Rexroth Servo Drive Fault Codes and Troubleshooting Methods

Common faults of Rexroth servo drives / servo controllers include: no display, phase loss, overcurrent, overvoltage, undervoltage, overheating, overload, grounding, parameter errors, display but no output, module damage, etc. The following introduces some Rexroth servo drive fault codes and troubleshooting methods.

By reading the following, you can quickly determine the causes of some common Rexroth servo drive failures, and take corresponding measures to solve the failure in a timely manner and reduce production losses.

1. Rexroth Servo Drive Fault Code Explanation and Troubleshooting Methods

1.1 Fault Code: C0270

Cause:
Motor encoder data reading error.

Remedy:
The motor encoder circuit is faulty. Check three places where problems may occur: motor encoder, feedback line and CSB encoder feedback port.

1.2 Fault Code: C0285

Cause:
Incorrect motor model parameter P-0-4014.

Remedy:
Confirm the motor model and encoder model (P-0-4014). Check three places where problems may occur: motor encoder, feedback line and CSB encoder feedback port.

1.3 Fault Code: E2074 F2076 C0210 C0220 C0271

Cause:
Some related encoder fault alarms.

1.4 Fault Code: C0201

Cause:
Invalid parameters. When switching to operating mode P4, the internal parameters are detected. This alarm occurs when a parameter exceeds its defined range.

Remedy:
(1) Check the S-0-0022 parameter, which contains all invalid parameters, and then change the invalid parameters (version 02, 03 firmware).
(2) Check the S-0-0423 parameter, which contains all invalid parameters, and then change the invalid parameters (version 04 firmware).
(3) Usually after loading the basic parameters, importing the backup parameters can solve this problem.

1.5 Fault Code: E8260

Cause:
Torque overload.

Remedy:
(1) Reduce acceleration;
(2) Increase the corresponding limit values S-0-0082, S-0-0083, S-0-0092, P-0-109;
(3) Optimize speed loop parameters;
(4) Add an external braking resistor.

1.6 Fault Code: F2026

Cause:
Drive power unit undervoltage alarm.

Remedy:
(1) Check the external 380V main power supply and the DC bus voltage;
(2) If the drive power unit cannot generate DC, replace the HCS power unit;
(3) Check PLC timing, Ab, AF.

1.7 Fault Code: F2077

Cause:
Current detection error, hardware failure. Besides, the drive monitors the current in real time, and this alarm occurs if it exceeds the allowed range.

Remedy:
(1) If the Hall current sensor of the drive power unit fails, replace the HCS power unit;
(2) If there is a problem with the current calculation circuit of the control unit CSB, replace the CSB control unit.

1.8 Fault Code: F2816

Cause:
DC bus failure.

Remedy:
(1) Check external 380V power supply;
(2) Check DC bus and external braking resistor wiring;
(3) If the drive rectifier unit is faulty, replace the HCS power section.

1.9 Fault Code: F2018

Cause:
Device over-temperature shutdown.

Remedy:
(1) Reduce the ambient temperature;
(2) Check the cooling device in the cabinet;
(3) Clean the fan inside the drive;
(4) If the temperature sensor inside the drive is faulty, replace the HCS power section.

1.10 Fault Code: F2019

Cause:
Motor over-temperature alarm (S-0-0204 is the temperature limit parameter).

Remedy:
(1) Check whether the machine is stuck, causing the motor to overload and heat up;
(2) Check whether the temperature cables (X6-1, 2) from the motor to the drive are loose;
(3) If the motor temperature sensor is faulty, replace the sensor;
(4) If the drive temperature detection circuit is faulty, replace the HCS power unit.

1.11 Fault Code: F2820

Cause:
Braking resistor alarm.

Remedy:
(1) Reduce the deceleration and the speed command value;
(2) Replace the braking resistor and increase the resistance;
(3) HCS-check the external braking resistor and the connection with the drive (X6-3, 4);
(4) HMV-if the internal braking resistor is faulty, replace the HMV power module.

1.12 Fault Code: F2100

Cause:
Abnormal access to the Flash memory. Every time a parameter is modified it is immediately stored in the Flash memory, causing memory overflow.

Remedy:
(1) Set bit0 of S-0-0269 parameter to 1;
(2) Use an MMC memory card.

1.13 Fault Code: F2074

Cause:
The current position of the motor exceeds the absolute encoder monitoring window. The position of the motor when it is powered off is too different from the position after it is powered on again, exceeding the monitoring window value P-0-0095.

Remedy:
Reset and restart or re-establish the position reference point.

14. Fault Code: F2048

Cause:
The battery in the motor is exhausted.

Remedy:
Replace the battery inside the motor back cover.

1.15 Fault Code: F2008

Cause:
The motor type has changed. It is because a new parameter file is downloaded to the drive, or it is the first time that the drive is powered on, and S-0-0141 (motor type) is inconsistent with the current motor.

