KWE 5000 LM - FVS 3201 Manual PDF

Instruction Manual
PT Eastern Pearl Flour Mills

Indonesia
KWE 5000 LM
FVS 3201
Checkweigher
Auger filler
Order data
Translation of the original instructions
Customer Overall order no.

PT Eastern Pearl Flour Mills 11020431
Indonesia
Year of construction
2012
Type of machine: Designation Order/machine no.

KWE 5000 LM Checkweigher 717079MS5025W
FVS 3201 Auger filler 717078MS3822W
Declaration of conformity : Chapter 1 - Important Information
Robert Bosch GmbH

Packaging Technology
Postfach 11 27
D‐71301 Waiblingen
Telefon: +49 711 811‐0
Fax: +49 711 811‐45000
E‐Mail: pa@boschpackaging.com
www.bosch.de/pa
Robert Bosch GmbH 2012

All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
These documents are destined for the purchasers of our machines only and may neither be reproduced nor made known to a third party without our written approval.
Chapter overview
Chapter 1
Important Information
Chapter 2
Basic Safety Information
Chapter 3
Transport, Installation and Connections
Chapter 4
Description of the Machine
Chapter 5
Operation
Chapter 6
Troubleshooting
Chapter 7
Change of Size / Product
Chapter 8
Maintenance
Chapter 9
Appendix
Chapter 10
Operation and maintenance-relevant Purchase Parts
(OEM)
Important Information
1
Chapter 1: Important Information
1 | Important Information 1/8
Contents
Target group 3
Further documentation 3
Electrics documentation 3
Spare parts list 3
Information for these operating instructions 4

Safety instructions and their significance 4
Information symbol 4
Danger symbols in safety instructions 5
Declaration of conformity 6
Version overview 7
Notes 8
Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

T
2/8 1 | Important Information
This page is empty on purpose!
717079MS5025W | Version 1.0 | en Bosch Packaging Technology

S_Leer
Target group
These operating instructions are intended for:

u The operating staff
These members of staff have been introduced to the machine and are informed about
potential danger situations due to incorrect behavior.
u Skilled staff
These members of staff received a suitable expert training, have additional experience and
in-depth technical knowledge. They are capable to assess the task at hand and recognize
potential hazards or danger situations.
Persons working with the machine must be informed regularly on the operational hazards with
regard to the machine.
u The operating and maintenance staff must have read and understood the operating
instructions, in particular the chapter ”Basic Safety Information” and any valid regulations
before commencing work.
u Keep the operating instructions and valid regulations so that they are accessible for the
operating and maintenance personnel.
Further documentation
The following documentations are supplied in addition to these operating instructions:
Electrics documentation
The electrics documentation consists of:
u Wiring diagram, including list of devices
One copy is normally kept inside the control cabinet.
u Software folder
The folder includes the Software Recovery Disc (Image-CD) and Software CDs / DVDs and
license documents of the implemented programs.
Spare parts list

The spare parts catalog lists all wear parts of the machine.
Electric components inside the control cabinet or the terminal boxes are not included in the spare
parts catalogue.

S_01_Zielgruppe (7.1)
Information for these operating instructions
Safety instructions and their significance
DANGER
Signifies direct and imminent danger which if not heeded will lead
to serious bodily injury or fatal injuries causing death.
WARNING
Refers to direct and imminent danger which if not heeded might

lead to serious bodily injury or fatal injuries causing death.
CAUTION
Refers to a potentially dangerous situation which if not heeded

might lead to minor injuries.
NOTICE
Refers to a potentially harmful situation which if not heeded might

lead to damage to the machine or its environment.
Information symbol
INFORMATION
Refers to user suggestions and other especially useful information.

S_01_Hinweise (7.1)
Information for these operating instructions
Danger symbols in safety instructions

These danger symbols can be used in the individual safety instructions. They indicate the type of
hazard or danger:
Symbol Significance Symbol Significance
Danger in general Hot surface
Voltage / Current Suspended load
Health-impairing or irritating Corrosive substances

materials
Fire Explosive substances
Crushing - hands Explosive atmosphere
Crash Laser radiation
X-ray radiation

S_01_Hinweise (7.1)
Declaration of conformity

CE_Konformitaet
Bosch Packaging Technology
Version overview
1 | Important Information
Type of machine: Customer Order/machine no.
KWE 5000 LM PT Eastern Pearl Flour Mills 717079MS5025W
/ Indonesia
Version Date Chapter New pages Changed pages Scope of supply Changed by
1.0 06.02.2012 1 - 10 all ‐ all srw2wa2
717079MS5025W | Version 1.0 | en
S_01_Version (2)
7/8
Notes
1.

S_Notiz
Basic Safety Information
2
Chapter 2: Basic Safety Information
2 | Basic Safety Information 1 / 12
Contents
Warranty and liability 3

Software amendments 3
Illustrations and drawings 3
Proprietary rights 3
Storage 3
Transport 3
Information for the plant operator 4

Inspection in compliance with the accident prevention 4
regulations
Operator control of the machine 5

Machine in operation 5
Reference/synchronous run 5
Hot surfaces 5
Machines with heat-sealing devices 5
Guard devices 6
Measures prior to working on the machine 7
Measures prior to working on electrical/electronic 8

devices
Measures for electrical welding work 9
Dust explosion 10
Notes 11

T
2 / 12 2 | Basic Safety Information

S_Leer
Warranty and liability
Warranty and liability are governed by the terms and conditions defined in the contract.
Software amendments
If there are any software amendments without the knowledge of or authorization by Robert Bosch
GmbH, the liability and warranty rights shall lapse.
Illustrations and drawings

Pictures and drawings are for the purpose of general illustration. Operating facilities and
illustrations may deviate from the machine supplied. The specified dimensions are not binding.
Proprietary rights
The company Robert Bosch GmbH retains all rights in its drawings, software, other documents and
all powers of disposal such as copying and dissemination rights. This also applies to patent
applications.
Storage
The company Robert Bosch GmbH assumes no warranty whatsoever for any corrosion damage that
occurs through improper storage.
Transport
We draw attention to the fact that improper transport provides no entitlement to replacement or
warranty rights of any kind. If in doubt, consult the company Robert Bosch GmbH before carrying
out any transportation.
If a fitter from Robert Bosch GmbH is present, he may be asked for advise on transportation
matters. However, he cannot assume any responsibility for transportation nor for any damage
caused by it.

S_02_Gewaehrl (7)
Information for the plant operator
INFORMATION
All work and activities may be carried out by trained and duly
authorized persons only.
u The machine is constructed in accordance with the statutory regulations that were valid at the
time of delivery and represents the state of the art in terms of safety.
u Any residual dangers are designated by relevant safety information and are described in the
operating instructions.
u All safety information attached to the machine must be heeded and observed. All safety
information must be available in full and be easily readable.
u Operate the machine only if all guard devices are in place.
u Secure danger zones that exist between Bosch machines and customer equipment.
u The legally stipulated checking and inspection intervals for the line must be adhered to. The
checking and inspection results must be recorded in an inspection certificate and kept on
record until the next inspection.
u Have the guard devices, warning systems, locks and couplings to packaging machines and
auxiliary packaging machines checked at least once annually by a skilled person as to their
safe condition.
u Devices that serve to extract harmful substances must be checked by a skilled specialist as to
their functional effectiveness prior to their commissioning.
Inspection in compliance with the accident prevention regulations

In the following cases the plant operator must perform prior to commissioning an inspection in
conformity with the valid accident prevention regulations and rules of electrical engineering:
u When combining and installing machines, systems and operating means from various
manufacturers or suppliers.
u Following conversion work on products supplied by us in which the electrical equipment has
been interfered with.

S_02_Hinw-Betreiber (7)
Operator control of the machine
Machine in operation
WARNING
Moving masses and revolving or hot components inside the

machine.
Long hair worn open, loose clothing, jewelry or similar can be
seized and drawn in by rotating components.
Serious bodily injury can occur.
u Do not climb on the machine.

u Do not reach over high guards that are open at the top.
u Wear tight-fitting clothing.
u Protect long hair, e.g. with a hair net.
u Take off any jewelry.
Reference/synchronous run
WARNING
During the machine's reference/synchronous run, movements of the

machine drives occur that are not apparent to the operator.
u Keep a sufficient safety distance to the machine during the

reference/synchronous run.
Hot surfaces
CAUTION
Hot surfaces on heated machine parts.

Contact with hot surfaces might cause burns.
Allow machinery parts to cool down sufficiently before touching them.
Machines with heat-sealing devices
CAUTION
Fire hazard due to overheating of machine parts.

Injury and damage to the machine can occur.
Switch Off heaters during extended machine standstill (in excess of
15 minutes).

S_02_Masch-Bedieng (7)
Guard devices
The machine is equipped with the following guard devices:

u Movable guard devices: electrically locked or openable only with special tools.
u EMERGENCY STOP strike button.
u Safety information for residual dangers on the machine.
u Control cabinet with mechanically lockable main switch.
WARNING
Risk of accidents due to missing or defective guard devices.

Arbitrary changes to the machine can lead to serious bodily injury.
u Do not carry out any modifications, changes, attachments or

conversions that may constitute a safety risk.
u Do not modify or change any safety guards.
u Do not carry out any welding work at load-carrying components.

S_02_Schutzeinrichtg (7)
Measures prior to working on the machine
WARNING

machine.
There exists the risk of serious bodily injury during work at the
running machine!
u Any work on the machine may be carried out only while the
machine is stationary and not running.
u Secure the machine against being switched On.
WARNING
Media supply systems, e.g. pneumatics, steam pressure or gassing

systems are pressurized. Risk of explosion!
When working with pressurized media supply systems there exists
the risk of parts exploding. Serious bodily injury can occur.
u Close all cut-off valves of the media supply systems prior to

carrying out any work.
u Interlock cut-off valves with a U-lock.
u Release existing pressures.
WARNING
When working above body height there is a danger of falling!

u When working high up, wear an anti-fall harness!

u Use safety-compatible climbing aid. Do not use machine parts as
climbing aid.
u Keep all handles, steps, railings, platforms, stages and ladders
free of dirt.
WARNING
Servomotors in use. Moving masses.

u Prior to working on the machine the strike button EMERGENCY

STOP must be actuated without fail.

S_02_Maßn-vor-Arbeit (7)
Measures prior to working on electrical/electronic devices
INFORMATION
All electric work may be carried out by trained and duly authorized
electricians only.
WARNING
There exists peril of loss of life in case of contact with

current-carrying lines or components.
Serious bodily injury or death can occur.
u The entire machine must be separated from mains prior to

working on electric installations:
Switch Off the main switch (after switching Off the main
switch, excepted electrical circuits can still carry live voltage
- see wiring diagram).
Disconnect mains plug (if present).

u Use a test device to reliably ensure the absence of voltage.

S_02_Maßn-vor-Elektrik (7.1)
Measures for electrical welding work
WARNING
In the event of any welding, burning or grinding work on the

machine there exists the risk of fire or explosion.
u Easily inflammable or combustible materials may not be located

within the vicinity of the work place.
u One additional person must be ready with a suitable fire
extinguisher for fighting potential fires.
NOTICE
High electric current flows during electric welding processes.

Incorrect earthing of the welding device may lead to damage of the
machine.
Have electric welding work carried out by skilled staff only.
u Switch off the machine's main switch.
u Clean the machine of dust and combustible substances.
u Do not plug the welding device into or connect it to the
machine's control cabinet.
u Pull the electronic devices (e.g. control devices) and boards out
of the control cabinet, otherwise there will be a danger of
connecting voltage spikes to these.
u Unplug or disconnect any electronic devices (e.g. angle encoders,
pulse generators) existing on the machine.
u Place the ground connection of the welding device immediately
next to the welding point and make perfect contact.
INFORMATION
The welding current must not flow via the ground cable or screening
of the electrical equipment.
The above mentioned measures must be performed, if any electrical
welding is takes place at machines or units connected mechanically,
i.e. conductively, to Bosch machines (e.g. hoppers, feed belts etc.).

S_02_Maßn-bei-Schweissen (7)
Dust explosion
DANGER
Combustible dust such as flour dust, cocoa dust, coffee dust, sugar
dust or starch dust can serve, mixed with air, as an ignition source
causing an explosion. An only millimeter thick dust layer, whirled up
and simultaneously ignited by a spark, can cause a dust explosion.
Danger of explosion! The explosion can be triggered by:

A spark, caused by pulling an electrical plug.
A defective electrical appliance.
Discharge of electrostatically charged clothing.
u Check electrical devices at regular intervals!

u Ground statically rechargeable objects!
u Keep the machine clean as required!

S_02_Staubex_PKM (7)
Notes

S_Notiz_2s
Notes
2.

S_Notiz_2s
Transport, Installation and
Connections
3
Chapter 3: Transport, Installation and Connections
3 | Transport, Installation and Connections 1 / 10
Contents
Transport 3
Scope of supply 3
Damage in transit 3
Weight of the machine 3
Transport information 3
Installation and connection of checkweigher 4

Installation and alignment of checkweigher 4
Assemble the weighing belt 5
Connect power supply and compressed air 6
Quality of the operating substances and auxiliary 6
substances
Dismantling, storage and disposal 7

Dismantling 7
Storage 7
Disposal 7
Transport drawing 8
Checkweigher KWE 5000 LM 8
Auger filler FVS 3201 9
Notes 10

T
2 / 10 3 | Transport, Installation and Connections

S_Leer
Transport
Scope of supply
Refer to the order documents for the scope of supply and compare this with the delivery note.
Damage in transit
u Note in the shipment papers any visible damage detected upon delivery and report the
damage immediately to the insurance agency.
u Report any hidden damage immediately after detection to the insurance agency.
Weight of the machine

Machine weight - see transport drawing or type plate on the machine.
Transport information
WARNING
Moving loads can fall or trap personnel.

