Bosch REXROTH IndraDrive User manual
Levante Sistemas de
Automatización y Control S.L.
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R911297319
Edition 01
Rexroth IndraDrive
Troubleshooting Guide
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
About this Documentation Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
Rexroth IndraDrive
Troubleshooting Guide
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
Document Number 120-2400-B307-01/EN
This document is designed to assist maintanenance personnel in
identifying errors with the machinery.
It serves to:
•help in understanding error messages
•help in finding the cause of errors
•describe the procedure for trouble shooting
Description Release
Date Notes
DOK-INDRV*-GEN-**VRS**-WA01-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
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Telephone +49 (0)93 52/40-0 •Tx 68 94 21 •Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. ED
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Note
Rexroth IndraDrive Contents I
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
Contents
1 Basics on Device Diagnosis 1-1
1.1 Diagnostic System ........................................................................................................................1-1
Coded Diagnostic Drive Messages..........................................................................................1-1
Status Classes, Status Displays, Control Parameters.............................................................1-4
1.2 Control Panel of the IndraDrive Controllers..................................................................................1-9
Brief Description.......................................................................................................................1-9
Functional Description ...........................................................................................................1-10
Notes on Commissioning.......................................................................................................1-16
1.3 Extended Diagnostic Possibilities ...............................................................................................1-16
1.4 Kinds of Diagnostic Messages....................................................................................................1-16
Error.......................................................................................................................................1-16
Warnings................................................................................................................................1-17
Commands.............................................................................................................................1-18
States/Operating States.........................................................................................................1-18
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 Diagnostic Messages when Booting the Devices 4-1
4.1 Devices with Valid Firmware.........................................................................................................4-1
4.2 Devices without Valid Firmware....................................................................................................4-1
II Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
4.3 Error Messages when Booting the Devices..................................................................................4-2
PLC ?.......................................................................................................................................4-2
Stop PLC..................................................................................................................................4-2
Run PLC...................................................................................................................................4-2
No IDN on MMC !.....................................................................................................................4-2
Load new Param. ?..................................................................................................................4-3
End C29..................................................................................................................................4-3
MMC not correct! .....................................................................................................................4-3
IBF not correct! ........................................................................................................................4-3
Firmware update ?...................................................................................................................4-4
Update Error ! ..........................................................................................................................4-4
5 Operating States 5-1
Ab.............................................................................................................................................5-1
AC............................................................................................................................................5-1
AE ............................................................................................................................................5-1
AF.............................................................................................................................................5-1
AH............................................................................................................................................5-1
AS ............................................................................................................................................5-1
ASP..........................................................................................................................................5-1
AU............................................................................................................................................5-1
bb.............................................................................................................................................5-1
charg........................................................................................................................................5-2
LB.............................................................................................................................................5-2
P0.............................................................................................................................................5-2
P-1............................................................................................................................................5-2
P1.............................................................................................................................................5-2
P2.............................................................................................................................................5-2
P3.............................................................................................................................................5-2
PL.............................................................................................................................................5-2
RL.............................................................................................................................................5-2
SBB..........................................................................................................................................5-2
SBH..........................................................................................................................................5-2
SH............................................................................................................................................5-2
ZKS..........................................................................................................................................5-3
6 Status Diagnostic Messages 6-1
A0000 Communication phase 0...............................................................................................6-1
A0001 Communication phase 1...............................................................................................6-2
A0002 Communication phase 2...............................................................................................6-3
A0003 Communication phase 3...............................................................................................6-4
A0009 Automatic baud rate detection for SERCOS interface.................................................6-5
A0010 Drive HALT...................................................................................................................6-5
A0011 Starting lockout active ..................................................................................................6-6
A0012 Control and power sections ready for operation ..........................................................6-6
A0013 Ready for power on......................................................................................................6-7
Rexroth IndraDrive Contents III
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
A0014 Drive interlock active ....................................................................................................6-8
A0015 Safety related standstill active......................................................................................6-9
A0016 Safety related operational stop active........................................................................6-10
A0017 Special mode motion active .......................................................................................6-11
A0100 Drive in TORQUE control...........................................................................................6-12
A0101 Drive in VELOCITY control.........................................................................................6-12
A0102 Position mode with encoder 1 ....................................................................................6-13
A0103 Position mode with encoder 2 ....................................................................................6-13
A0104 Position mode lagless, encoder 1 ..............................................................................6-14
A0105 Position control lagless, encoder 2.............................................................................6-14
A0106 Drive controlled interpolation, encoder 1....................................................................6-15
