BCMS, List of Internal Errors

BCMS, LIST OF INTERNAL ERRORS

• asseAdd: DAC already used <dac>

The procedure to add an axis (internal procedure of program initialization) has verified
that an axis device (DAC) is already used by another axis.
cause: not valid machine configuration or corrupted .cfg files.

• asseAdd: ENC already used <enc>

The procedure to add an axis (internal procedure of program initialization) has verified
that an axis device (encoder) is already used by another axis
cause: not valid machine configuration or corrupted .cfg files

• Assertion failed: Bad id, file bfile.c line 1686 value 51 main task busy
During the writing on disk of an optimization BCMS has found in its internal structures a
cutting identifier '3' (character 51) instead of the usual 'X', 'Y' ...'A' ....'M' ... therefore it
has signaled an "internal error "

• Assertion failed: conta_blocchi_allocati==0, file LGRAPH.c, line 468 [value=1]

The warning message is displayed only leaving BCMS and once you have changed the
language; it neither signals nor causes problems and is shown only once, the first time
you exit from BCMS and go to the DOS Prompt.

• axe already stopped <axis>

Attempt to stop an already stopped axis
cause: internal debug warning, not serious

• axe too slow < axis >

Attempt to stop a too slow axis (speed < 1 [mm/s])
cause: internal debug warning, not serious

• azzDeltaPos <err> on axe < axis >

At the end of the zeroing it displays the value of the encoder count (that should be 0)
<err> position difference expressed in encoder impulses (1/100 mm for X and Y); < axis
>: 0==X, 1==Y ...
cause: it is normal if electronics is switched OFF between two resets.
It is anomalous in normal conditions: it could be caused by the wrong mounting of the
proximity switch, that resets the machine in different positions or by the wrong
detecting of the encoder (noises or fault)

• bad lastCutQuote
it warns that it is not possible to restore a cycle that has been previously stopped
because of an emergency as the point where the cut should be carried out does not
match with the saved cutting point.
cause: it is normal, ex. when you stop a cycle because of an emergency and in the
following cycle you cut according to a different cutting diagram.

• basc578Car tout <phase>

On 578 the timeout has been released during the displayed phase.

• basc578Car: found 95° before 85°

During the tilting movement 95° point has been found before 85°

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 Documentation Collection for Technicians

• belt not DOWN neither UP

cause: on 805 belts are neither UP nor DOWN

• Carriages free: lock grind carriage manually

On LMT the grinding wheel is in a condition impossible to be managed: it is not linked
to the carriage and not in zero position.
cause: you have operated manually on valves unlocking the carriage.

• Carriage not on slow position

X and Y axes have to be on the slow-down proximity switch for some calibration
operations.

• cicloSag: Z correction skipped <err [DEG]>

When starting the cut of a shape you have to correct the head position of an
anomalous value so you can avoid the correction.

• cncInit: bad CFG_TIPOTAV

The internal machine code has an unexpected value (as TIPOTAV_BASCUL,
TIPOTAV_578)
cause: corrupted .cfg files.

• conta_blocchi_allocati
Error displayed when leaving the program: it signals that some assigned memory blocks
have not been let free: it is not a serious error, as when you leave the program and go
to DOS the memory is however let free, but it signals the anomalous situation. It is
normal if it happens when you have chosen a language for the first time.

• … Contain arc
The warning message means that the ScanCAD of BCMS has not been able to carry out
the enlargement of the shape: till to 4.06 version of BCMS, it was possible to carry out
the shape enlargement only if the shape would not contain arcs (i.e. if it had not been
geometrized yet).

• Dac 2
The warning message means that the DAC (“digital analog converter”, that component
changing an input numerical reference value into a voltage output, in this case toward
the drive) of Z-axis (0 means X, 1 means Y and 2 means Z) has received a “command”
that it has not been able to carry out. This command is described in the following
message (message ”Dac value -9227”).

• Dac value –9227

The warning message, always following the a.m. one (message “Dac 2”) means that
the (“digital analog converter”, that component changing an input numerical reference
value into a voltage output, in this case toward the drive) of Z-axis (0 means X, 1
means Y and 2 means Z) has received a “command” usually in case of “non-
convergence”, to show as output a reference having –9227 value, while the range is –
2048 ÷ +2047 (zero included), corresponding to voltage reference values included in
the range–10 [V] ÷ +10 [V]. The program “cuts” the reference value at–2048 (the
max. admissible negative value) and warns the operator.

