Bosch Rexroth IndraDrive MPH-02 Operating and installation instructions

R911299225
Edition 01
Rexroth IndraDrive
Firmware for Drive Controllers
MPH-02, MPB-02, MPD-02
Functional Description
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
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About this Documentation MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Rexroth IndraDrive
Firmware für Drive Controllers
MPH-02, MPB-02, MPD-02
Functional Description
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Box: 81-01V-EN
Document Number: 120-2400-B310-01/EN
This documentation describes all functional features of the IndraDrive
firmware in the variants MPH-02, MPB-02 and MPD-02.
Description Release
Date
Notes
DOK-INDRV*-MP*-02VRS**-FK01-EN-P 03.2004 First Edition
2004 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).
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 availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.com/
Dept. EDY (mw/mr/hm/bb)
This document has been printed on chlorine-free bleached paper.
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MPH-02, MPB-02, MPD-02 Contents I
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Contents
1 System Overview 1-1
1.1 General Information ...................................................................................................................... 1-1
Overview of Drive Firmware..................................................................................................... 1-1
Terms, Basic Principles ........................................................................................................... 1-2
How to Use this Documentation............................................................................................... 1-7
1.2 Drive Controllers ......................................................................................................................... 1-10
Overview ................................................................................................................................ 1-10
Power Sections ...................................................................................................................... 1-11
Control Sections..................................................................................................................... 1-11
1.3 Motors and Measuring Systems .................................................................................................1-15
Supported Motors .................................................................................................................. 1-15
Supported Measuring Systems.............................................................................................. 1-15
1.4 Master Communication ............................................................................................................... 1-16
1.5 Overview of Functions................................................................................................................. 1-17
Supported Operating Modes.................................................................................................. 1-17
Drive Functions ...................................................................................................................... 1-17
1.6 Functional Packages................................................................................................................... 1-18
Overview ................................................................................................................................ 1-18
Base Packages ...................................................................................................................... 1-24
Alternative Functional Packages ........................................................................................... 1-27
Additive Functional Packages................................................................................................ 1-28
2 Important directions for use 2-1
2.1 Appropriate use............................................................................................................................. 2-1
Introduction .............................................................................................................................. 2-1
Areas of use and application....................................................................................................2-2
2.2 Inappropriate use .......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction ................................................................................................................................... 3-1
3.2 Explanations.................................................................................................................................. 3-1
3.3 Hazards by Improper Use ............................................................................................................. 3-2
3.4 General Information ...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 3-6
3.7 Protection Against Dangerous Movements .................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting ....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts.................................................................................. 3-10
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II Contents MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
3.10 Protection During Handling and Mounting .................................................................................. 3-10
3.11 Battery Safety.............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Master Communication 4-1
4.1 Basic Functions of Master Communication................................................................................... 4-1
Address Assignment ................................................................................................................ 4-1
Command Processing..............................................................................................................4-3
Device Control (Status Machine) ............................................................................................. 4-5
4.2 Possibilities of Control/Additional Functions ............................................................................... 4-15
Configurable Signal Control Word ......................................................................................... 4-15
Configurable Signal Status Word........................................................................................... 4-17
4.3 Profile Types (with Field Bus Interfaces) ....................................................................................4-19
Overview ................................................................................................................................ 4-19
I/O Mode ................................................................................................................................ 4-21
Freely Configurable Mode (Rexroth Profile Type) ................................................................. 4-24
Exemplary Configurations...................................................................................................... 4-28
4.4 SERCOS interface ...................................................................................................................... 4-32
Brief Description..................................................................................................................... 4-32
Commissioning the SERCOS interface ................................................................................. 4-34
Cyclic Data Transfer .............................................................................................................. 4-37
Transmission of Non-Cyclical Data........................................................................................ 4-39
Interface Errors and Diagnostic Possibilities .........................................................................4-39
Real-Time Control Bits and Real-Time Status Bits................................................................4-40
4.5 PROFIBUS-DP............................................................................................................................ 4-41
Brief Description..................................................................................................................... 4-41
Configuring the PROFIBUS-DP Slave................................................................................... 4-43
Parameter Channel in the Cyclic Channel (Device-Specific) ................................................4-46
DPV1 Parameter Communication (ProfiDrive) ...................................................................... 4-50
Cyclic Communication via Process Data Channel................................................................. 4-52
Monitoring Functions and Diagnostic Functions.................................................................... 4-53
4.6 Parallel Interface ......................................................................................................................... 4-56
Brief Description..................................................................................................................... 4-56
