engineering

mannesmann
Rexroth

DIAX 03
ELS-05VRS

DKR DDS

DIAX03
Drive With Electric Gear
Function
Trouble Shooting Guide: ELS 05VRS

DOK-DIAX03-ELS-05VRS**-WAR1-EN-P

276241 Indramat
About this documentation DIAX03 Drive With Electric Gear Function

Titel DIAX03 Drive With Electric Gear Function

Type of documentation Trouble Shooting Guide

Documentation Type DOK-DIAX03-ELS-05VRS**-WAR1-EN-P

interner Ablagevermerk • Mappe 50-05V / Register 9

• Grundlage: 05V11
• 209-0072-4324-01

What is the purpose of this This document is designed to assist maintenance personnel in identifying
documentation? errors with the machinery
• help in understanding error messages
• help in finding the causes of errors
• describe the procedure for trouble shooting
• simplify the process of establishing contact with the INDRAMAT
Customer service department

Use of this documentation This documentation is meant as a switch board panel for the machine
manufacturer.

Änderungsverlauf Document identification of Release Remarks

previous and present output Date
DOK-DIAX03-ELS-05VRS**-WAR1-EN-P 10.97 First edition

Copyright  INDRAMAT GmbH, 1998

Copying this document, and giving it to others or the use or
communication of the contents there of without express authority, are
forbidden. Offenders are liable for the payment of demage. All ritghts are
reserved in the event of the grant of a patent or the registration of a utility
model or design. (DIN 34-1)

Validity All rights are reserved with respect to the content of this documentation
and the availabillity of the product.

Published by INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telefon 09352/40-0 • Tx 689421 • Fax 09352/40-4885

Dept. END (KT/HP)

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Contents I

Contents
1 Diagnostic Message Descriptions 1-1
1.1 Overview of the diagnostic message descriptions ............................................................................... 1-1
Diagnostic Message Types ........................................................................................................... 1-1
Construction of a diagnostic message .......................................................................................... 1-1

2 Description of diagnostic letters F... and E... 2-1

2.1 Error diagnostic messages F... ............................................................................................................ 2-1
F207 Switching to uninitialized operation mode ............................................................................ 2-2
F208 UL The motor type has changed.......................................................................................... 2-2
F209 PL Load parameter default values ....................................................................................... 2-3
F218 Amplifier overtemp. shutdown.............................................................................................. 2-3
F219 Motor overtemp. shutdown .................................................................................................. 2-3
F221 Error Motor temp. surveillance defective ............................................................................. 2-4
F228 Excessive deviation.............................................................................................................. 2-4
F229 Motor encoder failure: quadrant error .................................................................................. 2-5
F233 External power supply error ................................................................................................. 2-5
F236 Excessive position feedback difference............................................................................... 2-6
F237 Excessive position command difference.............................................................................. 2-6
F242 External encoder failure: signal too small ............................................................................ 2-7
F245 External encoder failure: quadrant error .............................................................................. 2-8
F248 Low battery voltage .............................................................................................................. 2-8
F249 Master drive encoder failure: signal too small...................................................................... 2-9
F252 Master drive encoder failure: quadrant error........................................................................ 2-9
F253 Incr. encoder emulator: pulse frequency too high.............................................................. 2-10
F254 Incr. encoder emulator: hardware fault .............................................................................. 2-10
F255 External power supply DAE 02 error.................................................................................. 2-10
F267 Erroneous internal hardware synchronization.................................................................... 2-10
F268 Brake fault.......................................................................................................................... 2-10
F270 Error power supply home switch ........................................................................................ 2-11
F271 Error power supply travel limit switch................................................................................. 2-11
F272 Error power supply probe input .......................................................................................... 2-12
F273 Error power supply E-Stop ................................................................................................. 2-12
F276 Absolute encoder out of allowed window ........................................................................... 2-12
F280 Short circuit to earth........................................................................................................... 2-13
F281 Mains fault.......................................................................................................................... 2-13
F282 Phase loss fault.................................................................................................................. 2-13
F283 Line voltage fault ................................................................................................................ 2-13
F284 Main contactor off, low voltage .......................................................................................... 2-13
F401 Double MST error shutdown .............................................................................................. 2-14

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
II Contents DIAX03 Drive With Electric Gear Function

F402 Double MDT error shutdown.............................................................................................. 2-14

F403 Invalid communication phase shutdown ............................................................................ 2-14
F404 Error during phase progression ......................................................................................... 2-14
F405 Error during phase regression ........................................................................................... 2-15
F406 Phase switching without ready signal ................................................................................ 2-15
F434 Emergency-Stop ................................................................................................................ 2-15
F629 Positive travel limit exceeded............................................................................................. 2-15
F630 Negative travel limit exceeded ........................................................................................... 2-16
F634 Emergency-Stop ................................................................................................................ 2-16
F643 Positive travel limit switch detected.................................................................................... 2-16
F644 Negative travel limit switch detected .................................................................................. 2-17
F820 Bleeder overload ................................................................................................................ 2-17
F822 Motor encoder failure: signal too small .............................................................................. 2-17
F827 Drive interlock while drive activated ................................................................................... 2-18
F860 Overcurrent: short in power stage...................................................................................... 2-19
F861 Overcurrent: short to ground.............................................................................................. 2-19
F869 +/-15Volt DC error.............................................................................................................. 2-19
F870 +24Volt DC error ................................................................................................................ 2-19
F871 +10Volt DC error ................................................................................................................ 2-20
F878 Velocity loop error .............................................................................................................. 2-20
F879 Velocity limit S-0-0091 exceeded....................................................................................... 2-20
F889 Regeneration overcurrent .................................................................................................. 2-21
F890 Processor fault power supply unit ...................................................................................... 2-21
F891 Power stage fault ............................................................................................................... 2-21
F892 Wrong code of current measuring unit .............................................................................. 2-21
F893 No regenerating current to mains ...................................................................................... 2-21
F894 Checksum error ................................................................................................................. 2-22
2.2 Warning Diagnostic Messages E....................................................................................................... 2-23
E201 No mains connected .......................................................................................................... 2-23
E202 Not ready for power on ...................................................................................................... 2-23
E219 Warning Drive temp. surveillance defective ...................................................................... 2-23
E221 Warning Motor temp. surveillance defective...................................................................... 2-24
E225 Motor overload ................................................................................................................... 2-24
E226 Undervoltage in power section........................................................................................... 2-24
E247 Interpolation velocity = 0 .................................................................................................... 2-25
E248 Interpolation acceleration = 0............................................................................................. 2-25
E249 Positioning velocity S-0-0259 > S-0-0091.......................................................................... 2-25
E250 Drive overtemp. prewarning............................................................................................... 2-25
E251 Motor overtemp. prewarning.............................................................................................. 2-26
E253 Target position out of travel zone....................................................................................... 2-26
E255 Feedrate-override S-0-0108 = 0 ........................................................................................ 2-26
E257 Continuous current limit active........................................................................................... 2-27
E259 Command velocity limit active ........................................................................................... 2-27
E261 Continuous current limit prewarning .................................................................................. 2-27
E263 Velocity command value > limit S-0-0091.......................................................................... 2-28
E410 Slave not scanned or adress 0 .......................................................................................... 2-28
E825 Overvoltage in power stage ............................................................................................... 2-28

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Contents III

E826 Undervoltage in power section........................................................................................... 2-29

E829 Positive position limit exceeded ......................................................................................... 2-29
E830 Negative position limit exceeded ....................................................................................... 2-29
E834 Emergency-Stop ................................................................................................................ 2-30
E843 Positive limit switch activated............................................................................................. 2-30
E844 Negative limit switch activated ........................................................................................... 2-30

3 Description of Diagnostic Letters C... and A... 3-1

3.1 Command Diagnostic Messages C... and D........................................................................................ 3-1
3.2 Command diagnostic messages.......................................................................................................... 3-2
C100 Communication phase 3 transition check............................................................................ 3-2
C101 Invalid communication parameter (S-0-0021) ..................................................................... 3-2
C104 Config. IDN for MDT not configurable ................................................................................. 3-2
C105 Configurated length > max. length for MDT ........................................................................ 3-2
C106 Config. IDN for AT not configurable..................................................................................... 3-2
C107 Configurated length > max. length for AT............................................................................ 3-3
C108 Time slot parameter > Sercos cycle time ............................................................................ 3-3
C109 Position of data record in MDT (S-0-0009) even ................................................................. 3-3
C110 Length of MDT (S-0-0010) odd............................................................................................ 3-3
C111 ID9 + Record length - 1 > length MDT (S-0-0010) .............................................................. 3-4
C112 TNcyc (S-0-0001) or TScyc (S-0-0002) error ...................................................................... 3-4
C113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error ........................................................ 3-4
C114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)......................................................................... 3-4
C115 T2 too small ......................................................................................................................... 3-5
C200 Communication phase 4 transition check............................................................................ 3-5
C201 Invalid parameter(s) (->S-0-0022) ....................................................................................... 3-5
C202 Parameter limit error (->S-0-0022) ...................................................................................... 3-5
C203 Parameter calculation error (->S-0-0022)............................................................................ 3-5
C204 Motor type P-0-4014 incorrect ............................................................................................. 3-6
C210 External feedback required (->S-0-0022) ............................................................................ 3-6
C211 Invalid feedback data (->S-0-0022) ..................................................................................... 3-6
C212 Invalid amplifier data (->S-0-0022) ...................................................................................... 3-7
C213 Position data scaling error ................................................................................................... 3-7
C214 Velocity data scaling error ................................................................................................... 3-7
C215 Acceleration data scaling error ............................................................................................ 3-8
C216 Torque/force data scaling error ........................................................................................... 3-8
C217 Motor feedback data reading error ...................................................................................... 3-9
C218 External feedback data reading error .................................................................................. 3-9
C220 Motor feedback initializing error........................................................................................... 3-9
C221 Ext. feedback initializing error............................................................................................ 3-10
C223 Input value for max. range too high ................................................................................... 3-10
C225 Coprocessor not ready for initialization.............................................................................. 3-10
C226 Coprocessor acknowledge failed....................................................................................... 3-11
C227 Modulo range error ............................................................................................................ 3-11
C228 Controller type S-0-0140 wrong......................................................................................... 3-11
C231 Emulator not loadable........................................................................................................ 3-11
C232 Motor encoder interface not present.................................................................................. 3-11

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
IV Contents DIAX03 Drive With Electric Gear Function

C233 External encoder interface not present.............................................................................. 3-12

C234 Encoder combination not possible..................................................................................... 3-12
C235 Load-side motor encoder with inductance motor only ....................................................... 3-12
C236 Motor feedback required (P-0-0074) ................................................................................. 3-12
C300 Set absolute measuring..................................................................................................... 3-12
C302 Absolute measuring system not installed .......................................................................... 3-13
C400 Command: switch to parameter mode .............................................................................. 3-13
C401 Drive active, switching not allowed .................................................................................... 3-13
C402 Only allowed without master.............................................................................................. 3-13
C500 Reset class 1 diagnostic, error reset ................................................................................. 3-13
C501 Error delet only in parameter mode ................................................................................... 3-14
C600 Drive controlled homing procedure command................................................................... 3-14
C601 Homing only possible with drive enable............................................................................. 3-14
C602 Distance home switch - reference mark erroneous........................................................... 3-14
C604 Homing of absolute encoder not possible ......................................................................... 3-14
C700 Basic load .......................................................................................................................... 3-15
C701 Basic load not possible if drive is enabled ......................................................................... 3-15
C702 Default parameters not available....................................................................................... 3-15
C703 Default parameters invalid................................................................................................. 3-15
C704 Parameters not copyable................................................................................................... 3-15
C705 Locked with password ....................................................................................................... 3-16
C800 Default parameter load ...................................................................................................... 3-16
C801 Parameter default value erroneous (-> S-0-0021)............................................................. 3-16
C802 Locked with password ....................................................................................................... 3-16
D300 Command adjust commutation.......................................................................................... 3-16
D301 Drive not ready for commutation command ...................................................................... 3-16
D500 Command 'get mark position' ............................................................................................ 3-17
D501 Incremental encoder required............................................................................................ 3-17
D600 Cancel reference point procedure command .................................................................... 3-17
D700 Parking axis command ...................................................................................................... 3-17
D800 Command measuring wheel operation mode.................................................................... 3-18
D801 Measuring wheel operation not possible ........................................................................... 3-18
D802 Operation mode cancelled................................................................................................. 3-18
3.3 Status diagnostic messages .............................................................................................................. 3-19
A000 Communication phase 0 .................................................................................................... 3-19
A001 Communication phase 1 .................................................................................................... 3-19
A002 Communication phase 2 .................................................................................................... 3-19
A003 Communication phase 3 .................................................................................................... 3-20
A010 Drive HALT ........................................................................................................................ 3-20
A011 Drive interlock open ........................................................................................................... 3-20
A012 Control and power sections ready for operation ................................................................ 3-20
A013 Ready for power on............................................................................................................ 3-20
A100 Drive in TORQUE control .................................................................................................. 3-20
A101 Drive in VELOCITY control ................................................................................................ 3-21
A102 Position mode with encoder 1............................................................................................ 3-21
A103 Position mode with encoder 2............................................................................................ 3-21
A104 Position mode lagless, encoder 1...................................................................................... 3-21

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Contents V

A105 Position control lagless, feedback 2 .................................................................................. 3-21

A106 Drive controlled interpolation, encoder 1 ........................................................................... 3-21
A107 Drive controlled interpolation, encoder 2 ........................................................................... 3-22
A108 Drive controlled interpolation, lagless, encoder 1 .............................................................. 3-22
A109 Drive controlled interpolation, lagless, encoder 2 .............................................................. 3-22
A110 Velocity Synchronization, virtuell Lead drive ...................................................................... 3-22
A112 Phase synchronization, encoder 1, virtual master drive .................................................... 3-22
A113 Phase synchronization, encoder 2, virtual master drive .................................................... 3-23
A116 Phase synchr. lagless, encoder 1, virtual master drive ..................................................... 3-23
A117 Phase synchr. lagless, encoder 2, virtual master drive ..................................................... 3-23
A120 Pattern control, encoder 1, virtual master drive ................................................................. 3-23
A121 Pattern control, encoder 2, virtual master drive ................................................................. 3-24
A124 Pattern control lagless, enc. 1, virtual master drive ........................................................... 3-24
A125 Pattern control lagless, enc. 2, virtual master drive ........................................................... 3-24
A128 Cam shaft, encoder 1, virtual master drive........................................................................ 3-24
A129 Cam shaft, encoder 2, virtual master drive........................................................................ 3-25
A132 Cam shaft, lagless, encoder 1, virt. master drive .............................................................. 3-25
A133 Cam shaft, lagless, encoder 2, virt. master drive .............................................................. 3-25
A146 Relative drive controlled interpolation, encoder 1 .............................................................. 3-25
A147 Relative drive controlled interpolation, encoder 2 .............................................................. 3-26
A148 Relative drive contr. interpolation, enc. 1, lagless.............................................................. 3-26
A149 Relative drive contr. interpolation, enc. 2, lagless.............................................................. 3-26
A800 Unknown operation mode.................................................................................................. 3-27
3.4 Diagnostic messages for basic initialization and after fatal System errors ........................................ 3-28
Diagnostic Message Display: -0 .................................................................................................. 3-28
Diagnostic Message Display: -1 .................................................................................................. 3-28
Diagnostic Message Display: -2 .................................................................................................. 3-28
Diagnostic Message Display: -3 .................................................................................................. 3-28
Diagnostic Message Display: -5 .................................................................................................. 3-28
Diagnostic Message Display: -6 .................................................................................................. 3-29
Diagnostic Message Display: Watchdog ............................................................................... 3-29
3.5 Operation Status ................................................................................................................................ 3-30
bb ................................................................................................................................................ 3-30
Ab ................................................................................................................................................ 3-30
AF................................................................................................................................................ 3-30
AS................................................................................................................................................ 3-30
AH ............................................................................................................................................... 3-30
P0 ................................................................................................................................................ 3-30
P1 ................................................................................................................................................ 3-31
P2 ................................................................................................................................................ 3-31
P3 ................................................................................................................................................ 3-31

4 Exchanging Drive Components 4-1

4.1 Identification of the Drive Components ................................................................................................ 4-1
Supply Modules............................................................................................................................. 4-1
Drive Controllers............................................................................................................................ 4-2
Motors ........................................................................................................................................... 4-5

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
VI Contents DIAX03 Drive With Electric Gear Function

Electrical Connections................................................................................................................... 4-5

4.2 Replacing Drive Components .............................................................................................................. 4-6
Supply Modules............................................................................................................................. 4-6
Drive Controllers............................................................................................................................ 4-6
Motors ......................................................................................................................................... 4-11
Electrical Connections................................................................................................................. 4-12
Plug-in module ............................................................................................................................ 4-13
Software Module ......................................................................................................................... 4-13
4.3 Fault report......................................................................................................................................... 4-15

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Diagnostic Message Descriptions 1-1

1 Diagnostic Message Descriptions

1.1 Overview of the diagnostic message descriptions

Diagnostic Message Types

Each operational state of the drive will be characterized with a diagnostic
message.
Differentiations will be made between:
• Error diagnostic messages
• Warning diagnostic messages
• Command diagnostic messages
• Drive Mode diagnostic messages
• Operation status

Construction of a diagnostic message

A diagnostic message consists of:
• A diagnostic number and a
• diagnostic text

F228 Excessive Control Deviation

Diagnostic message

Diagnostic message number

Fig. 1-1: Diagnostic message with a diagnostic number and text.

For the example in the graphic, "F2" and "28" are shown alternately on
the H1-Display.
The control system can read out the diagnostic number in hexadecimal
form with the S-0-0390, Diagnostic message number parameter.
In addition, the drive allocates to the control system the diagnostic
number and diagnostic text as a string F228 Excessive deviation with
the S-0-0095, Diagnostic message parameter.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
1-2 Diagnostic Message Descriptions DIAX03 Drive With Electric Gear Function

H1-Display
The H1-Display serves as an optical display of the diagnostic message
on the drive.

L1 L2 L3 A1 A2 A3 N L K B1 B2 X10

V
220
Netz/Mains X5 Motor Steuerspannung
Aux.
V oltage

X6

•
•
•
•
•
TM+

0VB
TM-

BR
H1- Display U5
S1

H1
U1 U3

H2

S2

X9

1
U2 U4
X8
X2

7
1
1

DIGITAL COMPACT CONTROLLER

X3
X7
DKR 3
10 1 1 X4

DDS 2.2 DKR 3.1

FA5003d1.fh5

Fig. 1-2: H1-Display on DDS and DKR drives

The diagnostic number appears on this two-positional seven-segment

display. The image can be seen on the "Diagnostic Message Priority
Display".
This display quickly shows the current operation status without the use of
a communications interface.
The operating mode cannot be seen from the H1-Display. If the drive
follows the operating mode and no command was activated, then the
symbol "AF" appears on the display.

Diagnostic Message Output If more than one diagnostic message is waiting, then the message with
Priority the highest priority will be displayed.
The following graphic classifies operation status in order of importance.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Diagnostic Message Descriptions 1-3

Error
P
R
Warning
I
O
R Command error
I
T Command active
Y

Ready to operate ?

yes no
Operation lock
active

Ready to Communicationphase
operate

Drive ready

Drive stop

Drive is
following
operating mode Da0001f1.fh5

Fig. 1-3: Diagnostic message priority diagram

Clear Coded Diagnostic Message

The clear coded diagnostic message contains the diagnostic number
followed by the diagnostic text, as shown in the example, "Excessive
Output Error" (Fig. 1-1). It can be read out with the S-0-0095, Diagnostic
message parameter and directly displays the operation status on an
operator surface.
The clear coded diagnostic message will be switched to the current
language.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
1-4 Diagnostic Message Descriptions DIAX03 Drive With Electric Gear Function

Notes

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-1

2 Description of diagnostic letters F... and E...

2.1 Error diagnostic messages F...

Many areas are monitored in connection with operating modes and
parameter settings. An error message is generated if a condition is
discovered which no longer allows proper operation.

