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IndraDrive Trouble Shooting Guide


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Rexroth IndraDrive MPx02, MPx03, MPx0

4, MPx05 and HMV
Troubleshooting Guide

R911297319 Edition 04

Bosch Rexroth AG | Electric Drives and Controls

Rexroth IndraDrive | Troubleshooting Guide

Title

Rexroth IndraDrive MPx02, MPx03, MPx04, MPx05 and HMV

Type of Documentation Document Typecode Internal File Reference Purpose of Documentation

Troubleshooting Guide DOK-INDRV*-GEN--**VRS-WA04-EN-P RS-433860a81543c6250a6846a000de6594-1-en-US-11 This documentation contains the descriptions of all diagnostic messages im‐ plemented in the firmware for drive controllers and supply units of the IndraDrive range. It assists machine operators and installation programmers with trouble shoot‐ ing.

Record of Revision

Edition DOK-INDRV*-GEN-**VRS-WA01-EN-P DOK-INDRV*-GEN-**VRS-WA02-EN-P DOK-INDRV*-GEN-**VRS-WA03-EN-P

Release Date 2004-03-17 2004-11-26 2005-12-23

Notes First edition Also valid for MPx03 firmware Also valid for MPx04 firmware; 2005-07-27, 1st prototype documen‐ tation; 2005-11-30, 2nd prototype documentation Edition after code close for MPx05V12; also valid for MPx05 firmware

DOK-INDRV*-GEN-**VRS-WA04-EN-P

2007-10-05

Copyright

? 2007 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

Validity

The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availa‐ bility of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main Telephone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85 http://www.boschrexroth.com/ Dept. BRC/EDY1 (SA, BB)

Note

This document has been printed on chlorine-free bleached paper.

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Table of Contents

Table of Contents
Page

1
1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4

Introduction.................................................................................................................... 1
About This Documentation..................................................................................................................... 1 Reference Documentations.................................................................................................................... 2 Drive Systems, System Components.................................................................................................. 2 Motors.................................................................................................................................................. 2 Cables................................................................................................................................................. 2 Firmware.............................................................................................................................................. 2

2
2.1 2.1.1 2.1.2 2.2

Important Directions for Use ......................................................................................... 5
Appropriate Use ..................................................................................................................................... 5 Introduction.......................................................................................................................................... 5 Areas of Use and Application.............................................................................................................. 5 Inappropriate Use................................................................................................................................... 6

3
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8

Safety Instructions for Electric Drives and Controls....................................................... 7
Safety Instructions - General Information............................................................................................... 7 Using the Safety Instructions and Passing them on to Others............................................................ 7 How to Employ the Safety Instructions................................................................................................ 7 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 8 Hazards by Improper Use.................................................................................................................... 9 Instructions with Regard to Specific Dangers....................................................................................... 10 Protection Against Contact with Electrical Parts and Housings......................................................... 10 Protection Against Electric Shock by Protective Extra-Low Voltage................................................. 11 Protection Against Dangerous Movements....................................................................................... 11 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 14 Protection Against Contact with Hot Parts......................................................................................... 14 Protection During Handling and Mounting......................................................................................... 14 Battery Safety.................................................................................................................................... 15 Protection Against Pressurized Systems........................................................................................... 15

4
4.1 4.1.1

Basics on Device Diagnosis......................................................................................... 17
Diagnostic System................................................................................................................................ 17 Coded Diagnostic Messages of the Drive......................................................................................... 17 Brief Description............................................................................................................................. 17 Drive-Internal Generation of Diagnostic Messages........................................................................ 17 Structure of a Diagnostic Message................................................................................................. 18 Language Selection........................................................................................................................ 20 Status Classes, Status Displays, Control Parameters....................................................................... 20 General Information........................................................................................................................ 20 Status Classes................................................................................................................................ 20 Fixed Status Displays..................................................................................................................... 23 Control Parameters........................................................................................................................ 25 Control Panels of the IndraDrive Controllers........................................................................................ 25

4.1.2

4.2

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Bosch Rexroth AG | Electric Drives and Controls

Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 4.2.1 General Information on the Operation Options ................................................................................. 25 Variants of the Control Panels........................................................................................................ 25 Standard Control Panel.................................................................................................................. 26 Comfort Control Panel.................................................................................................................... 26 Independent VCP Operator Terminals........................................................................................... 27 Standard Control Panel..................................................................................................................... 27 Brief Description............................................................................................................................. 27 Functional Description.................................................................................................................... 28 Notes on Commissioning................................................................................................................ 40 Terms, Basic Principles........................................................................................................................ 40 Parameters........................................................................................................................................ 40 Data Storage and Parameter Handling............................................................................................. 40 Password........................................................................................................................................... 41 Commands........................................................................................................................................ 42 Operating Modes............................................................................................................................... 42 Warnings........................................................................................................................................... 43 Errors................................................................................................................................................. 43

4.2.2

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7

5
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27

Operating States.......................................................................................................... 45
General Information.............................................................................................................................. 45 Ab......................................................................................................................................................... 45 AC......................................................................................................................................................... 45 AE......................................................................................................................................................... 45 AF......................................................................................................................................................... 45 AH......................................................................................................................................................... 45 AR......................................................................................................................................................... 45 AS......................................................................................................................................................... 45 ASP....................................................................................................................................................... 45 AU......................................................................................................................................................... 45 bb.......................................................................................................................................................... 45 charg..................................................................................................................................................... 46 LB......................................................................................................................................................... 46 OM........................................................................................................................................................ 46 P0......................................................................................................................................................... 46 P-1........................................................................................................................................................ 46 P1......................................................................................................................................................... 46 P2......................................................................................................................................................... 46 P3......................................................................................................................................................... 46 PM........................................................................................................................................................ 46 PL......................................................................................................................................................... 46 RL......................................................................................................................................................... 46 SBB....................................................................................................................................................... 47 SBB1..................................................................................................................................................... 47 SBB2..................................................................................................................................................... 47 SBB3..................................................................................................................................................... 47 SBB4..................................................................................................................................................... 47

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Table of Contents Page 5.28 5.29 5.30 SBH...................................................................................................................................................... 47 SH......................................................................................................................................................... 47 ZKS....................................................................................................................................................... 47

6
6.1 6.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12

Diagnostic Messages When Booting the Devices....................................................... 49
Devices With Valid Firmware................................................................................................................ 49 Devices Without Valid Firmware........................................................................................................... 49 Error Messages When Booting the Devices......................................................................................... 50 PLC ? ................................................................................................................................................ 50 Stop PLC .......................................................................................................................................... 50 Run PLC ........................................................................................................................................... 50 Load New Safety ?............................................................................................................................ 50 No IDN on MMC !.............................................................................................................................. 50 Load Par from MMC.......................................................................................................................... 51 End C29 ............................................................................................................................................ 51 New MMC activate............................................................................................................................ 51 MMC not correct!............................................................................................................................... 51 IBF not correct!.................................................................................................................................. 52 Firmware update ?............................................................................................................................. 52 Update Error !.................................................................................................................................... 52

7
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23

Diagnostic Status Messages........................................................................................ 53
A0000 Communication phase 0............................................................................................................ 53 A0001 Communication phase 1............................................................................................................ 53 A0002 Communication phase 2............................................................................................................ 54 A0003 Communication phase 3............................................................................................................ 54 A0009 Automatic baud rate detection for SERCOS interface.............................................................. 55 A0010 Drive HALT................................................................................................................................ 56 A0011 Starting lockout active............................................................................................................... 56 A0012 Control and power sections ready for operation........................................................................ 56 A0013 Ready for power on................................................................................................................... 57 A0014 Drive interlock active................................................................................................................. 57 A0015 Safety related standstill active................................................................................................... 58 A0016 Safety related operational stop active....................................................................................... 58 A0017 Special mode motion active...................................................................................................... 59 A0018 Special mode motion 1 active................................................................................................... 60 A0019 Special mode motion 2 active................................................................................................... 61 A0020 Special mode motion 3 active................................................................................................... 62 A0021 Special mode motion 4 active................................................................................................... 63 A0050 Parameterization level 1 active................................................................................................. 64 A0051 Operating mode......................................................................................................................... 64 A0100 Torque control........................................................................................................................... 65 A0101 Velocity control.......................................................................................................................... 65 A0102 Position mode, encoder 1.......................................................................................................... 65 A0103 Position mode, encoder 2.......................................................................................................... 66

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Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 7.24 7.25 7.26 7.27 7.28 7.29 7.30 7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39 7.40 7.41 7.42 7.43 7.44 7.45 7.46 7.47 7.48 7.49 7.50 7.51 7.52 7.53 7.54 7.55 7.56 7.57 7.58 7.59 7.60 7.61 7.62 7.63 7.64 7.65 7.66 7.67 7.68 7.69 A0104 Position mode lagless, encoder 1............................................................................................. 66 A0105 Position mode lagless, encoder 2............................................................................................. 66 A0106 Drive controlled interpolation, encoder 1................................................................................... 67 A0107 Drive controlled interpolation, encoder 2................................................................................... 67 A0108 Drive controlled interpolation, lagless, encoder 1...................................................................... 68 A0109 Drive controlled interpolation, lagless, encoder 2...................................................................... 68 A0110 Velocity synchronization, virtual master axis............................................................................. 68 A0111 Velocity synchronization, real master axis................................................................................ 69 A0112 Phase synchronization, encoder 1, virtual master axis............................................................. 69 A0113 Phase synchronization, encoder 2, virtual master axis............................................................. 69 A0114 Phase synchronization, encoder 1, real master axis................................................................. 70 A0115 Phase synchronization, encoder 2, real master axis................................................................. 70 A0116 Phase synchr. lagless, encoder 1, virtual master axis.............................................................. 71 A0117 Phase synchr. lagless, encoder 2, virtual master axis.............................................................. 71 A0118 Phase synchr. lagless, encoder 1, real master axis.................................................................. 71 A0119 Phase synchr. lagless, encoder 2, real master axis.................................................................. 72 A0128 Cam shaft, encoder 1, virtual master axis................................................................................. 72 A0129 Cam shaft, encoder 2, virtual master axis................................................................................. 73 A0130 Cam shaft, encoder 1, real master axis..................................................................................... 73 A0131 Cam shaft, encoder 2, real master axis..................................................................................... 73 A0132 Cam shaft, lagless, encoder 1, virt. master axis........................................................................ 74 A0133 Cam shaft, lagless, encoder 2, virt. master axis........................................................................ 74 A0134 Cam shaft, lagless, encoder 1, real master axis....................................................................... 75 A0135 Cam shaft, lagless, encoder 2, real master axis....................................................................... 75 A0136 Motion profile, encoder 1, virtual master axis............................................................................ 76 A0137 Motion profile, encoder 2, virtual master axis............................................................................ 76 A0138 Motion profile, encoder 2, real master axis............................................................................... 76 A0139 Motion profile, encoder 1, real master axis............................................................................... 77 A0140 Motion profile lagless, encoder 1, virtual master axis................................................................ 77 A0141 Motion profile lagless, encoder 2, virtual master axis................................................................ 78 A0142 Motion profile lagless, encoder 1, real master axis................................................................... 78 A0143 Motion profile lagless, encoder 2, real master axis................................................................... 79 A0150 Drive-controlled positioning, encoder 1..................................................................................... 79 A0151 Drive-controlled positioning, encoder 1, lagless........................................................................ 80 A0152 Drive-controlled positioning, encoder 2..................................................................................... 80 A0153 Drive-controlled positioning, encoder 2, lagless........................................................................ 81 A0154 Position mode drive controlled, encoder 1................................................................................ 81 A0155 Position mode drive controlled, encoder 2................................................................................ 82 A0156 Position mode lagless, encoder 1 drive controlled.................................................................... 82 A0157 Position mode lagless, encoder 2 drive controlled.................................................................... 82 A0160 Position mode drive controlled.................................................................................................. 83 A0161 Drive-controlled positioning....................................................................................................... 83 A0162 Positioning block mode............................................................................................................. 84 A0163 Position synchronization............................................................................................................ 84 A0164 Velocity synchronization............................................................................................................ 85 A0206 Positioning block mode, encoder 1........................................................................................... 85

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Table of Contents Page 7.70 7.71 7.72 7.73 7.74 7.75 7.76 7.77 7.78 7.79 7.80 7.81 7.82 A0207 Positioning block mode lagless, encoder 1............................................................................... 85 A0210 Positioning block mode, encoder 2........................................................................................... 86 A0211 Positioning block mode lagless, encoder 2............................................................................... 86 A0403 Quick stop with probe detection is active.................................................................................. 86 A0500 Supply module in voltage control.............................................................................................. 87 A0502 Supply module in operation....................................................................................................... 87 A0503 DC bus charging active............................................................................................................. 88 A0520 DC bus quick discharge active.................................................................................................. 88 A0800 Unknown operating mode......................................................................................................... 88 A4000 Automatic drive check and adjustment...................................................................................... 89 A4001 Drive deceleration to standstill.................................................................................................. 89 A4002 Drive in automatic mode............................................................................................................ 90 A4003 Setting-up mode is active.......................................................................................................... 90

