REXROTH VisualMotion 9 Troubleshooting Manual
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REXROTH VisualMotion 9 Troubleshooting Manual

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

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Summary of Contents for REXROTH VisualMotion 9

  • Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraControl VCP 20 VisualMotion 9 R911292841 Edition 02 Multi-Axis Motion Control using GPP and GMP Firmware Troubleshooting Guide...
  • Page 2 About this Documentation VisualMotion 9 Troubleshooting Guide VisualMotion 9 Title Multi-Axis Motion Control using GPP and GMP Firmware Troubleshooting Guide Type of Documentation DOK-VISMOT-VM*-09VRS**-WA02-EN-P Document Typecode Document Number, z.B. 209-0049-4306-02/EN Internal File Reference Part of Box Set, 20-09V-EN (Material No.: 293201) This documentation describes …...

  • Page 3: Table Of Contents

    VisualMotion 9 Troubleshooting Guide Table of Contents Table of Contents VisualMotion 9 Overview System Overview ........................... 1-1 GPP 9 System Overview........................ 1-1 GPP 9 System Components ....................1-2 GPP 9 PLC Support......................... 1-2 GPP 9 Interface Support......................1-2 Drive I/O Support ........................1-3 GMP 9 System Overview .......................
  • Page 4 Table of Contents VisualMotion 9 Troubleshooting Guide Warning Messages (201-399)......................3-7 201 Invalid jog type or axis selected..................3-8 202 Drive %d is not ready......................3-8 203 Power Fail detected ......................3-8 204 SERCOS ring was disconnected ..................3-8 205 Parameter transfer warning in Task %c ................3-9 207 Axis %d position limit reached ..................
  • Page 5 VisualMotion 9 Troubleshooting Guide Table of Contents 429 Calc: too many operands ....................3-22 430 Calc: invalid operator ...................... 3-22 431 Calc error: see Task %c diag..................3-22 432 Calc: too many nested expressions................3-23 433 Setup instruction outside of a task.................. 3-23 434 Axis %d configured more than once ................
  • Page 6 Table of Contents VisualMotion 9 Troubleshooting Guide 515 PLC Communications Error .................... 3-36 516 More than %d registration functions enabled ..............3-36 519 Lost Fieldbus/PLC Connection ..................3-36 520 Fieldbus Mapping Timeout ..................... 3-36 521 Invalid Virtual Master ID: %d ..................3-37 522 Invalid ELS Master ID: %d ....................
  • Page 7 VisualMotion 9 Troubleshooting Guide Table of Contents 567 ELS Config. Error, see ext. diag..................3-50 568 Axis %d: Assigned Task is Not Defined................3-51 570 ELS Max. Vel. Exceeded, see ext. diag................3-51 571 No Program Found ......................3-52 Communication Error Codes and Messages ................
  • Page 8 Table of Contents VisualMotion 9 Troubleshooting Guide !42 Mapper: invalid operator ....................3-57 !43 Mapper: too many operations ..................3-57 !44 Mapper: invalid register....................3-57 !45 Mapper: invalid bit or mask ..................... 3-57 !46 Mapper: register is read-only ..................3-57 !47 Invalid Unit Number ......................
  • Page 9 VisualMotion 9 Troubleshooting Guide Table of Contents !103 Bit combination not valid ....................3-62 Index Service & Support Helpdesk ............................5-1 Service-Hotline..........................5-1 Internet ............................5-1 Vor der Kontaktaufnahme... - Before contacting us............... 5-1 Kundenbetreuungsstellen - Sales & Service Facilities ..............5-2...
  • Page 10 VIII Table of Contents VisualMotion 9 Troubleshooting Guide DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 11: Visualmotion 9 Overview

    VisualMotion 9 Overview System Overview VisualMotion is a programmable multi-axis motion control system capable of controlling up to 40 intelligent digital drives from Bosch Rexroth. The PC software used for motion control management is named VisualMotion Toolkit. VisualMotion 9 supports the following hardware form factors and firmware versions: •...

  • Page 12: Gpp 9 System Components

    – • HMI interfaces (BTC06, BTV04, BTV05, BTV06) GPP 9 PLC Support The Bosch Rexroth MTS-R is a PLC unit that interfaces with the VisualMotion control (PPC-R) and is available preconfigured in two sizes. • MTS-R01.1 with one expansion slot •...

