Page 1 Rexroth ECODRIVE03 Drive for Machine Tool Applications With SERCOS-, Analog- and Parallelinterface Troubleshooting Guide: SMT-02VRS 7=78)1 Rexroth Indramat DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 2 About this Documentation ECODRIVE03 SMT-02VRS ECODRIVE03 Drive for Machine Tool Applications With SERCOS-, Title Analog- and Parallelinterface Troubleshooting Guide: SMT-02VRS Type of Documentation DOK-ECODR3-SMT-02VRS**-WA01-EN-P Document Typecode • Box 71-02V-EN Internal File Reference • Based on: SMT-02VRS • 120-1000-B11-01/EN The following documentation describes the functions of the firmware Purpose of Documentation FWA-ECODR3-SMT-02VRS.
Page 3 ECODRIVE03 SMT-02VRS About this Documentation Summary of Documentation - Box Functional Description: Description of all implemented Function based on SERCOS Parameters Order designation: DOK-ECODR3-SMT-02VRS**-FK01-EN-P 2 8 2 8 0 1 Parameter Description: A description of all parameters used in the firmware...
Page 4 About this Documentation ECODRIVE03 SMT-02VRS Notes DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 5: Table Of Contents
ECODRIVE03 SMT-02VRS Contents Contents Diagnostic Message Descriptions Overview of the diagnostic message descriptions .................. 1-1 Diagnostic Message Types...................... 1-1 Construction of a diagnostic message..................1-1 Safety Instructions for Electric Servo Drives and Controls Introduction............................. 2-1 Explanations........................... 2-1 Hazards by inappropriate use ......................2-2 General Information ........................
Page 6 Contents ECODRIVE03 SMT-02VRS F246 Max signal frequency of encoder 2 exceeded.............. 3-11 F248 Low battery voltage....................... 3-11 F253 Incr. encoder emulator: pulse frequency too high ............3-12 F260 Command current limit shutoff..................3-12 F262 External short at status outputs ..................3-12 F267 Erroneous internal hardware synchronization ..............
Page 7 ECODRIVE03 SMT-02VRS Contents E258 Selected process block is not programmed..............3-31 E259 Command velocity limit active ..................3-32 E260 Command Current limit active ..................3-32 E261 Continuous current limit prewarning................3-32 E263 Velocity command value > limit S-0-0091 ..............3-33 E264 Target position out of num.
Page 8 Contents ECODRIVE03 SMT-02VRS C102 Limit error communication parameter (S-0-0021) ............4-5 C104 Config. IDN for MDT not configurable ................4-5 C105 Configurated length > max. length for MDT ..............4-6 C106 Config. IDN for AT not configurable ................4-6 C107 Configurated length > max. length for AT ..............4-6 C108 Time slot parameter >...
Page 9 ECODRIVE03 SMT-02VRS Contents C606 Reference mark not detected..................4-20 C700 Basic load........................4-20 C702 Default parameters not available ................. 4-21 C703 Default parameters invalid ................... 4-21 C704 Parameters not copyable ..................... 4-21 C800 Default parameter load....................4-21 C801 Parameter default value erroneous (-> S-0-0021) ............4-22 C802 Locked with password ....................
Page 10 Contents ECODRIVE03 SMT-02VRS A101 Drive in VELOCITY control................... 4-33 A102 Position mode with encoder 1 ..................4-33 A103 Position mode with encoder 2 ..................4-33 A104 Position mode lagless, encoder 1 ................4-34 A105 Position control lagless, feedback 2 ................4-34 A106 Drive controlled interpolation, encoder 1..............
Page 11 ECODRIVE03 SMT-02VRS Contents JF ............................4-42 P0............................4-43 P1............................4-43 P2............................4-43 P3............................4-43 PL............................4-43 UL............................4-43 Replacing or Exchanging Drive Components Procedure on Replacing the Unit ....................5-3 Replacing the DKC: ......................... 5-3 Replacing the Motor:........................ 5-4 Replacing cables:........................5-4 Replacing Firmware Replacing the Parameter Module ....................
Page 12 VIII Contents ECODRIVE03 SMT-02VRS Notes DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 13: Diagnostic Message Descriptions
ECODRIVE03 SMT-02VRS Diagnostic Message Descriptions Diagnostic Message Descriptions Overview of the diagnostic message descriptions Diagnostic Message Types Each operational state of the drive will be characterized with a diagnostic message. Differentiations will be made between: • Error diagnostic messages • Warning diagnostic messages •...
Page 14 Diagnostic Message Descriptions ECODRIVE03 SMT-02VRS H1-Display The H1-Display serves as an optical display of the diagnostic message on the drive. H1-Display FA5047f1.fh7 Fig. 1-2: H1-/Display The diagnostic number appears on this two-positional seven-segment display. The image can be seen on the "Diagnostic Message Priority Display".