• Dangerous speed or ref: gap <ref>

ax=<axis> vel=<aver. speed> rif=<applied reference>
reference error between the applied value and the set value for the actual speed of the
axis.

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BCMS, List of Internal Errors

• domain square error

error detected by the mathematic library: communicate the sequence of operations that
has caused the anomaly.

• driver KO
Error shown together with the servo error, to understand if when the error occurred
drives were OK (therefore the error is due to external causes) or if they were in error
condition (therefore the error is due to a drive fault).

• etn_cold_init() error: missing ETN card

At program start BCMS has not found some of the peripheral boards.
causes: machine OFF or disconnection/malfunctioning of some boards.

• ETN err enc records <enc>

During the first communication with the encoders there has been an error during the
dialog with <enc> encoder.

• Err in confLabLoad(&cardsLab) <err>

During reading of the cards*.cfg file some errors occurred
as for all confLabLoad errors, the possible errors are:
>0 number of items not loaded from disk (labels not found)
-1 file not found
-2 the identification code (magic number) or the file version are wrong
-3 data read from.bak file
-4 data not complying with expiring limits
-5 in CONFLABGRP_MULTIPLE mode the program has detected a label having
index higher than the max. acceptable one (passed in gp->extData)
-7 label defined more than once

• Error adding axe <err>

Error occurred again when creating a new axis (internal procedure for program
initialization)
-1 no free spaces
-2 DAC or encoder already used by another axis

• Glass pusher outside

The electronics detects the glass pusher out of the table
causes: if the pusher is really out of the table, there are problems on pneumatic
equipment, if the glass pusher is not out of the table, there are problems on electrical
equipment (sensor that does not detect or burnt input)

• Glass too much rotated <deg>

During the test for calibration of 90°, pieces have to be laid with an angle lower than 2
degrees; being the angle higher, an error will be signaled and the angle value will be
displayed.

• HOMING: stop before ramp end <axis>

During the zeroing the axis has detected the signal of “axis stop” before ending the
slow-down ramp; < axis >: 0==X, 1==Y ...
cause: slow-down proximity switch too close to the stop one

• HOMING: stop before slow < axis >

During the zeroing the axis has detected the signal of “axis stop” while it was waiting
for the slow-down; < axis >: 0==X, 1==Y ...
causes: the slow-down proximity switch has been mounted wrong, it is out of
service or an input is burnt.

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 Documentation Collection for Technicians

• ioDecodeIoAddr: bad form <form>

During reading of io*.cfg file the input description is wrong

• ioLoadCards: card addr already used <addr>

one or more of the peripheral boards in cards.cfg file have the same address (in .cfg,
but not in reality).
cause: damaged file cards*.cfg

• ioRemInit: no cards data

The data of the present boards have not been loaded
cause: there is no cards.cfg file or it is damaged

• Main task busy

This error can be displayed during an automatic operation (as reading of an
optimization block at the beginning of the cycle) causing an error displayed through a
special window that you have to close to return to the sequence of operations that has
caused the anomaly.

• 1 mancate convergenze
The warning message means that the BCMS interpolator has not been able to manage
a too big speed change of the axis; this warning was displayed in the first versions of
Scan.
It does not occur anymore in the latest versions.

• manMain: unknown manSelectedOp <op>

Not foreseen manual operation

• Missing 3 vars on file cfg\bcms.cfg:

for any .cfg file, during reading a check of the presence of all foreseen fields is carried
out; when installing a more recent version of the program it is possible that it requires
fields that were not present in the former version, therefore, this message warns about
this situation, but missing files are automatically created with the default value valid for
the machine.
It must not occur again when restarting the program

• molaCarr: missing IN_CARR_TWIN

On the wheel there is no “twin-carriages” input.

• molaRotaz: grind driver KO

Driver for grinding wheel rotation KO

• movimStart: unused axle <axis>

Attempt to start the movement on a non-configured axis
cause: not valid machine configuration or corrupted .cfg files

• Multiscan buffer full: press B

During the shape scanner, the buffer of "shape starts" is full and it is not possible to
add any other shape; it is possible to start the scanning.

