Bosch Rexroth OptiFeed-FS EcoDrive 03 FLP04VRS Operating and installation instructions

R911296265
Edition 01
Rexroth OptiFeed-FS EcoDrive 03
with Integrated NC Control
FLP04VRS
Functional Description
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics

About this Documentation ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
Rexroth OPTIFEED-FS
ECODRIVE03
with Integrated NC Control
Functional Description
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
•Box 20-04V-EN
•Based on: FLP 04VRS
•Document Number, 120-1000-B352-01/EN
This documentation is a functional description for the firmware
FWA-ECODR3-FLP-04VRS-MS.
This documentation:
•describes the functional characteristics
Description Release
Date Notes
FWA-ECODR3-FLP-04VRS-MS 8/2003 First release
2003 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. BRC/ESG1 (wk/jb)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by
Note

ECODRIVE03-FL*-04VRS Table of Contents I
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
Table of Contents
1 System Overview 1-1
1.1 ECODRIVE03 - The Universal Drive Solution for Automation......................................................1-1
1.2 ECODRIVE03 – A Family of Drives..............................................................................................1-1
1.3 Drive Controllers and Motors ........................................................................................................1-2
1.4 Function Overview: FWA-ECODR3-FLP-04VRS-MS...................................................................1-3
Command Communications Interface .....................................................................................1-3
Supported Motor Types ...........................................................................................................1-3
Supported Measuring Systems................................................................................................1-3
Firmware Functions .................................................................................................................1-4
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
3.10 Protection During Handling and Mounting..................................................................................3-10
3.11 Battery Safety..............................................................................................................................3-11
3.12 Protection Against Pressurized Systems....................................................................................3-11
4 General Instructions for Start-Up 4-1
4.1 Explanation of Terms....................................................................................................................4-1
Communication........................................................................................................................4-1
Data Storage............................................................................................................................4-2
Operating Modes .....................................................................................................................4-3
Inputs / Outputs / Marker Flags ...............................................................................................4-4
Warning....................................................................................................................................4-4
Faults .......................................................................................................................................4-5

II Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
Basic Parameter/Basic Load....................................................................................................4-6
4.2 Quick Setup Instructions...............................................................................................................4-7
Downloading the Firmware......................................................................................................4-8
4.3 Diagnostic Message Options ........................................................................................................4-9
Overview of Diagnostic Message Options...............................................................................4-9
Drive-internal Diagnostic Message Generation.......................................................................4-9
Diagnostic Message Composition ...........................................................................................4-9
4.4 Language Selection ....................................................................................................................4-10
4.5 Firmware Update using the DOLFI Program ..............................................................................4-11
Firmware Update of ECODRIVE............................................................................................4-11
Firmware Update in BTV04/05...............................................................................................4-13
Error Message in the Firmware Loader .................................................................................4-14
Additional Problems when Loading Firmware .......................................................................4-17
5 Motor Configuration 5-1
5.1 Characteristics of the Motor Types...............................................................................................5-1
Motor-Feedback Data Memory................................................................................................5-1
Temperature Monitoring...........................................................................................................5-2
Load Default.............................................................................................................................5-2
5.2 Setting the Motor Type..................................................................................................................5-2
Automatic Setting of the Motor Type for Motors with Feedback Memory................................5-2
5.3 Synchronous Motors.....................................................................................................................5-3
5.4 Motor Holding Brake .....................................................................................................................5-3
Pertinent Parameters...............................................................................................................5-3
Setting the Motor Holding Brake Type.....................................................................................5-4
Setting Maximum Braking Time...............................................................................................5-6
Connecting the Motor Holding Brake.......................................................................................5-6
6 Writing the User Program 6-1
6.1 Overview of All User Commands..................................................................................................6-1
6.2 General Information ......................................................................................................................6-3
6.3 Program Input ...............................................................................................................................6-3
6.4 Starting the User Program ............................................................................................................6-4
6.5 Stopping the User Program ..........................................................................................................6-4
6.6 Variables .......................................................................................................................................6-5
User-Programmable Variables.................................................................................................6-6
General System Variables.......................................................................................................6-6
Axis-Related System Variables................................................................................................6-7
Indexed Variables ..................................................................................................................6-12
Additional Variable Definitions...............................................................................................6-14
6.7 Description of Commands...........................................................................................................6-15
ACC - Acceleration Change...................................................................................................6-15
AEA - Bit Set / Clear ..............................................................................................................6-16
AKN - Acknowledge Bit..........................................................................................................6-16
AKP - Acknowledge Byte.......................................................................................................6-17
APE - Byte Set / Clear ...........................................................................................................6-18

