Troubleshooting Guide: SGP 03VRS
DOK-ECODR3-SGP-03VRS**-WA01-EN-P
SYSTEM200
ECODRIVE03/DURADRIVE
Drive for General Automation
with SERCOS and Parallel Interface
Page 1: ...Troubleshooting Guide SGP 03VRS DOK ECODR3 SGP 03VRS WA01 EN P SYSTEM200 ECODRIVE03 DURADRIVE Drive for General Automation with SERCOS and Parallel Interface...
Page 2: ...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...
Page 3: ...l Description Description of all implemented Function based on SERCOS Parameters Parameter Description A description of all parameters used in the firmware Troubleshooting Guide Explanation of the dia...
Page 4: ...About this Documentation ECODR3 SGP 03VRS DOK ECODR3 SGP 03VRS WA01 EN P Notes...
Page 5: ...otective Low Voltage PELV 3 6 3 7 Protection Against Dangerous Movements 3 7 3 8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 3 9 3 9 Protection Against Contact...
Page 6: ...14 F276 Absolute encoder out of allowed window 4 15 F277 Current measurement trim wrong 4 15 F281 Mains fault 4 16 F386 No ready signal from supply module 4 16 F401 Double MST failure shutdown 4 16 F4...
Page 7: ...E259 Command velocity limit active 4 34 E260 Command Current limit active 4 34 E261 Continuous current limit pre warning 4 35 E263 Velocity command value limit S 0 0091 4 35 E264 Target position out...
Page 8: ...S 0 0010 5 6 C112 TNcyc S 0 0001 or TScyc S 0 0002 error 5 6 C113 Relation TNcyc S 0 0001 to TScyc S 0 0002 error 5 7 C114 T4 TScyc S 0 0002 T4min S 0 0005 5 7 C115 T2 too small 5 7 C118 Order of MDT...
Page 9: ...default value erroneous S 0 0021 5 21 C802 Locked with password 5 21 D300 Command adjust commutation 5 21 D301 Drive not ready for commutation command 5 21 D302 Torque Force too small to move 5 21 D3...
Page 10: ...chronization virtual master drive 5 33 A111 Velocity synchronization real master drive 5 33 A112 Phase synchronization encoder 1 virtual master drive 5 34 A113 Phase synchronization encoder 2 virtual...
Page 11: ...agnostic Message Display 0 5 41 Diagnostic Message Display 1 5 41 Diagnostic Message Display 2 5 41 Diagnostic Message Display 3 5 41 Diagnostic Message Display 4 5 41 Diagnostic Message Display 5 5 4...
Page 12: ...DOK ECODR3 SGP 03VRS WA01 EN P 6 Index 6 1 7 Service Support 7 1 7 1 Helpdesk 7 1 7 2 Service Hotline 7 1 7 3 Internet 7 1 7 4 Vor der Kontaktaufnahme Before contacting us 7 1 7 5 Kundenbetreuungsste...
Page 13: ...tion status Construction of a Diagnostic Message A diagnostic message consists of Diagnostic message number Diagnostic text F228 Excessive deviation diagnostic message number diagnostic message Fig 1...
Page 14: ...1516 1718 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 DKC 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 figure...
Page 15: ...e Da0003f1 fh7 communication phase P R I O R I T Y Ready for operation yes no error warning command error command active drive interlock active ready for operation drive ready drive check adjustment d...
Page 16: ...ostic message contains the diagnostic message number followed by the diagnostic text as shown in the example Excessive deviation Fig 1 1 It can be read out with parameter S 0 0095 Diagnostic message a...
Page 17: ...cases the guarantee and the right to payment of damages resulting from inappropriate use are forfeited The user alone carries all responsibility of the risks Before using Rexroth Indramat products mak...
Page 18: ...ecified in the relevant function descriptions The machine user and visualization terminal is designed for control tasks in an installation with multiple axes Available for an application specific use...
Page 19: ...the person or persons responsible for the safe operation of this equipment If the equipment is resold rented or transferred or passed on to others then these safety instructions must be delivered with...