  • Page 13: Drive I/O Support

    Controller (SoftPLC) handles the system logic, fieldbus and Ethernet communications. Just like the PPC-R, the PPC-P supports Bosch Rexroth DIAX04 and ECODRIVE03 digital servo drives. Communication between the control and digital servo drives is performed via the SERCOS fiber optic interface.

  • Page 14: Gmp 9 Firmware Features

    • Link Ring for Master/Slave interfacing of VisualMotion controls. Drive I/O Support Bosch Rexroth digital drives support the following I/O devices: • DEA0x.2M (x = 4, 5 or 6) I/O cards for DIAX04 digital drives • EMD I/O module using the EcoX interface for DKC22.3 digital...

  • Page 15: Visualmotion Tools For Diagnosing

    PC's Com port. Note: Communication can also be established using the ETH01 Ethernet card. Refer to the VisualMotion 9 Project Planning Manual for details. 2. Power-up VisualMotion System (drives, control, motors, etc.). 3. Start VisualMotion Toolkit in "Service" mode by selecting the (view and edit control data in "Service"...
  • Page 16 VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide Communication Error If a connection can not be established, the DDE server will issue an error and the following Diagnostic dialog box will open. This indicates that either there is a problem in the physical connection or that the communication settings of the control do not match the settings of the DDE sever.
  • Page 17 VisualMotion 9 Troubleshooting Guide VisualMotion Tools for Diagnosing Serial_Comm.tif Fig. 2-3: Serial Communications Changing the Serial Communication Baud Rate From VisualMotion Toolkit's main menu, select Tools ⇒ ⇒ ⇒ ⇒ Control Settings. Select the control's X10 or X16 port and change the baud rate.

  • Page 18: The Diagnostics Menu

    VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide The Diagnostics Menu The diagnostics menu provides system information for logging and monitoring system errors and diagnostics. DiagnosticsSystem.tif Fig. 2-5: Diagnostics Menu System Diagnostics The system diagnostic window displays current diagnostic information for diagnostic messages, hardware and firmware information, installed option cards, diagnostic log, hardware status, and control load status.
  • Page 19 Date and Time Date and time are relative to the power on of the control; they have no battery-backup clock unless the PPC-R is equipped with a battery. Refer to chapter 4 of the VisualMotion 9 Project Planning Manual DOK-VISMOT-VM*-09VRS**-PR02-EN-P for installation instructions.
  • Page 20 VisualMotion Tools for Diagnosing VisualMotion 9 Troubleshooting Guide Tasks Diagnostics Selecting Diagnostics ⇒ ⇒ ⇒ ⇒ Task opens the Task Diagnostics window and uploads data regarding all active VisualMotion tasks. Task letters are displayed only if they contain an icon program that has been compiled and downloaded to the control.
  • Page 21 VisualMotion 9 Troubleshooting Guide VisualMotion Tools for Diagnosing Drive Overview… Selecting Drive Overview from the Commission menu opens the DriveTop drive selection window. Select the desired drive and click on the Overview button to launch the DriveTop drive status window.

  • Page 22: Using Visualmotion's End User Tool For Diagnosing

    • Password Security Note: The End User Tool installation is included, by default, as part of the VisualMotion 9 installation. The End User Tool can be launched from the \\Rexroth\VisualMotion 9 folder, by double clicking on the EndUserTool.exe file. End_User_Tool.tif Fig.

  • Page 23: Monitoring And Diagnostics

    • Shutdown messages An identifying 3-digit code number precedes diagnostic messages. Example: 400 Emergency Stop These identifying code numbers are assigned by Bosch Rexroth and are broken up into the following groups: • (001-199) Status messages • (201-399) Warning messages •...
  • Page 24 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide Param_Overview.tif Fig. 3-1: Parameter Overview Window Access to Parameters The Parameter Overview tool controls access to parameters whether in Phase 2 or Phase 4. Parameters are displayed in different colors to provide a visual representation of their access level. The following table explains the color code / access combination.

  • Page 25: Drivetop

    VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics DriveTop Parameters pertaining to drive diagnostics can be viewed by selecting Commission ⇒ ⇒ ⇒ ⇒ Drive Overview. This menu selection opens DriveTop. Note: The Drive Parameter Editor used with VisualMotion 8 can only be accessed when communicating with GPP08 firmware.

