REXROTH SERVO DRIVES PROGRAMMING:

Page 1 of 56
 TABLE OF CONTENT

TABLE OF CONTENT Pages 1-2

1.0 REXROTH SERVO DRIVES SET-UP/CONFIGURATION Pages 3 - 5

2.0 ESTABLISHING COMMUNICATION

 To set up Laptop IP Address Page 6

 To Ping the Drive Page 7

3.0 START REXROTH INDRAWORKS SOFTWARE Page 8

 Start new Project Page 9 - 15

4.0 LOAD DEFAULT DRIVE PARAMETERS Page 16 – 20

5.0 SET UP INDIVIDUAL SERVO MOTOR PARAMETERS Page 21

 Set up Real-Time Input (AT) Parameters Page 22

 Set up Real-time Output (MDT) Parameters Page 23

 Motor, Brake, measuring System Settings Page 24 - 29

6.0 SET SCALING / MECHANICAL SYSTEM Page 30

 Scaling / Units Extended Page 31

 Mechanical Gear Page 32

 Motion Limit Values Page 33

7.0 SETTING LIMITS AND HOMING Page 34

 Torque / Force Limits Page 35

8.0 DRIVE AND AXIS CONTROL

 Gains Page 36

 Axis Control Settings Page 37 - 38

Page 2 of 56
Table of content cont.

9.0 OPERATION MODE / DRIVE HALT

 Typical Operational Modes Page 39

 Clamp Operational Modes Page 39

10.0 SAFETY SETTINGS Page 40

11.0 SAVING DRIVE PARAMETERS Page 41

12.0 LOADING PARAMETERS IN MMC CARD Page 42

APPENDIX Page 43

 Re-homing After Power Up Page 43 - 44

 Scaling Data From Mechanical Engineering Page 45 - 46

 Power Up/Down Sequence PAGES 47 - 48

 Drive Power Supply Display status Codes PAGE 49

 Troubleshooting PAGES 51 – 54

 Control Words PAGES 55 - 56

Page 3 of 56
1.0 Rexroth Servo drives set-up/configuration:

SET UP ENGINEERING IP ADDRESS:

 To initially communicate with the servo drive, set the engineering IP address manually
through the drive keypad. Access parameter 2.3.7 to enter the IP address used to allow the
computer the ability to communicate with the Servo Drive. The procedure is a follows:

PRESS AND HOLD THE “ESC” AND “ENTER” BUTTON AT

THE SAME TIME UNTIL THE DISPLAY STARTS TO BLINK
(ABOUT 8 SECONDS) . When the display blinks then the
Drive will allow you to change parameters>

Page 4 of 56
With the display blinking the servo drive indicates it is in program mode. Access the parameter below to
enter the IP Address.

 Parameter needed to enter engineering IP address is parameter 2.3.7

 Press the up “arrow” button to access 2. Then hit “enter”
 Press the up “arrow” button to access 3. Then hit “enter”
 Press the up “arrow” button to access 7. Then hit “enter”
 NOW ENTER THE IP ADDRESS = 192.168.1.xxx
 Cycle power for new address to take effect

Page 5 of 56
2.0 ESTABLISHING COMMUNICATION:

TO SET UP LAPTOP IP ADDRESS:

Typical “Internet Protocol Properties” for communication to Drive.

Page 6 of 56
 TO PING THE DRIVE:

Goto Control Panel/Run. Then enter “cmd”.

Type PING then enter the drive Ethernet address and hit enter.

Page 7 of 56
3.0 START REXROTH INDRAWORKS SOFTWARE:

 Use latest version 9.12.331.0. From Windows Start Menu See path below:

Page 8 of 56
Start a new project:

Enter project name:

Page 9 of 56
 FROM REXROTH SOFTWARE, IN THE PROJECTS MENU, SCAN FOR DEVICES;

Page 10 of 56
 Choose “IndraDrive (Ethernet)”:

Page 11 of 56
 Enter IP address of Drives to be Scanned:

Page 12 of 56
Drives that are online will show up in the dialog box below:

Project screen with showing all drives in the system:

Page 13 of 56
To get online with a particular drive, highlight the particular drive desired and do the following:

Right click on the drive and select “Switch Online”.

To make edits Online find the “Start Parameterization Level 1” option and click. This option becomes
visible when Online.

To make edits Offline click on “Start Offline Parameterization” option.