A0107 Drive controlled interpolation, encoder 2....................................................................6-15
A0108 Drive controlled interpolation, lagless, encoder 1 ......................................................6-16
A0109 Drive controlled interpolation, lagless, encoder 2 ......................................................6-16
A0110 Velocity synchronization, virtual master axis..............................................................6-17
A0111 Velocity synchronization, real master axis .................................................................6-17
A0112 Phase synchronization, encoder 1, virtual master axis..............................................6-18
A0113 Phase synchronization, encoder 2, virtual master axis..............................................6-18
A0114 Phase synchronization, encoder 1, real master axis..................................................6-19
A0115 Phase synchronization, encoder 2, real master axis..................................................6-19
A0116 Phase synchr. lagless, encoder 1, virtual master axis...............................................6-20
A0117 Phase synchr. lagless, encoder 2, virtual master axis...............................................6-20
A0118 Phase synchr. lagless, encoder 1, real master axis...................................................6-21
A0119 Phase synchr. lagless, encoder 2, real master axis...................................................6-21
A0128 Cam shaft, encoder 1, virtual master axis..................................................................6-22
A0129 Cam shaft, encoder 2, virtual master axis..................................................................6-22
A0130 Cam shaft, encoder 1, real master axis......................................................................6-23
A0131 Cam shaft, encoder 2, real master axis......................................................................6-23
A0132 Cam shaft, lagless, encoder 1, virt. master axis ........................................................6-24
A0133 Cam shaft, lagless, encoder 2, virt. master axis ........................................................6-24
A0134 Cam shaft, lagless, encoder 1, real master axis........................................................6-25
A0135 Cam shaft, lagless, encoder 2, real master axis........................................................6-25
A0150 Drive-controlled positioning, encoder 1......................................................................6-26
A0151 Drive-controlled positioning, encoder 1, lagless.........................................................6-27
A0152 Drive-controlled positioning, encoder 2......................................................................6-28
A0153 Drive-controlled positioning, encoder 2, lagless.........................................................6-29
A0154 Position mode with encoder 1 drive controlled...........................................................6-30
A0155 Position mode with encoder 2 drive controlled...........................................................6-30
A0156 Position mode lagless, encoder 1 drive controlled.....................................................6-31
A0157 Position control lagless, encoder 2 drive controlled...................................................6-31
A0206 Positioning block mode, encoder 1 ............................................................................6-32
A0207 Positioning block mode lagless, encoder 1................................................................6-32
A0210 Positioning block mode, encoder 2 ............................................................................6-33
A0211 Positioning block mode lagless, encoder 2................................................................6-33
A0500 Supply module in voltage control ...............................................................................6-34
A0501 Supply module in current control................................................................................6-34
IV Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
A0502 Supply module in operation........................................................................................6-34
A0503 DC bus charging active ..............................................................................................6-35
A0510 Test run for voltage control.........................................................................................6-35
A0511 Test run for current control.........................................................................................6-35
A0512 Test run active............................................................................................................6-36
A0520 DC bus quick discharge active...................................................................................6-36
A0800 Unknown operating mode ..........................................................................................6-36
A4000 Automatic drive check and adjustment.......................................................................6-37
A4001 Drive deceleration to standstill ...................................................................................6-37
A4002 Drive in automatic mode.............................................................................................6-38
7 Error Messages 7-1
7.1 Fatal System Errors (F9xxx and E-xxxx) ......................................................................................7-1
Behavior in the Case of Fatal System Error ............................................................................7-1
E-0000 Processor exception error...........................................................................................7-2
F9001 Error internal function call.............................................................................................7-3
F9002 Error internal RTOS function call..................................................................................7-3
F9003 Watchdog......................................................................................................................7-4
F9004 Hardware trap...............................................................................................................7-4
7.2 Fatal Errors (F8xxx) ......................................................................................................................7-5
Behavior in the Case of Fatal Error .........................................................................................7-5
F8010 Autom. commutation: max. motion range when moving back......................................7-6
F8011 Commutation offset could not be determined...............................................................7-7
F8012 Autom. commutation: max. motion range.....................................................................7-8
F8013 Automatic commutation: current too low ......................................................................7-9
F8014 Automatic commutation: overcurrent..........................................................................7-10
F8015 Automatic commutation: timeout................................................................................7-11
F8016 Automatic commutation: iteration without result.........................................................7-12
F8022 Enc. 1: enc. signals incorr. (can be cleared in ph. 2) .................................................7-13
F8023 Error mechanical link of encoder or motor connection...............................................7-14
F8027 Starting lockout while drive enabled...........................................................................7-14
F8057 Device overload shutdown .........................................................................................7-15
F8060 Overcurrent in power section......................................................................................7-15
F8069 +/-15Volt DC error ......................................................................................................7-16
F8070 +24Volt DC error.........................................................................................................7-16
F8078 Speed loop error.........................................................................................................7-17
F8079 Velocity limit S-0-0091 exceeded...............................................................................7-18
F8091 Power section defective..............................................................................................7-18
F8100 Error during initialization of control section.................................................................7-19
F8102 Error when initializing power section..........................................................................7-20
F8118 Invalid power section/firmware combination...............................................................7-20
F8120 Invalid control section/firmware combination..............................................................7-21
F8122 Control section defective ............................................................................................7-21
F8129 Firmware of option 1 of safety technology defective..................................................7-22
F8130 Firmware of option 2 of safety technology defective..................................................7-23
F8133 Error when checking interrupting circuits....................................................................7-24
Rexroth IndraDrive Contents V
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
F8201 Safety command for basic initialization incorrect .......................................................7-25
F8203 Safety technology configuration parameter invalid.....................................................7-26
F8806 Timeout during loading process .................................................................................7-27
F8813 Connection error mains choke....................................................................................7-27
F8838 Overcurrent external braking resistor.........................................................................7-28
7.3 Safety Technology Errors (F7xxx) ..............................................................................................7-29
Behavior in the Case of Safety Technology Error..................................................................7-29
F7010 Safety related limited increment exceeded.................................................................7-30