8
8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 8.2.15 8.2.16 8.2.17 8.2.18 8.2.19 8.2.20 8.2.21 8.2.22 8.2.23

Error Messages............................................................................................................ 91
Fatal System Errors (F9xxx and E-0000)............................................................................................. 91 Behavior in the Case of Fatal System Errors.................................................................................... 91 E-0000 Processor exception error..................................................................................................... 91 F9001 Error internal function call....................................................................................................... 92 F9002 Error internal RTOS function call............................................................................................ 93 F9003 Watchdog............................................................................................................................... 93 F9004 Hardware trap......................................................................................................................... 93 Fatal Errors (F8xxx).............................................................................................................................. 93 Behavior in the Case of Fatal Errors................................................................................................. 93 F8000 Fatal hardware error............................................................................................................... 94 F8010 Autom. commutation: max. motion range when moving back................................................ 95 F8011 Commutation offset could not be determined......................................................................... 96 F8012 Autom. commutation: max. motion range............................................................................... 96 F8013 Automatic commutation: current too low................................................................................ 97 F8014 Automatic commutation: overcurrent...................................................................................... 98 F8015 Automatic commutation: timeout............................................................................................ 98 F8016 Automatic commutation: iteration without result..................................................................... 99 F8017 Automatic commutation: incorrect commutation adjust.......................................................... 99 F8022 Enc. 1: enc. signals incorr. (can be cleared in ph. 2)........................................................... 100 F8023 Error mechanical link of encoder or motor connection......................................................... 101 F8025 Overvoltage in power section............................................................................................... 101 F8027 Safety related standstill while drive enabled........................................................................ 102 F8028 Overcurrent in power section............................................................................................... 102 F8042 Encoder 2 error: signal amplitude incorrect.......................................................................... 103 F8057 Device overload shutdown................................................................................................... 103 F8060 Overcurrent in power section............................................................................................... 104 F8064 Interruption of motor phase.................................................................................................. 104 F8067 Synchronization PWM-Timer wrong..................................................................................... 105 F8069 +/-15Volt DC error................................................................................................................ 106 F8070 +24Volt DC error.................................................................................................................. 106 F8076 Error in error angle loop....................................................................................................... 107

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Bosch Rexroth AG | Electric Drives and Controls

Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 8.2.24 8.2.25 8.2.26 8.2.27 8.2.28 8.2.29 8.2.30 8.2.31 8.2.32 8.2.33 8.2.34 8.2.35 8.2.36 8.2.37 8.2.38 8.2.39 8.2.40 8.2.41 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 8.3.13 8.3.14 8.3.15 8.3.16 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 8.4.8 8.4.9 8.4.10 F8078 Speed loop error................................................................................................................... 107 F8079 Velocity limit value exceeded............................................................................................... 108 F8091 Power section defective....................................................................................................... 108 F8100 Error when initializing the parameter handling..................................................................... 109 F8102 Error when initializing power section.................................................................................... 110 F8118 Invalid power section/firmware combination......................................................................... 110 F8120 Invalid control section/firmware combination........................................................................ 111 F8122 Control section defective...................................................................................................... 111 F8129 Incorrect optional module firmware...................................................................................... 111 F8130 Firmware of option 2 of safety technology defective............................................................ 112 F8133 Error when checking interrupting circuits............................................................................. 112 F8134 Safety related holding system: fatal error............................................................................. 113 F8135 Velocity exceeded with trend monitoring.............................................................................. 114 F8140 Fatal CCD error.................................................................................................................... 114 F8201 Safety command for basic initialization incorrect................................................................. 114 F8203 Safety technology configuration parameter invalid............................................................... 115 F8813 Connection error mains choke............................................................................................. 116 F8838 Overcurrent external braking resistor................................................................................... 117 Safety Technology Errors (F7xxx)...................................................................................................... 117 Behavior in the Case of Safety Technology Errors.......................................................................... 117 F7010 Safety related limited increment exceeded.......................................................................... 118 F7011 Safety rel. position limit val., exc. in pos. dir......................................................................... 119 F7012 Safety rel. position limit val., exc. in neg. dir........................................................................ 119 F7013 Velocity threshold exceeded................................................................................................ 120 F7014 Acceleration threshold exceeded......................................................................................... 120 F7020 Safety related maximum speed exceeded........................................................................... 121 F7021 Safety related end position exceeded.................................................................................. 121 F7030 Pos. window for safety rel. operational stop exceeded........................................................ 122 F7031 Incorrect direction of motion................................................................................................. 122 F7040 Validation error parameterized - effective threshold............................................................. 123 F7041 Actual position value validation error.................................................................................... 124 F7042 Validation error of safety related operating mode................................................................ 124 F7043 Error of output stage interlock.............................................................................................. 125 F7050 Time for stopping process exceeded................................................................................... 125 F7051 Safety related deceleration exceeded.................................................................................. 126 Travel Range Errors (F6xxx).............................................................................................................. 127 Behavior in the Case of Travel Range Errors.................................................................................. 127 F6010 PLC Runtime Error............................................................................................................... 128 F6024 Maximum braking time exceeded......................................................................................... 129 F6028 Position limit value exceeded (overflow).............................................................................. 130 F6029 Positive travel limit exceeded............................................................................................... 130 F6030 Negative travel limit exceeded............................................................................................. 131 F6034 Emergency-Stop................................................................................................................... 132 F6042 Both travel range limit switches activated............................................................................ 133 F6043 Positive travel range limit switch activated........................................................................... 133 F6044 Negative travel range limit switch activated......................................................................... 134

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Table of Contents Page 8.4.11 8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8 8.5.9 8.5.10 8.5.11 8.5.12 8.5.13 8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.6.7 8.6.8 8.6.9 8.6.10 8.6.11 8.6.12 8.6.13 8.6.14 8.6.15 8.6.16 8.6.17 8.6.18 8.6.19 8.6.20 8.6.21 8.6.22 8.6.23 8.6.24 8.6.25 8.7 8.7.1 8.7.2 8.7.3 8.7.4 F6140 CCD slave error (emergency halt)........................................................................................ 135 Interface Errors (F4xxx)...................................................................................................................... 135 Behavior in the Case of Interface Errors ........................................................................................ 135 F4001 Sync telegram failure............................................................................................................ 136 F4002 RTD telegram failure............................................................................................................ 137 F4003 Invalid communication phase shutdown............................................................................... 138 F4004 Error during phase progression............................................................................................ 138 F4005 Error during phase regression.............................................................................................. 138 F4006 Phase switching without ready signal................................................................................... 139 F4009 Bus failure............................................................................................................................ 139 F4012 Incorrect I/O length............................................................................................................... 141 F4016 PLC double real-time channel failure................................................................................... 141 F4017 S-III: incorrect sequence during phase switch...................................................................... 141 F4034 Emergency-Stop................................................................................................................... 142 F4140 CCD communication error.................................................................................................... 143 Non-Fatal Safety Technology Errors (F3xxx)..................................................................................... 143 Behavior in the Case of Non-Fatal Safety Technology Errors......................................................... 143 F3111 Refer. missing when selecting safety related end pos......................................................... 144 F3112 Safety related reference missing.......................................................................................... 144 F3115 Error, brake check time interval exceeded........................................................................... 145 F3117 Actual position values validation error.................................................................................. 146 F3122 Safety related holding system: system error........................................................................ 147 F3123 Safety related holding system: brake check missing............................................................ 148 F3130 Error when checking input signals........................................................................................ 148 F3131 Error when checking acknowledgment signal...................................................................... 149 F3132 Error when checking diagnostic output signal...................................................................... 150 F3133 Error when checking interrupting circuits............................................................................. 151 F3134 Dynamization time interval incorrect.................................................................................... 152 F3135 Dynamization pulse width incorrect...................................................................................... 153 F3140 Safety parameters validation error....................................................................................... 156 F3141 Selection validation error...................................................................................................... 156 F3142 Activation time of enabling control exceeded....................................................................... 157 F3143 Safety command for clearing errors incorrect...................................................................... 158 F3144 Incorrect safety configuration............................................................................................... 159 F3145 Error when unlocking the safety door................................................................................... 160 F3146 System error channel 2........................................................................................................ 161 F3147 System error channel 1........................................................................................................ 161 F3150 Safety command for system start incorrect.......................................................................... 162 F3151 Safety command for system halt incorrect........................................................................... 163 F3152 Incorrect backup of safety technology data.......................................................................... 164 F3160 Safety bus communication error........................................................................................... 165 Non-Fatal Errors (F2xxx).................................................................................................................... 165 Behavior in the Case of Non-Fatal Errors........................................................................................ 165 F2003 Motion step skipped............................................................................................................. 165 F2004 Error in motion profile........................................................................................................... 166 F2005 Cam shaft invalid.................................................................................................................. 167

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Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 8.7.5 8.7.6 8.7.7 8.7.8 8.7.9 8.7.10 8.7.11 8.7.12 8.7.13 8.7.14 8.7.15 8.7.16 8.7.17 8.7.18 8.7.19 8.7.20 8.7.21 8.7.22 8.7.23 8.7.24 8.7.25 8.7.26 8.7.27 8.7.28 8.7.29 8.7.30 8.7.31 8.7.32 8.7.33 8.7.34 8.7.35 8.7.36 8.7.37 8.7.38 8.7.39 8.7.40 8.7.41 8.7.42 8.7.43 8.7.44 8.7.45 8.7.46 8.7.47 8.7.48 8.7.49 8.7.50 F2006 MMC was removed.............................................................................................................. 168 F2007 Switching to non-initialized operating mode......................................................................... 168 F2008 RL The motor type has changed.......................................................................................... 169 F2009 PL Load parameter default values....................................................................................... 170 F2010 Error when initializing digital I/O (-> S-0-0423)..................................................................... 171 F2011 PLC - Error nr. 1................................................................................................................... 171 F2012 PLC - Error nr. 2................................................................................................................... 172 F2013 PLC - Error nr. 3................................................................................................................... 172 F2014 PLC - Error nr. 4................................................................................................................... 172 F2018 Device overtemperature shutdown....................................................................................... 173 F2019 Motor overtemperature shutdown........................................................................................ 174 F2021 Motor temperature monitor defective................................................................................... 174 F2022 Device temperature monitor defective.................................................................................. 175 F2025 Drive not ready for Control................................................................................................... 175 F2026 Undervoltage in power section............................................................................................. 176 F2027 Excessive oscillation in DC bus............................................................................................ 176 F2028 Excessive deviation.............................................................................................................. 177 F2031 Encoder 1 error: signal amplitude incorrect.......................................................................... 177 F2032 Validation error during commutation fine adjust................................................................... 178 F2033 External power supply X10 error.......................................................................................... 179 F2036 Excessive position feedback difference............................................................................... 179 F2037 Excessive position command difference.............................................................................. 180 F2039 Maximum acceleration exceeded......................................................................................... 181 F2040 Device overtemperature 2 shutdown.................................................................................... 181 F2042 Encoder 2: encoder signals incorrect................................................................................... 182 F2043 Measuring encoder: encoder signals incorrect..................................................................... 183 F2044 External power supply X15 error.......................................................................................... 183 F2048 Low battery voltage.............................................................................................................. 184 F2050 Overflow of target position preset memory........................................................................... 185 F2051 No sequential block in target position preset memory.......................................................... 185 F2053 Incr. encoder emulator: pulse frequency too high................................................................ 186 F2054 Incr. encoder emulator: hardware fault................................................................................. 186 F2055 External power supply X31/X32 error................................................................................... 187 F2057 Target position out of travel range........................................................................................ 187 F2058 Internal overflow by positioning input................................................................................... 188 F2059 Incorrect command value direction when positioning........................................................... 189 F2063 Internal overflow master axis generator............................................................................... 190 F2064 Incorrect cmd value direction master axis generator............................................................ 190 F2067 Synchronization to master communication incorrect............................................................ 191 F2069 Error when releasing the motor holding brake..................................................................... 191 F2074 Actual pos. value 1 outside absolute encoder window......................................................... 192 F2075 Actual pos. value 2 outside absolute encoder window......................................................... 193 F2076 Actual pos. value 3 outside absolute encoder window......................................................... 194 F2077 Current measurement trim wrong......................................................................................... 194 F2086 Error supply module............................................................................................................. 195 F2087 Module group communication error...................................................................................... 195