Functional Description ........................................................................................................... 4-56
Notes on Commissioning/Parameterization........................................................................... 4-59
Diagnostic and Status Messages .......................................................................................... 4-62
4.7 Analog Interface.......................................................................................................................... 4-63
Brief Description..................................................................................................................... 4-63
Functional Description ........................................................................................................... 4-66
Notes on Commissioning/Parameterization........................................................................... 4-68
Diagnostic and Status Messages .......................................................................................... 4-70
5 Motor, Mechanical Axis System, Measuring Systems 5-1
5.1 General Information on the Operation of Motors with IndraDrive ................................................. 5-1
Basics on the Motors to be Controlled..................................................................................... 5-1
Motor Temperature Monitoring ................................................................................................ 5-2
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MPH-02, MPB-02, MPD-02 Contents III
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Motor Holding Brake ................................................................................................................ 5-5
5.2 Rexroth Motors............................................................................................................................ 5-17
Basics on Rexroth Motors...................................................................................................... 5-17
Rexroth Housing Motors with Encoder Data Memory ........................................................... 5-19
Rexroth Housing Motors without Encoder Data Memory ...................................................... 5-21
Rexroth Kit Motors ................................................................................................................. 5-23
Rexroth Kit Motors, Synchronous .......................................................................................... 5-23
Rexroth Kit Motors, Asynchronous ........................................................................................ 5-25
5.3 Third-Party Motors at IndraDrive Controllers .............................................................................. 5-25
General Information on Third-Party Motors ........................................................................... 5-25
Requirements on Third-Party Motors..................................................................................... 5-27
General Information on Controlling Third-Party Motors......................................................... 5-28
Determining the Motor Parameter Values ............................................................................. 5-31
Forms for Required Manufacturer-Side Output Data............................................................. 5-44
Forms for Parameter Values.................................................................................................. 5-47
Notes on Commissioning ....................................................................................................... 5-49
5.4 Measuring Systems .................................................................................................................... 5-50
Basics on Measuring Systems, Resolution............................................................................ 5-50
Monitoring the Measuring Systems ....................................................................................... 5-56
Absolute Measuring Systems ................................................................................................ 5-62
Relative Measuring Systems ................................................................................................. 5-66
5.5 Mechanical Axis System and Measuring Systems ..................................................................... 5-70
Measuring Systems for Motor and Axis Control, Arrangement ............................................. 5-70
Scaling of Physical Data ........................................................................................................5-77
6 Drive Control 6-1
6.1 Overview of Drive Control ............................................................................................................. 6-1
Open-Loop Axis Control (Open-Loop Operation) .................................................................... 6-1
Closed Loop Axis Control (Closed-Loop Operation) ...............................................................6-2
6.2 Motor Control ................................................................................................................................ 6-2
General Information on Motor Control ..................................................................................... 6-2
Voltage-Controlled Operation (Open-Loop U/f Control) .......................................................... 6-3
Field-Oriented Closed-Loop Current Control......................................................................... 6-10
Commutation Setting .............................................................................................................6-19
6.3 Axis Control (Open-Loop Operation) .......................................................................................... 6-34
Brief Description..................................................................................................................... 6-34
Functional Description ........................................................................................................... 6-36
Diagnostic and Status Messages .......................................................................................... 6-36
6.4 Axis Control (Closed-Loop Operation)........................................................................................ 6-37
Overview ................................................................................................................................ 6-37
Automatic Setting of Axis Control .......................................................................................... 6-42
Velocity Loop (with Respective Filters).................................................................................. 6-50
Position Loop (with Respective Feedforward Functions) ...................................................... 6-60
6.5 Limitations ................................................................................................................................... 6-63
Overview ................................................................................................................................ 6-63
Current and Torque Limitation (Open-Loop).......................................................................... 6-64
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IV Contents MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Current and Torque Limitation (Closed-Loop) ....................................................................... 6-64
Velocity Limitation .................................................................................................................. 6-71
Position Limitation/Travel Range Limit Switch....................................................................... 6-72
6.6 Power Supply.............................................................................................................................. 6-79
Possibilities of Power Supply for IndraDrive.......................................................................... 6-79
Functional Description ........................................................................................................... 6-83
Notes on Commissioning ....................................................................................................... 6-91
7 Operating Modes 7-1
7.1 Overview of Operating Modes ...................................................................................................... 7-1
Supported Operating Modes.................................................................................................... 7-1
Operating Mode Handling........................................................................................................ 7-1
7.2 Torque/Force Control.................................................................................................................... 7-4
Brief Description....................................................................................................................... 7-4
Command Value Processing in Torque/Force Control ............................................................ 7-5