Error Classes The errors are separated into four different error classes. The error class
is evident from the diagnostic message. They are determined with the
drive's error response..

Error class : Diagnostic Drive Reaction:

Message:
Fatal F8xx Torque free switching
Travel range F6xx Velocity command value-zero
switch
Interface F4xx In accordance with best
possible deceleration
Non-fatal F2xx In accordance with best
possible deceleration
Fig. 2-1: Error Classes and Drive Reaction

Drive's Error Reaction If an error state is detected in the drive then an automatic operation of
the drive's error response will be started as long the drive is in control.
The H1 display blinks a Fx / xx.
The drive's reaction can be parameterized by P-0-0119, Deceleration as
best as possible, with interface and non-fatal errors. At the end of each
error reaction the drive is switched off.

Reset the Error Errors will not be automatically deleted but must be:

• Reset from the control through the initialization of the command

S-0-0099, Reset Class 1 Diagnostics, or
• reset by pressing the "S1" button.

If the error state is still present then the error will be immediately detected
again.
A positive edge bit on the control enable signal is necessary in order to
turn on the drive again.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-2 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

F207 Switching to uninitialized operation mode

Cause:
0 has been selected in at least one of the four mode parameters S-0-
0032..35. This mode was selected by the bits 8 and 9 in the master
control word when the drive controller was on.
Remedy:
Enter the required mode in the activated mode parameter.

Valid modes are:

Bit list of the mode
Meaning: parameters:
Torque control 0000 0000 0000 0001
Velocity control 0000 0000 0000 0010
Position control with act. feedback val. 1 0000 0000 0000 x011
Position control with act. feedback val. 2 0000 0000 0000 x100
Drive-internal interpolation with actual 0000 0000 0001 x011
feedback value 1
Drive-internal interpolation with actual 0000 0000 0001 x100
feedback value 2
Relative drive-internal interpolation with 0000 0010 0001 x011
actual feedback value 1
Relative drive-internal interpolation with 0000 0010 0001 x100
actual feedback value 2
Fig. 2-2: Modes

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
Check for input of the permissible interpolation method.

F208 UL The motor type has changed.

Description:
The settings for current regulation, velocity command, and position loop
are stored in the eedback of the motor. After powering up, the drive
motor type. If the two do not match, the drive remains in this state.
By pressing the S1 key, the drive overwrites its stored parameters with
the control loop parameters from the motor feedback.
Cause:
• The motor has been exchanged.
• A parameter file has been loaded, but the parameter P-0-4036,
Contacted motor type contained a different motor type.

Remedy:
Command C700 Basic Load or press the S1 button.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-3

F209 PL Load parameter default values

Description:
After the firmware is replaced (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 by starting the command “load
basic parameters”, all the parameters will be erased and restored with
the default values.
Cause:
Product was replaced. The number of parameters in comparison to the
new products has changed.
Remedy:
Press S1 button on the drive controller and all the paramters will be
erased and restored with default values

⇒ This overwrites all parameters and positioning blocks.

WARNING

F218 Amplifier overtemp. 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.
Class: non-fatal

F219 Motor overtemp. shutdown

If the motor temperature exceeds the value in S-0-0204, Motor
shutdown temperature, the drive will generate this error message. The
value in S-0-0204 is fixed at 150°C for MDD-,MKD- and MKE motors.
The appropriate value must be entered from the motor's technical
specifications for all other types of motors.
For motors of series: 2AD, 1MB, LAF, LAR, and MBW, the current motor
temperature can be called up with parameter S-0-0383, Motor
temperature.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-4 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Cause:
1. The motor became overloaded. The effective torque demand on
the motor was above its permissible continuous torque level for
too long.
2. Short circuit or ground in the connection to
motor temperature monitoring.
3. Instability in the velocity control loop.
Remedy:
For 1. Check the layout of the motor. For motors which have been in
operation for longer periods of time, check to see if the operating
conditions have changed (in regards to cleanliness, friction,
moved components, etc.).
For 2. Check the wiring to the motor temperature monitor X6/1 and
X6/2 for grounds and short circuits.
For 3. Check the velocity control loop parameters (see
the functional description).

F221 Error Motor temp. surveillance defective

Cause:
Short-circuit in the wiring to the motor temperature monitoring.
Remedy:
Check the wiring to the motor temperature monitoring X6/1 and X6/2 for
short-circuits.
The DC bus voltage is monitored in the power supply module. The drive
controller is notified via the control voltage bus whether the DC bus
voltage is above a minimum permissible value. If the CD bus voltage falls
below that threshold, the DC bus voltage message will be removed by
the power supply unit and the selected P-0-0119, Best possible
deceleration will be performed.
Requirement: The P-0-0118, Power off on error parameter has been
set such that the undervoltage condition is handled as a fault.
Cause:
1. The power is switched off without having de-activated the drive
via the controller enabling signal (RF) before.
2. The drive has been activated via the controller enabling signal
(RF) without having activated the power section before.
3. Malfunction of the power supply unit.
Remedy:
Ref. 1.+2. Checking the logic that is used for activating the drive in the
connected controller.
Ref. 3. Eliminate the malfunction of the power supply unit. See
Applications Manual of the power supply unit.

F228 Excessive deviation

When the position loop is closed, the drive monitors whether it is able to
follow the specified command value. This is done by calculating a model
position value in the drive and comparing that value with the actual
feedback value. This error is generated if the difference between
theoretical and actual position value permanently exceeds the value of
the S-0-0159, Monitoring window parameter.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-5

Cause:
1. The drive's acceleration capacity is exceeded.
2. The axis is blocked.
3. Incorrect parameter values set in the drive parameters.
4. Incorrect parameter values in S-0-0159, Monitoring window
5. The power supply has been switched of while the controller
enabling signal is applied. Possible cause: Malfunction in an AC
servo drive at the common power supply module.
Remedy:
Ref. 1. Check the S-0-0092, Bipolar torque/force limit value
parameter and set it to the maximum permissible value of the
application. Reduce the specified acceleration value from the
controller (see controller Manual).
Ref. 2. Check the mechanical system and eliminate jamming of the axis.
Ref. 3. Check the drive parameters.
Ref. 4. Set the parameter values of S-0-0159, Monitoring window.
Ref. 5. Check AC servo drive with error message different than "28".

F229 Motor encoder failure: quadrant error

A hardware error was discovered in the motor encoder interface being
used.
Cause:
1. Defective encoder cable.
2. Disruptive electro-magnetic interference on the encoder cable.
3. Defective motor encoder interface.
4. Defective drive controller.
Remedy:
For 1. Exchange the encoder cable.
For 2. Keep the encoder cable well away from the power cables.
For 3. Exchange the motor encoder interface.
For 4. Exchange the drive controller.

F233 External power supply error

Cause:
The DEA plug-in modules have isolated inputs and outputs. Proper
operation of those inputs and outputs requires an external 24-V voltage
to be applied. The drive monitors that voltage as soon as a DEA plug-in
module has been installed.
Remedy:
Check the external 24-V power supply.
Name: Unit: min.: typ.: max.:
External operating V 18 24 32
voltage +UL
Fig. 2-3: External power supply

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-6 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

F236 Excessive position feedback difference

Cause:
In the communication phase 4 transition check command, position
feedback value 1 and position feedback value 2 are set to the same
value and the cyclic evaluation of both encoders is started. In cyclic
operation (phase 4), the position feedback difference of both encoders is
compared with S-0-0391, Monitoring window ext. feedback. If the
amount of the difference exceeds the monitoring window, error F236
Excessive position feedback difference is diagnosed, the parameter-
selected error response performed, and the reference bits of both
encoders are cleared.
1. Incorrect parameter for the external encoder
(S-0-0115, Position feedback 2 type parameter,
S-0-0117, Resolution of external feedback).
2. Incorrect parameter setting of mechanical system between motor
shaft and external encoder.
(S-0-0121, Input revolutions of load gear;
S-0-0122, Output revolutions of load gear
S-0-0123, Feed constant).
3. The mechanical system between motor shaft and external
encoder is not rigid (e.g. gear play).
4. Defective encoder cable.
5. Defective module (DLF or DEF) for the evaluation of the external
measuring system.
6. Maximum input frequency of the encoder interface exceeded.
7. External encoder is not mounted to the driven axis.
8. Incorrect reference dimension of an absolute encoder.
Remedy:
Ref. 1. Check S-0-0115, Position feedback 2 type parameter and
S-0-0117, Resolution of external feedback
Ref. 2. Check S-0-0121, S-0-0122, Input/Output revolutions of load
gear and S-0-0123, Feed constant
Ref. 3. Increase S-0-0391, Monitoring window ext. feedback.
Ref. 4. Replace encoder cable.
Ref. 5. Replace module for the evaluation of the external measuring
system.
Ref. 6. Reduce the velocity.
Ref. 7. Set S-0-0391, Monitoring window ext. feedback to 0 (de-
activate monitoring function)
Ref. 8. Perform P-0-0012, C300 Command 'Set absolute
measurement'.

F237 Excessive position command difference

Cause:
When the drive is operating in position control, position command values
which come via the SERCOS interface are monitored. If the velocity
required of the drive by two successive position command values is
greater than or equal to the value in S-0-0091, Bipolar velocity limit
value, position command value monitoring is initiated. The Excessive
position command value is stored in parameter P-0-0010. The last
valid position command value is stored in parameter P-0-0011.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-7

If position data are to be processed in modulo format, then the

interpreation of the command values is also dependent on the value set
in S-0-0393, Command value mode for modulo format. The
parameter should be set for the "shortest path" (0).
Remedy:
Compare S-0-0091, Bipolar velocity limit value with the velocity in the
program and adjust to match it, if necessary.

F242 External encoder failure: signal too small

Cause:
The analog signals of an external measurement system are used for high
resolution analysis of that measurement system. These are monitored
according to two criteria:
1. The pointer length, which is calculated from the sine and cosine
signals, must be at least 1 V.
2. The maximum pointer length resulting from the sine and cosine
signals must not exceed 11.8 V.

pointer length = sin2 + cos2

Fig. 2-4: Pointer length

Fig. 2-5: Correct signal amplitude

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-8 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Example:
Ucos = -6.5V
Usin = 6.5V

pointer length = (- 6.5V)2 + 6.5V 2 ≈ 9.2V

Remedy:
1. Check the measurement system cable.
2. Check the measurement system.

F245 External encoder failure: quadrant error

A hardware error was discovered in the high resolution position interface
for "DLF" sine signals of the external measurement system.
Cause:
1. Defective encoder cable.
2. Disruptive electro-magnetic interference on the encoder cable.
3. Defective DLF module.
Remedy:
For 1. Exchange the encoder cable.
For 2. Keep the encoder cable well away from the power cables.
For 3. Exchange the DLF module.

F248 Low battery voltage

Cause:
For motors of series MKD and MKE, the absolute position information is
stored by a battery-powered buffer in the motor feedback. The battery is
designed for a 10-year life span. If the battery voltage falls below 2.8 V,
this message appears. The absolute encoder function will still be
preserved for about 2 weeks.
CAUTION
Source of danger: Malfunction in the control of motors and
moving elements
Possible damages: Mechanical injuries
Precautionary measures: Replace the battery as soon as possible
Instructions for Exchanging Batteries
Have the following tools and accessories ready:
• Torx screwdriver size 10
• Needle-nose pliers, torque wrench
• New packaged battery (Part No.: 257101)
CAUTION
Source of danger: A malfunction in the control of motors
and moving elements
Possible damages: Mechanical injuries
Precautionary measures: Turn off the power supply.
Make sure it will not be turned back on.
Exchange the battery while the
control voltage is turned on.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-9

If the control voltage is turned off while the battery is taken out, the
absolute reference point will be lost.
The reference point must then be reestablished.

Removing the Battery

• Unscrew torx screw with a size 10 screwdriver.
• Pull out the resolver feedback (RSF) lid by hand.
• Pull off the battery connection.
• Loosen battery clamp and remove the battery.
• Place the factory-made battery (Part No.: 257101) in the housing and
screw on the clamp. WARNING! Do not kink the battery cable.
• Attach connection to the battery.
Close the resolver feedback lid, screw in 4 torx screws and tighten to 1.8
Nm with the torque wrench.

F249 Master drive encoder failure: signal too small

The signals of the master encoder are monitored. If its signal amplitude
falls below a minimum threshold value, then 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 signals
must give at least 1 V.
2. The maximum pointer sum of the sine and cosine signals may not
exceed 11.8 V.
Cause:
The analog signals of the measurement system at the master axis do not
have the correct amplitude.
Remedy:
1. Check the encoder cable.
2. Check the encoder.

F252 Master drive encoder failure: quadrant error

A hardware error was discovered in the high resolution position interface
for "DLF" sine signals of the external measurement system.
Cause:
1. Defective encoder cable
2. Insulation distrubance on the encoder cable
3. Defective DLF plug-in card
Remedy:
For 1. Exchange the encoder cable
For 2. Separate the encoder cable from the power cables.
For 3. Exchange the DLF plug-in card

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-10 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

F253 Incr. encoder emulator: pulse frequency too high

The incremental encoder emulator can process a maximum of 1023 lines
per scan period (250 µs). This value was exceeded.
Remedial action:
1. Reduce the number of lines of the incremental encoder emulator
(P-0-0502).
or
2. Reduce the travel velocity.

F254 Incr. encoder emulator: hardware fault

Before the next increment output is started, the system checks at the end
of each scan interval (250 µs) whether all increments have been output.
this error is generated if the outputs overlap.
Remedial action:
Write down the number of lines (P-0-0502) and the travel velocity at
which the error has occurred, and notify INDRAMAT Service.

F255 External power supply DAE 02 error

The analog interface DAE 02.1 requires an external 24-V power supply
that must be connected to terminal X75, pin 8 (+24 V) and pin 9 (0 V).
This error message is issued if the external power supply is missing or
outside the range 18...32 V. This function also detects transient faults,
caused by spikes, etc.
Remedial action:
1. Provide power to the interface from a regulated power supply
unit.
2. Use different power supply units or motor brake and interface; in
particular if long motor cables are used.

F267 Erroneous internal hardware synchronization

Cause:
The drive control of all drives in a SERCOS ring is synchronized by a
phase control loop. Proper functioning of the synchronization is
monitored. This error is generated if the average deviation is greater than
5 usec.
Remedy:
• Exchange DSS module.
• Exchange the drive controller.

F268 Brake fault

The drive controller takes control of the brake for motors with an
integrated holding brake. The braking current is monitored.
If the braking current is outside of the permissible range between:
0.4 -1.6 * P-0-0511, Break current
this error message will be generated.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-11

Cause:
1. The power supply for the brake is not
connected properly or is outside of the
(24 V +/- 10%) tolerance.
2. The motor cable is incorrectly connected
(wiring error).
3. Defective brake.
4. Defective drive controller.

Note: A metallic connector between the 0V brake supply and the 0V of

the drive controller is required.

Remedy:
For 1. Check the power supply.
For 2. Check the motor cable.
For 3. Exchange the motor.
For 4. Exchange the drive controller.

F270 Error power supply home switch

To be able to monitor the home switch in drive-controlled homing, the
DSS2.1 plug-in module requires an external 24-V power supply. The
drive monitors the external 24-V power supply if homing with home
switch has been selected via S-0-0147, Homing parameter (bit 5).
Cause:
The external 24-V power supply of the DSS2.1 plug-in module is missing.
Remedy:
1. Set S-0-0147, Homing parameter to "Homing without home
switch" (bit 5 = 1).
2. Check the 24-V power supply at connector X12 of the DSS2.1
module.
Name: Unit: min.: typ.: max.:
External operating V 18 24 32
voltage +UL
External current mA 100
consumption IL
Fig. 2-6: External power supply

F271 Error power supply travel limit switch

To be able to monitor the travel limit switches, the DSS2.1 plug-in
module requires an external 24-V power supply. The drive monitors the
external 24-V power supply if the travel limit switches have been
activated via the P-0-0090, Travel limit parameter.
Cause:
The external 24-V power supply of the DSS2.1 plug-in module is missing.
Remedy:
1. De-activate P-0-0090, Travel limit parameter.
2. Check the 24-V power supply at connector X12 of the DSS2.1
module.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-12 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

F272 Error power supply probe input

The probe inputs of the DSS2.1 plug-in module require an external 24-V
power supply. The drive monitors the external 24-V power supply if the
probes are activated via the S-0-0170, Probing cycle procedure
command.
Cause:
The external 24-V power supply of the DSS2.1 plug-in module is missing.
Remedy:
Connect the 24-V power supply to the connector X12 of the DSS2.1
module.

F273 Error power supply E-Stop

The emergency stop input of the DSS2.1 plug-in module requires an
external 24-V power supply. The drive monitors the external 24-V power
supply if the emergency stop function is activated via the P-0-0008,
Activation E-Stop-Function parameter.
Cause:
The external 24-V power supply of the DSS2.1 plug-in module is missing.
Remedy:
1. Connect 24-V power supply to the connector X12 of the DSS2.1
module.
2. Use the P-0-0008, Activation E-Stop-function parameter to de-
activate the emergency stop function.

F276 Absolute encoder out of allowed window

When a drive controller with an absolute encoder motor (multiturn) is
switched off, the actual feedback position is saved. When it is turned
back on, the position determined by the absolute encoder evaluation is
compared with this stored position. This error is given if the deviation is
greater than the value set by parameter in P-0-0097, Absolute encoder
control window.
Cause:
1. Turning on for the first time (invalid stored position).
2. The axis was moved further in switched-off state than allowed by
parameter P-0-0097, Absolute encoder monitoring window.
3. Incorrect position initialization.

Remedy:
For 1. Clear the error and set the reference point.
For 2. The axis was moved while turned off and is located
outside of its permissible position.
Check to see if a new travel command would cause damage.
Then clear errors.
For 3. Danger of Accident through Unwanted Axis Motion
Check reference point. If the reference point is incorrect, there is
a problem with the feedback. The feedback should be
exchanged (with MDD-, MKD- or MKE absolute motor encoders,
exchange the whole motor).

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-13

F280 Short circuit to earth

Cause:
Ground short in the DC bus or in the motor.
This error is reported only in compact devices.
Remedy:
- Isolation test of the motor and motor power supply cable.
- Disconnect the power supply cable from the motor to the drive and turn
on the drive and the power. If the error recurs, the drive should be
exchanged.

F281 Mains fault

Cause:
The power supply voltage was not present during operation for at least 3
power periods. As a result, the drive controller was brought to a standstill
according to the set error response.
Remedy:
Check the power supply connection according to the project planning
specifications.

F282 Phase loss fault

The power supply voltage is checked each time the control voltage is
switched on and each time the controller enable is switched off. A phase
error was found during this check.
Cause:
A power supply phase has failed or is outside of the permissible
tolerance.
Remedy:
Check the power supply connection according to the project planning
specifications of the drive controller being used.

F283 Line voltage fault

Cause:
The power supply voltage is above the permissible value > 460V+15%
Remedy:
Make sure the power supply is connected properly according to the
project planning specifications of the drive controller being used.

