Mannesmann ecodrive03, Troubleshooting Manual

Page 1: ...ODRIVE03 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 ...

Page 2: ...nt 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 Rexrot...

Page 3: ...n 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...

Page 4: ...About this Documentation ECODRIVE03 SMT 02VRS DOK ECODR3 SMT 02VRS WA01 EN P Notes ...

Page 5: ...0 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 shut...

Page 6: ...ceeded 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 F8...

Page 7: ...881 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 feedba...

Page 8: ...ed 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 initi...

Page 9: ...09 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...

Page 10: ...e 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 ...

Page 11: ...ive Components 5 1 5 1 Procedure on Replacing the Unit 5 3 Replacing the DKC 5 3 Replacing the Motor 5 4 Replacing cables 5 4 6 Replacing Firmware 6 7 6 1 Replacing the Parameter Module 6 7 6 2 Replacing the Firmware Module 6 8 6 3 Replacing the Programming Module complete module 6 8 7 Index 7 1 8 Kundenbetreuungsstellen Sales Service Facilities 8 1 ...

Page 12: ...VIII Contents ECODRIVE03 SMT 02VRS DOK ECODR3 SMT 02VRS WA01 EN P Notes ...

Page 13: ...atus Construction of a diagnostic message A diagnostic message consists of A diagnostic number and a diagnostic text F228 Excessive Control Deviation Diagnostic message number Diagnostic message Fig 1 1 Diagnostic message with a diagnostic number and text For the example in the graphic F2 and 28 are shown alternately on the H1 Display The control system can read out the diagnostic number in hexade...

Page 14: ...diagnostic number appears on this two positional seven segment display The image can be seen on the Diagnostic Message Priority Display This display quickly shows the current operation status without the use of a communications interface The operating mode cannot be seen from the H1 Display If the drive follows the operating mode and no command was activated then the symbol AF appears on the displ...

Page 15: ...ating mode Drive automatic check Drive error reaction Fig 1 3 Diagnostic message priority diagram Clear Coded Diagnostic Message The clear coded diagnostic message contains the diagnostic number followed by the diagnostic text as shown in the example Excessive Output Error Fig 1 1 It can be read out with the S 0 0095 Diagnostic message parameter and directly displays the operation status on an ope...

Page 16: ...1 4 Diagnostic Message Descriptions ECODRIVE03 SMT 02VRS DOK ECODR3 SMT 02VRS WA01 EN P Notes ...

Page 17: ...diately to the person or persons responsible for the safe operation of this equipment If the product is resold rented or transferred or passed on to others then these safety instructions must be delivered with the product WARNING Inappropriate use of this equipment failure to follow the safety instructions in this document or tampering with the product including disabling of safety devices may res...

Page 18: ...entional motor movements WARNING High electrical voltage due to wrong connections Danger to life severe electrical shock and severe bodily injury WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equipment CAUTION Surface of machine housing could be extremely hot Danger of injury Danger of burns CAUTION Risk of injury due to inapprop...

Page 19: ...racticed in the country of use The equipment is designed for installation on commercial machinery European countries see directive 89 392 EEC machine guideline The ambient conditions given in the product documentation must be observed Use only safety features that are clearly and explicitly approved in the Project Planning manual For example the following areas of use are not allowed Construction ...

Page 20: ...e working with electrical parts with voltage potentials higher than 50 V the equipment must be disconnected from the mains voltage or power supply The following should be observed with electrical drives power supplies and filter components Wait five 5 minutes after switching off power to allow capacitors to discharge before beginning work Measure the voltage on the capacitors before beginning work...

Page 21: ...rical shock and personal injury European countries EN 50178 1998 section 5 3 2 1 USA See National Electrical Codes NEC National Electrical Manufacturers Association NEMA and local building codes The user of this equipment must maintain the above noted instructions at all times 2 6 Protection by protective low voltage PELV against electrical shock All connections and terminals with voltages between...

Page 22: ...ctive components software errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitors in the drive components make faulty operation almost impossible Regarding personnel safety especially the danger of bodily harm and property damage this alone should not be relied upon to ensure complete safety Until the ...

Page 23: ...stall protective coverings install light curtains or light barriers Fences must be strong enough to withstand maximum possible momentum Mount the emergency stop switch E stop in the immediate reach of the operator Verify that the emergency stop works before startup Don t operate the machine if the emergency stop is not working Isolate the drive power connection by means of an emergency stop circui...

Page 24: ...rts of motors with permanent magnets are being stored operated repaired or mounted If it is necessary for a person with a pacemaker to enter such an area then a physician must be con sulted prior to doing so Pacemaker that are already implanted or will be implanted in the future have a considerable deviation in their resistance to interference Due to the unpredictable behavior there are no rules w...

Page 25: ...ty shoes and safety gloves Never stay under suspended loads Clean up liquids from the floor immediately to prevent personnel from slipping 2 11 Battery safety Batteries contain reactive chemicals in a solid housing Inappropriate handling may result in injuries or equipment damage CAUTION Risk of injury through incorrect handling Do not attempt to reactivate discharged batteries by heating or other...