• Multiscan: points too near

During the shape scanner, you have given to points of shape start too close one
another.
cause: maybe you have pressed accidentally twice the shape start key.

• photScan: concave: no exit

During the shape scanner, the machine has found a concave zone; it tries to leave it
taking a step backward.

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BCMS, List of Internal Errors

• photScan: missing shape

During the shape scanner, the machine has not found glass (the point of shape start
you have given is too far from the shape).

• photScan: stop on glass

During the shape scanner, the shape start is already on the glass.

• photScan: shape too much acute concave

During the shape scanner, the machine has found a too concave zone (or a low-
contrast zone, therefore the photoelectric cell has gone on the material to scan) and
the program is no able to exit anymore. This happens when the master-shape has been
made on plywood (very difficult to scan) or of the photoelectric cell is dirty or
misaligned.

• photScan: shape too much acute convex

During the shape scanner, the machine has found a too convex zone (or a low-contrast
zone, therefore the photoelectric cell has gone on the material to scan) and the
program is no able to exit anymore. This happens when the master-shape has been
made on plywood (very difficult to scan) or of the photoelectric cell is dirty or
misaligned.

• photSquar: X can't find glass

Glass has not been detected during the search for the front squaring

• photSquar: Y can't exit glass

During the front squaring the glass is too far and the photoelectric cell could not leave
and engage the glass again.

• photSquar: Y2 stop on glass

The warning message (it is not an error) signals that, during the electronic squaring
cycle, BCMS has detected that, on the third squaring point (as you know, BCMS squares
once on the front and twice on the base, points called X1, Y1 and Y2) the photoelectric
cell was already on glass and it has had to leave it and to come on it again in order to
detect the sheet position; this operations makes the cycle slower, therefore BCMS
warns the operator; this usually happens when the sheet is inclined a lot with reference
to the theoretical zero line for squaring.

• Sag conv Join prof

The warning message signals that BCMS interpolator has not been able to manage the
join of two profiles as they were not tangent, that is typical in case of acute angles; this
warning was displayed in the first versions of Scan, it does not occur anymore in the
latest versions.

• scanEnd t=<secs>
It is displayed at the end of the shape scanning; it shows also the time taken for
scanning; e.g. “Scan end t=106” means that the shape Scan operation has taken 106
seconds, i.e. 1 minute and 46 seconds).

• scanStart
It is displayed at the start of every shape scanner cycle.

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 Documentation Collection for Technicians

• Servo error: X pt=0 pr=-565 e-535 rif=140 vr=-65

The warning message means that the X-axis has reached and is gone over the
tolerance limit of 5 [mm] (-535 hundredths of [mm] = 5.35 [mm]) during the
movement, therefore it has been considered “out of control” and stopped; pt means
“theoretical position” of the axis, expressed in encoder steps, therefore in 1/100 of
[mm]; pr means “effective position”, expressed in encoder steps, therefore in 1/100 of
[mm]; e means “error”, first error value expressed in encoder steps , therefore in 1/100
of [mm], error that has caused the machine stop; rif means “reference”, i.e. the value
of the digital reference applied to the axis in the precise moment at which the error has
happened and expressed in digits, with a range–2048 ÷ +2047 (including zero) and
corresponding to an analog reference value with a range –10 [V] ÷ +10 [V]; vr means
“effective speed”, detected in the moment at which the error causing the machine stop
has happened and expressed in 1/100 [mm] for 1/10 [sec].

• Servo warn 0 –119

The warning message means that X-axis (0 means X, 1 means Y and 2 means Z) has
reached and is gone over the tolerance limit of 1 [mm] (-119 hundredths of [mm] =
1.19 [mm]) during the movement; if it happens during a Scan, there is no reason to
worry, the control of axes during the Scan will be “softer”; the latest versions of the
program do not display the warning during the Scan anymore.
The maximum tolerance value is equal to:
100 on machines with standard performance (CC motors)
200 on machines with high performance levels (brushless motors)
The BCMS 4.39 has been modified in terms of servo warning message generation, the axis name
no longer consisting of 0, 1 , 2..., but X , Y , Z…
The error is given at the end of the movement and not at the moment that the threshold is
exceeded, so as to be able to display the maximum value reached; otherwise it always displays a
value near the threshold; now both the minimum and maximum values of this movement are
displayed, therefore if one is high and one is not it means that incorrect calibration has been
made, while if both are high it means that there is an axis weakness (delay on departure and
protracted on braking)