F284 Main contactor off, low voltage

Cause:
When the main contactor was turned off, the DC bus voltage went below
400 V while controller enable was set.
Remedy:
Switch off the controller enable before switching off the main contactor.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-14 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

F401 Double MST error shutdown

The master sync telegram was not received in the drive controller in two
successive SERCOS cycles.
Cause:
1. Disruption in the LWL transmission line.
2. Too much attenuation in the light signal.
3. Malfunction in the SERCOS interface (general).
Remedy:
For 1. Check all LWL connections in the SERCOS ring.
For 2. Measure the attenuation in the LWL cable.
The maximum attenuation between TX and RX must not fall
below 12.5 dB.
For 3. Exchange the SERCOS interface module in the drive controller.

F402 Double MDT error shutdown

The master data message frame (MDT) has not been received in the
drive in two consecutive SERCOS cycles.
Causes:
1. Fault in the fiber optics transmission line.
2. Excessive damping of the light signals.
3. Malfunction in the SERCOS interface (general).
Remedy:
Ref. 1. Check all fiber optics connections in the SERCOS loop.
Ref. 2. Measure the damping in the fiber optics cable.
The maximum damping between TX and RX may not be less
than 12.5 dB.
Ref. 3. Replace the SERCOS interface module in the drive.

F403 Invalid communication phase shutdown

An invalid communications phase was given by the SERCOS master
module (phase > 4).
Cause:
Error in the SERCOS master module of the control system.
Remedy:
Consult the control system manufacturer.

F404 Error during phase progression

The prescribed order was not maintained during phase progression.
Cause:
Error in the SERCOS master module of the control system.
Remedy:
Consult the control system manufacturer.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-15

F405 Error during phase regression

Switching back from a communication phase did not switch to phase 0.
Cause:
Malfunction in the SERCOS master module of the controller.
Remedy:
Contact the controller manufacturer.

F406 Phase switching without ready signal

The SERCOS master attempted a phase switch without waiting for the
drive controller's ready signal.
Cause:
Error in the SERCOS master module of the control system.
Remedy:
Consult the control system manufacturer.

F434 Emergency-Stop
Pressing the emergency stop switch has caused the drive to perform the
emergency stop function that was selected in the P-0-0119, Best
possible deceleration parameter. Setting bit 15 of S-0-0011, Class 1
diagnostics causes an error message to be issued to the controller.
Cause:
The emergency stop switch has been pressed.
Remedy:
Eliminate the malfunction that has caused the emergency switch to be
actuated, and clear the error.

F629 Positive travel limit exceeded

The drive has received a command value which has led to an axis
position outside the positive travel range. The axis was brought to a
standstill with the error response "Set velocity command value to zero".
Bit 2 of paramater P-0-0090, Travel limit parameter is set for
"Exceeding travel range is an error", or after exceeding the position limit
a drive control command has been started (such as the drive-controlled
homing procedure).
Cause:
S-0-0049, Positive position limit value exceeded.
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 supply was turned off, turn it back on.
• Move the axis into the permissible working range.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-16 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Note: Only such command values will be accepted which lead back
into the allowed working range. With other command values, the
drive will stop again. - The parameter S-0-0057, Position
window defines a hysteresis for the travel limits.

F630 Negative travel limit exceeded

The drive has received a command value which has led to an axis
position outside the negative travel range. The axis was brought to a
standstill with the error response "Set velocity command value to zero".
Bit 2 of paramater P-0-0090, Travel limit parameter is set for
"Exceeding travel range is an error", or after exceeding the position limit
a drive control command has been started (such as the drive-controlled
homing procedure).
Cause:
S-0-0050, Negative travel limit value exceeded.
Remedy:
1. Check S-0-0050, Negative travel 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 supply was turned off, turn it back on.
• Move the axis into the permissible working range.

Note: Only such command values will be accepted which lead back
into the allowed working range. With other command values, the
drive will stop again. - The parameter S-0-0057, Position
window defines a hysteresis for the travel limits.

F634 Emergency-Stop
Pressing the emergency stop switch has caused the drive to stop the
drive by setting the velocity command value to zero. An error is reported
in the S-0-0011, Class 1 diagnostics parameter.
Cause:
The emergency stop switch has been pressed.
Remedy:
Eliminate the malfunction that has caused the emergency switch to be
actuated, and clear the error.

F643 Positive travel limit switch detected

The positive travel limit switch was encountered. The axis was brought to
a standstill with the "Set velocity command value to zero" error response.
Bit 2 of parameter P-0-0090, Travel limit parameter is set for
"Exceeding travel range as error," or exceeding the position limit began a
drive control command (such as the drive-controlled homing procedure).
Cause:
The positive range limit switch is detected.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-17

Remedy:
1. Reset the error.
2. Turn the power supply on again.
3. Move the axis into the permissible travel region.

Note: The drive will not accept command values which lead out of the
permissible travel range. Entering these command values in the
drive controller will result in this error.

F644 Negative travel limit switch detected

The negative travel limit switch was encountered. The axis was brought
to a standstill with the "Set velocity command value to zero" error
response. Bit 2 of parameter P-0-0090, Travel limit parameter is set for
"Exceeding travel range as error," or exceeding the position limit began a
drive control command (such as the drive-controlled homing procedure).
Cause:
The negative travel limit switch was detected.
Remedy:
1. Reset the error.
2. Turn the power supply on again.
3. Move the axis into the permissible travel region.

Note: The drive will not accept command values which lead out of the
permissible travel range. Entering these command values in the
drive controller will result in this error.

F820 Bleeder overload

Cause:
The energy of a braking motor cannot be converted quickly enough by
the bleeder resistors.
The energy converted by the internal bleeder is analyzed. When the
maximum energy capacity of the bleeder is exceeded, it is shut off. The
bleeder overload error is generated.
Remedy:
The braking slope should have a flatter parameter, or the bleeder
capacity can be increased by adding an additional bleeder.
The drive can be used again after the bleeder has cooled down.

F822 Motor encoder failure: signal too small

The analog signals of an external measurement system are used for high
resolution analysis of that measurement system. These are monitored
according to two criteria:
1. The pointer length, which is calculated from the sine and cosine
signals, must equal at least.> 1 V.
2. The maximum pointer length resulting from the sine and cosine
ignals must not exceed 11.8 V.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-18 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

pointer length = sin2 + cos2

Fig. 2-7: Pointer length

Fig. 2-8: Correct signal amplitude

Example:
Ucos = -6,5V
Usin = 6,5V

pointer length = (- 6.5V)2 + 6.5V 2 ≈ 9.2V

Note: The error cannot be cleared in communications phase 4. Before

clearing the error, switch to communications phase 2.

Remedy:
• Check the measurement system cable.
• Lay the feedback cable well away from the motor power cable. The
cover must be placed over the drive controller (see drive controller
project specifications.)
• Check the measurement system and exchange, if necessary.

F827 Drive interlock while drive activated

Cause:
The drive interlock was activated while controller enable was set. The
drive controller switches to torque-free state immediately.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-19

Remedy:
The drive interlock should not be activated when controller enable is set.
Check the control system of the drive interlock input.

F860 Overcurrent: short in power stage

The current in the power transistor bridge has exceeded the twofold
value of the device peak current. The drive is immediately set to no
torque. An optional blocking brake is applied immediately.
Cause:
1. Short-circuit in the motor cable.
2. Power stage of the drive controller is defective.
3. Parameter values of the current regulator do not comply.
Remedy:
Ref. 1. Check the motor cable for short-circuit
Ref. 2. Replace the drive controller.
Ref. 3. The current regulator parameters and the initial values from the
feedback should not differ.

F861 Overcurrent: short to ground

The phase current sum is monitored. Sum = 0 in normal mode. The
ground-fault fuse responds if the current sum exceeds 0.5 x IN.
Cause:
1. Defective motor cable.
2. Ground fault in the motor.
Remedy:
Check motor cable and motor for ground fault; replace if necessary.

F869 +/-15Volt DC error

The drive controller found a malfunction in the ± 15 V power supply.
Cause:
1. Defective control voltage bus cable.
2. Defective supply module.

Remedy:
For 1. Check the control voltage bus cable or plug connection and
exchange if necessary.
For 2. Check supply module (see supply moduleinstructions for use).

F870 +24Volt DC error

The drive controller requires a 24-V control voltage. The drive's torque is
released immediately when the maximum permissible tolerance of +20%
is exceeded. An optional blocking brake is applied.
Causes:
1. Defective cable for the control voltages.
2. 24-V power supply overload.
3. Defective power supply unit.
4. Short-circuit in the emergency stop circuit.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-20 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Remedy:
Ref. 1. Check and, if necessary, replace the cable and connections of
the control voltages.
Ref. 2. Check the 24-V power at the power supply unit.
Ref. 3. Check the power supply unit.
Ref. 4. Check the emergency stop circuit for a short-circuit.

F871 +10Volt DC error

The power supply voltage for the current sensors has been disrupted.
Cause:
A defect in the drive controller.
Remedy:
Exchange the drive controller.

F878 Velocity loop error

If the difference between velocity command value and feedback value is
greater than 10% of the maximum motor velocity while the velocity
control loop is active, then the feedback velocity value must move in the
direction of the command value. This error is generated if the feedback
value does not come closer to the command value within 20 ms and the
effective torque/force command value is at the limit (=P-0-4046, Active
peak current).
Cause:
1. Motor cable is connected incorrectly.
2. Defective power section of the drive.
3. Defective feedback.
4. Parameters set incorrectly for velocity controller.
5. Parameters for acceleration or brake slope are too steep.
6. Effective peak current is too low.
Remedy:
For 1. Check motor cable connection.
For 2. Exchange the drive controller.
For 3. Exchange the motor.
For 4. Check the velocity controller according to the user instructions
(see the velocity controller chapter).
For 5. Decrease the maximum acceleration in the control system or
decrease P-0-1201, Ramp 1 pitch.

F879 Velocity limit S-0-0091 exceeded

In torque control, the actual velocity is monitored. This error is generated
if the programmed velocity in the S-0-0091, Bipolar velocity limit value
parameter is exceeded by the 1.125-fold value and/or a minimum of 100
rpm (rotary motor) or 100 mm/min (linear motor).
Cause:
The torque command value was for too long a time greater than the load
torque. This causes the actual speed to be increased up to the maximum
possible motor speed.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-21

Remedy:
Assign the correct torque command value to the required task. Reduce
the S-0-0092, Bipolar torque/force limit value parameter value.

F889 Regeneration overcurrent

Cause:
The feedback current of the drive is greater than 1.2 times the type
current (with HDD only).
Remedy:
Replace the drive.

F890 Processor fault power supply unit

Cause:
The RSK processor on the plug-in storage card is not working.
Remedy:
Exchange drive controller or the plug-in storage card.

F891 Power stage fault

The DC bus voltage is not established after the main contactor has been
switched on.
Cause:
If there is a short-circuit in the DC bus, voltage cannot build up after the
drive has been switched on. This error is generated if the voltage
remains under 100 V for approx. 200ms.
Remedy:
Exchange the drive controller.

F892 Wrong code of current measuring unit

A faulty current measuring unit was discovered after the control voltage
was turned on.
Cause:
The current measuring unit has an incorrect code. The coding does not
work with the RSK circuit board.
Remedy:
Exchange the current measuring unit.

F893 No regenerating current to mains

This error message is generated if the feedback current command value
is at its maximum and no current is flowing for approx. 50ms.
Cause:
1. Power supply not properly connected.
2. Defective feedback.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-22 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Remedy:
For 1. Check the power supply connection according to the project
planning specifications.
For 2. Exchange the drive controller.

F894 Checksum error

Cause:
The checksum is stored in the EPROM during the initial programming.
Each time the drive is turned on, the processor checks to see if the
checksum which was created from the processor corresponds to the one
which has been stored. This error is generated if this is not the case.
Remedy:
Exchange the RSK circuit board EPROM.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-23

2.2 Warning Diagnostic Messages E...

Many areas are monitored in connection with operating modes and
Warnings do not lead to an parameter settings. As a result, if a state is discovered which is still
automatic shutdown allowed by the order of operation, but in continuous operation generates
an error and thereafter 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
The warning class is will perform an automatic response with the appearance of a warning.
evident from the diagnostic
message

Warning Class: Diagnostic Drive Reaction:

Message:
with Drive Response E8xx Drive Stop
without Drive E2xx --
Response
Fig. 2-9: Division of the Warning Classes

Warnings can not be externally deleted.

E201 No mains connected

Cause:
After the control voltage has been switched on, the drive checks to see if
the mains connection of the power supply has also been switched on.
This warning is given if this has not happened correctly.
Remedy:
Check power connections (external relay, fuse, etc.).

E202 Not ready for power on

Cause:
As usually happens, the main contactor K1 was turned off when the
controller enable was not set. Because of the drive controller capacities,
the DC bus voltage must not decrease suddenly after the main contactor
is turned off. This message is generated as long as the DC bus voltage >
250V and prevents the main contactor from being turned on. This serves
to protect discharging resistors.
Remedy:
The warning is automatically recalled by the drive controller when the DC
bus voltage falls below 250V.

E219 Warning Drive temp. surveillance defective

Temperature monitoring checks to see if the measured drive controller
temperature is within reasonable bounds. If it determines that it is lower
than -10°C, then it is assumed the measuring unit is defective. Warning
E219 Warning Drive temp. surveillance defective will appear for 30
seconds. Afterwards the drive will be brought to a standstill according to
the selected error response and message F220 Bleeder overload
shutdown will be generated.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-24 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Cause:
1. Sensor not connected to the DRP3 circuit board.
2. Broken cable in the drive controller, or defective sensor.
Remedy:
Exchange or repair the drive controller.

E221 Warning Motor temp. surveillance defective

Temperature monitoring checks to see if the measured motor
temperature is within reasonable bounds. If it determines that it is lower
than -10°C, then it is assumed the measuring unit is defective. Warning
E221 Warning Motor temp. surveillance defective will appear for 30
seconds. Afterwards the drive controller will be brought to a standstill
according to the selected error response and message F221 Error
Motor temp. surveillance defective will be generated.
Cause:
1. Motor temperature sensor not connected.
2. Broken cable.
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 wiring between the drive controller and the motor.
For 3. Exchange the motor.
For 4. Exchange the drive controller.

E225 Motor overload

The maximum possible motor current is reduced in order to protect the
motor from being destroyed.
If a current flows in the that is greater than 2.2 times the motor current at
standstill S-0-0111, the maximum possible motor current (motor peak
current S-0-0109) is reduced. With 4-fold motor current at standstill, the
reduction starts after 400 ms. With 5-fold current it starts earlier, and with
3-fold current later.
The E225 Motor overload warning is issued when the motor peak
current is reduced by the limitation.
The reduction also has an effect on the active permanent current P-0-
4045.

E226 Undervoltage in power section

If bit 5 of the P-0-0118, Power off on error parameter has been set, an
undervoltage condition will be handled as a nonfatal warning. The drive
issues this warning if the drive enabling signal is present and the DC bus
voltage message disappears.
Cause:
Power supply unit is switched off or mains failure occurs while the drive
enabling signal is set.
Remedy:
Switch off the drive enabling signal before you switch off the power
supply unit.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-25

E247 Interpolation velocity = 0

The drive-internal position command value interpolator is active if
• the "drive-internal interpolation" mode,
• the "relative drive-internal interpolation" mode,
• drive-controlled homing
• drive halt
are active.
The E247 warning is issued if the employed velocity specification is 0.
Possible velocity specifications are:
• S-0-0259, Positioning velocity
• S-0-0041, Homing velocity
• S-0-0091, Bipolar velocity limit value

E248 Interpolation acceleration = 0

The drive-internal position command value interpolator is active if
• the "drive-internal interpolation" mode,
• the "relative drive-internal interpolation" mode,
• drive-controlled homing
• drive halt
are active.
The E248 warning is issued if the employed acceleration specification is
0. Possible acceleration specifications are:
• S-0-0260, Positioning acceleration
• S-0-0042, Homing acceleration
• S-0-0138, Bipolar acceleration limit value

E249 Positioning velocity S-0-0259 > S-0-0091

Cause:
A velocity that is used for approaching a target position is specified in the
S-0-0259, Positioning velocity parameter for the "drive-internal
interpolation" and "relative drive-internal interpolation" modes.
Message E249 is generated if this velocity is greater than the permissible
maximum value S-0-0091, Bipolar velocity limit value. At the same
time, bit 5 of S-0-0012, Class 2 diagnostics is set.
Remedy:
Reduce the value of S-0-0259, Positioning velocity.

E250 Drive overtemp. prewarning

The temperature of the heatsink in the drive controller has reached the
maximum permissible temperature. The drive controller follows the
command value input for a period of 30 seconds. This makes it possible
to bring the axis to a standstill with the control system while keeping true
to the process (for example, close the operation, leave the collision area,
etc.).
After 30 seconds, the response set in parameter P-0-0119, Best
possible deceleration will be performed by the drive controller.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-26 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Cause:
1. Failure of the drive's internal blower.
2. Failure of the control cabinet's climate control.
3. Incorrect control cabinet dimensioning in regards to
heat dissipation.
Remedy:
For 1. If the blower fails, exchange the drive controller.
For 2. Install climatization feature in the cabinet.
For 3. Check the dimensions of the control cabinet.

E251 Motor overtemp. prewarning

The motor is too hot. The motor temperature, which is displayed in
parameter S-0-0383, Motor temperature, has exceeded the value in S-
0-0201, Motor warning temperature. Warning E251 is generated. If the
temperature increases above the value in S-0-0204, Motor shutdown
temperature, error F219 Motor overtemp. shutdown will be generated.
The values for parameters S-0-0201, Motor warning temperature and
S-0-0204, Motor shutdown temperature are set at 140°C and 150°C
for MKD and MDD motors respectively.
Set MDD, MKD and MKE motors to 145°C or 155°C.
Cause:
The motor became overloaded. The effective torque required of the
motor was above the permissible continuous standstill torque for too
long.
Remedy:
Check the layout of the motor. For systems which have been in use for a
long time, check to see if the drive controller conditions have changed (in
regards to pollution, friction, components which have been moved, etc.).

E253 Target position out of travel zone

Cause:
In "Drive-controlled interpolation" operating mode, a check is performed
to see whether the specified S-0-0258, Target position, is within the
possible travel region of the drive.
This is defined by parameters S-0-0049, Positive position limit value
and S-0-0050, Negative position limit value.
Message E253 is generated if the target position lies outside of the travel
range. Additionally, warning bit 13 is set in S-0-0012, Class 2
diagnostic.
Remedy:
Check the specified S-0-0258, Target position and correct it, if
necessary.

E255 Feedrate-override S-0-0108 = 0

The travel velocity used in drive-controlled travel commands can be
changed with parameter S-0-0108, Feedrate override.
This warning is given if the value of this parameter is 0, since the drive
cannot then follow command values.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-27

Cause:
1. The control system's feed potentiometer is
set to zero or is being evaluated incorrectly.
2. The parameter was set to an incorrect value.
Remedy:
For 1. Check the feed potentiometer.
For 2. Set the parameter to the correct value for the application.

E257 Continuous current limit active

The thermal controller load is monitored. If a rated current profile is
demanded of the drive controller which would require too high a power
transistor load over time (too much warming of the power output stage),
the drive controller will react by dynamically reducing the effective peak
current. This warning will be given at the same time. Parameter P-0-
4046, Active peak current is reduced. Before the peak current is
actually limited, the advance warning message E261 Continuous
current limitation prewarning should have been generated.
Cause:
The drive controller was overloaded.
Remedy:
1. Check the drive layout.
2. Reduce acceleration.
With systems which have been used for longer periods of time,
check to see if drive controller conditions have changed
in regards to:
- Friction
- Components which have been moved.

