Indramat Ecodrive Diagnostic Messages (error codes)

Indramat / Rexroth diagnostic letters F / E

2.1    Error Diagnostic Messages

 UL       Motor Type not Reported

Description:

The settings for current regulation, velocity command, and position loop are stored in the feedback of the motor.  
After powering up, the drive compares the motor type stored in the parameters with the connected motor type. If the
two do not match, the drive remains at this state.

By pressing the S1 button, the drive overwrites its stored parameters with the control loop parameters from the
motor feedback.

Cause:

Motor was exchanged.

The parameter “P-0-4036, contacted motor type” from which the motor type is selected would be loaded..

Remedy:

Command “C700 Basic Load” or press the S1 button.

PL       Default Value of the Parameter Load

Description:

After the exchange of the product (EPROMs), if the parameters have been changed in regards to the old product,
the drive displays “PL”. By pressing the S1 button on the drive or through starting of the „command load basic
parameter”, all the parameters will be erased and restored with the default values.

Cause:

Product  was  exchanged  and  the  number  of  parameters  of  the  new product has changed in regards to the old.

Remedy:

Press the S1 button on the drive controller and all the parameters will be erased and restored with default values
WARNING

With this  procedure  all  parameters  and  process blocks will be overwritten.

F207    Switching to an Uninitialized Operating Mode

Description:

A valid operating mode has not been defined.

In the DKC 01, this error cannot occur because the input of the operating mode will be tested when entered.

Remedy:

Input correct operating mode

F218    Heatsink Over temperature Shutdown

Description:

The  temperature  of  the  DKC  heatsink  will  be  monitored.     If the temperature of the heatsink is too high, the
drive will power down in order to protect against damage.

Cause:

1.         Ambient temperature is too high. The specified operational data is valid up to an ambient temperature of
45°C.

2.         The DKC’s heatsink is dirty.

3.         Air flow is prevented by other assembly parts or a control cabinet panel assembly.

4.         Heatsink blower may be defective.

Remedy:

For 1.   Reduce the ambient temperature; for example, through cooling of the control cabinet.

For 2.   Remove any obstruction or dirt from the heatsink.

For 3.   Install the device vertically and clear a large enough area for proper heatsink ventilation.

For 4.   Exchange drive.

F219    Motor Overtemperature Shutdown

The motor is too hot. The drive controller has issued the warning “E251

Motor Overtemperature Warning for approx. 30 seconds. The drive immediately shuts down.

Cause:

1.   The motor was overloaded. The effective torque demanded from the motor was above its allowable continuous
torque level for too long.

2.  The motor thermal connection is shorted or grounded.

3.   Instability in the velocity loop.

Remedy:

For 1.   Check the installation of the motor. If the system

has been in operation for a long time, check to see if the  operating conditions have changed. (in regards to
pollution, friction, moved components, etc.)

For 2.   Check wires and cables to the motor temperature monitor for wire breaks and short circuits.

For 3.   Check velocity loop parameters.

F220    Bleeder Overtemperature Shut Down

Description:

The regenerated energy from the mechanism of the machine via the motor has exceeded the power capability of
the bleeder resistor.     By exceeding the maximum resistance energy, the drive will shutdown according to the set
error reaction.   Thereby protecting the bleeder from temperature damage.

Cause:

The reflected energy from the machine’s mechanism over the motor is too large.

Remedy:

With too much power —> reduce the acceleration value

With too much energy —> reduce the velocity

Check the drive installation.

F226    Undervoltage Error

Description:

The level of the DC bus voltage will be monitored by  the drive controller. If the DC bus voltage falls below a minimal
threshold, the drive independently shuts down according to the set error reaction.

Cause:

1.         The power source has been interrupted without first switching off the drive enable signal (RF).

2.         Disturbance in the power supply

Remedy:

For 1    Check the logic regarding the activation of the drive within the connected control.

For 2    Check the power supply

The error can be cleared by removing the control enable signal.

F228    Excessive Deviation

Description:

The  drive  could  not  process  the  given  command  value  and  reacted according to the set error reaction.

Cause:

1.         The acceleration ability of the drive was exceeded.

2.         The motor shaft was blocked.

3.         Parameterization error in the drive parameters.

4.         “S-0-0159, Monitoring Window” was parameterized incorrectly

Remedy:

For 1.   Check the Bipolar Torque Limit, S-0-0092 parameter and set it equal to the maximum allowable value for

the application.
For 2.   Check the mechanical system and eliminate any jamming of the motor shaft.

For 3.   Check the drive parameters

For 4.   Parameterize “S-0-0159, Monitoring Window”

 F229    Motor Encoder Error: Quadrant Error

Description:

An encoder signal error was found during the encoder evaluation.