ECODRIVE03-FL*-04VRS Table of Contents III
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
APZ - Byte Set / Clear and Count..........................................................................................6-19
BAC - Branch Conditional on Count ......................................................................................6-19
BCE - Branch Conditional on Bit............................................................................................6-20
BIC - Branch Conditional on Bit Field Value..........................................................................6-20
BIO - Branch Conditional on Byte Compare..........................................................................6-22
BPA - Branch Conditional on Byte.........................................................................................6-23
CAN - Cam Shaft: Feed Angle...............................................................................................6-23
CID - Change Variable Value.................................................................................................6-24
CIO - Copy Bit Field...............................................................................................................6-25
CLC - Clear Counter ..............................................................................................................6-25
CLG - Cam Shaft: Stroke.......................................................................................................6-26
CMM - Cam Shaft: Assignment .............................................................................................6-26
CON - Continuous Operation.................................................................................................6-28
COU - Count ..........................................................................................................................6-28
CPJ - Compare and Jump .....................................................................................................6-30
CPL - Clear Position Lag .......................................................................................................6-31
CPS - Compare and Set a Bit................................................................................................6-31
CST - Clear Subroutine Stack ...............................................................................................6-32
CSY - Cam Shaft: Activation..................................................................................................6-33
CVT - Convert Variable <-> Marker.......................................................................................6-33
FAK - Length Scaling Factor..................................................................................................6-35
FOL - Follow Master ..............................................................................................................6-36
FUN - Functions.....................................................................................................................6-37
HOM - Home Axis..................................................................................................................6-38
JMP - Jump Unconditional.....................................................................................................6-39
JSR - Jump to Subroutine......................................................................................................6-39
JST - Jump and Stop .............................................................................................................6-40
JTK - Jump in Task................................................................................................................6-40
LAE - End: for Synchronization by Precise Positioning.........................................................6-41
LAL - Length: for Synchronization by Precise Positioning.....................................................6-41
LAR - Raster: for Synchronization by Precise Positioning.....................................................6-42
MAT - Mathematics................................................................................................................6-43
MOM - Torque Limitation.......................................................................................................6-44
NOP - No Operation...............................................................................................................6-45
PBK - Stop Motion .................................................................................................................6-45
PFA - Positioning, Absolute to Positive Stop.........................................................................6-46
PFI - Positioning, Incremental to Positive Stop......................................................................6-46
POA - Positioning, Absolute...................................................................................................6-48
POI - Positioning, Incremental...............................................................................................6-49
PSA - Positioning, Absolute with In-Position .........................................................................6-50
PSI - Positioning, Incremental with In-Position......................................................................6-51
REP - Registration Position Limit...........................................................................................6-52
RTM - Rotary Table Mode .....................................................................................................6-52
RTS - Return from Subroutine...............................................................................................6-53
SA1 - Set Analog Output 1.....................................................................................................6-54
SAC - Set Absolute Position Counter....................................................................................6-56

IV Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
SET - Set Variable Value.......................................................................................................6-60
SRM - Search for Registration Mark......................................................................................6-61
SRP - Print Mark Registration................................................................................................6-63
TXT - Text Row......................................................................................................................6-66
VCC - Velocity Change..........................................................................................................6-67
VEO - Velocity Override.........................................................................................................6-69
VMC - Virtual Master (Test Mode).........................................................................................6-72
WAI Wait (Time Delay) .........................................................................................................6-72
7 Logic Task 7-1
7.1 General Information ......................................................................................................................7-1
7.2 Overview of All Commands...........................................................................................................7-1
7.3 Description of Commands.............................................................................................................7-2
Load and Save Commands: ....................................................................................................7-2
Set and Reset Commands:......................................................................................................7-2
AND Logic:...............................................................................................................................7-3
OR Logic:.................................................................................................................................7-4
XOR Logic:...............................................................................................................................7-5
Other Assignments: .................................................................................................................7-6
Operands: ................................................................................................................................7-6
Constants:................................................................................................................................7-6
7.4 Program Examples........................................................................................................................7-7
8 Functions 8-1
8.1 Operating Modes...........................................................................................................................8-1
8.2 Measuring Wheel Mode................................................................................................................8-1
Pertinent Parameters...............................................................................................................8-2
Functioning...............................................................................................................................8-2
Diagnostic Messages...............................................................................................................8-3
Systemvariable ........................................................................................................................8-3
8.3 Homing..........................................................................................................................................8-3
Pertinent Parameters...............................................................................................................8-4
Setting the Homing Parameter ................................................................................................8-4
Overview of the Type and Configuration of Reference Marks of Incremental
Measuring Systems .................................................................................................................8-5
How Drive-Controlled Homing Works in Incremental Measuring Systems .............................8-6
Sequence Control for "Homing"...............................................................................................8-7
Initial Startup with "Evaluation of Reference Mark/Home-switch Signal Edge".......................8-8
Initial Startup with "Evaluation of Distance-coded Reference Marks" ...................................8-11
Starting, Interrupting and Completing the "Homing" Function...............................................8-14
Possible Error Messages During "Homing" ...........................................................................8-14
Placement of the Home Switch..............................................................................................8-15
8.4 Velocity Override.........................................................................................................................8-16
Override via Analog Input ......................................................................................................8-16
Override via Gray-Code Inputs..............................................................................................8-17
Override via Binary-Code Inputs............................................................................................8-18
8.5 Rotary Table................................................................................................................................8-18

