey image will be used instead of file loaded from the hard drive.

31 CIVCore and Tracking Module s/faults Database error: Unable to start new session, data will not be stored Matrox key error: Lip tool license missing Internal error: Could not allocate MIL buffer, serious error Internal error: MIL has generated a fault: ({0}) Tool setting error: Mosaic tool (Camera {0}, Tool {1}) source tool invalid. Invalid source tools have been removed File system error: Move Failed : {0} : {1} Internal database error when starting a new database session to hold inspection data. Matrox licensing for lip tools was not found, but is required for loaded part. Internal error creating new buffer to store camera image. Internal vision library error. Change in part configuration has caused a Mosaic tool to no longer be configured properly. A file move operation on the hard drive failed. Serious internal error, data may have been lost. Was the database working before this event? If not then get it working. If it was working - Contact CI-Vision Service. Server debug logs of the event may be requested. Deleting and recreating the database may temporarily help. Database can be disabled temporarily in "Database.txt" configuration file to stop this error from showing up. Once database is disabled, all statistics will be unavailable. Get correct license, check to verify license is working properly, or remove tools if they are not required. Contact CI-Vision Service department. Server debug log files may be required which capture the event happening. Rebooting the computer may clear up the issue, but the root cause should be found. Possibly the system falling too far behind, not enough ram in the computer, or memory corruption. Report error to CI-Vision service department. Server log files, or image of message should be sent in to determine problem. Rebooting PC may resolve issue temporarily. Could be caused by PC having hardware or power issues. Correct configuration on Mosaic tool listed in the message. Check hard drive operation. Verify CI-Vision directory is not read only. Verify system is logged in as administrator and has write permission to CI-Vision directory. The system WILL NOT log data to the database. Statistics will not be able to report on system data. Customer will not be able to export data using CSV export or scheduled CSV exports. The lip tools will not inspect on the system until the licensing is corrected and the CIVCore software is restarted. System is unlikely to continue functioning, more errors and erratic behaviour possible. System is unlikely to continue functioning, more errors and erratic behaviour possible. Mosaic tool will not inspect until configuration is corrected. System will attempt to continue operations. s may continue to occur and system stability will be compromised.