F7011 Safety rel. position limit val., exc. in pos. dir...............................................................7-31
F7012 Safety rel. position limit val., exc. in neg. dir. .............................................................7-31
F7013 Velocity threshold exceeded.......................................................................................7-32
F7014 Acceleration threshold exceeded ...............................................................................7-33
F7020 Safety related maximum velocity exceeded...............................................................7-34
F7021 Safety related end position exceeded ........................................................................7-34
F7030 Pos. window for safety rel. operational stop exceeded..............................................7-35
F7031 Incorrect direction of motion .......................................................................................7-36
F7040 Plausibility error parameterized - effective threshold .................................................7-37
F7041 Plausibility error actual position value ........................................................................7-38
F7042 Plausibility error safety related operating mode.........................................................7-39
F7043 Error of output stage interlock ....................................................................................7-39
F7050 Time for stopping process exceeded..........................................................................7-40
7.4 Travel Range Errors (F6xxx).......................................................................................................7-41
Behavior in the Case of Travel Range Error..........................................................................7-41
F6024 Maximum braking time exceeded...............................................................................7-42
F6029 Positive travel limit exceeded .....................................................................................7-43
F6030 Negative travel limit exceeded....................................................................................7-44
F6034 Emergency-Stop activated .........................................................................................7-45
F6042 Both travel range limit switches activated...................................................................7-46
F6043 Positive travel range limit switch activated.................................................................7-47
F6044 Negative travel range limit switch activated................................................................7-48
7.5 Interface Errors (F4xxx) ..............................................................................................................7-49
Behavior in the Case of Interface Error .................................................................................7-49
F4001 Double MST failure shutdown ....................................................................................7-50
F4002 Double MDT failure shutdown....................................................................................7-51
F4003 Invalid communication phase shutdown.....................................................................7-52
F4004 Error during phase progression..................................................................................7-52
F4005 Error during phase regression....................................................................................7-53
F4006 Phase switching without ready signal.........................................................................7-53
F4009 Bus failure...................................................................................................................7-54
F4012 Incorrect I/O length.....................................................................................................7-54
F4014 PLC watchdog ............................................................................................................7-55
F4034 Emergency-Stop.........................................................................................................7-56
7.6 Non-Fatal Safety Technology Errors (F3xxx) .............................................................................7-57
Behavior in the Case of Non-Fatal Safety Technology Error.................................................7-57
F3111 Refer. missing when selecting safety related end pos...............................................7-58
F3112 Reference missing when selecting safety related pos. ..............................................7-59
VI Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
F3117 Plausibility error of actual position values...................................................................7-60
F3130 Error when checking input signals..............................................................................7-61
F3131 Error when checking acknowledgment signal ............................................................7-62
F3132 Error when checking diagnostic output signal............................................................7-63
F3133 Error when checking interrupting circuits....................................................................7-64
F3134 Dynamization time interval incorrect...........................................................................7-65
F3135 Dynamization pulse width incorrect............................................................................7-66
F3140 Plausibility error of safety parameters........................................................................7-67
F3141 Plausibility error of selection.......................................................................................7-67
F3142 Activation time of enabling control exceeded.............................................................7-68
F3143 Safety command for clearing errors incorrect ............................................................7-69
F3145 Error when unlocking the safety door.........................................................................7-70
F3146 System error channel 2...............................................................................................7-71
F3147 System error channel 1...............................................................................................7-72
F3150 Safety command for system start incorrect................................................................7-73
F3151 Safety command for system halt incorrect .................................................................7-73
F3152 Incorrect backup of safety technology data................................................................7-74
7.7 Non-Fatal Errors (F2xxx) ............................................................................................................7-75
Behavior in the Case of Non-Fatal Error................................................................................7-75
F2005 Cam shaft invalid........................................................................................................7-75
F2006 MMC was removed.....................................................................................................7-76
F2007 Switching to non-initialized operating mode...............................................................7-77
F2008 RL The motor type has changed. ...............................................................................7-78
F2009 PL Load parameter default values..............................................................................7-79
F2010 Error when initializing digital inputs/outputs ...............................................................7-80
F2011 PLC - Error nr. 1 .........................................................................................................7-80
F2012 PLC - Error nr. 2 .........................................................................................................7-81
F2013 PLC - Error nr. 3 .........................................................................................................7-81
F2014 PLC - Error nr. 4 .........................................................................................................7-82
F2018 Device overtemperature shutdown.............................................................................7-83
F2019 Motor overtemperature shutdown...............................................................................7-84
F2021 Motor temperature monitor defective..........................................................................7-85
F2022 Device temperature monitor defective........................................................................7-85
F2026 Undervoltage in power section...................................................................................7-86
F2028 Excessive deviation....................................................................................................7-87
F2032 Plausibility error during commutation fine adjust........................................................7-88
F2033 External power supply X10 error................................................................................7-89
F2036 Excessive position feedback difference .....................................................................7-90
F2037 Excessive position command difference ....................................................................7-91
F2039 Maximum acceleration exceeded...............................................................................7-92
F2040 Device overtemperature 2 shutdown..........................................................................7-93
F2042 Encoder 2: encoder signals incorrect.........................................................................7-94
F2043 Measuring encoder: encoder signals incorrect...........................................................7-95
F2044 External power supply X15 error................................................................................7-96
F2048 Low battery voltage.....................................................................................................7-97
F2050 Overflow of target position preset memory.................................................................7-98
Rexroth IndraDrive Contents VII
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
F2051 No sequential block in target position preset memory................................................7-99
F2053 Incr. encoder emulator: pulse frequency too high....................................................7-100
