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Over 100 years cumulative experience
24 hour rush turnaround / technical support service
Established in 1993
The leading independent repairer of servo motors and drives in North America.
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Summary of Contents for Bosch Rexroth Servodyn-D Series

  • Page 1 Over 100 years cumulative experience 24 hour rush turnaround / technical support service Established in 1993 The leading independent repairer of servo motors and drives in North America. Visit us on the web: www.servo-repair.com www.servorepair.ca www.ferrocontrol.com www.sandvikrepair.com www.accuelectric.com Scroll down to view your document! For 24/7 repair services : USA: 1 (888) 932 - 9183 Canada: 1 (905) 829 -2505...
  • Page 2 Industrial Electric Drives Linear Motion Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth Servodyn D 1070 066 032 Ausgabe 03 Diagnostics, maintenance Maintenance Guidelines...
  • Page 3 Date DOK-SERV*D-DIAGNOSTICS-WA03-EN-P 07.2003 Software releases refer to page 1–10 E Bosch Rexroth AG, Copyright 1998 – 2003 Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34–1).
  • Page 4: Table Of Contents

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG and Controls Contents Contents Page Safety Instructions ..... . .
  • Page 5 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Contents Overview of DS..K xxx1-D ......
  • Page 6: Safety Instructions

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 1–1 and Controls Safety Instructions Safety Instructions Please read this manual before commissioning the Servodyn-D drives. Store this manual in a place to which all users have access at any time.
  • Page 7 1–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Safety Instructions This is a Class A device. In a residential area, this device may cause radio interference. In such case, the user may be required to introduce suitable countermeasures, and to bear the cost of the same.
  • Page 8: Qualified Personnel

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 1–3 and Controls Safety Instructions Qualified personnel The requirements as to qualified personnel depend on the qualification profiles described by ZVEI (central association of the electrical industry) and VDMA (association of German machine and plant builders) in:...
  • Page 9: Safety Markings On Products

    1–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Safety Instructions Safety markings on products Warning of dangerous electrical voltage! Warning of hot surface > 60 _C! Electrostatically sensitive components! Warning of hazardous light emissions...
  • Page 10: Safety Instructions In This Manual

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 1–5 and Controls Safety Instructions Safety instructions in this manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of a dangerous electrical voltage. The failure to observe the instructions in this manual in whole or in part may result in personal injury.
  • Page 11: Safety Instructions For The Described Product

    1–6 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Safety Instructions Safety instructions for the described product DANGER Danger of life through inadequate EMERGENCY-STOP devices! EMERGENCY-STOP devices must be active and within reach in all system modes.
  • Page 12 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 1–7 and Controls Safety Instructions DANGEROUS ELECTRICAL VOLTAGE Unless described otherwise, maintenance works must be per- formed on inactive systems! The system must be protected against unauthorized or accidental reclosing.
  • Page 13 1–8 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Safety Instructions CAUTION Observe all precautions for ESD protection when handling mod- ules and components! Avoid electrostatic discharge! The following protective measures must be observed for modules and...
  • Page 14: Documentation, Software Release And Trademarks

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 1–9 and Controls Safety Instructions Documentation, software release and trademarks Documentation The present manual informs you about the diagnostics options of the Servodyn-D drive series. Overview of available documentation Part no.
  • Page 15 1–10 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Safety Instructions Release The present manual applies to the following releases: DM/DS software: SERCOS interface V0.049 or higher CANopen/rho V0.002 or higher Analog interface V0.17 or higher PROFIBUS-DP V0.004 or higher...
  • Page 16: Mains Connection At The Place Of Installation

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 2–1 and Controls Mains connection at the place of installation Mains connection at the place of installation CAUTION A reversed phase sequence or winding direction of a line reactor will destroy the mains connection module.
  • Page 17 2–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Mains connection at the place of installation Earth connections in the switch cabinet must be designed in the form of a grid mesh. The module housing and mounting plate of the switch cabinet must be earthed.
  • Page 18: Earth-Leakage Circuit-Breaker