Page 20: ...nts WARNING High electrical voltage due to wrong connections Danger to life or bodily harm by electric shock WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in...
Page 21: ...arts and accessories approved by the manufacturer Follow all safety regulations and requirements for the specific application as practiced in the country of use The equipment is designed for installat...
Page 22: ...instructions for installation in accordance with EMC requirements can be found in the documentation EMC in Drive and Control Systems The machine or installation manufacturer is responsible for complia...
Page 23: ...e even for brief measurements or tests if the ground wire is not permanently connected to the points of the components provided for this purpose Before working with electrical parts with voltage highe...
Page 24: ...conductor connection Prior to startups even for brief tests always connect the protective conductor or connect with ground wire Otherwise high voltages can occur on the housing that lead to electric...
Page 25: ...mponents software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitoring in the drive co...
Page 26: ...ive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start Make sure that the drives are brought to a safe standstill before accessing or enter...
Page 27: ...emakers hearing aids and metal implants are not permitted to enter the following areas Areas in which electrical equipment and parts are mounted being operated or started up Areas in which parts of mo...
Page 28: ...Mounting Under certain conditions incorrect handling and mounting of parts and components may cause injuries CAUTION Risk of injury by incorrect handling Bodily harm caused by crushing shearing cuttin...
Page 29: ...ers corresponding to the information in the respective Project Planning Manual must be provided with pressurized media such as compressed air hydraulic oil cooling fluid and cooling lubricant supplied...
Page 30: ...3 12 Safety Instructions for Electric Drives and Controls ECODRIVE03 SGP 03VRS DOK ECODR3 SGP 03VRS WA01 EN P Notes...
Page 31: ...deceleration Non fatal F2xx In accordance with Best possible deceleration Fig 4 1 Error classes and drive reaction If an error state is detected in the drive then an automatic operation of the drive...
Page 32: ...escription 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 Se...
Page 33: ...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 B...
Page 34: ...rque 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 sys...
Page 35: ...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 t...
Page 36: ...mit value Also see the function description Motor Holding Brake F226 Undervoltage in power section The level of the DC bus voltage is monitored by the drive controller If the DC bus voltage falls belo...
Page 37: ...encoder evaluation a hardware error has been discovered in the encoder interface 1 being used Cause 1 Defective encoder cable 2 Disruptive electro magnetic interference on the encoder cable 3 Defecti...
Page 38: ...eedback 2 type parameter S 0 0117 Resolution of feedback 2 2 Incorrect parameter setting of mechanical system between motor shaft and encoder 2 S 0 0121 Input revolutions of load gear S 0 0122 Output...
Page 39: ...Compare S 0 0091 Bipolar velocity limit value with the velocity in the program and adjust to match it if necessary F242 Encoder 2 failure signal amplitude wrong Cause The analog signals of the measur...
Page 40: ...ls are not monitored Example Ucos 6 5V Usin 6 5V pointerlength 6 5V 6 5V 9 2V 2 2 Remedy 1 Check the measuring system cable 1 Check the measuring system 2 In the case of linear measuring systems check...
Page 41: ...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...
Page 42: ...this error message appears The drive performs the best possible deceleration as selected in the parameter P 0 0119 Criteria for correct encoder signals 1 The pointer addition of the sine and cosine s...
Page 43: ...he travel velocity See function description Activating Encoder Emulation F260 Command current limit shutoff If the current setpoint reaches the peak value then warning E260 Command current limit shuto...
Page 44: ...0 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 Prof...
Page 45: ...isplayed position is correct in relation to the machine zero point Then reset the error 3 Check whether the error is generated again If yes the electronics module is possibly defective and will have t...
Page 46: ...h 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 t...
Page 47: ...nections signal level 5 Switch master on and start up cyclic communications see Control Manual See also the functional description SERCOS Interface Error F403 Invalid communication phase shutdown An i...
Page 48: ...owever cannot be moved Cause The error F407 Error during initialization of master communication is entered if there has no master communication card been plugged in the wrong master communication card...