E259 Command velocity limit active

In the position control and velocity control operating modes, the effective
velocity command value is limited to the value in parameter S-0-0091,
Bipolar velocity limit value. The warning is given if the resulting velocity
command value reaches this limit.
Cause:
Parameter S-0-0091, Bipolar velocity limit value was set too low.
Remedy:
In normal operating conditions, set parameter S-0-0091, Bipolar
velocity limit value to a value 10% greater than the NC effective
velocity.

E261 Continuous current limit prewarning

Digital drives are monitored by a continually operating temperature
model. If the thermal load reaches 100%, the continuous current limit will
be activated shortly thereafter.
Before the torque is reduced, 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 parameter.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-28 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

Cause:
The drive controller was overloaded.
Remedy:
1. Check the drive layout.
2. Reduce acceleration.
3. Increase the switching threshold in parameter
P-0-0127, Overload warning
4. With systems which have been used for longer periods of time,
check to see if drive controller conditions have changed
in regards to:
- Friction
- Components which have been moved
- Feed during processing.

E263 Velocity command value > limit S-0-0091

Cause:
The value given to the drive for S-0-0036, Velocity command value was
greater than permissible.
Remedy:
It is limited to S-0-0091, Bipolar velocity limit value.

E410 Slave not scanned or adress 0

While the SERCOS ring is being initialized in communications phase 1,
each slave which is to participate in the additional phase uptake must be
addressed by the SERCOS master. Slaves which are not addressed or
which have been set to drive address "0" indicate this by generating
warning E410. Communication with these slaves in higher
communications phases is not possible. They work only in the repeater
mode.
Cause:
The slave was not scanned in phase 1, or "0" address is set.
Remedy:
• Set the correct slave address.
• Check the SERCOS master configuration.

E825 Overvoltage in power stage

The DC bus voltage has reached impermissibly high values. (Ud > 475
V). The drive controller was switched to torque-free operation so as not
to endanger the drive's power amplifier.
Cause:
The energy regenerated by a braking drive controller (a main-spindle
drive, for example) cannot be converted by the bleeder resistors quickly
enough.
Remedy:
The braking slope should have a flatter parameter, or the bleeder
capacity can be increased by adding an additional bleeder.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of diagnostic letters F... and E... 2-29

E826 Undervoltage in power section

If bit 3 of the P-0-0118, Power off on error parameter has been set, an
undervoltage condition will be handled as a "fatal warning", and the
motor-driven operation will be shut down. The drive issues this warning if
the drive enabling signal is present and the DC bus voltage message
disappears.
Cause:
Power supply unit is switched off or mains failure occurs while the drive
enabling signal is set.
Remedy:
Switch off the drive enabling signal before you switch off the power
supply unit.

E829 Positive position limit exceeded

The drive received a command value which resulted in an axis position
outside the positive travel range. The axis was brought to a standstill by
setting the velocity command value to zero. A class 1 diagnostic error is
not generated. The drive will automatically follow command values which
lead into the allowable range after they are entered. "Handle travel range
exceeded as warning" is set in bit 2 of parameter P-0-0090, Command
value transmit time (TMTSG).
Cause:
S-0-0049, Positive position limit value exceeded.
Remedy:
Enter command values which lead back into the allowable range.

Note: Only such command values will be accepted which lead back
into the allowed working range. With other command values, the
drive will stop again. - The parameter S-0-0057, Position
window defines a hysteresis for the travel limits.

E830 Negative position limit exceeded

The drive received a command value which resulted in an axis position
outside the negative travel range. The axis was brought to a standstill by
setting the velocity command value to zero. A class 1 diagnostic error is
not generated. The drive will automatically follow command values which
lead into the allowable range after they are entered. "Handle travel range
exceeded as warning" is set in bit 2 of parameter P-0-0090, Travel limit
parameter.
Cause:
S-0-0050, Negative travel limit value exceeded.
Remedy:
Enter command values which lead back into the allowable range.

Note: Only such command values will be accepted which lead back
into the allowed working range. With other command values, the
drive will stop again. - The parameter S-0-0057, Position
window defines a hysteresis for the travel limits.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
2-30 Description of diagnostic letters F... and E... DIAX03 Drive With Electric Gear Function

E834 Emergency-Stop
The emergency stop switch was pressed, thus causing the drive to
perform the emergency stop function that has been selected via the P-0-
0119, Best possible deceleration parameter. There is no error
message issued to the controller.
Cause:
The emergency stop switch was pressed.
Remedy:
Eliminate the malfunction that led to the activation of the emergency stop
switch. The warning will then extinguish.

E843 Positive limit switch activated

The drive has been provided with a command value that leads to an axis
position outside the positive travel range. The axis is topped by setting
the velocity command value to zero. A status class 1 error is not
generated. The drive automatically follows command values that lead
back into the valid range. Bit 2 of P-0-0090, Travel limit parameter is set
to "Overtravelling is handled as a warning".
Cause:
Positive limit switch has been actuated.
Remedy:
Specify command values that lead back to the valid range.

E844 Negative limit switch activated

The drive has been provided with a command value that leads to an axis
position outside the negative travel range. The axis is topped by setting
the velocity command value to zero. A status class 1 error is not
generated. The drive automatically follows command values that lead
back into the valid range. Bit 2 of P-0-0090, Travel limit parameter is set
to "Overtravelling is handled as a warning".
Cause:
Negative limit switch has been actuated.
Remedy:
Specify command values that lead back to the valid range.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-1

3 Description of Diagnostic Letters C... and A...

3.1 Command Diagnostic Messages C... and D

The commands are used for control of complex features in the drive.
For example, the features "drive controlled homing procedure" or
"Communication Phase 4 Transition Check" are defined as commands.
Commands can start, interrupt or 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 H1 display where the x stands for the number of the command.
It can distinguish between 3 types of commands.
• Drive Commands
Command Types - Lead to an eventual automatic drive movement
- Can be started only through an inputted control enable
- Deactivates the active operating mode during its operation
• Monitor Commands
Activation or deactivation of monitors or features
• Management Commands
- Lead management tasks that are not interruptable

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-2 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

3.2 Command diagnostic messages

C100 Communication phase 3 transition check

Meaning:
The command S-0-0127, C1 Communication phase 3 transition
check has been activated.

C101 Invalid communication parameter (S-0-0021)

Cause:
Communications parameters which are needed to operate the drive in
communication phase 3 are invalid.
Remedy:
A list of the invalid parameters can be seen in parameter S-0-0021, List
of invalid op. data for comm. ph. 2.
The invalid parameters must be rewritten so they are correct.

C104 Config. IDN for MDT not configurable

Cause:
Telegram type 7 was set in parameter S-0-0015, Telegram type
parameter. Parameters which are missing in S-0-0188, List of
configurable data in MDT are kept in S-0-0024, Configuration list for
the master data telegram.
Remedy:
You must either set a priority telegram (Telegram type = 0..6) or else
provide S-0-0024, Config. list of the master data telegram with
parameters. These parameters are also contained in S-0-0188, List of
configurable data in the MDT.

C105 Configurated length > max. length for MDT

Cause:
Telegram type 7 was set in parameter S-0-0015, Telegram type
parameter. The length of the configured record in MDT, which is
determined by S-0-0024, Configurations list of the master data
telegram, exceeds the maximum permissible length S-0-0186, Length
of the configurable data record in the MDT.
Remedy:
You must either set a priority telegram in S-0-0015, Telegram type
parameter (telegram type = 0..6 ) or else reduce the number of
configurable parameters in MDT.

C106 Config. IDN for AT not configurable

Cause:
Telegram type 7 was set in parameter S-0-0015, Telegram type
parameter. Parameters which are not contained in S-0-0187, List of
configurable data in AT can be seen in S-0-0016, Custom amplifier
telegram configuration list.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-3

Remedy:
You must either set a priority telegram in parameter S-0-0015, Telegram
type parameter (telegram type = 0..6) or you must provide S-0-0016,
Custom amplifier telegram configuration list with parameters that are
contained in S-0-0187, List of configurable data in the AT.

C107 Configurated length > max. length for AT

Cause:
Message frame type 7 has been selected in S-0-0015, Telegram Type
Parameter. The length of the configured data record in the AT, that is
defined via S-0-0016, Custom amplifier telegram configuration list,
exceeds the maximum permissible S-0-0185, Length of the
configurable data record in the AT.
Remedy:
Either select the priority message frame via S-0-0015, Telegram Type
Parameter (message frame type = 0...6) or reduce the number of
configured parameters in the AT ( S-0-0016 ).

C108 Time slot parameter > Sercos cycle time

Cause:
One of the time slot parameters:
• S-0-0006, AT transmission starting time (T1)
• S-0-0089, MDT transmission starting time (T2)
• S-0-0007, Feedback acquisition starting time (T4)
• S-0-0008, Command valid time (T3)
exceeds S-0-0002, SERCOS Cycle time (Tscyc).
Remedy:
Correct the appropriate parameter(s). These times are determined by the
manufacturer of the control system and are specified by the SERCOS
interface.

C109 Position of data record in MDT (S-0-0009) even

Cause:
Parameter S-0-0009, Beginning address in master data telegram
contains an even value. This is not permitted.
Remedy:
Parameter S-0-0009, Beginning address in master data telegram
must be set to an odd value. These parameters are determined by the
manufacturer of the control system, and are specified by the SERCOS
interface.

C110 Length of MDT (S-0-0010) odd

Cause:
Parameter S-0-0010, Length of master data telegram contains an odd
value. This is not permitted.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-4 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Remedy:
Parameter S-0-0010, Length of master data telegram must be set to
an even value. These parameters are determined by the manufacturer of
the control system, and are specified by the SERCOS interface.

C111 ID9 + Record length - 1 > length MDT (S-0-0010)

Cause:
Parameter(s) are set incorrectly for S-0-0009, Beginning address in
master data telegram and S-0-0010, Length of master data telegram.
The length of the record in MDT for the drive plus the starting address in
MDT is greater than the total length of the MDT.
Remedy:
The parameters for S-0-0009, Beginning address in master data
telegram and S-0-0010, Length of master data telegram must be
corrected. Those parameters are determined by the manufacturer of the
control system and are specified by the SERCOS interface.

C112 TNcyc (S-0-0001) or TScyc (S-0-0002) error

Cause:
Only 500 us or even multiples of 1ms are permitted as valid values for S-
0-0001, NC Cycle time (TNcyc) and S-0-0002, SERCOS Cycle time
(Tscyc). Here, this is not the case.
Remedy:
S-0-0001, NC Cycle time (TNcyc) and S-0-0002, SERCOS Cycle time
(Tscyc) must be corrected. These parameters are determined by the
manufacturer of the control system, and are specified by the SERCOS
interface.

C113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error

Cause:
The value of S-0-0001, NC Cycle time (TNcyc) can only be equal to or
be a multiple of S-0-0002, SERCOS Cycle time (Tscyc). Here this is not
the case.
Remedy:
S-0-0001, NC Cycle time (Tncyc) and S-0-0002, SERCOS Cycle time
(Tscyc) must be corrected. These parameters are determined by the
manufacturer of the control system and are specified by the SERCOS
interface.

C114 T4 > TScyc (S-0-0002) - T4min (S-0-0005)

Cause:
The maximum permissible value for S-0-0007, Feedback acquisition
starting time (T4) is:
S-0-0002, SERCOS Cycle time (Tscyc) -
S-0-0005, Minimum feedback acquisition time(T4min).
The value for S-0-0007, Feedback acquisition starting time (T4) is
incorrect.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-5

Remedy:
**Correct S-0-0007, Feedback acquisition starting time (T4). These
parameters are determined by the manufacturer of the control system,
and are specified by the SERCOS interface.

C115 T2 too small

Cause:
The value set for S-0-0089, MDT Transmit starting time (T2) is
incorrect. The drive cannot work with this value.
Remedy:
**Correct S-0-0089, MDT Transmit starting time (T2).
These parameters are determined by the manufacturer of the control
system, and are specified by the SERCOS interface.

C200 Communication phase 4 transition check

Meaning:
The command S-0-0128, C200 Communication phase 4 transition
check has been activated.

C201 Invalid parameter(s) (->S-0-0022)

Cause:
Parameters which will be necessary to operate the drive in
communications phase 4 are invalid. The invalid parameters can be seen
in S-0-0022, IDN list of invalid op. data for comm. ph. 3.
Remedy:
The parameters of S-0-0022, IDN list of invalid op. data for comm. ph.
3 must be rewritten so they are correct.

C202 Parameter limit error (->S-0-0022)

Cause:
Parameters which are necessary to operate the drive in communications
phase 4 are either outside of their minimum or maximum input values or
the entered value can't be processed (for BIT bars). The incorrect
parameters are listed in S-0-0022, IDN list of invalid op. data for
comm. ph. 3.
Remedy:
The parameters of S-0-0022, IDN list of invalid op. data for comm. ph.
3 must be rewritten so they are correct.

C203 Parameter calculation error (->S-0-0022)

Cause:
Parameters that are required for phase-4 operation (operating mode)
cannot be processed in that way. The incorrect parameters are listed in
S-0-0022, IDN List of Invalid Op. Data for Comm. Ph. 3.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-6 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Remedy:
Write correct values to the parameters in S-0-0022, IDN List of Invalid
Op. Data for Comm. Ph. 3.

C204 Motor type P-0-4014 incorrect

An MDD-, MKD or MKE motor (value 1 or 5) is entered into parameter P-
0-4014, Motor type. The appropriate abbreviation "MDD", "MKD", or
MKE however, was not found in parameter S-0-0141, Motor type in the
motor feedback data memory.
Cause:
1. Incorrect parameter set for type of motor.
2. The motor feedback memory cannot be
read.
Remedy:
For 1. Enter the type of motor used in parameter P-0-4014, Motor type
For 2. Check feedback connection.
If feedback is defective, exchange motor.

C210 External feedback required (->S-0-0022)

Cause:
Values that require an external encoder have been entered in S-0-0147,
Homing Parameter or in the S-0-0032...35, Mode of Operation
parameters. However, zero (not available) has been entered in the P-0-
0075, Interface Feedback 2, external parameter.
The ident number of the parameter that requires the external encoder is
entered in S-0-0022, IDN List of Invalid Op. Data for Comm. Ph. 3.
Remedial action:
Modify S-0-0147, Homing Parameter or the S-0-0032...35, Mode of
Operation parameters to utilization of the motor encoder instead of
external encoder.
Set P-0-0075, Interface Feedback 2, external to a value different than
zero to activate the external measuring system.

C211 Invalid feedback data (->S-0-0022)

Invalid data has been encountered when the parameters stored in the
motor feedback were read, or an error has occurred when the data was
read.
Causes:
1. Motor feedback cable not connected or defective
2. Motor feedback defective
3. Drive controller defective
Remedy:
Ref. 1. Check motor feedback cable; connect both sides
Ref. 2. Replace motor
Ref. 3. Replace amplifier

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-7

C212 Invalid amplifier data (->S-0-0022)

During drive initialization, the operating software fetches data from an
EEPROM in the drive controller. This error message is generated after
that access has failed.
Causes:
Defective hardware in the drive controller.
Remedial action:
Replace drive controller.

C213 Position data scaling error

Cause:
The scaling parameters for position data permit the position data display
format to be selected. The drive-internal position data format depends on
the employed motor encoder and the encoder resolution. The factor used
for converting the position data from the drive-internal format into the
display format or vice versa is outside the processable range, because
either
• linear motor and rotary position scaling with motor reference, or
• rotary motor and linear position scaling with motor reference, or
• linear motor with modulo scaling has been selected; or
• the determined factor used for converting the position data from the
display format to the internal format, and vice versa, cannot be
represented.
Remedy:
Checking and correcting the relevant parameters, such as:
• S-0-0076, Position data scaling type
• S-0-0077, Linear position data scaling factor
• S-0-0078, Linear position data scaling exponent
• S-0-0079, Rotational position resolution
• S-0-0116, Resolution of motor feedback
• S-0-0121, Input revolutions of load gear
• S-0-0122, Output revolutions of load gear
• S-0-0123, Feed constant
• P-0-0074, Interface feedback 1
• S-0-0277, Position feedback 1 type parameter

C214 Velocity data scaling error

Cause:
The scaling parameters for velocity data permit the velocity data display
format to be selected. The drive-internal velocity data format depends on
the employed motor encoder and the encoder resolution. The factor used
for converting the velocity data from the drive-internal format into the
display format or vice versa is outside the processable range.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-8 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Remedy:
Checking and correcting the relevant parameters, such as:
• S-0-0044, Velocity data scaling type
• S-0-0045, Velocity data scaling factor
• S-0-0046, Velocity data scaling exponent
• S-0-0116, Resolution of motor feedback
• S-0-0121, Input revolutions of load gear
• S-0-0122, Output revolutions of load gear
• S-0-0123, Feed constant
• P-0-0074, Interface feedback 1
• S-0-0277, Position feedback 1 type parameter

C215 Acceleration data scaling error

Cause:
The display format of the acceleration data can be set for the
acceleration data using scaling parameters. The drive-controlled format
of the acceleration data is dependent on what motor encoder and
encoder resolution are used. The factor for converting acceleration data
from internal drive format to display format (or vice-versa) is outside the
workable range.
Remedy:
Check and set the relevant parameters correctly as follows:
• S-0-0160, Acceleration data scaling type
• S-0-0161, Acceleration data scaling factor
• S-0-0162, Acceleration data scaling exponent
• S-0-0116, Resolution of motor feedback
• S-0-0121, Input revolutions of load gear
• S-0-0122, Output revolutions of load gear
• S-0-0123, Feed constant
• P-0-0074, Interface feedback 1
• S-0-0277, Position feedback 1 type parameter

C216 Torque/force data scaling error

Cause:
The display format of the torque/force data can be set for the
torque/force data using scaling parameters. The factor for converting
torque data from drive-controlled format to display format (or vice-versa)
is outside the workable area.
Remedy:
Check and set the relevant parameters correctly as follows:
• S-0-0086, Torque/force data scaling type
• S-0-0093, Torque/force data scaling factor
• S-0-0094, Torque/force data scaling exponent
• S-0-0110, Amplifier peak current
• S-0-0111, Motor current at standstill

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-9

C217 Motor feedback data reading error

If you have entered these values into P-0-0074, Interface feedback 1:
• "1" for standard interface,
• "4" for DFF module, or
• "8" for DAG module (Endat)
then the attached encoder must have a feedback data memory. The
values for the encoder resolution and the feedback type are taken from
there. An error was discovered while reading these values.
Cause:
1. Defective motor feedback cable.
2. Defective motor feedback.
Remedy:
For 1. Check the motor feedback cable.
For 2. Exchange the motor.

C218 External feedback data reading error

If P-0-0075, Interface feedback 2, external is set at
• "1" for standard interface,
• "4" for DFF module, or
• "8" for DAG module (Endat)
then the attached encoder must have a feedback data memory. The
values for the encoder resolution and the feedback type are taken from
there. An error was discovered while reading these values.
Cause:
1. Defective measurement system cable.
2. Defective measurement system.
Remedy:
For 1. Check the measurement system cable.
For 2. Exchange the measurement system.

C220 Motor feedback initializing error

A number of tests are performed when the motor encoder is initialized.
An error was detected during this process. This error may be:
• Error while reading the angle rectification data
• Error while copying the angle rectification data
• Interruption of communication with the encoder
• Assembly error with the position of an initialization track
• Error while reading the analog signal of an initialization track
• Error in the pointer length of the analog signal of an initialization track
• Invalid offset between the high and low resolution track
• Error in the measuring system micro-controller
Cause:
1. Defective motor feedback cable.
2. Defective motor feedback.
3. Defective measurement system interface.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-10 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Remedy:
For 1. Check the motor feedback cable.
For 2. Exchange the motor.
For 3. Exchange the measuring system interface (module).