  • Page 26: Control Startup Messages

    Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide Control Startup Messages On power up, the control’s boot-up sequence displays a series of numbers and/or letters on the H1 display. These represent each step in the initialization process. The display stops on a numeric value if a step fails.

  • Page 27: Status Messages (001-199)

    VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Status Messages (001-199) A Status Message indicates the normal operating status of an axis, task, or the system when there are no errors. A change in status that generates a new status message overwrites the previous message. No user acknowledgment is required for a change in a status message.

  • Page 28: 007 Program Running: Abcd

    Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 007 Program Running: ABCD The user program tasks indicated at the end of the message are running, and the rest are not running or are single stepping. 008 Single-Stepping: ABCD The user program tasks indicated at the end of the message are in single- step mode.

  • Page 29: Warning Messages (201-399)

    VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Warning Messages (201-399) Warning messages are issued when an improper system condition exists. The condition is important enough to be brought to an operator's immediate attention, but not critical enough to shut down the system.

  • Page 30: 201 Invalid Jog Type Or Axis Selected

    Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 201 Invalid jog type or axis selected This message is issued before a coordinated I/O jog when an invalid type or axis is selected. Causes: 1. The axis selected for jogging is not defined as a coordinated motion axis.

  • Page 31: 205 Parameter Transfer Warning In Task %C

    Warning message 208 is only issued while in phase 4 if the Fieldbus Error Reaction in the Fieldbus Slave Configuration window is set to warning. Remedy: 1. Check and verify all cable connects between the slave and master Fieldbus connections. 2. Contact Bosch Rexroth service for assistance. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 32: 209 Fieldbus Mapping Timeout

    Fig. 3-7: Fieldbus Slave Configuration Remedy: The PPC-R mapping list is scanned every 4 ms for GPP09 and fixed at 8 ms for GPP08. If this error occurs, contact Bosch Rexroth Service for assistance. 210 File System Defrag: %d completed...

  • Page 33: 212 Option Card Pls Warning, See Ext. Diag

    (0x0001) and C-0-2613 (Fieldbus/PLC Cyclic Channel: Timeout Counter) increments by 1. Remedy: The control’s mapping list is scanned every 4 ms for GPP09 and fixed at 8 ms for GPP08. If this error occurs, contact Bosch Rexroth Service for assistance. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 34: 215 Reco I/O Failure, See Ext. Diag

    3-12 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 215 RECO I/O Failure, see ext. diag. Cause: This message is generated when GPP is configured to react to RECO I/O errors with a warning. Remedy: Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒...

  • Page 35: 217 Plc Communication, See Ext. Diag

    3-13 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 217 PLC Communication, see ext. diag Cause: During power up, the PLC communication is initialized with the control. This warning is issued when a communication error is encountered. Refer to the extended diagnostic message for details.

  • Page 36: 220 Excessive Deviation In Pmg%D, See Ext. Diag

    3-14 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 220 Excessive deviation in PMG%d, see ext. diag. If the PMG Configuration parameter (C-0-3205, C-0-3215, C-0-3225, C-0- 3235, C-0-3245, C-0-3255, C-0-3265, C-0-3275) bit 2 is set to 0 (Warning), the group is enabled and the current deviation exceeds the allowed deviation, this warning is displayed.

  • Page 37: Shutdown Messages (400 - 599)

    3-15 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Shutdown Messages (400 - 599) A Shutdown is issued in an emergency situation or when the system or drives cannot operate correctly. During a shutdown, the control switches the user program tasks into manual mode, decelerates all motion to zero velocity, and sets the error bit in the status register.

  • Page 38: 403 System Error See Ext. Diag

    Diagnostics ⇒ ⇒ ⇒ ⇒ System in VisualMotion Toolkit. Remedy: Recycle system power. If recycling power does not resolve the error, contact Bosch Rexroth service for assistance. 405 Phase %d: Drive did not respond Cause: A time-out in the SERCOS ring occurred when the control did not receive a response from the drive during Phase %d (where %d = phase number) initialization.

  • Page 39: 409 Sercos Disconnect Error

    3-17 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 409 SERCOS Disconnect Error The SERCOS fiber optic ring was disconnected or a drive connected to the ring was powered down while in Phase 3 or 4. A more descriptive message will be displayed in the extended diagnostic control parameter C-0-0124.

