DINA SAFELINE VARIO User manual

SAFELINE VARIO
Diagnosis
Instruction Manual
dina.de
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DINA Elektronik GmbH
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72649 Wolfschlugen
Deutschland
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Handbook: Instruction manual
Target group: Electricians, electrical designers
Editor: DINAElektronik GmbH
File name: Slvario-diag-en-v0351.docx
Language: ENG
Publication as at: 5. October 2021

Instruction Manual SAFELINE VARIO Diagnostics 
Table of contents
Table of contents
1 Online-Diagnostics 6
1.1 Starting the Online Diagnostics 
1.2. Display of the symbols in the online diagnostics 
2 Rack-Diagnostics 11
2.1. Starting the Rack Diagnostics 
2.2. Diagnostics Buttons 
2.3. Read out Rack information 
2.3.1. Overview of possible representation types of modules 
2.4. Module Diagnostics 
2.4.1. Overview of possible module terminals representation 
2.4.2. Overview of LED display possibilities 
2.4.3. Overview of LED display possibilities to speed monitoring 
2.5. Status information 
2.5.1. Status information central module ZMV 
2.5.2. Latch for speed monitoring at ZMV 
2.5.3. Status information about timers 
2.5.4. Status information about counters 
2.5.5. Status information about safety mats 
2.5.6. Status information about copier 
2.5.7. Status information about cams 
2.5.8. Status information about synchronicity comparator 
2.5.9. Status information about analog-terminals 
2.5.10. Status Information about Analog-Input Comparator 
2.5.11. Status Information about Safe brake test 
2.5.12. Tables 
2.6. Status information for the speed monitoring modules 
2.6.1. Latch function 
2.7. Status information about Fieldbus Module FBV 
2.8. Status information about Input Module INV 
2.9. Status information about In/Output Module IOV 
2.10. Status information about module RMV 
2.11. Status information about network module NIV 
3 Error Diagnostics 35
3.1 Show detailed information 
4 History 38
4.1. Read out History 
4.2. Delete History 

Instruction Manual SAFELINE VARIO Diagnostics 
Table of contents
SL VARIO Diagnostics
Fast detecting of error and operating states
Product description
The graphical programming software SL VARIO Designer allows extensive diagnostics options. Status
information as well as set points and actual values of the SL VARIO-modules are captured and displayed
by the software.
The use of graphic elements makes it very easy to detect errors and to identify the operational states
of the SL VARIO-modules and errors can be quickly and effectively eliminated.
For the diagnosis the central module ZMK respectively ZMVK needs to be connected to the PC via the
USB port.There are two diagnostic options available:
In the online diagnostic conditions can be detected with an open application.
The rack diagnostics, the states can be read out to the connected modules without opening an application.

Instruction Manual SAFELINE VARIO Diagnostics 
1 Online-Diagnostics
1 Online-Diagnostics
In the online diagnosis the logic states of the application can be observed. The system status as
well as the requirements for a fault free operation can be retraced.
1.1 Starting the Online Diagnostics
3Open designer and link SL VARIO
to the computer with the USB interface.
3Open application, if necessary enter
password for authorization to use the
application. (Fig. 1-1)
Fig. 1-1
3Adjust interface in the menu
“transmission-interface” (Fig. 1-2),
see designer manual.
Fig. 1-2
3Select „DIAGN“ in the menu “logic”. (Fig. 1-3)
Fig. 1-3
The diagnostics is started and the actual states of the modules are displayed.
A color change of the button indicates the active diagnostics. (Fig. 1-4)
Fig. 1-4
During the diagnosis not all functions of the Designer are available.
Blocked functions are displyed in grey. (Fig. 1-5)
Fig. 1-5