C221 Ext. feedback initializing error

Several checks are performed during the initialization of an external
encoder. An error was detected during this process. This error may be:
• Error while reading the angle rectification data
• Error while copying the angle rectification data
Interruption of communication with the encoder
• Assembly error with the position of an initialization track
• Error while reading the analog signal of an initialization track
• Error in the pointer length of the analog signal of an initialization track
• Invalid offset between the high and low resolution track
• Error in the measuring system micro-controller
• External 24V set for SSI interface with DAG 1.2
Cause:
1. External encoder cable defect.
2. Defective feedback.
3. Defective measurement system interface.

Remedy:
For 1. Check the external feedback cable.
For 2. Exchange feedback.
For 3. Exchange the measuring system interface (module).

C223 Input value for max. range too high

Cause:
An internal position resolution has been selected via the S-0-0278,
Maximum travel range parameter that no longer guarantees a correct
commutation of the motor.
Remedy:
Select a smaller value for the S-0-0278, Maximum travel range
parameter.

C225 Coprocessor not ready for initialization

The drive controller has a coprocessor. This coprocessor is initialized
during the transfer command. The coprocessor signals that it is ready for
initialization. If it is not ready, this error is generated.
Cause:
Coprocessor failed.
Remedy:
Exchange the drive controller.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-11

C226 Coprocessor acknowledge failed

The drive controller has a coprocessor. This coprocessor is initialized
during the transfer command. If the coprocessor does not confirm the
initialization by the master processor, this error will be generated.
Cause:
The coprocessor failed.
Remedy:
Exchange the drive controller.

C227 Modulo range error

Causes:
The selected modulo value is greater than half the position
representation range of the drive.
Remedy:
Decrease the modulo value.

C228 Controller type S-0-0140 wrong

Several internal software settings are made based on parameter S-0-
0140, Controller type. If the content of this parameter cannot be used,
then this error will be generated.
Cause:
1. The controller type cannot be processed by this software.
2. Amplifier EEProm defective.
Remedy:
For 1. Contact Indramat.
For 2. Exchange/repair the control device.

C231 Emulator not loadable

Cause:
The position emulator on the DAE02.1 interface is loaded from a ROM
module according to the selection made in P-0-4020. With ELS firmware,
the incremental encoder firmware is always loaded; P-0-4020 does not
exist in this case. The loading process is monitored; this error message
is generated in the event of a malfunction. The cause is a hardware
defect on the DAE02.1 interface.
Remedial action:
Replace the DAE02.1 interface.

C232 Motor encoder interface not present

Cause:
The encoder interface that was selected in the P-0-0074, Interface
feedback 1 parameter has not been installed or cannot be found by the
drive (due to a defect).
Remedy:
Install or replace the selected encoder interface.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-12 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

C233 External encoder interface not present

Cause:
The encoder interface that has been selected in the P-0-0075, Interface
Feedback 2, external parameter has not been installed, or is defective
and can therefore not be recognized by the drive.
Remedy:
Install or replace the selected encoder interface.

C234 Encoder combination not possible

Cause:
The encoder interface that has been selected in the P-0-0075, Interface
Feedback 2, external parameter cannot be supported by the drive; it has
already been allocated to the motor encoder.
Remedy:
Select another external encoder.

C235 Load-side motor encoder with inductance motor only

Cause:
The functionality of the external encoder can be defined in the P-0-0185,
Function of ext. encoder parameter. If 'load-side motor encoder' has
been selected as the function of the external encoder, that function will
only be supported for asynchronous motors.
Remedy:
Set the P-0-4014, Motor type parameter according to the employed
motor type.
Check the P-0-0185, Function of ext. encoder parameter.

C236 Motor feedback required (P-0-0074)

Cause:
A motor encoder is not required (P-0-0074 = 0) if a load-sided motor
encoder has been selected via the P-0-0185, Function of ext. encoder
parameter. However, S-0-0147, Homing parameter or the S-0-
0032...35, Mode of Operation parameters contain values that require a
motor encoder.
Remedy:
Change S-0-0147, Homing parameter or the S-0-0032...35, Mode of
Operation parameters such that they are suitable for using an external
encoder.
Enter a value ≠ 0 in the P-0-0074, Interface feedback 1 parameter to
activate the motor encoder.

C300 Set absolute measuring

Command P-0-0012, C300 Command 'Set absolute measurement'
was activated by the control system in use.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-13

C302 Absolute measuring system not installed

Command P-0-0012, C300 Command 'Set absolute measurement'
was started without an absolute measuring system being present.
The command cannot be processed because no absolute measuring
system is available.
Cause:
1. The command should not have been activated.
2. The contacted motor or the external measurement system was
not executed as an absolute encoder.
Remedy:
For 1. Stop execution of the command.
For 2. Equip the motor or external measurement system with an
absolute encoder function.

C400 Command: switch to parameter mode

Description:
The command for transition is in parameter mode. While editing the
parameters that can be edited only in parameter mode, this command
must be processed.

C401 Drive active, switching not allowed

Cause:
The command C400 Command: Switch to parameter mode would be
started without the control enable being activated.
Remedy:
End the command and turn off the drive enable, then the command can
be started from the beginning.

C402 Only allowed without master

Cause:
The command P-0-4023, C400 Communication phase 2 transition
was started via the serial interface. The command is not executed and
terminated with this error message because the active SERCOS
interface is of a higher priority and was disturbed.
The command can only be executed if the SERCOS interface is inactive
(i.e. there are no signals applied to the receiver of the SERCOS
interface).
Remedy:
Perform phase selection via SERCOS interface or de-activate SERCOS
interface before the command is started.

C500 Reset class 1 diagnostic, error reset

The command for clearing errors, S-0-0099, C500 Reset class 1
diagnostic was activated by the control system in use.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-14 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

C501 Error delet only in parameter mode

Cause:
An attempt has been made of clearing the error F822 Motor encoder
failure: signal too small in communication phase 4 (operating mode).
This is only possible in communication phases < 4 (parameter setting
mode).
Remedy:
1. Switch back the communication phase.
2. Activate the command again.

C600 Drive controlled homing procedure command

Command S-0-0148, C600 Drive controlled homing procedure
command was activated by the control system in use.

C601 Homing only possible with drive enable

Cause:
The controller enabling signal was not active when the program was
started. This is not permitted.
Remedy:
1. Switch on the controller enable signal.
2. Start the command again.

C602 Distance home switch - reference mark erroneous

Cause:
The evaluation of the homing 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, Reference cam shift by.. parameter
and enter it in the S-0-0299, Home switch offset parameter.

C604 Homing of absolute encoder not possible

Command S-0-0148, C600 Drive controlled homing procedure
command was activated. An absolute measuring system was selected
using the encoder selection in S-0-0147, Homing parameter. This
command can only run if command P-0-0012, C300 Command 'Set
absolute measurement' has been previously activated.
Remedy:
First activate command P-0-0012, C300 Command 'Set absolute
measurement', and then start command S-0-0148, C600 Drive
controlled homing procedure command. This procedure will define
the absolute reference point.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-15

C700 Basic load

With motors of the MDD, MKD and MKE series, the controller
parameters for the connected motor that are stored in the controller are
set to their default values by activating the controller parameters that are
stored in the motor feedback. The drive controller issues the C7
message to indicate that the C700 Basic load command has been
activated via the command parameter S-0-0262, C700 Command basic
load.
Cause:
The command C700 Basic load has been activated.

C701 Basic load not possible if drive is enabled

Cause:
Command S-0-0262, C700 Command basic load cannot be run if the
controller enable is set.
Remedy:
1. Disable controller enable.
2. Start the command again.

C702 Default parameters not available

With motors of the MDD, MKD and MKE series, adapting the control
loops to the connected digital drive is done by activating the speed
controller parameters that are stored in the motor feedback. The drive
controller employs the C702 message to signal that the S-0-0262, C700
Command basic load command has been activated, but that there is no
data memory at the connected motor.
Remedy:
Order the parameter sheet of the employed motor from INDRAMAT
Service, and enter the parameters.

C703 Default parameters invalid

Cause:
The default parameters are read from the motor feedback data memory.
At least one of these parameters is invalid.
Remedy:
Check the connection to the motor feedback. Exchange motor if
necessary.

C704 Parameters not copyable

Cause:
The default parameters in use are not compatible with this software
version.
Remedy:
Contact Indramat.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-16 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

C705 Locked with password

The parameter S-0-0267, Password offers the possibility to set a write
protection for the drive parameters. The diagnostic message C705
Locked with Password indicates, that the command C700 Basic Load
has been started, although the drive parameters are protected with the
customer password.

C800 Default parameter load

Default values of all parameters in the S-0-0192, IDN-list of backup
operation data are stored in the drive. Those values define a basic state
of the drive that permits the drives to be switched "operational".
Mechanical components and control loop settings are not taken into
consideration. Starting the C800 Default parameter load command
loads the default values into the related parameters and sets them valid.
Cause:
The C800 Default parameter load command has been activated.

C801 Parameter default value erroneous (-> S-0-0021)

Cause:
During the execution of P-0-4094, C800 Command Base-parameter
load, a default value that has been stored in the drive was recognized as
being incorrect. The related parameter is entered in S-0-0021, IDN-list of
invalid op. data for comm. Ph. 2.

C802 Locked with password

The parameter S-0-0267, Password offers the possibility to set a write
protection for the drive parameters. The diagnostic message C705
Locked with password indicates, that the command P-0-4094, C800
Command Base-parameter load has been started, although the drive
parameters are protected with the customer password.

D300 Command adjust commutation

Meaning:
A correctly adjusted commutation offset is mandatory for the operation of
synchronous motors. The "D3“ message indicates that the command has
been activated, that is used for determining the commutation offset.
Cause:
The commutation setting command has been activated.

D301 Drive not ready for commutation command

Cause with linear motor:
There must not be a controller enable signal when the command is
started. However, it must be in communication phase 4 ("bb“ or "Ab“
displayed).
Cause with rotary synchronous motor:

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-17

The drive must be in torque control mode when the "D3“ command is
started.
This error message is generated if those conditions are not satisfied.
Remedial action with linear motor:
Depending on the motor type, switch off the controller enable signal and
start the command again.
Remedial action with rotary synchronous motor:
Activate torque control and start the command again.

D500 Command 'get mark position'

Meaning:
The P-0-0014, D500 Command determine marker position command
can be used for checking the correct acquisition and position of the
reference marker of an incremental measuring system. The "d5“ display
shows that the command has been activated.
Cause:
The Determine marker position command has been activated.

D501 Incremental encoder required

Cause:
The command has been started for a measuring system that does not
possess real reference markers. These include measuring systems such
as DSF, EnDat, SSI or resolver measuring systems.
Remedy:
Check whether the correct encoder has been selected in S-0-0147,
Homing parameter.
Employ an encoder system with real reference markers.

D600 Cancel reference point procedure command

Meaning:
The reference of the encoder that has been selected via S-0-0147,
Homing parameter is canceled.

Cause:
The D600 Cancel reference point procedure command has been
activated.

D700 Parking axis command

Meaning:
The command permits one or more drives of a drive package to be
stopped without error messages being issued to the controller and/or the
power supply module. The remaining drives of the package can be
handled without any restrictions.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-18 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Cause:
The S-0-0139, D700 Command parking axis command has been
activated.

D800 Command measuring wheel operation mode

Meaning:
The command is active.
The position loop is closed with encoder 1 and 2.
Control loop monitoring is de-activated.
Cause:
The P-0-0220, D800 Command measuring wheel operation mode
command has been activated.

D801 Measuring wheel operation not possible

Meaning:
The measuring wheel command cannot be executed because one of the
following conditions is not satisfied:
• External encoder available
• External encoder logged on as measuring wheel encoder (P-0-0185 =
3)
• Position control is active.
Cause:
The P-0-0220, D800 Command measuring wheel operation mode
command has been activated without the above-mentioned conditions
being fulfilled.

D802 Operation mode cancelled

Meaning:
Processing the measuring wheel operation mode command cannot be
continued because the required position control mode has been
deactivated.

Cause:
The drive enabling signal has been removed while the measuring wheel
operation mode command was active; or an error has lead to an
erroneous reaction.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-19

3.3 Status diagnostic messages

A000 Communication phase 0

The communication process is divided into four communications phases:
Phases 0 and 1 are used to recognize the participants. Phase 2 is used
to provide the time and data protocols for communications phases 3 and
4.
Initialization is performed in ascending order of the sequence. The
defaults of the communications phase are set by the control system.
When the switch to communications phase 4 takes place, initialization is
completed and input power is enabled.
If the delayed phase switch is interrupted, the status display in the
communications phase which has already been reached freezes.
If diagnostic message A000 Communication phase 0 is active, the drive
is in phase 0 and is waiting for a phase transfer to 1 by the control
system.

A001 Communication phase 1

The communication process is divided into four communications phases:
Phases 0 and 1 are used to recognize the participants. Phase 2 is used
to provide the time and data protocols for communications phases 3 and
4.
Initialization is performed in ascending order of the sequence. The
defaults of the communications phase are set by the control system.
When the switch to communications phase 4 takes place, initialization is
completed and input power is enabled.
If the delayed phase switch is interrupted, the status display in the
communications phase which has already been reached freezes.
If diagnostic message A001 Communication phase 1 is active, the drive
is in phase 1, and transfer from phase 1 to 2 has not yet been initiated by
the control system.

A002 Communication phase 2

The communication process is divided into four communications phases:
Phases 0 and 1 are used to recognize the participants. Phase 2 is used
to provide the time and data protocols for communications phases 3 and
4.
Initialization is performed in ascending order of the sequence. The
defaults of the communications phase are set by the control system.
When the switch to communications phase 4 takes place, initialization is
completed and input power is enabled.
If the delayed phase switch is interrupted, the status display in the
communications phase which has already been reached freezes. If
diagnostic message A002 Communication phase 2 is active, the drive
is in phase 2.Before the control system transfers to communications
phase 3, command S-0-0127, C100 Communication phase 3
transition check must be started. If the command is acknowledged
negatively, transfer to communications phase 3 is not possible. The
problems that were diagnosed by the drive must be solved first.

Note: The parameters are not checked to see if they are correct.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-20 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

A003 Communication phase 3

The communication connection is divided into four communication
phases: Phases 0 and 1 are used to recognize the participants. Phase 2
is used to provide the time and data protocols for communications
phases 3 and 4.
Initialization is performed in ascending order of the sequence. The
defaults of the communications phase are set by the control system.
When the switch to communications phase 4 takes place, initialization is
completed and input power is enabled.
If the delayed phase switch is interrupted, the status display in the
communications phase which has already been reached freezes. If
diagnostic message A003 Communication phase 3 is active, the drive
is in phase 3.
Before the control system transfers to communications phase 4
(operating mode), command S-0-0128, C200 Communication phase 4
transition check must be started. If the command is acknowledged
negatively, transfer to communications phase 4 is not possible. The
problems that were diagnosed by the drive must be solved first.

Note: The parameters are not checked to see if they are correct.

A010 Drive HALT

The feature "Halt drive" was activated. The halt drive feature serves to
stop the motor at a defined deceleration and a defined jerk.
This feature can either be activated by deleting the drive halt bits (BIT 13)
in the master control word or by interrupting a drive control command
(i.e., in drive-controlled homing).

A011 Drive interlock open

Digital drive controllers are equipped with a starting lockout device that
prevents an unwanted start of a servo axis. Activating the starting lockout
device separates the power stage control electronics from the power
stage via a relay contact.
+24 V is applied to the AS+; AS– terminals of the X3 connector.

A012 Control and power sections ready for operation

The drive is supplied with control voltage and the power is switched on.
The drive is ready for power delivery.

A013 Ready for power on

The drive is supplied with a control voltage; there are no errors in the
drive controller. The drive is ready to be turned on.

A100 Drive in TORQUE control

The drive is in the torque control operating mode. It follows the torque
command value sequence which was set by the control system.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-21

A101 Drive in VELOCITY control

The drive is in the velocity control operating mode. It follows the velocity
command value sequence set by the control system. The RPM control
loop is closed in the drive.

A102 Position mode with encoder 1

The drive is in position control mode. The position loop is closed in the
drive by a position encoder. The control system only sets the position
command value sequence; the drive follows the command value with
following (lag) error.
Encoder 1 indicates that the position encoder is installed on the motor
shaft (indirect measurement of the axis position).

A103 Position mode with encoder 2

The drive is in position control mode. The position loop is closed in the
drive by a position encoder. The control system only sets the position
command value sequence; the drive follows the command value with
following (lag) error.
Encoder 2 indicates that the position encoder is installed on the machine
axis (direct axis position measurement).

A104 Position mode lagless, encoder 1

The drive is in position control mode. The position loop is closed in the
drive by a position encoder. The control system only sets the position
command value sequence; the drive follows the command value without
following (lag) error.
Encoder 1 indicates that the position encoder is installed on the motor
shaft (indirect measurement of axis position).

A105 Position control lagless, feedback 2

The drive is in position control mode. The position loop is closed in the
drive by a position encoder. The control system only sets the position
command value sequence; the drive follows the command value without
following (lag) error.
Encoder 2 indicates that the position encoder is installed on the machine
axis (direct axis position measurement).

A106 Drive controlled interpolation, encoder 1

The drive receives a position command value from the control system
which is identical to the target position of the travel path. Then the drive
generates (interpolates) an internal position command value sequence,
which uses the control system to maintain maximum values for jerk,
velocity and acceleration sequences.
The drive moves with following (lag) error to the target position of the
travel path.
Encoder 1 indicates that the position encoder is installed on the motor
shaft (indirect measurement of the axis position).

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-22 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

A107 Drive controlled interpolation, encoder 2

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 value sequence,
which uses the control system to maintain maximum values for jerk,
velocity and acceleration sequences.
The drive moves with following (lag) error to the target position of the
travel path.
Encoder 2 indicates that the position encoder is installed on the machine
axis (direct axis position measurement).

A108 Drive controlled interpolation, lagless, encoder 1

The drive receives a position command value from the control system
which is identical to the target position of the travel path. Then the drive
generates (interpolates) an internal position command value sequence,
which uses the control system to maintain maximum values for jerk,
velocity and acceleration sequences.
The drive moves without following error to the target position of the
travel path.
Encoder 1 indicates that the position encoder is installed on the motor
shaft (indirect measurement of the axis position).

A109 Drive controlled interpolation, lagless, encoder 2

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 value sequence,
which uses the control system to maintain maximum values for jerk,
velocity and acceleration sequences.
The drive moves without following error to the target position of the
travel path.
Encoder 2 indicates that the position encoder is installed on the machine
axis (direct axis position measurement).

A110 Velocity Synchronization, virtuell Lead drive

The drive is in velocity control mode. The velocity command will be
determined in the drive under consideration of the gear ratio as well as
the master encoder position.
Virtual Master Encoder means that the position of the master encoder
is calculated by the control system.

A112 Phase synchronization, encoder 1, virtual master drive

The drive is in Position mode. The position loop is closed at the drive
through a position encoder.The position command value is determined in
the drive under consideration of the gear ratio as well as the position of
the master encoder.
The drive follows the command value with lag error
Encoder 1 indicates that the position encoder is mounted at the motor
shaft (axis position measurement not directly)
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the contro systeml.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-23

A113 Phase synchronization, encoder 2, virtual master drive

The drive is in Position mode. The position loop is closed at the drive
through a position encoder. The position command value will be
determined in the drive under consideration of the gear ratio as well as
the position of the master encoder.
The drive follows the command value with a lag error.
Encoder 2 indicates that the position encoder is mounted at the machine
axis (axis position measurement direcly).
Virtual Master Encoder means, that the position of the master encoder
will be calculated through the control.