  • Page 40: 414 Parameters Were Lost

    3-18 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 414 Parameters were lost System, task, and axis parameters were lost, and default values have been loaded. Cause: This error has occurred for one of the following reasons: • new firmware was loaded on the PSM memory card •...

  • Page 41: 416 Invalid Instruction At %04X

    Remedy: Recompile the program using VisualMotion Toolkit and download it again. If the error still occurs, call Bosch Rexroth Service for assistance. 420 Drive %d Shutdown Error Cause: Drive %d (where %d = drive number) has issued a shutdown error, which disables motion.

  • Page 42: 421 User Program Stack Overflow

    <F7> function can identify the icon. Remedy: Recompile the program without the instruction indicated by the current instruction pointer or update the firmware or VisualMotion software. Contact Bosch Rexroth for updated firmware and software information. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 43: 425 Instruction Error: See Task %C Diag

    3-21 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 425 Instruction error: see Task %c diag. Cause: An error has occurred in a user program instruction. A more specific message is displayed in the diagnostic message for task %c (where %c = task letter) in which the error occurred (T-0-0122).

  • Page 44: 428 Calc: Division By Zero

    VisualMotion Toolkit. Remedy: Check the compiler and firmware version numbers, and call Bosch Rexroth service for assistance in upgrading software. Version information can be found for menu selection Diagnostics ⇒ ⇒ ⇒ ⇒ System. 431 Calc error: see Task %c diag.

  • Page 45: 432 Calc: Too Many Nested Expressions

    3-23 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 432 Calc: too many nested expressions Cause: In a user program calculation instruction, more than 16 operations were pending. See the diagnostic message for each task to find the task and the instruction.

  • Page 46: 438 Invalid Axis Selected: %D

    3-24 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 438 Invalid Axis Selected: %d Cause: Axis %d (where %d = axis number) was not found on the SERCOS ring or is an invalid axis number. This error is issued during single-axis or ELS motion commands.

  • Page 47: 450 Event %D: Invalid Event Type

    The %d indicates the communication error code returned by the drive. Remedy: Try homing the axis again. If this error still occurs, call Bosch Rexroth Service for assistance. 454 Axis %d homing not complete Cause: The drive did not successfully complete the homing procedures instructed by axis %d (where %d = axis number).

  • Page 48: 459 Axis %D Target Position Out Of Bounds

    3-26 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 459 Axis %d target position out of bounds Cause: The programmed position in an axis/move command or the Move icon for axis %d (where %d = axis number) exceeds the drive's travel limits.

  • Page 49: 464 Can't Activate While Program Running

    3-27 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 464 Can't activate while program running Cause: A new program cannot be activated through the Binary Program Select inputs, bit 8 of register 1, unless the program is stopped. Remedy: Stop the currently running program by setting register 1 bit 8 to 0. Set the desired program number in binary format through bits 9-12 and activate the new program by setting bit 8 to 1.

  • Page 50: 467 Invalid Els Master Option

    Search the program for the axis in fault and verify that the axis options in parameter A-0-0004 are correct and within range. Refer to the VisualMotion 9 Functional Description for an explanation of axis parameter A-0-0004. 468 ELS adjustment out of bounds...

  • Page 51: 478 Calc: Operand Out Of Range

    This error indicates a problem in the control executive firmware. Remedy: See the extended diagnostics parameter (C-0-0124) for more information or select Diagnostics ⇒ ⇒ ⇒ ⇒ System within VisualMotion Toolkit, and call the Bosch Rexroth service department for assistance. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 52: 486 Sercos Device %D Is Not A Drive

    3-30 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 486 SERCOS Device %d is not a drive Cause: The SERCOS device %d (where %d = SERCOS address) was enabled in the user program or parameterized as an axis, but an I/O slave or other type of slave was detected.

  • Page 53: 490 System Memory Allocation Error

    7 events use up unnecessary memory resources. Decrease each field within the sizing icon to free up memory space. 3. If the problem persists, contact Bosch Rexroth Service for assistance. 492 Programs were lost, see ext. diag. Cause: User programs and data have been erased from the control’s memory.

  • Page 54: 496 Can't Execute This Instruction From An Event

    3-32 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 496 Can't execute this instruction from an event Cause: This user program instruction (icon) cannot be executed from within an event function. See the task error descriptions and the current program instruction. Some operations, such as sequencer initialization, cannot take place during an event.

