Appendix

Resonance analysis function

Clock signal

Internal count pulses, 1 pulse = 1 / 2²⁰ turn^-1

Regulates the difference between the current setpoint and the actual value to 0
Output : power output voltage

Rectified and smoothed power voltage

Removal of the ENABLE signal

electrically erasable memory in the servo amplifier, data that are stored in the EEPROM are not lost if the auxiliary voltage is switched off

Enable signal for the servo amplifier, Hardware-Enable with 24V signal to X3, Software-Enable command by setup Software, fieldbus or permanently set. Both are required for enabling the amplifier.

CANopen, PROFIBUS, PROFINET, EtherCAT, SERCOS etc.

Maximum value for the speed normalization at ±10 V

Special format for representing binary numbers

Brake in the motor, that can only be used when the motor is at standstill

Monitoring of the r.m.s. current that is actually required

The effective value of the peak current

The r.m.s. value of the continuous current

Proportional gain of a control loop

Switch limiting the traverse path of the machine; implemented as n.c. (break) contact

The complete assembly of all connected parts or devices, of which at least one is movable

output of an analog measurement

Data packet with all the position control parameters which are required for a motion task

Control loop with purely proportional behavior

Compensation for the lag between the electromagnetic and magnetic fields in the motor

control loop with proportional, integral and differential response

Regulates the difference between the position setpoint and the actual position to 0
Output: speed setpoint

Volatile memory in the servo amplifier. Data that are stored in the RAM are lost when the auxiliary voltage is switched off.

New start of the microprocessor

Operation with a periodic change of direction

Incremental position output

Control device for regulating the speed, torque and position of a servomotor

Limits for the rate of change of the speed setpoint

Regulates the difference between the speed setpoint and the actual value to 0
Output : current setpoint

Cyclically absolute, serial position output

Integral component of a control loop

DC-Link voltage ok. Amplifier is enabled.

DC-Link voltage ok. Amplifier is disabled.

Amplifier is updating the startup configuration

Status message, no error, programming mode

STO-Enable input is 0V (with disabled drive only)

FPGA program not loaded

Non Dual Use Firmware (labeled with “_ND0") is used.

An AL-3A225 (ECCN 3A225) export classified Dual Use Firmware (labeled with “_ND1") is used.

Access problems memory card

An AL-3A225 (ECCN 3A225) export classified firmware cannot be uploaded to a non Dual Use amplifier. A firmware labeled with “_ND0" must be used.

Heat sink temperature too high limit is set by manufacturer to 80°

Overvoltage in DC bus link limit depends on the electrical supply voltage

Message from the position controller

Cable break, short-circuit, short to ground

Undervoltage in DC bus link, limit is set by manufacturer to 100V

Motor temperature too high or temp. sensor defect

Internal amplifier supply voltages are out of tolerance

Motor over-revs, speed is too high

Checksum error

Cable break, short-circuit, short to ground

Motor cable break, short-circuit, short to ground

Motor phase missing (cable break or similar)

Ambient temperature too high

Fault in the power output stage or wrong motor cable or bad cable shielding

I²t maximum value exceeded

2 or 3 phases missing in the mains supply feed

Error in the analog-digital conversion

Brake circuit faulty or incorrect setting

DC bus link breakdown

Slot error, depends on the type of expansion card, see ERRCODE

Handling error on the expansion card

Reserved

Severe CAN bus communication error

Warning is displayed as fault

Commutation error

Hardware limit switch error on homing move

Operational error with STO, input for STO-Enable and ENABLE have been set at the same time

Fieldbus error, see ERRCODE

Communication disturbed, see ERRCODE

Timeout emergency stop

Safety Error code (see document Errors with S1, S2, S3, S4 Safety Cards from Download Page):
oXX=error number

iYY=error subindex

DC-Link voltage ok. Amplifier is enabled.

DC-Link voltage ok. Amplifier is disabled.

Amplifier is updating the startup configuration

Status message, no error, programming mode

STO-Enable input is 0V (with disabled drive only)

FPGA program not loaded

Non Dual Use Firmware (labeled with “_ND0") is used.

An AL-3A225 (ECCN 3A225) export classified Dual Use Firmware (labeled with “_ND1") is used.

I²t threshold exceeded

reached preset regen power limit

Exceeded preset following error limit

Response monitoring (fieldbus) has been activated

Mains supply phase missing

Underrun software limit switch 1

Overrun software limit switch 2

A faulty motion task was started

No reference point (Home) set at start of motion task

PSTOP limit-switch activated

NSTOP limit-switch activated

Only for ENDAT/ HIPERFACE: discrepancy between motor number saved in the encoder and the amplifier, motor default values loaded

24V supply of the I/O expansion board is missing

SinCos commutation (wake & shake) not completed, will be canceled when amplifier is enabled and wake & shake carried out

Speed-Current table INXMODE 35 fault

Summarized warning for n17 to n31

CAN sync is not logged in

Max. number of motor turns exceeded

Range overflow on motion task data

Invalid motion task

For details see PLC code

The user can shut down the process before the temperature eror will interrupt the process immediately

Warning level reached

Configuration is not logical

reserved

Use null-modem cable

Plug cable into the correct sockets on the servo amplifier and PC

Select correct interface

Max. value MAXTEMPH adjusted by manufacturer to 80°C. Decrease ambient temperature.