A116 Phase synchr. lagless, encoder 1, virtual master drive

The drive is in position mode. The position loop is closed at the drive
through a position encoder. The position command value is determined
in the drive under consideration of the gear ratio as well as the position of
the master encoder.
The drive follows the command value without a lag error.
Encoder 1 indicates that the position encoder is mounted at the motor
shaft (axis position measurement not directly)
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control system.

A117 Phase synchr. lagless, encoder 2, virtual master drive

The drive is in Position mode. The position loop is closed at the drive
through a position encoder. The position set value is determined in the
drive under consideration of the gear ratio as well as the position of the
master encoder.
The drive follows the command value without a lag error.
Encoder 2 indicates that the position encoder is mounted at the machine
axis (axis position measurement direcly).
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control.

A120 Pattern control, encoder 1, virtual master drive

The drive is now in operation mode Patterned gearing. The position set
points are depending on:
• the position of the master encoder
• stored tables in the drive
• a pattern calculator created from conveyed target positions
The drive follows the command with a lag error.
Encoder 1 indicates that the position feedback is mounted at the motor
shaft (axis position measurement not directly)
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-24 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

A121 Pattern control, encoder 2, virtual master drive

The drive is now in operation mode patterned gearing. The position
command values are dependent on:
• the position of the master encoder
• stored tables in the drive
• a pattern calculator created from conveyed target positions
The drive follows the command value with a lag error.
The encoder 2 indicates that the position feedback is mounted at the
machine axis (axis position measurement direcly).
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control system.

A124 Pattern control lagless, enc. 1, virtual master drive

The drive is now in operation mode patterned gearing. The position
command values are dependent on:
• the position of the master encoder
• stored tables in the drive
• a pattern calculator created from conveyed target positions
The drive follows the command value without a lag error.
Encoder 1 indicates that the position feedback is mounted at the motor
shaft (axis position measurement not directly)
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control.

A125 Pattern control lagless, enc. 2, virtual master drive

The drive is now in operation mode patterned gearing. The position
command values are depending on:
• the position of the master encoder
• stored tables in the drive
• a pattern calculator created from conveyed target positions
The drive follows the set value lagless.
Encoder 2 indicates that the position feedback is mounted at the
machine axis (axis position measurement direcly).
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control.

A128 Cam shaft, encoder 1, virtual master drive

The drive is in operation mode cam shaft. The feature has it's origin
from the mechanical cam shaft. With this setting a set position relation
exists between master- and following axis. The position command values
are retrieved from a table, which will be created from the average
position of the master encoder.
The drive follows the command value with a lag error.
Encoder 1 indicates that the position feedback is mounted at the motor
shaft (axis position measurement not directly)
Virtual Master Encoder means, that the position of the master encoder
wiil be calculated by the control.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-25

A129 Cam shaft, encoder 2, virtual master drive

The drive is in operation mode cam shaft. The feature has it's origin
from the mechanical cam shaft. With this setting a set position relation
exists between master- and following axis. The position command values
are retrieved from a table which will be created from the average
position. of the master encoder.
The drive follows the command value with a lag error.
Encoder 2 indicates that the position feedback is mounted at the
machine axis (axis position measurement direcly).
Virtual Master Encoder means, that the position of the master encoder
will be calculated by the control.

A132 Cam shaft, lagless, encoder 1, virt. master drive

The drive is in operation mode cam shaft. The feature has it's origin
from the mechanical cam shaft. With this setting a set position relation
exists between master- and following axis. The position command values
are retrieved from a table which willbe created from the average position
of the master encoder.
The drive follows the command value without a lag error.
Encoder 1 indicates that the position feedback is mounted at the motor
shaft (axis position measurement not directly)
Virtual master Encoder means, that the position of the master encoder
will be calculated by the control.

A133 Cam shaft, lagless, encoder 2, virt. master drive

The drive is in operation mode cam shaft. The feature has it's origin
from the mechanical cam shaft. With this setting a set position relation
exists between master- and following axis. The position command values
are retrieved from a table which will be created from the average position
of the master encoder.
The drive follows the command value without a lag error.
Encoder 2 indicates that the position feeback is mounted at the machine
axis (axis position measurement direcly).
Virtual Master Encoder means that the position of the master encoder
will be calculated by the control.

A146 Relative drive controlled interpolation, encoder 1

In the S-0-0282, Travel distance parameter, the drive receives a
distance specification from the controller. When bit 0 of the S-0-0346,
Setup flag for relative command values parameter is toggled, this
distance is summed up to the value in S-0-0258, Target position. 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 is done taking the limit values of velocity, acceleration, and jerk in
the parameters
• S-0-0259, Positioning velocity
• S-0-0260, Positioning acceleration
• S-0-0193, Positioning jerk
into account.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-26 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

The drive approaches the target position with a position lag that is
proportional to the velocity.
Encoder 1 means that the position encoder is attached to the motor
shaft (indirect measurement of the axis position).

A147 Relative drive controlled interpolation, encoder 2

In the S-0-0282, Travel distance parameter, the drive receives a
distance specification from the controller. When bit 0 of the S-0-0346,
Setup flag for relative command values parameter is toggled, this
distance is summed up to the value in S-0-0258, Target position. 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 is done taking the limit values of velocity, acceleration, and jerk in
the parameters
• S-0-0259, Positioning velocity
• S-0-0260, Positioning acceleration
• S-0-0193, Positioning jerk
The drive approaches the target position with a position lag that is
proportional to the velocity.
Encoder 2 means that the position encoder that is attached to the load is
used for closing the position control loop (direct axis position
measurement).

A148 Relative drive contr. interpolation, enc. 1, lagless

In the S-0-0282, Travel distance parameter, the drive receives a
distance specification from the controller. When bit 0 of the S-0-0346,
Setup flag for relative command values parameter is toggled, this
distance is summed up to the value in S-0-0258, Target position. 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 is done taking the limit values of velocity, acceleration, and jerk in
the parameters
• S-0-0259, Positioning velocity
• S-0-0260, Positioning acceleration
• S-0-0193, Positioning jerk
into account.
The drive approaches the target position of the travel path without a
position lag.
Encoder 1 means that the position encoder is attached to the motor
shaft (indirect measurement of the axis position).

A149 Relative drive contr. interpolation, enc. 2, lagless

In the S-0-0282, Travel distance parameter, the drive receives a
distance specification from the controller. When bit 0 of the S-0-0346,
Setup flag for relative command values parameter is toggled, this
distance is summed up to the value in S-0-0258, Target position. 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 is done taking the limit values of velocity, acceleration, and jerk in
the parameters

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-27

• S-0-0259, Positioning velocity

• S-0-0260, Positioning acceleration
• S-0-0193, Positioning jerk
The drive approaches the target position of the travel path without a
position lag.
Encoder 2 means that the position encoder that is attached to the load is
used for closing the position control loop (direct axis position
measurement).

A800 Unknown operation mode

There is no diagnosis for the activated mode.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-28 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

3.4 Diagnostic messages for basic initialization and after

fatal System errors

Diagnostic Message Display: -0

Cause:
The data storage for the controller is tested for its functional capability.
If an error is detected, this display will remain.
Remedy:
The drive controller is defective (DRP3) and must be exchanged.

Diagnostic Message Display: -1

Cause:
The data storage for the DSS 2.1 Module is tested for its functional
capability.
If an error is detected, this display will remain.
Remedy:
The DSS Module or the connection to the main device is defective.
• If DSS module is defective > exchange
• If drive controller is defective > exchange

Diagnostic Message Display: -2

Cause:
Makeup of the parameter structure.
If the EPROMS are exchanged for another version of the firmware, the
parameter memory on the programming module is erased (duration
appx. 5 sec.).

Diagnostic Message Display: -3

Cause:
The motor type and the type of the motor feedback are determined by
reading their parameter storage areas.

Diagnostic Message Display: -5

During basic initialization, an error was reported by the coprocessor.
Cause:
1. Control voltage error (+24 V or +/-15 V).
2. +/-10 V - error.
Remedy:
For 1. Check the control voltage supply.
For 2. Replace the drive.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-29

Diagnostic Message Display: -6

Cause:
A fatal processor or program error was encountered.

Remedy:
The error in question is a system error. Please contact the appropriate
software development company.

Diagnostic Message Display: Watchdog

Cause:
A fatal processor or program error (Watchdog) was encountered.

Remedy:
Replace the drive.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-30 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

3.5 Operation Status

bb
"read for operation"
The drive is ready to be turned on.

Diagnostic message text:

Ready to be turned on (ready for operation)

Ab
"Drive is ready"
The control and power components of the drive are ready for operation.

Diagnostic message text:

Control and power components are ready (drive is ready)

AF
"Drive enable"
The drive enable was issued and operated the activation of the drive.
This follows a command value input.

Diagnostic message text:

according to selected operating mode.

AS
"Drive interlock"
The power output was locked. This signal serves the secured torque free
switching of the drive independent from existing operating states of the
drive packs.

Diagnostic message text:

Drive interlock

AH
"Drive Halt"
The drive will be stopped under the conditions of the acceleration
parameter and stays in control.

P0
Phase 0
The drive is in phase 0 and is waiting on the phase transition from phase
0 to phase 1.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Description of Diagnostic Letters C... and A... 3-31

Diagnostic message text:

Phase 0

P1
Phase 1
The transition from phase 1 to phase 2 was still not initiated from the
control system.

Remedy:
see the control handbook

P2
Phase 2
Before the control system switches in the communications phase 3, the
controller checks inputted parameters for content of the input limits and
for completeness. If invalid parameter values were found, the phase
progression switch will stop the drive.

Note: The parameters are not checked for exactness.

Remedy:
In the parameter "Identification Number List Invalid Operating Data
Communications Phase 2", the ID numbers S-0-0021 are recorded which
were recognized as invalid from the drive before the phase progression
switch in communications phase 3. The completion of this parameter is
required in order for switching into communications phase 3.

P3
Phase 3
Before the control system switches in the communications phase 4, the
controller checks inputted parameters for content of the input limits and
for completeness. If invalid parameter values are recognized, the phase
progression switch will be stopped by the controller.

Note: The parameters are not checked for exactness.

Remedy:
In the parameter "ID Number Lists of Invalid Operating Data
Communications Phase 3", ID number S-0-0022 records the parameters
which were recognized as invalid by the drive before the phase
progression switch in communications phase 4. The completion of this
parameter is required in order for switching into communications
phase 4.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
3-32 Description of Diagnostic Letters C... and A... DIAX03 Drive With Electric Gear Function

Notes

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-1

4 Exchanging Drive Components

4.1 Identification of the Drive Components

Supply Modules
The rating plate of the supply module is below the DC supply terminals
L+/L- for the DC bus.

Rating plate of supply module

Prod. week/-year
Type designations

TVD1.3-08-03 K26/96
Part number 246503
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken. Verbindung nie unter Spannung

of
Schwarze Leitung immer unten! lösen bzw. stecken. lösen bzw. stecken.
Schwarze Leitung immer unten! Schwarze Leitung immer unten!

basic unit
SN247368-08751 B26

codierte
Serial number Change index

Serial number

DX3_ID_1.FH7

Fig. 4-1: Rating plate on the supply module (Example)

Servicing When contacting INDRAMAT's Customer Service, it is important to have

readily available
• the type designation and the
• serial number
of the supply module.

Procuring a Replacement Unit Replacement units are ordered from INDRAMAT with type designation.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-2 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

Drive Controllers
There are three rating plates on the drive controller to identify firmware
and hardware.
DDS02.2/DDS03.2 Firmware rating plate

FWA-DIAX03-ELS-03VRS-MS Firmware type

266233 K31/96 designation
Coded serial
SN266233-02829 RS
no.

Serial number Internal code

Configuration rating plate

SYSTEMCONFIGURATION Type designation of the

DDS02.2-W200-BE23-00-FW configured
drive controller
DDS02.2-W200-B Type designation
of the basic unit
U DSS 2.1M
FWA-DIAX03-ELS-03VRS-MS
266233 K31/96
1 Type designation of
SYSTEMCONFIGURATION
H1 DDS02.2-W200-BE23-00-FW
U plug-in module
2 DEA 4.1M
DDS02.2-W100-B
U5 U
1 DSS2.1M
U DEA 4.1M
2
U
3 COVER
U COVER
4
U
3 COVER
U DSM 2.3-FW
5

ATTENTION Achtung
Hier muß das korrekte Hier muß das korrekte

U COVER
Typenschild gemäß Typenschild gemäß

Konfigurationsblatt Konfigurationsblatt

aufgeklebt sein aufgeklebt sein

4
U DSM 2.3-FW Type designation of
5 software module
Production
K31/96
week/year

Rating plate of the basic unit

Type designation of
DDS02.2-W200-B the basic unit

Coded serial
no.
SN247199-02094 A02

Serial no. Internal code

DX3_ID_2.FH3

Fig. 4-2: The rating plate of the DDS02.2 and DDS03.2 (Example)

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-3

DKR03 Rating plate of basic unit

Type designation
DKR03.1-W100-B of
basic unit
coded serial no.
L1 L2 L3 A1 A2 A3 N L K B1 B2 X10
SN247199-02094 A02
220 V
Netz/Mains X5 Motor Steuerspannung
Aux.
Voltage

X6 Serial no. Internal code

TM+ •
TM- •
•
•
0VB •
BR
Firmware rating plate

FWA-DIAX03-ELS-03VRS-MS firmware type desig.

266233 K31/96

coded serial no.

SN266233-02829 RS
U5
S1
Serial no. Internal code
FWA-DIAX03-ELS-03VRS-MS
266233 K31/96

H1
U1 U2
SYSTEMCONFIGURATION
DKR03.1-W100N-BE23-00-FW Configuration rating plate
DKR03.1-W100N-B
U
1 DSS2.1M

SYSTEMCONFIGURATION
U
2 DEA 4.1M

Type designation
U
3 COVER
U COVER
4

of configured
U DSM 2.3-FW
5
H2
S2
TYS-DKR03.1-W100N-BE23-00

DKR03.1-W100N-BE23-00-FW
drive controller
1

X9
6
DKR03.1-W100-B Type designation
1

X8
U3 U4
of
7
X2

1
DIGITAL COMPACT CONTROLLER DKR
3 U DSS 2.1M software module
Type designation
1

X7
X3 1
of
10 11
X4
U DEA 4.1M plug in module
2
U
3 COVER
U COVER
4 Type designation
U DSM 2.3-FW of
5 software module
K31/96 Production week/
year
DX3_ID_3.FH5

Fig. 4-3: Rating plate of the DKR03.1 (Example)

DKR02, DKR04 Firmware rating plate

FWA- DIAX03-ELS-03VRS-MS Firmware type

266233 K31/96 designation
Coded serial no.
SN266233-02829 RS
Serial no. Internal code

Configuration rating plate

Systemconfiguration Type designation of the

DIGITAL COMPACT CONTROLLER DKR DKR04.1-W400N-BE23-00-FW configured controller
4

DKR04.1-W400-B Basic unit type

U
1 DSS 2.1M Type designation
U plug- in module
U5
S1 2 DEA4.1M
H1
U1 U3
U
3 COVER
SYSTEMCONFIGURATION
DKR04.1-W400N-BE23-00-FW

DKR04.1-W400N-B
U
H2 1 DSS2.1M

S2
U
2 DEA 4.1M
U
4 COVER
U
1 3 COVER
X9 U COVER
4
6
U DSM 2.3-FW
1
5
U2 U4
X8

7
X2
U Software module type
5 DSM2.3-FW
1
1

X3
X7

11
10 X4

K31/96 Production week/

year
Basic unit rating plate

DKR04.1-W400-B Type designation of

the basic unit

Coded serial no.

SN247199-02094

serial no. internal code

Dx3_id_4.fh5

Fig. 4-4: Rating plate of the DKR02.1 and DKR04.1 (Example)

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-4 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

Servicing When contacting INDRAMAT's Customer Service, it is important to have

readily available
• the type designation of the configured drive controller,
• the serial number of the basic unit
• and the firmware type designation.

Procuring a configured Replacement units can be obtained from INDRAMAT in the form of
replacement unit completely configured drive controllers . When ordering, please indicate
• the type designation of the configured drive controller and the
• firmware designation.
The drive controller is then delivered with plug-in modules U1 to U4, and
the software module (U5) plus firmware.

Putting a replacement unit The replacement unit can be put together with the basic unit and the plug-
together in modules. When placing the order or taking it out of a replacement parts
facility, e.g., possibly the customer's own, then
• the type designation of the basic unit and the
• type designation of the plug-in module are needed.
In the case of a self-configured replacement unit, it is not necessary to
order the software module as it can be re-utilized in the replacement. This
means that no adjustments of the replacement are needed.

Procuring a new software It only makes sense to replace a software module if the drive firmware
module has a significant error or the functions are to be expanded with a new
firmware release status.

Note: The machine parameters are stored on the software module of

the drive controller. They can be lost when replacing a module.
This means it is advisable to replace the software module only
when absolutely necessary!

Needed when ordering are the

• type designations of the software module
• and the firmware type designations.

The most recent and up-to-date firmware version is always delivered.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-5

Motors
A rating plate is mounted on every motor in close proximity to the terminal
box or power connector. Should this rating plate be covered by any part of
the machine, then an additional rating plate could be mounted in a more
visible location on the motor. An additional rating plate is always delivered
with every motor. It is taped over the motor rating plate.

Servicing When contacting INDRAMAT Customer Service, have ready

• the type designation and the
• serial number of the motor.

Procuring a replacement motor A replacement motor is ordered from INDRAMAT with the entire type
designation.

Electrical Connections
Ready-made cables
164871-96064849 Internal code
Type code of IKS 374 15.00m Length in meter
ready-made cable
19.08.96 230

Date of Internal code

performance test
DX3_ID_5.FH5

Abb. 4-5: Rating plate of ready-made INDRAMAT cables (Example)

Servicing It is advisable with damaged cables to replace them with tested, ready-
made INDRAMAT cables.

Procuring ready-made cables When ordering, indicate

• type designation of the ready-made cable and the
• length of the cable.
The rating plate is located near the end of the cable.

Components for a customer- The replacement cable can also be put together with components, i.e.,
made cables plug-in connectors, leads, ferrules and ring terminals. Special tools are
required, in particular for the power connectors. When obtaining
components, have ready
• the type designation of the plug-in connector and
• type designation of the lead.

Information about special tools and assembly guidelines are available

from INDRAMAT upon request!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-6 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

4.2 Replacing Drive Components

Supply Modules
See document "Supply Modules for AC Drives; Error Messages,
Diagnoses and Fault Clearance“, no. 209-0049-4308.

Drive Controllers
To avoid production downtime of the machine, it makes sense to simply
replace defective drive controllers.
INDRAMAT drive controllers are conceived towards a safe, quick and
simple replacement, keeping downtime to an absolute minimum.
The drive controller diagnosis faults in the drive system. Depending upon
the fault diagnosis, the remedial action, "Replacing the Drive Controller" is
detailled in the document „DIAX03 - ....; Notes on Fault Clearance".
Production can be resumed immediately after the unit is replaced as the
drive does not have to be set to the machine in any way.

Replacing DDS02.2/DDS03.2
Procuring a replacement unit • To achieve the highest degree of safe functioning, procuring a
configured drive controller for replacement is recommended. See
section on „Identification of the Drive Components“ on page 4-1.

Filling out a fault report • There is a sample of the fault report in section "Fault Report" of this
document on page 4-15. It can be copied for your convenience.
Carefully and completely fill it out! This information will ensure a rapid
completion of any repair tasks and help identify the application and
technical problems!