F2054 Incr. encoder emulator: hardware fault.....................................................................7-101
F2067 Synchronization to master communication incorrect................................................7-102
F2069 Error when releasing the motor holding brake .........................................................7-103
F2074 Actual pos. value 1 outside absolute encoder window.............................................7-104
F2075 Actual pos. value 2 outside absolute encoder window.............................................7-105
F2076 Actual pos. value 3 outside absolute encoder window.............................................7-106
F2077 Current measurement trim wrong.............................................................................7-107
F2086 Error supply module..................................................................................................7-108
F2087 Module group communication error..........................................................................7-109
F2100 Incorrect access to command value memory...........................................................7-109
F2101 It was impossible to address MMC...........................................................................7-110
F2102 It was impossible to address I2C memory................................................................7-111
F2103 It was impossible to address EnDat memory...........................................................7-112
F2104 Commutation offset invalid .......................................................................................7-113
F2110 Error in non-cyclical data communic. of power section............................................7-114
F2174 Loss of motor encoder reference..............................................................................7-115
F2175 Loss of optional encoder reference..........................................................................7-116
F2176 Loss of measuring encoder reference......................................................................7-117
F2177 Modulo limitation error of motor encoder..................................................................7-118
F2178 Modulo limitation error of optional encoder ..............................................................7-118
F2179 Modulo limitation error of measuring encoder..........................................................7-119
F2802 PLL is not synchronized............................................................................................7-119
F2814 Undervoltage in mains..............................................................................................7-120
F2815 Overvoltage in mains................................................................................................7-120
F2816 Softstart fault power supply unit ...............................................................................7-121
F2817 Overvoltage in power section ...................................................................................7-121
F2818 Phase failure.............................................................................................................7-122
F2819 Mains failure .............................................................................................................7-122
F2820 Braking resistor overload.........................................................................................7-123
F2821 Error in control of braking resistor ............................................................................7-124
F2825 Switch-on threshold braking resistor too low............................................................7-125
F2833 Ground fault in motor line .........................................................................................7-125
F2834 Contactor control error..............................................................................................7-126
F2836 Error balancing monitor/ground fault........................................................................7-126
F2840 Error supply shutdown..............................................................................................7-127
F2860 Overcurrent in mains-side power section.................................................................7-127
F2890 Invalid device code...................................................................................................7-127
F2891 Incorrect interrupt timing...........................................................................................7-128
F2892 Hardware variant not supported...............................................................................7-128
7.8 SERCOS error codes / Error messages in service channel.....................................................7-129
8 Warning Diagnostic Messages (Exxxx) 8-1
8.1 Fatal Warning Diagnostic Messages (E8xxx)...............................................................................8-1
E8025 Overvoltage in power section.......................................................................................8-1
VIII Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
E8028 Overcurrent in power section .......................................................................................8-2
E8029 Positive position limit exceeded ...................................................................................8-3
E8030 Negative position limit exceeded..................................................................................8-4
E8034 Emergency-Stop...........................................................................................................8-5
E8040 Torque/force actual value limit active...........................................................................8-6
E8041 Current limit active........................................................................................................8-6
E8042 Both travel range limit switches activated ....................................................................8-7
E8043 Positive travel range limit switch activated...................................................................8-8
E8044 Negative travel range limit switch activated .................................................................8-9
E8055 Motor overload, current limit active ............................................................................8-10
E8057 Device overload, current limit active...........................................................................8-11
E8058 Drive system not ready for operation .........................................................................8-12
E8260 Torque/force command value limit active...................................................................8-13
8.2 Non-Fatal Safety Technology Warning Diagnostic Messages (E31xx)......................................8-14
E3100 Error when checking input signals..............................................................................8-14
E3101 Error when checking acknowledgment signal............................................................8-15
E3102 Plausibility error of actual position values ..................................................................8-15
E3103 Dynamization failed....................................................................................................8-16
E3104 Plausibility error of safety parameters........................................................................8-16
E3105 Plausibility error of safety related operating mode.....................................................8-17
E3106 System error channel 2 ..............................................................................................8-17
E3107 Error when unlocking the safety door.........................................................................8-18
E3110 Time interval of forced dynamization exceeded.........................................................8-18
8.3 Non-Fatal Warning Diagnostic Messages (E2xxx).....................................................................8-19
E2011 PLC - Warning no. 1...................................................................................................8-19
E2012 PLC - Warning no. 2...................................................................................................8-19
E2013 PLC - Warning no. 3...................................................................................................8-19
E2014 PLC - Warning no. 4...................................................................................................8-20
E2026 Undervoltage in power section...................................................................................8-20
E2040 Device overtemperature 2 prewarning.......................................................................8-21
E2047 Interpolation velocity = 0.............................................................................................8-22
E2048 Interpolation acceleration = 0.....................................................................................8-23
E2049 Positioning velocity >= S-0-0091................................................................................8-24
E2050 Device overtemp. Prewarning ....................................................................................8-25
E2051 Motor overtemp. prewarning ......................................................................................8-26
E2053 Target position out of travel range..............................................................................8-27
E2054 Not homed..................................................................................................................8-28
E2055 Feedrate override S-0-0108 = 0.................................................................................8-29
E2056 Torque limit = 0...........................................................................................................8-30
E2058 Selected process block is not programmed. ..............................................................8-31
E2059 Velocity command value limit active...........................................................................8-32
E2061 Device overload prewarning.......................................................................................8-33
E2063 Velocity command value > limit S-0-0091..................................................................8-34
E2064 Target position out of num. range ..............................................................................8-34
E2069 Brake torque too low...................................................................................................8-35