Instruction Manual SAFELINE VARIO Diagnostics 
1 Online-Diagnostics
1.2. Display of the symbols in the online diagnostics
The states are displayed differently according to the configured symbol. (Fig. 1-6)
Fig. 1-6
This way at the speed monitoring both the parameterized target and the actual values are displayed.
The current value is always displayed at the time and counters. Setpoints and actual values are
also visible on all analog elements in the symbol.
The terminals on the inputs and outputs or safety circuits change color depending on whether the terminal
is connected or not connected or if an error is detected in this terminal.
In case an entire symbol turns orange, a fault is indicated, but does not necessarily
lead to SLOK OFF.
Errors can be dedected more specific by applying the rack diagnostics.
The color of the connecting lines indicates the high / low state of this connection.
Symbol Display Description
Input
(also for safety-related
functions)
Terminal grey = Input off
Terminal green = Input on
Terminal orange = error at the input,
e.g. clocked input is activated static
Output
Terminal grey = output off
Terminal green = output on

Instruction Manual SAFELINE VARIO Diagnostics 
1 Online-Diagnostics
Connection
The color of the connections
between the elements can
be set via the project options-
view options menu.
Connection not shifted
Connection shifted
speed monitoring
Upper value = setpoint
Lower value = actual value
Bei zweikanaliger Überwachung durch
Initiatoren werden jeweils die Werte
beider Kanäle angezeigt.
Operating mode MUTE and the function
“Muting without sensor monitoring” is
active.
Timer Current value (blue)
is indicated
Counter Upper value (black):
parameterized count value
Lower value (blue):
Current count value
Safe brake test Black: set parameter
Blue: current values
T1: Stabilization time
T2: Testing time
Step: Test step Timeout

Instruction Manual SAFELINE VARIO Diagnostics 
1 Online-Diagnostics
Comparator
Synchronous comparator
Black: set parameter
Blue: current or calculated frequencies
H: max. tolerance
L: min. tolerance
Safety mat
Current voltage value is displayed.
Terminal green:
safety mat shifts
Terminal red:
short circuit or wire break
Analog input
Upper values: parameterized limits
Upper value: current analog value
Terminal gray: analog value is outside
the configured limits.
Terminal green: analog value within
the configured limits.
Terminal red:short circuit or wire
break or voltage/current more than
13.5V / 25mA
Multiplexer Setpoint for Fx3
Setpoint for Fx2
Setpoint for Fx1
Setpoint for Standstill
according to DNCO table
and selected terminal
Green: Selected terminal

Instruction Manual SAFELINE VARIO Diagnostics 
1 Online-Diagnostics
Adder Black: set parameter
Blue: current analog values
Subtractor Black: set parameter
Blue: current analog values
Normalizer Black: set parameter
Blue: current analog values
Analog Input Comparator Black: set parameter
Blue: current analog values
Analog Output Black: set parameter
Blue: current analog values
ANA terminal changes from gray
to green when voltage is in the
configured range
Copier Q: analog value at the given source
Act: Copied value
Cam Blue: current values
ERR-MESS Blue: current values
of encoder 1 and 2

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2 Rack-Diagnostics
Besides the online diagnostics the Rack diagnostics is also available for the SL VARIO. A hardware
image of the application which is located on the central module will be reproduced. The operating
conditions of the respective modules and their details such as axis states, operating modes, safety
circuits, etc. can be detected.
2.1. Starting the Rack Diagnostics
3
Open designer and link SL VARIO
to the computer with the USB
interface.
3
Start a new application.
„File New“ (Fig. 2-1)
3
Adjust interface in the menu
“transmission-interface”
(Fig. 2-2), see designer manual.
3
Select „Rack diagnostics“
in the menu “logic”. (Fig. 2-3)
Fig. 2-1
Fig. 2-2
Fig. 2-3

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
The application is read out of the
central module. (Fig. 2-4)
Fig. 2-4
The status of the hardware specified in the application is displayed. . (Fig. 2-5)
The main menu is divided into 4 areas:
In Section 1 the diagnostic buttons are located. These open different diagnostic functions or start
or close a diagnostic. The functionality of the menu items is described more detailed in the chapter
“Diagnostics buttons“.
In Section 2 the real rack is simulated. Not used slots are displayed empty. More information to
this section in chapter “Read out Rack information”.
In Section 3 is located in the right corner of the window. The modules selected by the operater from
area 2 are shown here enlarged. For more information see chapter „Modul Diagnostics“.
In Section 4 status information selected modules related to area 3 are displayed. More information
in chapter “Status information“.
Fig. 2-5