Page 26: ...er of injury when pressurized systems are handled by untrained personnel Do not attempt to disassemble to open or to cut a pressurized system Observe the operation restrictions of the respective manufacturer Before the disassembly of pressurized systems lower pressure and drain off the fluid or gas Use suitable protective clothing for example protective eyewear safety shoes and gloves Remove any f...

Page 27: ... deceleration Non fatal F2xx In accordance with best possible deceleration Fig 3 1 Error Classes and Drive Reaction If an error state is detected in the drive then an automatic operation of the drive s error response will be started as long the drive is in control The H1 display blinks a Fx xx The drive s reaction can be parameterized by P 0 0119 Deceleration as best as possible with interface and...

Page 28: ...elative drive internal interpolation with actual feedback value 2 0000 0010 0001 x100 Fig 3 2 Operation Modes Which operation modes can be selected in a certain device is written in the description for the operation mode parameters Parameter Primary mode of operation S 0 0032 Secondary operation mode 1 S 0 0033 Secondary operation mode 2 S 0 0034 Secondary operation mode 3 S 0 0035 Check for input...

Page 29: ...d restored with the default initial values Cause The firmware has been exchanged the number of parameters in comparison to the old product has changed Remedy Press S1 button on the drive controller and all the parameters will be erased and restored with the factory preset default values WARNING This overwrites all parameters and positioning blocks See also the functional description Basic paramete...

Page 30: ...om the motor has been above its allowable continuous torque level for too long 2 Wire break short disconnection or circuit in the motor temperature monitor line 3 Instability in the velocity loop Remedy For 1 Check the installation of the motor If the system has been in operation for a long time check to see if the the operating conditions have changed in regards to pollution friction moved compon...

Page 31: ...revents power input from the mains The control switches the installation machine off as soon as this warning is generated Parametrize undervoltgage as an error then the drive switches the machine off with the error reaction which has been set See also the functional description Current Limit F221 Motor temp surveillance defective Cause Wire break or interruption in the wires for the motor temperat...

Page 32: ... 0126 Maximum braking time then the drive is brought to a torque free standstill and error F224 Maximum braking time exceeded is generated Remedy 1 extend P 0 0126 Maximum braking time 2 increase brake ramp of error reaction P 0 1203 P 0 1201 or P 0 1211 and P 0 1213 3 reduce external moment of inertia 4 increase torque limit value See also the function description Motor Holding Brake F226 Undervo...

Page 33: ...leration value from the controller see controller Manual Ref 2 Check the mechanical system and eliminate jamming of the axis Ref 3 Check the drive parameters control loop tuning Ref 4 Set the parameter values of S 0 0159 Monitoring window See also the functional description Position Control Loop Monitoring F229 Encoder 1 failure quadrant error With wrong signals in the encoder evaluation a hardwar...

Page 34: ... If the amount of the difference exceeds the monitoring window the error F236 Excessive position feedback difference is diagnosed the parameter selected error response is performed and the reference bits of both encoders are cleared Note The monitoring is off when the parameter S 0 0391 Monitoring window feedback 2 is set to the value 0 Possible Causes 1 Incorrect parameter for the encoder 2 S 0 0...

Page 35: ...and values is greater than or equal to the value in S 0 0091 Bipolar velocity limit value position command value monitoring is initiated The Excessive position command value is stored in parameter P 0 0010 The last valid position command value is stored in parameter P 0 0011 If position data are to be processed in modulo format then the interpretation of the command is also dependent on the value ...

Page 36: ...squarewave signals is used the signal is not monitored Example Ucos 6 5V Usin 6 5V pointerlength 6 5V 6 5V 9 2V 2 2 Remedy 1 Check the measurement system cable 2 Check the measurement system F245 Encoder 2 failure quadrant error The evaluation of the additional optional encoder encoder 2 is active In the evaluation of the sinusoidal input signals of the optional encoder a plausibility check is per...

Page 37: ...cleared to 0 F248 Low battery voltage Cause For motors of series MKD and MKE the absolute position information is stored by a battery powered electronic in the motor feedback The battery is designed for a 10 year life span If the battery voltage falls below 3 1 V this message appears The absolute encoder function will still be preserved for about 2 weeks CAUTION Malfunction in the control of motor...

Page 38: ...ntal encoder emulator P 0 0502 or 2 Reduce the travel velocity See also the functional description Encoder Emulation F260 Command current limit shutoff If the current setpoint reaches the peak value then warning E260 Command current limit shutoff is generated If the limit remains standing for more than 1 5 ms then the drive is shutdown with error message F260 Command current limit shutoff Error ca...

Page 39: ...mA See also the functional description Setting the Operating Mode Parameters F267 Erroneous internal hardware synchronization Cause The drive control is synchronized on the bus interface SERCOS Profibus Interbus The correct function of the synchronization is monitored If the average value of the deviation exceeds 5 µs this error is generated Remedy Replace drive controller F269 Error during releas...

Page 40: ...ition is correct in relation to the machine zero point Reset subsequent errors For 3 WARNING An accident may occur by accidental shaft movement Check absolute position information The feedback is defective if the absolute position information is wrong The motor should be exchanged and sent to the Rexroth Indramat Customer Service Note If a customer password is activated and the drive controller is...

