Mannesmann ecodrive03 User manual

ECODRIVE03
Drive for Machine Tool Applications
With SERCOS-, Analog- and Parallelinterface
Troubleshooting Guide: SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
mannesmann
Rexroth
engineering
Indramat
Rexroth
7=78)1

About this Documentation ECODRIVE03 SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
ECODRIVE03 Drive for Machine Tool Applications With SERCOS-,
Analog- and Parallelinterface
Troubleshooting Guide: SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
•Box 71-02V-EN
•Based on: SMT-02VRS
•120-1000-B11-01/EN
The following documentation describes the functions of the firmware
FWA-ECODR3-SMT-02VRS.
This documentation serves:
•for error diagnosis and error removal
Description Release
Date Notes
DOK-ECODR3-SMT-02VRS**-WA01-DE-P 12.99 First edition
1999 Rexroth Indramat GmbH
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).
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Rexroth Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 689421 •Fax [phone]
http://www.rexroth.com/indramat
Dept. ECD (MK/JR)
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 SMT-02VRS About this Documentation
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
Summary of Documentation - Box
Order designation:
DOK-ECODR3-SMT-02VRS**-FK01-EN-P
Order designation:
DOK-ECODR3-SMT-02VRS**-PA01-EN-P
Order designation:
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
Order designation:
DOK-ECODR3-SMT-02VRS**-FV01-EN-P
Order designation:
DOK-ECODR3-DKC**.3****-PR01-EN-P
282801
FK
282801
PA
282801
WA
282801
FV
282801
PR
Functional Description:
Description of all implemented Function
based on SERCOS Parameters
Parameter Description:
A description of all parameters
used in the firmware
Troubleshooting Guide:
-Explanation of the diagnostic states
-How to proceed when eliminating faults
Firmware Version Notes:
Description of new and changed functions
in terms of the derivatives:
-FWA-ECODR3-SMT01VRS-MS
Project Planning Manual:
-Planning control cabinet construction
-Planning the electric layout in the control cabinet
Order designation
DOK-ECODR3-SMT-02VRS**-7101-EN-P
partnumber:
282411
V
ersion:
01
Win3.1 and
Win95&NT
(6-:),)04
CD: DRIVEHELP
Collection of Windows help systems which
contain documents on firmware derivatives
Order designation:
DOK-GENERL-DRIVEHELP**-GExx-MS-D0600

About this Documentation ECODRIVE03 SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
Notes

ECODRIVE03 SMT-02VRS Contents I
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
Contents
1 Diagnostic Message Descriptions 1-1
Overview of the diagnostic message descriptions..................................................................................1-1
Diagnostic Message Types......................................................................................................1-1
Construction of a diagnostic message.....................................................................................1-1
2 Safety Instructions for Electric Servo Drives and Controls 2-1
2.1 Introduction.....................................................................................................................................2-1
2.2 Explanations...................................................................................................................................2-1
2.3 Hazards by inappropriate use........................................................................................................2-2
2.4 General Information .......................................................................................................................2-3
2.5 Protection against contact with electrical parts..............................................................................2-4
2.6 Protection by protective low voltage (PELV) against electrical shock ...........................................2-5
2.7 Protection against dangerous movements.....................................................................................2-6
2.8 Protection against magnetic and electromagnetic fields during operations and mounting............2-8
2.9 Protection against contact with hot parts.......................................................................................2-8
2.10 Protection during handling and installation....................................................................................2-9
2.11 Battery safety.................................................................................................................................2-9
2.12 Protection against pressurized Systems......................................................................................2-10
3 Description of diagnostic letters F... and E... 3-1
3.1 Error diagnostic messages F... ......................................................................................................3-1
F207 Switching to uninitialized operation mode ......................................................................3-2
F208 UL The motor type has changed....................................................................................3-2
F209 PL Load parameter default values..................................................................................3-3
F218 Amplifier overtemp. shutdown ........................................................................................3-3
F219 Motor overtemp. shutdown.............................................................................................3-4
F220 Bleeder overload shutdown............................................................................................3-4
F221 Motor temp. surveillance defective.................................................................................3-5
F223 Error during initialisation of the parking axis...................................................................3-5
F224 Maximum braking time exceeded...................................................................................3-6
F226 Undervoltage in power section .......................................................................................3-6
F228 Excessive deviation........................................................................................................3-7
F229 Encoder 1 failure: quadrant error....................................................................................3-7
F230 Max. signal frequency of encoder 1 exceeded...............................................................3-7
F236 Excessive position feedback difference..........................................................................3-8
F237 Excessive position command difference ........................................................................3-9
F242 Encoder 2 failure: signal amplitude wrong......................................................................3-9
F245 Encoder 2 failure: quadrant error..................................................................................3-10