The load might drop if not fastened correctly or due to breaking of
the hoisting gear. Serious bodily injury can occur.
u Never stand under or in front of moving loads.

u Use suitable lifting gear and fastening means.
u Transport the machine in accordance with the transportation drawing.

u Machines delivered with transportation carriers may be transported with such transportation
carriers only.
u The machine operator must be entitled to drive the lifting gear.
u Before lifting the machine all personnel must leave the working area of the lifting gear.
u Cables and chains must be free of damage and possess the relevant loadbearing capacity.
u Cables and chains must not touch the machine while it is being lifted off the ground. The
carriers must be hooked only into the lug rings provided for that purpose.
u If using transport rollers, carefully set down the transport unit and push it to the place of
installation, e.g. with a fork-lift truck.

S_03_Transport (7)
Installation and connection of checkweigher
NOTICE
The checkweighers is a sensitive measuring device.

Any shock or impact may lead to damage of the checkweigher.
u Avoid any shock or impact exerted on the weighing belt.

u Please comply with the limit values indicated on the rating plate
or the calibration plate.
Installation and alignment of checkweigher
1. Set up the checkweigher on a firm and

stable vibration‐free surface.
2. Aligning the checkweigher:
1
u Height of the infeed belt (1) suited for the
transfer of the downstream machine.
u Horizontal both lengthwise and in
transverse direction with the help of an air
lever (2).
3. Secure feet (3) with counternuts (4).

108589 (1)
Assemble the weighing belt
INFORMATION
To avoid damage at the weighing cell, the weighing belt has to be

dismounted during transport.
NOTICE
When assembling the weighing cell please heed the tightening

torque of the screws (5).
Any excessive tightening torque will damage the weighing cell.
Fasten screws (5) with tightening torque of max. 9 Nm!
1. Place the belt carrier (1) onto the weighing

cell (2). 6
2. Unscrew two screws (3) from the belt

carrier and locate into the bores (4) to aid
assembly.
3. Align the belt carrier (1) and fasten the
two screws (5) with max. 9 Nm.
7
4. Remove two screws (3) from the bores (4) 5 1
and screw in at the front side of the belt
carrier (1). 2
5. Place the weighing belt (6) onto the belt

carrier (1).
Make sure that the screws (3) are located
in the recesses (7).
6. Fasten two screws (3) each at the front 3 4
and rear.
The belts may not be offset with regard to
height and must not contact one another.

108589 (1)
Assemble the weighing belt
7. Connect the plug (1) to the weighing belt

drive (2) and secure with screws.
4
The cable (3) must not be twisted and
must have slack; it may, however, not
contact the base plate.
8. Fit the guard cover (4) over the cable (3)
of the weighing belt drive and fasten with
screws.
2
The guard cover (4) may not touch the
cable (3) between plug and clamping 1
point.
3
Connect power supply and compressed air
1. For connection data, see the layout drawing and the wiring diagrams.
2. Check if the existing supply voltage complies with the voltage indicated on the type plate.
3. Connect the power supply cable to the mains input according to VDE requirements or the
locally valid legal regulations.
4. Check the direction of rotation.
u Check the direction of rotation with the help of the arrow or
u check the phase rotation with a phase rotation meter.
Quality of the operating substances and auxiliary substances
Use only the contractually agreed type and quality of the required operating and auxiliary sub
stances.
The quality of the supplied compressed air must be in conformity with ISO 85731 Item 6.3 Class 1
in terms of total oil content.

108589 (1)
Dismantling, storage and disposal
Dismantling
WARNING
The machine is run with electric current, compressed air and other
energy sources. On dismantling, these energy sources might still be
present.
u Before dismantling the machine, disconnect it from all external

energy supplies.
u Release existing energy.
INFORMATION
The machine may be disassembled only by trained, skilled and duly

authorized technicians.
u Fully remove all oils and other matters hazardous to water prior to disassembly.
u Dismantle the machine with suitable tool.
Storage
To maintain the operability of a machine that is not going to be used for a long period of time, the
following points must be heeded:
u The storage room must be dry and cool.

u Storage conditions:
Room temperature: +5C to +35C (41F to 95F).
Relative air humidity: 30% to 60%.
u Set the machine down on level ground to prevent distortion.
u Secure the machine against tipping and being set in motion unintentionally.
u Clean the machine and provide the bright parts with a film of acid-free oil as protection
against corrosion.
u Cover the machine completely so that no dirt or dust is able to penetrate.
Disposal
u Disassemble dismounted modular componentry into individual parts.
u Dispose of components in compliance with environmental and regulatory stipulations, thereby
adhering to all legal and operational regulations.

S_03_Abbau-Lagerg-Entsrg (7.1)
Transport drawing
Checkweigher KWE 5000 LM
Weight approx. 250 kg
Infeed belt (transport separately)
Transport fork (fork length 1100 mm)

8108255484
Transport drawing
Auger filler FVS 3201
Weight approx. 300 kg
4 x steel rope
Length approx. 1.5 m
4 x 8-108-100-5014 eye bolt

Load per eye bolt:
vertical 340 kg,
up to 45 rope incline 240 kg,
see also PA standard 2 4720
Doser
Type: FVS 3120
Weight: max. 300 kg
(configuration as shown:
approx. 210 kg)

FVS3201 (1)
Notes
5.

S_Notiz
Description of the Machine
4
Chapter 4: Description of the Machine
4 | Description of the Machine 1 / 20
Contents
Structure and operating method 3
Technical data 4
Environmental conditions 4
Noise measurement 4
Measuring conditions 4
Measuring 4
Intended and proper use 5
Installation layout drawing 8-108-255-586 7
Classification (division into weight ranges) checkweigher 9

Operating modes for classification 9
”Finished Package Regulation (FPR)” 10
”According to Input” 11
Control checkweigher 12
Task 12
Calculating the regulating increment 12
Test whether the computed regulating increment will be 13
output
Converting the regulating increment from grams into time 13
i.e. pulses
Output of the regulating increment 14
Suppressed increments 14
Function startup mode 14
Configuration options 15
Structure of the auger filler 16

Modular groups 16
Description 18
Notes 19

T
2 / 20 4 | Description of the Machine

S_Leer
Structure and operating method
3 6 10 7 9 8 5 2
Pos. Designation Pos. Designation
1 Infeed belt 6 Discharge

2 Weighing belt 7 Guard cover
3 Discharge belt 8 Control cabinet
4 Weighing cell 9 Operating and display terminal
5 Light-barrier 10 Metal detector
The product is conveyed on conveyors (1-3) through the checkweigher and thereby weighed.
Weighed product with a faulty weight is sorted out by the discharge unit (6) (depending on the
discharge mode and weight limits).
INFORMATION
The checkweigher is available with the transportation options from right

to left and vice versa.
The graphics refer to the transportation direction ”from right to left”.

107131 (2)
Technical data
Model KWE 5000 5010 5020
Gross weighing range 10 – 1 250 g 20 – 2 800 g 40 – 6 000 g
Display increment 0.5 g 1.0 g 2.0 g
Belt width 100/200 mm 100/200 mm 100/200 mm
Output 150 packages/min 150 150
Current type see Installation Drawing
Air consumption
Air pressure
Environmental conditions
The machine has been designed in accordance with European Standard EN 60 204 and can be
used under the following ambient conditions:
u Room temperature between +5 and +40 C (41 to 104 F),
u Relative humidity max. 50 % at +40 C (104 F),
u Altitude between 1 000 m (3 281 ft) above sea level.
Noise measurement
Measuring conditions
Machine model: KWE 5000 LM.

Location: Robert Bosch GmbH, Packaging Technology Division.
Measuring to be effected as per DIN 45635 Part 1 and Part 28. Class 2.
Implemented measuring device: Brüel & Kjaer, Type 2260.
The measuring device complies with IEC 651 Class 1 and ANSI S1.4 Type S2a.
The measuring device was checked before and after the measuring process.
Measuring
The sound pressure level at a distance of 1m from the machine and at a height of 1.6 m off the
floor is
LpAeq:  70 dB (A).

107700 (1)
Intended and proper use
The KWE 5000 LM is a checkweigher for weight verification of finished packages in terms of the
Finished Package Regulation (FPR).
The checkweigher is basically designed for particulate products / solids from the food industry.
Non-solid products can be weighed only in packaged condition.
The KWE 5000 LM is not suitable for:

u operation in a potentially explosive environment,
u the weighing of explosive products,
u the weighing of packages outside the weighing range.
Robert Bosch GmbH cannot be held liable for damage resulting from this.
The risk is assumed by the owner/user exclusively.
Operation of the machine is not permitted:

u With power sources, products, packaging materials, packaging etc. that are subject to the
hazardous substances ordinance or that in some way can affect the health of the operating
personnel,
u With machine devices that have been modified by the plant operator.

107701 (1)

S_Leer
Installation layout drawing 8-108-255-586

8108255586

8108255586
Classification (division into weight ranges) checkweigher
Operating modes for classification
INFORMATION
The machine is operated via the operating and display terminal of the
package maker.
The classification can be changed in the menu screen ”checkweigher
setup / weights”.
The checkweigher provides two operating modes (”Finished Package Regulation (FPR)” and
“According to input”. and for classification for weight limits.
The classification type is item-related and must be specified by the user in articles which are to
be created or changed:
FPR
”According to input”
Item Designation Function
1 Finished Package Regulation (FPR) Application in the food industry, (”e” marking).
Automatic weight limit calculation.
2 According to input Item‐related manually set fixed limit values.
You can select all values.

103536 (1)
”Finished Package Regulation (FPR)”
Definition of terms
u To = upper tolerance limit (overweight)
u Tu = bottom tolerance limit (underweight)
u Nominal weight = default weight
u Net weight = weight of weighed product after deduction of packaging weight
u Tare = weight of packaging.
Task
This operating mode is utilized for checking finished packs in compliance with
the fill volume requirement of the European Union.
Only packs meeting this EU-Guideline may carry the ”e” symbol.
The Finished Package Regulation is used mainly in the foodstuff industry.
Function
The reject limits are set automatically according to the FPR requirements in dependence on the
nominal weight.
Packages with weights below TU2 and above TO2 are always rejected.
For packs in the range between TU1 and TU2 active continuous monitoring is performed, which
ensures that only a maximum of 2 % of all packs (at any point in time during production) that are
within this range reach the retail trade.
In case of upper deviation of 2% unit count rejection takes place already as of weight limit TU1.
The limit value TO1 is only for the purpose of trend detection by way of the count function of
packs in the range TO1 to TO2. No rejection takes place.
Required inputs
u Nominal weight
u Tare
Changing the automatically set limits for overweight, underweight and TO1 limit is possible only
to a narrower pass-range.
The weight limit values relate to the net weight.
Weight limits
Nominal weight
Rejection Rejection
TU2 TU1 TO1 TO2 Weight
ACCEPT RANGE

103536 (1)
”According to Input”
Task
The weight limits for overweight and underweight are entered randomly for each
article depending on requirements. They are a fixed component of each article.
Function
The rejection of packs with a weight outside of underweight and overweight. The weight limits
G2 and G3 are additional range limits for trend recognition, with a counting function in the
statistics program for packages within the range
u G2 to underweight G1.
u G3 to overweight G4
In the standard version, packages within those ranges are not rejected.
Required inputs
u Nominal weight
u Overweight
u Underweight
u Tare
u G2, G3: values are set as the midpoint between the rejection limits and the nominal weight;
if required other values can be entered for G2 and G3.
The weight limit values relate to the net weight.
Weight limits
Nominal weight
Rejection Rejection
G1 G2 G3 G4 Weight
ACCEPT RANGE
G = weight limit

103238 (1.1)
Control checkweigher
Task
The regulating system controls one upstream filling unit (such as a dosing unit) so that the
required fill volume will be filled as accurately as possible.
Additionally, in classification mode FPR (Finished Package Regulation) the filler will be controlled
so as to be in compliance with the legal FPR.
Calculating the regulating increment
The regulation must be enabled immediately with production startup so that the setpoint fill
volume can be obtained as quickly as possible.
The regulation system takes samples from the running production and calculates the mean value
and the standard deviation (S). Then the mean value is compared with the default setpoint fill
volume and the resulting difference serves to compute the increment toward plus or minus
(P‐percentage).
With the classification mode FPR the mean value of the total production is included additionally
for computing the regulating increment (I‐percentage). This way the regulation system brings the
mean value of the total production to the setpoint filling quantity, albeit the mean value of the
random sample corresponds the setpoint filling volume while the mean value of the total
production still ranges below the setpoint filling volume.
A higher random sampling size renders the regulation more precise, but slower.
The random sampling scope can be filed for each item in the article data memory.