Page 41: ...tion from mains section to BbN input on drive 3 If the drive does not have a separate power section then switch the input monitor off See also P 0 4062 Monitoring the Mains section See also the functional description Current Limit F401 Double MST failure shutdown The master sync telegram was not received in the drive controller in two successive SERCOS cycles Cause 1 Disruption in the fiber optic ...

Page 42: ...20dBm 10µW and 5dBm 320µW If it does not then adjust transmission power or check attenuation of the fiber optic cable maximum attenuation between TX and RX may not exceed 12 5 dB On 3 SERCOS interface module in drive has to be replaced On 4 Check fieldbus connector and cable connections signal level On 5 Switch master on and start up cyclic communications see Control Manual See also Function Descr...

Page 43: ...he drive to perform the emergency stop function that was selected in the P 0 0119 Best possible deceleration parameter Setting bit 15 of S 0 0011 Class 1 diagnostics causes an error message to be issued to the controller Cause The emergency stop switch has been pressed Remedy Eliminate the malfunction that has caused the emergency switch to be actuated and clear the error See also the functional d...

Page 44: ...tside the negative travel range The axis has been brought to a standstill with the error response Set velocity command value to zero Bit 2 of paramater P 0 0090 Travel limit parameter is set for Exceeding travel range is an error or after exceeding the position limit a drive control command has been started such as the drive controlled homing procedure Cause S 0 0050 Negative travel limit value ex...

Page 45: ...arted after the end switch had been actuated e g drive controlled homing Cause The positive travel range limit switch has been activated Remedy 1 clear error 2 turn power source back on 3 move axis into the allowed travel range Note The drive will not accept command values which lead out of the permissible travel range Entering these command values in the drivecontroller will result in this error ...

Page 46: ...matic Commutation adjustment If this range is exceeded this error message appears Cause 1 The drive enable has been set while the axis was still in motion 2 The axis has been moved by a mechanical force 3 Parameters P 0 0560 Commutation adjustment current and P 0 0562 Commutation adjustment periodic time are set too high Possibly the mechanical properties of the axis like friction or weight load h...

Page 47: ... amplified sine and cosine signals must be at least 1 V 2 The maximum pointer length resulting from the sine and cosine signals must not exceed 11 8 V 2 2 cos sin length pointer Fig 3 5 Pointer length Permissible signal amplitudes for sine and cosine signals cosine signal amplitude 15 10 0 5 10 5 15 15 10 5 0 5 10 15 sine signal amplitude Dg5004a1 fh7 nominal pointer length 9 2V minimum pointer le...

Page 48: ...The transistor IGBT current has exceeded the allowed maximum peak value The drive is immediately disabled the motor freewheels to a stop Cause 1 Short circuit in the motor or motor cable 2 Defective power section of the drive controller 3 The current regulator was parameterized with wrong values Remedy For 1 Check the motor cable for a short For 2 Exchange the drive controller For 3 Check that the...

Page 49: ... too low Remedy Exchange drive controller F878 Velocity loop error The velocity loop monitor will appear when the following conditions occur simultaneously The current command value is at the peak current limit Command accel and actual velocity have different qualifying signs Actual velocity 20 rpm or 20 mm min Command and actual acceleration have different qualifying signs Cause 4 Motor cable is ...

Page 50: ...ameter is exceeded by the 1 125 fold value or a minimum of 100 rpm rotary motor or by 100 mm min linear motor Cause The torque command value was for too long a time greater than the load torque This causes the actual speed to increase up to the maximum possible motor speed Remedy Assign the correct torque command value for the required task Reduce the S 0 0092 Bipolar torque force limit value para...

Page 51: ...Division of the Warning Classes Warnings can not be externally deleted E221 Warning Motor temp surveillance defective Temperature monitoring checks to see if the measured motor temperature is within reasonable bounds If it determines that it is lower than 10 C then it is assumed the measuring unit is defective Warning E221 Warning Motor temp surveillance defective will appear for 30 seconds Afterw...

Page 52: ...voltage in power section If bit 5 of the P 0 0118 Power off on error parameter has been set an undervoltage condition will be handled as a nonfatal warning The drive issues this warning if the drive enabling signal is present and the DC bus voltage message disappears Cause Power supply unit is switched off or mains failure occurs while the drive enabling signal is set Remedy Switch off the drive e...

Page 53: ...titled Drive internal format of position data Operation modes with drive internal position command generation 1 Drive internal interpolation 2 Relative drive internal interpolation 3 Drive controlled homing 4 Drive Halt 5 Process block mode 6 jog Remedy Input a reasonable value 0 for the employed acceleration Possible acceleration specifications depending from the operation mode are For 1 2 and 6 ...

Page 54: ...l cabinet s climate control 3 Incorrect control cabinet sizing in regards to heat dissipation Remedy For 1 If the blower fails exchange the drive controller For 2 Install climate control feature in the cabinet For 3 Check the sizing of the control cabinet See also the functional description Current Limit E251 Motor overtemp prewarning As soon as the temperature warning threshold 145 C is exceeded ...

