Bosch Rexroth IndraDrive MPx02

The drive's control system failed to establish communication or access data within the Hiperface memory. This often indicates a corrupted memory module, a physical connection issue, or an internal hardware defect related to the memory interface. Such a fault can prevent the drive from booting, loading essential configuration data, or operating correctly.

A fault occurred during non-cyclical data communication within the power section of the drive. This indicates an issue with data exchange that is not part of the regular control loop, potentially affecting configuration, diagnostics, or parameter updates. This can lead to improper power stage operation or failure to respond to commands.

The MultiMediaCard (MMC) used by the drive is either defective, corrupted, or entirely missing from its slot. The MMC is crucial for storing operating system files, parameters, and application data. Without a functional MMC, the drive cannot operate and may fail to boot.

The MultiMediaCard (MMC) contains incorrect data or a faulty file that prevents proper drive operation. This could be due to a corrupt configuration file, an incompatible firmware version, or a damaged application program stored on the card. The drive will likely fail to initialize or execute its intended function.

The IBF file stored on the MultiMediaCard (MMC) is incorrect or corrupted. The IBF (IndraDrive Boot File) contains critical boot and system configuration information. An incorrect IBF file will prevent the drive from starting up properly or loading its operational parameters, rendering it inoperable.

The drive was unable to perform or complete a backup of its retain data. Retain data typically includes critical parameters and settings that need to persist across power cycles. Failure to back up this data could lead to loss of configuration upon restart or prevent safe operation.

The MultiMediaCard (MMC) is experiencing excessively slow write speeds during data saving operations. This could indicate a failing MMC card, a heavily fragmented card, or an issue with the drive's internal memory interface. Slow saving can lead to operational delays, data corruption, or failed parameter saves.

A fault has been detected in the comfort control panel, which is typically an HMI or operator interface for the drive. This error indicates a problem with the panel's hardware, software, or its communication link with the main drive unit. This can prevent operators from monitoring or controlling the drive effectively.

A communication error has occurred with a CCD (Cascaded Communication Device) slave unit. CCD is a communication protocol used for connecting multiple devices in a daisy-chain or cascaded fashion. This fault signifies that one of the slave devices is not communicating properly, which can disrupt control of the entire chain.

An error has been detected within an MLD (Motion Logic Drive) motion function block. MLD provides integrated motion control capabilities, and this fault indicates a problem with the execution or configuration of a specific motion sequence or function. This can lead to unexpected machine movements or an inability to perform required motion tasks.

The drive has lost the reference signal from the motor encoder. This encoder provides critical feedback on the motor's position and speed, which is essential for precise control. Loss of this reference means the drive cannot accurately determine motor shaft position, leading to uncontrolled movement or immediate shutdown for safety.

The drive has lost the reference signal from an optional encoder. This optional encoder provides additional feedback, perhaps for a secondary axis, master axis, or external position measurement. Loss of this reference will compromise the accuracy and synchronization of the system relying on this feedback, potentially leading to operational faults.

The drive has lost the reference signal from the measuring encoder. This encoder is often used for high-precision position measurement, distinct from the motor's primary encoder. Loss of its reference means the system cannot accurately track or control the position of the monitored component, impacting measurement and control accuracy.

A modulo limitation error has occurred with the motor encoder. This typically indicates that the encoder's position value has exceeded or fallen below its configured modulo range, or that an unexpected wrap-around occurred. This suggests an issue with encoder scaling, position tracking, or data integrity within the modulo calculation.

A modulo limitation error has occurred with the optional encoder. Similar to the motor encoder, this suggests that the optional encoder's position value has violated its defined modulo range, or an unexpected wrap-around. This can lead to incorrect position feedback for the system components relying on this optional encoder.

A modulo limitation error has occurred with the measuring encoder. This means the measuring encoder's reported position has gone outside its defined modulo operating range, or experienced an unexpected position wrap. This can lead to highly inaccurate position measurements, impacting critical machine operations and product quality.

The Ethernet network configuration of the drive is incorrect or incompatible. This fault indicates that the drive cannot properly establish or maintain communication over its Ethernet interface, affecting control, monitoring, and data exchange with other network devices. This will prevent network-based operation.

The drive has triggered a shutoff due to the command current exceeding its defined limit. This indicates that the control system demanded more current than the drive's safety or operational parameters allow, often to achieve a desired torque or acceleration. This can protect the motor and drive from overstress.

A wire break has been detected on either analog input 1 or analog input 2 of the drive. These inputs are used for signals such as speed reference or torque command, typically 0-10V or 4-20mA. A broken wire means the drive is not receiving the expected input signal, leading to loss of control or incorrect operation.

The Phase-Locked Loop (PLL) in the drive's control system is not synchronized. The PLL is critical for internal timing and synchronization with external signals, such as encoder inputs or master clock signals. A lack of synchronization can lead to unstable control, incorrect speed/position tracking, or communication errors.