Page 15 ECODRIVE03 SMT-02VRS Diagnostic Message Descriptions Error Warning Command error Command active Ready to operate ? Operation lock active Communicationphase Ready to operate Drive ready Drive automatic check Drive error reaction Drive Halt Drive is following Da0001f1.fh7 operating mode Fig. 1-3:...
Page 16 Diagnostic Message Descriptions ECODRIVE03 SMT-02VRS Notes DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 17: Safety Instructions For Electric Servo Drives And Controls
ECODRIVE03 SMT-02VRS Safety Instructions for Electric Servo Drives and Controls Safety Instructions for Electric Servo Drives and Controls Introduction Read these instructions before the equipment is used and eliminate the risk of personal injury or property damage. Follow these safety instructions at all times.
Page 18: Hazards By Inappropriate Use
Safety Instructions for Electric Servo Drives and Controls ECODRIVE03 SMT-02VRS Hazards by inappropriate use High voltage and high discharge current ! Danger to life, risk of severe electrical shock and risk of injury ! DANGER Dangerous movements ! Danger to life and risk...
Page 19: General Information
ECODRIVE03 SMT-02VRS Safety Instructions for Electric Servo Drives and Controls General Information • Rexroth Indramat GmbH is not liable for damages resulting from failure to observe the warnings given in these documentation. • Order operating, maintenance and safety instructions in your language before starting up the machine.
Page 20: Protection Against Contact With Electrical Parts
Safety Instructions for Electric Servo Drives and Controls ECODRIVE03 SMT-02VRS Protection against contact with electrical parts Note : This section refers to equipment with voltages above 50 Volts. Making contact with parts conducting voltages above 50 volts could be dangerous to personnel and cause an electrical shock. When operating electrical equipment, it is unavoidable that some parts of the unit conduct dangerous voltages.
Page 21: Protection By Protective Low Voltage (Pelv) Against Electrical Shock
ECODRIVE03 SMT-02VRS Safety Instructions for Electric Servo Drives and Controls To be observed with electrical drives, power supplies, and filter components: High electrical voltage ! High leakage current ! Danger to life, danger of injury and bodily harm from electrical shock ! ⇒...
Page 22: Protection Against Dangerous Movements
Safety Instructions for Electric Servo Drives and Controls ECODRIVE03 SMT-02VRS Protection against dangerous movements Dangerous movements can be caused by faulty control or the connected motors. These causes are be various such as: • unclean or wrong wiring of cable connections •...
Page 23 ECODRIVE03 SMT-02VRS Safety Instructions for Electric Servo Drives and Controls Dangerous movements ! Danger to life and risk of injury or equipment damage ! ⇒ Personnel protection must be secured for the above listed reason by means of superordinate monitors or DANGER measures.
Page 24: Protection Against Magnetic And Electromagnetic Fields During Operations And Mounting
Safety Instructions for Electric Servo Drives and Controls ECODRIVE03 SMT-02VRS Protection against magnetic and electromagnetic fields during operations and mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids.
Page 25: 2.10 Protection During Handling And Installation
ECODRIVE03 SMT-02VRS Safety Instructions for Electric Servo Drives and Controls 2.10 Protection during handling and installation Under certain conditions unappropriate handling and installation of parts and components may cause injuries. Risk of injury through incorrect handling ! Bodily harm caused by crushing, shearing, cutting and mechanical shock ! ⇒...
Page 26: 2.12 Protection Against Pressurized Systems
2-10 Safety Instructions for Electric Servo Drives and Controls ECODRIVE03 SMT-02VRS 2.12 Protection against pressurized Systems Certain Motors (ADS, ADM, 1MB etc.) and drives, corresponding to the information in the Project Planning manual, must be provided with and remain under a forced load such as compressed air, hydraulic oil, cooling fluid or coolant.
Page 27: Description Of Diagnostic Letters F
ECODRIVE03 SMT-01VRS Description of diagnostic letters F... and E... Description of diagnostic letters F... and E... Error diagnostic messages F... Many areas are monitored in connection with operating modes and parameter settings. An error message is generated if a condition is discovered which no longer allows proper operation.
Page 28: F207 Switching To Uninitialized Operation Mode
3-2 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS F207 Switching to uninitialized operation mode Cause: 0 has been selected in at least one of the four mode operating mode parameters S-0-0032..35. This mode has been selected by the bits 8 and 9 in the master control word while the drive controller was on.