E2074 Encoder 1: encoder signals disturbed........................................................................8-36
Rexroth IndraDrive Contents IX
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
E2075 Encoder 2: encoder signals disturbed........................................................................8-37
E2076 Measuring encoder: encoder signals disturbed .........................................................8-38
E2086 Prewarning supply module overload..........................................................................8-39
E2800 DC bus timeout...........................................................................................................8-39
E2802 HW control braking resistor........................................................................................8-40
E2810 Drive system not ready for operation .........................................................................8-41
E2814 Undervoltage in mains................................................................................................8-42
E2815 Overvoltage in mains..................................................................................................8-43
E2816 Undervoltage in power section...................................................................................8-43
E2818 Phase failure...............................................................................................................8-44
E2819 Mains failure ...............................................................................................................8-44
E2820 Braking resistor overload prewarning.........................................................................8-45
E2829 Not ready for power on...............................................................................................8-45
9 Command Diagnostic Messages 9-1
9.1 Commands....................................................................................................................................9-1
C0100 Communication phase 3 transition check ....................................................................9-1
C0200 Communication phase 4 transition check ....................................................................9-1
C0300 Command Set absolute measuring..............................................................................9-2
C0400 Switching to parameter mode ......................................................................................9-2
C0500 Reset class 1 diagnostics, error reset..........................................................................9-3
C0600 Drive-controlled homing procedure command.............................................................9-3
C07_0 Load defaults procedure com. (load controller param.)...............................................9-4
C07_2 Load def. proc. com. (load def. pr. for safety techn.)...................................................9-5
C07_1 Load defaults procedure com. (load basic parameters) ..............................................9-6
C0800 Load basic parameters command................................................................................9-6
C0900 Position spindle command ...........................................................................................9-6
C1200 Commutation offset setting command..........................................................................9-7
C1300 Positive stop drive procedure command......................................................................9-7
C1400 Command Get marker position ....................................................................................9-8
C1700 Command measuring wheel mode ..............................................................................9-8
C1800 Command automatic control loop setting.....................................................................9-9
C2000 Command Release motor holding brake ...................................................................9-10
C2100 Brake check command...............................................................................................9-10
C2200 Backup working memory procedure command..........................................................9-10
C2300 Load working memory command...............................................................................9-11
C2400 Selectively backup working memory procedure command........................................9-11
C2500 Copy IDN from optional memory to internal memory.................................................9-11
C2600 Copy IDN from internal memory to optional memory.................................................9-12
C2800 Analog input adjust command....................................................................................9-12
C2900 Command Firmware update from MMC.....................................................................9-13
C3000 Synchronize and store safety technology IDN...........................................................9-13
C3100 Recalculate actual value cycle...................................................................................9-14
C3200 Command Calculate data for asynchronous motor....................................................9-14
C3300 Set coordinate system procedure command .............................................................9-15
C3400 Shift coordinate system procedure command............................................................9-15
XContents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
C3500 Command Determine encoder correction..................................................................9-15
C3700 Manually unlocking the safety door............................................................................9-16
C3800 Command Apply motor holding brake........................................................................9-16
C3900 Command Abrasion of brake .....................................................................................9-16
C4000 Homing procedure command channel 2....................................................................9-17
9.2 Command errors.........................................................................................................................9-17
C0101 Invalid parameters (-> S-0-0021)...............................................................................9-17
C0102 Limit error in parameter (-> S-0-0021).......................................................................9-18
C0103 Parameter conversion error (->S-0-0021)..................................................................9-18
C0104 Config. IDN for MDT not configurable........................................................................9-19
C0105 Maximum length for MDT exceeded..........................................................................9-20
C0106 Config. IDNs for AT not configurable .........................................................................9-20
C0107 Maximum length for AT exceeded .............................................................................9-21
C0108 Time slot parameter > Sercos cycle time...................................................................9-21
C0109 Position of data record in MDT (S-0-0009) even .......................................................9-22
C0110 Length of MDT (S-0-0010) odd..................................................................................9-22
C0111 ID9 + Record length - 1 > length MDT (S-0-0010).....................................................9-23
C0112 TNcyc (S-0-0001) or TScyc (S-0-0002) error.............................................................9-23
C0113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error...............................................9-24
C0114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)...............................................................9-25
C0115 T2 too small................................................................................................................9-25
C0116 T3 (S-0-0008) within MDT (S-0-0089 + S-0-0010).....................................................9-26
C0119 Max. travel range too large ........................................................................................9-26
C0120 Error when reading encoder data => motor encoder.................................................9-27
C0121 Incorrect parameterization of motor encoder (hardware)...........................................9-27
C0122 Incorr. parameteriz. of motor enc. (mechanical system)............................................9-28
C0123 Modulo value for motor encoder cannot be displayed...............................................9-28
C0124 Motor encoder unknown.............................................................................................9-29
C0125 Error when reading encoder data => optional encoder..............................................9-30
C0126 Incorrect parameterization of optional enc. (hardware) .............................................9-31
C0127 Incorr. parameteriz. of opt. enc. (mechanical system)...............................................9-31
C0128 Modulo value for optional encoder cannot be displayed............................................9-32
C0129 Optional encoder unknown ........................................................................................9-33
C0130 Maximum travel range cannot be displayed internally...............................................9-34
C0131 Switching to phase 3 impossible................................................................................9-34
C0132 Invalid settings for controller cycle times ...................................................................9-35
C0134 Invalid motor data in encoder memory (->S-0-0021).................................................9-36
C0135 Type of construction of motor P-0-4014 incorrect......................................................9-37
C0136 Several motor encoders connected ...........................................................................9-37
C0137 Error during initialization of motor data (->S-0-0021).................................................9-38
C0138 Invalid control section data (->S-0-0021)...................................................................9-39
C0139 T2 (S-0-089) + length MDT (S-0-010) > TScyc (S-0-002) .........................................9-39
C0140 Rotary scaling not allowed .........................................................................................9-40
C0153 Error at init. of synchr. motor with reluctance torque .................................................9-41