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2.2. Diagnostics Buttons
The diagnosis buttons are selected or deselected using the left mouse button.
Only one function can be activated.
RACK READING
The first time you start the diagnostics specific data of the present
application is read once from SL VARIO. If the user changes the saved
SL VARIO application data or a new rack is connected to the diagnosis,
a new diagnostics has to be started by pressing this button so the dia-
gnosis information can be activated.
STANDARD  DIAGNOSIS
The standard diagnosis of SL VARIO is activated with this button and
disabled. Diagnostics and status information are read out.
TRIGGER DIAGNOSIS
This function is currently not yet implemented.
ERROR DIAGNOSIS
Clicking on this button takes the user to the error diagnostics window. In
this window all errors are listed in detail. This window is described in the
chapter “Error Diagnostics”.
HISTORY
After each SL VARIO programming, information as the programming
time, checksums, author, machine description on SL VARIO are per-
manently stored on SL VARIO as history points. A maximum of 16 history
points can be stored on SL VARIO. By clicking the History button, this
data is read and displayed. For more information, see Chapter “History”.
DIAGNOSTICS SELECTION FOR NO MODULE  ALL MODULES
By clicking this button, all modules located in the rack can be selected
or deselected for the diagnosis. Individual modules can be also selected
or deselected for diagnosis by right clicking on the module image in the
section 2. Thus, the update time can be increased for the diagnostics
data of selected modules.
2.3. Read out Rack information
Section 2 shows the entire rack, the states at the inputs and outputs of the SL VARIO modules
and fault states.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2.3.1. Overview of possible representation types of modules
No error
Module ok
A red highlighted central module signals a SLOK-OFF State, i.e. a faulty
operating state. In this connection, the slot number under the module is
red highlighted and the A1 terminal is shown in orange.
SLOK-OFF always requires a restart of the central module.
If only the slot number is red highlighted and the corresponding module
yellow, it indi-cates a plausibility error, however, does not necessarily lead
to a SLOK-OFF state. Error information of the modules can be accessed
by clicking on the red slot number. These errors are then displayed with
an error number and a brief description.
The module number is highlighted with a blue outline of the selected
diagnostic modules. In case a module number is not outlined means
this module is not selected for the diagnostics. For these modules, the
associated diagnostic information is not updated.
Modules that are configured in the application, but not present
in the rack as hardware (muting), are shown in gray.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2.4. Module Diagnostics
By left clicking on one of the modules in the rack (section 2), this specific module will appear in
section 3. The terminals and the LEDs of this module are shown here enlarged. The states are
constantly updated.
2.4.1. Overview of possible module terminals representation
A1 24V/DC
Only at ZMV and ZMVK
A1 Terminal orange: SLOK OFF
A1 Terminal green: SLOK
Digital inputs
Green complies with H-level
Grey complies with L-level
Reset input
A framed terminal symbolizes a digital input that has been
parameterized as a reset input.
Analog inputs
If the inputs of ZMV are used as analog inputs, the following applies:
• Green: if voltage / current within the configured range
• Grey: if voltage / current is outside the configured range
• Blinking: reading is 0V, wire breakage
Frequency inputs
If the inputs of the ZMV are used as analog inputs, terminals flash with
the applied frequency.
Digital inputs
Orange terminals indicate a functional error, e.g. Error on the safety
circuit sein.
In order to clear this error message the application must be provided
by the element RTSK.
Outputs
Green signal level corresponds to H-level
Gray corresponds to signal L-level
Flashing output terminal: Short circuit on output
Clocked output pairs are flashing.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2.4.2. Overview of LED display possibilities
• Green signal level corresponds to H-level
• Gray signal level corresponds to L-level
• Orange LEDs indicate a functional error, e.g.
Error on the safety circuit.
• Blinking of an input LED: Frequency input
• Blinking (with 2Hz) at LED output: transistor error
2.4.3. Overview of LED display possibilities to speed monitoring
At the SL VARIO modules that enable speed monitoring shows the mean row LED the status