ECODRIVE03-FL*-04VRS Table of Contents V
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
8.6 Vector Programming...................................................................................................................8-19
Manual Vector........................................................................................................................8-19
Interrupt Vector......................................................................................................................8-19
8.7 Multitasking.................................................................................................................................8-20
8.8 Master Encoder and motion type Cam .......................................................................................8-22
Overview................................................................................................................................8-22
Slave Axis ..............................................................................................................................8-24
Positioning Command Pxx with Pre-Set Cam .......................................................................8-25
Synchronization by Precise Positioning.................................................................................8-26
Axis Motion with Cam Absolute Master Encoder (SSI) .........................................................8-30
Axis Motion with Cam (Incremental Master Encoder (optional Encoder 2))..........................8-31
8.9 Application: Flying Cutoff............................................................................................................8-32
Parameters ............................................................................................................................8-33
User Program.........................................................................................................................8-33
Immediate Cut / Cut Inhibit ....................................................................................................8-34
Functions................................................................................................................................8-34
8.10 Control Loop Settings..................................................................................................................8-40
Setting the Current Controller................................................................................................8-42
Setting the Velocity Loop.......................................................................................................8-42
Velocity Control Loop Monitoring...........................................................................................8-47
Setting the Position Controller ...............................................................................................8-47
Position Control Loop Monitoring...........................................................................................8-48
Setting the Acceleration Feedforward....................................................................................8-50
8.11 Mechanical Data .........................................................................................................................8-51
Mechanical Transmission Elements......................................................................................8-51
Modulo Function ....................................................................................................................8-52
8.12 Movement to Positive Stop .........................................................................................................8-53
8.13 Encoder Emulation......................................................................................................................8-54
Activating Encoder Emulation................................................................................................8-55
Operating Principle: Incremental Encoder Emulation............................................................8-55
Diagnostic Messages with Incremental Encoder Emulation..................................................8-57
Operating principle: Absolute Encoder Emulation.................................................................8-58
8.14 Indexed Variables in NC Commands..........................................................................................8-60
8.15 Logic Task Controlled Diagnostics for Status Message 25 ........................................................8-63
8.16 PLS..............................................................................................................................................8-66
9 Parameters 9-1
9.1 Basic Information ..........................................................................................................................9-3
Online Changeable Parameters ..............................................................................................9-4
Input Unit..................................................................................................................................9-4
9.2 System Parameters.......................................................................................................................9-5
A100 Application Type...........................................................................................................9-5
A101 Feed Constant..............................................................................................................9-6
A102 Gearing.........................................................................................................................9-6
A103 Negative Position Limit.................................................................................................9-7
A104 Positive Position Limit ..................................................................................................9-7

VI Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
A105 Modulo Value................................................................................................................9-8
A106 Maximum Velocity ........................................................................................................9-8
A107 Jog Velocity..................................................................................................................9-9
A108 Bipolar Acceleration......................................................................................................9-9
A109 Acceleration / Deceleration ..........................................................................................9-9
A110 Bipolar Jerk Limiting Time Constant...........................................................................9-10
A111 Switching Threshold...................................................................................................9-11
A112 Reserved Stop Window..............................................................................................9-11
A113 In-Position Window.....................................................................................................9-12
A114 Presignaling................................................................................................................9-12
A115 Monitoring...................................................................................................................9-13
A116 Feed Angle Monitoring ...............................................................................................9-14
A117 Encoder Difference Monitoring...................................................................................9-15
A118 Absolute Encoder Monitoring Window .......................................................................9-15
A119 Best Possible Deceleration ........................................................................................9-16
9.3 Function Parameters...................................................................................................................9-17
AA00 Tasks 2 & 3................................................................................................................9-17
AA01 Manual Vector............................................................................................................9-17
AA02 Interrupt Vector ..........................................................................................................9-18
AA03 Reserved Restart......................................................................................................9-18
AA04 Override .....................................................................................................................9-18
AA05 Open Feed Roll I........................................................................................................9-19
AA06 Open Feed Roll II.......................................................................................................9-20
AA07 Measuring Wheel Mode.............................................................................................9-21
AA08 Various Functions ......................................................................................................9-21
AA09 Feed-To-Length Monitoring .......................................................................................9-22
AA10 Setup Mode................................................................................................................9-23
AA11 Tool Wear...................................................................................................................9-24
AA12 Press: Signal Offset ...................................................................................................9-25
AA13 Press: Signal, Intermittent..........................................................................................9-26
AA14 Signal Control: Enable ...............................................................................................9-27
AA15 Signal Control Bit 1 ....................................................................................................9-28
AA15 Signal Control Bit 2 ....................................................................................................9-28
AA15 Signal Control Bit 3 ....................................................................................................9-28
AA15 Signal Control Bit 4 ....................................................................................................9-28
AA19 Press: Time Monitoring..............................................................................................9-30
9.4 General Parameters....................................................................................................................9-31
B000 Display........................................................................................................................9-31
B001 Serial Interface Parameter 1 ......................................................................................9-31
B002 Serial Interface Parameter 2 ......................................................................................9-32
B003 Analog Output 1, Signal Select ..................................................................................9-33
B004 Analog Output 1, Expanded Signal Select.................................................................9-34
B005 Analog Output 1, Scaling per 10V Full Scale.............................................................9-36
B006 Analog Output 2, Signal Select ..................................................................................9-36
B007 Analog Output 2, Expanded Signal Select.................................................................9-37
B008 Analog Output 2, Scaling per 10V Full Scale.............................................................9-39

