REXROTH VisualMotion 9 User manual

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
VisualMotion 9
Multi-Axis Motion Control
using GPP and GMP Firmware
R911292841
Edition 02
Troubleshooting Guide

About this Documentation VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
VisualMotion 9
Multi-Axis Motion Control
using GPP and GMP Firmware
Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Document Number, z.B. 209-0049-4306-02/EN
Part of Box Set, 20-09V-EN (Material No.: 293201)
This documentation describes …
•the use of VisualMotion Toolkit for assitance in diagnostics
•the proper steps for indentifing diagnostic faults
•and the suggested remedies for clearing faults
Description Release
Date Notes
DOK-VISMOT-VM*-09VRS**-WA02-EN-P 02/2003 Second release
2003 Bosch Rexroth AG
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Bosch Rexroth Corporation •Electric Drives and Controls
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http://www.boschrexroth.com/
Dept. ESG4 (DPJ)
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VisualMotion 9 Troubleshooting Guide Table of Contents I
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Table of Contents
1 VisualMotion 9 Overview 1-1
1.1 System Overview...........................................................................................................................1-1
1.2 GPP 9 System Overview................................................................................................................1-1
GPP 9 System Components....................................................................................................1-2
GPP 9 PLC Support.................................................................................................................1-2
GPP 9 Interface Support..........................................................................................................1-2
Drive I/O Support .....................................................................................................................1-3
1.3 GMP 9 System Overview...............................................................................................................1-3
GMP 9 Firmware Features.......................................................................................................1-4
GMP 9 System Components ...................................................................................................1-4
GMP 9 Interface Support.........................................................................................................1-4
Drive I/O Support .....................................................................................................................1-4
2 VisualMotion Tools for Diagnosing 2-1
2.1 Using VisualMotion Toolkit for Diagnosing ....................................................................................2-1
VisualMotion to PC Connection...............................................................................................2-1
The Diagnostics Menu.............................................................................................................2-4
2.2 Using VisualMotion's End User Tool for Diagnosing .....................................................................2-8
3 Monitoring and Diagnostics 3-1
3.1 System Diagnostics - Codes and Message...................................................................................3-1
Parameters ..............................................................................................................................3-1
DriveTop...................................................................................................................................3-3
3.2 Control Startup Messages..............................................................................................................3-4
PPC Boot-Up Sequence..........................................................................................................3-4
Control Firmware Sequence....................................................................................................3-4
3.3 Status Messages (001-199)...........................................................................................................3-5
001 Initializing System.............................................................................................................3-5
002 Parameter Mode...............................................................................................................3-5
003 Initializing Drives...............................................................................................................3-5
004 System is Ready...............................................................................................................3-5
005 Manual Mode ....................................................................................................................3-5
006 Automatic Mode: ABCD....................................................................................................3-5
007 Program Running: ABCD..................................................................................................3-6
008 Single-Stepping: ABCD.....................................................................................................3-6
009 Select Parameter Mode to Continue.................................................................................3-6
010 Breakpoint Reached: ABCD .............................................................................................3-6
011 Waiting for PLC.................................................................................................................3-6
018 Please cycle power to continue ........................................................................................3-6
019 Executing User Initialization Task.....................................................................................3-6