Cause:

1.         Defective encoder cable

2.         Insulation disturbance on the encoder or the encoder cable

3.         Defective drive controller

Remedy:

For 1.   Check the encoder cable and change if necessary. For 2.   Use only insulated motor cable and power
cables

Separate encoder cable from power cables

For 3.   Exchange drive controller

F248    Low Battery Voltage

 Cause:

The connected motor has an absolute encoder.   The absolute position information is stored in the motor feedback.
This memory has a battery powered backup for the electronic circuit.   The battery is designed for a operating life of
10 years. If the battery voltage drops below 2.8 V, this message appears. The absolute encoder function is
preserved for about

2 weeks.

Instructions for Exchanging Batteries

Have the following tools and accessories ready: Torx screwdriver, size 10

Needle nose pliers, torque wrench

If the control voltage of the installed battery is turned off, the absolute position is lost.

The absolute position must be re-established through the process of the command Set Absolute
Measurement.

 F262    Status Outputs Short Circuited

Description:

If the status outputs of the DKC are short circuited, the drive controller will issue an error.

Cause:

Short circuited outputs (X2/6, X2/7, X2/8, X2/9, X2/10, X2/20, X2/21, X2/22)

Remedy:

Eliminate short circuit

F276    Absolute Encoder Error, Position Deviation > P-0-0097

 Description:

When turning off the drive controller with a absolute encoder (multiturn), the actual feedback position will be stored.
When powered up, the absolute  position  given  by  the  encoder  is    compared  to  the  stored position. If  the
deviation  is  larger  than  the  paramaterized “Absolute Encoder-Monitoring Window”,  the  error  “F276,
Absolute  Encoder Error” will appear and be given to the control system.

Cause:

1.         Turning on for the first time (invalid stored position).

2.         The motor was moved further than allowed by the parameter in the absolute encoder monitoring window, P-
0-0097, while it was turned off.

3.         Incorrect position initialization

Remedy:

For 1.   Press S1 to reset the error and set the absolute position.

For 2.   The motor was moved while turned off and sits outside of its permissible position. Check to see if the
displayed position is corrects in relation to the machine zero point. Reset subsequent errors.
For 3.   An accident may occur by accidental shaft movement.

Check absolute position information. A feedback defect is present if the absolute position information is false. The
motor should be exchanged and sent to the INDRAMAT Customer Service .

see also the “Absolute Encoder Monitoring” function description

F630    Travel Limit Value Exceeded

Description:

The drive controller has been given a position command value which lies outside of the allowable travel area. The
drive controller has been instructed to give an error when the travel range has been exceeded.

Exceeding the travel area as an error:

The drive controller brakes with maximum torque. After it has been stopped the drive controller shifts to torque free
operation.  After the error has been cleared, the drive can be once again activated and moved into the allowable
travel area.

Cause:

Position feedback value lies outside of the travel area

Remedy:

1.         Input a command value in the direction of the travel area.

2.         Shift the position limits

3.         Turn off the position limit monitor

(when displaying the position data in modulo format).

F644    Travel Limit Switch Detected

 Description:

The motor was moved and tripped one of the two travel limit switches. The control drive has been instructed to give
an error when the travel range has been exceeded.

Exceeding the travel area as an error:

The drive brakes with maximum torque. Subsequently, the drive goes into moment free operation. After the error
has been cleared, the drive can be activated again and moved into the allowable travel area.
Cause:

One of the travel limit switches was tripped.

Remedy:

1.         Input a command value in the direction of the travel area.

2.         Move the travel limit switches, if necessary.

3.         Turn off the position limit monitor (when displaying the position data in modulo format).

F822    Motor Encoder Failure: Signal too Small

Description:

The motor encoder signals are monitored. If the signal amplitudes as measured via AK1 and AK2 are outside of the
allowable region between Uss = 12.0V and Uss = 18.0 V, then the error message appears. The drive becomes
torque-free and an optional brake is immediately activated.

Cause:

1.         Defective feedback cable.

2.         Defective feedback.

Remedy:

For 1.   Check the feedback cable

Lay the power cables separate from the feedback cable. The cable shield must be connected to the drive controller.
(see project reference of the drive control).

F860  Overcurrent: Short in Powerstage

Description:

The current in the power transistor bridge has exceeded twice the peak current of the drive.  As a result, the drive
will be immediately turned off. The drive has switched to a torque-free condition. An optional brake is immediately
activated.

Cause:

1.         Short circuit in the motor cable.

3.         The current regulator was incorrectly parameterized.

Remedy:

For 1.   Check the motor cable for a short. For 2.   Exchange drive controller.

For 3.   The current regulator parameters should not deviate from the default values of the feedback.