Current Loop ............................................................................................................................ 7-7
Diagnostic Messages and Monitoring Functions ..................................................................... 7-8
7.3 Velocity Control ............................................................................................................................. 7-8
Brief Description....................................................................................................................... 7-8
Command Value Adjustment in Velocity Control................................................................... 7-10
Velocity Control Loop............................................................................................................. 7-13
Notes on Commissioning ....................................................................................................... 7-14
Diagnostic Messages and Monitoring Functions ................................................................... 7-15
7.4 Position Control with Cyclic Command Value Input.................................................................... 7-16
Brief Description..................................................................................................................... 7-16
Command Value Processing in Position Control................................................................... 7-18
Position Controller.................................................................................................................. 7-19
Diagnostic Messages and Monitoring Functions ................................................................... 7-20
7.5 Drive-Internal Interpolation.......................................................................................................... 7-21
Brief Description..................................................................................................................... 7-21
Command Value Processing with Drive-Internal Interpolation .............................................. 7-23
Position Loop with Drive-Internal Interpolation ...................................................................... 7-24
Notes on Commissioning ....................................................................................................... 7-24
Diagnostic Messages and Monitoring Functions ................................................................... 7-26
7.6 Drive-Controlled Positioning ....................................................................................................... 7-28
Brief Description..................................................................................................................... 7-28
Command Value Processing with Drive-Controlled Positioning............................................ 7-30
Position Loop with Drive-Controlled Positioning.................................................................... 7-35
Notes on Commissioning ....................................................................................................... 7-35
Diagnostic Messages and Monitoring Functions ................................................................... 7-38
7.7 Positioning Block Mode............................................................................................................... 7-40
Brief Description..................................................................................................................... 7-40
Command Value Processing in Positioning Block Mode....................................................... 7-43
Single-Block Processing ........................................................................................................ 7-43
Sequential Block Processing ................................................................................................. 7-60
Notes on Commissioning/Parameterization........................................................................... 7-71
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MPH-02, MPB-02, MPD-02 Contents V
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Diagnostic and Status Messages, Acknowledgment............................................................. 7-73
7.8 Synchronization Modes............................................................................................................... 7-76
Basic Functions of the Synchronization Modes..................................................................... 7-76
Velocity Synchronization with Real/Virtual Master Axis......................................................... 7-96
Phase Synchronization with Real/Virtual Master Axis ......................................................... 7-102
Electronic Cam Shaft with Real/Virtual Master Axis ............................................................ 7-112
8 Drive Functions 8-1
8.1 Drive Halt ...................................................................................................................................... 8-1
Brief Description....................................................................................................................... 8-1
Functional Description ............................................................................................................. 8-1
Notes on Commissioning ......................................................................................................... 8-3
8.2 Establishing the Position Data Reference.....................................................................................8-4
General Information on Establishing the Position Data Reference ......................................... 8-4
Establishing Position Data Reference for Relative Measuring Systems ................................. 8-7
Establishing Position Data Reference for Absolute Measuring Systems .............................. 8-26
Shifting the Position Data Reference for Relative and Absolute Measuring Systems .......... 8-31
8.3 Error Reactions ........................................................................................................................... 8-35
Overview of Error Reactions .................................................................................................. 8-35
Best Possible Deceleration .................................................................................................... 8-36
Package Reaction on Error.................................................................................................... 8-42
NC Reaction on Error............................................................................................................. 8-44
8.4 E-Stop Function .......................................................................................................................... 8-45
Brief Description..................................................................................................................... 8-45
Functional Description ........................................................................................................... 8-45
Notes on Commissioning ....................................................................................................... 8-46
Diagnostic and Status Messages .......................................................................................... 8-47
8.5 Compensation Functions/Corrections......................................................................................... 8-48
Friction Torque Compensation............................................................................................... 8-48
Encoder Correction ................................................................................................................ 8-50
Axis Error Correction.............................................................................................................. 8-53
Quadrant Error Correction ..................................................................................................... 8-68
8.6 Detecting the Marker Position..................................................................................................... 8-72
Brief Description..................................................................................................................... 8-72
Functional Description ........................................................................................................... 8-72
8.7 Measuring Wheel Mode/Hybrid Position Control ........................................................................ 8-73
Brief Description..................................................................................................................... 8-73
Functional Description ........................................................................................................... 8-74
Notes on Commissioning ....................................................................................................... 8-77
8.8 Positive Stop Drive Procedure .................................................................................................... 8-78
Brief Description..................................................................................................................... 8-78