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Table of Contents Page 8.7.51 8.7.52 8.7.53 8.7.54 8.7.55 8.7.56 8.7.57 8.7.58 8.7.59 8.7.60 8.7.61 8.7.62 8.7.63 8.7.64 8.7.65 8.7.66 8.7.67 8.7.68 8.7.69 8.7.70 8.7.71 8.7.72 8.7.73 8.7.74 8.7.75 8.7.76 8.7.77 8.7.78 8.7.79 8.7.80 8.7.81 8.7.82 8.7.83 8.7.84 8.7.85 8.7.86 8.7.87 8.7.88 8.7.89 8.7.90 8.7.91 8.7.92 8.7.93 8.7.94 8.8 F2100 Incorrect access to command value memory....................................................................... 196 F2101 It was impossible to address MMC....................................................................................... 196 F2102 It was impossible to address I2C memory............................................................................ 197 F2103 It was impossible to address EnDat memory....................................................................... 197 F2104 Commutation offset invalid................................................................................................... 198 F2105 It was impossible to address Hiperface memory.................................................................. 198 F2110 Error in non-cyclical data communic. of power section........................................................ 199 F2120 MMC: defective or missing, replace..................................................................................... 199 F2121 MMC: incorrect data or file, create correctly......................................................................... 200 F2122 MMC: incorrect IBF file, correct it......................................................................................... 201 F2123 Retain data backup impossible............................................................................................ 201 F2124 MMC: saving too slowly, replace.......................................................................................... 202 F2130 Error comfort control panel................................................................................................... 202 F2140 CCD slave error.................................................................................................................... 203 F2150 MLD motion function block error.......................................................................................... 203 F2174 Loss of motor encoder reference......................................................................................... 204 F2175 Loss of optional encoder reference...................................................................................... 205 F2176 Loss of measuring encoder reference.................................................................................. 205 F2177 Modulo limitation error of motor encoder.............................................................................. 206 F2178 Modulo limitation error of optional encoder.......................................................................... 206 F2179 Modulo limitation error of measuring encoder...................................................................... 207 F2190 Incorrect Ethernet configuration........................................................................................... 207 F2260 Command current limit shutoff............................................................................................. 208 F2270 Analog input 1 or 2, wire break............................................................................................. 209 F2802 PLL is not synchronized....................................................................................................... 209 F2814 Undervoltage in mains.......................................................................................................... 210 F2815 Overvoltage in mains............................................................................................................ 210 F2816 Softstart fault power supply unit........................................................................................... 210 F2817 Overvoltage in power section............................................................................................... 211 F2818 Phase failure........................................................................................................................ 212 F2819 Mains failure......................................................................................................................... 212 F2820 Braking resistor overload...................................................................................................... 213 F2821 Error in control of braking resistor........................................................................................ 214 F2825 Switch-on threshold braking resistor too low........................................................................ 214 F2833 Ground fault in motor line..................................................................................................... 215 F2834 Contactor control error......................................................................................................... 215 F2835 Mains contactor wiring error................................................................................................. 216 F2836 DC bus balancing monitor error........................................................................................... 216 F2837 Contactor monitoring error................................................................................................... 216 F2840 Error supply shutdown.......................................................................................................... 217 F2860 Overcurrent in mains-side power section............................................................................. 218 F2890 Invalid device code............................................................................................................... 218 F2891 Incorrect interrupt timing....................................................................................................... 218 F2892 Hardware variant not supported........................................................................................... 219 SERCOS Error Codes / Error Messages of Serial Communication.................................................... 219

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Table of Contents Page

9
9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 9.1.8 9.1.9 9.1.10 9.1.11 9.1.12 9.1.13 9.1.14 9.1.15 9.1.16 9.1.17 9.1.18 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.2.9 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.3.10 9.3.11 9.4 9.4.1 9.4.2 9.4.3

Warnings (Exxxx)....................................................................................................... 221
Fatal Warnings (E8xxx)...................................................................................................................... 221 E8025 Overvoltage in power section............................................................................................... 221 E8026 Undervoltage in power section............................................................................................. 221 E8027 Safety related standstill while drive enabled........................................................................ 222 E8028 Overcurrent in power section............................................................................................... 222 E8029 Positive position limit exceeded........................................................................................... 223 E8030 Negative position limit exceeded.......................................................................................... 224 E8034 Emergency-Stop.................................................................................................................. 225 E8035 Quick stop with probe detection is active............................................................................. 225 E8040 Torque/force actual value limit active................................................................................... 226 E8041 Current limit active............................................................................................................... 226 E8042 Both travel range limit switches activated............................................................................ 227 E8043 Positive travel range limit switch activated........................................................................... 227 E8044 Negative travel range limit switch activated......................................................................... 228 E8055 Motor overload, current limit active...................................................................................... 229 E8057 Device overload, current limit active.................................................................................... 229 E8058 Drive system not ready for operation................................................................................... 230 E8260 Torque/force command value limit active............................................................................. 231 E8819 Mains failure......................................................................................................................... 232 Warnings of Category E4xxx.............................................................................................................. 232 E4001 Double MST failure shutdown.............................................................................................. 232 E4002 Double MDT failure shutdown.............................................................................................. 233 E4005 Command value input impossible via master communication............................................. 234 E4008 Invalid addressing command value data container A........................................................... 235 E4009 Invalid addressing actual value data container A................................................................. 235 E4010 Slave not scanned or address 0........................................................................................... 235 E4012 Maximum number of CCD slaves exceeded........................................................................ 236 E4013 Incorrect CCD addressing.................................................................................................... 236 E4014 Incorrect phase switch of CCD slaves................................................................................. 237 Possible Warnings When Operating Safety Technology (E3xxx)....................................................... 238 Behavior in Case a Safety Technology Warning Occurs................................................................. 238 E3100 Error when checking input signals....................................................................................... 238 E3101 Error when checking acknowledgment signal...................................................................... 239 E3102 Actual position values validation error.................................................................................. 239 E3103 Dynamization failed.............................................................................................................. 240 E3104 Safety parameters validation error....................................................................................... 240 E3105 Validation error of safety related operating mode................................................................ 241 E3106 System error safety technology............................................................................................ 241 E3107 Safety related reference missing.......................................................................................... 242 E3110 Time interval of forced dynamization exceeded................................................................... 243 E3115 Prewarning, end of brake check time interval...................................................................... 243 Non-Fatal Warnings (E2xxx)............................................................................................................... 244 E2010 Position control with encoder 2 not possible........................................................................ 244 E2011 PLC - Warning no. 1............................................................................................................. 244 E2012 PLC - Warning no. 2............................................................................................................. 244

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Table of Contents Page 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.4.10 9.4.11 9.4.12 9.4.13 9.4.14 9.4.15 9.4.16 9.4.17 9.4.18 9.4.19 9.4.20 9.4.21 9.4.22 9.4.23 9.4.24 9.4.25 9.4.26 9.4.27 9.4.28 9.4.29 9.4.30 9.4.31 9.4.32 9.4.33 9.4.34 9.4.35 9.4.36 9.4.37 9.4.38 9.4.39 9.4.40 9.4.41 9.4.42 9.4.43 9.4.44 E2013 PLC - Warning no. 3............................................................................................................. 245 E2014 PLC - Warning no. 4............................................................................................................. 245 E2021 Motor temperature outside of measuring range................................................................... 245 E2026 Undervoltage in power section............................................................................................. 246 E2040 Device overtemperature 2 prewarning................................................................................. 247 E2047 Interpolation velocity = 0...................................................................................................... 247 E2048 Interpolation acceleration = 0............................................................................................... 248 E2049 Positioning velocity >= limit value........................................................................................ 249 E2050 Device overtemp. Prewarning.............................................................................................. 250 E2051 Motor overtemp. prewarning................................................................................................ 251 E2053 Target position out of travel range....................................................................................... 251 E2054 Not homed............................................................................................................................ 253 E2055 Feedrate override S-0-0108 = 0........................................................................................... 253 E2056 Torque limit = 0.................................................................................................................... 254 E2058 Selected process block is not programmed......................................................................... 255 E2059 Velocity command value limit active.................................................................................... 255 E2061 Device overload prewarning................................................................................................. 256 E2063 Velocity command value > limit value.................................................................................. 257 E2064 Target position out of num. range........................................................................................ 258 E2069 Brake torque too low............................................................................................................ 258 E2070 Acceleration limit active........................................................................................................ 259 E2074 Encoder 1: encoder signals disturbed.................................................................................. 260 E2075 Encoder 2: encoder signals disturbed.................................................................................. 260 E2076 Measuring encoder: encoder signals disturbed................................................................... 261 E2077 Absolute encoder monitoring, motor encoder (encoder alarm)............................................ 262 E2078 Absolute encoder monitoring, opt. encoder (encoder alarm)............................................... 262 E2079 Absolute enc. monitoring, measuring encoder (encoder alarm).......................................... 263 E2086 Prewarning supply module overload.................................................................................... 263 E2092 Internal synchronization defective........................................................................................ 264 E2100 Positioning velocity of master axis generator too high......................................................... 264 E2101 Acceleration of master axis generator is zero...................................................................... 265 E2140 CCD error at node................................................................................................................ 265 E2270 Analog input 1 or 2, wire break............................................................................................ 265 E2802 HW control of braking resistor.............................................................................................. 266 E2810 Drive system not ready for operation................................................................................... 267 E2814 Undervoltage in mains......................................................................................................... 267 E2816 Undervoltage in power section............................................................................................. 268 E2818 Phase failure........................................................................................................................ 268 E2819 Mains failure......................................................................................................................... 269 E2820 Braking resistor overload prewarning................................................................................... 269 E2829 Not ready for power on......................................................................................................... 270

10
10.1 10.1.1 10.1.2

Diagnostic Command Messages............................................................................... 271
Commands......................................................................................................................................... 271 C0100 Communication phase 3 transition check............................................................................ 271 C0200 Exit parameterization level procedure command................................................................. 271

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Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8 10.1.9 10.1.10 10.1.11 10.1.12 10.1.13 10.1.14 10.1.15 10.1.16 10.1.17 10.1.18 10.1.19 10.1.20 10.1.21 10.1.22 10.1.23 10.1.24 10.1.25 10.1.26 10.1.27 10.1.28 10.1.29 10.1.30 10.1.31 10.1.32 10.1.33 10.1.34 10.1.35 10.1.36 10.1.37 10.1.38 10.1.39 10.1.40 10.1.41 10.1.42 10.1.43 10.1.44 10.1.45 10.1.46 10.1.47 10.1.48 C0300 Command Set absolute measuring...................................................................................... 271 C0400 Activate parameterization level 1 procedure command....................................................... 272 C0500 Reset class 1 diagnostics, error reset.................................................................................. 272 C0600 Drive-controlled homing procedure command..................................................................... 272 C0700 Load defaults procedure com. (load controller param.)....................................................... 273 C0720 Load def. proc. com. (load def. pr. for safety techn.)........................................................... 274 C0730 Load def. proc. com. (load defaults procedure for PLC)...................................................... 274 C0750 Load defaults procedure com. (load basic parameters)....................................................... 275 C0800 Load basic parameters command........................................................................................ 275 C0900 Position spindle command................................................................................................... 276 C1200 Commutation offset setting command................................................................................. 276 C1300 Positive stop drive procedure command.............................................................................. 276 C1400 Command Get marker position............................................................................................ 277 C1500 Cancel reference point procedure command....................................................................... 277 C1600 Parking axis command......................................................................................................... 277 C1700 Command measuring wheel mode...................................................................................... 277 C1800 Command automatic control loop setting............................................................................. 278 C2000 Command Release motor holding brake............................................................................. 278 C2100 Brake check command........................................................................................................ 279 C2200 Backup working memory procedure command.................................................................... 279 C2300 Load working memory command......................................................................................... 279 C2400 Selectively backup working memory procedure command.................................................. 280 C2500 Copy IDN from optional memory to internal memory........................................................... 280 C2600 Copy IDN from internal memory to optional memory........................................................... 280 C2800 Analog input adjust command.............................................................................................. 281 C2900 Command Firmware update from MMC............................................................................... 282 C3000 Synchronize and store safety technology IDN..................................................................... 282 C3100 Recalculate actual value cycle............................................................................................. 282 C3200 Command Calculate motor data.......................................................................................... 283 C3300 Set coordinate system procedure command....................................................................... 283 C3400 Shift coordinate system procedure command...................................................................... 283 C3500 Command Determine encoder correction values................................................................. 284 C3600 Command Motor data identification..................................................................................... 284 C3700 Manually unlocking the safety door...................................................................................... 284 C3800 Command Apply motor holding brake.................................................................................. 285 C3900 Command Abrasion of brake............................................................................................... 285 C4000 Homing procedure command channel 2.............................................................................. 285 C4100 Switch parameter set command.......................................................................................... 286 C4200 Drive-controlled oscillation command.................................................................................. 286 C4300 NC-controlled homing procedure command........................................................................ 286 C4400 Calculate displacement procedure command...................................................................... 287 C4500 Displacement to referenced system procedure command................................................... 287 C4600 Command Calculate motor control parameters................................................................... 287 C4700 Command Activate easy startup mode................................................................................ 288 C4900 PLC command..................................................................................................................... 288 C5200 Communication phase 4 transition check............................................................................ 288