071456 (5)
Test whether the computed regulating increment will be output
Setpoint filling volume
Deviation - < > + Deviation

<‐k*S +k*S>
Regulating increment No regulating increment Regulating increment
S = Standard deviation of the random sample

k = A statistical parameter, dependent on the scope of the random sample and of the
assertion probability.
If the computed regulating increment is smaller than the result of k * S the regulating increment
will not be output. Unnecessary regulating increments would lead to a higher standard deviation
of the fill weight without simultaneous increase the filling accuracy.
If the computed regulating increment drops below the minimum time which the output medium
can transfer to an external filler (e.g. relay) there will be no output of that increment as well.
Special case: For the random sampling size consisting of only one unit, a regulating increment is
issued after each package and there will be no test as per k * S!
If the regulating system determines that no regulating increment will be required, the next
random sample is taken immediately. An execution of the suppressed-increment function is not
required.
Converting the regulating increment from grams into time i.e. pulses
Regulating increment [Imp] = weight deviation [g] * regulating factor [Imp/g]
Decisive for the correct function of the regulation is the correct determination of the regulating
factor (ms/g or pulse/g).

071456 (5)
Output of the regulating increment
Direct pulse default for the dosing scroll
Suppressed increments
After output of the regulating increment, the regulation for the entered package count is
suppressed (suppressed increments). The next random sample may be taken only from packs
with the adjusted fill volume.
The number of suppressed increments must at least be equal to the number of packages between
dosing unit and checkweigher.
The suppressed-increments count can be filed for each item in the article data memory.
After an article change i.e. a RESET the regulation begins with the suppressed cycles.
Function startup mode
After certain downtimes the product can either settle in the filler or the filling characteristics of
the product may change. Upon restart, undesirable regulating increments may therefore occur
briefly until product characteristics and behavior have returned to normal.
These undesirable regulating increments can be suppressed by the regulating system.
There are the following input options:
u Standstill detection time in minutes and seconds
u Unit count default, defining the duration of the startup interlock.
If there is no package on the checkweigher any more, the countdown starts for the preselected
standstill detection time, which is displayed on the screen.
As soon as the time reaches the value zero the startup interlock is automatically activated upon
restart. Regulation is disabled for the preset unit count.
If the time will not reached the value zero, startup interlock will not be activated. Regulation
instantly picks up operation in the regular operating mode.

071456 (5)
Configuration options
The following setting options are available for each of the 100 article data memory units:
u Desired excess fill volume (with negative suffix also possible as under-filling option).
u Separate setting of the regulating factor [ms/g] e.g. [pulse/g] for plus and minus adjustment
(0.1...9999.9 ms/g).
u Suppressed cycles up to the next random sampling (0...9999).
u Random sampling count of which the regulating increment is computed (1...9999 units).
u Serial fault recognition:
If all packages in sequence are outside a regulating range of plus or minus 20 % of the
regulating reference point, the checkweigher (and thus also the packaging line) is switched
Off after a preset unit count (0...9999 units). A fault message is shown on the screen.
INFORMATION
The settings indicated above may be modified during weighing mode:
u for the current article, or

u in the article data memory.

071456 (5)
Structure of the auger filler
Modular groups
2
1
4
3
Item Designation
1 Feed hopper (option)

2 Fill level sensor feed hopper
3 Crossfeed auger (option)
4 Drive motor crossfeed auger
5 Fill level sensor agitator hopper
6 Ventilation nozzle with dust filter
7 Agitator hopper
8 Drive motor agitator

101188 (1)
Modular groups
12
14
10
15
11
16
13
Item Designation
9 Agitation holder with agitator

10 Clamping piece
11 Filling auger
12 Drive motor filling auger
13 Filling connection
14 Closure drive unit (option) for long filling auger
15 Control cabinet with air conditioner
16 Pipe connection for flushing the bearings

101188 (1)
Description
5 3
Depending on the product handled, the product is either filled directly via the filling opening or
the feed hopper (1) and the crossfeed auger (2) into the agitator hopper (3).
A sensor (4) in the agitator hopper monitors the fill height. As required, the crossfeed auger is
switched on or off.
The agitator (5) in the agitator hopper provides uniform product flow.
The exact filling quantity is determined by the revolution number of the filling auger (6).

101190 (1)
Notes

S_Notiz_2s
Notes
6.

S_Notiz_2s
Operation
5
Chapter 5: Operation
5 | Operation 1 / 68
Contents
Safety instructions 3
Position of operator 4
Control elements 5
Commissioning 6
Set up individual passwords 6
Calibration - calibrating the checkweigher 6
Adjusting sizes 6
Checkweigher startup 7
Auger filler startup 8

Control System 8
Information on production 9
Switching off checkweigher 10
Shutdown in case of emergency (EMERGENCY STOP) 11
Control and display terminal 12

Start screen - basic structure 12
Frequently appearing buttons 13
Buttons for switching on and off 13
Text and number input 14
Information area 15
Weight display 16
User and passwords 17

Preset passwords 17
User log-in 17
Log off user 18
Change password 18
Reset all passwords 19
Basic functions 20

T
2 / 68 5 | Operation
Checkweigher 21
Basic data 21
Parameter input - package 22
Zero point 23
Ejector 24
Calibrating 25
Random samples 27
Shift start/shift end 28
Parameter display - statistics 29
Histogram 30
Last 60 weights 31
Last 100 tare changes 32
Manual random samplings 33
Cyclical random samples 35
Conveyor belts 36
Size management 37
Create new recipe 38
Change size 38
Delete size 39
Setup 40
Adjust the network connection (option) 42
Regulation auger filler - parameter input 43
Regulation auger filler - parameter display 45
Metal detector ‐ basic screen 46
Metal detector ‐ statistic 47
Metal detector ‐ inputs 48
Filling auger 50
Basic data 50
Operating modes 51
Operating modes ‐ single filling 52
Operating modes ‐ emptying 53
Operating modes ‐ calibrated filling 54
Operating modes ‐ turn filling auger backwards 56
Filling auger 57
Cross-feed auger 58
Agitator 59
Closure 60
Product sensor 61
Dosing data 62
Menu tree 63
Notes 67

T
Safety instructions
INFORMATION
WARNING
The machine presents a danger, if it is operated improperly or if it is

not in a correct condition.
u Operate the machine only if all guard devices and safety-related

devices, e.g. detachable guard devices, EMERGENCY STOP
devices, acoustic insulation, extraction devices, are in place.
u Before switching On the machine ensure that nobody can be
endangered by the machine starting up.

S_05_Sicherheit (7)
Position of operator

108590 (1)
Control elements
Item Element Assignment Function
1 Operating and depends on menu Commands are entered by tapping the relevant
display terminal called up button.
(touchscreen)
Never use sharp objects to tap the buttons!
2 Main switch MAIN SWITCH Switch On/Off power supply of the checkweigher
and the auger filler (option).
Secure against switching On:
Throw switch to position "0" and lock with a
padlock.

108591 (1)
Commissioning
Set up individual passwords
The checkweigher is delivered with standard passwords for the 4 user groups.
See “default passwords”.
These passwords should be changed during commissioning!
u See page 18 “Change password”.

Perform password change for further user groups as well!
Calibration - calibrating the checkweigher
The weighing cell must be recalibrated after installation and alignment.
u See page 25 “Calibrate checkweigher”.
Adjusting sizes
Upon delivery, the checkweigher has a default setting with the ordered and tested sizes.
Should further sizes be required, these can be set easily by copying existing sizes.
u See page 38 “Set up new size”.

with auger filler (option),
additionally "perform a calibration dosing" for every new size and adapt the parameters
accordingly.
u See “Perform calibration dosing”.
Repeat process for each additional size one more time!

107463 (2)
Checkweigher startup
NOTICE
Weighing cell fault

Do not use any radio‐operated devices within an area of two meters
around the weighing cell.
u Incorrect weighing can occur.
Requirement
u The upstream machine is still switched off
u There is no product or no other load on the weighing belt.
Procedure
u Set main switch to "1".
The “start screen” is displayed.
The “home screen” is displayed.

(home screen: see page 12)
The checkweigher is switched on.

107464 (1)
Auger filler startup
Control System
INFORMATION
Operation is carried out at the operating and display terminal.

This may be
u an individual device
u a checkweigher with dosing option, or
u a machine control system with appropriate option.

101192 (1)
Auger filler startup
Information on production
INFORMATION
The auger filler is inspected at our plant. Any readjustments may be

performed only by Bosch service technicians.
1. The product feed has to be set out by the

customer so that the product quality is
uniform:
u no segregation
u smallest possible batch or container
fluctuations
u minor air admixtures etc.
2. Attach a customer-provided extraction line

at the venting connections (if installed)
and connect with the on-site extraction
device.
u The crossfeed auger (1) must convey more 3 1

product than the filling auger (2) pours.
u The rotational speed of the feed auger is
selected via the relevant control device
and during operation is automatically
optimized as a derivative of the switching
frequency of the sensors (3).
Option
u Two operating modes are selectable on the
control device:
a) switching mode (crossfeed auger on or
off)
b) controller mode: automatic rotational
speed adjustment.
u The air fed at the hose connection (4) has

to be oil-free and microfiltered.
2 5 4
Set maximum 0.2 bar at the pressure
controller (5).

101193 (1)
Switching off checkweigher
Requirement
u The upstream machine is switched off to avoid infeed backup
u There is no longer any product on the belts for weighing.
Procedure
1. Touch the button
The belts of the checkweigher come to a
stop
2. Set main switch to "0"
The display goes out
3. The checkweigher is switched off.
INFORMATION
The checkweigher cannot be switched on again for approx. 30 seconds

after having been switched off.

107465 (1)
Shutdown in case of emergency (EMERGENCY STOP)
INFORMATION
The checkweigher does not have its own EMERGENCY STOP button.
The EMERGENCY STOP function is performed via the upline machine.

090907 (6)
Control and display terminal
Start screen - basic structure
1 Information section (see Page 15). Overview of current machine status.

2 Basic functions (see Page 20). Basic functions for machine operation.
3 Machine configuration (see Page 21). Adjust and manage machine sections.

099269 (6)
Frequently appearing buttons
Button Function
Accept/save input.
Designation in these operating instructions: button Ļ.
Close window.
or
Abort input.
Designation in these operating instructions: button ĺ.
Delete input.
Print screen shots or logs (option).
Buttons for switching on and off
Button Function
Switched Off.
Switched On.

099269 (6)
Text and number input
Button Function
Dialog window for input of numbers.

1
1. Admissible input range (min. - max.)
Dialog window for text input.

099269 (6)
Information area
Function
u Overview of current machine status.
1 2
A
3
5
4
Item Designation
1 Password administration see Page 17.

2 Display panel
Display of the latest message or fault including number and time.
u Green background: Messages (operating status of the machine).
u Red background: Faults.
Press button:
The list of all pending messages, warnings and faults appears.
Acknowledge faults with screen button (A) (see “Help system” in Section 6).
3 For weight display see page 16.
4 Current format.
5 Date and time.

107704 (1)
Information area
Weight display
1 2 3
Item Description
1 Display gross (B) / net (N).

Press to switch over.
2 Weight display.
Press screen button: display zooms to screen size.
Press again: display is reset.
3 Display flashing = new package being weighed.

4 Display AT = automatic zero point taring is switched On.

107705 (1)
User and passwords
Preset passwords
There are 4 user groups equipped with different levels of authorization (see "menu tree").
INFORMATION
Ex-factory the user groups are password-protected.

Change supplier passwords for security reasons.
User group Password level Manufacturer password
Operator 1 1 pass1
Operator 2 2 pass2
Setup engineer 1 3 pass3
Setup engineer 2 4 pass4
User log-in
Requirements
To log on, the password must be known.
If the user does not have authorization for a function:
u For signing in, the password administration menu is shown with a different user group.
Procedure
1. Click on button.
2. Press screen button Enter password.
3. Enter password and confirm Ļ.

The user is logged in.
4. The user screen button switches to the 1

display of the password level (1 - 4).
If an incorrect password is entered:

u The user is not logged in.

107706 (1)
User and passwords
Log off user
1. Press screen button Log Off.

The user is logged off.
Change password
Requirement:
The user must be logged on.
Procedure 1
1. Click on button.
2. Press screen button Change password.
3. Enter old password (1).

4. Enter new password (2).
5. Enter new password (3). 1
The password is changed.

2

107706 (1)
User and passwords
Reset all passwords
Requirement:
Setup engineer 2 must be logged in.
Procedure 4
1. Press screen button User.
2. Press screen button Reset passwords.
CAUTION !
Reset passwords to DELIVERY STATUS?
3. Confirm Ļ.
All passwords are reset to the status on
delivery
(see “default passwords”).
If the password for setup engineer 2 is no longer known, log On with the master password
and carry out the procedure described above.
See “Master password” in Section 9.

107706 (1)
Basic functions
Function
u Basic functions for machine operation.
1 2 3 4 5 6 7 8 9 10
4.
1 Conveyor belts Switch conveyor belts On and Off.

2 Basic data Return to start screen.
3 Parameter input See page 22.
4 Parameter display See page 29.
5 Format administration Create, change formats.
6 Setup Language, user administration and program
data.
7 FVS (filler) See page 50.
8 Metal detector See page 46.
9 Cleaning the touchscreen Clean Touchscreen.
The touch sensitivity of the screen is
switched Off for approx. 30 s. The
remaining time is displayed.
10 Information Go to Online Help.

108596 (1)
Checkweigher
Basic data
6
2
1 Counter pass-packages. Display.

2 Tare weight. Input.
3 Display output (packages per minute). Pre‐set value/actual value.
4 Mean value. Display.
5 Standard deviation.
6 Diagram with the most recent weight
values.

107708 (2)
Checkweigher
Parameter input - package
1 5 8
2 6
4 7
1 Overweight limit. Input.