Functional Description ........................................................................................................... 8-79
Notes on Commissioning ....................................................................................................... 8-80
8.9 Spindle Positioning...................................................................................................................... 8-80
Brief Description..................................................................................................................... 8-80
Functional Description ........................................................................................................... 8-81
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VI Contents MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Notes on Commissioning ....................................................................................................... 8-84
Diagnostic Messages.............................................................................................................8-85
8.10 Rexroth IndraMotion MLD-S (Drive-Integrated PLC).................................................................. 8-86
Brief Description..................................................................................................................... 8-86
Notes on Installation/System Configuration........................................................................... 8-88
Overview of Available Libraries.............................................................................................. 8-89
8.11 Drive-Integrated Safety Technology ........................................................................................... 8-91
Safety Related Starting Lockout ............................................................................................ 8-91
Integrated Safety Functions................................................................................................... 8-92
9 Extended Drive Functions 9-1
9.1 Probe Function.............................................................................................................................. 9-1
Brief Description....................................................................................................................... 9-1
Functional Description ............................................................................................................. 9-2
Notes on Commissioning ......................................................................................................... 9-6
9.2 Measuring Encoder....................................................................................................................... 9-8
Brief Description....................................................................................................................... 9-8
Functional Description ........................................................................................................... 9-10
Notes on Commissioning ....................................................................................................... 9-16
9.3 Encoder Emulation...................................................................................................................... 9-18
Brief Description..................................................................................................................... 9-18
Basic Information on the Function ......................................................................................... 9-20
Incremental Encoder Emulation............................................................................................. 9-21
Absolute Encoder Emulation.................................................................................................. 9-24
Notes on Commissioning ....................................................................................................... 9-26
Diagnostic and Status Messages .......................................................................................... 9-28
9.4 Analog Inputs .............................................................................................................................. 9-28
Brief Description..................................................................................................................... 9-28
Functional Description ........................................................................................................... 9-30
Notes on Commissioning ....................................................................................................... 9-34
Diagnostic Messages and Status Displays............................................................................ 9-35
9.5 Analog Outputs ........................................................................................................................... 9-36
Brief Description..................................................................................................................... 9-36
Functional Description ........................................................................................................... 9-37
Notes on Commissioning ....................................................................................................... 9-41
9.6 Digital Inputs/Outputs.................................................................................................................. 9-42
Brief Description..................................................................................................................... 9-42
Notes on Commissioning for Digital I/Os of Control Section ................................................. 9-44
Notes on Commissioning for Digital I/Os of Optional Module MD1....................................... 9-49
Diagnostic Messages and Status Displays............................................................................ 9-53
Hardware Requirements ........................................................................................................ 9-54
10 Handling, Diagnostic and Service Functions 10-1
10.1 Parameters, Basics..................................................................................................................... 10-1
Properties, Features of Parameters....................................................................................... 10-1
Loading, Storing and Saving Parameters.............................................................................. 10-3
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MPH-02, MPB-02, MPD-02 Contents VII
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
IDN Lists of Parameters....................................................................................................... 10-11
Using a Password ................................................................................................................ 10-13
10.2 Device Configuration................................................................................................................. 10-17
Controller Design ................................................................................................................. 10-17
Circuit Board Code............................................................................................................... 10-18
Hours-Run Meter ................................................................................................................. 10-19
Error Memory (Power Section and Control Section) ........................................................... 10-20
10.3 Diagnostic System .................................................................................................................... 10-21
Coded Diagnostic Drive Messages...................................................................................... 10-21
Status Classes, Status Displays, Control Parameters.........................................................10-24
10.4 Control Panel of the IndraDrive Controllers .............................................................................. 10-30
Brief Description................................................................................................................... 10-30
Functional Description ......................................................................................................... 10-31
Notes on Commissioning ..................................................................................................... 10-37
10.5 MultiMediaCard (MMC)............................................................................................................. 10-37
Brief Description................................................................................................................... 10-37
MMC Folder Structure.......................................................................................................... 10-38
Firmware Update with MMC ................................................................................................ 10-39
Notes on Commissioning ..................................................................................................... 10-41
10.6 Firmware Update....................................................................................................................... 10-43