  • Page 55: 499 Axis Number %D Not Supported In This Version

    The control contains a firmware version that is not capable of performing ELS and Cam functions. Verify the version of firmware in control parameter C-0-0100 or using VisualMotion Toolkit under menu selection Diagnostics ⇒ ⇒ ⇒ ⇒ System. Contact Bosch Rexroth Service for assistance. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 56: 504 Communication Timeout

    If the *.iom file does not upload from the control, use File ⇒ Note: Open from the Ladder Editor screen and open a valid *.iom file. 7. If the error is still encountered, contact Bosch Rexroth Service for assistance. DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

  • Page 57: 508 User Watchdog Timeout

    3-35 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 508 User Watchdog Timeout Cause: The user watchdog timer enforces a time constraint on a user task or a user interface. Every time a nonzero timeout value is written to C-0-0021, a timer is triggered in the control.

  • Page 58: 515 Plc Communications Error

    4. Check and verify all cable connects between the slave and master Fieldbus connections. 5. Set C-0-2635, Fieldbus Error Reaction, from 0x0000 (shutdown) to 0x0002 (ignore). 6. Contact Bosch Rexroth Service for assistance. 520 Fieldbus Mapping Timeout Cause: The Fieldbus Mapper continually scans the system for sufficient resources to process the cyclic data mapping list (2600-list).

  • Page 59: 521 Invalid Virtual Master Id: %D

    Fig. 3-13: Fieldbus Shutdown Error Reaction Remedy: PPC controls currently run the fieldbus mapper at a fixed 4ms SERCOS scan time. If this error occurs, contact Bosch Rexroth Service for assistance. 521 Invalid Virtual Master ID: %d Cause: This diagnostic is displayed if an ID number (%d) other than 1 or 2 is used to identify a Virtual Master.

  • Page 60: 523 Ifs Status, Facility = 0X%X

    Remedy: Bring all motion to a stop and cycle power to the control. If the problem persist, contact Bosch Rexroth Service for assistance. 525 I/O Configuration error, see ext. diag. Cause: This diagnostic is displayed when the I/O User Configuration C-0-2017 does not match the actual I/O configuration on the machine (Visible I/O Stations, C-0-2013).

  • Page 61: 526 Sercos Multiplex Channel Config, See Ext. Diag

    3-39 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 526 SERCOS Multiplex Channel Config, see ext. diag. Cause: The SERCOS multiplex channel is enabled by either the selection of the Drive PLS Fast Write feature or the detection that the AT or MDT has exceeded the 16-byte limit.

  • Page 62: 528 System Event %D Occurred

    3-40 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 528 System Event %d Occurred Cause: This diagnostic can only be viewed using VisualMotion's diagnostic log. It monitors status information and also functions as a debugging log for unexpected firmware errors related to the File System. The File System consists of…...

  • Page 63: 530 Cam %D Is Active, Can't Overwrite

    3-41 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 530 Cam %d is active, can't overwrite Cause: This error is displayed during Phase 4 (automatic mode) initialization and is a result of trying to assign an already active CAM %d (where %d = cam number) to a new build.

  • Page 64: 534 Hardware Version Not Supported

    (PPC-R0*.1) that is not supported by the current version of GPP firmware. Remedy: Upgrade your current PPC hardware to a newer version (PPC-R0*.2 or later) for support of the current GPP firmware. Contact Bosch Rexroth service for assistance. 539 Invalid Parameter Number...

  • Page 65: 541 Link Ring Error, See Ext. Diag

    3-43 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Extended Diagnostic C-0-0124 Description 032: Synchronization error The Option Card PLS software could not synchronize to the PPC. 0yy: Maximum PLS speed exceeded at axis zz The maximum speed of 3500 RPM had been exceeded. yy is an error number between 33 and 40;...

  • Page 66: 542 Plc Cyclic Mapping Timeout

    Fig. 3-16: Fieldbus Slave Shutdown Error Remedy: The control’s mapping list is scanned every 4 ms for GPP09 and fixed at 8 ms for GPP08. If this error occurs, contact Bosch Rexroth Service for assistance. 543 PLC Runtime Error Cause: This error is issued when trying to download a PLC program while the control is in phase 4.

  • Page 67: Invalid Coordinated Articulation Function Id: %D

    3-45 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Remedy: Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒ ⇒ ⇒ ⇒ System in VisualMotion Toolkit. Extended Diagnostic C-0-0124 Description Module Initialization Error, Slot 2,...