Page 55: ...beyond the position limits and the position limit check is activated The motion profile results in a target position greater than the maximum allowed position Results This warning message E253 appears The drive stops The drive does not accept the target position or the process block In S 0 0012 Class 2 diagnostic warning bit 13 is set Remedy 1 For the Drive controlled interpolation mode input the ...

Page 56: ...vel velocity of all drive controlled travel commands can be changed proportionally in If the value of this parameter is 0 the travel velocity is also 0 With velocity 0 the motor remains stationary despite having a commanded value Causes 1 The parameter S 0 0108 Feedrate override is 0 2 For devices with analog inputs Feedrate override via analog input is activated and the voltage at the analog inpu...

Page 57: ... Continuous current limit active The drive controller sets the peak current available for 400 ms Thereafter the continuous current limit becomes active and dynamically limits the peak current to the continuous current Cause More continuous torque was required than was available Remedy 1 Check the drive installation 2 Check the installation of the motor For systems which have been in use for a long...

Page 58: ...on between command and actual values lag error Remedy In position control reduce parametrized accel value or speed value so that the drive can follow the position command value Increase torque limit value if necessary E261 Continuous current limit prewarning Digital drives are monitored by a continually operating temperature model If the thermal load reaches 100 the continuous current limit will b...

Page 59: ...ion can be enlarged by enlarging the maximum travel range E269 Brake torque too low When switching the drive enable off or with the brake monitoring command the motor has moved while checking the brake torque The motor holding brake thus no longer supplies the nominal torque Possible causes for the holding torque that is too low 1 brake is covered with a layer of oxidization due to storage 2 brake...

Page 60: ...continues to operate despite the warning then error F220 Bleeder overload shutdown could be generated Remedy 1 Check mains section 2 Check the mains section connection to input ingang BbN on the drive 3 If the drive is not supplied by a separate mains section then the input of the monitor must be switched off See P 0 4062 Power supply monitor See the Function Description Current Limit E408 Invalid...

Page 61: ...h Cause 1 During braking decelerating the energy regenerated from the mechanical system via the motor was so high for a moment that it could not be sufficiently dissipated to heat by the bleeder resistor The regenerated current could not be dissipated and therefore charged the DC bus so that the voltage has become too high 2 The mains voltage AC input is too high Result In case of overvoltage the ...

Page 62: ...ed that lead back into the allowed working range With other command values the drive will stop again The parameter S 0 0057 Position window defines a tolerance for the travel limits See also the functional description Travel Range Limits E830 Negative position limit exceeded The drive has received a command value which resulted in an axis position outside the negative travel range The axis has bee...

Page 63: ... 0119 Best possible deceleration parameter There is no error message issued to the controller Cause The emergency stop switch was pressed Remedy Eliminate the malfunction that led to the activation of the emergency stop switch The warning will then disappear See also the functional description Emergency stop feature E843 Positive limit switch activated The drive has received a command value which ...

Page 64: ...ns fault Cause The mains voltage has failed for at least three mains cycles during operation Mains errors and undervoltage errors were set as fatal warnings in parameter P 0 0118 Power off on error The drive switches the motor off Recovery Checked the mains connections to ensure that they are as specified in the project planning manual See function description Current Limit E886 No ready signal fr...

Page 65: ... erase a primary control A parameter belongs to each command whereby the command can be controlled by the parameter During the command operation the diagnostic message Cx appears in the H1 display where the x stands for the number of the command It can distinguish between 3 types of commands Drive Commands Lead to an eventual automatic drive movement Can be started only through an inputted control...

Page 66: ...0 0550 B000 Pulse wire Resolver offset detection Drive enable is removed B003 Power supply is off If the power supply is off then it is not possible to conduct command P 0 0550 B000 Pulse wire Resolver offset detection B004 S pulse not found within travel range S pulse was not found as pulse wire encoder is defective B005 Error writing to feedback EEPROM An error occurred while writing via the IIC...

Page 67: ... Release motor holding brake The command P 0 0542 Command Release motor holding brake has been activated See also the functional description Motor Holding Brake B101 Command not enabled The command P 0 0542 Command Release motor holding brake has been activated without prior enabling via the parameter P 0 0538 Bit 8 See also the functional description Motor Holding Brake B200 Brake check command T...

Page 68: ...brake The motor holding brake thus does not supply the nominal torque Possible causes for the low holding torque 4 Brake covered by oxidized layer due to storage 5 Brake covered by oil or lubricant 6 Brake is worn down Remedy on 1 Re start command brake monitor on 2 Re start command brake monitor The command brake monitor re checks the brake torque again If detected that the torque is too low then...

Page 69: ...ameters can be seen in parameter S 0 0021 List of invalid op data for comm ph 2 The invalid parameters must be rewritten with values between the respective min and the max value to be correct See also the functional description S 0 0127 C100 Communication phase 3 transition check C104 Config IDN for MDT not configurable Cause Telegram type 7 was set in parameter S 0 0015 Telegram type parameter Pa...