General Information ............................................................................................................. 10-43
Firmware Update with "Dolfi" Program ................................................................................ 10-43
Firmware Update with MultiMediaCard (MMC).................................................................... 10-43
10.7 Notes on How to Replace the Devices ..................................................................................... 10-44
Supply Units......................................................................................................................... 10-44
Drive Controllers .................................................................................................................. 10-44
10.8 Enabling of Functional Packages.............................................................................................. 10-49
Brief Description................................................................................................................... 10-49
Functional Description ......................................................................................................... 10-50
Notes on Commissioning ..................................................................................................... 10-53
Monitoring the Enabling of Functional Packages ................................................................ 10-54
10.9 Extended Diagnostic Possibilities ............................................................................................. 10-55
Monitoring Function ............................................................................................................. 10-55
Logbook Function ................................................................................................................ 10-56
Patch Function ..................................................................................................................... 10-57
10.10 Oscilloscope Function............................................................................................................... 10-62
Brief Description................................................................................................................... 10-62
General Information on the Oscilloscope Function.............................................................. 10-64
Trigger Function................................................................................................................... 10-66
Synchronizing the Measuring Signals of Several Axes ....................................................... 10-70
Parameterizing the Oscilloscope Function .......................................................................... 10-72
Diagnostic and Status Messages ........................................................................................ 10-73
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VIII Contents MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
10.11 Serial Communication............................................................................................................... 10-74
Overview of Serial Communication...................................................................................... 10-74
Functional Principle Independent of Protocol ...................................................................... 10-76
Communication with ASCII Protocol.................................................................................... 10-81
Communication with SIS Protocol ....................................................................................... 10-91
11 Commissioning 11-1
11.1 Commissioning Motors................................................................................................................ 11-1
Checking the Installation/Assembly ....................................................................................... 11-1
Initial Commissioning/Serial Commissioning ......................................................................... 11-1
Initial Start in "Easy Startup" Mode........................................................................................ 11-4
Initial Start with DriveTop Commissioning Tool ................................................................... 11-10
11.2 Commissioning Machine Axes.................................................................................................. 11-14
Overview and Practical Tips ................................................................................................ 11-14
12 Index 12-1
13 Service & Support 13-1
13.1 Helpdesk ..................................................................................................................................... 13-1
13.2 Service-Hotline............................................................................................................................ 13-1
13.3 Internet ........................................................................................................................................ 13-1
13.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................... 13-1
13.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 13-2
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MPH-02, MPB-02, MPD-02 System Overview 1-1
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
1 System Overview
1.1 General Information
Overview of Drive Firmware
Firmware Variants
For the IndraDrive range, there are different application-related firmware
variants available that are characterized by their scope of functions and
their performance:
•MTH: Drives for Machine Tool Applications with SERCOS interface
(Advanced Performance and Functionality)
•MPX: Drives for General Automation (Incl. Machine Tool Applications)
with SERCOS interface, Profibus, as well as Parallel and Analog
Interface
(the variants of design are MPH, MPB and MPD; see below)
Note: The first two letters of the firmware designation identify the
application and profile of the firmware:
•MT: "Machine Tool" →Drives for Machine Tool
Applications with SERCOS interface
(drive profile according to SERCOS)
•MP: "Multi Purpose" →Drives for General Automation
(Incl. Machine Tool Applications) with
SERCOS interface, Profibus, as well as Parallel and
Analog Interface
(drive profile according to SERCOS)
The third letter of the firmware designation identifies the
hardware and performance and functionality of the firmware
(Xincludes H, B and D):
•H:single-axis firmware with advanced performance and
functionality
•B:single-axis firmware with basic performance and
functionality
•D:double-axis firmware with basic performance and
functionality
This documentation describes the functionality of the following firmware
variants:
•FWA-INDRV*-MPH-02VRS-MS
•FWA-INDRV*-MPB-02VRS-MS
•FWA-INDRV*-MPD-02VRS-MS
The "DriveTop" commissioning tool in version DTOP16 is available for
commissioning these firmware variants.
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1-2 System Overview MPH-02, MPB-02, MPD-02
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Organization of the Firmware
For application-specific definition of drive functionality the firmware
functions are divided into different "functional packages". There are a
generally available basic package and various additional functional
packages (e.g. drive-integrated safety technology, IndraMotion MLD-S)
that can be optionally activated.
Note: The scope of functions of the functional packages and their
possible combinations are described in the section "Functional
Packages" in the same chapter.
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
requirements, 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 parameters 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.
Data Storage and Parameter Handling
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
controller.
Condition as supplied of the Rexroth drive components:
•The controller memory contains the drive firmware and the controller-
specific 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.
The application-specific parameter values are stored in the controller. Due
to the limited number of writing cycles of non-volatile storage media,
application-specific parameter values can be stored in the working
memory (volatile memory), too.
Data Memory
Condition As Supplied
Storing the Application-Specific
Parameter Values
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MPH-02, MPB-02, MPD-02 System Overview 1-3
DOK-INDRV*-MP*-02VRS**-FK01-EN-P
Saving application-specific parameter values is required in the following
cases:
•after initial commissioning of the machine axis or the motor
•before replacing the controller for servicing (if possible)
Application-specific parameter values can be saved via:
•MMC →copying the parameter values by command
•"DriveTop" commissioning tool →saving the parameter values on
external data carrier
•control master →saving the parameter values on master-side data
carrier
The drive supports master-side saving of parameter values by listing
parameter identification numbers (IDNs). Using these lists guarantees
complete storage of the application-specific parameter values. It is also
possible to determine IDN lists defined by the customer.