ECODRIVE03-FL*-04VRS Table of Contents VII
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
B009 Serial I/O Control for BTV04.......................................................................................9-39
B010 System Control...........................................................................................................9-40
B011 Fieldbus Cycle Time...................................................................................................9-41
B012 Fieldbus Baudrate ......................................................................................................9-41
B013 Fieldbus Format..........................................................................................................9-42
B014 EMD Configuration.....................................................................................................9-42
9.5 Encoder Parameters...................................................................................................................9-43
C000 Working Polarity.........................................................................................................9-43
C001 Interface Feedback 1 (Motor)....................................................................................9-43
C002 Position Feedback 1 Type.........................................................................................9-44
C003 Feedback 1 Resolution (Motor).................................................................................9-45
C004 Interface Feedback 2 .................................................................................................9-45
C005 Position Feedback 2 Type.........................................................................................9-46
C006 Feedback 2 Resolution..............................................................................................9-46
C007 Feed Constant 2.........................................................................................................9-47
C008 Reserved....................................................................................................................9-47
C009 Homing Configuration.................................................................................................9-47
C010 Homing.......................................................................................................................9-48
C011 Reference Distance....................................................................................................9-48
C012 Home Switch Offset ...................................................................................................9-48
C013 Distance-Coded Reference Offsets ...........................................................................9-49
C014 Encoder Emulation Configuration ..............................................................................9-49
C015 Encoder Emulation Resolution...................................................................................9-50
C016 Marker Pulse Offset ...................................................................................................9-50
C017 SSI Encoder (Press Encoder)....................................................................................9-51
C018 SSI Encoder Homing..................................................................................................9-52
C019 SSI Encoder Reference Distance ..............................................................................9-52
9.6 Control Parameters.....................................................................................................................9-53
CR00 Current Loop Proportional Gain 1..............................................................................9-53
CR01 Current Loop Integral Action Time 1..........................................................................9-53
CR02 Velocity Loop Proportional Gain................................................................................9-54
CR03 Velocity Loop Integral Action Time............................................................................9-55
CR04 Velocity Loop Smoothing Time Constant ..................................................................9-56
CR05 Rejection Frequency Velocity Loop...........................................................................9-56
CR06 Rejection Bandwidth Velocity Loop...........................................................................9-57
CR07 Kv Factor ...................................................................................................................9-57
CR08 Acceleration Feedforward Gain.................................................................................9-58
CR09 Switching Frequency .................................................................................................9-59
CR10 Actual Position Filter, Time Constant for Measuring Wheel Mode............................9-59
9.7 Motor Parameters .......................................................................................................................9-60
CM00 Motor Type................................................................................................................9-60
CM01 Bipolar Torque/Force Limit Value..............................................................................9-60
CM02 Motor Peak Current / Stall Current............................................................................9-61
CM03 Maximum Motor Speed.............................................................................................9-61
CM04 Number of Pole Pairs/Pole Pair Distance .................................................................9-62
CM05 Torque/Force Constant .............................................................................................9-62

VIII Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
CM06 Moment of Inertia of the Rotor ..................................................................................9-63
CM07 Holding Brake Type...................................................................................................9-63
CM08 Holding Brake Current...............................................................................................9-63
CM09 Motor Temperature....................................................................................................9-64
CM10 Motor Inductance.......................................................................................................9-64
CM11 Commutation Setting.................................................................................................9-64
CM12 Commutation Offset ..................................................................................................9-64
9.8 PLS Parameters..........................................................................................................................9-65
N100 PLS.............................................................................................................................9-65
N101 Output Channel 1.......................................................................................................9-65
N109 SSI Encoder Monitoring .............................................................................................9-66
N110 Reserved....................................................................................................................9-66
N111 Function of Output Channel 1 ....................................................................................9-67
N119 Reserved....................................................................................................................9-67
N120 Reserved....................................................................................................................9-67
N121 Switch 1......................................................................................................................9-68
9.9 List of FLP Parameters ...............................................................................................................9-69
10 Interface 10-1
10.1 Inputs / Outputs / Marker Flags...................................................................................................10-1
System Inputs ........................................................................................................................10-3
System Outputs .....................................................................................................................10-6
Parallel Interface DKC21.3 Programmable Inputs/Outputs..................................................10-7
EMD Programmable Inputs/Outputs.....................................................................................10-7
Profibus Interface DKC 03.3 Programmable Inputs/Outputs................................................10-8
BTV04 Programmable Inputs/Outputs...................................................................................10-8
Marker Flags........................................................................................................................10-10
10.2 Serial Interface..........................................................................................................................10-14
Overview..............................................................................................................................10-14
Communications via RS232 Interface .................................................................................10-16
Communications via RS485 Interface .................................................................................10-17
Transmission Protocols........................................................................................................10-17
ASCII Protocol .....................................................................................................................10-18
Generating the Checksum...................................................................................................10-20
Interface Confirmation..........................................................................................................10-21
NC Program Instructions......................................................................................................10-21
Parameter ............................................................................................................................10-24
Variables..............................................................................................................................10-28
Logic Task............................................................................................................................10-30
Cam......................................................................................................................................10-31
Readout of Status Information.............................................................................................10-33
Interface Commands............................................................................................................10-42
Polling Query........................................................................................................................10-46
SIS Protocol.........................................................................................................................10-46
11 Command Communications 11-1