2 Upper warning limit.
3 Lower warning limit.
4 Underweight limit.
5 Nominal weight.
6 Tare weight.
7 Package length.
8 FPR or “according to input”. Select classification type.
As shown on the display.

107709 (2)
Checkweigher
Zero point
1 4
2 5
1 Maximally admissible zero point Input.

difference.
2 Max. zero point difference.
3 Number of zero point error.
Exceeding this causes a machine
standstill.
4 Automatic zero point taring. On/Off.
The zero point can be disabled for testing
purposes.
5 Machine stop with zero point error.

107710 (1)
Checkweigher
Ejector
1 2 3 4
6 7 8 9 10 11
12
1 Ejector. Selection.
2 Distance between the ejector light barrier Input.
and ejector.
3 Dead time of the ejector.
4 After series fault, belt is switched off
automatically.
5 Pushing time of the ejector.
6 Eject overweight and underweight On/Off.
packages.
7 Eject overweight packages.
8 Eject underweight packages.
9 Switch Off ejector.
10 Eject pass-packages.
11 Eject metal-containing packages.
12 Number of ejected packages. Display.

108592 (1)
Checkweigher
Calibrating
1 Calibrating process. Start.

2 Calibration switch.
Procedure
1. Remove product residue.
2. Press select button (1).
Wait for message "Ready measuring empty
weigher".
3. Press screen button (2).
Following the message "Ready measuring
calibration weight":
4. Emplace calibration weight and press
screen button (2) once again.

107712 (1)
Checkweigher
Calibrating
Potential fault messages during and after the calibration process
Cause Remedy
Errors while reading the serial number. Check the cable connection between the
control unit and weigher cell.
Unsteadiness during zero point determination. Erratic running of the belt, air draft etc.
Unsteadiness during adjusting measurement. Erratic running of the belt, air draft etc.
Unsteadiness during individual measurement. Erratic running of the belt, air draft etc.
Adjusting weight too small. Check the imposed adjusting weight and
compare with input.
Calibration value input error. Check the input.
Adjusting weight input error. Check the input.

107712 (1)
Checkweigher
Random samples
1 1
While the manual random sample is started by hand (by pressing the start button, see
"Displays Manual random sample"), the cyclical random sample operates automatically.
Either a time or a number of packs can be selected for this as a pause between 2 random
samples.
1 Random sampling size. Input.

Number of packages per random sample.
2 Interval with cyclic random sampling: Selection.
n = number of packages (target unit
count).
t = time (time target).
3 Target unit count. Input.

4 Time target.

107713 (2)
Checkweigher
Shift start/shift end
Item Designation
1 Shift start.
Press screen button if the start of the shift is not congruent with the end of the last
shift.
2 End of shift.
Press screen button to end the current shift.
A new shift begins automatically.

107714 (1)
Checkweigher
Parameter display - statistics
1 8 14
2 9
3 10
5 11
6 12
7 13
Item Designation
1 Number of packages above the overweight limit.

2 Number of packages between the upper warning limit and the overweight limit.
3 Number of packages between the lower warning limit and the underweight limit.
4 Number of packages below the underweight limit.
5 Number of packages with weighing fault (unsettled, overload, underload).
6 Monitoring of package length.
7 Number of packages with too small a distance between packages.
8 Number of pass‐packages.
9 Number of ejected packages of the checkweigher.
10 All packages (regardless of being pass or fail packages).
11 Total packaged mass in kg.
12 Mean value.
14 Count of rejected packages.

108102 (2)
Checkweigher
Histogram
Item Designation
1 The scale of the histogram is done automatically according to the input overweight
and underweight limits.
u Green bars: pass-weights.
u Red bars: weighing error or fail-packs.
2 Print statistics data.

107716 (2)
Checkweigher
Last 60 weights
2 3 4 5
Item Designation
1 A list of the last 60 weights with status is displayed.

The latest weight is in position 1.
A newly added weight replaces the oldest weight.
2 Scroll page by page.
3 Scroll line by line.
4 Print statistics data.
5 Delete statistics data.

107717 (1)
Checkweigher
Last 100 tare changes
Item Designation
1 The last 100 tare changes (tare = weight of package) are saved with date and time.
If the statistics are deleted this table is deleted as well.
All tare changes are noted on the statistics printout.

107718 (1)
Checkweigher
Manual random samplings
1 6 11
2 7
3 8
4 9
12
5 10
1 Number of packages above the Display.

overweight limit.
2 Number of packages between the upper
warning limit and the overweight limit.
3 Number of packages between the lower
warning limit and the underweight limit.
4 Number of packages below the
underweight limit.
5 Count of good packages.
6 Number of packages with weighing fault
(unsettled, overload, underload).
7 All packages (regardless of being pass or
fail packages).

107719 (2)
Checkweigher
Manual random samplings
1 6 11
2 7
3 8
4 9
12
5 10
9 Standard deviation. Display.

10 Mean value.
11 Number of manual samplings subject to Input.
the defaulted number of packages
(pass-packages/random sampling size).
12 Start manual random sampling Start.

107719 (2)
Checkweigher
Cyclical random samples
1 6 11
2 7
3 8
4 9
5 10
1 Number of packages above the overweight limit. Display.

2 Number of packages between the upper warning
limit and the overweight limit.
3 Number of packages between the lower warning
limit and the underweight limit.
4 Number of packages below the underweight limit.
5 Count of good packages.
6 Number of packages with weighing fault
(unsettled, overload, underload).
7 All packages (regardless of being pass or fail
packages).
10 Mean value.
11 Number of cyclical samplings subject to the Input.
defaulted number of packages
(pass-packages/random sampling size).

107720 (2)
Checkweigher
Conveyor belts
1 2
1 Belt speed in packages/min. Display.

2 Belt speed in meters/min.
3 Post-feed time. On/Off.
4 Post-feed time in seconds. Input.

107721 (1)
Checkweigher
Size management
1 2 3
Item Designation
1 Size number.
2 Size list.
3 Set up new size, see Page 38.
4 Change to new size, see Page 38.
5 Delete size, see Page 39.

107722 (1)
Checkweigher
Create new recipe
INFORMATION
Creating a new size means copying the current size.

All parameters are taken over.
It is recommended to select the most similar size as a template (e.g.
same product or same weight).
1. Press size you wish to use as a template.

The size name is shown against a blue
background.
2. Press screen button.
3. Enter new size name into the text box and

confirm Ļ.
A new size has been created.
4. Adapt all required parameters to the new
size in the respective menu screens.
For information whether a parameter is
size-dependent please see Section 9
“Access Rights”.
Change size
1. Press size to which you wish to go.

background.
3. Confirm size name Ļ.

The selected size is active.

107723 (2)
Checkweigher
Delete size
Delete one size

1. Press size which you wish to delete.
background.
3. Confirm delete command Ļ.

The size selected is deleted.
Delete all formats

Caution!
There is no second query "Are you sure you
wish to delete?"!
2. Press clear all formats.
All sizes are deleted.

107724 (1)
Checkweigher
Setup
1 4 7 10 11
7 12
2 5 8 13
3 6 9 14
Item Designation
1 Press: switch languages Æ Menu selection language.

Press flag representing the desired language. All texts switch to the selected
language.
2 Outputs for random wiring.
3 Filler regulation (see page 43).
4 Electronic type plate.
5 Individual weight interface (option).
6 Set the network connection (e.g. IP address, gateway etc.) (option).
For the unique addressing of computers in the network (see next page).
7 General settings.
8 Metal detector (option).

095949 (7)
Checkweigher
Setup
1 4 7 10 11
7 12
2 5 8 13
3 6 9 14
Item Designation
9 Camera system (option).

10 Generate weighing curve.
11 Set time and date.
12 Option overview (display in German and English).
The options can be modified by a Bosch Service Technician only.
13 Service inputs.
The inputs can be modified by a Bosch Service Technician only.
14 Fault history.

095949 (7)
Checkweigher
Adjust the network connection (option)
1
3
Requirement:
The checkweigher must be connected to a network with an Ethernet cable.
Procedure
1. Press screen button (1) and enter new
address.
2. Save input (2).
Abort input with ĺ.

3. Press screen button (3) for connecting with
a network.

095949 (7)
Checkweigher
Regulation auger filler - parameter input
1 5
9
2 6
10
3 7 11
4 8 12
1 Overfilling: shifting the reference point Input.

towards the nominal weight.
Modification is possible during operation.
2 Min. adjustment increment.
3 Number of packages for random
sampling.
4 Number of packages between filling unit
and checkweigher.
5 Startup operation per: time target in
seconds, after expiry of which the startup
disable becomes effective.
6 Startup disable: number of packages until
the first measuring is performed again
after a standstill.
7 Regulating time factor Plus (option).
8 Regulating time factor Minus (option).

100041 (6)
Checkweigher
Regulation auger filler - parameter input
1 5
9
2 6
10
3 7 11
4 8 12
9 Regulation. On/Off.
10 Number of packages per multipack Input.
(option).
11 Increase regulating increment.
12 Reduce regulating increment.

100041 (6)
Checkweigher
Regulation auger filler - parameter display
3 4
1 Startup disable: number of packages until Display.

the first measuring is performed again
after a standstill.
2 Number of packages for measured value
acquisition (random sample).
3 Number of packages between filling unit
and checkweigher.
4 Calculated regulating step.

099286 (4)
Checkweigher
Metal detector ‐ basic screen
2 4
1 Metal detector. On/off.

2 Sensitivity. Input.
Sensitivity for the triggering
threshold of the metal fault in
percent.
3 Angle. Input.
Product angle: Is determined during
the teach‐in process. Is different
depending on the type of metal.
4 Triggering threshold. Input.
The triggering threshold is used for
fine tuning the sensitivity.
5 Setting metal detector. Display.

108593 (1)
Checkweigher
Metal detector ‐ statistic
2 3 4
Item Designation
1 A list of statistics including value, date and time is displayed.

3 Scroll line by line.
4 Delete statistics data.

108593 (1)
Checkweigher
Metal detector ‐ inputs
1 4
5
2
6
3
1 Distance weigher‐coil. Input.

Distance between the metal coil and
the infeed light barrier of the
weighing belt.
2 Start teach in. On/off.
Teach in process: Start the teach in
process with the button <Start teach
in>. A minimum of 3 packages must
be transported through the metal
detector. The packages must be
placed on the infeed belt of the
checkweigher. The press the button
”Continue teach in”.
3 Continue teach. On/off.

108593 (1)
Checkweigher
Metal detector ‐ inputs
1 4
5
2
6
3
4 Tracking On/off.
Low drifts of product angle (due to
product deviations) that do not yet
result in an error message are
corrected. The product angle is
automatically updated.
5 Teach in (quick learn) On/off.

Abrupt changes in product angle up
to a deviation of max. 5° are detected
and corrected within 2 packages.
6 Half cycle On/off.
Some criteria are deactivated that a
signal must fulfill so that a metal
alarm is triggered (less susceptible to
interferences).

108593 (1)
Filling auger
Basic data
2
1
3
6
4
7
1 Auger filler. On/Off.

2 Cross-feed auger setting. Display.
3 Agitator setting.
4 Filling auger setting.
5 Correction weight. Input.
6 Capacity utilization motor filling auger. Display.
Load is not to exceed 100 %.
7 Cycle time utilization.
Running time of dosing unit in
relation to the cycle time
(packages/min).

103225 (2)
Filling auger
Operating modes
6
1
7 8
1 Automatic mode On/Off.

2 Single filling. See page 52. Start.
3 Emptying. See page 53.
4 Calibrated filling. See page 54.
5 Turn filling auger backwards. See page
56.
6 Operating mode manual. On/Off.
7 Time (ms) that is waited for after filling. Input.
8 Time (ms) for weighing and determining
the weight.

103226 (2)
Filling auger
Operating modes ‐ single filling
Function
u If the machine is at a standstill a single dosing can be triggered for testing purposes.
1 Trigger single dosing. Start.

For checking of function and weight.

103226 (2)
Filling auger
Operating modes ‐ emptying
Conditions
u The cross-feed auger is switched optionally on or off.
u The agitator is switched optionally on or off.
u The sensor is not active for minimum level.
u The closure is open.
1 2
1 Start emptying (continuous operation of Start.

the auger).
Place a sufficiently large container
under the opening.
2 Speed. Input.

103226 (2)
Filling auger
Operating modes ‐ calibrated filling
Function
u To adjust the filler to the product.
The pulse/weight factor is calculated and displayed.
1 Standard revolutions target value (see data Input.

sheet).
2 Start calibrated filling. Start.
Triggering of the calibrated filling,
weighing out of the calibrated filling. The
standard weight should be close to the
nominal weight. Adapt the standard
revolutions as necessary and perform the
calibrated filling again.
Change the value of the standard
revolutions (1) until the standard
weight is achieved.
3 Standard weight. Input.
4 Standard weight factor Display.

103226 (2)
Filling auger
Operating modes ‐ calibrated filling
Procedure:
1. Enter target value calibrated revolutions.
(See data sheet).
Put suitable container under the filler.

Write down the weight of the container.
2. Trigger the calibrated filling process.
Carry out the calibrated filling process
three times using the data to calculate the
mean value.
3. Determine the weight of the dosing
quantity.
4. Enter the determined ”Calibration weight”.
The calibration factor is automatically
calculated.

103226 (2)
Filling auger
Operating modes ‐ turn filling auger backwards
Function
u Turn filling auger backwards,
u Withdraw filling auger by turning.
1 Turning filling auger backwards. Start.

One revolution is performed for each
actuation.