Loading parameter values is required in the following cases:
•initial commissioning of the motor (loading basic parameter values and
motor-specific parameter values)
•serial commissioning of machine axes at series machines (loading the
values saved after initial commissioning)
•reestablishing a defined original status (repeated loading of the values
saved after initial commissioning)
•replacing the controller for servicing (loading the current parameter
values saved before servicing)
Possibilities of loading parameter values to the controller:
•motor encoder data memory →loading the parameter values by
command or via the control panel during initial motor commissioning
•MMC →loading the parameter values by command
•"DriveTop" commissioning tool →loading the parameter values from
external data carrier
•control master →loading the parameter values from master-side data
carrier
By means of checksum comparison, the control master can determine
whether the values of the application-specific parameter values currently
active in the drive correspond to the values saved on the master side.
Password
IndraDrive controllers provide the possibility to protect parameter values
against accidental or unauthorized change by means of a password. With
regard to write protection, there are 3 groups of parameters that can be
written:
•Parameters that are write-protected as a standard, such as motor
parameters, hardware code parameters, encoder parameters, error
memory etc. ("administration parameters"). The values of these
parameters guarantee correct function and performance of the drive.
•Parameters the customer can combine in groups and protect them
with a so-called customer password. This allows protecting parameter
values, that are used for adjusting the drive to the axis, after having
determined them.
•All other parameters that can be written and are not contained in the
above-mentioned groups. They are not write-protected.
Saving Parameter Values
Parameter IDN Lists
Loading Parameter Values
Checksum of Parameter Values
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1-4 System Overview MPH-02, MPB-02, MPD-02
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The drive firmware allows activating and deactivating the write protection
for parameter values by means of three hierarchically different
passwords:
•Customer password
The parameter values of a parameter group combined by the
customer can be protected.
•Control password
Parameters protected by a customer password can be written;
"administration parameters" remain write-protected.
•Master password
All parameters that can be written, including "administration
parameters" and parameters protected by a customer password, can
be changed.
Commands
Commands are used to activate and control complex functions or
monitoring features in the drive. The higher-level master can start,
interrupt or clear commands.
Each command is assigned to a parameter by means of which the
execution of the command can be controlled. During the execution of the
command the display of the control panel reads "Cx", "C" representing the
diagnostic command message and "x" representing the number of the
command.
Note: Each command that was started must be actively cleared
again.
All commands available in the drive are stored in the S-0-0025, IDN-list
of all procedure commands parameter.
There are 3 different kinds of commands:
•Drive control commands
•can cause automatic drive motion,
•can be started only when drive enable has been set,
•deactivate the active operating mode during its execution.
•Monitoring commands
•activate or deactivate monitors or functions in the drive.
•Administration commands
•carry out administration tasks,
•cannot be interrupted.
See also "Command Processing" in chapter "Master Communication"
Kinds of Passwords
Kinds of Commands
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Operating Modes
The selection of operating modes defines which command values will be
processed in which way, in order to lead to the desired drive motion. The
operating mode does not determine how these command values are
transmitted from the master to the slave.
One of the four operating modes defined in the parameters
S-0-0032 to S-0-0035 is always active when the following conditions have
been fulfilled:
•control section and power section are ready for operation
•drive enable signal sees a positive edge
•drive follows command value
•"Drive Halt" function has not been activated
•no drive control command is active
•no error reaction is carried out
The display of the control panel reads "AF" when an operating mode was
activated.
Note: All implemented operating modes are stored in the S-0-0292,
List of all operating modes parameter.
See also chapter "Operating Modes"
Warnings
Depending on the active operating mode and the parameter settings,
many monitoring functions are carried out. If a status is detected that still
allows correct operation but in case this status persists will cause an error
to occur and therefore cause the drive to be automatically switched off,
the drive firmware generates a warning message.
Note: Warnings do not cause automatic shutdown (exception: fatal
warning).
Warnings are classified in different warning classes which determine
whether the drive, when the warning is generated, carries out an
automatic reaction or not.
Note: The warning class can be recognized by the diagnostic
message.
The following classes of warnings are distinguished:
•without drive reaction →diagnostic message numbers E1xxx to
E7xxx
•with drive reaction →diagnostic message number E8xxx
Note: Warnings cannot be cleared. They persist until the condition
that activated the warning is no longer fulfilled.