Page 14 of 56
 BLACK-
OFFLINE

BLUE-
ONLINE

RED-ONLINE
FAULTED

FA

DRIVE STATUS SCREEN AS SHOWN ABOVE: F

The color of the drive names above indicates the status of the drive. The COLOR codes are as follows:

BLACK – Drive is OFFLINE.

BLUE – Drive is ONLINE HAPPY with no FAULTS.
RED – Drive is ONLINE and a FAULT EXISTS.
ORANGE – Drive is in OFFLINE PARAMETERIZATION mode (not shown above).

Page 15 of 56
4.0 LOAD DEFAULT DRIVE PARAMETERS:

This is done to clear the memory to assure a clean start on the project

Page 16 of 56
LOAD DRIVE PARAMETERS FROM EXISTING PROJECT:

Set System Communication Protocol from “Master Communication” project tree:

Page 17 of 56
 Set to EtherNet/IP.

Engineering IP address should be set from Key Pad on front of drive:

Page 18 of 56
Set Communication to PLC IP Address from “Master Communication” project tree:

Enter IP address for Servo Drive.

Set Language to English. Parameter P265 (or S265) is where desired language is set:

Value = 1, for ENGLISH

Page 19 of 56
Set SERVO Node to be the last 3 digits of IP ADDRESS. Change Parameter P4025 for SERVO Node:

Enter node Number in VALUE field.

NOW POWER DOWN SERVO AND THEN POWER BACK

UP SO THAT COMMUNICATION IP ADDRESS WILL BE
SAVED AND THE ETHERNET PARAMETERS WILL BE
VISIBLE!!!

Page 20 of 56
SET UP INDIVIDUAL SERVO MOTOR PARAMETERS, COMMUNICATIONS, OPERATION AND MOTOR
DATA :

Open Axis:

Open Master Communication - Axis:

Page 21 of 56
SET UP REAL-TIME INPUT (AT) PARAMETERS:

These are typical communication parameters (Servo Drive to PLC).

These parameters are for Cuber Clamps (Servo Drive to PLC).

Page 22 of 56
SET UP REAL-TIME OUTPUT (MDT) PARAMETERS:

These are typical communication parameters (PLC to Servo Drive).

These parameters are for Cuber Clamps (PLC to Servo Drive).

Page 23 of 56
MOTOR, BRAKE, MEASURING SYSTEM SETTINGS:

Motor:

W/Rexroth motor this information will automatically be read from motor by the servo drive:

W/Non Rexroth motor this information is entered manually (Clamps):

Motor Temperature Monitoring:

Page 24 of 56
W/Rexroth motor this information will automatically be read from motor by the servo drive:

W/Non Rexroth motor this information is entered manually (Clamps):

Page 25 of 56
Brake:

W/Rexroth motor this information will automatically be read from motor by the servo drive:

W/Non Rexroth motor this information is entered manually (Clamps):

Page 26 of 56
Setting of Motor Encoder:

W/Rexroth motor this information will automatically be read from motor by the servo drive:

W/Non Rexroth motor this information is entered manually (Clamps):

Page 27 of 56
Data Reference Motor Encoder:

W/Rexroth motor this information will automatically be read from motor by the servo drive:

W/Non Rexroth motor this information is entered manually (Clamps):

Page 28 of 56
SET SCALING/MECHNICAL SYSTEM:

Scaling/Units:

Typical Scaling:

Set “Negation of position” to “yes” if there is a need to reverse travel direction.

Scaling for Rotation Axis:

Absolute for non resettable positioning

Modulo for resettable positioning; used in applications like Splitter Flight Bar where there is infinite
travel in one direction.

Page 29 of 56
Scaling/Units Extended:

Typical Extended Scaling:

Change from mm/min to mm/s.

Access parameter S-383 for actual motor temperature.

Page 30 of 56
Scaling/Units Extended:

Rotation Axis Extended Scaling:

Mechanical Gear: mm to rpm mm to rad/s2

Carriage Axis (values set using data provided by mechanical engineering):

Page 31 of 56
Mechanical Gear:

Hoist Axis (values set using data provided by mechanical engineering):

Clamp Axis (values set using data provided by mechanical engineering):

Set to twice expected max travel. How far load travels w/on rev of gear box

If ratio is not a whole number : With a ration of 3.3 to 1 load 33 in n1 and 10 in n2

Page 32 of 56
LIMIT VALUES:

Motion Limit Values:

Typical motion limits:

Typically “Negative position limit value” will be -10. This is the Home position -10.