The input mains voltage has dropped below the permissible undervoltage threshold. This indicates a problem with the electrical supply to the drive, which can lead to insufficient power for the internal circuitry and the power stage. Prolonged undervoltage can cause erratic behavior, reduced performance, or damage to components.

The input mains voltage has risen above the permissible overvoltage threshold. This indicates an issue with the electrical supply, potentially damaging the drive's input rectifiers, DC bus capacitors, or other sensitive components. Overvoltage can lead to immediate drive shutdown to prevent hardware damage.

A fault has occurred in the softstart circuit of the power supply unit. The softstart limits inrush current during power-up to protect components. This fault indicates that the softstart mechanism either failed to activate, failed to limit current effectively, or timed out. This can lead to high current surges and potential damage upon power-on.

An overvoltage condition has been detected within the drive's power section, specifically on the DC bus. This typically occurs when regenerative energy from the motor cannot be dissipated, causing the DC bus voltage to rise beyond safe limits. High DC bus voltage can damage the inverter's power semiconductors.

One or more phases of the three-phase AC mains input power supply have failed or are missing. This leads to an unbalanced or insufficient supply voltage for the drive's rectifier and DC bus. Operating with a phase failure can cause excessive ripple on the DC bus, overheating, and damage to the drive components.

A complete loss of the AC mains input power supply has occurred. The drive is no longer receiving power from the grid, which means it cannot operate and will initiate a controlled shutdown. This fault indicates that the entire power source is interrupted, not just a single phase.

The external braking resistor has been overloaded, indicating it has dissipated too much energy and its temperature has likely exceeded safe limits. This occurs during regenerative braking when the motor feeds energy back into the drive. Continuous overload can damage the resistor or cause a fire hazard.

A fault has occurred in the control circuit responsible for managing the braking resistor. This circuit typically involves a braking chopper that switches the resistor in and out to dissipate regenerative energy. An error here means the resistor may not be activated when needed or may be permanently connected, leading to overvoltage or overheating.

The configured switch-on threshold for the braking resistor is set too low. This threshold defines the DC bus voltage at which the braking chopper activates the resistor. If set too low, the resistor may activate unnecessarily or too frequently, potentially leading to premature wear or overload, even at normal operating conditions.

A ground fault has been detected in the motor wiring or the motor itself. This means that current is flowing from one of the motor phases to ground, bypassing the normal current path. A ground fault is a serious safety concern and can cause damage to the drive's output stage or the motor insulation.

An error has occurred in the control circuit for a contactor, typically the mains contactor or a motor contactor. This implies that the drive commanded the contactor to switch, but the feedback signal indicated a discrepancy (e.g., contactor failed to close/open, or opened unexpectedly). This can compromise safety or prevent motor operation.

A wiring error has been detected in the circuit connecting the mains contactor to the drive. This could include incorrect connections for the contactor coil, auxiliary contacts, or power lines. Improper wiring can lead to the contactor failing to engage, disengage, or provide correct status feedback, affecting safe power-up and operation.

An error has been detected by the DC bus balancing monitor. This system ensures that the voltage across series-connected DC bus capacitors remains balanced. An imbalance can indicate a faulty capacitor, a problem with the balancing resistors, or an issue with the monitoring circuit itself, potentially leading to capacitor overvoltage and failure.

The drive's internal monitoring system has detected an inconsistency with a contactor's status. This could mean the contactor is not opening or closing as expected, or the feedback signals do not match the commanded state. This failure mode can lead to unsafe operation, such as unexpected motor starts or inability to remove power.

An error occurred during the process of shutting down the power supply. This could indicate a problem with the controlled discharge of DC bus capacitors, a failure in the power-down sequence, or an inability to fully remove power. An uncontrolled shutdown can risk personnel safety or damage sensitive components.

An excessive current has been detected in the mains-side power section (input rectifier) of the drive. This indicates a high current draw from the AC mains supply, potentially due to a short circuit, an internal component failure in the rectifier, or extreme loading conditions. This fault triggers an immediate shutdown to protect the drive from damage.

The device code detected by the drive is invalid. This code identifies the specific hardware variant or type of the drive or an installed module. An invalid code suggests an incompatibility between hardware components, an incorrectly installed module, or a firmware issue preventing proper device identification. The drive may refuse to operate with unrecognized hardware.

The drive's internal interrupt timing is incorrect. Interrupts are critical for real-time operation and processing, allowing the drive to respond to events promptly. Improper timing can lead to missed events, delayed responses, unstable control loops, and general erratic behavior of the drive's control system.

The detected hardware variant of the drive or an installed module is not supported by the current firmware. This typically occurs when a new or different hardware version is used with an older or incompatible firmware release. The drive will not be able to operate safely or correctly without compatible firmware.

A required reference for selecting a safety-related end position is missing. For safety functions like 'Safely Limited Position', precise reference points are essential to ensure the machine stays within safe boundaries. Without this reference, the safety function cannot be reliably established, leading to a safety fault and machine halt.