ECODRIVE03-FL*-04VRS Table of Contents IX
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
11.1 Parallel Interface.........................................................................................................................11-1
Diagnostic LED for Parallel Interface.....................................................................................11-1
11.2 Profibus.......................................................................................................................................11-2
Fieldbus Parameters..............................................................................................................11-3
Process Data Channel...........................................................................................................11-3
Service Data Channel............................................................................................................11-9
Inputs X1 and X3 .................................................................................................................11-17
Assignment of Profibus Connector X30...............................................................................11-17
Diagnostic LED for Profibus.................................................................................................11-17
12 Diagnostic Message Descriptions 12-1
12.1 Overview of the Diagnostic Message Descriptions.....................................................................12-1
Diagnostic Message Types....................................................................................................12-1
Composition of a Diagnostic Message ..................................................................................12-1
12.1 Error Diagnostics for Amplifier F. .............................................................................................12-4
F208 UL The motor type has changed..................................................................................12-4
F209 PL Load parameter default values................................................................................12-4
F217 Blower not connected...................................................................................................12-4
F218 Amplifier overtemp. shutdown ......................................................................................12-5
F219 Motor overtemp. shutdown...........................................................................................12-5
F220 Bleeder overload shutdown..........................................................................................12-6
F221 Motor temp. surveillance defective...............................................................................12-6
F226 Undervoltage in power section .....................................................................................12-6
F228 Excessive deviation......................................................................................................12-7
F229 Encoder 1 failure: Quadrant error.................................................................................12-7
F230 Max. signal frequency of encoder 1 exceeded.............................................................12-7
F234 Emergency-Stop...........................................................................................................12-8
F236 Excessive position feedback difference........................................................................12-8
F237 Excessive position command difference ......................................................................12-9
F242 Encoder 2 failure: Signal amplitude wrong...................................................................12-9
F245 Encoder 2 failure: Quadrant error...............................................................................12-10
F246 Max. signal frequency of encoder 2 exceeded...........................................................12-10
F248 Low Battery Voltage....................................................................................................12-10
F253 Incr. encoder emulator: Frequency too high...............................................................12-11
F267 Erroneous internal hardware synchronization............................................................12-11
F276 Absolute encoder out of allowed window ...................................................................12-12
F277 Current measurement trim wrong...............................................................................12-12
F281 Mains fault ..................................................................................................................12-12
F288 Error during firmware update of EMD Module firmware.............................................12-13
F291 Timeout in EMD Module.............................................................................................12-13
F292 Overtemperature in EMD Module...............................................................................12-14
F294 Timeout in EcoX Slave ...............................................................................................12-14
F296 Number of EcoX Slaves incorrect...............................................................................12-15
F297 Error in EcoX Slave ....................................................................................................12-15
F386 No ready signal from supply module..........................................................................12-15
F407 Error during initialization of master communication....................................................12-16

XTable of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
F408 Fatal error of the interface card..................................................................................12-16
F411 Double SST failure shutdown.....................................................................................12-16
F434 Emergency-Stop.........................................................................................................12-17
F629 Positive travel limit exceeded.....................................................................................12-17
F630 Negative travel limit exceeded....................................................................................12-18
F634 Emergency-Stop.........................................................................................................12-18
F643 Positive travel limit switch detected............................................................................12-18
F644 Negative travel limit switch detected ..........................................................................12-19
F822 Encoder 1 failure: Signal amplitude wrong.................................................................12-19
F860 Overcurrent: short in power stage..............................................................................12-20
F870 +24Volt DC error.........................................................................................................12-20
F873 Power supply driver stages fault.................................................................................12-21
F878 Velocity loop error.......................................................................................................12-21
F895 4-kHz signal wrong....................................................................................................12-22
12.2 Warning Diagnostics for Amplifier E. .. ...................................................................................12-23
E221 Warning, Motor temp. surveillance defective .............................................................12-23
E225 Motor overload............................................................................................................12-23
E250 Drive overtemp. prewarning .......................................................................................12-24
E251 Motor overtemp. prewarning ......................................................................................12-24
E252 Bleeder overload prewarning .....................................................................................12-24
E256 Torque limit = 0...........................................................................................................12-25
E257 Continuous current limit active...................................................................................12-25
E259 Command velocity limit active....................................................................................12-25
E261 Continuous current limit prewarning...........................................................................12-26
E263 Velocity command value > limit S-0-0091..................................................................12-26
E267 Hardware synchronization defective ..........................................................................12-26
E288 Firmware update of EMD Module active....................................................................12-27
E289 Waiting for scan by EcoX Master...............................................................................12-27
E291 Timeout in EMD Module.............................................................................................12-28
E293 Undervoltage in EMD Module ....................................................................................12-28
E296 Number of EcoX Slaves incorrect ..............................................................................12-28
E300 Processor watchdog timer..........................................................................................12-29
E408 Invalid addressing of MDT Data container A..............................................................12-29
E411 Double SST Failure....................................................................................................12-30
E825 Overvoltage in power stage........................................................................................12-30
E826 Undervoltage in power section...................................................................................12-31
12.3 Command Diagnostics C.. ., D. ............................................................................................12-32
C100 Communication phase 3 transition check ..................................................................12-32
C200 Communication phase 4 transition check ..................................................................12-32
C201 Invalid Parameters .....................................................................................................12-32
C202 Parameter limit error...................................................................................................12-32
C203 Parameter calculation error........................................................................................12-32
C204 Motor type Parameter CM00 incorrect.......................................................................12-33
C207 Load error LCA...........................................................................................................12-33
C210 Feedback 2 required ..................................................................................................12-33
C211 Invalid feedback data .................................................................................................12-33