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 2–3 and Controls Mains connection at the place of installation Earth-leakage circuit-breaker Inverters incorporate switched power units which are always associated with capacitive leakage currents against earth. The leakage currents may depend on the number of inverters, the earthing conditions as well as the design and length of motor power cables.
  • Page 19 2–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Mains connection at the place of installation Notes:...
  • Page 20: Marks, Certifications

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 3–1 and Controls Marks, certifications Marks, certifications CE-marking Low-Voltage Directive The CE marking confirms compliance of drive modules of the Servodyn- D series with the Low-Voltage Directive. The rating and construction sat- isfy the requirements of EN 50178.
  • Page 21: Eu Design Type Certification

    3–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Marks, certifications EU design type certification The certification covers Servodyn-D with redundant safety monitoring RSU. RSU complies with the requirements concerning: D Safety-relevant parts of controllers in accordance with EN 954-1...
  • Page 22: Ul/Csa Certification

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 3–3 and Controls Marks, certifications UL/CSA certification For a number of Servodyn-D modules in compact mechanics, a UL/CSA certification is available for the U.S. and Canada. They are marked by adhesive labels.
  • Page 23 3–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Marks, certifications Notes:...
  • Page 24: Diagnostics Displays At The Drive

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–1 and Controls VMA..KB, VMA..KE status, warning and error displays Diagnostics displays at the drive VMA..KB, VMA..KE status, warning and error displays 7-segment Status Action display Ready – Standard ready display...
  • Page 25: Vma

    4–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F status displays VMA..KR, VMA..B,C,D,F status displays Status Action – Drive On LED lights up at 24 V at X06.7 (AE) Enable internal if –...
  • Page 26 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–3 and Controls VMA..KR, VMA..B,C,D,F warning displays VMA..KR, VMA..B,C,D,F warning displays Displays Warning Action flash alternately The drive can switch off without delay. Overload In continuous operation: reduce load.
  • Page 27: Status Displays Dm And Ds (Without Frequency Inverter)

    4–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Status displays DM and DS (without frequency inverter) Status displays DM and DS (without frequency inverter) Status Action Axis enable external if – D 24 V at X06.3 (FG) Enable internal if –...
  • Page 28: Vma

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–5 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays VMA..KR, VMA..B,C,D,F and DM/DS error displays (without frequency inverter) For a more detailed analysis, please refer to parameter S-0-0095, refer to page 4–14, where you will find a lot of specific information concerning the errors displayed at the drives.
  • Page 29 4–6 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Normal operation: For details of the fault, refer to Encoder error S-0-0095, cf.
  • Page 30 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–7 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Normal operation: D Observe speed limit Maximum speed exceeded (channel 2)
  • Page 31 4–8 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Load contactor is not released D Replace mains connection module Synchronization error in VM..B,C,D...
  • Page 32 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–9 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Drives do not stand still D Check time limit setting in VM...
  • Page 33 4–10 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Normal operating mode: ASTS signal in module cross-connection D Check X810 signal cross-connection...
  • Page 34 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–11 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Initialization error I C-Bus D Replace module Initialization error AD converter...
  • Page 35 4–12 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. Assignment mains connection mod- D Combine compatible modules ule – VM...
  • Page 36 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–13 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays Displays flash Error Action alternately. The drive has switched off. VM off with active control D Switch VM on Motors are shut down because of a shut-...
  • Page 37: List Of Error Number In Parameter P-0-0095