103226 (2)
Filling auger
Filling auger
1 6
2 8
3 9
4 10
1 Preset fill weight parameter. Input.

2 Dosing screw rotational speed.
3 Revolution/weight factor of the last Display.
calibration dosing.
4 Revolution/weight factor current.
5 Percentage of regulation.
6 Ramp time acceleration. Input.
7 Ramp time brakes.
8 Relation foreign mass to motor mass.
9 Positioning accuracy.
10 Programmed cams of servo motors.

103227 (2)
Filling auger
Cross-feed auger
1 3 5
2 4
1 Cross-feed scroll. On/Off.

2 Regulation.
3 Revolution speed crossfeed scroll. Input.
4 Setpoint product level in chute if with
option measuring probe.
5 Response time sensor until start of
crossfeed scroll.

103228 (2)
Filling auger
Agitator
1 2 3
1 Agitator. On/Off.
2 Agitator revolution speed. Input.
3 Agitator slow-down-to-stop time.

103229 (2)
Filling auger
Closure
1 Closure pre-switch-off time. Input.

103230 (2)
Filling auger
Product sensor
2
1
1 Product sensor. On/Off.

Selection which sensor (vibration
rod/ capacitive initiator) is to be
used.
2 Delay material sensor. Input.
Delay time until product available is
reported.
3 Delay empty detection.
If the product sensor is not occupied
for this period of time, an empty
message is sent to the machine
control and production stops.
4 Remaining quantity.
Quantity that is still produced after
the product monitoring was switched
off until an empty message is issued.

103232 (2)
Filling auger
Dosing data
INFORMATION
This is where dosing data can be stored.

There is only one display to facilitate the size setting process.
1 Dosing data for size parts. Input.

101372 (3)
Menu tree
Basic screen
1
Password Conveyor belts Basic data Parameter input Parameter display Format
administration administration
Target tare weight 1 3 1 3

Log on/Log off Nominal output 3 Package Statistics Create size
4 1 1
Change password Zero point Histogram Change size
4 4 1 4
Reset password Ejector Last 60 weights Delete size
4 3 1
Password administration On /
Off Adjusting weigher Last 100 tare
changes.
3 1
Man. random
Random samples samplings
1 2
Shift start/ Cycl. random
shift end samplings
1 Post-feed time On / Off 3

Conveyor belts Enter post-feed time 3
1 Password level 1 - operator 1

3 Password level 3 - setup engineer 1

107726 (1)

107726 (1)
Menu tree
Basic screen
1
Setup Filler (FVS) Netweigher (FIW) Cleaning the Information
touchscreen
1 2 Online help for current menu

screen
Language Basic data 2
Single dosing
4
Regulation 3
Special function auger filler - Operating modes
parameter input 2
3 Run empty
Dosing unit control Regulation Dosing scroll

1
auger filler -
parameter display 2
1 3
Calibration dosing
Electr. designation Cross-feed scroll
plate
4 3 2
Interface Race auger filler
single weight Agitator backwards
4 3
Network connection Closure
3
Enter regulating
General settings increment
4 1
Adjust weighing
curve Display regulating
increment
3 3
Time + date Product sensor
3 2 Password level 2 - operator 2
Metal detector Dosing data 3 Password level 3 - setup engineer 1
For Bosch Service

107727 (1)

107727 (1)
Notes

S_Notiz_2s
Notes
5.

S_Notiz_2s
Troubleshooting
6
Chapter 6: Troubleshooting
6 | Troubleshooting 1 / 126
Contents
Safety information 11
Preparations for troubleshooting 11
Measures after faults and prior to switching back on 11
Checkweigher faults 12
Possible faults 12
Faults without fault message 12
Troubleshooting checkweigher 13
401 Package length too small 13
402 No new measured values 13
403 Fault zero point 13
404 Wrong weighing cell connected 13
405 No weighing cell connected 13
406 No valid adjusting values 13
407 Communication weighing cell master distorted 14
408 Zero point unsteadiness 14
410 Adjusting weight too small. 14
411 Calibration value input error. 14
412 Adjusting weight input error. 14
413 Operating values inconsistent 14
414 Fail pack not ejected 15
415 Zero point too high 15
416 Zero point too low 15
417 Zero point unsteadiness 15
418 Input weighing belt length = 0 15
419 No adjusting process with calibration dongle 15
420 Monitoring of cycle time 16
423 Measuring level too short. 16
424 Fault frequency converter 16
425 Start initialization could not be completed 16
426 Input performance = 0 16
428 Profibus connection PMC2 disturbed! 16
429 Profibus connection BX3110 disturbed! 17
450 PMC2 internal fault 17
451 Too many fail packs 17
452 External belt release missing 17
453 Only possible when belts are running 17
454 Size is unreadable 17
455 New size cannot be saved 17
461 Pass package missing in counter-check 18

T
2 / 126 6 | Troubleshooting
462 Unexpected package in counter-check 18

600 Fault initialization printer 18
601 Printer interface reception disturbed 18
602 Printer interface sending disturbed 18
611 Printing unit blocked 18
612 Printer: end of paper reached 18
613 Printer: cutter is blocked 19
615 No I/O data exchange with slave PMC2 19
616 Inputs CX9000 defective 19
617 Outputs CX9000 defective 19
650 Only allowed when machine is standing still 19
651 External stop 19
652 Please clear belts 20
653 Size data are transferred 20
699 Unknown printer error 20
1706 Check light barrier package scanner! 20
2421 Printer not enabled 20
2423 Option: Printer not installed. 20
7300 Belts are blocking 21
Auger filler faults 22

Faults without fault message 22
Troubleshooting auger filler 23

System of the fault message numbers 23
9110 A job timeout 24
9120 Output stage short circuit 24
9131 Bleeder defective 24
9148 MEM no module 25
9149 No MEM parameters 25
9163 Incompatible EPROMs 25
9164 SW WatchD MC/VC 26
9165 VC fatal error 26
9167 Wiring 26
9171 Error encoder_1: 27
9176 EEprom checksum. 27
9177 Internal voltage error 28
9178 ECL error 1 28
9195 Mot/res pairs of poles 28
9197 SINCOS_1 28
9198 SINCOS_2/INK_2 29
9207 Parameter invalid 29
9209 MC fatal error 29
9211 JOB timeout 29

T
9217 Default parameters 30

9221 Excess current 30
9223 Intermediate circuit voltage too high 30
9225 Motor temp / +UL 31
9232 Output stages I²T 31
9234 Unknown errors 31
9241 Encoder stoppage 32
9242 Encoder jump 32
9247 MEM CRC error 33
9255 Parameter error. 33
9258 Breakpoint number 33
9268 Wrong encoder no. 33
9269 Max. rotational speed 34
9270 Max current 34
9275 Parameter > v_max 35
9279 ECL error 2 35
9291 8-fold lag error 35
9293 Parameter < A max 35
9301 HW limit switch negative 36
9302 HW limit switch positive 36
9303 SW limit switch negative 36
9304 SW limit switch positive 36
9305 Lag error 37
9312 Arithmetical overflow 37
9313 Division by zero 38
9314 Time overflow 38
9315 Blending timeout 38
9335 Invalid reference run mode 38
9336 Limit switch before zero pulse 39
9337 No zero pulse in a revolution 39
9339 Not referenced 39
9345 Sector invalid 39
9346 MEM R/W error 40
9350 BCD format error 40
9351 Variable number 40
9352 Variable range 40
9353 Nesting 40
9354 Program location 41
9356 PGM trans active 41
9357 No valid PGM 41
9359 VEL <= 0 41
9360 VEL too high 41

T
9361 ACC <= 0 42

9362 ACC too high 42
9366 Defective. SYN data: 42
9380 ECL error 3 42
9383 ECL COM 43
9386 Pos overflow 43
9390 PLC PT function 43
9416 Target window timeout 44
9426 Heat sink temperature too high 44
9427 Inner temperature high 44
9430 Bleeder I²T 44
9481 ECL error 4 45
9522 Phase failure 45
9524 Intermediate circuit voltage too low 45
9526 Heat sink temperature too high 45
9528 Motor I²T 46
9529 Output stages I²T rpm 46
9582 ECL error 5 46
9584 EEPROM ANA-1 47
9587 BE timeout 47
9588 Control voltage low 47
9589 Communication module 47
9592 EG sequence error 47
9596 Axis pos timeout 48
9700 EMERGENCY STOP 48
9701 Cross-feed auger faulty 48
9702 Agitator faulty 48
9703 Protective motor switch 49
9704 Closure does not open 49
9705 Cycle too short 49
9707 No material/empty message 49
9708 Closure's advance switch-off time is too long 50
9710 Address in the secure memory area 50
9711 Data loss in the RAM, transfer again 50
9712 Max. top-off volume exceeded 50
9713 Transfer the value < = 0 50
9714 Weight too low or no new value 51
9715 No calibrated filling, product is missing 51
9716 Weight regulation at the stop 51
9717 Closure is closing during dosing 51
9718 Profibus faulty 51
9719 Voltage for outputs is missing 52
9720 Fuse for outputs defective 52
9721 Motor temperature of agitator 52
9722 Motor temperature of cross-feed auger 52

T
9723 Agitator hopper open 52

9724 Wrong operating mode 53
10037 Battery low 54
10038 Power fail 54
10100 I2T Motor 54
10101 Amplifier power-off due to excess temperature 54
10102 Motor - power-off due to excess temperature 55
10103 Power-off due to cooling error 55
10104 Power-off due to control voltage error 55
10105 Feedback error (track monitoring) 56
10106 Communication error DC controller 56
10107 Excess current 56
10108 Excess voltage 57
10109 Undervoltage 57
10110 Phase error (power supply) 57
10111 Excessive following error 57
10112 Communication error real-time bus 58
10113 Braking resistor defective 58
10114 Reading error EEPROM 58
10115 Gate-power failure 58
10116 Commutation error 59
10117 Reading error encoder EEPROM 59
10118 Error on serial interface to encoder 59
10119 Short or ground circuit in output stage 59
10120 Overload power-off output stage 60
10121 Bleeder temperature too high 60
10122 Max. motor speed reached 60
10123 Error "Inverter Enable" 61
10124 Power-off due to overload 61
10125 "2t Motor" warning 61
10126 Amplifier excess temperature warning 61
10127 Excess temperature motor warning 62
10128 Cooling error warning 62
10129 Power-off overload output stage warning 62
10130 Bleeder temperature rising 62
10131 Phase failure of power supply warning 62
10132 Following error 63
10133 Speed-dependent power reduction 63
10134 External 24 V power supply too low 63
10135 Undervoltage warning 64
10136 "Inverter Enable" warning 64
10137 Motorless 64
10138 Inadmissible motor 64
10139 Error in DC-circuit charge 65
10140 Stop time limit 65

T
10141 Reading error EncoderPosition 65

10142 Board power-off due to overtemperature 66
10143 Encoder temperature warning 66
10144 DC bus short circuit 66
10145 DC bus ground circuit 66
10146 DC bus overload 67
10147 24 V power supply overload 67
10148 Internal voltage error 15 V 67
10149 Internal voltage error 12 V 67
10150 Phase L1 failure 68
10153 DC bus discharge failure 68
10154 Phase L1 warning 69
10157 DC bus overload warning 69
10158 24 V supply overload warning 69
10159 DC bus no discharge warning 70
10160 Undervoltage power stage driver 70
10161 Overtemperature board warning 70
10162 Wiring error O_0 70
10163 SERCOS: C1D error 70
10164 SERCOS: C1D manufacturer-specific error 71
10165 SERCOS: C2D warning 71
10167 SERCOS: C3D operation status 71
10169 Single SERCOS error (SLAVE) 72
10170 DrvEncPosition reading error 72
10171 Encoder communication warning 72
10172 Extebded diagnosis message 73
10173 Feedback message (track monitoring) 73
10174 Excess current warning 73
10175 Bleeder overload 73
10176 Reserved 73
10177 Power-Board-excess temperature power-off 74
10178 Device error 74
10179 Warning braking resistance overloaded 74
10180 Warning power board excess temperature 74
power-off
10181 Warning fan defective 75
10182 External 24 V supply too high 75
10200 Faulty log. address of the parameter 75
10201 Faulty parameter type code 75

T
10202 Faulty configuration file 75

10203 Faulty parameter file 76
10204 IEC program cannot be loaded 76
10205 Illegal parameter value 76
10206 Faulty ObjType of Log Adr 77
10207 Hardware module does not exist 77
10208 Too many real axes in config 77
10209 Last boot failed 78
10210 Boot failed 79
10211 Invalid configuration 79
10300 Division error 79
10301 Coprocessor segment overflow 79
10302 Stack error 80
10303 General protection error 80
10304 Coprocessor error 80
10305 Memory limit exceeded 80
10306 Arithmetic overflow 80
10307 Double execution error 80
10308 Invalid task state segment 81
10309 No memory segment 81
10310 Faulty memory segment adjustment 81
10311 Coprocessor division error 81
10312 Parameter relocation failed 81
10313 Serious cycle time overflow 82
10314 Defective program file 82
10315 Library function not implemented 82
10316 Faulty NvRam CRC 83
10317 Cycle time overflow 83
10318 Profile to be calculated was deleted 83
10319 TPEdge inaccurate at 4 ms 84
10320 Array access error(check) 84
10321 Division by 0 (check) 84
10322 IEC task exception processing 84
10323 Max. string length exceeded 84
10324 UPS internal error 85
10325 Corrupt file 85
10326 Function not available 85
10327 Invalid PositionSource 85
10328 Invalid destination 86
10329 Invalid BitNumber 86
10330 Bad master parameter data 86
10331 Licensing 86
10332 Licensing 87
10333 Fatal error receiving encoder data 87
10334 Error receiving encoder data (warning) 87