Check / blow out ventilation slots. Use air filters.

Check the air flow / fan noise; if defective, send the amplifier to the manufacturer for repair.

Range 20 .. 85°C, default 80°C

Conversion of the switchgear cabinet. Install an air-conditioning unit.

Return the servo amplifier to manufacturer for repair

"n02" displayed beforehand. Possibly use an external braking resistor or, in the case of multiple amplifiers, connect DC links.

Set the mains voltage correctly on the Basic Setup screen page

Set the details for the internal or external braking resistor correctly on the Basic Setup screen page

Check the wiring (see Instructions Manual). Internal braking resistor: Bridge must be present on the connector! External braking resistor: Bridge must be removed from the connector!

Replace fuse

Extend the braking ramps on the

Velocity Loop screen page

In the case of multiple amplifiers from the same family, connect the DC links (see Instructions Manual)

Check the mechanical system

Travel along flatter ramps (ACC,

DEC)

Lower the acceleration ramp (ACC) and braking ramp (DEC) in the speed controller

Adjust the amplification. Velocity Loop and possibly Position Loop screen pages

Adjust the amplification. Velocity Loop and possibly Position Loop, screen pages, insert a filter

Enlarge the following error window (Position Data screen page) or use a larger amplifier / motor, increase IPEAK.

Check the feedback cable

Exchange encoder / motor

Check contacts

See FBTYPE

Check cable (particularly critical in the cable trailing device)

See FBTYPE

Use suitable cables (see Instructions Manual)

Adhere to the max. permissible cable length (see Instructions Manual)

Check shielding, ensure compliance with the minimum spacing between the power cables and the signal connections (see Instructions Manual)

Wiring / Emergency stop / Control logic / ...

First of all switch on the power contactor which is connected via the BTB contact. Then switch the enable signal on approx. 0.5s later

Operator information

Adjustment of the parameter, e.g. in 48VDC applications.

Example: Positioning the axis in the event of mains failure.

Incorrect motor parameters / Poor cooling

Measure the sensor resistance.

Switch:
- low temperature: switch closed
- high temperature: switch open.

PTC thermistor:
- low temperature: low resistance
- high temperature: high resistance

Connector / cable control

Installation of a bridge in the connector

Set the MAXTEMPM parameter (to the cutoff threshold, see parameter description)

Bridge the temperature contact for testing at the resolver or SinCos interface

Contact Customer Support

Disconnect all the connectors apart from 24V and check whether the error occurs again when you switch on

Adhere to the tolerance criteria for the 24V voltage supply (see Instructions Manual)

Adhere to the maximum motor brake current (see Instructions Manual); supply brake with external voltage.

Return the servo amplifier to manufacturer for repair

Contact Customer Support

Check the VOSPD (limit speed) and raise it, if necessary.

Reduce overswing by assigning amplification parameters

(Possibly check by shaking the cable) Replace the cable

When a new motor is loaded, quicker motors with a max. of only 3,000 rpm are also entered. The end speed and overspeed have to be adapted for higher speeds.

Parameter adaptation

Increase target times or use a motor with a higher nominal speed

Check and correct assignment

Check the pin assignment

Set angle offset correctly (MPHASE)

Re-enter parameters and save them

Change the lower-case lettering to upper case

Return the servo amplifier to manufacturer for repair

Check connectors / cables.

Set the parameter SDLY to 8,000. (FW 1.31 or higher)

Signal sources must switch between

–5V and 5 V, not between 0V and 5V.

Replace the cable

Connect the right motor cable

Set MBRAKE to 0

Raise current consumption to a minimum of 150mA (e.g. through parallel resistors).

Return the servo amplifier to manufacturer for repair

Check the shield connections

Additional design of motor shields on the mounting plate of the switchgear cabinet.

• Use a motor choke
• Shorten the cable
• Use Kollmorgen cables

Check contactor

Check contactor

Return the servo amplifier to manufacturer for repair

Check connector

Use a cooling device

Return the servo amplifier to manufacturer for repair

Increase TEMPE

Use a cooling device

Replace motor cable

Return the servo amplifier to manufacturer for repair

Conduct measurements with an ohmmeter between the motor phases: must be symmetrical. Measure the motor phases to the PE; it must be unending. If there is a high-voltage tester available, use it to measure the motor phases to PE.

Check the switching sequence

Replace motor contactor.