Warning Classes
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1-6 System Overview MPH-02, MPB-02, MPD-02
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Errors
Depending on the active operating mode and the parameter settings,
many monitoring functions are carried out. If a status is detected that
affects or prevents correct operation the drive firmware generates an
error message.
Errors are classified in different error classes. There are 6 error classes
with different drive error reactions.
Note: The error class can be recognized by the diagnostic message
number.
Diagnostic message
number
Error class
F2xxx non-fatal error
F3xxx non-fatal safety technology error
F4xxx interface error
F6xxx travel range error
F7xxx safety technology error
F8xxx fatal error
F9xxx fatal system error
E-xxxx fatal system error "processor exception"
Fig. 1-1: Overview of error classes
Note: Apart from the mentioned error classes that can occur during
operation, errors can occur when the devices are booted and
during firmware download. These errors are not displayed at
the control panel with a diagnostic message number of the
"Fxxxx" pattern, but with a short text. Boot errors and firmware
download errors are separately described in the
documentation "Troubleshooting Guide".
If the drive controller is in control and an error status is detected, the
execution of a drive error reaction is automatically started. The diagnostic
message number "Fxxxx" flashes on the display of the control panel.
The drive reaction in the case of interface errors and non-fatal errors is
determined in parameter P-0-0119, Best possible deceleration At the
end of each error reaction, the drive is torque-free.
See also "Error Reactions" in chapter "Drive Functions"
Error messages are not cleared automatically but by the following action:
•activating the S-0-0099, C0500 Reset class 1 diagnostics command
- or -
•actuating the "Esc" button on the standard control panel
If the error status persists the error message is immediately generated
again.
Error Classes
Error Reactions of the Drive
Clearing Error Messages
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MPH-02, MPB-02, MPD-02 System Overview 1-7
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If a drive error occurs while operating with drive enable having been set,
the drive carries out an error reaction. The drive automatically deactivates
itself at the end of each error reaction; in other words, the output stage is
switched off and the drive switches from an energized to a de-energized
state.
To reactivate the drive:
•clear the error message and
•input a positive edge for drive enable again.
The diagnostic message numbers of occurring errors are written to an
error memory. This memory contains the diagnostic message numbers of
the last 50 errors that occurred and the time when they occurred. Errors
caused by a shutdown of the control voltage (e.g. F8070 +24Volt DC
error) are not stored in the error memory.
The diagnostic message numbers in the error memory are mapped to the
P-0-0192, Diagnostic numbers of error memory parameter and can be
displayed by means of the control panel. By means of the "DriveTop"
commissioning tool it is possible to display the diagnostic message
numbers and the respective times at which the errors occurred.
How to Use this Documentation
Structure of the Functional Description
The functional descriptions of the IndraDrive firmware are divided into
fixed chapters. The individual subjects of the firmware description are
assigned to these chapters according to their content.
The description of the respective firmware functionality is basically divided
into the following sections:
•Brief Description
•Functional Description
•Notes on Commissioning
•Diagnostic and Status Messages, Monitoring Functions
Within one subject these sections are always contained in the mentioned
order, but for practical and formal reasons they are not always existing or
may have a different title.
The brief description contains an overview of the firmware function or the
subject of the section. The brief description can contain, for example,
general basics, the most important features of the function, overviews and
examples of application. At the end of the brief description you can find,
where possible and reasonable, a list of the parameters and diagnostic
messages that are associated with this functions.
The section "Functional Description" explains the operating principle of
the respective drive function in an application-oriented way. The relevant
parameters of this function are described with regard to their settings and
effects. The parameter configuration is only explained in detail where this
is necessary for the description of the function. As a basic principle, the
functional description contains references to the separate documentations
for parameters and diagnostic messages.
Clearing Error Messages when
Drive Enable Was Set
Error Memory
Brief Description
Functional Description
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1-8 System Overview MPH-02, MPB-02, MPD-02
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The detailed description of the parameters, their function and
structure is contained in the separate documentation "Rexroth IndraDrive,
Parameter Description".
The detailed description of the diagnostic messages, their causes
and remedies is contained in the separate documentation
"Rexroth IndraDrive, Troubleshooting Guide" (description of diagnostic
messages).
The section "Notes on Commissioning" or "Notes on Parameterization"
provides the user with the steps required for commissioning the function,
similar to a checklist. The necessary parameter settings are described in
compact form and, if necessary, instructions are given for activating the
function and the diagnostic messages of the immediate functional
sequence are mentioned.