    4–14 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays 4.5.1 List of error number in parameter P-0-0095 Parameter P-0-0095 contains additional error numbers which provide for a more detailed analysis of various error displays of the modules.
  • Page 38 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–15 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number Excessive system deviation; Drive is unable to follow defined nominal value Monitoring error dual encoder Excessive system deviation spindle Positioning threshold exceeded;...
  • Page 39 4–16 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number RSU: Security, Initialization error – Without detailed documentation RSU: Security counter CNT0 does not count up...
  • Page 40 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–17 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number Measuring system initialization error – Without detailed fault documentation Defective motor rating plate; faulty data transfer Missing interface –>...
  • Page 41 4–18 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number Defective encoder; Faults upon absolute-value data transfer Missing hardware trigger on pin NP_2 (zero-marker-storage-error)
  • Page 42 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–19 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number Faulty data transfer; Defective motor rating plate Faulty data transfer; Defective motor rating plate I2C bus not addressable (defective cable;...
  • Page 43 4–20 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 1210 Motor rating plate: Parameter set 1: Standstill torque = 0 1211 Motor rating plate: Parameter set 1: Max. torque = 0...
  • Page 44 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–21 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 1253 Motor rating plate: Parameter set 1: Speed: Maximum = 0 1254 Motor rating plate: Parameter set 1: Force: Nominal thrust = 0...
  • Page 45 4–22 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 1305 Motor rating plate: Parameter set 2: Max. velocity = 0 1306 Motor rating plate: Parameter set 2: Nominal current = 0...
  • Page 46 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–23 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 1351 Motor rating plate: Parameter set 2: Pole pitch = 0 1352 Motor rating plate: Parameter set 2: Speed: Nominal value = 0...
  • Page 47 4–24 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 2203 Flash rating plate: Parameter set 1: Encoder pulses = 0 2204 Flash rating plate: Parameter set 1: Nominal velocity = 0 2205 Flash rating plate: Parameter set 1: Max.
  • Page 48 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–25 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 2242 Flash rating plate: Parameter set 1: Single-turn value = 0 2243 Flash rating plate: Parameter set 1: Single-turn or multi-turn value = 0 2244 Flash rating plate: Parameter set 1: Signal periods between ref.
  • Page 49 4–26 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 2316 Flash rating plate: Parameter set 2: Temp. characteristic, B-value = 0 2317 Flash rating plate: Parameter set 2: Temp. characteristic, T-reference = 0...
  • Page 50 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–27 and Controls VMA..KR, VMA..B,C,D,F and DM/DS error displays F code Error Meaning display number 2362 Flash rating plate: Parameter set 2: Distance between reference marks = 0 2363...
  • Page 51: Profibus-Dp Errors

    4–28 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls PROFIBUS-DP errors PROFIBUS-DP errors Displays flash Error Action alternately. The drive has switched off. Initialization error D Check structure of the parameterization Incorrect parameterization data data (refer to “Servodyn with PROFIBUS-DP...
  • Page 52: Servodyn-D Frequency Inverter Displays

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–29 and Controls Servodyn-D frequency inverter displays Servodyn-D frequency inverter displays 4.8.1 Status/warning displays Status Action Axis enable external if – D 24 V at X06.3/4 (FG) Enable internal if –...
  • Page 53 4–30 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Servodyn-D frequency inverter displays Read Unit Description from A00 A-0-1000 Actual output frequency Current motor frequency A01 A-0-1001 Commanded output fre- Specified output frequency quency f...
  • Page 54: Error Displays

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 4–31 and Controls Servodyn-D frequency inverter displays 4.8.2 Error displays Displays in vertical Error Action arrangement on the The drive has switched off. module Power supply fault D Check module cross-connection...
  • Page 55 4–32 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Servodyn-D frequency inverter displays Displays in vertical Error Action arrangement on the The drive has switched off. module Driver fault D Replace module Invalid driver parameter...
  • Page 56: Connection Overview

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 5–1 and Controls Connection overview Connection overview VMA..KB, VMA..KE supply module (with ballast switch) 8 – NAF relay 7 – 6 – BTB relay 5 – 4 – MT 3 –...
  • Page 57: (With Current Regeneration)

    5–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Connection overview VMA..KR, VMA..B,C,D,F supply module (with current regeneration) Figure shows VMA 35B, interface is identical for all modules 1 – STA relay 2 – S1:Power-off delay 3 –...
  • Page 58: Dma Module With Analog Interface Or Positioning Function (Mc)

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 5–3 and Controls Connection overview DMA module with analog interface or positioning function (MC) Motor encoder Test signals for service personnel 1 – A_Out 1 Encoder switch / 2 – GND...
  • Page 59: Dma Module With Sercos Interface

