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
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Tel.: [phone] •Fax: [phone] •Telex: 68 94 21
Bosch Rexroth Corporation •Electric Drives and Controls
5150 Prairie Stone Parkway •Hoffman Estates, IL 60192 •USA
Tel.: [phone] •Fax: [phone]
http://www.boschrexroth.com/
Dept. ESG4 (DPJ)
This document has been printed on chlorine-free bleached paper.
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Note

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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
!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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
!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
DOK-VISMOT-VM*-09VRS**-WA02-EN-P

VisualMotion 9 Troubleshooting Guide VisualMotion 9 Overview 1-1
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
1 VisualMotion 9 Overview
1.1 System Overview
VisualMotion is a programmable multi-axis motion control system capable
of controlling up to 40 intelligent digital drives from Bosch Rexroth. The
PC software used for motion control management is named VisualMotion
Toolkit.
VisualMotion 9 supports the following hardware form factors and firmware
versions:
•PPC-R (RECO-version) using GPP 9 firmware
•PPC-P11.1 (PCI-version) using GMP 9 firmware
1.2 GPP 9 System Overview
The PPC-R is a stand-alone multi-axis motion control. It has the
RECO02 form factor, a form factor used by Bosch Rexroth for motion
controls, PLCs and I/O modules. These devices share the RECO02
back-plane bus for data exchange.
It is recommended to use the VisualMotion motion control with Bosch
Rexroth's DIAX04 and/or ECODRIVE03 digital servo drives. The
communication between control and digital servo drives is performed
using the SERCOS fiber optic interface, the international standard for
real-time communication for digital servo drives.
VisualMotion can provide multi-axis coordinated or non-coordinated
motion control with tightly integrated RECO02 I/O logic control functions.
The flexibility of GPP 9 firmware supports a variety of applications, from
general motion control to sophisticated multiple master electronic line
shafting (ELS) and robotics.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
X6
X7
0V
24V
0V
24V
NSW01.1R
RDY RUN
ERR STA
ETHERNET
X99
9
10
11
12
13
14
15
16
24V
0V
RDY RUN
ERR STA
DP-SLAVE
X79
X75
X94
1
2
3
4
5
6
7
8
24V
0V
PPC-R02.2PPC-R01.2
RECO
RECO
PPC-R01.2
H1
PROG
U2
X10
X1
I1
I3
I2
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
PPC-R02.2
H1
PROG
X10
X1
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
COM
X16
I1
I3
I2
U2 U3 U4
X16
COM
PPCR_Overview.FH7
Fig. 1-1: PPC-R Motion Control

1-2 VisualMotion 9 Overview VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
GPP 9 System Components
The VisualMotion GPP 9 system is comprised of the following
components:
•PPC-R control using GPP 9 firmware
•RECO02 I/O modules (Local and SERCOS)
•VisualMotion Toolkit (VMT) Windows program for motion control
programming, parametrization, system diagnostics and motion control
management. VMT also includes DDE and OPC servers. These
servers are the communication protocol between Windows programs
and the control.
•Up to 40 intelligent digital drives can be connected to one control over
the SERCOS fiber optic ring
–DIAX04 (using SSE03 or ELS05 firmware) drives and motors
–ECODRIVE03 (using SMT02, SGP01, SGP03 or SGP20
firmware) drives and motors
–ECODRIVE C (using MPG01 firmware) drives and motors
•HMI interfaces (BTC06, BTV04, BTV05, BTV06)
GPP 9 PLC Support
The Bosch Rexroth MTS-R is a PLC unit that interfaces with the
VisualMotion control (PPC-R) and is available preconfigured in two sizes.
•MTS-R01.1 with one expansion slot
•MTS-R02.1 with three expansion slot
Note: The expansion slot(s) on the MTS-R can be configured with
fieldbus master interface or serial interface cards.
GPP 9 Interface Support
VisualMotion GPP 9 supports the following interfaces:
Fieldbus Interfaces
•Profibus-DP slave interface (32 words)
•Interbus slave interface (16 words)
•DeviceNet, ControlNet or EtherNet/IP slave interface (32 words)
Note: When using EtherNet/IP in a VisualMotion 9 system, no other
fieldbus interface card (i.e., Profibus, DeviceNet, ControlNet,
Interbus) or the MTS-R PLC interface can be installed.
EtherNet/IP uses firmware version FMC-ETH01*-PHT-02VRS-
NN.
Note: The word size in parenthesis indicates the maximum number
of words allowed in the cyclic telegram for both the Input and
Output directions.