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Table of Contents Page 10.1.49 C5400 Command Save PLC retain data on MMC........................................................................... 288 10.1.50 C5500 Command Load PLC retain data from MMC........................................................................ 289 10.1.51 C5600 Command subsequent optimization of commutation offset................................................. 289 10.1.52 C6000 Command Set absolute measuring...................................................................................... 290 10.1.53 C6100 Command Activate IP settings............................................................................................. 290 10.1.54 C7000 CCD: command adjust slave addresses.............................................................................. 291 10.2 Command Errors................................................................................................................................ 291 10.2.1 Clearing Command Errors............................................................................................................... 291 10.2.2 C0101 Invalid parameters (-> S-0-0021)......................................................................................... 291 10.2.3 C0102 Limit error in parameter (-> S-0-0021)................................................................................. 292 10.2.4 C0103 Parameter conversion error (->S-0-0021)............................................................................ 292 10.2.5 C0104 Config. IDN for MDT not configurable.................................................................................. 293 10.2.6 C0105 Maximum length for MDT exceeded.................................................................................... 293 10.2.7 C0106 Config. IDNs for AT not configurable................................................................................... 294 10.2.8 C0107 Maximum length for AT exceeded....................................................................................... 294 10.2.9 C0108 Time slot parameter > Sercos cycle time............................................................................. 295 10.2.10 C0109 Position of data record in MDT (S-0-0009) even................................................................. 295 10.2.11 C0110 Length of MDT (S-0-0010) odd............................................................................................ 296 10.2.12 C0111 ID9 + Record length - 1 > length MDT (S-0-0010)............................................................... 296 10.2.13 C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error....................................................................... 296 10.2.14 C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error......................................................... 297 10.2.15 C0114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)......................................................................... 298 10.2.16 C0115 T2 too small......................................................................................................................... 298 10.2.17 C0116 T3 (S-0-0008) within MDT (S-0-0089 + S-0-0010)............................................................... 299 10.2.18 C0118 Order of cyclic command value configuration incorrect....................................................... 299 10.2.19 C0119 Max. travel range too large.................................................................................................. 300 10.2.20 C0120 Error when reading encoder data => motor encoder........................................................... 300 10.2.21 C0121 Incorrect parameterization of motor encoder (hardware)..................................................... 301 10.2.22 C0122 Incorr. parameteriz. of motor enc. (mechanical system)...................................................... 301 10.2.23 C0123 Modulo value for motor encoder cannot be displayed......................................................... 301 10.2.24 C0124 Motor encoder unknown...................................................................................................... 302 10.2.25 C0125 Error when reading encoder data => optional encoder........................................................ 303 10.2.26 C0126 Incorrect parameterization of optional enc. (hardware)....................................................... 303 10.2.27 C0127 Incorr. parameteriz. of opt. enc. (mechanical system)......................................................... 304 10.2.28 C0128 Modulo value for optional encoder cannot be displayed...................................................... 304 10.2.29 C0129 Optional encoder unknown.................................................................................................. 305 10.2.30 C0130 Maximum travel range cannot be displayed internally......................................................... 305 10.2.31 C0131 Switching to phase 3 impossible.......................................................................................... 306 10.2.32 C0132 Invalid settings for controller cycle times............................................................................. 306 10.2.33 C0134 Invalid motor data in encoder memory (->S-0-0021)........................................................... 307 10.2.34 C0135 Type of construction of motor P-0-4014 incorrect................................................................ 308 10.2.35 C0136 Several motor encoders connected..................................................................................... 308 10.2.36 C0137 Error during initialization of motor data (->S-0-0021)........................................................... 309 10.2.37 C0138 Invalid control section data (->S-0-0021)............................................................................. 309 10.2.38 C0139 T2 (S-0-0089)+length MDT (S-0-0010)>TScyc (S-0-0002)................................................. 310 10.2.39 C0140 Rotary scaling not allowed................................................................................................... 310

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Rexroth IndraDrive | Troubleshooting Guide

Table of Contents Page 10.2.40 10.2.41 10.2.42 10.2.43 10.2.44 10.2.45 10.2.46 10.2.47 10.2.48 10.2.49 10.2.50 10.2.51 10.2.52 10.2.53 10.2.54 10.2.55 10.2.56 10.2.57 10.2.58 10.2.59 10.2.60 10.2.61 10.2.62 10.2.63 10.2.64 10.2.65 10.2.66 10.2.67 10.2.68 10.2.69 10.2.70 10.2.71 10.2.72 10.2.73 10.2.74 10.2.75 10.2.76 10.2.77 10.2.78 10.2.79 10.2.80 10.2.81 10.2.82 10.2.83 10.2.84 10.2.85 C0151 IDN for command value data container not allowed............................................................ 311 C0152 IDN for actual value data container not allowed.................................................................. 311 C0153 Error at init. of synchr. motor with reluctance torque........................................................... 312 C0154 Field bus: IDN for cycl. command val. not configurable....................................................... 312 C0155 Field bus: max. length for cycl. command val. exceeded.................................................... 313 C0156 Field bus: IDN for cycl. actual val. not configurable............................................................. 313 C0157 Field bus: length for cycl. actual values exceeded............................................................... 314 C0158 Field bus: Tcyc (P-0-4076) incorrect.................................................................................... 314 C0159 Field bus: P-0-4077 missing for cycl. command values....................................................... 314 C0160 Error when reading encoder data => measuring encoder................................................... 315 C0161 Incorr. prarmeterization of measuring enc. (hardware)........................................................ 315 C0162 Measuring encoder unknown............................................................................................... 316 C0163 Modulo value for measuring encoder cannot be displayed.................................................. 317 C0164 Incorrect measuring encoder configuration.......................................................................... 317 C0170 Config. IDNs for CC not configurable................................................................................... 318 C0171 Maximum length for CC exceeded....................................................................................... 318 C0199 Functional package selection changed. Restart.................................................................. 318 C0201 Invalid parameters (->S-0-0423).......................................................................................... 319 C0202 Parameter limit error (->S-0-0423)....................................................................................... 319 C0203 Parameter calculation error (->S-0-0423)............................................................................ 320 C0210 Feedback 2 required (->S-0-0423)....................................................................................... 321 C0212 Invalid control section data (->S-0-0423)............................................................................. 321 C0218 Double signal selection master axis format converter......................................................... 322 C0219 Max. travel range too large.................................................................................................. 322 C0220 Error when initializing position of encoder 1........................................................................ 323 C0221 Initialization velocity encoder 1 too high.............................................................................. 323 C0223 Invalid settings for controller cycle times............................................................................. 324 C0224 Error when initializing position of encoder 2........................................................................ 324 C0225 Initialization velocity encoder 2 too high.............................................................................. 325 C0227 Error when initializing position of measuring encoder.......................................................... 325 C0228 Initialization velocity measuring encoder too high................................................................ 326 C0229 Field bus: IDN for cycl. command val. not configurable....................................................... 326 C0230 Field bus: max. length for cycl. command val. Exceeded.................................................... 327 C0231 Field bus: IDN for cycl. actual val. not configurable............................................................. 327 C0232 Field bus: length for cycl. actual values exceeded............................................................... 327 C0233 Field bus: Tcyc (P-0-4076) incorrect.................................................................................... 328 C0234 Field bus: P-0-4077 missing for cycl. command values....................................................... 328 C0238 Order of cyclic command value configuration incorrect....................................................... 329 C0239 IDN for command value data container not allowed............................................................ 329 C0240 IDN for actual value data container not allowed.................................................................. 330 C0241 Incorrect motion task parameterization................................................................................ 330 C0242 Multiple configuration of a parameter (->S-0-0423)............................................................. 331 C0243 Brake check function not possible....................................................................................... 333 C0244 Act. modulo value cycle greater than max. travel range...................................................... 333 C0245 Operating mode configuration (->S-0-0423) not allowed..................................................... 333 C0246 Trav. range lim. switch not ass. to dig. input........................................................................ 335

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Table of Contents Page 10.2.86 10.2.87 10.2.88 10.2.89 10.2.90 10.2.91 10.2.92 10.2.93 10.2.94 10.2.95 10.2.96 10.2.97 10.2.98 10.2.99 10.2.100 10.2.101 10.2.102 10.2.103 10.2.104 10.2.105 10.2.106 10.2.107 10.2.108 10.2.109 10.2.110 10.2.111 10.2.112 10.2.113 10.2.114 10.2.115 10.2.116 10.2.117 10.2.118 10.2.119 10.2.120 10.2.121 10.2.122 10.2.123 10.2.124 10.2.125 10.2.126 10.2.127 10.2.128 10.2.129 10.2.130 10.2.131 C0247 Dig. output already assigned to other axis........................................................................... 335 C0248 Dig. input assigned differently to axes................................................................................. 336 C0249 Dig. I/Os: bit number too large............................................................................................. 336 C0250 Probe inputs incorrectly configured...................................................................................... 337 C0251 Error during synchronization to master communication....................................................... 337 C0252 Incorrect MLD initialization (write access->S-0-0423).......................................................... 338 C0253 Error in combination operating mode - encoder (->S-0-0423)............................................. 338 C0254 Configuration error PROFIsafe............................................................................................ 339 C0255 Safety command for system init. incorrect........................................................................... 339 C0256 Safety technology configuration error.................................................................................. 340 C0257 Error in safety technology encoder initialization................................................................... 340 C0258 Error in relation TNcyc (S-0-0001) to fine interpol............................................................... 341 C0259 MLD configuration error (->S-0-0423).................................................................................. 341 C0260 Incremental enc. emulator resol. cannot be displayed......................................................... 342 C0261 Emulator (P-0-0902) activated for both axes....................................................................... 343 C0265 Incorrect CCD address configuration................................................................................... 343 C0266 Incorrect CCD phase switch................................................................................................ 343 C0267 CCD timeout phase switch................................................................................................... 344 C0270 Error when reading encoder data => motor encoder........................................................... 345 C0271 Incorrect parameterization of motor encoder (hardware)..................................................... 345 C0272 Incorr. parameteriz. of motor enc. (mechanical system)...................................................... 346 C0273 Modulo value for motor encoder cannot be displayed......................................................... 346 C0274 Motor encoder unknown...................................................................................................... 347 C0275 Error when reading encoder data => optional encoder........................................................ 347 C0276 Incorrect parameterization of optional enc. (hardware)....................................................... 348 C0277 Incorr. parameteriz. of opt. enc. (mechanical system)......................................................... 348 C0278 Modulo value for optional encoder cannot be displayed...................................................... 349 C0279 Optional encoder unknown.................................................................................................. 350 C0280 Maximum travel range cannot be displayed internally......................................................... 350 C0281 Commutation via encoder-2 impossible............................................................................... 351 C0282 Sensorless posit. of synchr. motors, invalid ctrl parameters................................................ 351 C0283 Error during initialization of motor control (->S-0-0423)....................................................... 352 C0284 Invalid motor data in encoder memory (->S-0-0423)........................................................... 352 C0285 Type of construction of motor P-0-4014 incorrect................................................................ 353 C0286 Several motor encoders connected..................................................................................... 354 C0287 Error during initialization of motor data (->S-0-0423)........................................................... 355 C0288 Rotary scaling not allowed................................................................................................... 356 C0289 Error at init. of synchr. motor with reluctance torque........................................................... 357 C0290 Error when reading encoder data => measuring encoder................................................... 358 C0291 Incorr. prarmeterization of measuring enc. (hardware)........................................................ 358 C0292 Measuring encoder unknown............................................................................................... 359 C0293 Modulo value for measuring encoder cannot be displayed.................................................. 360 C0294 Incorrect measuring encoder configuration.......................................................................... 360 C0298 Impossible to exit parameterization level............................................................................. 360 C0299 Configuration changed. Restart........................................................................................... 361 C0301 Measuring system unavailable............................................................................................. 362