II Contents ECODRIVE03 SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
F246 Max signal frequency of encoder 2 exceeded..............................................................3-11
F248 Low battery voltage.......................................................................................................3-11
F253 Incr. encoder emulator: pulse frequency too high........................................................3-12
F260 Command current limit shutoff......................................................................................3-12
F262 External short at status outputs....................................................................................3-12
F267 Erroneous internal hardware synchronization..............................................................3-13
F269 Error during release of the motor holding brake...........................................................3-13
F276 Absolute encoder out of allowed window .....................................................................3-14
F277 Current measurement trim wrong.................................................................................3-14
F281 Mains fault ....................................................................................................................3-15
F386 No ready signal from supply module............................................................................3-15
F401 Double MST failure shutdown ......................................................................................3-15
F402 Double MDT failure shutdown......................................................................................3-16
F403 Invalid communication phase shutdown.......................................................................3-16
F404 Error during phase progression....................................................................................3-16
F405 Error during phase regression......................................................................................3-17
F406 Phase switching without ready signal...........................................................................3-17
F434 Emergency-Stop...........................................................................................................3-17
F629 Positive travel limit exceeded.......................................................................................3-17
F630 Negative travel limit exceeded......................................................................................3-18
F634 Emergency-Stop...........................................................................................................3-19
F643 Positive travel limit switch detected..............................................................................3-19
F644 Negative travel limit switch detected ............................................................................3-19
F811 Commutation offset could not be determined...............................................................3-20
F812 Motion range exceeded during commutation ...............................................................3-20
F822 Encoder 1 failure: signal amplitude wrong....................................................................3-21
F860 Overcurrent: short in power stage................................................................................3-22
F870 +24Volt DC error...........................................................................................................3-22
F873 Power supply driver stages fault...................................................................................3-23
F878 Velocity loop error.........................................................................................................3-23
F879 Velocity limit S-0-0091 exceeded .................................................................................3-24
3.2 Warning diagnostic messages.....................................................................................................3-25
E221 Warning Motor temp. surveillance defective ................................................................3-25
E225 Motor overload..............................................................................................................3-26
E226 Undervoltage in power section.....................................................................................3-26
E247 Interpolation velocity = 0...............................................................................................3-26
E248 Interpolation acceleration = 0.......................................................................................3-27
E249 Positioning velocity >= S-0-0091..................................................................................3-27
E250 Drive overtemp. prewarning .........................................................................................3-28
E251 Motor overtemp. prewarning ........................................................................................3-28
E252 Bleeder overload prewarning .......................................................................................3-29
E253 Target position out of travel range................................................................................3-29
E254 Not homed....................................................................................................................3-30
E255 Feedrate-override S-0-0108 = 0...................................................................................3-30
E256 Torque limit = 0.............................................................................................................3-31
E257 Continuous current limit active .....................................................................................3-31

ECODRIVE03 SMT-02VRS Contents III
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
E258 Selected process block is not programmed. ................................................................3-31
E259 Command velocity limit active......................................................................................3-32
E260 Command Current limit active......................................................................................3-32
E261 Continuous current limit prewarning.............................................................................3-32
E263 Velocity command value > limit S-0-0091....................................................................3-33
E264 Target position out of num. range ................................................................................3-33
E269 Brake torque too low.....................................................................................................3-33
E281 Mains fault ....................................................................................................................3-34
E386 No ready signal from supply module............................................................................3-34
E408 Invalid addressing of MDT-data container A................................................................3-34
E409 Invalid addressing of AT-data container A ...................................................................3-34
E410 Slave not scanned or address 0...................................................................................3-35
E825 Overvoltage in power stage..........................................................................................3-35
E826 Undervoltage in power section.....................................................................................3-35
E829 Positive position limit exceeded ...................................................................................3-36
E830 Negative position limit exceeded..................................................................................3-36
E831 Position limit reached during jog ..................................................................................3-37
E834 Emergency-Stop...........................................................................................................3-37
E843 Positive limit switch activated.......................................................................................3-37
E844 Negative limit switch activated .....................................................................................3-38
E881 Mains fault ....................................................................................................................3-38
E886 No ready signal from supply module............................................................................3-38
4 Description of Diagnostic Letters B..., C..., D... and A... 4-1
4.1 Command Diagnostic Messages B..., C... and D...........................................................................4-1
B000 Pulse wire/Resolver offset detection..............................................................................4-2
B001 Motor does not have resolver feedback.........................................................................4-2
B002 Drive active at command start........................................................................................4-2
B003 Power supply is off .........................................................................................................4-2
B004 S pulse not found within travel range.............................................................................4-2
B005 Error writing to feedback EEPROM................................................................................4-2
B006 Error in feedback processor, SDAI does not show 1 .....................................................4-2
B008 Drive must be in operation mode (phase 4)...................................................................4-2
B009 Drive does not control in secondary operation mode 1..................................................4-2
B010 5 pulses found, but min. distance to move not reached.................................................4-3
B011 SDAI goes immeadiately back to 0, old PIC version......................................................4-3
B012 Master password required..............................................................................................4-3
B013 Shaft does not turn as expected.....................................................................................4-3
B100 Command Release motor holding brake........................................................................4-3
B101 Command not enabled...................................................................................................4-3
B200 Brake check command...................................................................................................4-3
B201 Brake check only with drive enable................................................................................4-3
B202 Error during bedding in the brake...................................................................................4-4
B203 Brake torque too low.......................................................................................................4-4
C100 Communication phase 3 transition check ......................................................................4-4
C101 Invalid communication parameter (S-0-0021)................................................................4-5