F870    +24 V Error

Description:

The  DKC  requires a  24V  control  voltage.  If  the  maximum  allowable tolerance of  +  or  –  20%  is  exceeded,
then  the  drive  is  immediately switched to torque free operation. An optional brake is activated.

Cause:

Disturbance or overload of the 24 V supply voltage.   Measure control voltages.

Remedy:

Check wiring and/or replace power supply module.

F873    Power Supply Driver Stage Fault

Description:

The voltage supply of the driver stage is monitored and if the voltage is too low then the drive is turned off.

Cause:

Voltage supply of the driver stage is too low

Remedy:

Exchange drive controller

F878    Velocity Loop Error

Description:

The velocity loop monitor will appear when the following conditions occur simultaneously:

The current command value is at the peak current limit

The velocity control deviation does not become smaller over a time frame of 20ms.

Cause:

1.         Motor cable is connected incorrectly.

2.         Defective controller section of the drive.

3.         Defective feedback.

4.         Velocity loop paramaterized incorrectly.

Remedy:

For 1.   Check motor cable connection. For 2.   Exchange drive controller.

For 3.   Exchange motor

For 4.   Check velocity controller to see if it is within operational parameters.

F879    Velocity Limit Value Exceeded (S-0-0092)

 Description:

The actual velocity is monitored in torque regulation mode. This error is generated if the programmed velocity in the
“S-0-0091, bipolar velocity limit value” parameter is exceeded by 1.25 times or a maximum of 100 Rpm.

Cause:

The load torque was smaller or larger than the torque command value for too long a time. This leads to an increase
in the actual velocity up to the maximum possible motor velocity.

Remedy:

Check the primary control loop.

see also the “Velocity Monitoring in Torque Control” function description

F895    4 kHz Signal Error

Description:
The 4 kHz signal is synchronized with the software processing for creation of   the   resolver   signal.   This   error 
message   is   created   when synchronization occurs improperly.

Cause:

1.         The synchronization of the resolver controller voltage is invalid in regards to the software.

2.         The error can be produced through an electrical discharge.

Remedy:

For 1.   Exchange drive controller and return for testing.

For 2.   Power down and then on. If this in not successful; exchange drive controller.

2.2    Indramat Ecodrive DKC 1.1 / DKC 11.1 Warning

Description:

The temperature of the heatsink in the drive controller has reached the maximum allowable temperature. Within a
time frame of 30 seconds, the drive follows the command value input. Consequently, there exists the possibility to
shut down the motor with the control so that it remains true to the process. (For example close the operation, leave
the collision area, etc.) After 30 seconds, the parameter “Best Possible Deceleration, P-0-

0119” set reaction appears during operation.

Cause:

1.         Deficiency of the drive’s internal blower.

2.         Deficiency of the control cabinet’s climate control.

3.         Incorrect control cabinet dimensioning regarding the head ventilation.

Remedy:

For 1.   If the blower fails exchange the drive controller. For 2.   Install climitization feature to the cabinet.

For 3.   Check the dimensions of the control cabinet.

E251   Motor Overtemperature Warning

The motor is too hot. Within in a time frame of 30 seconds, the drive follows the command value input.
Consequently, there exists the possibility to shut down the motor with the control so that it remains true to the
process. (For example close operation, leave the collision area, etc.). After 30  seconds, the  parameter “Best
Possible Deceleration, P-0-0119” set reaction will appear during operation.

Cause:

The motor became overloaded. The effective torque required of the motor was above the allowable standstill
continuous torque for too long.

Remedy:

Check the installation of the motor. For systems which have been in use for a long time, check to see if the drive
conditions have changed (in regards to pollution, friction, components which have been moved, etc).

E252   Bleeder Overtemperature Warning

 Description:

(see cause)

Cause:

The dampening resistance in the DKC is balanced through the energy that   is   reflected   from   the   motor 
(about   90%).   The   bleeder overtemperature warning shows that an overload of the bleeder is expected with
continued increasing feedback energy.

Remedy:

Reduce acceleration value or velocity. Check the drive installation.

E253   Target Position Out of Range

Description:

If a position is entered which would exceed the target position, it will not be accepted. With “command controlled
operation”, the drive will not move.

Cause:

1.         Position limit value monitor was activated

3.         In  the  “Command  Controlled  Operation”  operating  mode,  the target position of the selected process
block will be checked to see if it lies within the travel range.

The possible travel range is defined through the two parameters “S-0-0049 Position Limit Positive,”  and “S-0-
0050,  Position Limit Nega- tive.”

The E253 message will be generated if the target position lies outside of the travel range.

Remedy:

For 1.   Deactivate the position limit monitor

For 2.   Check the  entered  S-0-0258,  target  position  and  correct  if necessary.