• Servo warn 1 –121:

The warning message means that X-axis (0 means X, 1 means Y and 2 means Z) has
reached and is gone over the tolerance limit of 1 [mm] (-121 hundredths of [mm] =
1.21 [mm]) during the movement; if it happens during a Scan, there is no reason to
worry, the control of axes during the Scan will be “softer”; the latest versions of the
program do not display the warning during the Scan anymore.
The maximum tolerance value is equivalent to:
100 on machines with standard performance (CC motors)
200 on machines with high performance levels (brushless motors)
The BCMS 4.39 has been modified in terms of servo warning message generation, the axis name
no longer consisting of 0, 1 , 2..., but X , Y , Z…
The error is given at the end of the movement and not at the moment that the threshold is
exceeded, so as to be able to display the maximum value reached; otherwise it always displays a
value near the threshold; now both the minimum and maximum values of this movement are
displayed, therefore if one is high and one is not it means that incorrect calibration has been
made, while if both are high it means that there is an axis weakness (delay on departure and
protracted on braking)

• Servo Warn 2 157

The warning message means that Z-axis (0 means X, 1 means Y and 2 means Z) has
reached and is gone over the tolerance limit of 100 steps during rotation;
cause: the previous error of “mancate convergenze”
The maximum tolerance value is equivalent to:
100 on machines with standard performance (CC motors)
50 on machines with high performance levels (brushless motors)
The BCMS 4.39 has been modified in terms of servo warning message generation, the axis name
no longer consisting of 0, 1 , 2..., but X , Y , Z…

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BCMS, List of Internal Errors

The error is given at the end of the movement and not at the moment that the threshold is
exceeded, so as to be able to display the maximum value reached; otherwise it always displays a
value near the threshold; now both the minimum and maximum values of this movement are
displayed, therefore if one is high and one is not it means that incorrect calibration has been
made, while if both are high it means that there is an axis weakness (delay on departure and
protracted on braking)

• sezCarico: Find belt STOP waiting slow

During the sheet load on the cutting table a stop has been found while waiting for slow-
down

• sezCarico: rise IN_BELT_STOP waiting homing

During the sheet load on the cutting table the sheet has reached the stop sensor before
the end of the bridge zeroing.

• Simultaneous cycle & unload

Cycle and unload command give at the same time.
cause: the two keys have been pressed at the same time or dangerous synchronism of
the PLC of the coupled machines.

• Timeout zeroing Z Slow down not found

During axis zeroing of axis Z the motor moves fast until the stop proximity is engaged, it escapes
and resumes engagement at slow speed (Slow down).
This message means that the axis is moving neither fast or slowly.
Cause: analogue card or activations off, out of order, or incorrectly calibrated; the encoder has
no effect as at that time the movement is made in a n open ring without any position check.

• too many axes <qty>

The internal structures of the program describe a too high number of axes.

• Transport quote too big <quote>

On the tilting table the transport has calculated a too high value.
cause: one of these parameters: “dimensione X lastra” (X size of the sheet),
“offLastraX” (offset X sheet) and ”distTassTraspInd” (distance of transport lugs
backwards) is wrong for the table size ( “dimXTavolo”).

• Unknown transp. config <bad value>

On the tilting table a not existing transport mode has been configured.
cause:. corrupted cfg. files

• Unload req without transp. config

The tilting table has received a transport request (input IN_CMD_UNLOAD) but the
program has not been configured to manage it (forward or backward transport).
cause: not valid machine configuration or corrupted .cfg files.

1.1 28 may 2002 Modified “Servo warning” and add “Timeout zeroing Z Slow down not found” by
Dalmasso Fulvio
1.0 July 18th , 2000 First issue of the document, adaptation of the original version of Bisotto by Boggia
Rev. n. Date Description of the modification
WRITTEN BY: APPROVED BY:
Name: Date: Signature: Name: Date: Signature:
Claudio Boggia 18/07/2000
…………………………

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