II Table of Contents VisualMotion 9 Troubleshooting Guide
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3.4 Warning Messages (201-399)........................................................................................................3-7
201 Invalid jog type or axis selected........................................................................................3-8
202 Drive %d is not ready........................................................................................................3-8
203 Power Fail detected..........................................................................................................3-8
204 SERCOS ring was disconnected......................................................................................3-8
205 Parameter transfer warning in Task %c ...........................................................................3-9
207 Axis %d position limit reached..........................................................................................3-9
208 Lost Fieldbus Connection .................................................................................................3-9
209 Fieldbus Mapping Timeout .............................................................................................3-10
210 File System Defrag: %d completed ................................................................................3-10
211 Program- & Data memory cleared..................................................................................3-10
212 Option Card PLS Warning, see ext. diag........................................................................3-11
213 SERCOS cycle time changed.........................................................................................3-11
214 PLC Cyclic Mapping Timeout .........................................................................................3-11
215 RECO I/O Failure, see ext. diag.....................................................................................3-12
216 Control PLS %d warning, see ext. diag..........................................................................3-12
217 PLC Communication, see ext. diag ................................................................................3-13
218 PLC Register Mapping Timeout......................................................................................3-13
219 PLC Lifecounter Timeout................................................................................................3-13
220 Excessive deviation in PMG%d, see ext. diag. ..............................................................3-14
221 Excessive Master Position Slip Deviation.......................................................................3-14
222 ELS Config. Warning, see ext. diag................................................................................3-14
3.5 Shutdown Messages (400 - 599).................................................................................................3-15
400 EMERGENCY STOP......................................................................................................3-15
401 SERCOS Controller Error: %02d....................................................................................3-15
402 SERCOS Config. Error: see ext. diag.............................................................................3-15
403 System Error see ext. diag..............................................................................................3-16
405 Phase %d: Drive did not respond...................................................................................3-16
407 Drive %d Phase 3 Switch Error ......................................................................................3-16
409 SERCOS Disconnect Error.............................................................................................3-17
411 Drive %d Phase 4 Switch Error ......................................................................................3-17
412 No drives were found on ring..........................................................................................3-17
414 Parameters were lost......................................................................................................3-18
415 Drive %d was not found..................................................................................................3-18
416 Invalid Instruction at %04x..............................................................................................3-19
417 SYSTEM ERROR: pSOS #%04x ...................................................................................3-19
418 No program is active.......................................................................................................3-19
419 Invalid Program File: code = %d.....................................................................................3-19
420 Drive %d Shutdown Error ...............................................................................................3-19
421 User Program Stack Overflow ........................................................................................3-20
422 Parameter transfer error in Task %c...............................................................................3-20
423 Unimplemented Instruction.............................................................................................3-20
425 Instruction error: see Task %c diag................................................................................3-21
426 Drive %d is not ready......................................................................................................3-21
427 Calc: invalid table index %d............................................................................................3-21
428 Calc: division by zero......................................................................................................3-22

VisualMotion 9 Troubleshooting Guide Table of Contents III
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429 Calc: too many operands................................................................................................3-22
430 Calc: invalid operator......................................................................................................3-22
431 Calc error: see Task %c diag..........................................................................................3-22
432 Calc: too many nested expressions................................................................................3-23
433 Setup instruction outside of a task..................................................................................3-23
434 Axis %d configured more than once...............................................................................3-23
435 Axis %d is not assigned to a task...................................................................................3-23
436 General Compiler Error: %04x........................................................................................3-23
438 Invalid Axis Selected: %d................................................................................................3-24
439 Axis %d: Invalid Motion Type..........................................................................................3-24
440 I/O Transfer Error: see task diag. ...................................................................................3-24
450 Event %d: invalid event type...........................................................................................3-25
451 Invalid event number ‘%d’...............................................................................................3-25
452 More than %d event timers armed..................................................................................3-25
453 Homing param. transfer error: %d..................................................................................3-25
454 Axis %d homing not complete ........................................................................................3-25
459 Axis %d target position out of bounds ............................................................................3-26
460 Invalid program %d from binary inputs...........................................................................3-26
463 Ratio command: invalid ratio ..........................................................................................3-26
464 Can't activate while program running..............................................................................3-27
465 Drive %d config. error, see ext. diag...............................................................................3-27
467 Invalid ELS Master Option..............................................................................................3-28
468 ELS adjustment out of bounds........................................................................................3-28
470 Axis %d velocity > maximum..........................................................................................3-28
474 Drive %d cyclic data size too large.................................................................................3-28
478 Calc: operand out of range .............................................................................................3-29
483 Parameter Init. Error: see Task %c diag.........................................................................3-29
484 Control SYSTEM ERROR...............................................................................................3-29
486 SERCOS Device %d is not a drive.................................................................................3-30
487 Cam %d is invalid or not stored......................................................................................3-30
488 Cam Error: See Task %c diag. .......................................................................................3-30
489 More than %d cam axes selected...................................................................................3-30
490 System Memory Allocation Error....................................................................................3-31
492 Programs were lost, see ext. diag. .................................................................................3-31
496 Can't execute this instruction from an event...................................................................3-32
497 Limit switch config. error, see ext. diag..........................................................................3-32
498 Drive %d Shutdown Warning..........................................................................................3-32
499 Axis number %d not supported in this version................................................................3-33
500 Axis %d is not referenced...............................................................................................3-33
501 Drive %d comm. error, see ext. diag. .............................................................................3-33
502 ELS and cams not supported in this version ..................................................................3-33
504 Communication Timeout.................................................................................................3-34
505 Axis %d is not configured................................................................................................3-34
506 I/O Mapper initialization error..........................................................................................3-34
508 User Watchdog Timeout.................................................................................................3-35
509 Control System Timing Error (%d)..................................................................................3-35