C0154 Field bus: IDN for cycl. command val. not configurable.............................................9-42
C0155 Field bus: max. length for cycl. command val. exceeded ..........................................9-42
Rexroth IndraDrive Contents XI
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
C0156 Field bus: IDN for cycl. actual val. not configurable...................................................9-43
C0157 Field bus: length for cycl. actual values exceeded.....................................................9-43
C0158 Field bus: Tcyc (P-0-4076) incorrect..........................................................................9-44
C0159 Field bus: P-0-4077 missing for cycl. command values.............................................9-44
C0160 Error when reading encoder data => measuring encoder .........................................9-45
C0161 Incorr. prarmeterization of measuring enc. (hardware)..............................................9-46
C0162 Measuring encoder unknown.....................................................................................9-47
C0163 Modulo value for measuring encoder cannot be displayed........................................9-48
C0164 Incorrect measuring encoder configuration................................................................9-48
C0199 Functional package selection changed. Restart........................................................9-49
C0201 Invalid parameters (->S-0-0022)................................................................................9-49
C0202 Parameter limit error (->S-0-0022).............................................................................9-50
C0203 Parameter calculation error (->S-0-0022)..................................................................9-50
C0212 Invalid control section data (->S-0-0022)...................................................................9-51
C0220 Error when initializing position of encoder 1 ..............................................................9-52
C0221 Initialization velocity encoder 1 too high.....................................................................9-53
C0224 Error when initializing position of encoder 2 ..............................................................9-54
C0225 Initialization velocity encoder 2 too high.....................................................................9-55
C0227 Error when initializing position of measuring encoder................................................9-56
C0228 Initialization velocity measuring encoder too high......................................................9-57
C0242 Multiple configuration of a parameter (->S-0-0022)...................................................9-58
C0243 Brake check function not possible..............................................................................9-59
C0244 Act. modulo value cycle greater than max. travel range............................................9-59
C0245 Operating mode configuration (->S-0-0022) not allowed...........................................9-60
C0246 Trav. range lim. switch not ass. to dig. input..............................................................9-61
C0247 Dig. output already assigned to other axis.................................................................9-61
C0248 Dig. input assigned differently to axes .......................................................................9-62
C0249 Dig. I/Os: bit number too large...................................................................................9-62
C0250 Probe inputs incorrectly configured............................................................................9-63
C0251 Error during synchronization to master communication.............................................9-63
C0255 Safety command for system init. incorrect.................................................................9-64
C0257 No encoder assigned to slot 1....................................................................................9-65
C0258 Error in relation TNcyc (S-0-0001) to fine interpol. ....................................................9-66
C0260 Incremental enc. emulator resol. cannot be displayed...............................................9-67
C0301 Measuring system unavailable...................................................................................9-68
C0302 Absolute evaluation of measuring system impossible ...............................................9-68
C0303 Absolute encoder offset cannot be saved..................................................................9-69
C0401 Drive active, switching not allowed ............................................................................9-69
C0501 Error clearing only in parameter mode.......................................................................9-70
C0601 Homing only possible with drive enable.....................................................................9-70
C0602 Distance home switch - reference mark erroneous ...................................................9-71
C0604 Homing of absolute encoder not possible..................................................................9-72
C0606 Reference mark not detected.....................................................................................9-73
C0607 Reference cam input not assigned.............................................................................9-74
C0702 Default parameters not available ...............................................................................9-74
C0703 Default parameters invalid .........................................................................................9-75
XII Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
C0704 Parameters not copyable ...........................................................................................9-75
C0706 Error when reading the controller parameters ...........................................................9-76
C0722 Parameter default value incorrect (-> S-0-0021)........................................................9-76
C0723 Safety command for load defaults procedure incorrect .............................................9-77
C0724 Timeout of safety command for load defaults procedure...........................................9-78
C0751 Parameter default value incorrect (-> S-0-0021)........................................................9-79
C0752 Locked with password................................................................................................9-79
C0799 An invalid index was set.............................................................................................9-80
C0851 Parameter default value incorrect (-> S-0-0021)........................................................9-80
C0852 Locked with password................................................................................................9-81
C0902 Spindle positioning requires drive enable ..................................................................9-81
C0903 Error during initialization.............................................................................................9-82
C0906 Error during search for zero pulse..............................................................................9-82
C1204 Error in offset calculation............................................................................................9-83
C1208 No adjustment with asynchronous motor...................................................................9-83
C1209 Proceed to phase 4....................................................................................................9-84
C1211 Commutation offset could not be determined. ...........................................................9-84
C1214 Command only possible with linear synchronous motor............................................9-85
C1215 Command only possible in ’bb’...................................................................................9-86
C1216 Commutation determination not selected...................................................................9-86
C1217 Setting only possible in ’Ab’........................................................................................9-87
C1218 Automatic commutation: current too low....................................................................9-88
C1219 Automatic commutation: overcurrent .........................................................................9-89
C1220 Automatic commutation: timeout................................................................................9-89
C1221 Automatic commutation: iteration without result ........................................................9-90
C1222 Error when writing offset parameters.........................................................................9-91
C1301 Class 1 diagnostics error at command start...............................................................9-91
C1701 Measuring wheel operation not possible....................................................................9-92
C1801 Start requires drive enable.........................................................................................9-92
C1802 Motor feedback data not valid....................................................................................9-93
C1803 Inertia detection failed................................................................................................9-94
C1804 Automatic controller setting failed..............................................................................9-95
C1805 Travel range invalid....................................................................................................9-96
C1806 Travel range exceeded...............................................................................................9-97
C1807 Determining travel range only via travel distance ......................................................9-97
C2001 Command not enabled...............................................................................................9-98
C2101 Brake check only possible with drive enable .............................................................9-98
C2103 Brake torque too low ..................................................................................................9-99
C2104 Command execution not possible............................................................................9-100
C2202 Error when writing data to non-volatile memory.......................................................9-100
C2301 Error when reading non-volatile memory.................................................................9-101