  • Page 68: 547 Task %C Coordinated Articulation Error, See Ext. Diag

    Cause: A problem has occurred during Fieldbus initialization. Remedy: If this error occurs, contact Bosch Rexroth Service for assistance. Reference the three-digit diagnostic message in the error code displayed under menu selection Diagnostic ⇒ ⇒ ⇒ ⇒ System. 550 User Initialization Task Timeout Cause: Task could not be completed before the 300 seconds (5 mins.) timeout.

  • Page 69: Master Slip Config. Error, See Ext. Diag

    3-47 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 551 Master Slip Config. Error, see ext. diag Cause: A Slip Monitoring configuration error has occurred. Refer to the extended diagnostic message for details. Remedy: Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒...

  • Page 70: 555 Plc Register Mapping Timeout

    3-48 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide 555 PLC Register Mapping Timeout The control and PLC can communicate across the DPR's register channel. The rate in which each device accesses the register channel varies by device and control firmware.

  • Page 71: 559 Pmg%D Number Of Offsets Does Not Match Number Of Axis

    3-49 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics 559 PMG%d Number of offsets does not match number of Axis During PMG group enabling (control register 86), all parameterized PMG offsets are checked. This error is issued if the number of offsets doesn’t match the number of parameterized PMG axes for PMG%d (where %d = PMG number).

  • Page 72: 566 Filter Sample Rate And Cutoff Frequency Mismatch

    3-50 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide Remedy: Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒ ⇒ ⇒ ⇒ System in VisualMotion Toolkit. Extended Diagnostics C-0-0124 Description Measuring wheel config error, S-0-0386...

  • Page 73: 568 Axis %D: Assigned Task Is Not Defined

    3-51 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒ ⇒ ⇒ ⇒ System in VisualMotion Toolkit. Extended Diagnostic C-0-0124 Description Virtual Master %d Max. Vel. Exceeds %d = Virtual Master number 1 or 2 %.f RPM...

  • Page 74: 571 No Program Found

    3-52 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide Remedy: Refer to the extended diagnostics for details. Extended diagnostics can be viewed by selecting Diagnostics ⇒ ⇒ ⇒ ⇒ System in VisualMotion Toolkit. Extended Diagnostic C-0-0124 Description Remedy The signal from the Real Master The velocity of the Real Master Sys.

  • Page 75: Communication Error Codes And Messages

    !01 SERCOS Error Code # xxxx (xxxx = Error code) This is the code set in the data status word of the drive if SERCOS communication is invalid. Call Bosch Rexroth Service if this error occurs. !02 Invalid Parameter Number The requested or sent parameter does not exist on the control or the drive, or the format of the parameter is incorrect.

  • Page 76: Service Channel Is Not Open

    3-54 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide !11 Service channel is not open When switching between initialization phases, data from the drive is momentarily invalid, and this message is sent instead of the requested data. !12 Invalid Command Class A serial port command is invalid or not supported at this time.

  • Page 77: Parameter Is Not A List

    3-55 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics !21 Parameter is not a List Only Variable-Length List parameters can use the Parameter List sequence. !22 Invalid Variable Number The variable mnemonic was not 'I' or 'F', or the variable number is greater than the maximum number of variables allocated.

  • Page 78: Invalid I/O Register Or Bit Number

    3-56 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide !30 Invalid I/O Register or Bit Number The I/O register mnemonic is invalid or a register number greater than the maximum number of registers was sent. !31 Invalid Table Index The ABS, REL, or EVT table name was incorrect, or the index number was greater than the maximum number of points or events.

  • Page 79: No Programs Are Active

    3-57 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics !40 No programs are active No programs are active on the control. Download a program to the control’s memory. !41 System Error: pSOS #XXXX This is an internal system error. Call Bosch Rexroth Service for assistance.

  • Page 80: Waiting For Service Channel

    !59 SERCOS handshake/busy timeout This is an internal error generated by the SERCOS ASIC. Change modes or reset the control. If it happens again, call Bosch Rexroth Service. !60 Executable program is too large (ddK) The executable portion of the user program downloaded to the control exceeds the maximum limit, which is indicated in the message (‘dd’) in...