Page 49: ...ceeded Remedy 1 Check S 0 0049 Positive position limit value 2 Check the software limits of the control system 3 Activate the axis after the error response Procedure Clear the error If the power suppl...
Page 50: ...g 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 Cause The emergency sto...
Page 51: ...the axis into the permissible travel range 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 resu...
Page 52: ...ent cycle time 4 milliseconds 4 Afterwards start the command D300 Commutation adjustment to evaluate once again the optimal parameters See also the functional description Synchronous Motors F822 Encod...
Page 53: ...6 5 V V 9 2 6 5V 6 5V length pointer 2 2 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 sq...
Page 54: ...o shut the drive down in a controlled way when this encoder fails F860 Overcurrent short in power stage The transistor IGBT current has exceeded the allowed maximum peak value The drive is immediately...
Page 55: ...roller 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...
Page 56: ...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 c...
Page 57: ...eafter leads to shutdown of the drive a warning will be generated in the case where this state appears again Warning Classes Warnings can be separated into 2 classes They differentiate if the drive wi...
Page 58: ...3 Defective sensor 4 Broken cable in drive controller Remedy For 1 Connect the sensor to the drive controller and to the motor see project planning specifications for the motor For 2 Exchange the wiri...
Page 59: ...command value interpolator is active if the drive internal interpolation mode the relative drive internal interpolation mode drive controlled homing jog drive halt process block mode is active The E2...
Page 60: ...the employed acceleration Possible acceleration specifications depending from the operation mode are For 1 2 and 6 S 0 0260 Positioning acceleration 0 For 3 S 0 0042 Homing acceleration 0 For 4 S 0 0...
Page 61: ...cription Current Limit E251 Motor overtemp prewarning As soon as the temperature warning threshold 145 C is exceeded the warning E251 is output and the drive keeps on following the command value This...
Page 62: ...hin the position limits Don t input moves which are greater than the maximum allowed position minus the current position In positioning sequence operating mode always set S 0 4006 Command Targetpositi...
Page 63: ...the evaluation for it See also the functional description Drive Controlled Homing E256 Torque limit 0 Cause 1 For protection against mechanical overload the maximum torque can be limited by the S 0 0...
Page 64: ...escription Positioning Block Mode 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 parame...
Page 65: ...duced a continuous current limit early warning is given via a switching threshold which is determined by parameter P 0 0127 Overload warning To deactivate the warning enter P 0 0127 100 into the param...
Page 66: ...brake is covered with a layer of oxidization due to storage 2 brake is covered with oil or grease 3 brake is worn down Remedy of 1 if the warning occurs when the drive enable is removed then start com...
Page 67: ...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...
Page 68: ...ing initialized in communications phase 1 each slave which is to participate in the additional phase uptake must be addressed by the SERCOS master Slaves which are not addressed or which have been set...
Page 69: ...is warning 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 exc...
Page 70: ...es a tolerance for the travel limits See also the functional description Travel Range Limits E831 Position limit reached during jog If the position limit monitor is activated and the drive is IN REFER...
Page 71: ...setting the velocity command to zero A class 1 diagnostic error is not generated The drive will automatically follow command values that lead back into the allowed range Bit 2 of P 0 0090 Travel limit...
Page 72: ...ual See also the functional description Current Limit E886 No ready signal from supply module Cause Input BbN Mains section readyl on the drive controller is at 24V i e the mains section connected is...
Page 73: ...r 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 display where...
Page 74: ...e also the functional description Motor Holding Brake B201 Brake check only with drive enable P 0 0541 B200 command brake monitor was activated and the drive enable was not activated See also the func...
Page 75: ...result in the brake still not reaching the holding torque then the motor holding brake has to be replaced See also the functional description Motor Holding Brake C100 Communication phase 3 transition...
Page 76: ...ata telegram with parameters These parameters are also contained in S 0 0188 List of configurable data in the MDT Note List parameters only allowed in multiplex channel See also the function descripti...