    5–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Connection overview DMA module with SERCOS interface Optional direct measuring system Motor encoder (OM 01, OM 02, OM 03) Also OM 04 possible, for connection refer to 1 –...
  • Page 60: Dma Module With Can Bus

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 5–5 and Controls Connection overview DMA module with CAN bus Motor encoder Test signals for service personnel 1 – A_Out 1 2 – GND Green LED for CAN operation 3 –...
  • Page 61: Dma Module With Profibus-Dp

    5–6 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Connection overview DMA module with PROFIBUS-DP Motor encoder Test signals for service personnel 1 – A_Out 1 2 – GND Green LED for PROFIBUS operation 3 – A_Out 2...
  • Page 62: Dm..8001-D Frequency Inverter With Analog Interface

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 5–7 and Controls Connection overview DM..8001-D frequency inverter with analog interface 1 – T1 2 – T2 3 – I1 For measuring 4 – I3 purposes only 5 – SW+ 6 –...
  • Page 63: Stand-Alone Module Ds, Supply Unit

    5–8 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Connection overview Stand-alone module DS, supply unit Stand-alone modules are single-axis drives with an integrated supply unit. The interfaces and functions correspond to those of the modules described in sections 5.3 to 5.7.
  • Page 64: Overview Of Ds..k Xxx1-D

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 5–9 and Controls Connection overview Overview of DS..K xxx1-D Other connectors corresponding to the interfaces: – analog interface, positioning function – frequency inverter – CAN bus – SERCOS interface 4 –...
  • Page 65 5–10 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Connection overview Notes:...
  • Page 66: Replacing Components

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 6–1 and Controls Replacing components Replacing components DANGER Danger caused by unqualified interventions. The maintenance and installation of the components is reserved to qualified personnel who observes the accident prevention reg- ulations (UVV VBG4, VDE 100, VDE 105) and installation standards (EN 60204-Part 1, prEN 50178).
  • Page 67 6–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Replacing components CAUTION Impacts and shocks applied to the shaft end will damage the rotary encoder and ball bearings! Drive elements such as pulleys, clutch disks, toothed wheels etc.
  • Page 68: Drive Modules

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 6–3 and Controls Replacing components Drive modules CAUTION Destruction of power units! Note the tightening torque of 3 Nm for the power connections U, V, W. 6.2.1 VM...K and DM...K The DC link connection is achieved with conductor bars ”C”...
  • Page 69: Dc Link Connection Of Vma..b,C,D And Dma..a,B,D

    6–4 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Replacing components 6.2.2 DC link connection of VMA..B,C,D and DMA..A,B,D with backplane modules The conductor bars are captivated in the backplane module terminal blocks. Mounting using a SW 4 Allen key: 1.
  • Page 70: Dc Link Connection Of Vmw

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG 6–5 and Controls Replacing components 6.2.3 DC link connection of VMW..F and DMW..F with water cooling The DC link connection is made at the bottom side of the modules using the conductor bars supplied together with the unit: 1.
  • Page 71 6–6 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Replacing components Notes:...
  • Page 72: Index

    1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG A–1 and Controls Annex Annex Index Computer errors, 4–28 Hard disk drive, 1–9 Connection overview Holding brake, 6–1 DMA with analog interface, 5–3 DMA with CAN bus, 5–5 IT protective system, 2–1 DMA with positioning function (MC), 5–3...
  • Page 73 A–2 Bosch Rexroth AG Electric Drives Servodyn-D 1070 066 032 / 03 and Controls Annex Tightening torque DC link in backplane modules, 6–4 DC link in compact mechanics, 6–3 Power connection, 6–3 Trademarks, 1–10 UL/CSA certification, 3–3 installation and operation, 3–3 Warnings Frequency inverter, 4–29...
  • Page 74 1070 066 032 / 03 Servodyn-D Electric Drives Bosch Rexroth AG A–1 and Controls Bosch Rexroth AG Electric Drives and Controls Bgm.-Dr.-Nebel-Str. 2 97816 Lohr a. Main, Germany info@boschrexroth.de www.boschrexroth.de Printed in Germany DOK-SERV*D-DIAGNOSTICS-WA03-EN-P...

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