For 3.   Check the target position of the process block. Add the relative path of travel to the actual position.

Additionally, check the position limit value.

E254   Drive not Referenced

Description:

If “Absolute Positioning Commands” are selected while in “Command Controlled Operation” the control drive must
be homed. If this is not the case, an absolute position cannot be reached. The drive rejects this positioning
command and stops. The warning will be given.

Cause:

Absolute positioning command was selected without the drive being referenced.

Remedy:

1.         Reference the drive

2.         Select “Relative Positioning Command”

 E255   Feedrate-Override(S-0-0108) = 0

Description:
The transversing velocity can be changed while jogging, homing and while in positioning operation with the “S-0-
0108, Feed rate Override” parameter. Since the  drive  controller  cannot  follow  command  values which do not
move, the warning will be given if the value of this parameter is 0.

Cause:

1.         Feed rate-override is set to zero.

2.         The  “Feed rate Override Via  Analog  Output”  field  is  activated and the voltage there is 0V.

Remedy:

For 1.   Set  the  S-0-0108  parameter  on  the  correct  value  for  the application.

For 2.   Deactivate the field or establish a voltage larger than 0V.

E256   Torque Limit Value = 0

Cause:

1.         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 command value which has been entered.

2.         Torque  reduction  is  set  through  an  analog  channel  and  the established current amounts to 10 V.

Remedy:

For 1.   Set the torque limit to a value larger than 0.

For 2.   Establish the analog voltage so that it is smaller than 10V.

E257   Continuous Current Limiting Active

 Description:

The drive controller sets the peak current available for 400ms. Thereafter, the continuous current limit becomes
active and dynamically limits the peak current to the continuous current.

Cause:

More continuous torque was required than was available.

Remedy:
1.         Check the drive installation.

2.    Check the installation of the motor. For systems which have been in use for a long time, check to see if the
drive conditions have changed

E258   Selected Process Block is not Programmed

Cause:

A positioning block was selected for which there is no set target position, positioning velocity, etc.

Remedy:

Select another positioning block or enter the required data.

E259   Command Velocity Limit Active

Description:

The velocity command value is limited to the value set in the “S-0-0091, Bipolar Velocity Limit” parameter when
in  the position and  velocity control operating modes. This warning is given if the value in the “S-0-0036, Velocity
Command Value” parameter reaches this limit.

Cause:

“S-0-0091, Bipolar Velocity Limit” parameter was set too low.

Remedy:

In normal operation, set the “S-0-0091, Bipolar Velocity Limit”

parameter to a value 10% higher than the NC operation velocity.

E264   Target Position not Representable

Cause:

When using the operating mode “command controlled operation, the target position of the selected additive process
block will be verified to see if it lies within the represented range.

Remedy:

1.         Check the target position and correct if necessary.

2.         Select the position data display channel in modulo format.

Cause:

1.         The mechanical system energy reflected via the motor was so large for a moment that it could not be
completely converted to heat by the bleeder.  As a result, the DC Bus voltage rose above the maximum allowable
value. The motor is then switched to torque free operation. If the DC Bus voltage falls below the maximum allowable
value, the controller will be turned on again.

2.         DC Bus voltage is too high

Remedy:

For 1.   Reduce the acceleration value and check the drive controller layout if necessary.

Install an auxiliary bleeder, if necessary.

For 2.   Check the supply voltage, if necessary.

E830   Position Limit Value Exceeded

Description:

A position command was given to the drive which lies outside of the allowable travel area. The reaction of the drive
regarding the travel area being exceeded would be selected as a warning.

Travel Area being exceeded as a warning:

The drive brakes with maximum torque until it is standing still and stays at that brake point in the activated state. If
command values are given that lead into the allowable travel area, the drive will once again follow these commands
and the warning will be disappear.

E831   Position Limit Value Reached During Jogging

Description:

If the position limit value monitor is activated and the drive is „IN REFERENCE”, then it will be positioned during
movement in the jogging operation on the position limit value. If the drive is positioned on the position limit value or
on the other side of the position limit value, then the drive stays still and signals „”position limit value reached during
jogging.”

Remedy:

1.         Move the motor back within the allowable travel area with the jog function.
2.         Turn off the position limit value monitor.

 E844   Travel Limit Switch Activated

Description:

The drive was moved to one of the two travel limit switches. The reaction of the drive regarding the travel area
being exceeded would be selected as a warning.

Exceeding the Travel Area as a Warning: The drive brakes with maximum torque until it reaches a standstill and
stays in an activated condition at this position. If command values are entered which lead into the allowable travel
area, the drive will once again follow these commands and the warning will disappear.