Page 70: ...re not contained in S 0 0187 List of configurable data in AT can be seen in S 0 0016 Custom amplifier telegram configuration list Remedy set preferred telegram telegram type 0 6 S 0 0016 Configuration list of drive telegrams must have parameters that are also in S 0 0187 List of configurable data in the AT Note List parameters only allowed in multiplex channel See also the function description Con...

Page 71: ...d in MDT S 0 0009 even Cause Parameter S 0 0009 Beginning address in master data telegram contains an even value This is not permitted Remedy Parameter S 0 0009 Beginning address in master data telegram must be set to an odd value These parameters are determined by the manufacturer of the control system and are specified by the SERCOS interface See also the functional description Configuration of ...

Page 72: ...yc S 0 0002 error Cause Only 500 µs or even multiples of 1ms are permitted as valid values for S 0 0001 NC Cycle time TNcyc and S 0 0002 SERCOS Cycle time Tscyc Here this is not the case Remedy S 0 0001 NC Cycle time TNcyc and S 0 0002 SERCOS Cycle time Tscyc must be corrected These parameters are determined by the manufacturer of the control system and are specified by the SERCOS interface See al...

Page 73: ...anufacturer of the control system and are specified by the SERCOS interface See also the functional description Configuration of the Telegram Send and Receive Times C118 Order of MDT configuration wrong The chronological order of processing the cyclical MDT data in the drive is the same order in which the configurated ident numbers IDN are placed in the parameter S 0 0024 Config list of the master...

Page 74: ...check C202 Parameter limit error S 0 0022 Cause Parameters which are necessary to operate the drive in communications phase 4 are outside of their minimum or maximum input values or the entered value can t be processed for bit bars The incorrect parameters are listed in S 0 0022 IDN list of invalid op data for comm ph 3 Remedy The parameters of S 0 0022 IDN list of invalid op data for comm ph 3 mu...

Page 75: ...peration parameters However 0 not available has been entered in the P 0 0075 Interface Feedback 2 optional parameter The ident number of the parameter that requires the optional encoder is entered in S 0 0022 IDN List of Invalid Op Data for Comm Ph 3 Remedy Modify S 0 0147 Homing parameter or the S 0 0032 35 Mode of Operation parameters to utilization of the motor encoder instead of optional encod...

Page 76: ... from the drive internal format into the display format or vice versa is outside the allowable range because either linear motor and rotary position scaling with motor reference or rotary motor and linear position scaling with motor reference or linear motor with modulo scaling has been selected or the determined factor used for converting the position data from the display format to the internal ...

Page 77: ... feedback 1 S 0 0277 Position feedback 1 type parameter See also the functional description S 0 0128 C200 Communication phase 4 transition check C215 Acceleration data scaling error Cause The display format of the acceleration data can be set using acceleration scaling parameters The drive controlled format of the acceleration data is dependent on what motor encoder and encoder resolution are used...

Page 78: ...ors have a data memory in the feedback unit From there settings for the encoder are read Cause During reading of the values from the feedback an error has occurred Remedy Check feedback cable Change motor See also the functional description S 0 0128 C200 Communication phase 4 transition check C218 Feedback 2 data reading error The initialization of the measuring systems is done in the command S 0 ...

Page 79: ...ring system micro controller Cause 1 Defective motor feedback cable 2 Defective motor feedback 3 Defective measurement system interface Remedy For 1 Check the motor feedback cable For 2 Exchange the motor For 3 Exchange the measuring system interface if it is a module or the complete drive controller See also the functional description S 0 0128 C200 Communication phase 4 transition check C221 Feed...

Page 80: ... been selected via the S 0 0278 Maximum travel range parameter that no longer guarantees a correct commutation of the motor Remedy Select a smaller value for the S 0 0278 Maximum travel range parameter See also the functional description S 0 0128 C200 Communication phase 4 transition check C227 Modulo range error Cause The marginal conditions for modulo processing were not maintained See functiona...

Page 81: ...er or the S 0 0032 35 Mode of Operation parameters contain values that require a motor encoder Remedy Change S 0 0147 Homing parameter or the S 0 0032 35 Mode of Operation parameters such that they are suitable for using an optional encoder Enter a value 0 in the P 0 0074 Interface feedback 1 parameter to activate the motor encoder See also the functional description S 0 0128 C200 Communication ph...

Page 82: ... that can be edited only in parameter mode this command must be processed See also the functional description Parametrization Mode Operating Mode C401 Drive active switching not allowed Cause The command C400 Command Switch to parameter mode has been started although the drive enable is on Remedy End the command and turn off the drive enable then the command can be started again See also the funct...

Page 83: ... Switch on the controller enable signal 2 Start the command again See also the functional description Functions of the Control During Drive Controlled Homing C602 Distance home switch reference mark erroneous Cause The evaluation of the homing switch has been activated The distance between the positive homing switch edge and the reference mark that shall be interpreted is outside the valid range R...

Page 84: ...h evaluation is not known if 0 is entered in parameter P 0 0153 Optimal distance home switch reference mark This is generally the case if the linear scale has no reference marks at equal and known distances Remedy Check the measuring system to be referenced as well as all cabling Check for correct parametrization Check the correction reference mark detection using command P 0 0014 D500 Command det...