De-energizing • Switch main switch of machine off and secure it against being
switched back on.
• Remove the transparent cover of the defective unit and the
immediately adjacent units.

Live conductor rail (greater than 50V) even with

mains voltage off!
Electrical shock upon contact!
⇒ Wait discharge time of the DC bus (L+/L-), check for
DANGER less than 50 V before touching!

• Release all electrical and mechanical connections, with the exception

of the fixing bolts, on the front, top and bottom of the unit.With liquid-
cooled units, the coolant connections can be removed with coolant in
the system. The coolant will not run out!
Removing the drive controller • Fixing bolts on top and bottom of unit must be removed.Lift unit up
with both hands and take it out.
• Software module (slot U5) must be removed from the defective and
inserted into the replacement unit.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-7

Note: The machine parameters are stored on the software module.

No new adjustments of the drive to machine are needed if the
original software module is used!

Mounting DDS02.2/DDS03.2- • Grasp the controller at the bottom and top and hang it onto the
W...or DDS02.2-F... slackened fixing bolts. Tighten screws.

Mounting DDS02.2-A...
Sharp-edged heatsink of the controller must be
pushed into the opening in the mounting panel!
Injuries to hands by crushing and cutting are possible!
⇒ When inserting the controller hold the long stay-bolts
CAUTION at the top and bottom.
Connecting the drive controller • Tighten stay-bolts at top and bottom of unit!

• Re-connect all the eletrical and coolant connections (for liquid cooling)
as per manufacturer's diagram!
• Remount the cover!

Restarting the controller • Re-start the machine as per the guidelines of the manufacturer.
• Check the functions and the cooling system of the controller! In units
with liquid cooling, check the coolant level in the tank after restarting!

Replacing DKR02 / DKR03

Procuring a replacement unit To achieve the highest degree of safe functioning, obtaining a configured
drive controller for replacement is recommended. See section on
„Identification of the Drive Components“ on page 4-1.

Filling out a fault report There is a sample of the fault report in section "Fault Report" of this
document on page 4-15. It can be copied for your convenience. It must be
carefully and completely filled out! This information will ensure a rapid
completion of any repair tasks and help identify the application and
technical problems!

De-energizing Switch off main switch of machine and secure it against being switched
back on.

Live supply terminals if not completely de-energized

Danger of electrical shock upon contact!
⇒ Check the mains supply terminals to make sure that
the power or the control electronics are de-energized!
DANGER

• Release all electrical and mechanical connections, with the exception

of the fixing bolts for the unit, on the front, top and bottom of the unit
and remove.
- With duct cooling, remove the ducts from their connections.
- With liquid-cooled units, the coolant connections on the unit can be
removed with coolant in the system. It will not run out!!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-8 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

Removing the drive controller Drive controller with sharp-edged housing and
excessive weight!
Injuries to hands from crushing and cutting!
⇒ When removing, use appropriate lifting devices and
CAUTION gloves!

• Slacken the fixing bolts at the top and bottom of the unit. Do not
remove them!
• Lift the unit up and remove it off of the fixing bolts using suitable lifting
equipment. Note that the DKR02 weighs approximately 120, the
DKR03 49 kg.
• Remove software module (slot U5) from the defective unit and insert it
into the replacement unit.

Note: The machine parameters are on the software module! If

reused, then no readjusting of the drive to machine is needed!

Check whether the cooling system of the replacement unit is the same as
that of the unit being replaced.

Converting the drive controller • If the cooling air is to be pulled in and blown out over vents in the back
wall of the control cabinet, then convert the drive controller!
⇒ Screw in the sealing lid at the top and bottom of the controller! (Two
lids with conversion guidelines are included in the delivery!)
• If the cooling air is to be pulled in via a duct, then the controller must
also be converted!
⇒ The duct connecting supports at the top and bottom of the defective
machine must be mounted onto the replacement unit!

Mounting the controller Controller with sharp-edged housing and excessive

weight!
Injuries to hands from crushing and cutting are possible!
⇒ Use suitable equipment and wear protective gloves
CAUTION when mounting!
• Hang the controller onto the slackened fixing bolts using suitable
equipment.
• Tighten screws!

Connecting the controller • Restore the electrical and the coolant connections (applies to
controllers with liquid or duct cooling) of the controller as per the
diagrams of the manufacturer!
Restarting the controller • Restart the machine as per the manufacturer's guidelines.
• Check the functions and the cooling system of the controller! In units
with liquid cooling, check the coolant level in the tank after restarting!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-9

Replacing the DKR04

Procuring a replacement unit To achieve the highest degree of safe functioning, it is recommended to
procure a configured drive controller for replacement. See section on
„Identification of the Drive Components“ from page 4-1.

Filling out a fault report There is a sample of the fault report in section "Fault Report" of this
document from page 4-16. It can be copied for your convenience.
Carefully and completely fill it out! The information will ensure a rapid
completion of any repair tasks and help identify the application and
technical problems!

De-energizing • Switch off main switch of machine. Secure it against being accidentally
or intentionally switched back on.

Live supply terminals if not completely de-energized!

Danger of electrical shock upon contact!
⇒ Check the mains supply terminals to make sure that
the power or the control electronics are de-energized!
DANGER

• Release all electrical and mechanical connections, except for the fixing
bolts of the unit, on the front, top and bottom of the unit and remove.
- With duct cooling, remove ducts from their connections.
- With liquid-cooled units, the coolant connections on the unit can
be removed with coolant in the system as it will not run out!

Removing the drive controller

Drive controller with sharp-edged housing and
excessive weight!
Injuries to hands from crushing and cutting are possible!
⇒ When removing, use appropriate lifting devices and
CAUTION gloves!

• Slacken fixing bolts at top and bottom of unit. Do not remove them!
Lift and remove the unit from the fixing bolts using the suitable
equipment. Note that the DKR04 weighs approximately 150 kg.
• Remove the software module (slot U5) from the defective unit and
insert it into the replacement unit.

Note: The parameters of the machine are on the software module!

Re-using it means that the drive does not have to be re-
adapted to the machine!

Check that the replacement unit is identical to the replaced unit with
respect to the cooling mode!
Converting the controller • If there are no vents in the mounting panel of the control cabinet, then
convert the controller!
⇒ Remove the round sealing lid (snap-on type) on the right and the
sealing lid (screw type) at the bottom of the unit!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-10 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

DI
GI
TA
LC
OM
PA
CT
CO
NT
RO
LL
ER

DK
R4

10

11

Dx3-AT-1.fh5

Abb. 4-6: Converting the DKR04 to control cabinet cooling!

• If the cooling air is to be pulled in and blown out via ducts, then convert
the controller!
⇒ Remove the duct connecting supports on the top and bottom of the
defective unit and mount them onto the replacement!

Mounting the controller

Controller with sharp-edged housing and excessive
weight
Injuries to hands from crushing and cutting are possible!
⇒ Use suitable lifting equipment and wear gloves when
CAUTION mounting!

• Hang the controller onto the slackened fixing screws.

• Tighten screws!

Connecting the controller • Restore electrical and coolant connections (controllers with liquid or
duct cooling) of the controller as per the manufacturer's diagrams!

Restarting the controller • Restart the machine as per the manufacturer's guidelines!
• Check the functions and the cooling system of the controller! In units
with liquid cooling, check the coolant level in the tank after restarting!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-11

Motors
Procuring a replacement motor See section. „Exchanging Drive Components“ from page Fehler!
Textmarke nicht definiert..
Filling out a fault report There is a sample of the fault report in section "Fault Report" of this
document on page 4-15 for AC drives with DDS or DKR. It can be copied
for your convenience. Carefully and completely fill it out! The information
will ensure a rapid completion of any repair tasks and help identify the
application and technical problems!
De-energizing • Switch off main switch of machine. Secure it against being accidentally
or intentionally switched back on.

High voltage at supply terminals with incomplete de-

energizing, or re-application of drive enable, or if
motor is still turning!
Electrical shock from contact!
DANGER
⇒ Mains supply terminals for power and control
electronics and DC bus must be checked to make
sure they are de-energized!
⇒ Make sure that the motor is standing still!

Removing the motor

Improper handling or mounting
Injuries, damage to the machine are possible!
⇒ Follow the manufacturer's instructions when removing
the defective motor!
CAUTION
⇒ Secure hanging axes against falling!
• Remove defective motor as per manufacturer's guidelines.

Note: Avoid dirt contamination of open connectors! Maximum

permissible degree of contamination is V2! Operating safety is
not secured by greater contamination!

V2

Contamination level Immediate ambient conditions

Dirt that is capable of conducting cannot occur

V2 during operation (IP65), but non-conductive
contamination can occur during installation or
during replacement of drive components. Some
condense water could also form for short periods.
DX3_AT_2.FH5

Abb. 4-7: Permissible contamination levels of plug-in connectors on the motor

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-12 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

Mounting the motor • Mount the replacement motor as per manufacturer's instructions.

Connecting the motor • Reconnect all electrical and liquid cooling connections of the motor as
per the manufacturer's guidelines.

Note: Insert plug-in connectors only if these are dry and clean!

Restarting the machine • Restart the machine as per manufacturer's guidelines. It may be
necessary to home the machine if the measuring system of the motor
supplies the actual position value for position control.
• Check the motor blower functions.
• The rotational direction of the blower must agree with the direction of
the arrow on the blower housing!
• Check coolant level in tank with liquid-cooled motors!

Electrical Connections
Procuring replacement cables To achieve the highest degree of safe functioning, it is recommended to
procure ready-made INDRAMAT cables for replacmenet. See section on
„Identification of the Components“ from page 1-1.

De-energizing • Switch off main switch of machine. Secure it against being accidentally
or intentionally switched back on.

High voltage at supply terminals with incomplete de-

energizing!
Electrical shock from contact!
⇒ Mains supply terminals for power and control
DANGER electronics and DC bus mus be checked to make sure
they are de-energized!
Mounting and removing cables • Remove defective cable, or attach new cable to defective one and
when pulling out the defective cable, immediately pull in the new one.

Note: Avoid dirt contamination of open connectors! Maximum

permissible degree of contamination is V2! Operating safety is
not secured by greater contamination!

V2 V2 V2 V2 V2

H1

U5

Machine housing Control cabinet

U1 U2 U3 U4

Contamination level Immediate ambient conditions

Conductive contamination cannot occur during

V2 operation of the drive (IP65) but non-conductive
dirt contamination can occur during installation or
replacement of the drive components. Some
condense water could also form.
DX3_AT_3.FH5

Abb. 4-8: Permissible degree of dirt contamination of plug-in connections

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-13

Connecting the cables • In the case of cables without plug-in connectors, connect the individual
strands of the cable as per the manufacturer's guidelines. Use ferrules
or ring terminals!
- Note phase when connecting motor power and motor blower!
- Make sure that the plug-in contact of cables with plug-in
connectors are clean!

Note: Insert plug-in connectors only when these are clean and dry!

Restarting the machine • Restart the machine as per the manufacturer's guidelines. Check
motor blower functions.
The rotational direction of the blower blade must agree with the
direction of the arrow on the blower housing!
• Dispose of the defective cable!

Plug-in module
Procuring a plug-in module See section „Exchanging Drive Components“ in “Drive Components" from
page 4-1.

De-energizing • Switch off the drive package with DDS02.2/DDS03.2 or the controller
DKR from the mains. Make sure that the power and control voltage
sources are absolutely switched off.
The LEDs on the supply module and the H1 status display on the
controller must be dark, i.e., not lit up.
• Remove all electrical or optical connections from the front panel of the
plug-in module. Do not remove the transparent cover of the controller!

Replacing the plug-in module

Improper handling!
A defect in the controller or plug-in module can be
caused when replacing the plug-in module with
voltage still being applied!
CAUTION
⇒ Neither insert or remove the plug-in module with
voltage applied.

⇒ Release the safety screws at the top and bottom of the defective plug-
in module.
⇒ Pull defective plug-in module out and then label it as "defective".
⇒ Insert new plug-in module and manually retighten the safety screws.
⇒ Reconnect all electrial and optical connections of the plug-in module.

Restarting the controller ⇒ Make sure that the cause of the plug-in module defect has been
eliminated (e.g., a defect in the external measuring system, etc.).
⇒ Restart the machine as per the guidelines of the machine
manufacturer.
This restarts the drive package with DDS or DKR controller as well.

Software Module
Procuring a software module
Note: All machine parameters are stored on software module. Prior
to mounting a new software module, it makes sense to secure
the parameter settings on an external data carrier to then
reload and store it on the new software module!

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-14 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

See section "Identifying the Drive Components" in "Drive Controller"

starting from page 4-1.

De-energizing • Separate the drive package with DDS or the DKR controller from the
mains. Make sure that the power and the control voltage sources are
safely switched off.
The LEDs on the supply module and the H1 status display on the
controller must be dark, i.e., not lit up.
(Applies only to DDS) • Remove transparent cover! Do not touch the conductor rails of the DC
bus which run horiztonally underneath the software module (slot U5)!

Live conductor rails (grater than 50V) even with

mains voltage off!
Electrical shock on contact!
DANGER ⇒ Wait discharge time of DC bus (L+/L-). Check to
make sure it is below 50 V before touching!

After switching off, when removing the software module make sure that
there is sufficient distance to the conductor rails

Replacing the software module

(with the DDS and DKR) Improper handling!
Hardware and firmware can be damaged if plug-in
module is replaced with energy applied!
⇒ Neither remove nor insert with voltage applied!
CAUTION

• Pull the software module out of slot U5 of the controller and label, if
necessary.
• Insert new software module and make sure it it locked into place!

(only with the DDS) • Screw the transparent cover back into place!

Restarting the controller A restart of the controller is necessary if the software module has been
replaced. This is the due to possible drive behavior changes caused by
correction of errors or function expansions of the firmware.

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Exchanging Drive Components 4-15

4.3 Fault report

Fault Report
for digital DDS AC Drives
This fault report supports clarification of problems and their causes. It is absolutely necessary for
finding and eliminating even hidden, sporadic or applications-specific problems.
- Always include a fault report when sending in a repair.
- In any other case, send the fault report to the respective INDRAMAT Customer Service office, or send
it into
office with the address found on the back for the INDRAMAT Quality Assurance Department.
INDRAMAT will process the matter quickly and efficiently.

Co: Lo Date:
Fault report
from: Dept.: Name Tel

Information on the problem: Configuration rating

SYSTEMCONFIGURATION
Type code of the
DDS_ _.2-_ _ _ _-_ _ _ _-_ _-FW configured
Firmware rating drive contoller
DDS_ _.2-_ _ _ _-_ Type code of the
Firmware type FWA-DIAX03-_ _ _-_ _V_ _-__ basic unit
code ______ K_ _/_ _ U _________________
1
Coded serial
no. U
SN______ -______ __ 2 _________________ Type code of the
Serial no. Int. code U plug- in module
3 _________________
U
Basic unit rating plate 4 _________________
U Type code of the
Type code of 5 _________________ software module
basic unit DDS_ _.2-_ _ _ _-_ Production week/
K_ _/_ _
year
Coded serial
no. Motor data
SN______ -______ A_ _ H2 H1
Serial no. Internal coder Type:

Status displays H1 and H2 Serial no:

(Record display info at time of
problem)

Data on the machine with problem:

Manufacturer: Type: Op. hours:

Machine number: Start-up date:

Manuf. of and machine controller type

Designation of machine axis in which problem occurred:

Please describe the problem:

Additional data:
Problem status: Causes: Accompanying
Air conditioner in control
is always present unknown problems in mechanics
cabinet? J/N
during commissioning conn. error power section failure
occurs sporadically external causes control failure
Have there been similar
occurs after hours mechanical damage motor failure
problems before ?
occurs with shocks loose cable connection cable break
is temperature dependent condensation in unit defective blower
How often?
foreign object in unit defective feedback
Additional data: Did the problems occur on certain days
or times of the day ?

DX3_AT_4.FH5

Abb. 4-9: Fault report for AC drives with DDS02.2/DDS03.2

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
4-16 Exchanging Drive Components DIAX03 Drive With Electric Gear Function

Fault Report
for digital DKR AC Drives
This fault report supports clarification of problems and their causes. It is absolutely necessary for finding and
eliminating even hidden, sporadic or applications-specific problems.
- Always include a fault report when sending in a repair.
- In any other case, send the fault report to the respective INDRAMAT Customer Service office, or send it into
the office with the address found on the back for the INDRAMAT Quality Assurance Department.
INDRAMAT will process the matter quickly and efficiently.

Co: Loc.Loc.t: Date:

Fault report from
Dept.: Name: Tele:

Information on the problem: Configuration rating plate

Rating plate of basic unit
SYSTEMCONFIGURATION Type code of the
L1 L2 L3 A1 A2 A3 N L K B B X10

Type code of basic Netz/Mains X5 Motor

220 V
Steuerspannung
Aux.
Voltage
DKR_ _._-_ _ _ _-_ _ _ _-_ _-FW configured
unit DKR_ _ ._-_ _ _ _-_ drive contoller
•
•
•
•
•
X6

TM+

0VB
TM-
BR
DKR_ _._-_ _ _ _-_ Type code of the
Coded serial basic unit
no. U _________________
1
U
Firmware rating plate 2 _________________
Type code of the
Firmware type code U plug- in module
FWA-DIAX03-_ _ _-_ _V_ _-__
K_ _/_ _ 3 _________________
______ U5

Coded serial
S1 U
no.
FWA-DIAX03-ELS-03VRS-MS
266233 K31/96 4 _________________
H1
U1 U2
SYSTEMCONFIGURATION
DKR03.1-W100N-BE23-00-FW
U Type designation of the
5 _________________ software module
DKR03.1-W100N-B
U
1 DSS2.1M
U
2 DEA 4.1M

Production week/
U
3 COVER
U COVER
4
U DSM 2.3-FW
K_ _/_ _
H2
S2
5
TYS-DKR03.1-W100N-BE23-00
year
1

X9
6

X8
X2
U3 U4
DIGITAL COMPACT CONTROLLER DKR
Motor data
H1 H2 7

1
1 3

X7
X3
Type:
11
10 X4

H1 and H2 displays Serial no:

(record display at time problem
occurred)

Data on the machine with problem:

Manufacturer: Typ: Op. hours:

Machine no.: Commissioning date:

Manuf. of and machine controller type:

Designation of machine axis in which problem occurred:

Please describe the problem:

Additional data:
Problem status: Causes: Accompanying prob.:
is there an air condition
is always present unknown problems in mechanics
in the cabinet ? J / N
during commissioning conn. error power section failure
occurs sporadically external causes control failure
Have there been similar
occurs after hours mechanical damage motor failure
problems before?
occurs with shocks loose cable conn. cable break
is temperature dependent conensation in unit defective blower
How often:
foreign object in unit defective feedback
Additional data: Did the problems occur on certain days or
times of the day?