ECODRIVE03-FL*-04VRS Table of Contents XI
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
C212 Invalid amplifier data ..................................................................................................12-34
C213 Position data scaling error..........................................................................................12-34
C214 Velocity data scaling error..........................................................................................12-34
C215 Acceleration data scaling error...................................................................................12-35
C216 Torque/force data scaling error..................................................................................12-35
C217 Feedback 1 data reading error...................................................................................12-35
C218 Feedback 2 data reading error...................................................................................12-36
C220 Feedback 1 initializing error.......................................................................................12-36
C221 Feedback 2 initializing error.......................................................................................12-37
C223 Input value for max. range too high............................................................................12-37
C227 Modulo range error.....................................................................................................12-37
C228 Wrong controller type.................................................................................................12-38
C234 Encoder combination not possible.............................................................................12-38
C235 Load-side motor encoder with inductance motor only ...............................................12-38
C300 Set absolute measuring..............................................................................................12-38
C301 Setting absolute encoder not possible when RF set..................................................12-38
C302 Absolute measuring system not installed...................................................................12-39
C400 Switch to Parameter Mode.........................................................................................12-39
C500 Reset class 1 diagnostic, error reset..........................................................................12-39
C600 Drive-controlled homing procedure command...........................................................12-39
C601 Homing only possible with drive enable.....................................................................12-39
C602 Distance home switch –reference mark erroneous...................................................12-40
C604 Homing of absolute encoder not possible..................................................................12-40
C605 Homing velocity too high............................................................................................12-40
C700 Basic load...................................................................................................................12-40
C701 Basic load not possible with drive enable ..................................................................12-41
C702 Default parameters not available ...............................................................................12-41
C703 Default parameters invalid .........................................................................................12-41
C704 Parameters not copyable ...........................................................................................12-41
C705 Locked with password................................................................................................12-41
C800 Default parameter load...............................................................................................12-42
C801 Parameter default value erroneous............................................................................12-42
C802 Locked with password................................................................................................12-42
D300 Command adjust commutation ..................................................................................12-42
D301 Drive not ready for commutation command...............................................................12-42
D302 Torque/force too small for movement ........................................................................12-43
D400 Command Move to Positive Stop...............................................................................12-43
D500 Command Detect Marker Position.............................................................................12-43
D501 No incremental measuring system.............................................................................12-43
D800 Command Measuring Wheel Mode............................................................................12-44
D801 Measuring Wheel Mode not possible.........................................................................12-44
12.4 Diagnostic Status Messages for Amplifier A. .........................................................................12-45
A002 Communication phase 2.............................................................................................12-45
A003 Communication phase 3.............................................................................................12-45
A010 Drive HALT.................................................................................................................12-45
A012 Control and power sections ready for operation. .......................................................12-45

XII Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
A013 Ready for power on....................................................................................................12-45
A102 Position mode with encoder 1 ....................................................................................12-45
A103 Position mode with encoder 2 ....................................................................................12-45
A104 Position mode without position lag (following error), encoder 1.................................12-46
A105 Position mode without lag, encoder 2 ........................................................................12-46
12.5 Diagnostic Messages for Basic Initialization and Fatal System Errors.....................................12-47
Diagnostic Message Display: -0...........................................................................................12-47
Diagnostic Message Display: -1...........................................................................................12-47
Diagnostic Message Display: -2...........................................................................................12-47
Diagnostic Message Display: -3...........................................................................................12-47
Diagnostic Message Display: -4...........................................................................................12-47
Diagnostic Message Display: -5...........................................................................................12-47
Diagnostic Message Display: -6...........................................................................................12-47
Diagnostic Message Display: Watchdog (2 Dots) .........................................................12-47
Diagnostic Message Display: E1 .........................................................................................12-48
Diagnostic Message Display: E2 .........................................................................................12-48
Diagnostic Message Display: E3 .........................................................................................12-48
Diagnostic Message Display: E4 .........................................................................................12-48
Diagnostic Message Display: E5 .........................................................................................12-48
12.6 Operation Status.......................................................................................................................12-49
bb.........................................................................................................................................12-49
Ab.........................................................................................................................................12-49
Ad.........................................................................................................................................12-49
AF.........................................................................................................................................12-49
AU........................................................................................................................................12-49
HA........................................................................................................................................12-49
PA ........................................................................................................................................12-49
Jb .........................................................................................................................................12-49
JF.........................................................................................................................................12-49
P2.........................................................................................................................................12-50
P3.........................................................................................................................................12-50
P4.........................................................................................................................................12-50
PL.........................................................................................................................................12-50
UL.........................................................................................................................................12-50
12.7 NC Error Diagnostics F- .. ......................................................................................................12-51
F- 0200 Parameter and automatic input simultaneously....................................................12-51
F- 0201 Wrong phase transition .........................................................................................12-51
F- 0203 Target position < negative position limit................................................................12-51
F- 0204 Target position > positive position limit .................................................................12-51
F- 0205 Stack overflow with JSR command.......................................................................12-51
F- 0206 Stack overflow with RTS command.......................................................................12-51
F- 0207 Invalid destination task number.............................................................................12-52
F- 0208 Per mil value in ACC command > 999.................................................................12-52
F- 0209 Invalid value in FAK command..............................................................................12-52
F- 0210 Feed angle loss.....................................................................................................12-52
F- 0211 Torque > 500%......................................................................................................12-52