Page 85: ...are read from the motor feedback data memory At least one of these parameters is invalid Remedy Check the connection to the motor feedback Exchange the motor if necessary See also the functional description Error Conditions of the Load Default Settings Procedure C704 Parameters not copyable Cause The default parameters in use are not compatible with this software version Remedy Please contact Indr...

Page 86: ...ption Basic parameter block C802 Locked with password The parameter S 0 0267 Password offers the possibility to set a write protection for the drive parameters The diagnostic message C705 Locked with password indicates that the command P 0 4094 C800 Command Base parameter load has been started although the drive parameters are protected with the customer password See also the functional descriptio...

Page 87: ...d successfully The encoder zero pulse has not been found or could not be assigned properly Remedy Check the parametrization of spindle positioning especially the used combination of encoder and reference home switch Check the encoder parametrization Check the distance between zero pulse and reference switch Do the drive controlled homing to check the homing procedure D300 Command adjust commutatio...

Page 88: ...reat as S 0 0092 2 Clear the jamming Check also the brake 3 At the motor connection switch 2 phases or turn rotational direction of encoder Parameter S 0 0277 position encoder type parameter 1 Note For devices with analog inputs the torque can be limited via an analog torque reduction See also the functional description Determining commutation offset D303 Drive in control at start of command If th...

Page 89: ...c Commutation adjustment If this range is exceeded this error message appears Cause 1 The drive enable has been set while the axis was still in motion 2 The axis has been moved by a mechanical force 3 Parameters P 0 0560 Commutation adjustment current and P 0 0562 Commutation adjustment cycle time are set too high Possibly the mechanical properties of the axis like friction or weight load have cha...

Page 90: ...mmand again See also the functional description Positive stop drive procedure D500 Command Get mark position The P 0 0014 D500 Command determine marker position command can be used for checking the correct acquisition and position of the reference marker of an incremental measuring system The d5 display shows that the command has been activated Cause The Determine marker position command has been ...

Page 91: ...a drive package to be stopped without error messages being issued to the controller and or the power supply module The remaining drives of the package can be handled without any restrictions Cause The S 0 0139 D700 Command parking axis command has been activated See also the functional description Command Parking Axis D701 Parking axis only while drive is disabled The start of command Command Park...

Page 92: ...description Safety Instructions for Electric Servo Drives and Controls During command D9 the drive autonomously conducts motions i e without external command value D901 Start requires drive enable Description To ensure that the drive is in the loop when starting the command P 0 0162 D9 automatic control loop setting such is queried at command start Cause Drive enable not set at command start NO RF...

Page 93: ...tor speed too low load moment of inertia too big Remedy increase bipolar torque force value S 0 0092 increase pos accel S 0 0260 increase pos speed S 0 0259 increase feedrate override S 0 0108 See also Function description Prerequisites for starting the automatic control loop settings D904 Gain adjustment failed Description In exceptional cases difficulties in the automatic control loop setting ma...

Page 94: ...dy clear command error by ending the command a input new limits whereby upper lower limits b redefine limits to define a larger traversing range restart command with sensible traversing range See also Function description Prerequisites for starting the automatic control loop settings D906 Travel range exceeded Description During automatic control loop setting there is a constant monitoring of the ...

Page 95: ...s Phase 2 is used to prepare the time and data protocols for communication phases 3 and 4 Initialization is performed in ascending order of the sequence The defaults of the communications phase are set by the control system When the switch to communications phase 4 takes place initialization is completed and input power is enabled If the delayed phase switch is interrupted the status display remai...

Page 96: ...fore switching to communication phase 4 is possible the command S 0 0128 C200 Communication phase 4 transition check must be done In this command the drive checks e g the validity of the parameters needed for the communication phase 4 operation mode After successful execution of the command the control switches the drive to comm phase 4 with field bus and SERCOS devices or the drive switches by it...

Page 97: ...he control system The velocity control loop is closed in the drive See also the functional description Operating Mode Velocity Control A102 Position mode with encoder 1 The drive is in position control mode The position loop is closed in the drive by a position encoder The control system only sets the position command value sequence the drive follows the command value with a systematical lag follo...

Page 98: ...rpolation encoder 1 The drive receives a position command value from the control system which is identical to the target position of the travel path Then the drive generates interpolates an internal position command value sequence which uses the control system to maintain maximum values for jerk velocity and acceleration sequences The drive moves with a systematical lag following error to the targ...

Page 99: ...lues for jerk velocity and acceleration sequences The drive moves without following error lagless to the target position Encoder 2 indicates that the position encoder is installed on the machine axis direct axis position measurement See also the functional description Operating Mode Drive Internal Interpolation A146 Relative drive controlled interpolation encoder 1 In the S 0 0282 Travel distance ...

Page 100: ...ttached to the load is used for closing the position control loop direct axis position measurement See also the functional description Mode Relative drive internal interpolation A148 Relative drive contr interpolation enc 1 lagless In the S 0 0282 Travel distance parameter the drive receives a distance specification from the controller When bit 0 of the S 0 0346 Setup flag for relative command val...