A general safety-related reference value required for safe operation is missing. This reference could be related to position, speed, or other critical safety parameters. Without a valid safety reference, the system cannot guarantee safe functionality and will trigger a fault to prevent hazardous conditions.

The allowed time interval for performing a brake check has been exceeded. Safety-related brake checks are periodic tests to verify the holding brake's functionality. Failure to complete this check within the configured interval indicates either a brake malfunction, a system delay, or an issue preventing the check's execution, compromising holding safety.

An error occurred during the validation of actual position values, likely from a safety-related encoder. This means the system detected inconsistencies or implausible values in the position feedback, crucial for safety functions. This can indicate a problem with the encoder, its signal, or the validation logic, leading to a safety stop.

A general system error has occurred within the safety-related holding system. This system is responsible for safely holding the motor or axis in position, often through mechanical brakes. This fault indicates a critical failure in the holding mechanism's overall operation, requiring immediate attention to prevent unintended motion or dropping of loads.

A required safety-related brake check for the holding system was not performed or detected. Regular checks are vital to ensure the reliability of mechanical brakes used for safety. If a check is missing, the system cannot guarantee the brake's integrity, leading to a safety fault and potentially hazardous conditions.

An error occurred during the validation or monitoring of safety-related input signals. These inputs (e.g., emergency stop buttons, safety gates, light curtains) are crucial for machine and personnel safety. This fault indicates an inconsistency or malfunction in how these signals are read or processed, triggering a safety reaction.

An error occurred during the verification of a safety-related acknowledgment signal. Acknowledgment signals are used to confirm that a safety condition has been met or a safety command has been processed, often after a fault. Failure to correctly process this signal indicates a problem with the safety feedback loop, preventing system reset or safe operation.

An error was detected during the monitoring of a safety diagnostic output signal. These outputs provide status or diagnostic information from the safety system to external controllers. An error implies an inconsistency or malfunction in the safety module's ability to provide accurate diagnostic feedback, potentially masking safety issues.

An error was detected during the checking of safety-related interrupting circuits. These circuits are designed to safely remove power or stop motion in an emergency, often involving multiple redundant paths. This fault indicates a discrepancy or malfunction within these critical safety paths, potentially compromising the ability to safely shut down.

The time interval for dynamization of safety-related signals is incorrect. Dynamization involves periodically changing the state of safety inputs/outputs to detect latent faults like short circuits or stuck signals. If the interval is wrong, the diagnostic coverage for these faults is compromised, potentially leading to undetected hazards.

The pulse width used for dynamization of safety-related signals is incorrect. Dynamization pulses are short test signals applied to safety inputs/outputs to detect wiring faults. An incorrect pulse width means the diagnostic test may not be effective, potentially missing latent faults in the safety circuit and compromising safety integrity.

An error occurred during the validation of safety parameters. All safety-related parameters (e.g., speed limits, position limits, reaction times) must be correctly configured and validated to ensure the system operates safely. This fault indicates an inconsistency, invalid value, or corruption in these critical parameters, preventing safe operation.

An error occurred during the validation of a safety-related selection. This implies a problem when selecting or activating a specific safety function or operating mode (e.g., 'Safe Operating Stop', 'Safely Limited Speed'). The selection could be invalid, inconsistent, or fail a self-test, preventing the desired safety mode from being entered securely.

The activation time for the enabling control signal has been exceeded. The enabling control signal (e.g., Safe Torque Off - STO) is critical for allowing or disallowing motor torque. If it takes too long to activate after being commanded, it indicates a failure in the safety circuit's response time, compromising personnel and machine safety.

The safety command issued for clearing errors was incorrect or invalid. After a safety fault, a specific, validated command is required to acknowledge and reset the safety system. An incorrect command means the system cannot safely transition out of the fault state, preventing machine restart and maintaining a safe condition.

The overall safety configuration of the drive system is incorrect or inconsistent. This indicates a fundamental problem with how safety functions are defined, parameterized, or structured within the system. An incorrect configuration will prevent the drive from entering a safe operating state and will trigger a fault to prevent any hazardous motion.

An error occurred during the process of unlocking a safety door. Safety doors are typically interlocked and require a specific sequence or condition to unlock safely. This fault indicates a malfunction in the door interlock mechanism, its sensor, or the control logic, preventing the door from opening or confirming its open status, potentially trapping personnel.

A system error has been detected in safety channel 2. Safety systems often employ redundant channels to ensure reliability (e.g., dual-channel architecture). This fault indicates a failure or discrepancy within the second, independent safety processing path. This redundancy failure means the system can no longer guarantee its safety integrity, leading to a fault state.

A system error has been detected in safety channel 1. This indicates a failure or discrepancy within the primary safety processing path of a redundant safety system. Similar to a channel 2 error, this redundancy failure means the system cannot guarantee its safety integrity, leading to a fault state and requiring immediate attention.

The safety command issued to initiate a system start was incorrect or invalid. Safety systems require precise and validated commands to transition from a safe-stopped state to an operational state. An incorrect command means the system cannot safely initiate operation, preventing machine startup and maintaining a safe condition.