Page 29: F209 Pl Load Parameter Default Values
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-3 Causes: • The motor has been exchanged. • A parameter file has been loaded, but the parameter S-0-0141, Motor type contained a motor type different from the present one. Remedy: Command C700 Basic Load or press the S1 button.
Page 30: F219 Motor Overtemp. Shutdown
3-4 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Remedy: For 1. Reduce the ambient temperature, e.g. through cooling of the control cabinet. For 2. Remove obstructions or dirt from the heatsink. For 3. Install the device vertically and clear a large enough area for proper heatsink ventilation.
Page 31: F221 Motor Temp. Surveillance Defective
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-5 Remedy: Å reduce the acceleration value. With too much power Å reduce the velocity. With too much energy Check the drive installation. May require installation of an additional bleeder module.
Page 32: F224 Maximum Braking Time Exceeded
3-6 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS If an error occurs during these initialization procedures, then error F223 Error during initialisation of the parking axis is generated. To specify the error more precisely, it is necessary to activate the transition command phase 3 to 4.
Page 33: F228 Excessive Deviation
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-7 F228 Excessive deviation When the position loop is closed, the drive monitors whether it is able to follow the specified command value. This is done by calculating a model position value in the drive and comparing that value with the actual feedback value.
Page 34: F236 Excessive Position Feedback Difference
3-8 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Cause: Maximum speed of the feedback device is lower than the maximum motor speed. Suggestion: • Don’t allow the motor to run faster than the maximum allowed sensor speed by reducing parameter S-0-0091, Bipolar Speed Limit.
Page 35: F237 Excessive Position Command Difference
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-9 Remedy: Ref. 1. Check S-0-0115, Position feedback 2 type parameter and S-0-0117, Resolution of feedback 2. Ref. 2. Check S-0-0121, S-0-0122, Input/Output revolutions of load gear and S-0-0123, Feed constant.
Page 36: F245 Encoder 2 Failure: Quadrant Error
3-10 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Permissible signal amplitudes for sine and cosine signals maximum pointer length > 11,8V minimum pointer length > 1,0V nominal pointer length (9,2V) sine signal amplitude =non-permissible range Dg5004a1.fh7 Fig. 3-4:...
Page 37: F246 Max Signal Frequency Of Encoder 2 Exceeded
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-11 Remedy: For 1. Exchange the encoder cable. For 2. Keep the encoder cable well away from power cables. For 3. Exchange the encoder interface (DIAX) or the drive (Ecodrive). F246 Max signal frequency of encoder 2 exceeded The signal frequency of the encoder 2 (optional encoder) is checked whether the allowed max.
Page 38: F253 Incr. Encoder Emulator: Pulse Frequency Too High
3-12 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Removing the Battery • Unscrew torx screws with size 10 screwdriver. • Pull out the resolver feedback (RSF) lid by hand. • Pull off the battery connector. • Loosen battery clamp and remove the battery.
Page 39: F267 Erroneous Internal Hardware Synchronization
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-13 • With thermal overload, the error is set and the output(s) shut off. After the driver has cooled off, the outputs are switched back on and so on. The error, however, remains until it is cleared. Thermal overload can occur if several outputs are overloaded in excess of 80 mA.
Page 40: F276 Absolute Encoder Out Of Allowed Window
3-14 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS F276 Absolute encoder out of allowed window When turning off the drive controller with an absolute encoder, the actual feedback position will be stored. When powered up, the absolute position given by the encoder is compared with the stored position.
Page 41: F281 Mains Fault
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-15 F281 Mains fault Cause: The power supply voltage was not present during operation for at least 3 power periods. As a result, the drive controller was brought to a standstill according to the set error response.
Page 42: F402 Double Mdt Failure Shutdown
3-16 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS F402 Double MDT failure shutdown The master data telegram (MDT) has not been received in the drive over the course of two successive SERCOS or fieldbus cycles. Cause: Fiber optic bus: interference in the fiber optic transmission...
Page 43: F405 Error During Phase Regression
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-17 F405 Error during phase regression Switching back from a communication phase did not switch to phase 0. Cause: Malfunction in the SERCOS master module of the controller. Remedy: Contact the controller manufacturer.
Page 44: F630 Negative Travel Limit Exceeded
3-18 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Remedy: Check S-0-0049, Positive position limit value Check the software limits of the control system Activate the axis after the error response Procedure: • Clear the error. • If the power supply was turned off, turn it back on.
Page 45: F634 Emergency-Stop
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-19 F634 Emergency-Stop Pressing the emergency stop (E-Stop) switch has caused the drive to stop by setting the velocity command value to zero. An error is reported in the S-0-0011, Class 1 diagnostics parameter.
Page 46: F811 Commutation Offset Could Not Be Determined
3-20 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Note: The drive will not accept command values which lead out of the permissible travel range. Entering these command values in the drive controller will result in this error. See also the functional description: "Travel Range Limits".