standstill, speed ok or over speed. These states are also shown in the rack diagnostics.
DSV/DRV/SIV
ZMV/ZMVK
Speed monitoring with sin/cos, TTL/HTL
or resolver measuring systems
1 2 3 4
1if f<= parameterized standstill frequency at first monitoring
1if f> parameterized standstill frequency at first monitoring
2if f<= parameterized standstill frequency at second monitoring
2if f> parameterized standstill frequency at second monitoring
3if f<= parameterized speed frequency at first monitoring
3if f> parameterized speed frequency at first monitoring
4if f<= parameterized speed frequency at second monitoring
4if f> parameterized speed frequency at second monitoring
After shutdown
• LED for standstill switches on again if the actual frequency
< the parameterized frequency (at ZMV/ZMVK <4Hz).
• LED for over speed switches on if the actual frequency
< the parameterized frequency (at ZMV/ZMVK <4Hz)
and the acknowledgement has happened with RTDS.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
ZMV/ZMVK
One-channel sensor monitoring at ZMV/ZMVK
1 2 3 4
1if f<= parameterized speed frequency at I9
1if f> parameterized speed frequency at I9
2if f<= parameterized speed frequency at I10
2if f> parameterized speed frequency at I10
3if f<= parameterized speed frequency at I11
3if f> parameterized speed frequency at I11
4if f<= parameterized speed frequency at I12
4if f> parameterized speed frequency at I12
• After shutdown the LEDs switches on again, if the actual
frequency <4Hz and the acknowledgement has happened
with RTDS.
ZMV/ZMVK
Two-channel sensor monitoring at ZMV/ZMVK
1 2 3 4
1if f<= parameterized standstill frequency at I9/I10
1if f> parameterized standstill frequency at I9/I10
2if f<= parameterized standstill frequency at I11/I12
2if f> parameterized standstill frequency at I11/I12
3if f<= parameterized speed frequency at I9/I10
3if f> parameterized speed frequency at I9/I10
4if f<= parameterized speed frequency at I11/I12
4if f> parameterized speed frequency at I11/I12
After shutdown
• the LED for standstill switches on again if the actual frequency <4Hz)
• the LED for over speed switches on if the actual frequency <4Hz)
and the acknowledgement has happened with RTDS.
Mixed one-channel and two-channel sensor monitoring at ZMV/ZMVK
The LEDs for the two-channel monitoring switch as described above.
The LED for the both one-channel monitoring switches, if the conditions
for both single-channel monitoring are met.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
2.5. Status information
In section 4 the status information of a selected module in area 2 is displayed.
The image of the status information is module-dependent.
2.5.1. Status information central module ZMV
Status information ZMV
In the left panel, the following states are represented.
The boxes are checked, if the conditions are met.
SK1 - SK8 Conditions for safety circuit 1…. Safety circuit 8 is met.
ZH1 - ZH2 Conditions for two-hand control 1/2 are met.
MODS1 - MODS2 an output on the Operating mode selector (MODE SLCT) is set.
System OK SL VARIO is working properly.
IO1+IO2:CLK IO1 IO2 and are configured as clocked outputs.
IO3+IO4:CLK IO3 and IO4 are configured as clocked outputs.
RTDS Acknowledging of triggered Speed monitoring is due.
RTNI (S) Release for network input information is set.
RTNI (R) Release of network input information is reset.
RTSM Acknowledgment of the reclosing lockout at safety mats is due.
RTSK Acknowledgment of the safety circuit error message
and the latch error message is due.
RTFB Fieldbus outputs are activated.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
The upper area contains buttons. Left-click leads to further status information window.
Status information about timer, counters, safety mats, copiers, cams,
analog terminals, analog-input-comparator, safe braking test
see chapter “Information to…“
DNCO-Tables
See chapter „Tables“
The lower level contains information windows to hardware
Current and voltage at the terminals A1, O1 and O2 device temperature
The following additional area appears if the application contains the function speed monitoring.
(Fig. 2-6)
Fig. 2-6
SMx Configured speed monitoring. Selection with a left click.
The corresponding field is blue.
Initiators encoder type
Setpoint Programmed setpoint value of he selected mode
Actual current actual value
value
If the operating mode MT is selected, the observed target value for each speed module is defined
as infinite. In the display field for the corresponding setpoint the text appears „NO LIMIT“.
If "position monitoring" is activated, instead of the desired and actual frequencies, the incremental
values are displayed. In this case the term "ink" is displayed behind the numbers.