IV Table of Contents VisualMotion 9 Troubleshooting Guide
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515 PLC Communications Error............................................................................................3-36
516 More than %d registration functions enabled .................................................................3-36
519 Lost Fieldbus/PLC Connection .......................................................................................3-36
520 Fieldbus Mapping Timeout .............................................................................................3-36
521 Invalid Virtual Master ID: %d ..........................................................................................3-37
522 Invalid ELS Master ID: %d..............................................................................................3-37
523 IFS status, facility = 0x%x...............................................................................................3-38
524 Hardware Watchdog timeout..........................................................................................3-38
525 I/O Configuration error, see ext. diag..............................................................................3-38
526 SERCOS Multiplex Channel Config, see ext. diag.........................................................3-39
527 Control Initialization Error, see ext. diag.........................................................................3-39
528 System Event %d Occurred............................................................................................3-40
529 Invalid ELS Group ID: %d...............................................................................................3-40
530 Cam %d is active, can't overwrite...................................................................................3-41
531 Invalid variable for Fieldbus/PLC Mapping.....................................................................3-41
532 Power fail brown out condition detected.........................................................................3-41
533 Multiple instances of index cam: %d found.....................................................................3-41
534 Hardware Version Not Supported...................................................................................3-42
539 Invalid Parameter Number..............................................................................................3-42
540 Option Card PLS error....................................................................................................3-42
541 Link Ring Error, see ext. diag. ........................................................................................3-43
542 PLC Cyclic Mapping Timeout .........................................................................................3-44
543 PLC Runtime Error..........................................................................................................3-44
544 RECO I/O Failure, see ext. diag.....................................................................................3-44
545 Invalid Coordinated Articulation Function ID: %d ...........................................................3-45
546 Multiple Instance of Coordinated Articulation Function with ID: %d...............................3-45
547 Task %c Coordinated Articulation Error, see ext. diag...................................................3-46
548 Invalid Kinematic Number: %d........................................................................................3-46
549 Fieldbus Initialization Error .............................................................................................3-46
550 User Initialization Task Timeout......................................................................................3-46
551 Master Slip Config. Error, see ext. diag..........................................................................3-47
552 Excessive Master Position Slip Deviation.......................................................................3-47
553 Invalid Parameter Detected, see C-0-2002 ....................................................................3-47
554 Excessive Deviation in PGM%d, see ext. diag...............................................................3-47
555 PLC Register Mapping Timeout......................................................................................3-48
556 PLC Lifecounter Timeout................................................................................................3-48
557 PMG%d Maximum allowed deviation window is Zero....................................................3-48
558 PMG%d Only 1 axis parameterized................................................................................3-48
559 PMG%d Number of offsets does not match number of Axis..........................................3-49
560 PMG%d Max. allowed dev. window is larger than 25% of Modulo ................................3-49
561 PMG%d Offset is larger than Modulo.............................................................................3-49
562 PMG%d Parameterized Axis is not in system ................................................................3-49
563 Invalid Task Specified, Must be A-D...............................................................................3-49
564 PMG%d Invalid configuration, see ext. diag...................................................................3-49
565 Axis %d: Configuration error, see ext. diag. ...................................................................3-49
566 Filter sample rate and cutoff frequency mismatch..........................................................3-50

VisualMotion 9 Troubleshooting Guide Table of Contents V
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567 ELS Config. Error, see ext. diag. ....................................................................................3-50
568 Axis %d: Assigned Task is Not Defined..........................................................................3-51
570 ELS Max. Vel. Exceeded, see ext. diag..........................................................................3-51
571 No Program Found .........................................................................................................3-52
3.6 Communication Error Codes and Messages...............................................................................3-53
!01 SERCOS Error Code # xxxx (xxxx = Error code)...........................................................3-53
!02 Invalid Parameter Number..............................................................................................3-53
!03 Data is Read Only...........................................................................................................3-53
!04 Write Protected in this mode/phase................................................................................3-53
!05 Greater than maximum value .........................................................................................3-53
!06 Less than minimum value...............................................................................................3-53
!07 Data is Invalid .................................................................................................................3-53
!08 Drive was not found........................................................................................................3-53
!09 Drive not ready for communication.................................................................................3-53
!10 Drive is not responding...................................................................................................3-53
!11 Service channel is not open............................................................................................3-54
!12 Invalid Command Class..................................................................................................3-54
!13 Checksum Error: xx (xx= checksum that control calculated)..........................................3-54
!14 Invalid Command Subclass ............................................................................................3-54
!15 Invalid Parameter Set .....................................................................................................3-54
!16 List already in progress...................................................................................................3-54
!17 Invalid Sequence Number ..............................................................................................3-54
!18 List has not started..........................................................................................................3-54
!19 List is finished .................................................................................................................3-54
!20 Parameter is a List..........................................................................................................3-54
!21 Parameter is not a List....................................................................................................3-55
!22 Invalid Variable Number .................................................................................................3-55
!23 Insufficient Program Space.............................................................................................3-55
!24 Maximum number of files exceeded...............................................................................3-55
!25 Invalid Program Header..................................................................................................3-55
!26 Checksum Error in Program ...........................................................................................3-55
!27 Invalid Program Handle ..................................................................................................3-55
!28 Function not Implemented ..............................................................................................3-55
!29 Program not found on Control ........................................................................................3-55
!30 Invalid I/O Register or Bit Number..................................................................................3-56
!31 Invalid Table Index..........................................................................................................3-56
!32 Communication Port Error ..............................................................................................3-56
!33 Invalid Data Format.........................................................................................................3-56
!34 Active program can't be deleted .....................................................................................3-56
!35 Parameter mode is required ...........................................................................................3-56
!36 Invalid Event Number......................................................................................................3-56
!37 Invalid Event Function.....................................................................................................3-56
!38 Program file version mismatch .......................................................................................3-56
!39 Can't activate while program running..............................................................................3-56
!40 No programs are active...................................................................................................3-57
!41 System Error: pSOS #XXXX...........................................................................................3-57