DX3_AT_5.FH7

Abb. 4-10: Fault report für AC-Antriebe mit DKR

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Index 5-1

5 Index

A
A000 Communication phase 0 3-19
A001 Communication phase 1 3-19
A002 Communication phase 2 3-19
A003 Communication phase 3 3-20
A010 Drive HALT 3-20
A011 Drive interlock open 3-20
A012 Control and power sections ready for operation 3-20
A013 Ready for power on 3-20
A100 Drive in TORQUE control 3-20
A101 Drive in VELOCITY control 3-21
A102 Position mode with encoder 1 3-21
A103 Position mode with encoder 2 3-21
A104 Position mode lagless, encoder 1 3-21
A105 Position control lagless, feedback 2 3-21
A106 Drive controlled interpolation, encoder 1 3-21
A107 Drive controlled interpolation, encoder 2 3-22
A108 Drive controlled interpolation, lagless, encoder 1 3-22
A109 Drive controlled interpolation, lagless, encoder 2 3-22
A112 Phase synchronization, encoder 1, virtual master drive 3-22
A113 Phase synchronization, encoder 2, virtual master drive 3-23
A116 Phase synchr. lagless, encoder 1, virtual master drive 3-23
A117 Phase synchr. lagless, encoder 2, virtual master drive 3-23
A120 Pattern control, encoder 1, virtual master drive 3-23
A121 Pattern control, encoder 2, virtual master drive 3-24
A124 Pattern control lagless, enc. 1, virtual master drive 3-24
A125 Pattern control lagless, enc. 2, virtual master drive 3-24
A128 Cam shaft, encoder 1, virtual master drive 3-24
A129 Cam shaft, encoder 2, virtual master drive 3-25
A132 Cam shaft, lagless, encoder 1, virt. master drive 3-25
A133 Cam shaft, lagless, encoder 2, virt. master drive 3-25
A146 Relative drive controlled interpolation, encoder 1 3-25
A147 Relative drive controlled interpolation, encoder 2 3-26
A148 Relative drive contr. interpolation, enc. 1, lagless 3-26
A149 Relative drive contr. interpolation, enc. 2, lagless 3-26
A800 Unknown operation mode 3-27
Ab 3-30
AF 3-30
AH 3-30
AS 3-30

B
bb 3-30

C
C100 Communication phase 3 transition check 3-2
C101 Invalid communication parameter (S-0-0021) 3-2
C104 Config. IDN for MDT not configurable 3-2
C105 Configurated length > max. length for MDT 3-2

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
5-2 Index DIAX03 Drive With Electric Gear Function

C106 Config. IDN for AT not configurable 3-2

C107 Configurated length > max. length for AT 3-3
C108 Time slot parameter > Sercos cycle time 3-3
C109 Position of data record in MDT (S-0-0009) even 3-3
C110 Length of MDT (S-0-0010) odd 3-3
C111 ID9 + Record length - 1 > length MDT (S-0-0010) 3-4
C112 TNcyc (S-0-0001) or TScyc (S-0-0002) error 3-4
C113 Relation TNcyc (S-0-0001) to TScyc (S-0-0002) error 3-4
C114 T4 > TScyc (S-0-0002) - T4min (S-0-0005) 3-4
C115 T2 too small 3-5
C200 Communication phase 4 transition check 3-5
C201 Invalid parameter(s) (->S-0-0022) 3-5
C202 Parameter limit error (->S-0-0022) 3-5
C203 Parameter calculation error (->S-0-0022) 3-5
C204 Motor type P-0-4014 incorrect 3-6
C210 External feedback required (->S-0-0022) 3-6
C211 Invalid feedback data (->S-0-0022) 3-6
C212 Invalid amplifier data (->S-0-0022) 3-7
C213 Position data scaling error 3-7
C214 Velocity data scaling error 3-7
C215 Acceleration data scaling error 3-8
C216 Torque/force data scaling error 3-8
C217 Motor feedback data reading error 3-9
C218 External feedback data reading error 3-9
C220 Motor feedback initializing error 3-9
C221 Ext. feedback initializing error 3-10
C223 Input value for max. range too high 3-10
C225 Coprocessor not ready for initialization 3-10
C226 Coprocessor acknowledge failed 3-11
C227 Modulo range error 3-11
C228 Controller type S-0-0140 wrong 3-11
C231 Emulator not loadable 3-11
C232 Motor encoder interface not present 3-11
C233 External encoder interface not present 3-12
C234 Encoder combination not possible 3-12
C235 Load-side motor encoder with inductance motor only 3-12
C236 Motor feedback required (P-0-0074) 3-12
C300 Set absolute measuring 3-12
C302 Absolute measuring system not installed 3-13
C400 Command
switch to parameter mode 3-13
C401 Drive active, switching not allowed 3-13
C402 Only allowed without master 3-13
C500 Reset class 1 diagnostic, error reset 3-13
C501 Error delet only in parameter mode 3-14
C600 Drive controlled homing procedure command 3-14
C601 Homing only possible with drive enable 3-14
C602 Distance home switch - reference mark erroneous 3-14
C604 Homing of absolute encoder not possible 3-14
C700 Basic load 3-15
C701 Basic load not possible if drive is enabled 3-15
C702 Default parameters not available 3-15
C703 Default parameters invalid 3-15
C704 Parameters not copyable 3-15
C705 Locked with password 3-16

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Index 5-3

C800 Default parameter load 3-16

C801 Parameter default value erroneous (-> S-0-0021) 3-16
C802 Locked with password 3-16
Cable damage 4-7
configured drive controller 4-6

D
D300 Command adjust commutation 3-16
D301 Drive not ready for commutation command 3-16
D500 Command 'get mark position' 3-17
D501 Incremental encoder required 3-17
D600 Cancel reference point procedure command 3-17
D700 Parking axis command 3-17
D800 Command measuring wheel operation mode 3-18
D801 Measuring wheel operation not possible 3-18
D802 Operation mode cancelled 3-18
Diagnostic Message Display
-0 3-28
-1 3-28
-2 3-28
-3 3-28
-5 3-28
-6 3-29

Watchdog 3-29

E
E201 No mains connected 2-23
E202 Not ready for power on 2-23
E219 Warning Drive temp. surveillance defective 2-23
E221 Warning Motor temp. surveillance defective 2-24
E225 Motor overload 2-24
E226 Undervoltage in power section 2-24
E247 Interpolation velocity = 0 2-25
E248 Interpolation acceleration = 0 2-25
E249 Positioning velocity S-0-0259 > S-0-0091 2-25
E250 Drive overtemp. prewarning 2-25
E251 Motor overtemp. prewarning 2-26
E253 Target position out of travel zone 2-26
E255 Feedrate-override S-0-0108 = 0 2-26
E257 Continuous current limit active 2-27
E259 Command velocity limit active 2-27
E261 Continuous current limit prewarning 2-27
E263 Velocity command value > limit S-0-0091 2-28
E410 Slave not scanned or adress 0 2-28
E825 Overvoltage in power stage 2-28
E826 Undervoltage in power section 2-29
E829 Positive position limit exceeded 2-29
E830 Negative position limit exceeded 2-29
E834 Emergency-Stop 2-30
E843 Positive limit switch activated 2-30
E844 Negative limit switch activated 2-30

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
5-4 Index DIAX03 Drive With Electric Gear Function

F
F207 Switching to uninitialized operation mode 2-2
F208 UL The motor type has changed. 2-2
F209 PL Load parameter default values 2-3
F218 Amplifier overtemp. shutdown 2-3
F219 Motor overtemp. shutdown 2-3
F221 Error Motor temp. surveillance defective 2-4
F228 Excessive deviation 2-4
F229 Motor encoder failure
quadrant error 2-5
F233 External power supply error 2-5
F236 Excessive position feedback difference 2-6
F237 Excessive position command difference 2-6
F242 External encoder failure
signal too small 2-7
F245 External encoder failure
quadrant error 2-8
F248 Low battery voltage 2-8
F249 Master drive encoder failure
signal too small 2-9
F252 Master drive encoder failure
quadrant error 2-9
F253 Incr. encoder emulator
pulse frequency too high 2-10
F254 Incr. encoder emulator
hardware fault 2-10
F255 External power supply DAE 02 error 2-10
F267 Erroneous internal hardware synchronization 2-10
F268 Brake fault 2-10
F270 Error power supply home switch 2-11
F271 Error power supply travel limit switch 2-11
F272 Error power supply probe input 2-12
F273 Error power supply E-Stop 2-12
F276 Absolute encoder out of allowed window 2-12
F280 Short circuit to earth 2-13
F281 Mains fault 2-13
F282 Phase loss fault 2-13
F283 Line voltage fault 2-13
F284 Main contactor off, low voltage 2-13
F401 Double MST error shutdown 2-14
F402 Double MDT error shutdown 2-14
F403 Invalid communication phase shutdown 2-14
F404 Error during phase progression 2-14
F405 Error during phase regression 2-15
F406 Phase switching without ready signal 2-15
F434 Emergency-Stop 2-15
F629 Positive travel limit exceeded 2-15
F630 Negative travel limit exceeded 2-16
F634 Emergency-Stop 2-16
F643 Positive travel limit switch detected 2-16
F644 Negative travel limit switch detected 2-17
F820 Bleeder overload 2-17
F822 Motor encoder failure
signal too small 2-17
F827 Drive interlock while drive activated 2-18

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Index 5-5

F860 Overcurrent
short in power stage 2-19
F861 Overcurrent
short to ground 2-19
F869 +/-15Volt DC error 2-19
F870 +24Volt DC error 2-19
F871 +10Volt DC error 2-20
F878 Velocity loop error 2-20
F879 Velocity limit S-0-0091 exceeded 2-20
F889 Regeneration overcurrent 2-21
F890 Processor fault power supply unit 2-21
F891 Power stage fault 2-21
F892 Wrong code of current measuring unit 2-21
F893 No regenerating current to mains 2-21
F894 Checksum error 2-22
Firmware release status 4-6

P
P0 3-30
P1 3-31
P2 3-31
P3 3-31

R
Rating plate of ready-made INDRAMAT cables 4-7
Rating plate of the DDS02.2 4-3
Rating plate of the DDS03.2 4-3
Rating plate of the DKR02.1 4-4
Rating plate of the DKR03.1 4-4
Rating plate of the DKR04.1 4-4
Rating plate on the supply module 4-2
Ready-made cables 4-7
Release status of the firmware 4-6
Removing the motor 4-13
Replacement cable 4-7
Replacement motors 4-7
Replacing a software module 4-6
Replacing cables 4-14
Replacing DDS02.2/DDS03.2 4-8
Replacing DKR02 / DKR03 4-9
Replacing plug-in module 4-15
Replacing the DKR04 4-11
Replacing the software module 4-16

S
Supply module 4-2

V
Velocity Synchronisation, virtuell Lead drive 3-22

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
DIAX03 Drive With Electric Gear Function Customer Service Locations

Customer Service Locations

Germany
Sales area Center Sales area East Sales area West Sales area North

INDRAMAT GmbH INDRAMAT GmbH INDRAMAT GmbH INDRAMAT GmbH

D-97816 Lohr am Main D-09120 Chemnitz D-40880 Ratingen D-22525 Hamburg
Bgm.-Dr.-Nebel-Str. 2 Beckerstraße 31 Harkortstraße 25 Kieler Str.212
Telefon: 09352/40-4817 Telefon: 0371/3555-0 Telefon: 02102/4318-0 Telefon: 040/853157-0
Telefax: 09352/40-4989 Telefax: 0371/3555-230 Telefax: 02102/41315 Telefax: 040/853157-15

Sales area South Sales area South-West INDRAMAT Service-Hotline

INDRAMAT GmbH INDRAMAT GmbH INDRAMAT GmbH

D-80339 München D-71229 Leonberg Telefon: D-0172/660 040 6
Ridlerstraße 75 Böblinger Straße 25
-oder-
Telefon: 089/540138-30 Telefon: 07152/972-6
Telefon: D-0171/333 882 6
Telefax: 089/540138-10 Telefax: 07152/972-727

Customer service locations in Germany

Europe
Austria Austria Belgium Denmark

G.L.Rexroth Ges.m.b.H. G.L.Rexroth Ges.m.b.H. Mannesmann Rexroth N.V.-S.A. BEC AS

Geschäftsbereich INDRAMAT Geschäftsbereich INDRAMAT Geschäftsbereich INDRAMAT Zinkvej 6
Hägelingasse 3 Randlstraße 14 Industrielaan 8 DK-8900 Randers
A-1140 Wien A-4061 Pasching B-1740 Ternat
Telefon: +45 87/11 90 60
Telefon: +43 1/985 25 40-400 Telefon: +43 7229/644 01-36 Telefon: +32 2/582 31 80 Telefax: +45 87/11 90 61
Telefax:+43 1/985 25 40-93 Telefax: +43 7229/644 01-80 Telefax: +32 2/582 43 10

England Finnland France France

Mannesmann Rexroth Ltd. Rexroth Mecman OY Rexroth - Sigma S.A. Rexroth - Sigma S.A.
INDRAMAT Division Riihimiehentie 3 Division INDRAMAT Division INDRAMAT
Broadway Lane, South Cerney SF-01720 Vantaa Parc des Barbanniers 4, 17, Loree du Golf
Cirencester, Glos GL7 5UH Place du Village F-69380 Dommartin
Telefon: +358 9/84 91 11
F-92632 Gennevilliers Cedex
Telefon: +44 1285/86 30 00 Telefax: +358 9/84 63 87 Telefon: +33 4/78 43 56 58
Telefax: +44 1285/86 30 03 Telefon: +33 1/41 47 54 30 Telefax: +33 4/78 43 59 05
Telefax: +33 1/47 94 69 41

France Italy Italy Netherlands

Rexroth - Sigma S.A. Rexroth S.p.A. Rexroth S.p.A. Divisione Hydraudyne Hydrauliek B.V.
Division INDRAMAT Divisione INDRAMAT INDRAMAT Kruisbroeksestraat 1a
270, Avenue de lardenne Via G. Di Vittoria, 1 Via Borgomanero, 11 P.O. Box 32
F-31100 Toulouse I-20063 Cernusco S/N.MI I-10145 Torino NL-5280 AA Boxtel
Telefon: +33 5/61 49 95 19 Telefon: +39 2/923 65-270 Telefon: +39 11/771 22 30 Telefon: +31 41 16/519 51
Telefax: +33 5/61 31 00 41 Telex: 331695 Telefax: +39 11/771 01 90 Telefax: +31 41 16/514 83
Telefax: +39 2/92 36 55 12

Spain Spain Sweden Switzerland

Rexroth S.A. Goimendi S.A. AB Rexroth Mecman Rexroth SA

Centro Industrial Santiago División Indramat INDRAMAT Division Département INDRAMAT
Obradors s/n Jolastokieta (Herrera) Varuvägen 7 Chemin de l`Ecole 6
E-08130 Santa Perpetua de Apartado 11 37 S-125 81 Stockholm CH-1036 Sullens
Mogoda (Barcelona) San Sebastion, 20017
Telefon: +46 8/727 92 00 Telefon:+41 21/731 43 77
Telefon: +34 3/7 47 94 00 Telefon: +34 43/40 01 63 Telefax: +46 8/64 73 277 Telefax: +41 21/731 46 78
Telefax: +34 3/7 47 94 01 Telex: 361 72
Telefax: +34 43/39 93 95

Switzerland Russia

Rexroth AG Tschudnenko E.B.

Geschäftsbereich INDRAMAT Arsenia 22
Gewerbestraße 3 153000 Ivanovo
CH-8500 Frauenfeld Rußland
Telefon: +41 52/720 21 00 Telefon: +7 93/22 39 633
Telefax: +41 52/720 21 11

European Customer service locations without Germany

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
Customer Service Locations DIAX03 Drive With Electric Gear Function

Outside Europe
Argentina Argentina Australia Brazil

Mannesmann Rexroth S.A.I.C. Nakase Australian Industrial Machinery Mannesmann Rexroth Automação
Division INDRAMAT Asesoramiento Tecnico Services Pty. Ltd. Ltda.
Acassusso 48 41/7 Diaz Velez 2929 Unit ¾5 Horne ST Divisão INDRAMAT
1605 Munro (Buenos Aires) 1636 Olivos Campbellfield VIC 2061 Rua Georg Rexroth, 609
Argentina (Provincia de Buenos Aires) Australia Vila Padre Anchieta
Argentina BR-09.951-250 Diadema-SP
Telefon: +54 1/756 01 40 Telefon: +61 3/93 59 0228
Argentina Caixa Postal 377
+54 1/756 02 40 Telefax: +61 3/93 59 02886
BR-09.901-970 Diadema-SP
Telex: 262 66 rexro ar Telefon +54 1/790 52 30
Telefax: +54 1/756 01 36 Telefon: +55 11/745 90 65
+55 11/745 90 70
Telefax: +55 11/745 90 50

Canada China China China

Basic Technologies Corporation Rexroth (China) Ltd. Rexroth (China) Ltd. Rexroth (China) Ltd.
Burlington Division Shanghai Office Shanghai Parts & Service Centre 1430 China World Trade Centre
3426 Mainway Drive Room 206 199 Wu Cao Road, Hua Cao 1, Jianguomenwai Avenue
Burlington, Ontario Shanghai Intern. Trade Centre Minhang District Beijing 100004
Canada L7M 1A8 2200 Yanan Xi Lu Shanghai 201 103 P.R. China
Shanghai 200335 P.R. China
Telefon: +1 905/335-55 11 Telefon: +86 10/50 50 380
P.R. China
Telefax: +1 905/335-41 84 Telefon: +86 21/622 00 058 Telefax: +86 10/50 50 379
Telefon: +86 21/627 55 333 Telefax: +86 21/622 00 068
Telefax: +86 21/627 55 666

China Hongkong India Japan

Rexroth (China) Ltd. Rexroth (China) Ltd. Mannesmann Rexroth (India) Ltd. Rexroth Co., Ltd.
A-5F., 123 Lian Shan Street 19 Cheung Shun Street INDRAMAT Division INDRAMAT Division
Sha He Kou District 1st Floor, Cheung Sha Wan, Plot. 96, Phase III I.R. Building
Dalian 116 023 Kowloon, Honkong Peenya Industrial Area Nakamachidai 4-26-44
P.R. China Bangalore - 560058 Tsuzuki-ku, Yokohama 226
Telefon: +852 2741 13 51/-54 und
Japan
Telefon: +86 411/46 78 930 +852 741 14 30 Telefon: +91 80/839 21 01
Telefax: +86 411/46 78 932 Telex: 3346 17 GL REX HX +91 80/839 73 74 Telefon: +81 45/942-72 10
Telefax: +852 786 40 19 Telex: 845 5028 RexB Telefax: +81 45/942-03 41
+852 786 07 33 Telefax: +91 80/839 43 45

Korea Korea Mexico

Rexroth-Seki Co Ltd. Seo Chang Corporation Ltd. Motorización y

1500-12 Da-Dae-Dong Room 903, Jeail Building Diseño de Controles, S.A. de C.V.
Saha-Gu, Pusan, 604-050 44-35 Yoido-Dong Av. Dr. Gustavo Baz No. 288
Youngdeungpo-Ku Col. Parque Industrial la Ioma
Telefon: +82 51/264 90 01
Seoul, Korea Apartado Postal No. 318
Telefax: +82 51/264 90 10
54060 Tlalnepantla
Telefon: +82 2/780-82 07 ~9
Estado de Mexico
Telefax: +82 2/784-54 08
Telefon: +52 /397 86 44
Telefax: +52 /398 98 88

USA USA USA USA

Rexroth Corporation Rexroth Corporation Rexroth Corporation Rexroth Corporation

INDRAMAT Division INDRAMAT Division INDRAMAT Division INDRAMAT Division
5150 Prairie Stone Parkway 2110 Austin Avenue Northeastern Sales Office Southeastern Sales Office
Hoffman Estates, Illinois 60192 Rochester Hills, Michigan 48309 7 Columbia Blvd. 3625 Swiftwater Park Drive
Peabody, MA 019660 Suwanee, GA 30174
Telefon: +1 847/645-36 00 Telefon: +1 810/853-82 90
Telefax: +1 847/645-62 01 Telefax: +1 810/853-82 90 Telefon: +1 508/531-25 74 Telefon: +1 770/932 3200
Telefax: +1 508/531-2574 Telefax: +1 770/932-1903

Customer service locations outside Europe

DOK-DIAX03-ELS-05VRS-WAR1-EN-P
.
Indramat