Page 101: ...sition control loop direct axis position measurement See also the functional description Mode Relative drive internal interpolation A203 Stepper position mode Description The drive is functioning in position control with Stepper interface The device follows the position command which will be developed out of the stepper motor signals See also the functional description Operating Mode Stepper Motor...

Page 102: ...al lag The actual value comes from the encoder 2 ext encoder The command value profile is generated in the drive Target position velocity acceleration and jerk are determined by a pre programmed process block Depending on P 0 4019 Process block mode the target position is interpreted as an absolute value or as a relative distance to move See also the functional description Positioning Block Mode A...

Page 103: ...l delay structure of air gap field is asynchronous motor automatic determination of commutation offset if synchronous motor with incremental measuring system Depending on parametrization the following system status is checked Automatic brake monitor see P 0 0538 Motor function parameter 1 A401 Drive deceleration to standstill The drive is brought to standstill as defined in parameter P 0 0119 Best...

Page 104: ...se The control supply voltage of the encoder is missing Remedy Exchange the hardware Diagnostic Message Display 3 Initializing the parameters from the non volatile memory and calculating the respective data depending from the parameter contents Diagnostic Message Display 4 Initializing and checking the command communication Diagnostic Message Display 5 Initializing the system control Diagnostic Me...

Page 105: ... exchange the firmware module Diagnostic Message Display E3 Cause Caused by a hardware fault or by a static discharge the 1 st watchdog of the amplifier has triggered Remedy Switch the amplifier off and on again if E3 appears again exchange the amplifier In any case inform the customer service Please explain the exact circumstances under which the error occurred Diagnostic Message Display E4 Cause...

Page 106: ...ive is ready See also A012 Control and power sections ready for operation AC Drive Automatic Check See also A400 Automatic drive check and adjustment AE Drive Error Reaction See also A401 Drive deceleration to standstill AF Drive enable According to the operation mode in use you will find a more exact description of the display AF under the respective state diagnosis A101 A800 AH Drive Halt See al...

Page 107: ...SERCOS communication See also A000 Communication phase 0 P1 Phase 1 See also A001 Communication phase 1 P2 Phase 2 See also A002 Communication phase 2 P3 Phase 3 See also A003 Communication phase 3 PL Basic Parameter Load See also F209 PL Load parameter default values UL Basic Load See also F208 UL The motor type has changed ...

Page 108: ...4 44 Description of Diagnostic Letters B C D and A ECODRIVE03 SMT 02VRS DOK ECODR3 SMT 02VRS WA01 EN P Notes ...

Page 109: ... unit to Rexroth Indramat Customer Service please complete the Fault Report in its entirety This fault report is at the end of this section and may be copied for your convenience Note The new drive components must have the same type designations as the old To ensure this register the entire type designation when requesting a replacement part Position of the type plates The type plate of the DKC co...

Page 110: ...are ordered without the connector refer to the stamp on the cable sheathing Engine Feedback Cable IN 488 for instance AP5143F1 fh7 Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode Typenschild 1 2 3 4 5 6 7 8 9 1 2 3 4 11121314 1516 1718 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 Specifications for model label DKC _ _ _ _ _ _ _ S No _ _ _ _ _ _ FWA ECODR3 _ _ _ _ _ _VRS MS Hardware serialnu...

Page 111: ...s and terminals wait for the capacitor to discharge Only then work on the cables Remove contact protection and separate connecting line from DKC Release screws on top and bottom of housing Remove the DKC from the drive package Insert programming module from defective DKC into new one This eliminates the reloading of parameter files If the programming module is defective see section Replacing Firmw...

Page 112: ...xes with an indirect path measuring systems via a motor encoder will loose the reference dimension if the motor is replaced This reference to machine coordinate system must therefore be reestablished Servo axes with absolute motor encoder necessitate reestablishing the absolute reference Replacing cables Switch main switch off Secure against being switched back on ATTENTION Danger from high voltag...

Page 113: ...ation may momentarily occur AP5144F1 Fh7 Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode Typenschild 1 2 3 4 5 6 7 8 9 1 2 3 4 11121314 1516 1718 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 Fig 5 2 Dirt contamination per DIN VDE 0160 zum Austausch von Kabeln Angaben des Maschinenherstellers When replacing cables note the instructions of the machine manufacturer ATTENTION Connect power conn...

Page 114: ...les moisture in unit foreign object in unit problem with mechanics mains sec failure 24 Vext control failure motor failure cable break blower defective Feedback defective Is there an air conditioner in the cabinet Y N Have there been previous problems at this machine How often Did the problems occur on the same day or the same time of the day Additional data Additional data Information about machi...

Page 115: ...fh7 Fig 6 1 Locking the programming module Open the programming module Ap5146f1 fh7 Programming module Firmware module Parameter module Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode H1 S1 S3 S2 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 ISSI IS61C6416 20T C2110900 9728 splSI2032 110LT48 H813A08 ESF2 SDS Fig 6 2 Programming module Connect new parameter module and old firmware mod...