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
Following windows display the status of the speed monitoring SMx.
It applies for: recognized and acknowledged triggered off/ not recognized
Fxx, MTx operating mode
DZx Speed monitoring
SSx Standstill monitoring
BR Brake monitoring
L/R Left / right run
no encoder signals available
To access the trigger conditions press this button with the left mouse button.
For more information see “Latch for speed monitoring at ZMV/ZMVK“.
2.5.2. Latch for speed monitoring at ZMV
Shutdowns of speed monitoring can have various causes. The so-called latch function of the speed
monitoring in conjunction with the designer provides good diagnostic capabilities to determine the
causes of shutdowns. In case of a shutdown the state of the speed monitoring is latched or buffered
and can be displayed in the designer, as long as the power is not turned off and the latch function is
not acknowledged.
Press the button , following menu is displayed, "state of the speed control during
shutdown“(Fig. 2-7).
Monitoring via initiators Monitoring via TTL / HTL encoder
Fig. 2-7
setpoint Programmed setpoint value
actual value actual value at shut down
DZ1; SS1; BR Restores the state of the outputs at shut down.
F11-F13;MT1 Restores the state of the inputs at shut down.
L / R Describes the direction at shut down mode.
A PDF file will be created out of this data release

Instruction Manual SAFELINE VARIO Diagnostics 
2 Rack-Diagnostics
Possible causes of shut downs:
Exceeding the parameterized speed:
The shutdown frequency is displayed in the Latch window.
Exceeding the parameterized positions:
The position and increments are displayed in the Latch window.
Encoder error:
Caused by broken wire at one or more signals.
Sin/Cos = 0V:
Caused while sine and cosine differential voltages of <60mV.
This can for example arise by erected reading head of linear encoders.
Track comparison error:
The tracks Sin / Cos or A / B are monitored through 2 channels in the speed monitoring.
Two reasons, besides from internal hardware failure, can cause this error:
• At very different frequencies (> 20%) over a period of> 2.5 seconds.
• If a track stands still and the other track gives frequencies> 5x standstill frequency
about a time of > 2.5 seconds.
Both can be provoked by strong control behavior of the drive at a standstill.
Rectification: implement Standstill monitoring by position monitoring.
The standstill frequency has to be parameterized as high as possible corresponding
to about 1/6 of the reduced speed.
Error position comparison:
The increments of the tracks Sin / Cos or A / B are monitored through 2 channels at the position
monitoring. If the position deviates strongly from each other, it comes to a position comparison
error.
Cause, besides from internal hardware failure:
The control inputs F11, F12, F13, MT, etc. can be switched between frequency measurement and
position monitoring by increments if the position control is selected in the designer. If the control
inputs are all turned off, the position control is shifted.
In the event shifting to position monitoring happens when the drive is still running, an error on this
position comparison can occur, since the changeover will not be in perfect synchronized. The
application should ensure that the drive is at standstill, when switching to position control.
L/R-change >10kHz:
Only for position control possible. When direction changes faster than 10 kHz accordingly, the
error occurs. Have only been observed so far as internal hardware errors of the speed monitoring.
Sin+Cos unequal 1:
Only possible in SL VARIO DSV modules. If the option is selected in the designer and the Sin / Cos
signal is not equivalent to Sin + cos = 1, this error occurs, for example, on EMC problems.