VisualMotion 9 Troubleshooting Guide VisualMotion 9 Overview 1-3
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Additional Interfaces:
•Option Card Programmable Limit Switch (16 or 32 outputs)
•Link Ring for Master/Slave interfacing of VisualMotion controls
•Ethernet Interface
Note: The same EtherNet hardware is used for both EtherNet/IP
fieldbus and standard EtherNet TCP/IP networking
communication. When enabled as an EtherNet/IP fieldbus
interface in VisualMotion 9 using GPP 9 firmware, standard
TCP/IP communication between VisualMotion Toolkit over the
same network is possible.
Drive I/O Support
Bosch Rexroth digital drives support the following I/O devices:
•DEA0x.2M (x = 4, 5 or 6) I/O cards for DIAX04 digital drives
•EMD I/O module using the EcoX interface for DKC22.3 digital
drives using SGP20 firmware
1.3 GMP 9 System Overview
The PPC-P11.1 (PCI-version) is a PC-based stand-alone multi-axis
motion control. The GMP 9 firmware used with the PPC-P is designed to
work as a complete motion control solution. A host PC containing a Logic
Controller (SoftPLC) handles the system logic, fieldbus and Ethernet
communications.
Just like the PPC-R, the PPC-P supports Bosch Rexroth DIAX04 and
ECODRIVE03 digital servo drives. Communication between the control
and digital servo drives is performed via the SERCOS fiber optic
interface.
ppc_pci.tif
Fig. 1-2: PPC-P (PCI-version) Motion Control

1-4 VisualMotion 9 Overview VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
GMP 9 Firmware Features
All firmware functionality supported in GPP 9 will also be supported in
GMP 9 with the following restriction:
•VisualMotion fieldbus slave interfaces are not supported. If fieldbus
communication is required, the SoftPLC should be equipped with the
capability to communicate with a PC-based fieldbus card. The PPC-P
cyclic channel (real-time communication to/from DPR) is configured
using VisualMotion Toolkit's Fieldbus Mapper.
•Ethernet interface is also not supported
GMP 9 System Components
The VisualMotion GMP 9 system is composed of the following
components:
•PPC-P control using GMP firmware
•SERCOS RECO02 I/O modules
•VisualMotion Toolkit (VMT) Windows program for motion control
programming, parametrization, system diagnostics and motion control
management. VMT also includes DDE and OPC servers. These
servers are the communication protocol between Windows programs
and the control.
•Up to 40 intelligent digital drives can be connected to one control over
the SERCOS fiber optic ring
–DIAX04 (using SSE03 or ELS05 firmware) drives and motors
–ECODRIVE03 (SMT02, SGP01, SGP03 and SGP20 firmware)
drives and motors
–ECODRIVE C (using MPG01 firmware) drives and motors
•HMI interfaces (BTC06, BTV04, BTV05, BTV06)
Note: When using VisualMotion's I/O Setup tool to assign registers
to physical outputs, the location (either input or output
registers) will determine which device is the “master” of the
particular set of physical outputs. If they are mapped to the
PPC output section, then the PPC will have control of the
outputs. If they are mapped to the PPC input section, then the
SoftPLC will have control over the physical outputs.
GMP 9 Interface Support
VisualMotion GMP 9 supports the following interfaces:
•Optional Programmable Limit Switch Card (16 or 32 outputs).
•Link Ring for Master/Slave interfacing of VisualMotion controls.
Drive I/O Support
Bosch Rexroth digital drives support the following I/O devices:
•DEA0x.2M (x = 4, 5 or 6) I/O cards for DIAX04 digital drives
•EMD I/O module using the EcoX interface for DKC22.3 digital
drives using SGP20 firmware

VisualMotion 9 Troubleshooting Guide VisualMotion Tools for Diagnosing 2-1
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
2 VisualMotion Tools for Diagnosing
2.1 Using VisualMotion Toolkit for Diagnosing
VisualMotion Toolkit 9 (VMT) is Rexroth's Windowsbased development
environment for programming VisualMotion Controls. Along with VMT's
programming capabilities, it can also be used to help diagnose
VisualMotion programs, control and drive diagnostics.
Note: The information provided in this section is intended to illustrate
only those screens in VisualMotion Toolkit that can assist in
determining a diagnostic fault. For a complete description of
VisualMotion Toolkit's menu selections, refer to chapter 2 of
the VisualMotion 9 Functional Description.
VisualMotion to PC Connection
To establish communications between VisualMotion (PC) and the PPC-R
control, use an IKB0005 standard RS-232 serial communication cable.
RECO
PPC-R02.2
H1
PROG
U2
X10
X1
Q1
Q2
24Ve
0Ve
Bb
Bb
24V
0V
S1
RX
TX
U1
RESET
S2
H2
DIST
COM
X16
U3 U4
8888
I1
I3
I2
IKB0005
PPC-R_Serial.FH7
Fig. 2-1: VisualMotion (PC) to PPC-R Serial Connection
Use the following procedure to confirm hardware connections.
1. Connect communication cable IKB0005 between PPC-R X10 and the
PC's Com port.
Note: Communication can also be established using the ETH01
Ethernet card. Refer to the VisualMotion 9 Project Planning
Manual for details.
2. Power-up VisualMotion System (drives, control, motors, etc.).
3. Start VisualMotion Toolkit in "Service" mode by selecting the
(view and edit control data in "Service" mode) radio button.
4. From the VisualMotion Toolkit main menu, select Diagnostics ⇒
⇒⇒
⇒
System. If the System Parameters screen loads with information,
communications have been established. The user is now ready to
use VisualMotion Toolkit.