T
10335 Fatal synchronization error 87

10336 Synchronization error (warning) 89
10337 Insufficient system memory to create DynIECData 89
10338 UPS accu error 90
10339 UPS active - system temperature too high 90
10340 Outside limits (check) 90
10400 IEC diagnosis message class2 90
10406 IEC diagnosis message class 1 91
10407 IEC diagnosis message class 8 92
10500 Duplication of SERCOS slave address 92
10501 SERCOS slave not found 92
10502 Loop not closed 93
10503 error in parameter channel 93
10504 Read cycle overflow 94
10505 Simple SERCOS cycle error (MASTER) 94
10506 Multiple SERCOS error (MASTER) 95
10507 Write cycle error 95
10508 SERCOS boot error 96
10509 Wrong FW version 96
10510 RTB interrupt missing 97
10511 CPU time overflow 97
10512 SERCOS wrong device type 97
10513 Download result 98
10514 Error download configuration file 98
10516 SERCOS wrong device position 98
10517 Multiple use RealTimeBusAdr 99
10518 Too many real SERCOS slaves 99
10600 Serial interface disturbed 99
10601 Encoder track error 100
10700 CAN layer2 driver error 100
10701 CAN Layer 2 Init error 100
10702 CAN Layer 2 1 error occurred 100
10703 CAN Layer 2 error reaches warning limit 101
10704 CAN Layer 2 switched passive 101
10705 CAN system error 101
10706 CAN Layer 2 under warning limit 102
10707 CAN Layer 2 switched active 102
10720 No module found 102
10721 Module not ready 103
10722 No cyclic telegrams 103

T
10723 No Profibus configuration data 104

10724 No I/O range 104
10725 Module firmware replaced 104
10726 Module firmware invalid 104
10730 Faulty master parameter data 105
10731 Automatic bus deactivation 105
10732 No reply from slave 105
10733 Serious bus error 106
10734 Bus short circuit recognized 106
10735 Bus telegrams ignored 106
10736 No I/O data exchange with slave 106
10737 Duplication of IEC addresses 107
10738 Conf. IO data > admissible IO range 107
10739 Duplicate Profibus addresses 107
10750 CanOpen node does not exist 107
10751 CanOpen node not configured 107
10752 No CanOpen EDS file 108
10753 Init of CanOpen module failed 108
10754 CanOpen error message 108
10755 CanOpen node guarding error 108
10756 CanOpen DPM access time overflow 108
10757 CanOpen config error 109
10758 Size of application object not supported 109
10759 Max. no. of application objects limit reached 109
10770 Overflow of optional module ranges 109
10771 Duplicate IRQ config. of optional modules 110
10780 Frequency > 1 MHz 110
10781 No connection with encoder 110
10782 Track error 111
10785 Hardware defective 111
10786 Asynchronous to SERCOS-Bus 111
10787 Configuration error 111
10788 Connection error 113
10789 Simple bus error 113
10790 Module error 114
10800 Insufficient memory 114
10801 Error reading FAT 114
10802 Error writing FAT 114
10803 Inconsistency of FATs 115
10804 Corrupt cluster detected 115
10805 Corrupt file name detected 115
10806 Corrupt file size detected 115
10807 Multiple cluster/block detected 115
10808 Corrupt directory name detected 116
10809 Circularly linked clusters/blocks detected 116

T
10810 Error reading directory entry 116

10811 Error writing directory entry 116
10812 Lost cluster/block found 116
10813 Device <ide0:> not found 117
10814 Initialization of <ide0:> failed 117
10815 Error using function with <ide0:> 117
10816 Bootrom.sys 117
10817 No device name 117
10818 File not found 118
10819 File open error 118
10820 File read error 118
10821 File not continuously saved 118
10822 Cluster read error 118
10823 Contents of files different 119
10824 No file name 119
10825 Invalid directory size 119
10826 Error during PIC-FW update 119
10827 Power-Off due to hardware monitoring 120
10828 Library active 120
10900 Software error (suspend Task) 120
10901 Software error (invalid opcode) 120
10902 Software error (page fault) 121
10903 Software error (class 2) 121
10904 Software error (class 1) 121
11000 Reference run: initiator not found 121
11001 Reference run: no torque found 122
11002 Warmstart: outside window 122
11011 Reference run: initiator not found 122
11019 Cam definition higher than period 122
11020 Movement profile missing 123
11021 Error monitor mains contactor 123
11022 Error monitor "Inverter Enable" 123
11023 Error monitor Hardware Enable 123
11024 DC voltage too low 124
11025 Controller not ready 124
15000 Warmstart not finished 124
Notes 125

T
Safety information
INFORMATION
All work with electric devices may be carried out by trained and duly
Preparations for troubleshooting

u If necessary, switch Off the machine in compliance with these operating instructions and
secure it against being unexpectedly switched back On again.
u If required, lock the main command devices and withdraw the key and/or attach a warning sign
to the main switch.
u Cordon off a large area around the repair zone.
u Inform the operating personnel and appoint a supervisor.
Measures after faults and prior to switching back on

u When the cause of the fault has been eliminated, clear the fault (reset).
u Check the safety devices.
u Check the fault-free functional sequence of the machine (collision-free operation).

S_06_Sicherheit (7)
Checkweigher faults
Possible faults
INFORMATION
The checkweigher fault messages are displayed on the operating and

display terminal.
Faults without fault message
Fault Possible cause Remedy
The checkweigher does not The checkweigher is not Switch On the checkweigher at
switch On after service work. switched On. the operating and display
terminal of the machine.
Defective fuse. Replace defective fuse.
Signal from upstream machine Check signal from upstream

is missing (if installed by machine.
customer).
Belt starts running laterally. Unequal belt tension left/right. Rectify tension of respective
belt (see Chapter 8).
Belt slipping. Low belt tension.
Excessive load on 3-phase Excessive belt tension.

motor.
The discharge runs too slowly / Cylinder / air nozzle has Check air pressure.
low‐power. insufficient compressed air Check compressed air line for
supply. absence of leaks and bends.

037369 (7.1)
Troubleshooting checkweigher
401 Package length too small

Cause Remedy
The input of the carton length is too small. Increase the carton length on the control and
display terminal.
402 No new measured values

Cause Remedy
The measured value could not be transferred. Check connection to weighing cell.
403 Fault zero point

Cause Remedy
No zero point could be determined several Increase the cumulative error on the control
times in succession. and display terminal.
Reduce agitation.
Switch off the machine, then clean it and
switch it back on.
404 Wrong weighing cell connected

Cause Remedy
The serial number of the weighing cell differs Install the correct weighing cell.
from the stored serial number. Carry out another alignment process.
405 No weighing cell connected

Cause Remedy
No weighing cell has been detected. Check the connection cable between the
weighing cell and the weigher control unit.
Connect the weighing cell.
406 No valid adjusting values

Cause Remedy
The weigher control unit has not yet been Perform an adjusting procedure as described in
adjusted. the operating instructions.

108107 (1)
407 Communication weighing cell master distorted

Cause Remedy
The weighing cell control unit cannot Check the connection cable between the
communicate with the weighing cell. weighing cell and the weigher control unit.
Put switch S4 on the weighing module in
position Off.
408 Zero point unsteadiness

Cause Remedy
Zero point synchronization could not be Reduce agitation.
completed successfully because there was too
much agitation.
410 Adjusting weight too small.

Cause Remedy
The applied adjusting weight is too small. Check the imposed adjusting weight and
compare with input.
Carry out another alignment process.
411 Calibration value input error.

Cause Remedy
The calibration value input is outside the Check input and correct if necessary.
tolerance range.
412 Adjusting weight input error.

Cause Remedy
The adjusting weight input is outside the Check input and correct if necessary.
tolerance range.
413 Operating values inconsistent

Cause Remedy
Operating values could not be transferred from Check Profibus connection.
the master to the weighing module.
The weigher control system has failed (does Check the operability of the weigher coupler.
not respond).

108107 (1)
414 Fail pack not ejected

Cause Remedy
Ejector countercheck has detected a Check the ejector and sensor of the ejector
non-ejected fail pack. countercheck.
415 Zero point too high

Cause Remedy
Load on the weighing cell is too large. Clean belts and weighing cell and restart the
machine.
416 Zero point too low

Cause Remedy
Load on the weighing cell is too small. Check belts and weighing cell for damage, e.g.
for parts that fell off.
417 Zero point unsteadiness

Cause Remedy
Zero point synchronization could not be Reduce agitation.
completed successfully because there was too
much agitation.
418 Input weighing belt length = 0

Cause Remedy
The value 0 has been entered as the weighing Increase the value on the control and display
belt length. terminal.
419 No adjusting process with calibration dongle

Cause Remedy
An attempt has been made to adjust with a Pull off the dongle to adjust.
dongle inserted.

108107 (1)
420 Monitoring of cycle time

Cause Remedy
The internal cycle time was exceeded. Switch Off main switch.
Wait until the machine is switched Off.
Switch On main switch.
423 Measuring level too short.

Cause Remedy
No measuring level could be calculated. Check the inputs for pack width and output.
424 Fault frequency converter

Cause Remedy
Frequency converter signals malfunction. Check frequency converter.
See Operating Instructions for the frequency
converter.
425 Start initialization could not be completed

Cause Remedy
Initialization of the weigher control unit could Check at the operating and display terminal if
not be completed. further faults are pending and eliminate them
(e.g. zero point).
Switch the weigher on and off.
426 Input performance = 0

Cause Remedy
The value 0 has been entered as the Increase the value at the control and display
performance. terminal.
428 Profibus connection PMC2 disturbed!

Cause Remedy
Profibus connection between weigher and Check Profibus connection.
dosing unit is disturbed. Switch the weigher on and off.

108107 (1)
429 Profibus connection BX3110 disturbed!

Cause Remedy
Connection break between profibus modules. Check Profibus connection.
Switch the weigher on and off.
450 PMC2 internal fault

Cause Remedy
An internal fault has occurred. Check dosing unit.
Initialization of dosing unit is missing.
451 Too many fail packs

Cause Remedy
Too mane packs were discharged. If more than the indicated number of packs are
discharged in succession, the machine
performs a ”Normal Stop”
452 External belt release missing

Cause Remedy
The external belt release of the downstream Check the downstream machine.
machine is missing.
453 Only possible when belts are running

Cause Remedy
Belts are not switched on. Switch on belts.
Function cannot be executed. Execute function when machine is running.
454 Size is unreadable

Cause Remedy
The size is unreadable. Enter the valid size.
455 New size cannot be saved

Cause Remedy
The size cannot be saved. Check size name.

108107 (1)
461 Pass package missing in counter-check

Cause Remedy
A weighed package was removed from the Do not remove any weighed packages from the
outfeed belt. outfeed belt.
462 Unexpected package in counter-check

Cause Remedy
An unweighed package was put onto the Do not put any unweighed packages onto the
outfeed belt. outfeed belt.
600 Fault initialization printer

Cause Remedy
Initialization of the printer could not be Switch off weigher and check connecting cable
completed. to the printer.
601 Printer interface reception disturbed

Cause Remedy
The signal exchange to the printer interface is Switch off weigher and check connecting cable
disturbed. to the printer.
602 Printer interface sending disturbed

Cause Remedy
The signal exchange to the printer interface is Switch off weigher and check connecting cable
disturbed. to the printer.
611 Printing unit blocked

Cause Remedy
The printing tool is blocked. See separate operating instructions for the
printer.
612 Printer: end of paper reached

Cause Remedy
The printing paper roll is used up. See separate operating instructions for the
printer.

108107 (1)
613 Printer: cutter is blocked

Cause Remedy
The cutter at the printer is blocked. See separate operating instructions for the
printer.
615 No I/O data exchange with slave PMC2

Cause Remedy
The data exchange with the dosing unit is Check power supply the module.
disturbed.
No voltage supply. Check power supply the module.
Module PMC2 of the dosing unit is defective. Replace defective module.
616 Inputs CX9000 defective

Cause Remedy
The module is defective. Replace defective module.
617 Outputs CX9000 defective

Cause Remedy
The module is defective. Replace defective module.
650 Only allowed when machine is standing still

Cause Remedy
Downstream machine is not switched Off. Switch Off machine.
Function cannot be executed. Execute function when machine is standing
still.
651 External stop

Cause Remedy
The machine was stopped by the downstream Inform operating personnel of the downstream
machine. machine.
The downstream machine is switched Off. Switch on downstream machine or eliminate
Fault at downstream machine. fault.

108107 (1)
652 Please clear belts

Cause Remedy
There are packs on the belt. Remove packs from the belt.
653 Size data are transferred

Cause Remedy
User triggered a size data transfer. Wait until size data transfer is completed.
699 Unknown printer error

Cause Remedy
A printing error has occurred. Acknowledge fault and switch weigher on or
off, if necessary.
If fault occurs more frequently, inform Bosch
service technician.
1706 Check light barrier package scanner!

Cause Remedy
Sensor is dirty, defective, disconnected or Clean sensor.
adjusted incorrectly. Check sensor.
Replace defective sensor.
Cable to sensor is damaged. Check cable leading to the sensor.
2421 Printer not enabled

Cause Remedy
The printer is not enabled. Check if printer is enabled.
2423 Option: Printer not installed.