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Table of Contents Page 10.2.132 10.2.133 10.2.134 10.2.135 10.2.136 10.2.137 10.2.138 10.2.139 10.2.140 10.2.141 10.2.142 10.2.143 10.2.144 10.2.145 10.2.146 10.2.147 10.2.148 10.2.149 10.2.150 10.2.151 10.2.152 10.2.153 10.2.154 10.2.155 10.2.156 10.2.157 10.2.158 10.2.159 10.2.160 10.2.161 10.2.162 10.2.163 10.2.164 10.2.165 10.2.166 10.2.167 10.2.168 10.2.169 10.2.170 10.2.171 10.2.172 10.2.173 10.2.174 10.2.175 10.2.176 10.2.177 C0302 Absolute evaluation of measuring system impossible......................................................... 362 C0303 Absolute encoder offset cannot be saved............................................................................ 363 C0401 Switching not allowed.......................................................................................................... 363 C0403 Switching to CCD phase 2 impossible................................................................................. 364 C0501 Error clearing only in parameter mode................................................................................. 364 C0601 Homing only possible with drive enable............................................................................... 365 C0602 Distance home switch - reference mark erroneous............................................................. 365 C0603 Homing impossible with optional encoder............................................................................ 366 C0604 Homing of absolute encoder not possible............................................................................ 366 C0606 Reference mark not detected............................................................................................... 366 C0607 Home switch input not assigned.......................................................................................... 367 C0608 Pos. stop a. HW lim. switch not allowed f. modulo axes...................................................... 367 C0609 Different travel directions parameterized............................................................................. 368 C0610 Absolute encoder offset could not be saved........................................................................ 368 C0702 Default parameters not available......................................................................................... 369 C0703 Default parameters invalid................................................................................................... 369 C0704 Parameters not copyable..................................................................................................... 370 C0706 Error when reading the controller parameters..................................................................... 370 C0722 Parameter default value incorrect (-> S-0-0423).................................................................. 370 C0723 Safety command for load defaults procedure incorrect....................................................... 371 C0724 Timeout of safety command for load defaults procedure..................................................... 372 C0751 Parameter default value incorrect (-> S-0-0423).................................................................. 372 C0752 Locked with password.......................................................................................................... 373 C0799 An invalid index was set....................................................................................................... 373 C0851 Parameter default value incorrect (-> S-0-0021).................................................................. 374 C0852 Locked with password.......................................................................................................... 374 C0902 Spindle positioning requires drive enable............................................................................ 374 C0903 Error during initialization...................................................................................................... 375 C0906 Error during search for zero pulse....................................................................................... 375 C1204 Error in offset calculation..................................................................................................... 376 C1208 No adjustment with asynchronous motor............................................................................. 376 C1209 Proceed to phase 4.............................................................................................................. 377 C1211 Commutation offset could not be determined...................................................................... 377 C1212 Motion range exceeded during commutation....................................................................... 377 C1214 Command only possible with linear synchronous motor...................................................... 378 C1215 Command only possible in 'bb'............................................................................................ 378 C1216 Commutation determination not selected............................................................................ 379 C1217 Setting only possible in 'Ab'................................................................................................. 379 C1218 Automatic commutation: current too low.............................................................................. 380 C1219 Automatic commutation: overcurrent................................................................................... 380 C1220 Automatic commutation: timeout.......................................................................................... 381 C1221 Automatic commutation: iteration without result.................................................................. 381 C1222 Error when writing offset parameters................................................................................... 382 C1223 Command execution impossible.......................................................................................... 382 C1301 Class 1 diagnostics error at command start......................................................................... 383 C1402 Faulty reference mark signal................................................................................................ 383

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Table of Contents Page 10.2.178 10.2.179 10.2.180 10.2.181 10.2.182 10.2.183 10.2.184 10.2.185 10.2.186 10.2.187 10.2.188 10.2.189 10.2.190 10.2.191 10.2.192 10.2.193 10.2.194 10.2.195 10.2.196 10.2.197 10.2.198 10.2.199 10.2.200 10.2.201 10.2.202 10.2.203 10.2.204 10.2.205 10.2.206 10.2.207 10.2.208 10.2.209 10.2.210 10.2.211 10.2.212 10.2.213 10.2.214 10.2.215 10.2.216 10.2.217 10.2.218 10.2.219 10.2.220 10.2.221 10.2.222 10.2.223 C1701 Measuring wheel mode not possible.................................................................................... 383 C1801 Start requires drive enable................................................................................................... 384 C1802 Motor feedback data not valid.............................................................................................. 384 C1803 Inertia detection failed.......................................................................................................... 385 C1804 Automatic controller setting failed........................................................................................ 386 C1805 Travel range invalid.............................................................................................................. 386 C1806 Travel range exceeded........................................................................................................ 387 C1807 Determining travel range only via travel distance................................................................ 387 C1808 Drive not homed................................................................................................................... 387 C2001 Command not enabled......................................................................................................... 388 C2101 Brake check only possible with drive enable....................................................................... 388 C2103 Brake torque too low............................................................................................................ 389 C2104 Command execution not possible........................................................................................ 389 C2105 Load of holding system > test torque................................................................................... 390 C2106 Test torque of holding system not reached.......................................................................... 391 C2108 Error when releasing the holding system............................................................................. 394 C2109 Safety related holding system: test torque invalid................................................................ 394 C2202 Error when writing data to non-volatile memory................................................................... 395 C2301 Error when reading non-volatile memory............................................................................. 395 C2302 Error when converting parameters....................................................................................... 395 C2402 Error when saving parameters............................................................................................. 396 C2502 Error when accessing the MMC........................................................................................... 396 C2504 Error when writing data to internal memory......................................................................... 397 C2602 Error when accessing the MMC........................................................................................... 398 C2604 Error when reading the internal memory.............................................................................. 398 C2801 Analog input not configured................................................................................................. 399 C2802 Oscillations of input signal outside tolerance range............................................................. 399 C2803 Measured values at zero point and max. value identical..................................................... 400 C2804 Automatic adjust failed......................................................................................................... 400 C2903 Error when accessing the MMC........................................................................................... 400 C2904 Error when accessing the flash............................................................................................ 401 C2905 Programmed firmware defective.......................................................................................... 402 C3001 Synchronization and storage failed...................................................................................... 402 C3101 Act. modulo value cycle greater than max. travel range...................................................... 403 C3102 Drive is still in drive enable.................................................................................................. 403 C3201 Incorrect input for current..................................................................................................... 403 C3202 Incorrect input for voltage.................................................................................................... 404 C3203 Incorrect input for frequency................................................................................................ 404 C3204 Incorrect input for speed...................................................................................................... 405 C3205 Incorrect input for power factor............................................................................................ 405 C3206 Incorrect input for power...................................................................................................... 405 C3207 Type plate list incomplete.................................................................................................... 406 C3208 Error when writing parameters............................................................................................. 406 C3209 Command execution impossible.......................................................................................... 407 C3501 Acquisition velocity not allowed........................................................................................... 407 C3502 Motor encoder not available................................................................................................. 407

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Table of Contents Page 10.2.224 10.2.225 10.2.226 10.2.227 10.2.228 10.2.229 10.2.230 10.2.231 10.2.232 10.2.233 10.2.234 10.2.235 10.2.236 10.2.237 10.2.238 10.2.239 10.2.240 10.2.241 10.2.242 10.2.243 10.2.244 10.2.245 10.2.246 10.2.247 10.2.248 10.2.249 10.2.250 10.2.251 10.2.252 10.2.253 10.2.254 10.2.255 10.2.256 10.2.257 10.2.258 10.2.259 10.2.260 10.2.261 10.2.262 10.2.263 10.2.264 10.2.265 10.2.266 10.2.267 10.2.268 10.2.269 C3503 Optional encoder not available............................................................................................ 408 C3504 Measuring encoder not available......................................................................................... 408 C3505 No encoder selected............................................................................................................ 409 C3506 Correction value table cannot be stored.............................................................................. 409 C3601 Motor not or not correctly connected................................................................................... 410 C3602 Determined values invalid.................................................................................................... 410 C3603 Device current limit too low.................................................................................................. 410 C3604 Error when writing parameters............................................................................................. 411 C3605 Motor turning{....................................................................................................................... 411 C3606 Type of construction of motor not allowed........................................................................... 412 C3701 Error when manually unlocking the safety door................................................................... 412 C3901 Abrasion of brake only possible with drive enable............................................................... 413 C3902 Error during abrasion of brake............................................................................................. 413 C3903 Command execution impossible.......................................................................................... 414 C4001 Error during safety related homing procedure..................................................................... 414 C4002 Incorrect distance of dedicated point channel 1-2............................................................... 415 C4101 Switching only possible without AF...................................................................................... 415 C4102 Switching only possible in parameter mode......................................................................... 416 C4103 Preselect parameter set forbidden value............................................................................. 416 C4104 Error during parameter set switching (->S-0-0423).............................................................. 417 C4201 Oscillation requires drive enable.......................................................................................... 417 C4202 Oscillation command speed cannot be reached.................................................................. 417 C4302 Distance home switch - reference mark erroneous............................................................. 418 C4304 Homing of absolute encoder not possible............................................................................ 418 C4306 Reference mark not detected............................................................................................... 419 C4307 Home switch input not assigned.......................................................................................... 419 C4308 Pos. stop a. HW lim. switch not allowed f. modulo axes...................................................... 420 C4601 Error when writing parameters............................................................................................. 420 C4701 Drive active, activation of easy startup impossible.............................................................. 420 C4901 PLC command error no. 1.................................................................................................... 421 C4902 PLC command error no. 2.................................................................................................... 421 C4903 PLC command error no. 3.................................................................................................... 422 C4904 PLC command error no. 4.................................................................................................... 422 C4910 PLC command timeout........................................................................................................ 422 C5401 PLC program not ready for retain data backup.................................................................... 423 C5402 Error when writing data to the MMC.................................................................................... 423 C5501 PLC program not ready for loading retain data.................................................................... 424 C5502 MMC not available or not OK............................................................................................... 424 C5503 PLC retain data do not match PLC program........................................................................ 425 C5504 Unknown format in PLC retain file....................................................................................... 425 C5505 Invalid PLC retain data......................................................................................................... 426 C5601 Command requires drive enable.......................................................................................... 426 C5602 Axis blocked......................................................................................................................... 427 C5603 Timeout: axis in motion........................................................................................................ 427 C6001 Measuring system unavailable............................................................................................. 427 C6002 Absolute evaluation of measuring system impossible......................................................... 428

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Table of Contents Page 10.2.270 10.2.271 10.2.272 10.2.273 C6003 Absolute encoder offset cannot be saved............................................................................ 428 C6004 Command cannot be executed under drive enable............................................................. 429 C6101 Incorrect IP settings............................................................................................................. 429 C7001 CCD: impossible to adjust slave addresses......................................................................... 430

11 12
12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14 12.15 12.16 12.17 12.18 12.19 12.20 12.21

Extended Diagnosis (P-0-3219)................................................................................. 431 Handling, Diagnostic and Service Functions............................................................. 449
Replacing the Firmware...................................................................................................................... 449 Firmware Download............................................................................................................................ 449 Messages During the Firmware Download......................................................................................... 449 FL: DL ................................................................................................................................................ 449 FL:ERASE ......................................................................................................................................... 450 FL: PROG .......................................................................................................................................... 450 FL: CKS ............................................................................................................................................. 450 FL:E ADR ........................................................................................................................................... 450 FL:E SEC ........................................................................................................................................... 450 FL:E FW ............................................................................................................................................. 450 FL:E LD .............................................................................................................................................. 451 FL:E SEQ ........................................................................................................................................... 451 FL:F9002 ........................................................................................................................................... 451 FL:F2100 ........................................................................................................................................... 451 FL:F CKS ........................................................................................................................................... 451 FL:F ACC ........................................................................................................................................... 452 FL:F2101 ........................................................................................................................................... 452 FL:F8122 ........................................................................................................................................... 452 FL:F8129 ........................................................................................................................................... 452 FL:F8130 ........................................................................................................................................... 452 FL:F8120 ........................................................................................................................................... 453

13
13.1 13.2 13.3

Notes for Machine Operators..................................................................................... 455
General Information............................................................................................................................ 455 Diagnosing Malfunction and Removing Errors................................................................................... 455 Contacting the Service Department ................................................................................................... 456

14
14.1 14.2 14.3

Notes for Installation Programmers........................................................................... 457
How to Handle Command Errors........................................................................................................ 457 How to Handle Errors......................................................................................................................... 457 How to Handle Warnings.................................................................................................................... 458

15
15.1 15.2 15.3

Service and Support.................................................................................................. 461
Helpdesk............................................................................................................................................. 461 Service Hotline.................................................................................................................................... 461 Internet................................................................................................................................................ 461

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Table of Contents Page 15.4 Helpful Information.............................................................................................................................. 461

Index.......................................................................................................................... 463

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Introduction

1
1.1
What?

Introduction
About This Documentation
To make the reading of this documentation easier for you, the table below con‐ tains the means of representation and notations of recurring terms.
How? For example... As of MPx05VRS: In "P-0-4088, Master communi‐ cation, configuration", you can configure the reaction to the failure of the cyclic communi‐ cation as a warning or as an error. In parameter "S?0?0375, List of diagnostic numbers", the last 50 diagnostic message num‐ bers are...

Means of Representation in This Documentation

Important facts which are to be highlighted in continuous text Boldface

Parameter names, diagnostic message names, function des‐ Quotation marks ignations

Fig.1-1:

Conventions of notation

All important notes are highlighted. A symbol tells you what kind of note is used in the text. The symbols have the following significances:

... DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

... WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

... CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in injury or property damage.

This box contains important information which you should take into consideration. This symbol highlights useful tips and tricks.
Your Feedback

Your experience is important for our improvement processes of products and documentations. If you discover mistakes in this documentation or suggest changes, you can send your feedback to the following e-mail address: Dokusupport@boschrexroth.de We need the following information to handle your feedback: ● The number indicated under "Internal File Reference".

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Introduction ● The page number.