Remedy:
Just reset it directly.

1.16 Fault Code: F8070

Cause:
External 24V power supply fault.

Remedy:
Check 24V power supply and wiring.

1.17 Fault Code: F8069

Cause:
+/-15Volt DC error.

Remedy:
Replace supply unit.

1.18 Fault Code: F8060

Cause:
Overcurrent alarm. The internal current of the drive exceeds the maximum allowable current.

Remedy:
If there is no problem with the high-power tube, there is a problem with the current detection circuit of the drive and it must be replaced.

1.19 Fault Code: F8838

Cause:
(1) Resistance value of connected braking resistor is too low;
(2) Short circuit at braking resistor connection.

Remedy:
(1) Connect braking resistor unit with higher resistance value (take specification into account!);
(2) Remove the short circuit.

1.20 Fault Code: F8102

Cause: The drive hardware and firmware do not match.

Remedy:
(1) Check the firmware version.
(2) If the HCS power unit is faulty, replace it.

1.21 Fault Code: F8078

Cause:
Speed loop alarm.

Remedy:
(1) The phase sequence of the motor power lines is reversed;
(2) Optimize speed loop parameters;
(3) If the user has disassembled and assembled the motor encoder by himself (for synchronous motors), send it to Rexroth for calibration;
(4) If the motor encoder is broken, send it for repair or replacement.

1.22 Fault Code: F4001

Cause:
Optical cable ring communication error.

Remedy:
(1) Check the optical cable and optical cable connector;
(2) Replace the CSB control unit.

1.23 Fault Code: F8022

Cause:
Weak motor encoder signal.

Remedy:
The motor encoder circuit is faulty. Check three places where problems may occur: motor encoder, feedback line and CSB encoder feedback port.

2. Rexroth Drive Common Fault Code List

Fault code

Fault description

Fault code

Fault description

E-0000

E-0000 processor exception error

F8203

Safety technology configuration parameter invalid

F9001

Error internal function call

F8806

Timeout during loading process

F9002

Error internal RTOS function call

F8813

Connection error mains choke

F9003

Watchdog

F8838

Overcurrent external braking resistor

F9004

Hardware trap

F7010

Safety related limited increment exceeded

F8000

Fatal hardware failure

F7011

Safety rel. position limit val., exc. in pos. dir.

F8010

Autom. commutation: max. motion range when moving back

F7012

Safety rel. position limit val., exc. in neg. dir.

F8011

Commutation offset could not be determined

F7013

Velocity threshold exceeded

F8012

Autom. commutation: max. motion range

F7014

Acceleration threshold exceeded

F8013

Automatic commutation: current too low

F7020

Safety related maximum velocity exceeded

F8014

Automatic commutation: overcurrent

F7021

Safety related end position exceeded

F8015

Automatic commutation: timeout

F7030

Pos. window for safety rel. operational stop exceeded

F8016

Automatic commutation: iteration without result

F7031

Incorrect direction of motion

F8022

Enc. 1: enc. signals incorr. (can be cleared in ph. 2)

F7040

Plausibility error parameterized - effective threshold

F8023

Error mechanical link of encoder or motor connection

F7041

Plausibility error actual position value

F8027

Starting lockout while drive enabled

F7042

Plausibility error safety related operating mode

F8042

Encoder 2 fault: wrong signal amplitude

F7043

Error of output stage interlock

F8057

Device overload shutdown

F7050

Time for stopping process exceeded

F8060

Overcurrent in power section

F7051

Time for safety-related deceleration process exceeded

F8064

Motor interrupted due to phase loss

F6010

PLC runtime error

F8067

PWM timer synchronization failure

F6024

Maximum braking time exceeded

F8069

+/-15Volt DC error

F6029

Positive travel limit exceeded

F8070

+24Volt DC error

F6030

Negative travel limit exceeded

F8078

Speed loop error

F6034

Emergency-Stop activated

F8079

Velocity limit S-0-0091 exceeded

F6042

Both travel range limit switches activated

F8091

Power section defective

F6043

Positive travel range limit switch activated

F8100

Error during initialization of control section

F6044

Negative travel range limit switch activated

F8102

Error when initializing power section

F6140

CDD slave failure

F8118

Invalid power section/firmware combination

F4001

Double MST failure shutdown

F8120

Invalid control section/firmware combination

F4002

Double MDT failure shutdown

F8122

Control section defective

F4003

Invalid communication phase shutdown

F8129

Firmware of option 1 of safety technology defective

F4004

Error during phase progression

F8130

Firmware of option 2 of safety technology defective

F4005

Error during phase regression

F8133

Error when checking interrupting circuits

F4006

Phase switching without ready signal

F8140

CDD fatal failure

F4009

Bus failure

F8201

Safety command for basic initialization incorrect

F4012

Incorrect I/O length

F4014

PLC watchdog