C2302 Error when converting parameters...........................................................................9-101
C2402 Error when saving parameters.................................................................................9-102
C2502 Error when accessing the MMC...............................................................................9-103
C2504 Error when writing data to internal memory.............................................................9-104
C2602 Error when accessing the MMC...............................................................................9-105
Rexroth IndraDrive Contents XIII
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
C2604 Error when reading the internal memory..................................................................9-106
C2802 Oscillations of input signal outside tolerance range.................................................9-106
C2803 Measured values at zero point and max. value identical.........................................9-107
C2804 Automatic adjust failed.............................................................................................9-107
C2903 Error when accessing the MMC...............................................................................9-108
C2904 Error when accessing the flash................................................................................9-109
C2905 Programmed firmware defective ..............................................................................9-110
C3001 Synchronization and storage failed..........................................................................9-111
C3101 Act. modulo value cycle greater than max. travel range..........................................9-111
C3102 Drive is still in drive enable.......................................................................................9-112
C3201 Incorrect input for current.........................................................................................9-112
C3203 Incorrect input for voltage.........................................................................................9-113
C3202 Incorrect input for frequency.....................................................................................9-113
C3204 Incorrect input for speed...........................................................................................9-114
C3205 Incorrect input for power factor ................................................................................9-114
C3206 Incorrect input for power ..........................................................................................9-115
C3207 Type plate list incomplete.........................................................................................9-115
C3208 Error when writing parameters.................................................................................9-116
C3501 Acquisition velocity not allowed................................................................................9-116
C3502 Motor encoder not available.....................................................................................9-117
C3503 Optional encoder not available.................................................................................9-117
C3504 Measuring encoder not available.............................................................................9-118
C3505 No encoder selected ................................................................................................9-118
C3506 Correction value table cannot be stored ..................................................................9-119
C3701 Error when manually unlocking the safety door.......................................................9-119
C3901 Abrasion of brake only possible with drive enable...................................................9-120
C3902 Error during abrasion of brake .................................................................................9-120
C3903 Command execution impossible..............................................................................9-121
C4001 Error during safety related homing procedure .........................................................9-121
10 Handling, Diagnostic and Service Functions 10-1
10.1 Firmware Update.........................................................................................................................10-1
10.2 Firmware Download....................................................................................................................10-1
Messages During the Firmware Download............................................................................10-1
XX: DL....................................................................................................................................10-1
XX:ERASE.............................................................................................................................10-2
XX: PROG..............................................................................................................................10-2
XX: CKS................................................................................................................................10-2
XX:E ADR ..............................................................................................................................10-2
XX:E SEC...............................................................................................................................10-2
XX:E FW ...............................................................................................................................10-3
XX:E LD ................................................................................................................................10-3
XX:E SEQ ..............................................................................................................................10-3
XX:F9002...............................................................................................................................10-4
XX:F2100...............................................................................................................................10-4
XX:F CKS...............................................................................................................................10-4
XIV Contents Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
XX:F ACC...............................................................................................................................10-4
XX:F2101...............................................................................................................................10-4
XX:F8122...............................................................................................................................10-5
XX:F8129...............................................................................................................................10-5
XX:F8130...............................................................................................................................10-5
XX:F8120...............................................................................................................................10-5
10.3 Replacing Devices, Cables and Motors......................................................................................10-6
Supply Units...........................................................................................................................10-6
Drive Controllers ....................................................................................................................10-7
Control Section ....................................................................................................................10-11
Optional Modules.................................................................................................................10-11
Replacing the Motor.............................................................................................................10-12
Replacing Cables.................................................................................................................10-12
10.4 Fault Report ..............................................................................................................................10-14
11 Notes for Machine Operators 11-1
11.1 General Information ....................................................................................................................11-1
11.2 Diagnosing Failures and Removing Errors.................................................................................11-1
11.3 Contacting the Service Department............................................................................................11-2
12 Notes for Installation Programmers 12-1
12.1 How to Handle Command Errors................................................................................................12-1
12.2 How to Handle Errors..................................................................................................................12-3
12.3 How to Handle Warnings............................................................................................................12-5
13 Index 13-1
14 Service & Support 14-1
14.1 Helpdesk .....................................................................................................................................14-1
14.2 Service-Hotline............................................................................................................................14-1
14.3 Internet........................................................................................................................................14-1
14.4 Vor der Kontaktaufnahme... - Before contacting us....................................................................14-1
14.5 Kundenbetreuungsstellen - Sales & Service Facilities ...............................................................14-2
Rexroth IndraDrive Basics on Device Diagnosis 1-1
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
1 Basics on Device Diagnosis
1.1 Diagnostic System
Coded Diagnostic Drive Messages
Brief Description
The drive provides a diagnostic system including different possibilities that
are basically divided into two groups:
•recognizing and displaying the current drive status by means of drive-
internal, priority-dependent generation of diagnostic messages
•collective messages for diverse status messages
Additionally, there are parameters for all important operating data the
values of which can be transmitted both via master communication (e.g.