IV Contents ECODRIVE03 SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
C102 Limit error communication parameter (S-0-0021)..........................................................4-5
C104 Config. IDN for MDT not configurable............................................................................4-5
C105 Configurated length > max. length for MDT...................................................................4-6
C106 Config. IDN for AT not configurable...............................................................................4-6
C107 Configurated length > max. length for AT ......................................................................4-6
C108 Time slot parameter > Sercos cycle time.......................................................................4-7
C109 Position of data record in MDT (S-0-0009) even ...........................................................4-7
C110 Length of MDT (S-0-0010) odd......................................................................................4-7
C111 ID9 + Record length - 1 > length MDT (S-0-0010).........................................................4-8
C112 TNcyc (S-0-0001) or TScyc (S-0-0002) error.................................................................4-8
C113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error...................................................4-8
C114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)...................................................................4-9
C115 T2 too small....................................................................................................................4-9
C118 Order of MDT configuration wrong.................................................................................4-9
C200 Communication phase 4 transition check ....................................................................4-10
C201 Invalid parameter(s) (->S-0-0022)................................................................................4-10
C202 Parameter limit error (->S-0-0022)...............................................................................4-10
C203 Parameter calculation error (->S-0-0022)....................................................................4-10
C204 Motor type P-0-4014 incorrect......................................................................................4-11
C210 Feedback 2 required (->S-0-0022)...............................................................................4-11
C211 Invalid feedback data (->S-0-0022)..............................................................................4-11
C212 Invalid amplifier data (->S-0-0022)...............................................................................4-12
C213 Position data scaling error............................................................................................4-12
C214 Velocity data scaling error............................................................................................4-13
C215 Acceleration data scaling error.....................................................................................4-13
C216 Torque/force data scaling error....................................................................................4-14
C217 Feedback1 data reading error......................................................................................4-14
C218 Feedback 2 data reading error.....................................................................................4-14
C220 Feedback 1 initializing error .........................................................................................4-15
C221 Feedback 2 initializing error .........................................................................................4-15
C223 Input value for max. range too high..............................................................................4-16
C227 Modulo range error.......................................................................................................4-16
C234 Encoder combination not possible...............................................................................4-16
C235 Load-side motor encoder with inductance motor only .................................................4-17
C236 Feedback 1 required (P-0-0074)..................................................................................4-17
C238 Wrong function of encoder 2........................................................................................4-17
C300 Command Set absolute measuring..............................................................................4-17
C302 Absolute measuring system not installed.....................................................................4-18
C400 Switching to parameter mode ......................................................................................4-18
C401 Drive active, switching not allowed ..............................................................................4-18
C402 Only allowed without master........................................................................................4-18
C500 Reset class 1 diagnostic, error reset............................................................................4-19
C600 Drive controlled homing procedure command .............................................................4-19
C601 Homing only possible with drive enable.......................................................................4-19
C602 Distance home switch - reference mark erroneous .....................................................4-19
C604 Homing of absolute encoder not possible....................................................................4-19