ECODRIVE03-FL*-04VRS Table of Contents XIII
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
F- 0212 Program run without power...................................................................................12-53
F- 0213 Measuring Wheel Difference..................................................................................12-53
F- 0214 Wrong BCD information ........................................................................................12-53
F- 0215 FOL Factor > Max. ...............................................................................................12-53
F- 0216 V > 999 Per Mil.......................................................................................................12-53
F- 0217 HOM not allowed...................................................................................................12-54
F- 0218 RTM not allowed....................................................................................................12-54
F- 0219 Wrong variable value..............................................................................................12-54
F- 0220 Wrong constant value.............................................................................................12-54
F- 0221 Logic Task Program error......................................................................................12-54
F- 0222 SA1 not allowed.....................................................................................................12-55
F- 0223 Wrong variable index.............................................................................................12-55
F- 0224 APZ not allowed ....................................................................................................12-55
F- 0225 No curve data........................................................................................................12-55
F- 0226 Control signal bit 1 fault.........................................................................................12-55
F- 0227 Control signal bit 2 fault.........................................................................................12-56
F- 0228 Control signal bit 3 fault.........................................................................................12-56
F- 0229 Control signal bit 4 fault.........................................................................................12-56
F- 0230 Offset dimension too small....................................................................................12-56
F- 0300 Invalid I/O number in command instruction...........................................................12-56
F- 0301 I/O status illegal......................................................................................................12-56
F- 0302 NC instruction number illegal .................................................................................12-57
F- 0304 NC command illegal ...............................................................................................12-57
F- 0305 not homed..............................................................................................................12-57
F- 0307 Data loss parameter..............................................................................................12-57
F- 0308 AT Failure...............................................................................................................12-58
F- 0309 NC cycle error........................................................................................................12-58
F- 0310 Parameter error......................................................................................................12-58
F- 0311 Stack correction value > 9.....................................................................................12-59
F- 0312 Select Parameter Mode..........................................................................................12-59
F- 0313 Jump interval > 99..................................................................................................12-59
F- 0314 Instruction offset greater than 999.........................................................................12-60
F- 0315 BCD selection incorrect.........................................................................................12-60
F- 0316 Systemcontrol Error...............................................................................................12-60
F- 0317 Serial I/O Error.......................................................................................................12-60
F- 0319 NC cycle time exceeded........................................................................................12-61
F- 0320 FW Err. No. nnnn (System Error).....................................................................12-61
F- 0321 NC Variable Number illegal...................................................................................12-61
F- 0322 SSI-Encoder Error (PLS).......................................................................................12-61
F- 0323 PLS speed > N109 ................................................................................................12-61
F- 0324 Function terminated...............................................................................................12-62
F- 0325 Mode unauthorized................................................................................................12-62
12.8 NC Warning Diagnostics E- .. ................................................................................................12-63
E- 0100 Velocity = 0............................................................................................................12-63
E- 0102 ’Jog+’& ’Jog-’........................................................................................................12-63
E- 0103 Outputs overloaded...............................................................................................12-63

XIV Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
E- 0104 System control offline............................................................................................12-63
E- 0105 No serial I/O ...........................................................................................................12-63
E- 0106 Jog, Position < Limit.............................................................................................12-64
E- 0107 Jog, Position > Limit.............................................................................................12-64
E- 0108 IDS01 –Timeout ...................................................................................................12-64
E- 0109 Load default values...............................................................................................12-64
E- 0110 Jog, no power........................................................................................................12-64
12.9 NC- Status Diagnostics A- .. .. ................................................................................................12-65
A- 0007 Stop is active.........................................................................................................12-65
A- 0008 Manual vector program is active...........................................................................12-65
A- 0009 Function interrupt is active ....................................................................................12-65
A- 0011 Feed rolls open......................................................................................................12-65
A- 0012 Press Timeout.......................................................................................................12-65
A- 0013 Waiting for Feed Angle..........................................................................................12-65
A- 0026 Control signal bit 1 invalid.....................................................................................12-65
A- 0027 Control signal bit 2 invalid.....................................................................................12-65
A- 0028 Control signal bit 3 invalid.....................................................................................12-66
A- 0029 Control signal bit 4 invalid.....................................................................................12-66
13 Connectors 13-1
13.1 DKC21.3......................................................................................................................................13-1
13.2 DKC21.3 and DKC3.3.................................................................................................................13-2
13.3 Press Encoder.............................................................................................................................13-3
14 Display 14-1
14.1 BTV04 .........................................................................................................................................14-1
Parameter Settings ................................................................................................................14-2
PC->BTV04->DKC Push-Through Operation........................................................................14-2
Switching Between the User Interface and the Programming Displays................................14-2
BTV04 Key Descriptions........................................................................................................14-3
14.2 Programming Displays................................................................................................................14-5
BTV04 Display Menu.............................................................................................................14-5
Main Menu .............................................................................................................................14-6
Monitor - Menu.......................................................................................................................14-6
Setup Menu............................................................................................................................14-9
Diagnostic Messages...........................................................................................................14-13
Special Displays...................................................................................................................14-16
14.3 User Interface............................................................................................................................14-17
Introduction ..........................................................................................................................14-17
Text Programming ...............................................................................................................14-18
Data Display.........................................................................................................................14-20
Variable Value Editable........................................................................................................14-21
Graphic Elements ................................................................................................................14-22
Number of Lines...................................................................................................................14-23
Display Example..................................................................................................................14-24