Page 116: ...back of the programming module Open the programming module Insert old parameter module into new firmware module Close lock lock must be pushed outward Insert programming module Switch unit on 6 3 Replacing the Programming Module complete module Secure parameters DriveTop Switch unit off Pull programming module out Insert new programming module Switch unit on Load parameters ...

Page 117: ...t limit active 3 32 Command current limit shutoff 3 12 Command Get mark position 4 26 Command not enabled 4 3 Command Release motor holding brake 4 3 Command Set absolute measuring 4 17 Command velocity limit active 3 32 Communication phase 0 4 31 Communication phase 1 4 31 Communication phase 2 4 31 Communication phase 3 4 32 Communication phase 3 transition check 4 4 Communication phase 4 transi...

Page 118: ...control 4 33 Drive must be in operation mode phase 4 4 2 Drive not ready for commutation command 4 23 Drive overtemp prewarning 3 28 E Emergency Stop 3 17 3 19 3 37 Encoder 1 failure quadrant error 3 7 signal amplitude wrong 3 21 Encoder 2 failure quadrant error 3 10 signal amplitude wrong 3 9 Encoder combination not possible 4 16 Erroneous internal hardware synchronization 3 13 Error during beddi...

Page 119: ...mode negative 4 38 JOG mode positive 4 38 L Length of MDT S 0 0010 odd 4 7 Limit error communication parameter S 0 0021 4 5 Load side motor encoder with inductance motor only 4 17 Locked with password 4 22 Low battery voltage 3 11 M Mains fault 3 15 3 34 3 38 Master password required 4 3 Max signal frequency of encoder 2 exceeded 3 11 Max signal frequency of encoder 1 exceeded 3 7 Maximum braking ...

Page 120: ...h non init absolute encoder impossible 4 22 Positive limit switch activated 3 37 Positive position limit exceeded 3 36 Positive stop drive procedure command 4 26 Positive travel limit exceeded 3 17 Positive travel limit switch detected 3 19 Power is off 4 24 Power supply driver stages fault 3 23 Power supply is off 4 2 Proceed to phase 4 4 25 Process block mode lagless encoder 1 4 38 Process block...

Page 121: ...f num range 3 33 Target position out of travel range 3 29 Time slot parameter Sercos cycle time 4 7 TNcyc S 0 0001 or TScyc S 0 0002 error 4 8 Torque limit 0 3 31 Torque force data scaling error 4 14 Torque Force too small to move 4 24 Travel range exceeded 4 30 Travel range invalid P 0 0166 P 0 0167 4 30 U UL 4 43 UL The motor type has changed 3 2 Undervoltage in power section 3 6 3 26 3 35 Unkno...

Page 122: ...Index ECODRIVE03 SMT 02VRS DOK ECODR3 SMT 02VRS WA01 EN P Notes ...

Page 123: ...9 540138 10 indramat mue t online de Gebiet Südwest SALES Germany South West Service Mannesmann Rexroth AG Vertrieb Deutschland VD BI Geschäftsbereich Rexroth Indramat Regionalzentrum Südwest Ringstrasse 70 Postfach 1144 70736 Fellbach 70701 Fellbach Tel 49 0 711 57 61 100 Fax 49 0 711 57 61 125 Vertriebsgebiet Nord SALES Germany North Service Rexroth Indramat GmbH Kieler Straße 212 22525 Hamburg ...

Page 124: ...el Progresso 16 Zona Ind I 35020 Padova Telefon 39 049 8 70 13 70 Telefax 39 049 8 70 13 77 Italy SALES Service Mannesmann Rexroth S p A Divi sione Rexroth Indramat Via Mascia 1 I 80053 Castellamare di Stabia NA Telefon 39 081 8 71 57 00 Telefax 39 081 8 71 68 86 Italy SALES Service Mannesmann Rexroth S p A Divi sione Rexroth Indramat Viale Oriani 38 A I 40137 Bologna Telefon 39 051 34 14 14 Telef...

Page 125: ...10 65 05 03 79 China SALES Service Mannesmann Rexroth China Ldt A 5F 123 Lian Shan Street Sha He Kou District PRC Dalian 116 023 Telefon 86 411 46 78 930 Telefax 86 411 46 78 932 Hongkong SALES Service Rexroth China Ldt 1 F 19 Cheung Shun Street Cheung Sha Wan Kowloon Hongkong Telefon 852 22 62 51 00 Telefax 852 27 44 02 78 India SALES Service Mannesmann Rexroth India Ltd Rexroth Indramat Division...

Page 126: ...6 USA SALES Service Mannesmann Rexroth Corporation Rexroth Indramat Division Southeastern Technical Center 3625 Swiftwater Park Drive USA Suwanee Georgia 30174 Telefon 1 770 9 32 32 00 1 770 9 32 19 03 USA SALES Service Mannesmann Rexroth Corporation Rexroth Indramat Division Northeastern Technical Center 99 Rainbow Road USA East Granby Connecticut 06026 Telefon 1 860 8 44 83 77 1 860 8 44 85 95 U...

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Page 128: ...285852 Indramat Rexroth Printed in Germany ...