VI Table of Contents VisualMotion 9 Troubleshooting Guide
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!42 Mapper: invalid operator.................................................................................................3-57
!43 Mapper: too many operations.........................................................................................3-57
!44 Mapper: invalid register...................................................................................................3-57
!45 Mapper: invalid bit or mask.............................................................................................3-57
!46 Mapper: register is read-only..........................................................................................3-57
!47 Invalid Unit Number ........................................................................................................3-57
!50 Invalid Download Block...................................................................................................3-57
!52 Invalid Axis......................................................................................................................3-57
!53 Waiting for service channel.............................................................................................3-58
!54 List or String is too short.................................................................................................3-58
!55 List or String is too long ..................................................................................................3-58
!56 PC Communication Handshake Error.............................................................................3-58
!57 I/O Mapper: Max file size on Control Exceeded .............................................................3-58
!58 Cannot store CAM: already active for axis %d...............................................................3-58
!59 SERCOS handshake/busy timeout.................................................................................3-58
!60 Executable program is too large (ddK)...........................................................................3-58
!61 System Memory Allocation Error ....................................................................................3-58
!62 Cam X data is < 0 or greater than 360 ...........................................................................3-59
!63 X-Column does not start at 0 or end at 360....................................................................3-59
!64 Not supported in user prog file version 1.1.....................................................................3-59
!72 Program does not include a PLS....................................................................................3-59
!73 Invalid ABS or REL point index (%d)..............................................................................3-59
!74 Error in command execution...........................................................................................3-59
!75 Comm. port buffer overflow.............................................................................................3-59
!78 Service channel in use....................................................................................................3-59
!79 PID block number does not exist....................................................................................3-59
!80 Invalid Object Number ....................................................................................................3-60
!81 Invalid Mapping(s)...........................................................................................................3-60
!82 Write protected by password ..........................................................................................3-60
!83 Valid ELS Group numbers are 1 through 8.....................................................................3-60
!84 ELS Group is not currently active ...................................................................................3-60
!85 Data not limited to a specific ELS Master.......................................................................3-60
!86 No ELS Masters are currently active..............................................................................3-60
!87 Valid Virtual Master numbers are 1 and 2 ......................................................................3-60
!88 No Virtual Master are currently active.............................................................................3-61
!89 Unsupported Parameter for mapping .............................................................................3-61
!90 Invalid variable for mapping............................................................................................3-61
!91 CAM build: float table start index #.................................................................................3-61
!92 CAM build: float table end index #..................................................................................3-61
!93 CAM build: float table size # ...........................................................................................3-61
!96 Duplicate Message Sequence Number (MSN)................................................................3-61
!97 Requested operation prohibited from network.................................................................3-61
!99 Request in Progress ........................................................................................................3-61
!100 Reset Command Parameter..........................................................................................3-62
!101 Read only From This Port..............................................................................................3-62
!102 Does Not Match Password Requirements.....................................................................3-62

VisualMotion 9 Troubleshooting Guide Table of Contents VII
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!103 Bit combination not valid................................................................................................3-62
4 Index 4-1
5 Service & Support 5-1
5.1 Helpdesk ........................................................................................................................................5-1
5.2 Service-Hotline...............................................................................................................................5-1
5.3 Internet...........................................................................................................................................5-1
5.4 Vor der Kontaktaufnahme... - Before contacting us.......................................................................5-1
5.5 Kundenbetreuungsstellen - Sales & Service Facilities ..................................................................5-2

VIII Table of Contents VisualMotion 9 Troubleshooting Guide
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