1.2
1.2.1
Title

Reference Documentations
Drive Systems, System Components
Kind of documentation Project Planning Manual Project Planning Manual Project Planning Manual Project Planning Manual Project Planning Manual 1) Document typecode1) DOK-INDRV*-… SYSTEM*****-PRxx-EN-P KCU+KSM****-PRxx-EN-P HMV-S-D+HCS-PRxx-EN-P CSH********-PRxx-EN-P ADDCOMP****-PRxx-EN-P Part no. R911… 309636 320924 318790 295012 306140

Rexroth IndraDrive … Drive System Mi Drive Systems Supply Units and Power Sections Drive Controllers Control Sections Additional Components

Fig.1-2:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: PR01 is the first edition of a Project Plan‐ ning Manual)

Documentations – drive systems, system components

1.2.2
Title

Motors
Kind of documentation Project Planning Manual Project Planning Manual Project Planning Manual Project Planning Manual Project Planning Manual 1) Document typecode1) DOK-MOTOR*-… MAD/MAF****-PRxx-EN-P MBS-H******-PRxx-EN-P MLF********-PRxx-EN-P MSK********-PRxx-EN-P MBT********-PRxx-EN-P Part no. R911… 295781 297895 293635 296289 298798

Rexroth IndraDyn … A Series Asynchronous Motors MAD/ MAF H Frameless Synchronous Spindle Motors L Synchronous Linear Motors S MSK Synchronous Motors T Synchronous Torque Motors

Fig.1-3:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: PR01 is the first edition of a Project Plan‐ ning Manual)

Documentations – motors

1.2.3
Title

Cables
Kind of documentation Selection Data 1) Document typecode1) DOK-… CONNEC-CABLE*STAND-AUxxEN-P Part no. R911… 282688

Rexroth Connection Cables

Fig.1-4:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: AU03 is the third edition of the documen‐ tation "Selection Data")

Documentations – cables

1.2.4
Title

Firmware
Kind of documentation Functional Description Functional Description Document typecode1) DOK-INDRV*-… MP*-02VRS**-FKxx-EN-P MP*-03VRS**-FKxx-EN-P Part no. R911… 299223 308329

Rexroth IndraDrive … Firmware for Drive Controllers Firmware for Drive Controllers

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Introduction
Title Rexroth IndraDrive … Firmware for Drive Controllers Firmware for Drive Controllers Firmware for Drive Controllers Integrated Safety Technology Rexroth IndraMotion MLD Rexroth IndraMotion MLD Library 1) Functional Description Parameter Description Troubleshooting Guide Functional and Application Description Application Manual Library Description Kind of documentation Document typecode1) DOK-INDRV*-… MP*-04VRS**-FKxx-EN-P GEN-**VRS**-PAxx-EN-P GEN-**VRS**-WAxx-EN-P SI*-**VRS**-FKxx-EN-P MLD-**VRS**-AWxx-EN-P MLD-SYSLIB*-FKxx-EN-P Part no. R911… 315485 297317 297319 297838 306084 309224

Fig.1-5:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: PA02 is the second edition of a Parameter Description)

Documentations – firmware

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Important Directions for Use

2
2.1
2.1.1

Important Directions for Use
Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability.

Personal injury and property damage caused by incorrect use of the products! WARNING
The products have been designed for use in the industrial environment and may only be used in the appropriate way. If they are not used in the appropriate way, situations resulting in property damage and personal injury can occur. Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfei‐ ted. The user alone carries all responsibility of the risks. Before using Rexroth products, make sure that all the pre-requisites for an ap‐ propriate use of the products are satisfied: ● Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with ap‐ propriate use. If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.



● ●

2.1.2

Areas of Use and Application
Drive controllers made by Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the Drive controllers may require additional sensors and actors. The drive controllers may only used with the accessories and parts specified in this documentation. If a component has not been spe‐ cifically named, then it may neither be mounted nor connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and com‐ binations of components using the software and firmware as speci‐ fied in the relevant Functional Descriptions. Drive controllers have to be programmed before commissioning, making it pos‐ sible for the motor to execute the specific functions of an application. Drive controllers of the Rexroth IndraDrive line have been developed for use in single- and multi-axis drive and control tasks. To ensure application-specific use of Drive controllers, device types of different drive power and different interfaces are available. Typical applications include:

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Important Directions for Use ● ● ● ● handling and mounting systems, packaging and food machines, printing and paper processing machines and machine tools.

Drive controllers may only be operated under the assembly and installation conditions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of protection, humidity, EMC, etc.).

2.2

Inappropriate Use
Using the Drive controllers outside of the operating conditions described in this documentation and outside of the indicated technical data and specifications is defined as "inappropriate use". Drive controllers must not be used, if … ● they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum tem‐ peratures. Furthermore, Drive controllers must not be used in applications which have not been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general Safety Instructions!



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Safety Instructions for Electric Drives and Controls

3
3.1
3.1.1

Safety Instructions for Electric Drives and Controls
Safety Instructions - General Information
Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc‐ umentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent im‐ mediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official lan‐ guage of the user's country.

WARNING

Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safe‐ ty devices, may result in material damage, bodily harm, electric shock or even death!
Observe the safety instructions!

3.1.2

How to Employ the Safety Instructions
Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. ● ● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐ serve the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device. Only assign trained and qualified persons to work with electrical installa‐ tions: – Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assem‐ bly, installation and operation of the product, as well as an under‐ standing of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safe‐ ty equipment and be trained in first aid.









Only use spare parts and accessories approved by the manufacturer.

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Safety Instructions for Electric Drives and Controls ● ● ● ● Follow all safety regulations and requirements for the specific application as practiced in the country of use. The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be ob‐ served. Only use safety-relevant applications that are clearly and explicitly ap‐ proved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause dan‐ ger to persons and material damage. The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applica‐ tions and suggestions. The machine and installation manufacturer must – make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements.







Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application. Operation is only permitted if the national EMC regulations for the appli‐ cation are met. The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations.

● ●



Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times.

National regulations which the user must take into account ● European countries: according to European EN standards ● United States of America (USA): – National Electrical Code (NEC) – National Electrical Manufacturers Association (NEMA), as well as local engineering regulations – regulations of the National Fire Protection Association (NFPA) ● Canada: Canadian Standards Association (CSA) ● Other countries: – International Organization for Standardization (ISO) – International Electrotechnical Commission (IEC)

3.1.3

Explanation of Warning Symbols and Degrees of Hazard Seriousness
The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:

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Safety Instructions for Electric Drives and Controls
Degree of hazard serious‐ ness acc. to ANSI Z 535.4-2002 Death or severe bodily harm will occur. Death or severe bodily harm may occur. Minor or moderate bodily harm or material damage may occur.

Warning symbol

Signal word

Danger

Warning

Caution

Fig.3-1:

Hazard classification (according to ANSI Z 535)

3.1.4

Hazards by Improper Use
High electric voltage and high working current! Risk of death or severe bodily injury by electric shock!

DANGER

Observe the safety instructions!

Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! DANGER
Observe the safety instructions!

High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! WARNING
Observe the safety instructions!

Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! WARNING
Observe the safety instructions!

Hot surfaces on device housing! Danger of injury! Danger of burns!
Observe the safety instructions!

CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! CAUTION
Observe the safety instructions!

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Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling of batteries!
Observe the safety instructions!

CAUTION

3.2
3.2.1

Instructions with Regard to Specific Dangers
Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages of more than 50 Volt. Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoid‐ able that some parts of the devices conduct dangerous voltage.

High electrical voltage! Danger to life, electric shock and severe bodily injury! DANGER
● ● ● Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on pow‐ er installations. Before switching on the device, the equipment grounding conductor must have been non-detachably connected to all electrical equipment in ac‐ cordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measure‐ ments or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electric voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. ● Never touch the electrical connection points of a component while power is turned on. Do not remove or plug in connectors when the component has been powered. Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.













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Safety Instructions for Electric Drives and Controls For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions.

High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! DANGER
● Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 mA. Over the total length, use copper wire of a cross section of a minimum of 10 mm2 for this equipment grounding connection! Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high vol‐ tages may occur at the housing causing electric shock.



● ●

3.2.2

Protection Against Electric Shock by Protective Extra-Low Voltage
Protective extra-low voltage is used to allow connecting devices with basic in‐ sulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals.

High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! WARNING
If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2)

3.2.3

Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors. Some common examples are: ● ● ● ● ● ● improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors

Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.

1) 2)

"Protective Extra-Low Voltage" "Protective Extra-Low Voltage"

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Safety Instructions for Electric Drives and Controls The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

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Safety Instructions for Electric Drives and Controls

Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! DANGER
● Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. These measures have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possi‐ ble if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: ● Keep free and clear of the machine’s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine’s range of motion: – – – – ● ● use safety fences use safety guards use protective coverings install light curtains or light barriers

Fences and coverings must be strong enough to resist maximum possible momentum. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don’t operate the device if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: – – – mechanically securing the vertical axes, adding an external braking/ arrester/ clamping mechanism or ensuring sufficient equilibration of the vertical axes.

● ● ●



The standard equipment motor brake or an external brake controlled di‐ rectly by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: – – – maintenance and repair work cleaning of equipment long periods of discontinued equipment use





Prevent the operation of high-frequency, remote control and radio equip‐ ment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible mal‐ functions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

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Safety Instructions for Electric Drives and Controls

3.2.4

Protection Against Magnetic and Electromagnetic Fields During Oper‐ ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids.

Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! WARNING
● Persons with heart pacemakers and metal implants are not permitted to enter following areas: – – ● Areas in which electrical equipment and parts are mounted, being operated or commissioned. Areas in which parts of motors with permanent magnets are being stored, repaired or mounted.

If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of pres‐ ent or future implanted heart pacemakers differs greatly so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Oth‐ erwise health hazards may occur.



3.2.5

Protection Against Contact with Hot Parts
Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns!

CAUTION

● ● ● ●

Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than 60 °C, 140°F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 mi‐ nutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation.

● ● ●

3.2.6

Protection During Handling and Mounting
In unfavorable conditions, handling and mounting certain parts and compo‐ nents in an improper way can cause injuries.

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Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! CAUTION
● ● ● ● ● ● ● ● Observe the general construction and safety regulations on handling and mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety gog‐ gles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding.

3.2.7

Battery Safety
Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage.

Risk of injury by improper handling!


CAUTION

Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts in‐ stalled in the devices. Only use the battery types specified by the manufacturer. Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly.

● ● ● ● ●

3.2.8

Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be par‐ tially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.

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Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling of pressurized lines!


CAUTION

Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐ sion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecolog‐ ically harmful agents separately from other waste. Observe the local regulations in the country of assembly.

● ● ● ●

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4
4.1
4.1.1

Basics on Device Diagnosis
Diagnostic System
Coded Diagnostic Messages of the Drive
The drive provides a diagnostic system including different options that are ba‐ sically divided into two groups: ● ● Recognizing and displaying the current drive status by means of driveinternal, priority-dependent generation of diagnostic messages Collective messages for diverse status messages

Brief Description

Additionally, there are parameters for all important operating data the values of which can be transmitted both via master communication (e.g. SERCOS) and a parameterization interface (RS-232/485 in the ASCII protocol or SIS protocol; see "Serial Communication").")
Pertinent Parameters

● ● ● ● ● ● ● ● ● ● ●

S?0?0030, Manufacturer version S-0-0095, Diagnostic message S-0-0140, Controller type S?0?0142, Application type S?0?0375, List of diagnostic numbers S-0-0390, Diagnostic message number P?0?0007, Display text of diagnostic message P?0?0009, Error number P?0?0478, Logbook event P?0?0479, Logbook time stamp P-0-3219, Diagnostic safety technology message For integrated safety technology, an extended diagnosis option is provided in the form of a safety technology error code. When certain safety technology errors occur, this error code can be read in pa‐ rameter "P?0?3219, Diagnostic safety technology message" which allows quick error diagnosis.

Drive-Internal Generation of Diagnostic Messages
Operating states, activities and reactions of the drive controller are detected by drive-internal generation of diagnostic messages and appear in coded form on the display of the control panel. In addition, these diagnostic messages can be transmitted to the master (control unit or commissioning software, e.g. IndraWorks D). We distinguish the following categories of diagnostic messages (kinds of diag‐ nostic messages): ● ● ● ● Errors Warnings Commands/command errors Status displays/operating states

Generally, the current diagnostic message with the highest priority is displayed or stored at the following locations in the drive:

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Basics on Device Diagnosis ● Display of the control panel and parameter "P?0?0007, Display text of di‐ agnostic message" → The diagnostic message number or, if applicable, text appears on the 8-digit display of the standard control panel. The current display is stored in parameter P?0?0007. ● Parameter "S-0-0095, Diagnostic message" → This parameter, in the form of plain text, contains the operating status of the drive at present relevant. Preceding the text is the respective content of parameter S?0?0390. ● Parameter "S-0-0390, Diagnostic message number" → The diagnostic message number shown on the display is stored in this parameter. When a diagnostic message of the "error" category occurs, the corresponding diagnostic message number is stored in parameter "P?0?0009, Error number". When there isn't any error present, the value of parameter P?0?0009 equals zero. In parameter "S?0?0375, List of diagnostic numbers", the last 50 diagnostic message numbers of parameter S?0?0390 are recorded in chronological order. When reading this list, the number of the diagnostic message that last occurred is displayed as parameter element 1.
Priorities of Display

The following priorities apply for displaying the current diagnostic message:

Fig.4-1:

Priorities of displays (with example displays)

An overview of all diagnostic messages and their meanings is included in the documentation "Troubleshooting Guide (description of diagnostic messages)".