SERCOS) and a parameterization interface (RS-232/485 in the ASCII
protocol or SIS protocol; see "Serial Communication").
Pertinent Parameters
•S-0-0030, Manufacturer version
•S-0-0095, Diagnostic message
•S-0-0140, Controller type
•S-0-0142, Application type
•S-0-0375, List of diagnostic numbers
•S-0-0390, Diagnostic message number
•P-0-0009, Error number
•P-0-0478, Logbook event
•P-0-0479, Logbook time stamp
Drive-Internal Generation of Diagnostic Messages
Operating states, activities and reactions of the drive controller are
detected by drive-internal generation of diagnostic messages and appear
in coded form on the display of the control panel. In addition, these
diagnostic messages can be transmitted to the master (control unit or
commissioning software, e.g. DriveTop).
The following categories of diagnostic messages are differentiated (kinds
of diagnostic messages):
•errors
•warnings
•commands/command errors
•status displays/operating states
Generally, the current diagnostic message with the highest priority is
displayed or stored at the following locations in the drive:
•Display of the control panel
The diagnostic message number appears on the 8-digit display of the
standard control panel.
•S-0-0095, Diagnostic message
This parameter contains the operating status of the drive at present
relevant in the form of a plain text. Preceding the text is the respective
content of parameter S-0-0390.
1-2 Basics on Device Diagnosis Rexroth IndraDrive
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
•S-0-0390, Diagnostic message number
The diagnostic message number shown on the display is stored in this
parameter.
When a diagnostic message of the "error" category occurs, the
corresponding diagnostic message number is stored in the P-0-0009,
Error number parameter. When there isn’t any error present, the value of
parameter P-0-0009 equals zero.
In the S-0-0375, List of diagnostic numbers parameter the last 50
diagnostic message numbers of parameter S-0-0390 are recorded in
chronological order. When reading this list, the number of the diagnostic
message that last occurred is displayed as parameter element 1.
The following priorities apply for displaying the current diagnostic
message:
1 F4002
number of the drive in the
bus system of the
master
communication
error message
8-digit display
1 E2025
1 C0901
1 C09
1 AF
warning
command error
command
operating status
increasing priority
Fig. 1-1: Priorities of displays (with example displays)
An overview of all diagnostic messages and their meanings is included in
the documentation "Troubleshooting Guide" (description of diagnostic
messages).
Structure of a Diagnostic Message
Every diagnostic message consists of
•diagnostic message number and
•diagnostic text.
Priorities of Display
Rexroth IndraDrive Basics on Device Diagnosis 1-3
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
The diagnostic message for the non-fatal error "Excessive deviation", for
example, has the following structure:
F2028 Excessive deviation
diagnostic message number
diagnostic text
Fig. 1-2: Structure of a diagnostic message
"F2028" flashes on the display of the control panel. The diagnostic
message number is contained in the S-0-0390, Diagnostic message
number parameter in hexadecimal form (for this example: 0x00F2028).
The diagnostic message number and the diagnostic text are contained as
string F2028 Excessive deviation in the S-0-0095, Diagnostic message
parameter. "2028" (dec) is written to the P-0-0009, Error number
parameter because it is an error diagnosis.
Diagnostic Message on the Control Panel Display
The diagnostic message number appears on the 8-digit display of the
standard control panel. This allows recognizing the current operating
status of the drive quickly and without using a communication interface.
As a matter of principle, the following applies:
•status displays (P0, Ab, AF …) are displayed in right-aligned form
•warnings, command errors and other error messages are flashing
Kind of diagnostic message Diagnostic
message number Display
error F2xxx F2xxx
command C0200 C02
command error C02xx C02xx
warning E2xxx E2xxx
communication phase
e.g. communication phase 1 A0001 P1
drive ready for operation A0012 Ab
operating mode
e.g. velocity control A0101 AF
Fig. 1-3: Overview of diagnostic messages displayed
The current operating mode is not shown on the display. When the drive
follows the preset operating mode and no command was activated, the
display reads "AF".
Diagnostic Messages in Plain Text
The diagnostic message in plain text contains the diagnostic message
number followed by the diagnostic text. It can be read via the S-0-0095,
Diagnostic message parameter and directly displayed on an operator
interface as a language-dependent description of the drive status.
The diagnostic message in plain text is switched to the selected language
via the S-0-0265, Language selection parameter.
Diagnostic Message Number
The diagnostic message number contains only the diagnostic number
without the diagnostic text. It can be read with the S-0-0390, Diagnostic
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