Page 47: F822 Encoder 1 Failure: Signal Amplitude Wrong
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-21 F822 Encoder 1 failure: signal amplitude wrong The analog signals of a motor measurement system are used for high resolution analysis of that measurement system. These are monitored according to two criteria: The pointer length, which is calculated from the amplified sine and cosine signals, must be at least 1 V.
Page 48: F860 Overcurrent: Short In Power Stage
3-22 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Note: The error cannot be cleared in communications phase 4. Before clearing the error, switch to communications phase 2. Note: When an incremental encoder with squarewave signals is used, the signal is not monitored.
Page 49: F873 Power Supply Driver Stages Fault
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-23 Remedy: Ref. 1. Check and, if necessary, replace the cable and connections of the control voltages. Ref. 2. Check the 24-V power at the power supply unit. Ref. 3. Check the power supply unit.
Page 50: F879 Velocity Limit S-0-0091 Exceeded
3-24 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS F879 Velocity limit S-0-0091 exceeded In torque control, the actual velocity is monitored. This error is generated if the programmed velocity in the S-0-0091, Bipolar velocity limit value parameter is exceeded by the 1.125-fold value or a minimum of 100 rpm (rotary motor) or by 100 mm/min (linear motor).
Page 51: Warning Diagnostic Messages
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-25 Warning diagnostic messages Many areas are monitored in connection with operating modes and Warnings do not lead to an parameter settings. As a result, if a state is discovered which is still...
Page 52: E225 Motor Overload
3-26 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS E225 Motor overload The maximum possible motor current is reduced in order to protect the motor from being destroyed. If a current flows in the that is greater than 2.2 times the motor current at standstill S-0-0111, the maximum possible motor current (S-0-0109, Motor peak current) is reduced.
Page 53: E248 Interpolation Acceleration = 0
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-27 Note: Warning E247 is suppressed if S-0-0259, Positioning Velocity is cyclically configured. See also the functional description: "Operating Mode: Drive Internal Interpolation" E248 Interpolation acceleration = 0 Cause: The drive internal position command interpolator (profile generator) is active.
Page 54: E250 Drive Overtemp. Prewarning
3-28 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Remedy: S-0-0259, Positioning Velocity or P-0-4007, Process block velocity or P-0-4030, Jog velocity must be reduced See also functional description: "Operating Mode: Drive Internal Interpolation". E250 Drive overtemp. prewarning The temperature of the heatsink in the drive controller has reached the maximum permissible temperature.
Page 55: E252 Bleeder Overload Prewarning
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-29 E252 Bleeder overload prewarning Cause: The braking resistance (bleeder) in the amplifier is charged with the reflected energy from the motor by about 90%. The bleeder overtemperature warning shows that an overload of the bleeder is expected if the feedback energy increases on and on.
Page 56: E254 Not Homed
3-30 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS E254 Not homed If absolute positions are selected while in a positioning operation mode, the control drive must be homed to a reference position. If this is not the case, an absolute position cannot be reached. The drive rejects this positioning command and stops.
Page 57: E256 Torque Limit = 0
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-31 E256 Torque limit = 0 Cause: For protection against mechanical overload, the maximum torque can be limited by the S-0-0092, Bipolar Torque Limit parameter. If the actual value of this parameter is equal to 0, the motor does not develop torque and does not follow the given command values.
Page 58: E259 Command Velocity Limit Active
3-32 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS E259 Command velocity limit active In the position control and velocity control operating modes, the effective velocity command value is limited to the value in parameter S-0-0091, Bipolar velocity limit value. The warning is given if the resulting velocity command value reaches this limit.
Page 59: E263 Velocity Command Value > Limit S-0-0091
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-33 E263 Velocity command value > limit S-0-0091 Cause: The value given to the drive for S-0-0036, Velocity command value was greater than permissible. Remedy: It is limited to S-0-0091, Bipolar velocity limit value.
Page 60: E281 Mains Fault
3-34 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS E281 Mains fault Cause: The mains voltage has failed during operation for at least three mains cycles. In parameter P-0-0118, Power off on error mains failure and undervoltage failure have been set as warnings.
Page 61: E410 Slave Not Scanned Or Address 0
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-35 E410 Slave not scanned or address 0 While the SERCOS ring is being initialized in communications phase 1, each slave which is to participate in the additional phase uptake must be addressed by the SERCOS master.
Page 62: E829 Positive Position Limit Exceeded
3-36 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS Cause: Switching off the power supply or a loss of mains while the drive enable is on. Remedy: Switch off the drive enable before switching off the supply unit. E829 Positive position limit exceeded The drive has received a command value which resulted in an axis position outside the positive travel range.