The section "Diagnostic and Status Messages" (also "Monitoring
Functions", if necessary) summarizes the diagnostic messages and
possible status displays available for the respective function and
describes them briefly. If there are function-specific monitoring functions,
they are also described in this section.
The detailed description of the diagnostic messages, their causes
and remedies is contained in the separate documentation
"Rexroth IndraDrive, Troubleshooting Guide" (description of diagnostic
messages).
Markers and Terms
The complete functionality of the IndraDrive firmware is divided into
functional packages (base packages and optional expansion packages).
The scope of the available functions does not only depend on the
hardware design, but in the majority of cases also on the variant and
characteristic of the firmware.
The descriptions of the master communication, the drive functions and
the operating modes have a marker containing information on the
availability of this functionality in the respective functional package of the
firmware, e.g.:
The application-specific scalability of the hardware and firmware provides
a multitude of possibilities. For detailed information the following terms
are used in the Functional Description:
•firmware range e.g. IndraDrive
•firmware design single-axis, double-axis (multi-axis)
•firmware variant e.g. MPH, MPB, MPD
•firmware version e.g. MPH-02VRS
•firmware characteristic open-loop/closed-loop
•Firmware performance basic/advanced
•firmware type complete firmware type designation
Notes on Commissioning
Diagnostic and Status
Messages, Monitoring Functions
Terms
Base package of all variants
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MPH-02, MPB-02, MPD-02 System Overview 1-9
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Note: In many cases the availability of certain functions within the
functional packages also depends on design, variant and
characteristic of the firmware.
The exact dependence of the firmware functions on the design
of hardware and firmware can be seen in the tables in section
"Functional Packages".
Cross References
Many basic subfunctions of the firmware as well as necessary settings
and definitions are of multiple use within the overall functionality or have
an effect on neighboring areas of the drive functionality. Such
subfunctions normally are described only once. Descriptions that are part
of other IndraDrive documentations (Parameter Description,
Troubleshooting Guide, Project Planning Manuals ...) are only repeated in
detail in exceptional cases. Cross references indicate the source for more
detailed information.
Cross references to other sections or documentations follow this scheme:
•references to sections in the same chapter by indicating title without
chapter
•references to sections in a different chapter by indicating title of
section and chapter
•References to another documentation are additionally marked
by the "info icon" unless they are contained in a note or put in
parentheses.
Further Documentations
Firmware documentation:
•Parameter Description
DOK-INDRV*-GEN-**VRS**-PA**-EN-P; part no. R911297317
•Troubleshooting Guide (description of diagnostic messages)
DOK-INDRV*-GEN-**VRS**-WA**-EN-P; part no. R911297319
•Firmware Version Notes
DOK-INDRV*-MPX-02VRS**-FV**-EN-P; part no. R911297315
•Drive-integrated safety technology
DOK-INDRV*-SI*-**VRS**-FK**-EN-P; part no. R911297838
•IndraMotion MLD-S (drive-integrated PLC)
DOK-INDRV*-MLD-S*VRS**-AW**-EN-P; part no. R911306084
Hardware documentation (Project Planning Manuals):
•Power sections
DOK-INDRV*-HMS+HMD****-PR**-EN-P; part no. R911295014
•Control sections
DOK-INDRV*-CSH********-PR**-EN-P; part no. R911295012
•IndraDrive M supply units
DOK-INDRV*-HMV-*******-PR**-EN-P; part no. R911299229
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1-10 System Overview MPH-02, MPB-02, MPD-02
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1.2 Drive Controllers
Overview
Design of the IndraDrive Controllers
An IndraDrive controller basically consists of two hardware components:
•power section
•control section
BASIC single-axis
limited performance and i nterface flexibility
BASIC double-axis
limited performance and i nterface flexibility
A DVANCED single-axis
high
performance and interface flexibility
IndraDrive C
IndraDrive M
power section
•compact or modular design
•scalable power
•uniform design
Compact
1 ... 110 kW
M odular
1 ... 120 kW
DF000108v01_en.fh7
control section
•scalable performance
•scalable functionality
•safety technology
Fig. 1-2: Design and types of the IndraDrive controllers
The following are connected to the power section:
•power supply unit (DC bus voltage)
•24 V control voltage
•motor
Note: Each of the two types of the control section is described in the
separate documentation; e.g. "IndraDrive Drive Controllers,
Power Sections, Project Planning Manual"
(DOK-INDRV*-HMS+HMD****-PR**-EN-P; part no. R911295014).
The control section is a separate part of the IndraDrive controller and is
plugged in the power section. The drive controller is supplied ex works
complete with control section. The control section may only be replaced
by a qualified service engineer.
Power Section
Control Section
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