  • Page 81: X-Column Does Not Start At 0 Or End At 360

    3-59 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics !62 Cam X data is < 0 or greater than 360 All values in the x-column (right hand column) of the CAM file sent to the control must be between zero and the modulo value of the master.

  • Page 82: Invalid Object Number

    !82 Write protected by password The SERCOS parameter being modified is password protected. This password protection is reserved for Bosch Rexroth Service personnel. !83 Valid ELS Group numbers are 1 through 8 The ELS Group number being transmitted to the control by way of serial communications has become corrupted and is an invalid.

  • Page 83: No Virtual Master Are Currently Active

    3-61 VisualMotion 9 Troubleshooting Guide Monitoring and Diagnostics !88 No Virtual Master are currently active The Virtual Master number being transmitted to the control by way of serial communications is currently not active or is invalid. Valid Virtual Master numbers are 1 and 2. Verify that the request number is existing and active in the user program.

  • Page 84: 103 Bit Combination Not Valid

    3-62 Monitoring and Diagnostics VisualMotion 9 Troubleshooting Guide !100 Reset Command Parameter Global variables are flashed to memory by setting C-0-0082 to a binary 3. This communication error is issued when a second binary 3 is set in C-0-0082 without first setting the parameter to 0.

  • Page 85: Index

    VisualMotion 9 Troubleshooting Guide Index Index !44 Mapper: invalid register ..3-57 !45 Mapper: invalid bit or mask 3-57 !46 Mapper: register is read-only3- !01 SERCOS Error Code # xxxx !47 Invalid Unit Number ... 3-57 (xxxx = Error code) ....3-53 !50 Invalid Download Block..
  • Page 86 Index VisualMotion 9 Troubleshooting Guide 411 Drive %d Phase 4 Switch Error ..........3-17 412 No drives were found on ring3- 001 Initializing System....3-5 002 Parameter Mode....3-5 414 Parameters were lost..3-18 003 Initializing Drives....3-5 415 Drive %d was not found..3-18 004 System is Ready....3-5...
  • Page 87 VisualMotion 9 Troubleshooting Guide Index 483 Parameter Init. Error: see Task 539 Invalid Parameter Number 3-42 %c diag.........3-29 540 External Card PLS error..3-42 484 Control SYSTEM ERROR..3-29 541 Link Ring Error, see ext. diag.3- 486 SERCOS Device %d is not a drive........3-30...
  • Page 88 Index VisualMotion 9 Troubleshooting Guide Data Shutdown Messages (400 - 599)3- Parameters ......3-1 Diagnostic Log......2-5 Status Messages (001-199)..3-5 Diagnostics Menu .......2-4 System Diagnostics - Codes and Diagnostic Log......2-5 Message ........ 3-1 Drive Overview .......2-7 Tasks ........2-6 Drive Overview ......2-7 DriveTop ......

  • Page 89: Service & Support

    VisualMotion 9 Troubleshooting Guide Service & Support Service & Support Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.

  • Page 90: Kundenbetreuungsstellen - Sales & Service Facilities

    Service & Support VisualMotion 9 Troubleshooting Guide Kundenbetreuungsstellen - Sales & Service Facilities Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen! from abroad: don’t dial (0) after country code! Vertriebsgebiet Mitte Germany Centre S E R V I C E...
  • Page 91 VisualMotion 9 Troubleshooting Guide Service & Support Europa (West) - Europe (West) vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen from abroad: don’t dial (0) after country code, Italy: dial 0 after country code Austria - Österreich Austria –...
  • Page 92 Service & Support VisualMotion 9 Troubleshooting Guide Europa (Ost) - Europe (East) vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen Bosch -Rexroth, spol.s.r.o.
  • Page 93 VisualMotion 9 Troubleshooting Guide Service & Support Africa, Asia, Australia – incl. Pacific Rim vom Ausland: (0) nach Landeskennziffer weglassen! from abroad: don’t dial (0) after country code! Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth (China) Ltd.
  • Page 94 Service & Support VisualMotion 9 Troubleshooting Guide Nordamerika – North America USA Central Region - Mitte USA Southeast Region - Südwest USA SERVICE-HOTLINE Hauptniederlassung - Headquarters Bosch Rexroth Corporation Bosch Rexroth Corporation Bosch Rexroth Corporation Electric Drives and Controls Electric Drives and Controls...
  • Page 96 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911292841 DOK-VISMOT-VM*-09VRS**-WA02-EN-P...

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