Page 63: E831 Position Limit Reached During Jog
ECODRIVE03 SMT-02VRS Description of diagnostic letters F... and E... 3-37 E831 Position limit reached during jog If the position limit monitor is activated and the drive is “IN REFERENCE", then it will be positioned on the position limit during movement by jogging. If the drive is positioned on the position limit or beyond the position limit, the drive stops and signals "Position limit value...
Page 64: E844 Negative Limit Switch Activated
3-38 Description of diagnostic letters F... and E... ECODRIVE03 SMT-02VRS E844 Negative limit switch activated The drive has received a command value which resulted in an axis position outside the negative travel range. The axis has been brought to a standstill by setting the velocity command to zero. A class 1 diagnostic error is not generated.
Page 65: Description Of Diagnostic Letters B
ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Description of Diagnostic Letters B..., C..., D... and A... Command Diagnostic Messages B..., C... and D The commands are used for control of complex features in the drive. For example, the features "drive controlled homing procedure" or "Communication Phase 4 Transition Check"...
Page 66: B000 Pulse Wire/Resolver Offset Detection
Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS B000 Pulse wire/Resolver offset detection Command P-0-0550, B000 Pulse wire/Resolver offset detection is conducted. B001 Motor does not have resolver feedback If no motor with resolver feedback is connected, then command P-0-0550, B000 Pulse wire/Resolver offset detection cannot be conducted.
Page 67: B010 5 Pulses Found, But Min. Distance To Move Not Reached
ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... B010 5 pulses found, but min. distance to move not reached Five pulses if travel path is too short, interference or pulse wire encoder is defective. B011 SDAI goes immeadiately back to 0, old PIC version Signal SDAI goes back to "0", old PIC, setting not possible.
Page 68: B202 Error During Bedding In The Brake
Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS B202 Error during bedding in the brake The brake monitor command tries to bed in the motor brake. This means that the motor must be moved with closed holding brake. If the torque of the motor is too small to move the motor with closed brake, then the command error is generated.
Page 69: C101 Invalid Communication Parameter (S-0-0021)
ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C101 Invalid communication parameter (S-0-0021) Cause: Communications parameters which are needed to operate the drive in communication phase 3 are invalid. Remedy: A list of the invalid parameters can be seen in parameter S-0-0021, List of invalid op.
Page 70: C105 Configurated Length > Max. Length For Mdt
Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C105 Configurated length > max. length for MDT Cause: Telegram type 7 was set in parameter S-0-0015, Telegram type parameter. The length of the configured data in MDT, which is determined by...
Page 71: C108 Time Slot Parameter > Sercos Cycle Time
ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C108 Time slot parameter > Sercos cycle time Cause: One of the time slot parameters: • S-0-0006, AT transmission starting time (T1) • S-0-0089, MDT transmission starting time (T2) •...
Page 72: C111 Id9 + Record Length - 1 > Length Mdt (S-0-0010)
Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C111 ID9 + Record length - 1 > length MDT (S-0-0010) Cause: Parameter(s) are set incorrectly for S-0-0009, Beginning address in master data telegram and S-0-0010, Length of master data telegram.
Page 73: C114 T4 > Tscyc (S-0-0002) - T4Min (S-0-0005)
ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C114 T4 > TScyc (S-0-0002) - T4min (S-0-0005) Cause: The maximum permissible value for S-0-0007, Feedback acquisition starting time (T4) is S-0-0002, SERCOS Cycle time (Tscyc) - S-0-0005, Minimum feedback acquisition time(T4min) The value for S-0-0007, Feedback acquisition starting time (T4) is incorrect.
Page 74: C200 Communication Phase 4 Transition Check
4-10 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C200 Communication phase 4 transition check Meaning: The command S-0-0128, C200 Communication phase 4 transition check has been activated. See also the functional description "S-0-0128, C200 Communication phase 4 transition check".
Page 75: C204 Motor Type P-0-4014 Incorrect
4-11 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C204 Motor type P-0-4014 incorrect An MHD-, MKD or MKE motor (value 1 or 5) is entered into parameter P-0-4014, Motor type. The appropriate abbreviation "MHD", "MKD", or "MKE"...
Page 76: C212 Invalid Amplifier Data (->S-0-0022)
4-12 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C212 Invalid amplifier data (->S-0-0022) During drive initialization, the operating software accesses data from an EEPROM in the drive controller. This error message is generated if the attempt to read the data has failed.
Page 77: C214 Velocity Data Scaling Error
4-13 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C214 Velocity data scaling error Cause: The scaling parameters for velocity data permit the velocity data display format to be selected. The drive-internal velocity data format depends on the employed motor encoder and the encoder resolution.