Page 77: ...configurable data record in the AT Remedy set preferred telegram telegram type 0 6 number of configurated parameters in the AT S 0 0016 must be decreased See also the functional description Configurat...
Page 78: ...e set incorrectly for S 0 0009 Beginning address in master data telegram and S 0 0010 Length of master data telegram The length of the record in MDT for the drive plus the starting address in MDT is g...
Page 79: ...dback 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 Remedy...
Page 80: ...wrong 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 Communic...
Page 81: ...annot be read 3 motor feedback not connected Remedy for 1 Enter the type of motor used in parameter P 0 4014 Motor type 2 Check feedback connection If feedback is defective exchange motor See also the...
Page 82: ...in the drive controller Remedy Replace drive controller See also the functional description S 0 0128 C200 Communication phase 4 transition check C213 Position data scaling error Cause The scaling para...
Page 83: ...y data from the drive internal format into the display format or vice versa is outside the allowable range Remedy Checking and correcting the relevant parameters such as S 0 0044 Velocity data scaling...
Page 84: ...e 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 Remedy Check an...
Page 85: ...tem 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 An...
Page 86: ...interface Cause 1 External encoder cable defective 2 Defective feedback 3 Defective measurement system interface Note If this warning occurs in combination with an EnDat feedback device then the feedb...
Page 87: ...ter Description S 0 0128 C200 Communication phase 4 transition check C234 Encoder combination not possible Cause The encoder interface that has been selected in the P 0 0075 Interface Feedback 2 optio...
Page 88: ...r 2 as control encoder Encoder 2 is however being used as master axis encoder or measuring wheel encoder Recovery 1 Only operating modes with motor encoder in the operating mode parameter S 0 0032 S 0...
Page 89: ...on Remedy End the command and turn off the drive enable then the command can be started again See also the functional description Parametrization Mode Operating Mode C402 Only allowed without master...
Page 90: ...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 Remedy Read the value from the S 0 0298 Refe...
Page 91: ...trization Check the correction reference mark detection using command P 0 0014 D500 Command determine marker position C700 Basic load With motors of the MHD MKD and MKE series the controller parameter...
Page 92: ...ion which device and which motor type you have See also the functional description Error Conditions of the Load Default Settings Procedure C800 Default parameter load How to start the command This com...
Page 93: ...tional description Basic parameter block D300 Command adjust commutation A correctly adjusted commutation offset is mandatory for the operation of synchronous motors The D3 message indicates that the...
Page 94: ...ription Determining the commutation offset D303 Drive in control at start of command If the drive controller is in control then it is not possible to execute command P 0 0524 D300 Commutation adjustme...
Page 95: ...eck the encoder Invert the direction of movement of the encoder if necessary 3 Check motor connection to the controller 4 Release mechanical blocking 5 Check brake and control signals The brake must b...
Page 96: ...lt in an error message for class 1 diagnostic caused by blocking the drive with a positive stop is turned off Cause Command D400 Positive stop drive procedure command was activated See also the functi...
Page 97: ...oint procedure command has been activated See also the functional description Drive Controlled Homing D700 Parking axis command The command permits one or more drives of a drive package to be stopped...
Page 98: ...e the drive enable signal is applied WARNING The start of this command can trigger a movement if drive enable and drive start are at the drive The drive conducts autonomous movements within the range...
Page 99: ...omatic control loop setting the load moment of inertia is determined with an oscillation attempt This means that the speed change and the motor current must exceed a minimum value during acceleration...
Page 100: ...r than P 0 0166 lower traversing range Maximum traversing path P 0 0169 Travel distance for autom control loop adjust is less than 6 motor rotations and thus too small to start the automatic control l...
Page 101: ...ion 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 Init...
Page 102: ...ll many parameters are editable too which can no more be edited in communication phase 4 operation mode Before switching to communication phase 4 is possible the command S 0 0128 C200 Communication ph...