2-2 VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Communication Error
If a connection can not be established, the DDE server will issue an error
and the following Diagnostic dialog box will open. This indicates that
either there is a problem in the physical connection or that the
communication settings of the control do not match the settings of the
DDE sever.
DDE_Server_Error.tif
Fig. 2-2: VisualMotion DDE Server Error
1. Verify that power has been applied to the control and the proper cable
is being used (IKB0005) and the connections on both ends are made.
If this does not resolve the problem, then the serial parameters
should be verified.
Note: If a network connection is being used, verify that the Ethernet
control parameters are set properly and that the network
server is operating.
2. To view the current serial port settings on the PPC-R control, push
the S1 button and read the H1 display as follows.
Press S1 #
of Times Description
0 System Diagnostic Message
1 Firmware version
2 X10 communications type (RS-232, RS-422, RS-485)
3 X10 baud rate (9600, 19.2K, 38.4K, 57.6K, 115.2K)
4 X16 communications type (RS-232, RS-422, RS-485)
5 X16 baud rate (9600, 19.2K, 38.4K, 57.6K, 115.2K)
6 Unit number (0 to 126, used for RS-485 mode)
Table 2-1: PPC-R S1 Button Display
3. Selecting Settings for the screen in Fig. 2-2 will open the dialog box in
Fig. 2-3. Make sure that the baud rate setting in the Serial
Communication window matches the PPC-R's setting. Also, verify
that the Serial Port number matches that of the port used by the serial
cable. Checking Use Serial Event improves the communication
throughput of the PC hardware.

VisualMotion 9 Troubleshooting Guide VisualMotion Tools for Diagnosing 2-3
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Serial_Comm.tif
Fig. 2-3: Serial Communications
Changing the Serial Communication Baud Rate
From VisualMotion Toolkit's main menu, select Tools ⇒
⇒⇒
⇒Control
Settings. Select the control's X10 or X16 port and change the baud rate.
ControlSettings.tif
Fig. 2-4: Control Settings

2-4 VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
The Diagnostics Menu
The diagnostics menu provides system information for logging and
monitoring system errors and diagnostics.
DiagnosticsSystem.tif
Fig. 2-5: Diagnostics Menu
System Diagnostics
The system diagnostic window displays current diagnostic information for
diagnostic messages, hardware and firmware information, installed option
cards, diagnostic log, hardware status, and control load status. This
section will only focus on diagnostic messages and logging.
Status…
The Status tab displays the current diagnostic message with an extended
message, if available. The system's current mode and SERCOS phase is
also displayed.
system_parameters.tif
Fig. 2-6: Primary and Extended Diagnostic Message

VisualMotion 9 Troubleshooting Guide VisualMotion Tools for Diagnosing 2-5
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Diagnostic Log…
The diagnostic log tab displays the last 100 errors that the control has
encountered. Along with the error messages, the date, time and
extended error codes are displayed.
Diagnostic Help
Error codes displayed in the Diagnostic log contain context sensitive help.
Double clicking on an error code opens the context sensitive help for the
selected error.
diagnosticlog.tif
Fig. 2-7: Diagnostic Log Options
Date and Time
Date and time are relative to the power on of the control; they have no
battery-backup clock unless the PPC-R is equipped with a battery. Refer
to chapter 4 of the VisualMotion 9 Project Planning Manual
DOK-VISMOT-VM*-09VRS**-PR02-EN-P for installation instructions.
After power up, select the Set Time button to retrieve the date and time
from the PC. The date and time are stored in parameter C-0-0126.
Log Configuration
The user can select what options are best suited for their application.
Refresh, Save and Clear Log
Right clicking over the diagnostic errors opens a small pop-up window
where the user can perform the following features:
•Refresh Log
•Save Log to File
•Clear Log
•Help

2-6 VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide
DOK-VISMOT-VM*-09VRS**-WA02-EN-P
Tasks Diagnostics
Selecting Diagnostics ⇒
⇒⇒
⇒Task opens the Task Diagnostics window and
uploads data regarding all active VisualMotion tasks. Task letters are
displayed only if they contain an icon program that has been compiled and
downloaded to the control. All GPP9 programs will contain the
Initialization Task and Task A tabs. The Coordinated Motion tab is only
visible if any task contains a coordinated program. It displays the active
coordinated axes and their current X, Y, Z positions.
DiagnosticTask.tif
Fig. 2-8: Task Parameters
Status
This section indicates the type of motion programmed in the selected task
for the active program and the current control mode (Parameter,
Initialization, Manual or Automatic). Status and Diagnostic messages for
the selected task are also displayed.
Current Program Position
This section displays the subroutine and instruction executing and its
pointer. This display is useful when debugging in single-step mode. If a
program is running in automatic mode, the displayed instruction is the
instruction that was executing at the time that the SERCOS cycle
sampled instruction execution, which may appear to be random.