Page 78: C216 Torque/Force Data Scaling Error
4-14 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C216 Torque/force data scaling error Cause: The display format of the torque/force data can be set using torque/force scaling parameters. The factor for converting torque data from drive- controlled format to display format (or vice-versa) is outside the allowable area.
Page 79: C220 Feedback 1 Initializing Error
4-15 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Remedy: For 1. Check the measurement system cable. For 2. Exchange the measurement system. See also the functional description "S-0-0128, C200 Communication phase 4 transition check". C220 Feedback 1 initializing error A number of tests are performed when the motor encoder is initialized.
Page 80: C223 Input Value For Max. Range Too High
4-16 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Cause: External encoder cable defective. Defective feedback. Defective measurement system interface. Note: If this warning occurs in combination with an EnDat feedback device then the feedback device is defective.
Page 81: C235 Load-Side Motor Encoder With Inductance Motor Only
4-17 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C235 Load-side motor encoder with inductance motor only Cause: The functionality of the optional encoder can be defined in the P-0-0185, Function of opt. encoder parameter. If ’load-side motor encoder’ has been selected as the function of the optional encoder, that function will only be supported for asynchronous motors.
Page 82: C302 Absolute Measuring System Not Installed
4-18 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS C302 Absolute measuring system not installed Command P-0-0012, C300 Command ’Set absolute measurement’ was started without an absolute measuring system being present. The command cannot be processed because no absolute measuring system is available.
Page 83: C500 Reset Class 1 Diagnostic, Error Reset
4-19 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C500 Reset class 1 diagnostic, error reset The command for clearing errors, S-0-0099, C500 Reset class 1 diagnostic was activated by the control system in use. All drive internal errors are cleared.
Page 84: Ecodrive03 Smt-02Vrsv
4-20 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Remedy: Home the absolute encoder with the command "Set absolute measuring“. See also the functional description: "Possible Error Messages During Drive-Controlled Homing" C606 Reference mark not detected Cause: •...
Page 85: C702 Default Parameters Not Available
4-21 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... C702 Default parameters not available With motors of the MHD, MKD and MKE series, adapting the control loops to the connected digital drive is done by activating the speed controller parameters that are stored in the motor feedback.
Page 86: C801 Parameter Default Value Erroneous (-> S-0-0021)
4-22 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Default parameters: Default values are stored in the drive for all parameters which are listed in S-0-0192, IDN-list of backup operation data. They define a basic state of the drive that permits the drive to be switched "ready for operation"...
Page 87: C906 Error During Search For Zero Pulse
4-23 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Cause: The absolute encoder used as motor or spindle feedback is not in reference with the spindle. The command S-0-0152 Drive controlled spindle positioning cannot be executed, because the measuring system doesn’t have a reference position.
Page 88: D302 Torque/Force Too Small To Move
4-24 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS D302 Torque/Force too small to move The command D3 Command adjust commutation has been started. To perform this, the motor must move. But it doesn’t move. Cause: 1. The torque is too small to overcome mechanical resistances (friction or weight).
Page 89: D309 Proceed To Phase 4
4-25 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... D309 Proceed to phase 4 If the drive controller is not in phase 4 (bb), then it is not possible to executed command P-0-0524, D300 Commutation adjustment command.
Page 90: D400 Positive Stop Drive Procedure Command
4-26 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS D400 Positive stop drive procedure command When the positive stop drive procedure command is activated, all controller monitoring which would result in an error message for class 1 diagnostic caused by blocking the drive with a positive stop is turned off.
Page 91: D600 Cancel Reference Point Procedure Command
4-27 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... D600 Cancel reference point procedure command Meaning: The reference of the encoder that has been selected via S-0-0147, Homing parameter is canceled. Cause: The D600 Cancel reference point procedure command has been activated.
Page 92: D900 Command Automatic Loop Tuning
4-28 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS D900 Command automatic loop tuning Description: The start of this command means that an automatic control loop setting is executed in the drive if the drive is in the loop at command start, i.e., the drive enable signal is applied.
Page 93: D903 Inertia Detection Failed
4-29 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Remedy: If known, write the correct values back into the parameter or contact Indramat Customer Service to obtain the feedback data valid for your motor. In the worst case, it may be necessary to replace the motor.
Page 94: D905 Travel Range Invalid, P-0-0166 & P-0-0167
4-30 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS D905 Travel range invalid, P-0-0166 & P-0-0167 Description: Before starting an automatic control loop setting, both travel range limits, i.e., upper and lower, must be defined. When starting command P-0-0162, D9 automatic control loop setting the number values are automatically checked for validity.