Structure of a Diagnostic Message
General Information
Every diagnostic message consists of ● ● diagnostic message number - and diagnostic text. The diagnostic message for the non-fatal error "Excessive deviation", for ex‐ ample, has the following structure:

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Fig.4-2:

Structure of a diagnostic message

"F2028" flashes on the display of the control panel. The display "F2028" is out‐ put via parameter "P?0?0007, Display text of diagnostic message", too. The diagnostic message number is contained in parameter "S?0?0390, Diagnostic message number" in hexadecimal form (for this example: 0x00F2028). The di‐ agnostic message number and the diagnostic text are contained as string "F2028 Excessive deviation" in parameter "S?0?0095, Diagnostic message". "2028" (dec) is written to parameter "P?0?0009, Error number", because it is an error diagnosis.

Diagnostic Message on the Control Panel Display
The diagnostic message number appears on the 8-digit display of the standard control panel. This allows recognizing the current operating status of the drive quickly and without using a communication interface. As a matter of principle, the following applies: ● ● Status displays (P0, Ab, AF …) are displayed in right-aligned form Warnings, command errors and other error messages are flashing
Diagnostic message number F2xxx C0200 C02xx E2xxx A0001 A0012 A0101 Display F2xxx C02 C02xx E2xxx P1 Ab AF

Kind of diagnostic message error command command error warning communication phase e.g. communication phase 1 drive ready for operation operating mode e.g. velocity control

Fig.4-3:

Overview of diagnostic messages displayed

The current operating mode is not shown on the display. When the drive follows the preset operating mode and no command was activated, the display reads "AF".

Diagnostic Message in Plain Text
The diagnostic message in plain text contains the diagnostic message number followed by the diagnostic message text. It can be read via parameter "S?0?0095, Diagnostic message" and directly displayed on an operator interface as a language-dependent description of the drive status. The diagnostic message in plain text is switched to the selected language via parameter "S?0?0265, Language selection".

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Diagnostic Message Number
The diagnostic message number contains only the diagnostic number without the diagnostic text. It can be read via parameter "S?0?0390, Diagnostic mes‐ sage number" and is a language-independent possibility of determining and displaying the drive status on an operator interface.

Display Text of Diagnostic Message
The display text of a diagnostic message is the text appearing on the display of the control panel. It can be read via parameter "P?0?0007, Display text of diagnostic message" which allows an operator interface to determine the drive status and display it in a language-independent way.

Error Number
The error number contains only the error number without the diagnostic mes‐ sage text. It can be read via parameter "P?0?0009, Error number" and is a language-independent possibility of determining and displaying an error con‐ dition on an operator interface. This parameter only contains a value unequal zero when an error is present in the drive. The error number is generated from the lowest 4 digits of the diagnostic mes‐ sage number. For example, the error "F2028 Excessive deviation" with the diagnostic message number "(0x)F2028" would produce the error number "2028."

List of Diagnostic Numbers
The last 50 diagnostic message numbers displayed are stored in chronological order in parameter "S?0?0375, List of diagnostic numbers". Every change in the content of "S?0?0390, Diagnostic message number" means that the old content is applied to S?0?0375. When reading the parameter S?0?0375 the last trans‐ ferred diagnostic message number appears in the first element of the param‐ eter, the diagnostic message number transferred before from S?0?0390 in the second element, etc.

Language Selection
Via parameter "S?0?0265, Language selection", it is possible to define or switch the language of diagnostic message texts. See also Parameter Description "S?0?0265, Language selection"

4.1.2

Status Classes, Status Displays, Control Parameters
In the drive there are many parameters with important status information (bit lists). Some of the bits contained in these lists can be used for configuring realtime status bits and additionally can be assigned to digital outputs or to the configurable signal status word. See "Digital Inputs/Outputs" See "Configurable Signal Status Word"

General Information

Status Classes
Brief Description
The drive differentiates between 3 states (error, warning and message) for which there is status information. To make the status information available, there are so-called class diagnostics parameters (S?0?0011, S?0?0012, S?0?0013) which contain the respective status bits.

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Basics on Device Diagnosis In addition to these class diagnostics parameters, there are change bits con‐ tained in the status word of the field bus (e.g. S?0?0135 in the case of SERCOS) which display changes in one of the above-mentioned class diagnostics pa‐ rameters (collective information).
Features

● ● ● ● ●

Class diagnostics parameter for errors (cf. S?0?0011) Class diagnostics parameter for warnings (cf. S?0?0012) Class diagnostics parameter for messages (cf. S?0?0013) Change bits in status word of master communication (e.g. S?0?0135 in the case of SERCOS) Change bits of class 2 and 3 diagnostics (S?0?0097 and S?0?0098) can be masked in status word of master communication (e.g. S?0?0135 in the case of SERCOS) to suppress individual bits or status messages S?0?0011, Class 1 diagnostics S-0-0012, Class 2 diagnostics S?0?0013, Class 3 diagnostics S-0-0097, Mask class 2 diagnostics S-0-0098, Mask class 3 diagnostics S?0?0135, Drive status word S?0?0011, Class 1 diagnostics (status parameter for drive errors) – In case a drive error occurs, the bit assigned to the error is set in parameter S?0?0011. A separate bit is assigned in S?0?0011 to errors defined according to SERCOS. Manufacturer-specific errors cause bit 15 to be set in parameter S?0?0011 (see also Parameter Description "S?0?0011, Class 1 diag‐ nostics"). – In case a drive error occurs, bit 13 (drive interlock; error in class 1 diagnostics) is simultaneously set in the status word of the field bus (S?0?0135 in the case of SERCOS). All bits in class 1 diagnostics are cleared by executing the command C0500 (reset class 1 diagnostics). See also Parameter Description "S?0?0099, C0500 Reset class 1 diagnostics"

Pertinent Parameters

● ● ● ● ● ●

Functional Description
Status Class Parameters





S?0?0012, Class 2 diagnostics (status parameter for drive warnings) – In case a drive warning occurs, the bit assigned to the warning is set in parameter S?0?0012. A separate bit is assigned in S?0?0012 to warnings defined according to SERCOS. Manufacturer-specific warnings cause bit 15 to be set in parameter S?0?0012 (see also Parameter Description "S?0?0012, Class 2 diag‐ nostics"). – In case a drive warning occurs, bit 12 (change bit class 2 diagnostics) is simultaneously set in the status word of the field bus (S?0?0135 in the case of SERCOS), when the content of S?0?0012 changes (i.e. at least one bit toggles). The bits in parameter S?0?0012 are automatically cleared when the warning disappears. The change bit in the status word of the master communication (S?0?0135 in the case of SERCOS) remains set, however, until parameter S?0?0012 has been read once.



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Basics on Device Diagnosis Via parameter "S?0?0097, Mask class 2 diagnostics", warnings can be masked in terms of their effect on the change bit. ● S?0?0013, Class 3 diagnostics (status parameter for drive messages) – Messages of the drive are listed in parameter S?0?0013. A separate bit is assigned in S?0?0013 to messages defined according to SER‐ COS (see also Parameter Description "S?0?0013, Class 3 diagnos‐ tics"). In the case of a drive message, bit 11 (change bit class 3 diagnostics) is simultaneously set in the status word of the field bus (S?0?0135 in the case of SERCOS). The bits in parameter S?0?0013 are automatically cleared when the message disappears. The change bit in the status word of the master communication (S?0?0135 in the case of SERCOS) remains set, however, until parameter S?0?0013 has at least been read once. Each of these messages is stored in a separate parameter (S?0?0330 to S?0?0342).
Change Bits in Drive Status Word





If the status of a bit in "S?0?0012, Class 2 diagnostics" or "S?0?0013, Class 3 diagnostics" changes, the change bit for class 2 or 3 diagnostics is set in the field bus status word (e.g. S?0?0135 in the case of SERCOS). A change bit in the status word (bit 11 or 12) is always set due to a change of the parameter content of S?0?0012 or S?0?0013. This enables the master to recognize very quickly whether a change occurred in S?0?0012 or S?0?0013. A read access to one of the two parameters clears the respective change bit again.

Masking the Change Bit

By means of the parameters "S?0?0097, Mask class 2 diagnostics" and "S?0?0098, Mask class 3 diagnostics", it is possible to mask certain bits in terms of their effect on the change bit of the status word (bit 12 or bit 11). The figure below illustrates the principle of masking by means of an example:

Fig.4-4:

Generating the change bit of class 2 diagnostics

Notes on Commissioning
The figure below illustrates the handling of the change bits in the status word and of the status class parameters:

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Fig.4-5:

Handling the change bits and status class parameters

Fixed Status Displays
Function-Related Status Parameters
In the drive there are parameters the content of which has a direct relation to the status of the sequence of different drive functions. These parameters are used to display the current status information of the assigned function. The following parameters are available for function-related status display: ● S?0?0014, Interface status This parameter displays the status of the communication phase transition and the cyclic communication. ● S?0?0135, Drive status word

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Basics on Device Diagnosis This is the status word of the master communication (SERCOS) and con‐ tains all essential status information for the master. ● S-0-0403, Position feedback value status This parameter contains status bits for the position data reference of the individual measuring systems. ● S?0?0419, Positioning command acknowledge This status information is used for acknowledgment in the "drive-controlled positioning" mode. ● P?0?0046, Status word of current controller This parameter contains status bits of the internal motor control (e.g. over‐ voltage in DC bus). ● P?0?0115, Device control: Status word This parameter contains status bits of device control (see also "Device Control and State Machines"). ● P-0-0222, Travel range limit inputs This parameter displays the status of the travel range limit switch inputs (see also "Limitations: Travel Range Limit Switches")."). ● P?0?0223, E-Stop input This parameter displays the status of the E-Stop input (see also "E-Stop Function"). ● P-0-0445, Status word torque/current limit This parameter contains status bits to display the activation of torque/cur‐ rent limitation (see also "Limitations: Current and Torque/Force Limita‐ tion"). ● P?0?0539, Holding brake status word This parameter contains status bits for the status of the motor holding brake (see also "Motor Holding Brake"). ● P?0?0555, Status word of axis controller This parameter displays messages with regard to velocity and limits that have been reached. ● P?0?4029, Diagnostic report SCSB module Parameter for reading master communication settings and states (with SERCOS interface). ● P-0-4086, Master communication status This parameter displays control information of the master communication for handling phase switch, drive enable etc., defined during initialization.

Status Parameters for Real-Time Status Bits
The following list contains status parameters that only contain one bit and can therefore be used for configuring real-time status bits (see "SERCOS interface") ● ● ● ● ● ● ● S?0?0330, Message 'n_actual = n_command' S?0?0331, Status 'n_feedback = 0' S?0?0332, Message 'nactual < nx' S?0?0333, Message 'T >= Tx' S?0?0334, Message 'T >= Tlimit' S?0?0335, Message 'n command > n limit' S?0?0336, Message In position

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Basics on Device Diagnosis ● ● ● ● ● ● ● ● S?0?0337, Message 'P >= Px' S?0?0341, In-Position coarse message S?0?0342, Status "Target position attained" S?0?0343, Status "Interpolator halted" S?0?0409, Probe 1 positive latched S?0?0410, Probe 1 negative latched S?0?0411, Probe 2 positive latched S?0?0412, Probe 2 negative latched

Control Parameters
Apart from the parameters for status display, there are parameters available in the drive that are used to control the drive functions (see also description of corresponding parameter): ● ● ● ● ● ● P-0-0045, Control word of current controller P?0?0427, Control parameter of analog output P?0?0522, Control word for commutation setting P-0-0556, Config word of axis controller P?0?0612, Control word for setting absolute measuring P?0?4028, Device control word

4.2
4.2.1

Control Panels of the IndraDrive Controllers
General Information on the Operation Options
IndraDrive controllers are equipped with a control panel which consists of a display and keys located underneath it. The display shows operating states, command and error diagnoses, as well as present warnings. By means of the keys you can make settings, call information and trigger some commands. The extent of possible displays and settings depends on the available control panel of the IndraDrive controller. It can be supplied in two variants which differ as regards their performance: ● ● Standard control panel Comfort control panel

Variants of the Control Panels

Via the serial interface of the controller, it is additionally possible to connect an independent VCP operator terminal that can, for example, be integrated in the front of the control cabinet.