“Positive position limit value” is determined by moving to the furthest forward position and recording
the Actual Position. The axis must be “Homed” before setting Positive Limits for the Actual Position to
display the correct value. Drive must be “Disabled” for changes to take effect.

To move to Positive and Negative position for Setting Limits and Homing from a Laptop see next page.

Bipolar jerk limit vale = S ramp

Page 33 of 56
SETTING LIMITS AND HOMING (from Laptop):

This screen is used to move the axis to the Positive and Negative (Home) Position:

Engineering Port To take command of Axis click “Start Easy Startup Mode” then click “Enable”.

HOMING (from Laptop):

With the Axis in the “Home” Position click “Drive Controlled Homing”.

Page 34 of 56
Torque/Force Limits:

Typical Force Limits:

Cuber Clamp Force Limits:

Value adjusted for Clamp Cuber Clamp.

*Adjust Hoist Torque/Force limits as low as possible for down travel to limit force available during crash

Page 35 of 56
DRIVE CONTROL / AXIS CONTROL:

GAINS:

Velocity Loop Proportional Gain: The lower the number the tighter the control. Typically proper setting
is derived by adjusting the number downward until oscillation is detected then increase the number
until oscillation is no longer seen.

Position Loop Proportional Gain: Higher the number the tighter the control. Typically proper setting is
derived by adjusting the number upwards until oscillation is detected then lower the number until
oscillation is no longer seen.

Page 36 of 56
Axis Control Settings:

Values adjusted for Clamp Cuber Rotation.

Values adjusted for Clamp Cuber Carriage.

Page 37 of 56
Axis Control Settings:

Values adjusted for Clamp Cuber Clamp.

Values adjusted for Clamp Cuber Hoist.

Page 38 of 56
OPERATIONAL MODE / DRIVE HALT:

Typical Operational Modes (controlled positioning = Jog, internal interpolation = auto):

Clamp Operational Modes:

Page 39 of 56
SAFETY SETTINGS:

Check F8 error box on Carriages.

CATION: Decel must be set steep enough to stop axis before safety relay has timed out! Removing
power to the safety inputs before the axis has stopped allows the axis to free-wheel to the end of
travel.

Page 40 of 56
SAVING DRIVE PARAMETERS:

DESTINATION & FILENAME

ALL
PARAMETERS

Page 41 of 56
LOADING PARAMETERS IN MMC CARD:

Page 42 of 56
APPENDIX:

A: Re-homing After Power Up:

Here is the procedure for sending the actual position to the clamp motors (retained in the PLC), after
power-up:

1) Add parameter S-0-0052 to the Ethernet I/P ring. This value will be written to the actual
position when you perform the home command on this axis (P-0-4077, bit 2, control word).

2) Uncheck all the “Positive stop as zero switch” box. When homing ends select “Stop”.

Page 43 of 56
Page 44 of 56
B: Scaling Data From Mechanical Engineering:

Note the new Rotate data based on 114 gear teeth/24 pinion teeth:

S Morris Mechanical Data

Axis Parameter Value Unit

S-0-0278, Maximum Travel Range 10,000 mm

S-0-0123, Feed constant k 500 mm/rev

Carriage
S-0-0121, Input rev of load gear n1 7

S-0-0122, Output rev of load gear n2 1

S-0-0278, Maximum Travel Range 10,000 mm

S-0-0123, Feed constant k 500 mm/rev

Consolidator Carriage
S-0-0121, Input rev of load gear n1 10

S-0-0122, Output rev of load gear n2 1

S-0-0278, Maximum Travel Range 3000 mm

S-0-0123, Feed constant k 500 mm/rev

Hoist
S-0-0121, Input rev of load gear n1 30

S-0-0122, Output rev of load gear n2 1

S-0-0278, Maximum Travel Range 200 Deg

NO FEED CONSTANT - Rotary System

Rotate - Rotary Application S-0-0121, Input rev of load gear n1 3420

S-0-0122, Output rev of load gear n2 24

S-0-0278, Maximum Travel Range 1000 mm

Clamps
S-0-0123, Feed constant k 6 mm/rev

Page 45 of 56
 S-0-0121, Input rev of load gear n1 1

S-0-0122, Output rev of load gear n2 1

S-0-0278, Maximum Travel Range 10000 mm

S-0-0123, Feed constant k 480 mm/rev

Marshalling Pusher
S-0-0121, Input rev of load gear n1 20

S-0-0122, Output rev of load gear n2 1

Page 46 of 56
C: POWER UP/DOWN SEQUENCE:

To Enable Cuber Servos

From HMI (Panel View) “Servo Drive Screen”:

Press “Clear Errors” template

Press “Enable Power Supply” template

Press template for each axis (Carriage, Hoist, ect.)