Page 95: Status Diagnostic Messages
4-31 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Status diagnostic messages A000 Communication phase 0 The communication process is divided into four communication phases: Phases 0 and 1 are used to recognize the participants. Phase 2 is used to prepare the time and data protocols for communication phases 3 and 4.
Page 96: A003 Communication Phase 3
4-32 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Before switching to communication phase 3 is possible, the command S-0-0127, C100 Communication phase 3 transition check must be done. In this command, the drive checks e.g. the validity of the parameters needed for the communication phase 3.
Page 97: A012 Control And Power Sections Ready For Operation
4-33 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... A012 Control and power sections ready for operation The drive is supplied with control voltage, and the power is switched on. The drive is ready to deliver power.
Page 98: A104 Position Mode Lagless, Encoder 1
4-34 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS A104 Position mode lagless, 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;...
Page 99: A108 Drive Controlled Interpolation, Lagless, Encoder 1
4-35 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... A108 Drive controlled interpolation, lagless, 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...
Page 100: A147 Relative Drive Controlled Interpolation, Encoder 2
4-36 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS A147 Relative drive controlled interpolation, encoder 2 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 values parameter is toggled, this distance is summed up to the value in S-0-0258, Target position.
Page 101: A149 Relative Drive Contr. Interpolation, Enc. 2, Lagless
4-37 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... A149 Relative drive contr. interpolation, enc. 2, 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 values parameter is toggled, this distance is summed up to the value in S-0-0258, Target position.
Page 102: A207 Process Block Mode Lagless, Encoder 1
4-38 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS A207 Process block mode lagless, encoder 1 The drive performs a closed loop position control without lag. The actual value comes from the encoder 1 (motor encoder). The command value profile is generated in the drive.
Page 103: A400 Automatic Drive Check And Adjustment
4-39 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... A400 Automatic drive check and adjustment Diagnosis A400 is a group diagnosis for various system states. It is used in drive checks and adjustments. A through diagnosis is automatically run when the drive enable is switched on and off.
Page 104: Diagnostic Messages For Basic Initialization And After Fatal System Errors
4-40 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Diagnostic messages for basic initialization and after fatal System errors Diagnostic Message Display: -0 The writable data storage of the drive controller is tested for its functional capability.
Page 105: Diagnostic Message Display: E1
4-41 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... Diagnostic Message Display: E1 Cause: Processor fault, caused by static discharge, program error or hardware fault. More information is available via a terminal connected to the RS-232 interface.
Page 106: Operation Status
4-42 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Operation Status Hereafter, the possible states of operation are listed alphabetically. These are shown on the H1 display of the device. "Ready for operation" See also: A013 Ready for power on.
Page 107 4-43 ECODRIVE03 SMT-02VRS Description of Diagnostic Letters B..., C..., D... and A... "Phase 0" (only with SERCOS communication) See also: A000 Communication phase 0. "Phase 1" See also: A001 Communication phase 1. "Phase 2" See also: A002 Communication phase 2.
Page 108 4-44 Description of Diagnostic Letters B..., C..., D... and A... ECODRIVE03 SMT-02VRS Notes DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 109: Replacing Or Exchanging Drive Components
ECODRIVE03 SMT-02VRS Replacing or Exchanging Drive Components Replacing or Exchanging Drive Components The diagnostic display of ECODRIVE enables an aimed and effective problem search in order to: • avoid production downtimes due to extensive searches in individual units and repairs of units on the machine •...
Page 110 Replacing or Exchanging Drive Components ECODRIVE03 SMT-02VRS Specifications for model label DKC _._ - _ _ _ _ - _ S.No .: _ _ _ _ _ _ Pre- formed engine performance cable INDRAMAT - cable IKS _ _ _ No.:...
Page 111: Procedure On Replacing The Unit
ECODRIVE03 SMT-02VRS Replacing or Exchanging Drive Components Procedure on Replacing the Unit Note: Note the safety instructions in section 2 when exchanging any parts! Replacing the DKC: • Switch main switch off. • Secure against being switched back on. ⇒ Prior to touching bear connecting cables and...
Page 112: Replacing The Motor
Replacing or Exchanging Drive Components ECODRIVE03 SMT-02VRS Replacing the Motor: • Switch main switch off. • Secure against being switched back on. Note: When replacing the motor, cap open connector ends particularly if there might be the change that coolant or grease could be sprayed or splashed in their vicinity (allowable level of dirt contamination is V2).
Page 113 ECODRIVE03 SMT-02VRS Replacing or Exchanging Drive Components Machine housing ECO3 Switchboard wall Indramat-Motor Immediate environment requirements Conductive contamination cannot occur when operating the control drive (at least not with the IP 65); when installing or exchanging drive components, non- conductive contamination or light condensation may momentarily occur.