ECODRIVE03 SMT-02VRS Contents V
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
C606 Reference mark not detected.......................................................................................4-20
C700 Basic load.....................................................................................................................4-20
C702 Default parameters not available .................................................................................4-21
C703 Default parameters invalid ...........................................................................................4-21
C704 Parameters not copyable .............................................................................................4-21
C800 Default parameter load.................................................................................................4-21
C801 Parameter default value erroneous (-> S-0-0021).......................................................4-22
C802 Locked with password..................................................................................................4-22
C900 Position spindle command...........................................................................................4-22
C902 Spindle positioning requires drive enable ....................................................................4-22
C905 Positioning with non-init. absolute encoder impossible................................................4-22
C906 Error during search for zero pulse................................................................................4-23
D300 Command adjust commutation ....................................................................................4-23
D301 Drive not ready for commutation command.................................................................4-23
D302 Torque/Force too small to move ..................................................................................4-24
D303 Drive in control at start of command ............................................................................4-24
D306 Power is off...................................................................................................................4-24
D307 Drive does not move ....................................................................................................4-24
D308 No adjustment with asynchronous motor.....................................................................4-24
D309 Proceed to phase 4......................................................................................................4-25
D310 Input master password.................................................................................................4-25
D311 Commutation offset could not be determined..............................................................4-25
D312 Motion range exceeded during commutation...............................................................4-25
D400 Positive stop drive procedure command......................................................................4-26
D401 ZKL1-Error at command start.......................................................................................4-26
D500 Command Get mark position .......................................................................................4-26
D501 Incremental encoder required ......................................................................................4-26
D600 Cancel reference point procedure command...............................................................4-27
D700 Parking axis command.................................................................................................4-27
D701 Parking axis only while drive is disabled......................................................................4-27
D900 Command automatic loop tuning .................................................................................4-28
D901 Start requires drive enable...........................................................................................4-28
D902 Motor feedback data not valid......................................................................................4-28
D903 Inertia detection failed..................................................................................................4-29
D904 Gain adjustment failed..................................................................................................4-29
D905 Travel range invalid, P-0-0166 & P-0-0167..................................................................4-30
D906 Travel range exceeded.................................................................................................4-30
4.2 Status diagnostic messages ........................................................................................................4-31
A000 Communication phase 0...............................................................................................4-31
A001 Communication phase 1...............................................................................................4-31
A002 Communication phase 2...............................................................................................4-31
A003 Communication phase 3...............................................................................................4-32
A010 Drive HALT...................................................................................................................4-32
A012 Control and power sections ready for operation ..........................................................4-33
A013 Ready for power on......................................................................................................4-33
A100 Drive in TORQUE control.............................................................................................4-33

VI Contents ECODRIVE03 SMT-02VRS
DOK-ECODR3-SMT-02VRS**-WA01-EN-P
A101 Drive in VELOCITY control...........................................................................................4-33
A102 Position mode with encoder 1 ......................................................................................4-33
A103 Position mode with encoder 2 ......................................................................................4-33
A104 Position mode lagless, encoder 1 ................................................................................4-34
A105 Position control lagless, feedback 2.............................................................................4-34
A106 Drive controlled interpolation, encoder 1......................................................................4-34
A107 Drive controlled interpolation, encoder 2......................................................................4-34
A108 Drive controlled interpolation, lagless, encoder 1 ........................................................4-35
A109 Drive controlled interpolation, lagless, encoder 2 ........................................................4-35
A146 Relative drive controlled interpolation, encoder 1 ........................................................4-35
A147 Relative drive controlled interpolation, encoder 2 ........................................................4-36
A148 Relative drive contr. interpolation, enc. 1, lagless........................................................4-36
A149 Relative drive contr. interpolation, enc. 2, lagless........................................................4-37
A203 Stepper position mode..................................................................................................4-37
A204 Stepper position mode, lagless ....................................................................................4-37
A206 Process block mode, encoder 1...................................................................................4-37
A207 Process block mode lagless, encoder 1.......................................................................4-38
A208 JOG mode positive.......................................................................................................4-38
A210 Process block mode, encoder 2...................................................................................4-38
A211 Process block mode lagless, encoder 2.......................................................................4-38
A218 JOG mode negative......................................................................................................4-38
A400 Automatic drive check and adjustment.........................................................................4-39
A401 Drive deceleration to standstill .....................................................................................4-39
A800 Unknown operation mode ............................................................................................4-39
4.3 Diagnostic messages for basic initialization and after fatal System errors..................................4-40
Diagnostic Message Display: -0.............................................................................................4-40
Diagnostic Message Display: -1.............................................................................................4-40
Diagnostic Message Display: -2.............................................................................................4-40
Diagnostic Message Display: -3.............................................................................................4-40
Diagnostic Message Display: -4.............................................................................................4-40
Diagnostic Message Display: -5.............................................................................................4-40
Diagnostic Message Display: -6.............................................................................................4-40
Diagnostic Message Display: (2 dots) .............................................................................4-40
Diagnostic Message Display: E1 ...........................................................................................4-41
Diagnostic Message Display: E2 ...........................................................................................4-41
Diagnostic Message Display: E3 ...........................................................................................4-41
Diagnostic Message Display: E4 ...........................................................................................4-41
Diagnostic Message Display: E5 ...........................................................................................4-41
4.4 Operation Status..........................................................................................................................4-42
bb...........................................................................................................................................4-42
Ab...........................................................................................................................................4-42
AC..........................................................................................................................................4-42
AE ..........................................................................................................................................4-42
AF...........................................................................................................................................4-42
AH..........................................................................................................................................4-42
Jb ...........................................................................................................................................4-42