Page 47 of 56
Page 48 of 56
Page 49 of 56
POWER SUPPLY DISPLAY STATUS CODES:

Bb = no errors (ready for “Power On”)

Lb = “Power On” (buss charged)

DRIVE DISPLAY STATUS CODES:

Bb = “Control Voltage On” and no errors (ready for “Power On”).

Ab = “Control Voltage On” and “Power On” (ready for “Drive Enable”).

AF = “Control Voltage On”, “Power On”, and “Drive Enabled” w/Torque waiting for command.

STO = “Safe Torque Off” is enabled (no motion of axis allowed).

DEFINITIONS:

“Control Voltage On” status is achieved by applying 24VDC on terminals 24V and 0V of Power Supply
and Servo Drive control section.

“Power On” status is achieved by closing the circuit between terminals 6 and 7 of terminal group X32 on
the Servo Drive control section.

“Drive Enable” status is turned on when the PLC writes to the Servo Drive control word P-0-4077 and
sets bit 15 to equal 1.

“Safe Torque Off” status is achieved by opening the circuit to terminal 3 and closing the circuit to
terminal 2 of terminal group X41 on the Servo Drive control section.

Page 50 of 56
D: TROUBLE SHOOTING

To monitor Drive Status click on “Axis Status”.

Axis Status:

Page 51 of 56
Typical Drive Fault Codes and causes:

F2060 – “Under Voltage In Power Section”: Typically caused by enabling Drives with Power Section off or
with 3 Phase Supply off.

F2028 – “Excessive Deviation”: Accel or Decel set to high or mechanical problem.

F2174 – “Loss of Motor Encoder”: Clear position status, then set absolute measure (home), then cycle
power.

F2802 = unable to “Power On” due to drive error

F3131 – “Error when checking Input Signals”: Check Safety wiring at Drive Inputs X41.

F4005 – “Error during phase regression”: Ethernet IP error.

F4009 – “Bus Failure”

F6029 – “Positive Position Limit Exceeded”: The axis has traveled beyond programmed limits. Clear error
then Enable Power Supply, then enable the Drive, then give a command value that calls for a move to a
location that is within programmed travel limits.

F6030 – “Negative Position Limit Exceeded”: The axis has traveled beyond programmed limits. Clear
error then Enable Power Supply, then enable the Drive, then give a command value that calls for a move
to a location that is within programmed travel limits.

F8022 – “Encoder Signal Incorrect”: The encoder cable may be defective. Less likely cause is defective
Drive Control Section. Move axis with caution after this fault as the axis may need to be re-homed. This
error (after the problem has been corrected) must be cleared in “Parameter Mode” from the Indaworks
software or from the Drive Keypad with the Power Supply Off.

F8023 – “Mechanical Link W/Encoder”: Caused by loose of connection between Encoder and Drive
Control Section. Power Supply must be Off to clear error after problem has been corrected.

F8027 – “Drive Enable With Safe Off”: Caused by attempting to enable drive with Safe Off mode
enabled.

F8060 – “Over current in Power Section”: Typically caused by short in motor or motor cable. If motor
and cable are OK Drive Control Unit may be defective. Test by disconnecting motor and see if fault
clears. If not disconnect cable from Drive Power Section (A1,A2,A3) and see if fault clears.

F8260 – “Torque/Force command value limit active”: Can be caused by Torque/Force limits set to low or
the axis has crashed into something.

REFER TO INDRAWORKS HELP FOR ADDITIONAL FAULT CODES INFORMATION AS SHOWN ON NEXT
PAGE:

Page 52 of 56
Choose “Troubleshooting Guide”:

Choose “Error Messages”:

Page 53 of 56
Choose appropriate category below:

Page 54 of 56
E: CONTROL WORD DEFINITIONS

P-0-4077, Field bus: control word (PLC to Drive)

Page 55 of 56
P-0-4078, Field bus: status word (Drive to PLC)

Page 56 of 56