Page 103: ...ws the diagnostic message SH Safe Halt A100 Drive in TORQUE control The drive is in the torque control operating mode It follows the torque command value sequence set by the control system See also th...
Page 104: ...closed in the drive by a position encoder The control system only sets the position command value sequence the drive follows the command value without following error lagless Encoder 2 indicates that...
Page 105: ...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 valu...
Page 106: ...master axis position is fixed by the control See also the functional description Operating mode Phase synchronization with virtual master axis A114 Phase synchronization encoder 1 real master drive T...
Page 107: ...position command values are listed in the table and can be accessed using the master axis position The drive complies with the command value with lag distance Encoder 1 means that the position encode...
Page 108: ...ss encoder 2 virt master drive The drive is cam mode The function is derived from the mechanical cam principle This includes a fixed position relationship between master and slave axes The position co...
Page 109: ...sitioning encoder 1 lagless In the S 0 0282 Positioning command parameter the drive receives a distance specification from the controller When bit 0 of the S 0 0346 Positioning command latch parameter...
Page 110: ...mmed up to the value in S 0 0258 Target position In order to get from the current position to the new target position the drive now generates interpolates an internal position command value curve This...
Page 111: ...functional description Positioning Block Mode A208 JOG mode positive The drive moves with a jogging velocity P 0 4030 in the positive direction The motor is turning clockwise when viewing the motor sh...
Page 112: ...clude systems states that are run through independent on parametrization sequence of holding brake delay time P 0 0526 Brake control delay structure of air gap field is asynchronous motor automatic de...
Page 113: ...y 2 Cause The control supply voltage of the encoder is missing Remedy Exchange the hardware Diagnostic Message Display 3 Initializing the parameters from the NovRam and calculating the respective data...
Page 114: ...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 an...
Page 115: ...e is Ready Refer to description A012 Control and power sections ready for operation AC Drive Automatic Check Refer to description A400 Automatic drive check and adjustment AE Drive Error Reaction Refe...
Page 116: ...r to description A000 Communication phase 0 P1 Phase 1 only with SERCOS communication Refer to description A001 Communication phase 1 P2 Phase 2 Refer to description A002 Communication phase 2 P3 Phas...
Page 117: ...r 2 virtual master drive 5 35 Cam shaft lagless encoder 1 real master drive 5 36 Cam shaft lagless encoder 1 virt master drive 5 36 Cam shaft lagless encoder 2 virt master drive 5 36 Cancel reference...
Page 118: ...e active switching not allowed 5 17 Drive controlled homing procedure command 5 18 Drive controlled interpolation encoder 1 5 32 Drive controlled interpolation encoder 2 5 32 Drive controlled interpol...
Page 119: ...drate override S 0 0108 0 4 33 G Gain adjustment failed 5 27 H H1 Display 1 2 Homing of absolute encoder not possible 5 18 Homing only possible with drive enable 5 18 I ID9 Record length 1 length MDT...
Page 120: ...peration status 5 43 Order of MDT configuration wrong 5 7 Overcurrent short in power stage 4 24 Overflow of target position preset memory 4 12 Overvoltage in power stage 4 38 P P0 5 44 P1 5 44 P2 5 44...
Page 121: ...elected process block is not programmed 4 34 Slave not scanned or address 0 4 38 Start requires drive enable 5 26 Stepper position mode 5 38 Stepper position mode lagless 5 38 Switching to parameter m...
Page 122: ...SGP 03VRS DOK ECODR3 SGP 03VRS WA01 EN P W warning classes 4 27 warning diagnostic messages 4 27 Warning Motor temp surveillance defective 4 28 Wrong function of encoder 2 S 0 0022 5 16 Z ZKL1 Error a...
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Page 124: ...er Allee 8 10 80637 M nchen Tel 49 0 89 127 14 0 Fax 49 0 89 127 14 490 Gebiet S dwest Germany South West Bosch Rexroth AG Vertrieb Deutschland VD BI Gesch ftsbereich Rexroth Indramat Regionalzentrum...
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Page 130: ...Printed in Germany 295675...
