Rexroth Indradrive Fault Codes Explained

At the core of many manufacturing and industrial tasks is the Rexroth IndraDrive. But, if you stumble upon fault codes in your drive interface without proper understanding, it can be intimidating. We can make things easier by breaking down frequently observed fault codes, explaining their possible origins, and providing solutions.

A brief summary:

- F9xxx – Critical System Errors

- F8xxx – Severe Errors

- F7xxx – Errors in Safety Technology

- F4xxx – Errors in the Interface

- F3xxx – Non-Critical Safety Technology Errors

- F2xxx – Minor Errors

- Exxxx – Alert Diagnostic Messages

Deciphering Standard Fault Code Categories

F9XXX Range

The F9XXX codes depict critical issues that impede the routine functioning of the drive system, which can't be tackled using standard procedures. In the event of such errors, the drive's safety measures get disabled, drive torque is immobilized, and following a diagnostic message display, the power is terminated. It's imperative to reboot the system to restore its operation. Here are some specific error instances:

• F9001 – Internal Function Call Error: This indicates a broad software malfunction. To address this, turn the drive OFF, then switch it back ON. If the problem remains, drive replacement might be required.

• F9002 – Internal RTOS Function Call Error: This is activated by a software discrepancy. It's advised to consult the manufacturer's Service or Technical Support team.

• F9003 – Watchdog Alert: This error emerges from an activated watchdog timer. It's wise to reach out to the Service department for a potential drive replacement.

F8XXX Range

The F8XXX codes encompass severe errors that can surface during the drive's start-up or its regular operation. These errors, not being rectifiable through normal means, demand a comprehensive drive halt. Upon facing such anomalies, the drive's open-loop U/f control or its closed-loop system might not be assured. Rectifying these involves executing a cf, S-0-0099, C0500 Reset class 1 diagnostics error command, pinpointing and eradicating the primary issue, and then reactivating the drive.

• F8022 - Encoder Signal Anomalies: This error materializes when encoder signals deviate from the hardware-monitored parameters. Remedies include examining and, if necessary, replacing the encoder cable or cleaning up the encoder.
• F8070 - +24 Volt DC Discrepancy: This is detected when the regulation voltage supply diverges from the permissible range. Review the supply cable, inspect the control voltage connector, and assess the power supply module for possible solutions.

F7XXX Series

The F7XXX series errors denote issues related to Safety Technology, leading to an automatic deactivation of the drive. Once triggered, the drive shifts to a safety-related pause mode and the output is turned off. A specific set of steps, possibly including rectifying configuration mistakes, is required to reset. Let's delve into some sample errors:

• F7010 – Safety Related Position Increment Excess: Triggered when safety function position boundaries are surpassed. Address by executing the S-0-0099, C0500 Reset command.

• F7011 – Safety Related Positional Limit Breach in Positive Direction: Activated when a set limit is surpassed. Apply the S-0-0099, C0500 Reset command to resolve.

• F7012 – Safety Related Positional Limit Breach in Negative Direction: Emerges when there's a negative limit breach. Resolution involves employing the S-0-0099, C0500 Reset command.

F4XXX Series

F4XXX codes spotlight issues with the interface. These errors obstruct the regular initiation of NC reactions, rendering the drive without torque after an error response. Let's explore some cases:

• F4001 – Twin MST Shutdown Failure: This means the drive missed the Master Synchronization Telegram (MST) across two successive SERCOS cycles. Consider examining fiber optic links or modifying SERCOS timings.

• F4002 – Twin MDT Shutdown Failure: This suggests the drive missed the Master Data Telegram (MDT) through two consecutive bus or SERCOS cycles. Initiating cyclic communication or checking the fiber optic bus line might help.

• F4003 – Faulty Communication Phase Shutdown: Indicates an erroneous SERCOS master module communication stage. For these situations, liaising with the control unit's provider is advisable.

F3XXX Series

The F3XXX series errors are indicative of non-severe safety tech issues. When these arise, they enable users to determine the drive's action via suitable parameter configurations. Upon detection, the drive loses its torque, and power is shut down. This series encompasses various errors; a comprehensive list can be found elsewhere. A few instances are:

• F3111 - Missing Reference for Safety Related End Position Selection: Triggered when exceeding the acceleration boundary. Remedy involves resetting class 1 diagnostics and, if necessary, augmenting the value.

• F3112 - Missing Reference for Safety Related End Position Selection: Happens in the absence of a safety-related reference setup. Solution entails resetting safety-related position and class 1 diagnostics.

• F3117 - Discrepancy in Real Position Values: Caused by inconsistent values across channels 1 and 2. The recommended approach is to review parameterization and initiate channel 2's homing command.

F2XXX Series

The F2XXX series groups non-severe errors, offering flexibility in error responses. Typically, they indicate trivial glitches that can be addressed without major system intervention. A few examples are:

• F2026 - Power Section's Low Voltage: Signals that the DC bus voltage has plunged beneath the designated minimum. Solutions involve reengaging mains voltage or lightening the power supply load.

• F2816 - Power Supply's Softstart Discrepancy: Implies a marked shift in the DC bus voltage trajectory, hinting at a power segment problem. Remedial steps include either power section substitution or mains voltage inspection.

• F2174 - Motor Encoder Reference Disruption: Emerges when the drive controller can't determine a reference for encoder-centric position details. Clearing the issue and reestablishing position data reference is suggested.

EXXXX Series

The EXXXX group incorporates Warning Diagnostic Messages. These warnings indicate potential problems that may interfere with the efficient function of the system. Addressing these warning messages is vital to avoid escalating issues. Below are several specific examples:

• E8260 – Torque/Force Command Value Limit Active: This alert relates to the surpassing of drive-associated acceleration potentials or incorrect parameterization of torque/force limit values. The issue can be tackled by modifying the present velocity value, acceleration value, or torque/force limit values.

• E8057 – Device Overload, Current Limit Active: This notification points to an extreme thermal burden on the drive controller, resulting in unending activation of current limitation. Tuning the drive controller to align with motor or application demands or streamlining the mechanical system can resolve this issue.

• E8034 – Emergency-Stop: Initiated by the functionality of the drive controller to supervise its E-Stop input. Addressing the inception origin, adjusting the organization of digital outputs and inputs, or substituting a faulty control section can alleviate this problem.

Despite initial apprehension when confronted with Rexroth Indradrive Fault Codes, understanding what each series represents should empower you with enough knowledge to manage them efficiently! Reach out to us today for more information!