ECODRIVE03-FL*-04VRS Table of Contents XV
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
15 EMD Module (EcoX-Bus) 15-1
15.1 Digital Input/Output Module ........................................................................................................15-1
System Setup.........................................................................................................................15-1
15.2 Technical Data............................................................................................................................15-3
EcoX Bus System Data..........................................................................................................15-3
Input/Output Module Data......................................................................................................15-3
15.3 Important Notes...........................................................................................................................15-5
Appropriate Use.....................................................................................................................15-5
Inappropriate Use ..................................................................................................................15-6
15.4 Installation...................................................................................................................................15-7
Dimensions and Installation Measurements..........................................................................15-7
Installation/Removal...............................................................................................................15-9
15.5 Electrical Connection ................................................................................................................15-12
Position of Connections.......................................................................................................15-14
Power Supply, Protection and Grounding............................................................................15-14
Input Signals ........................................................................................................................15-15
Power Supply of the Outputs...............................................................................................15-16
Output Signals .....................................................................................................................15-16
Fieldbus Connectors............................................................................................................15-17
Connection Between Input/Output Module and Drive Controller.........................................15-17
Connection of Input/Output Modules ...................................................................................15-18
15.6 Initial Startup.............................................................................................................................15-20
Setting the Module Address.................................................................................................15-20
Assigning the Input/Output Numbers...................................................................................15-20
Setting the Drive Controller Parameters..............................................................................15-20
15.7 Faults and Messages................................................................................................................15-21
Display .................................................................................................................................15-21
15.8 Replacement of a Unit...............................................................................................................15-23
15.9 Factory Settings and Identifying the Components....................................................................15-24
Identifying the Components.................................................................................................15-24
16 IDS Accessories 16-1
16.1 INDRAMAT Decade Switch IDS1.1............................................................................................16-1
17 Index 17-1
18 Service & Support 18-1
18.1 Helpdesk .....................................................................................................................................18-1
18.2 Service-Hotline............................................................................................................................18-1
18.3 Internet........................................................................................................................................18-1
18.4 Vor der Kontaktaufnahme... - Before contacting us....................................................................18-1
18.5 Kundenbetreuungsstellen - Sales & Service Facilities ...............................................................18-2

XVI Table of Contents ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P

ECODRIVE03-FL*-04VRS System Overview 1-1
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
1 System Overview
1.1 ECODRIVE03 - The Universal Drive Solution for
Automation
The ECODRIVE03 universal automation system is an especially cost-
effective solution for open and closed-loop control tasks.
The ECODRIVE03 servo drive system features:
•a very broad range of applications
•many different integrated functions
•a highly favorable price/performance ratio
The ECODRIVE03 also features ease of assembly and installation, high
system availability, and a reduced number of system components.
The ECODRIVE03 can be used to implement many different kinds of
functions in a number of applications.
Typical applications are:
•metalworking
•printing and paper processing machines
•automatic handling systems
•packaging and food processing machines
•handling and assembly systems
1.2 ECODRIVE03 – A Family of Drives
OPTIFEED-FS
In addition to the firmware documented here (FWA-ECODR3-FLP-0xVRS-
MS, Drive with integrated NC control and Profibus / parallel
interface), other application-specific firmware versions exist:
•OPTIFEED-CS
Single-axis solution package for Feed-to-length mechanisms
•drive for machine tool applications with SERCOS, analog and parallel
interfaces
•drive for general automation tasks with SERCOS, analog and parallel
interfaces
•drive for general automation tasks with fieldbus interfaces
FWA-ECODR3-FLP-0xVRS-MS
FWA-ECODR3-CRP-0xVRS-MS
FWA-ECODR3-SMT-xxVRS-MS
FWA-ECODR3-SGP-xxVRS-MS
FWA-ECODR3-FGP-xxVRS-MS

1-2 System Overview ECODRIVE03-FL*-04VRS
DOK-ECODR3-FL*-04VRS**-FK01-EN-P
1.3 Drive Controllers and Motors
The ECODRIVE03 family of drives is at present made up of eight different
units. They differ primarily in terms of which interface is used for machine
control (e.g. SPS, CNC). The drive controllers are available in three
different rating classes with peak currents of 40A, 100A and 200A.
For the FLP, two different interfaces are supported:
•DKC21.3 Parallel Interface 2
•DKC03.3 Profibus-DP Interface
For other application-specific firmware versions:
•DKC11.3 Analog Interface
•DKC01.3 Parallel Interface
•DKC02.3 SERCOS Interface
•DKC03.3 Profibus-DP Interface
•DKC04.3 Interbus Interface
•DKC05.3 CANopen Interface
•DKC06.3 DeviceNet Interface
The following motor types can be operated using ECODRIVE03 firmware:
•synchronous motors for standard applications up to 48 Nm.
•synchronous motors for more stringent demands up to 64 Nm.
SH5040X1.BMP
Fig. 1-1: The ECODRIVE03 Family of Drives and the Motors Supported
Available Controllers
Supported Motor Types