Cause Remedy
No printer is installed in the machine. Option: Install printer to the machine.

108107 (1)
7300 Belts are blocking

Cause Remedy
The belt is mechanically blocked. Attention: danger of crushing!
Check if mechanically moving parts can easily
be moved.

108107 (1)
Auger filler faults
Faults without fault message
Fault Possible cause Remedy
The auger filler does not start

up after servicing or
changeover work.
The agitator hopper is not Close the agitator hopper.

closed.
Check the safety switch (1) and
Safety switch (1) is defective. replace it as necessary.
The auger filler stops or is not The gate valve does not open. Check the drive and valve.
filling any longer. Check the initiator in the gate
housing.
Foreign body in the agitator Open the agitator hopper and

hopper. remove any foreign bodies as
necessary.
The pouring volume is Encrusted product has built up Open the agitator hopper and
constantly diminishing. on the filling auger. clean the filling auger.
Fluctuations in volume in the Check the uniformity of the

product. product.
The filling weight is fluctuating The quality of the product is Ensure uniform quality of the
too intensively. changing. product.
Compare size parts with data Perform trial weighings more
sheet. frequently.
The cross-feed auger does not The fill level sensor signals full. Check the fill level sensor.
start.

101194 (1)
Troubleshooting auger filler
INFORMATION
Fault messages must always be deleted on the operator control unit!
System of the fault message numbers

Fault messages are given
a 4‐digit number, starting with the number 9100
or
a 5‐digit number, starting with the number 10000.
There are three main groups of messages:
u 9100 ... 9599 are faults or messages of the servo control unit (see page 24) that are passed on
to the operator control unit, with an addition of von 9000. Details can be referred to in the
manual of the servo control unit.
Example: Fault 9291 = 291 in the manual.
u 9700 ... 9799 are faults or messages that occur at the filler or due to a faulty filling sequence
(see page 48).
u 10000 ... 15000 are faults or messages of the Diagnosis servo control unit (see page 54).
Example: fault 10037 = 37 in the manual.

108530 (1)
Troubleshooting filling auger
9110 A job timeout

A job timeout has occurred.
Cause Remedy
Internal problem with the data interchange Encoder cable on SINCOS encoder not plugged
between the positioning and actuator parts. in correctly or is defective.
Please get in touch with our customer service
department.
In versions < V20.01.04 the AXIS SINCOS SET If AXIS SINCOS SET <no.> statement is needed,
<no.> statement has led to this error. a software update is required in the PMC-2.
9120 Output stage short circuit

A short circuit (phase short circuit) of the motor leads or of the motor is being checked.
Cause Remedy
Wiring defect: short circuit in motor cable. Replace motor cable or send in for repair.
Hardware defect: short circuit in motor (phase Replace motor or send in for repair.
to phase or phase to casing).
Hardware defect: the output stage in the Replace the PMC-2 or send it in for repair.
PMC-2 is defective.
9131 Bleeder defective

The bleeder resistance (brake resistance) is being checked for operability.
Cause Remedy
Wiring: the brake resistance is not connected Connect the brake resistance (terminals 2 and
to the PMC-2. 3).
Wiring: the brake resistance or supply line has Check the brake resistance and supply line.
a short circuit.
A mains voltage drop has occurred. Check the mains voltage.
Mains voltage too high. Check the mains voltage.
The brake resistance is wrongly dimensioned Check the brake resistance rating.
(ohm value too low).
Hardware defect: bleeder defective. Measure the bleeder resistance and replace the
bleeder as necessary.
Hardware defect: PMC-2 defective. Replace the PMC-2 or send it in for repair.

2TxtDosi106
9148 MEM no module

The memory module is an elementary component of the PMC-2 and must therefore be
plugged in for operation.
Cause Remedy
The memory module is not plugged in. Put on the MEM module.
Hardware defect: the memory module is Replace the MEM module.
defective.
9149 No MEM parameters

No valid parameters are stored on the memory module.
Cause Remedy
No parameters are stored on the memory Send parameters to PMC-2.
module.
Hardware defect: the memory module is Replace the MEM module.
defective.
The PMC-2 firmware version has been replaced Change parameters to EPAS-3 and send to
and the PMC-2 was unable to convert the old PMC-2.
parameters.
9163 Incompatible EPROMs

There are incompatible EPROMs in the in PMC-2.
Cause Remedy
You have replaced EPROMs yourself. When you Plug 2 compatible EPROM sets into the PMC-2.
did so, you plugged in incompatible EPROMs.

2TxtDosi106
9164 SW WatchD MC/VC

The cyclical process monitoring of the PMC-2 ascertains a defect in the actuator part.
Cause Remedy
In a version < V20.03.00 with SinCos encoders Plug the encoder cable into the encoder.
although the encoder cable is plugged into the
PMC-2, it is not plugged into the encoder. This
problem only occurs after a reset or power On.
EPROMs have been replaced that are not With "incompatible EPROMs”, under certain
compatible. circumstances this error is reported, although
the diagnostic message E163 would have to be
triggered (OV change!).
EPROMs have been replaced that are not Check whether the EPROMs are inserted in the
correctly plugged in. correct order and in the correct direction. It
may also be that an EPROM pin has been bent
over.
A processor failure has been determined in the Please get in touch with our customer service
actuator part. department.
Errors can occur when changing over from 8 to Please get in touch with our customer service
16 bit VECON (FPGA) (software version department.
V0X.XX.XX -> V10.XX.XX).
9165 VC fatal error

A serious software error has occurred in the actuator part.
Cause Remedy
The TAB operator has been used without a cam Load cam data into the function buffer BUF.
being available.
A fatal software error has occurred in the Please get in touch with our customer service
actuator part. department.
9167 Wiring
In the parameter set in the wiring table there wiring elements on optional modules that
are not plugged in.
Cause Remedy
In the wiring table wiring elements has been Adapt the wiring table (parameters) to the
performed on optional modules that are not optional module and transfer it to the PMC-2.
available in the PMC-2.
The optional module is not correctly plugged Check the code of the optional module in the
in. system variables S9.14 "A_POS_OPT_X19". If
the code is not correct, check whether the
module is plugged into the correct slot and
whether the module is correctly plugged in.
Hardware defect: the optional module is If the code of the optional module in the
defective. system variables S9.14 "A_POS_OPT_X19" is not
correct, replace the optional module or send it
in for repair.

2TxtDosi106
9171 Error encoder_1:

A hardware encoder error has occurred on encoder 1.
Cause Remedy
Wiring defect: an encoder cable on the encoder Check the encoder cable and replace it, if
or on the PMC-2 is pulled out or defective. necessary - check the ground connection
(screening).
The encoder voltage is not connected or is not Check the encoder voltage (see also encoder
correct. documents).
The parameter P1.05 "Lagegeber" = 1, but no Change the parameters or plug in the optional
optional module is plugged in. module.
The value in parameter P3.04 "Inkr_Geber_1" is Enter a valid value (4096, 8192, 16384, 32768
not a number for base 2 with a SinCos encoder or 65536).
as position encoder.
Hardware defect: the encoder is defective. Replace the encoder.

A hardware encoder error has occurred on encoder 2 (reference encoder).
Cause Remedy
(screening).
9176 EEprom checksum.

The checksum in the EEPROM is wrong.
Cause Remedy
The device is not balanced. Please get in touch with our customer service
department.

2TxtDosi106
9177 Internal voltage error

An internal device voltage is too low or has failed.
Cause Remedy
The control voltage is too low or there was a Check the 24 V control voltage (22...33 V DC).
brief voltage drop in the 24 V DC.
Wiring defect: there is a short circuit in the Check the encoder cable and replace it, if
encoder cable of an encoder. necessary.
Hardware defect: the power unit in the PMC-2 Please get in touch with our customer service
is defective. department.
9178 ECL error 1

With the ECL statement "ERROR 1” a class 1 error has been triggered in the ECL user
program. This error does not lead to the program part error, because it was triggered by
the user.
Cause Remedy
An error has been triggered by the user See ECL user program or description relating
program. to the ECL user program.
9195 Mot/res pairs of poles

The number of pairs of poles for the resolver and motor are not compatible.
The number of pole pairs of the motor must be an integral multiple of the number of resolver pole
pairs.
For example:
P4.04 Pol_Paare_Motor = 4 -> P3.02 Pol_Paare_Resolv = 1, 2, or 4; 3 is prohibited.
P4.04 Pol_Paare_Motor = 2 -> P3.02 Pol_Paare_Resolv = 1, or 2, 3 and 4 prohibited.
Cause Remedy
The number of pole pairs for the resolver or Check the parameter set.
motor are entered incorrectly in the parameter
set.
9197 SINCOS_1
No serial data was able to be received from the SinCos position encoder.
Cause Remedy
Wiring defect: the encoder cable is not Check the encoder cable and replace it, if
correctly plugged in or is defective. necessary.
The SinCos position encoder has moved upon The SinCos encoder must stop upon being
being switched on (power On or reset). switched on (< approx. 1 rpm).
Hardware defect: the SinCos encoder is Replace the encoder.
defective.
Hardware defect: SCI-1 optional module Replace the module.
defective.

2TxtDosi106
9198 SINCOS_2/INK_2
No serial data was able to be received from the SinCos reference encoder. Or the
incremental reference encoder is not present.
Cause Remedy
Wiring defect: the encoder cable is not Check the encoder cable and replace it, if
correctly plugged in or is defective. necessary.
This error also occurs on the SCI-1 optional Plug the encoder cable into the PMC-2 or check
module with incremental encoder as the the plug bridge (X12.1 pin 8 to pin 10 for
reference encoder, if the parameter P1.07 incremental encoder).
"Check reference encoder" is on "Yes" and no
encoder is plugged into the PMC-2.
Hardware defect: the SinCos encoder is Replace the encoder.
defective.
Hardware defect: SCI-1 optional module Replace the module.
defective.
9207 Parameter invalid

The parameter set in the PMC-2 is not valid. After switching on and receiving new
parameters a parameter check for limit values is performed.
Cause Remedy
Incorrect parameters have been transferred to Check and change the parameter set.
the PMC-2.
Hardware defect: the memory module is Replace the memory module.
defective.
9209 MC fatal error

A serious software error has occurred in the positioning part.
Cause Remedy
Hardware defect: the PMC-2 is defective. Replace the PMC-2.
Software error: the PMC-2 firmware version has Please get in touch with our customer service
errors. department.
9211 JOB timeout

An internal timeout has occurred during a data interchange between the positioning and
actuator parts.
Cause Remedy
Software error: the PMC-2 firmware version has Please get in touch with our customer service
errors. department.

2TxtDosi106
9217 Default parameters

No valid parameter set was found when the device was switched on. The standard
parameter set has therefore been loaded from the EPROM.
Cause Remedy
No valid parameters are available. Transfer parameters to the PMC-2.
defective.
9221 Excess current

The current via the output stage is too great (double the PMC-2 device peak current).
Cause Remedy
Wiring defect: the motor cable is not correctly Check the wiring.
connected or has a short circuit.
The current controller parameters (group 4) are Check the current controller parameters
not correct. (P4.11, P4.12 and P4.13).
Commutation defect, i.e. the encoder (resolver Balance or calibrate the encoder.
or SinCos) is not balanced or calibrated.
Hardware defect: the motor has a short circuit. Replace the motor.
9223 Intermediate circuit voltage too high

The intermediate circuit voltage is too high.
Cause Remedy
Wiring defect: brake resistance (bleeder Connect the brake resistance (terminals 2 and
resistance) not connected. 3).
The motor's braking energy fed back into the Decelerate slower. Check the dimensioning of
intermediate circuit of the motor is too high, the brake resistance (bleeder resistance).
which causes an increase in the voltage.
The mains voltage is too high. Check the mains infeed.
There has been a drop in the supply voltage. Check the mains infeed.
Hardware defect: the bleeder transistor is Replace PMC-2 or send it in for repair.
defective.

2TxtDosi106
9225 Motor temp / +UL

The internal motor temperature is too high (approx. 130 °C) or the 24 V supply to X5.1 is
missing.
Cause Remedy
Wiring defect: the 24 V +UL/L0 supply is Connect 24 V.
missing (X5.1).
Wiring defect: the temperature switch in the Check the wiring.
motor winding is not correctly connected.
The holding brake is not released. Release the brake.
The motor is overloaded. Run the line slower, check the drive rating,
possibly use a larger motor for this application.
Wiring defect: the temperature switch in the Replace the motor or send it in for repair.
motor winding is defective.
Hardware defect: the input for the temperature Replace PMC-2 or send it in for repair.
encoder on the PMC-2 is defective.
9232 Output stages I²T

The output stage is overloaded or the output stage wattage is too high.
When output stages I²T occur the motor current is limited to the PMC-2 device's rated current.
Monitoring of the output stages I²T is performed with the aid of an integrator, which is
determined by an equation.
Cause Remedy
The output stage is overloaded. Check the drive rating.
For further causes and remedies see 9528
motor I²t.
9234 Unknown errors

An unknown error has occurred.
Cause Remedy
The error text has not yet been defined. Take note of the change status. Please get in
touch with our customer service department.