Check mechanical system, use a larger amplifier/motor

Extend the acceleration/braking ramps (ACC, DEC)

Contact Customer Support

Correct the MPHASE , possibly reset with ZERO.

Extend the acceleration/braking ramps (ACC, DEC)

Extend the recovery intervals between motion tasks (Motion Tasks screen page)

Adjust the amplification of the MLGQ

and the KTN reset time

Replace motor

Check setting on screen page Basic Setup

Check wiring/fuses/main contactor

Contact Customer Support

Amplifier only enabled when the mains voltage is switched on (comply with switch-on sequence)

Reduce EMC interference; check shielding and earthing. Mount devices which generate electrical fields further away from the amplifier.

Return the servo amplifier to manufacturer for repair

Check setting on screen page

Basic Setup

Return the servo amplifier to manufacturer for repair

Check and switch on power supply

Adapt VBUSMIN

Adapt parameters or hardware

In the case of expansion card

I/O-14/08, check the card's external power supply unit

Contact Customer Support

Contact Customer Support

Remove the card and insert a new one and tighten it, following the instructions in the Instructions Manual.

Contact Customer Support

Terminal: enter CALCPOSIO

Contact Customer Support

Contact Customer Support

Check CAN cable and controller

With the WMASK parameter you can read out which warning(s) are evaluated as errors. On the basis of this information, refer to the list of warning messages. The LASTWMASK parameter indicates which warning last led to F24.

Test motor cable fully – Adapt DIR

Check direction of rotation in the monitor window, test feedback cable fully – Adapt DIR

Examine mechanical system and align it, if necessary

Raise VCOMM (VCOMM =

MSPEED means minimum sensitivity)

Check and correct amplifier-motor assignment.

Check resolver pole number (MRESPOLES), motor pole number (MPOLES) and offset (MPHASE)

Perform Wake&Shake

Check cable

Check and correct limit switch-axis assignment.

Disable input functions (Digital I/O screen page)

Assign PSTOP and NSTOP correctly to the inputs (Digital I/O screen page)

Consider Switch-On sequence (see Instructions Manual)

Check wiring, measure cable-resistance.

Adaptation of the specified values (VLIM / PVMAX)

Check EtherCAT system.

Set Hardware Enable first

Switch on mains voltage first

Upgrade firmware

Check performance of fieldbus master

Enter COLDSTART in the terminal screen

Select valid mapping number

Check mapping length

Apply set point after W&S procedure has ended

Check network structure

Replace fiber optic cable

Check SERCOS Master

Check programming

Check hardware

Decrease DECSTOP

Increase IPEAK

Increase EMRGTO

Select servo amplifier with higher rated/peak current

Check error code of the safety card (see file Errors with S1, S2, S3, S4 Safety Cards from Download Page).

Too many stations in the network/Baud rate too high/Functions too complex (PLC)

Check the mechanical system

Use an amplifier with a higher current

Use a motor with a higher current

Define recovery times

Check setting

Use external brake resistance, extend braking ramps (DEC / DECSTOP )

Check the mechanical system

Use an amplifier with a higher current

Define recovery times, extend ramps

Check setting

Disable watchdog temporarily (EXTWD = 0)

Check bus installation

Check the mains connection, fuses and mains contactor

Check the position of the axis and setting of the software limit switch

Check the position of the axis and setting of the software limit switch

Create a new motion task

Check software limit switches and target positions

Check units and numerical values

Set correct OPMODE

Perform homing or set reference point

Move the axis in a negative direction from the limit switch

Change the parameterization of digital I/Os or connect the limit switch

Insert break contacts as limit switches (instead of make contacts).

Move the axis in a positive direction from the limit switch

Change the parameterization of digital I/Os or connect the limit switch

Insert break contacts as limit switches (instead of make contacts).

SAVE motor number to the EEPROM and with HSAVE to the encoder.

Check wiring and 24V power supply

ENABLE the amplifier

See warning #

Check fieldbus settings

Ignore or disable monitoring with

DRVCNFG Bit7=1

Move motor to encode position 0 prior to installation

Check the process block data

Check the data from the last process block started. Also determine the process block number with MOVE.

Application-specific

Check the motor temperature.

Check the mechanical system

Check the signal amplitude, possibly re-measure with an oscilloscope

Undo the last configuration change

Apply Hardware ENABLE signal

Set software enable

Check setpoint cable

Correct motor phase sequence

Check brake control

Check mechanism

Set motor pole no.

Set up feedback correctly

Reduce Kp~GV (speed controller)

Replace feedback cable

Join AGND to CNC-GND

Increase Kp~GV (speed controller)

Use motor default value for Tn~GVTN (speed controller)

Reduce ARLPF / ARHPF

Reduce ARLP2

Reduce Kp~GV (speed controller)

Use motor default value for Tn~GVTN (speed controller)

Increase ARLPF / A RHPF

Increase ARLP2

Adjust offset (analog I/O)