Page 114 Replacing or Exchanging Drive Components ECODRIVE03 SMT-02VRS Fault Report for digital AC Servo Drives DKC This fault report is intended to clarify problems and their causes. It is absolutely necessary for finding and eliminating hidden, sporadic or application-related problems. - Always include a Fault report with any parts returned for repair.
Page 115: Replacing Firmware
ECODRIVE03 SMT-02VRS Replacing Firmware Replacing Firmware Replacing the Parameter Module • Secure parameters (DriveTop) • Switch unit off • Remove programming module • Open the lock on the back Push locking plate inside to open Ap5145f1.fh7 Fig. 6-1: Locking the programming module •...
Page 116: Replacing The Firmware Module
Replacing Firmware ECODRIVE03 SMT-02VRS Replacing the Firmware Module • Switch unit off • Pull programming module out • Open the lock on the back of the programming module • Open the programming module • Insert old parameter module into new firmware module •...
Page 117 ECODRIVE03 SMT-02VRS Index Index +24Volt DC error 3-22 5 pulses found, but min. distance to move not reached 4-3 Ab 4-42 Absolute encoder out of allowed window 3-14 Absolute measuring system not installed 4-18 AC 4-42 Acceleration data scaling error 4-13...
Page 118 Index ECODRIVE03 SMT-02VRS Default parameters not available 4-21 Diagnostic Message Display (2 dots) 4-40 Diagnostic Message Display -0 4-40 -1 4-40 -2 4-40 -3 4-40 -4 4-40 -5 4-40 -6 4-40 E1 4-41 E2 4-41 E3 4-41 E4 4-41 E5 4-41...
Page 119 ECODRIVE03 SMT-02VRS Index Gain adjustment failed 4-29 Homing of absolute encoder not possible 4-19 Homing only possible with drive enable 4-19 ID9 + Record length - 1 > length MDT (S-0-0010) 4-8 Incr. encoder emulator pulse frequency too high 3-12...
Page 120 Index ECODRIVE03 SMT-02VRS Not homed 3-30 Only allowed without master 4-18 Operation Status 4-42 Order of MDT configuration wrong 4-9 Overcurrent short in power stage 3-22 Overvoltage in power stage 3-35 P0 4-43 P1 4-43 P2 4-43 P3 4-43 Parameter calculation error (->S-0-0022) 4-10 Parameter default value erroneous (->...
Page 121 ECODRIVE03 SMT-02VRS Index Selected process block is not programmed. 3-31 Shaft does not turn as expected 4-3 Slave not scanned or address 0 3-35 Spindle positioning requires drive enable 4-22 Start requires drive enable 4-28 Stepper position mode 4-37 Stepper position mode, lagless 4-37...
Page 122 Index ECODRIVE03 SMT-02VRS Notes DOK-ECODR3-SMT-02VRS**-WA01-EN-P...
Page 123: Kundenbetreuungsstellen - Sales & Service Facilities
ECODRIVE03 SMT-02VRS Kundenbetreuungsstellen - Sales & Service Facilities Kundenbetreuungsstellen - Sales & Service Facilities Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!! from abroad: don’t dial (0) after country code! Vertriebsgebiet Mitte Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Ost SALES...
Page 124 SALES Service SALES Service Mannesmann Rexroth S.A. Mannesmann Rexroth S.A. Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A. Divi- Division Rexroth Indramat Division Rexroth Indramat Divisione Rexroth Indramat sione Rexroth Indramat 270, Avenue de Lardenne 91, Bd. Irène Joliot-Curie Via G. Di Vittoria, 1...
Page 125 SALES Service SALES Service Mannesmann Rexroth S.A.I.C. NAKASE AIMS - Australian Industrial Machi- Mannesmann Rexroth Pty. Ltd. Division Rexroth Indramat Servicio Tecnico CNC nery Services Pty. Ltd. No. 7, Endeavour Way Acassusso 48 41/7 Calle 49, No. 5764/66 Unit 3/45 Horne ST...
Page 126 Kundenbetreuungsstellen - Sales & Service Facilities ECODRIVE03 SMT-02VRS Außerhalb Europa / USA - outside Europe / USA SALES Service SALES Service SALES Service SALES Service Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Rexroth Indramat Division...
Page 128 285852 Rexroth Indramat...

Mannesmann ecodrive03 Troubleshooting Manual

1 Diagnostic Message Descriptions

2 Safety Instructions for Electric Servo Drives and Controls

3 Description of Diagnostic Letters F

4 Description of Diagnostic Letters B

5 Replacing or Exchanging Drive Components

6 Replacing Firmware

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Summary of Contents for Mannesmann ecodrive03

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