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Standard Control Panel

Fig.4-6:
Possibilities of Display of Standard Control Panel

Standard control panel with display and control elements (example of display)

The standard control panel allows the following displays: ● ● ● ● ● Status of the master communication Operating status Activated commands and command diagnoses Warnings and diagnostic error messages Extended displays such as contents of error memories, diagnostic mes‐ sage memory, operating hours counter of control section, operating hours counter of power section, type designation of firmware active in the device, safety technology code (if safety technology option available) Set the drive address (drive number in the bus system of the master com‐ munication) Set the length of the fiber optic cable Activate the master communication mode "Easy Startup" Activate "S?0?0262, C07_x Load defaults procedure command" (load con‐ troller parameters or basic parameters) Activate other commands, such as: – – – – – C2200 Backup working memory procedure command C2300 Load working memory procedure command C2500 Copy IDN from optional memory to internal memory C2600 Copy IDN from internal memory to optional memory C2900 Firmware update from MMC

Possible Settings with Standard Control Panel

The following settings can be made with the standard control panel: ● ● ●

Command Activation with Standard Control Panel

The following commands can be activated with the standard control panel: ● ●

Comfort Control Panel
Compared to the standard control panel, the comfort control panel, due to the fact that it can be programmed, provides additional settings, as well as addi‐ tional display and command functions.

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Possibilities of Display of Comfort Control Panel

Additional possibilities of display of the comfort control panel (in addition to the possibilities of display of the standard control panel), for example: ● ● ● ● Cyclic parameter display Measured value of motor temperature sensor Message threshold or shutdown threshold for motor temperature Active switching frequency (PWM)

Possible Settings with Comfort Control Panel

Additional possibilities of setting of the comfort control panel (in addition to the possible settings of the standard control panel), for example: ● ● ● Language selection Set/change single parameters Input of motor data acc. to type plate data for asynchronous third-party motors

Command Activation with Comfort Control Panel

Activation of further commands with the comfort control panel (in addition to the command activation with the standard control panel), for example: ● ● C3200 Command Calculate motor data C3600 Command Motor data identification

The comfort control panel particularly supports the commissioning of asyn‐ chronous third-party motors; another commissioning tool is not required for this purpose. The required steps are given by the display, the corresponding input is made by means of the keys of the control panel.

Independent VCP Operator Terminals
VCP operator terminals are separate components (terminals) that can be used in addition to the standard or comfort control panel. They are connected to the serial interface of the controller via a separate line. This allows integrating a VCP operator terminal in the front of the control cabinet, for example. By means of a configuration tool it is additionally possible to configure other application-dependent settings, displays and command functions.

4.2.2

Standard Control Panel
The standard control panel of an IndraDrive controller has an 8?digit display and four keys located underneath it. The display shows operating states, command and error diagnoses, as well as present warnings. Using the four keys, the commissioning engineer or service technician can opt to display extended diagnostic messages at the drive controller and to activate simple commands (in addition to master communication using the commis‐ sioning tool or NC control unit).

Brief Description

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Fig.4-7:

Standard control panel with display and control elements (example of display)

Functional Description
Standard Displays

The display of the IndraDrive controller automatically shows: ● ● ● ● Status of the master communication Operating status Activated commands and command diagnoses Warnings and diagnostic error messages

The displays have priorities because it is impossible to have various displays at the same time.

Fig.4-8:

Displays during phase progression of the master communication

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Fig.4-9:

Operating status displays

Fig.4-10:

Explanation of command error displays

Fig.4-11:
Priorities of Display

Explanation of error and warning displays

The current drive status is displayed with highest priority.

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Fig.4-12:

Priorities of displays (with example displays)

In the case of error messages, warnings and command errors, the diagnostic message text is displayed on the standard display in the form of a marquee text, in addition to the flashing diagnostic message number (see also Parameter Description "S?0?0095, Diagnostic message").
Activating Extended Display, Com‐ mand Menu and Service Menu

The extended Display can always (without interlock release) be accessed by pressing the "Enter" key. By simultaneously pressing the "Enter" and "Esc" keys (for 8 s) in the standard display, the command and the service menu can be called up in addition to the extended display.

Fig.4-13:
Extended Displays

Activating the extended display, the command menu and the service menu

By means of the extended displays it is possible to additionally call up the con‐ tents of certain parameters: ● ● ● ● ● Error memory Diagnostic message memory Operating hours counter control section Operating hours counter power section Type designation of the firmware active in the device

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Basics on Device Diagnosis ● Safety technology code, change counter of safety technology and oper‐ ating hours counter since last change (if safety technology option availa‐ ble) MAC address (when using CCD option, SERCOS III master communica‐ tion or control section CSH01.2) Diagnostic field bus message (P?0?4073) Active memory

● ● ●

Fig.4-14:

Activating the extended display

For more details on diagnostic messages, error messages and operating hours counters, see the respective sections of the present documentation.
Command Menu

Starting from the extended display, you can activate the command menu by pressing the "Up" key. In this menu, you can make several settings: ● ● ● Set the drive address (drive number in the bus system of the master com‐ munication) Set the length of the fiber optic cable Other communication settings (IP address, gateway address and subnet mask) for CCD option, SERCOS III master communication or control sec‐ tion CSH01.2

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Basics on Device Diagnosis ● ● ● Activate the easy master communication mode "Easy Startup" Activate "S?0?0262, C07_x Load defaults procedure command" (load con‐ troller parameters or basic parameters) Activate other commands, such as – – – – ● ● C2200 Backup working memory procedure command C2300 Load working memory procedure command C2800 Analog input adjust command C2000 Command Release motor holding brake (must be enabled by means of configuration) Switch the communication phases between operating mode (OM) and parameter mode (PM) Set the MMC storage mode (see P?0?4070)

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Basics on Device Diagnosis

Fig.4-15:
Settings for the "Load Defaults Pro‐ cedure" Command

Activating commands/settings that can be accessed via the control pan‐ el

The parameter "S-0-0262, C07_x Load defaults procedure command" can be activated via the standard control panel, too. Depending on the configuration in parameter "P?0?4090, Configuration for loading default values", different ba‐ sic parameter sets are loaded internally. The following configurations in pa‐

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Basics on Device Diagnosis rameter P?0?4090 are possible via the standard control panel, the last two digits of the hexadecimal parameter value being displayed on the standard display: ● ● ● ● ● ● Loading motor-specific control loop parameter values → 0x0000 Loading basic parameter values, without exception → 0x0001 Loading basic parameter values, except for master communication pa‐ rameters → 0x0011 Loading basic parameter values, except for parameters of the drive-inter‐ nal PLC (MLD) → 0x0021 Loading basic parameter values, except for master communication and MLD parameters → 0x0031 Loading default values to the MLD parameters → 0x0002 After the command C07_x has been executed, the parameter P?0?4090 is automatically reset to its default value (0x0000)!

Fig.4-16:
Setting the Ethernet Address

Setting the parameter P-0-4090 for "load defaults procedure" via the standard control panel

For communication in Ethernet networks, make the following settings for the relevant interfaces: ● ● ● IP address Subnet mask Default gateway

The following interfaces are Ethernet-based:

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Basics on Device Diagnosis ● ● ● Engineering Port of control section (P?0?1531, P?0?1532, P?0?1533) Master communication SERCOS III (S?0?1020, S?0?1021, S?0?1022) CCD interface (P?0?1641, P?0?1642, P?0?1643)

The settings can be made via the standard control panel and are basically the same for all Ethernet-based interfaces.

GW SN IP Switching the Communication Pha‐ ses

Fig.4-17:

gateway address, e.g. 0. 0. 0. 0 subnet mask, e.g. 255.255.255. 0 IP address, e.g. 192.168. 1. 2

Setting the Ethernet communication, as an example of the control sec‐ tion Engineering Port

Switching the communication phases between operating mode (OM) and pa‐ rameter mode (PM) via the control panel is possible with all master communi‐ cations, except for SERCOS interface. With SERCOS interface, phase switch controlled via the control panel can only be carried out with active "easy startup" mode! In order to carry out "C07_1 Load defaults procedure com. (load basic parameters)", the parameter mode (PM) has to be activated.

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Fig.4-18:

Activating the parameter mode via the control panel

Fig.4-19:
Defining the MMC Storage Mode

Switching back from parameter mode to operating mode via the control panel

The parameter "P?0?4070, Parameter storage configuration" defines how the controller handles the (optional) MMC memory card. This setting can be made directly via the command menu of the control panel (2.10). The following stor‐ age modes are possible for operating the MMC: ● ● ● MMC as programming module MMC as update medium MMC as backup medium

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Basics on Device Diagnosis
MMC as Programming Module

If the MMC has been defined as "programming module", all parameters are stored on the MMC. With active controller, the MMC must be permanently plugged in the control section. If the controller is switched on without MMC or the MMC is removed from the active controller, the controller signals an error. When the MMC has been defined as "update medium", the control section checks during the booting process whether an MMC was plugged in or not. Via the display, you will be queried whether the parameters are to be loaded from the MMC. If there is a newer firmware on the MMC, you will also be queried whether this firmware is to be loaded. The parameters are not stored on the MMC, but in the onboard flash memory. When the MMC has been defined as "backup medium", it is used as a demanddepending storage location for parameter settings. The parameter values are stored via a command, via FTP server or file services (MLD). When the MMC operation has been defined as "update medium" or as "backup medium", it is not necessary to have the MMC permanently plugged in the con‐ trol section. The MMC can be plugged in or removed with the drive active. Loading and storing parameter sets, however, is only possible with the MMC plugged in! The possibilities of use for the MMC in the IndraDrive controller are described in detail in the "MultiMediaCard (MMC)" section.

MMC as Update Medium

MMC as Backup Medium

Fig.4-20:
Service Menu

Setting the MMC storage mode with the control panel

Starting from the command menu, you can activate the service menu by press‐ ing the "Up" key. It supports the following actions:

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Rexroth IndraDrive | Troubleshooting Guide

Basics on Device Diagnosis ● Firmware update with previous saving of the parameter values on the in‐ ternal memory (flash), if the optional memory (MMC) is the active memory (MMC as "programming module"). After the update, the parameter values can be loaded to the MMC again from the internal memory (flash). Note: If the internal memory (flash) is the active storage medium ("hot plug" of the MMC), the parameter values are already available in the de‐ vice and do not need to be saved before the MMC-based firmware update. In this case, pressing the "Enter" key with the display "Save data" is without effect! ● Replacement of device with saving of parameter values on MMC, if the internal memory (flash) is the active memory. After the device has been replaced, firmware and values of the drive parameters, as well as PLC retain data, can be loaded from this MMC to the replacement controller. Note: If the control section has been equipped with the optional module "MDx", the retain data of the PLC are saved on the MMC in addition to the values of the drive parameters, when "Save data" is executed! When the MMC is the active memory, the drive parameters are not saved, because they have already been stored on the MMC, but the PLC data are stored on the MMC. ● Copy parameters: – Storing the parameter values and, if necessary, the PLC retain data from the device-internal, non-volatile memories (onboard flash and, if available, memory of optional module "MDx") on the MMC Loading the parameter values stored on the MMC to the non-volatile memories of the controller



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Electric Drives | Bosch Rexroth AG and Controls

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Basics on Device Diagnosis

Fig.4-21:

Activating the functions of the service menu

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Bosch Rexroth AG | Electric Drives and Controls

Rexroth IndraDrive | Troubleshooting Guide

Basics on Device Diagnosis

Notes on Commissioning
Property damage caused by command-dependent activation of motors and moving elements! CAUTION
? Bring axis resp. moving parts in safe initial position; limit travel range and drive power! By pressing the "Esc" key again the standard display will reappear. The input via the keys is polled in an 8 ms-cycle, the display is up‐ dated in an 8 ms-cycle, too!

4.3
4.3.1

Terms, Basic Principles
Parameters
Communication between master and drive takes place, with a few exceptions, by means of parameters. Parameters are used for: ● ● ● ● Determining the configuration Parameterizing the control loop Triggering and controlling drive functions and commands Transmitting command values and actual values (according to require‐ ments, cyclically or acyclically)

All operating data are mapped to parameters! The operating data stored in parameters can be identified by means of the IDN. They can be read and transferred, if required. The user write access to param‐ eters depends on the properties of the respective parameter and the current communication phase. Specific parameter values (operating data) are checked for validity by the drive firmware.

4.3.2

Data Storage and Parameter Handling
Data Memory

Several non-volatile data memories are available in an IndraDrive device: ● ● ● In the controller In the motor encoder (depending on motor type) As a MultiMediaCard (MMC), optional

In addition, a volatile data memory (working memory) is available in the con‐ troller.
Condition as Supplied

Condition as supplied of the Rexroth drive components: ● ● ● The controller memory contains the drive firmware and the controller-spe‐ cific parameter values. The motor encoder memory contains the encoder-specific and, depending on the motor type, the motor-specific parameter values. The MMC contains the drive firmware and the basic parameter sets.

Storing the Application-Specific Pa‐ rameter Values

The application-specific parameter values are stored in the controller. Due to the limited number of writing cycles of non-volatile storage media, applicationspecific parameter values can be stored in the working memory (volatile mem‐ ory), too. Saving application-specific parameter values is required in the following cases:

Storing of Parameter Values

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Basics on Device Diagnosis ● ● ● ● ●
Parameter IDN L

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