2TxtDosi106
9241 Encoder stoppage

The encoder is not supplying any position change, although a setpoint is pending.
If a setpoint of ¼ of the maximum rotational speed is pending and after 5 samplings of the
position controller no impulses have yet been returned, this message is triggered.
Important information:
this message (and E242) can be switched off via S1.21 "E_Geber_Stillstand".
Cause Remedy
The mechanical connection between motor and Check the mechanical connection to the
encoder is broken. position encoder.
Hardware defect: the holding brake of the Check the holding brake.
motor is defective.
9242 Encoder jump

A jump-like change in position has been determined on the encoder.
this message (and E242) can be switched off via S1.21 "E_Geber_Stillstand".
Cause Remedy
An encoder overflow (max. encoder range Check the maximum traversing range and
exceeded) has occurred on an absolute value resolution.
encoder (SSI) in an absolute system (P0.12)
that has been preselected as a position
encoder.
Wiring defect: the encoder cable is defective. Replace the encoder cable.

An error has occurred on the resolver.
In PMC-2 versions < 20.03.00 this error message can also occur on SinCos encoders
(position encoders).
Cause Remedy
Wiring defect: the encoder cable is defective or Plug in the encoder cable.
not correctly plugged in. Check the encoder cable.
Hardware defect: the resolver in the motor is Replace the motor.
defective.
Hardware defect: the resolver input on the Replace the PMC-2.
PMC-2 is defective.

2TxtDosi106
9247 MEM CRC error

A checksum error has occurred while reading from the memory module.
Cause Remedy
The data on the memory module is defective. Write new data to the memory module.
defective.
9255 Parameter error.

Limitation of the resolutions for the rotational speed pilot control is monitored by means
of this diagnostic message.
Rotational speed pilot control:
Under certain resolution conditions of standardization encoders (NG) and position encoders (LG)
a limitation of the rotational speed pilot control takes place and hence an increased lag error. The
resolutions must stay within limits (formula).
Cause Remedy
The parameters do not comply with the Adapt the parameters.
formula.
9258 Breakpoint number

The breakpoint number is too high.
Cause Remedy
The breakpoint number is entered too high. Use a valid breakpoint number.
9268 Wrong encoder no.

The position encoder number (P1.05) is not correctly entered in the parameter set.
Cause Remedy
SINCOS is entered in the parameter P0.24 Change parameter P1.05 "Lagegeber" to "1" or
"PMC_Variant", but the parameter P1.05 P0.24 "PMC_Variant" to "Standard".
"Lagegeber" is not entered on "1".

2TxtDosi106
9269 Max. rotational speed

The current rotational speed is greater than is entered in the parameter P4.03
"Max_Drehzahl".
Cause Remedy
Error occurring on the electrical cam on Check the cam data and program.
account of wrong data.
Jumps have occurred in the reference encoder. Check the reference encoder.
The error is occurring on the electrical Check the program.
transmission or electrical cam on account of a
wrong AXIS SETPOSG statement.
Parameter P0.02 "A_max" is so high that fast Check parameter P0.02 "A_max".
automatic control with the preset P4.02 Check the drive rating.
"Max_Strom" is not possible.
The rotational direction parameter is not Check the parameter P3.08 "Geber_Richt_1"
correctly entered. and P4.01 "Drehrichtung".
9270 Max current

The parameterized "Max_Strom" (Parameter 4.02) is greater than the PMC-2 peak current
or the
parameterized "Nenn_Strom" (Parameter 4.08) is greater than the PMC-2 rated current.
Cause Remedy
The parameters P4.02 and/or P4.08 are not Check the parameters.
correctly entered. Motor actuator combination correct?

A hardware encoder error has occurred on encoder 1.
Cause Remedy
(screening).
The parameter P1.05 "Lagegeber" = 1, but no Change the parameters or plug in the optional
optional module is plugged in. module.

2TxtDosi106

A hardware encoder error has occurred on encoder 2 (reference encoder).
Cause Remedy
(screening).
9275 Parameter > v_max

A velocity in the parameters is greater than parameter P0.01 "V_max".
Cause Remedy
One of the parameters P0.05 "Man_langsam", Check the parameters.
P0.06 "Man_schnell" or P0.09 "V_Referenz" is
greater than the parameter P0.01 "V_max".
9279 ECL error 2

With the ECL statement "ERROR 2" a class 2 error has been triggered in the ECL user
program.
This error does not lead to the program part error, because it was triggered by the user.
Cause Remedy
9291 8-fold lag error

Exceeding of the 8-fold lag error (8*P1.01) has occurred. The lag error time is not taken
into consideration with this error.
Cause Remedy
This error normally occurs only in conjunction Check your cam data.
with the electrical cam disk.
9293 Parameter < A max

Parameter P0.03 "A_Schnell_Halt" is less than P0.02 "A_max".
Cause Remedy
The parameter has not been correctly entered. Adapt the parameters.

2TxtDosi106
9301 HW limit switch negative

The negative hardware limit switch (X5.1 / I.5) has been actuated (see also S0.15
"E_Endschalter_neg").
Cause Remedy
The drive is outside of its physical traversing Put the drive out of the limit switch range and
range. possibly check the parameters.
The parameter P0.11 "End_Schalter" is wrongly Check parameter P0.11 "End_Schalter" (break
set. or make contact!).
The reference switch was not found on the Check the parameter P0.10 "Ref_Schalter"
reference run. (break or make contact!) and check the wiring.
9302 HW limit switch positive

The positive hardware limit switch (X5.1 / I.4) has been actuated (see also S0.14
"E_Endschalter_pos").
Cause Remedy
The drive is outside of its physical traversing Put the drive out of the limit switch range and
range. possibly check the parameters.
The parameter P0.11 "End_Schalter" is wrongly Check parameter P0.11 "End_Schalter" (break
set. or make contact!).
The reference switch was not found on the Check the parameter P0.10 "Ref_Schalter"
reference run. (break or make contact!) and check the wiring.
9303 SW limit switch negative

The negative software limit switch has been approached or should be approached or
crossed.
Cause Remedy
A positioning statement "POS" should cross the Check the ECL program.
negative software limit switch.
A traversing order should cross the negative Check the ECL program.
software limit switch.
9304 SW limit switch positive

The positive software limit switch will be approached or should be approached or
crossed.
Cause Remedy
A positioning statement "POS" should cross the Check the ECL program.
positive software limit switch.
A traversing order should cross the positive Check the ECL program.
software limit switch.

2TxtDosi106
9305 Lag error

A position lag error has occurred in the position controller of the PMC-2, which is greater
than the parameter P1.01 "Schleppfehler" and was pending longer than the time in the
parameter P1.02 "Schleppf_Zeit" (see also S2.09 "A_Schleppfehler" or the monitor
outputs of the PMC-2).
Cause Remedy
The "V_Vorsteuerung" is too small. Increase the parameter P2.02
"V_Vorsteuerung".
The lag error monitoring is too intolerant. Increase parameter P1.01 "Schleppfehler"
and/or P1.02 "Schleppf_Zeit".
The acceleration is too great. Reduce the acceleration (P0.02 "A_max" or in
the user program).
The lag error is a consequence of the In the system variables S4.02
diagnostic message E528 "Motor I²t". "A_Letzte_Warnung" it can be checked whether
the E528 "Motor I²t" has occurred previously.
See E528 "Motor I²t".
Mechanism stiff or blocked. Check the traversing range.
Parameterization not correct. Check parameter P1.00 "Lage_Kv", P1.01
"Schleppfehler", P1.02 "Schleppf_Zeit",
parameter group 2 (velocity controller), P4.11
"I_P_Verstärkung", P4.12 "I_I_Verstärkung" and
P4.13 "I_Vorsteuerung".
Wiring defect: conductors in the motor or Check the cable connection or cable.
resolver cable interchanged.
Wiring defect: wrong encoder plug or motor Check the encoder plug and motor plug.
plug inserted (possibly by the adjacent Check the encoder cable and motor cable.
actuator).
Wiring defect: holding brake not released. Check the holding brake.
Supply voltage missing. Check supply voltage to X1.
An encoder with the wrong number of Check the encoder.
graduations has been installed.
Hardware defect: the coupling is too loose. Check the encoder coupling.
Hardware defect: encoder signal is delivering Check the traversing range.
jumps.
9312 Arithmetical overflow

An overflow or underflow has occurred in an ECL arithmetical function.
Cause Remedy
The number format is insufficient. Check the numerical ranges and possibly make
calculations in DSET or FLOAT.

2TxtDosi106
9313 Division by zero

A division by 0 should be performed in the user program.
Cause Remedy
The divisor was equal to zero in an ECL division Check a division by 0 in the user program,
function. check the numerical ranges.
9314 Time overflow

The new target time in the WAITT command is greater than the overflow (24.8 days).
Cause Remedy
The time in the WAITT command is too great. Check the ECL program.
The PMC-2 has already been interrupted for Trigger a reset on the PMC-2 or an
24.8 days (without a reset or power OFF) in acknowledgment.
operation. This leads to an internal time Intercept this suitably in the ECL program ->
overflow. possibly consultation with the application.
9315 Blending timeout

A timeout has occurred while blending to the new traversing order.
Cause Remedy
The last positioning order on which blending Check the ECL program.
was performed, was not completed with
VELEND 0.
The positioning order on which blending was Check the ECL program.
performed is not available in good time.
9335 Invalid reference run mode

The selected reference run mode is unknown.
Cause Remedy
A wrong value has been entered in the Enter the valid reference run mode in
parameter P0.08 "Referenz_Modus". parameter P0.08.

2TxtDosi106
9336 Limit switch before zero pulse

During referencing the axis after the reference switch is hitting the limit switch before
the zero pulse arrives.
Cause Remedy
Wiring defect: encoder cable defective or zero Replace the encoder cable.
track is missing.
Reference switch is not correctly installed. The reference switch must be positioned at
least 1 revolution before the HW limit switch.
The encoder has been replaced and installed so Readjust the encoder.
that the zero pulse is outside of the traversing
range.
Hardware defect: encoder defective. Replace the encoder.
9337 No zero pulse in a revolution

During referencing it is checked whether a zero pulse arrives within a revolution of the
position encoder.
Cause Remedy
The parameter P3.01 "Inkr_Geber_0" or P3.04 Enter the parameter correctly.
"Inkr_Geber_1" is incorrectly entered.
Wiring defect: the position encoder cable is Check the encoder cable.
defective.
9339 Not referenced

The called function requires a referenced system. This diagnostic message can only occur
in systems with a resolver or incremental encoder as the position encoder.
Cause Remedy
The system is not referenced. Reference the system.
9345 Sector invalid

The memory module is subdivided into sectors. An error message is issued when writing
to a populated sector.
Cause Remedy
The sector is populated. Select a valid sector or delete the sector first
of all via EPAS-3.

2TxtDosi106
9346 MEM R/W error

Error during read or write access to the MEM module.
Cause Remedy
defective.
9350 BCD format error

A BCD conversion is not possible.
Cause Remedy
The number to be converted is not a BCD Check the numerical range.
notation or the binary number is greater than 8
decimal places or the number is negative.
Wiring defect: the BCD-value is read in via I/O Check the wiring.
wiring. In doing so, for example, the
conductors have got mixed up.
9351 Variable number

An illegal variable number has been used.
Cause Remedy
For example, it is verified for the PUT Check the numerical range.
statement whether the source index + quantity
> 10000 and whether the target index +
quantity > 3999.
9352 Variable range

The value cannot be represented by the variable.
Cause Remedy
For example, AXIS SETPOSG on an encoder Check the value range.
that is not present.
For a VARIO CAM statement (e.g. SYNG) Change Y-scaling in the cam file.
Y_NORM * Auflösung_NormGeber > 3276800.
AXIS SINCOS SET statement for encoder that is Use the statement only for SinCos encoders.
not a SinCos encoder.
9353 Nesting
A maximum nesting depth of 10 is envisaged for ECL subroutines.
Cause Remedy
The maximum nesting depth has been reached. Check subroutine calls.

2TxtDosi106
9354 Program location

An invalid program location has been used in an ECL statement (e.g. ECL START).
Cause Remedy
A program location number has been used that Check the user program.
is already populated (multiple calls).
A program location number has been used that Check the user program.
is greater than 8.
9356 PGM trans active

A program could not be started because it has only just been transferred.
Cause Remedy
A program start has been attempted during Comply with the chronological order.
transfer of the program (EPAS-3 or MEM -->
PMC).
9357 No valid PGM

A program start has been attempted without a valid program being available.
Cause Remedy
No program is available in the PMC-2. Send the program to the PMC-2.
There is no valid BASIC soft program in a Install a valid Elau BASIC soft program.
BASIC soft PMC-2.
9359 VEL <= 0

The preset velocity is zero or negative.
Cause Remedy
In the user program (VEL or VELEND Check the user program.
statement) a velocity is preselected that is zero
or negative.
9360 VEL too high

The preset velocity is greater than the maximum velocity in the parameter P0.01 "V_max".
Cause Remedy
In the user program (VEL or VELEND Check the user program.
statement) a velocity is preselected that is
greater than the maximum velocity in the
parameter P0.01 "V_max".

2TxtDosi106
9361 ACC <= 0

The preset acceleration is zero or negative.
Cause Remedy
In the user program (ACC statement) an Check the user program.
acceleration is preselected that is zero or
negative.
9362 ACC too high

The preset acceleration is greater than the maximum acceleration in the parameter P0.02
"A_max".
Cause Remedy
The preset acceleration is greater than the Check the user program.
maximum acceleration in the parameter P0.02
"A_max".
9366 Defective. SYN data:

Invalid data has been transferred for the SYNG statement "electrical cam".
Cause Remedy
The cam variable has not yet been transferred Transfer the cam variable file to the PMC-2.
to the PMC-2.
The cam variable data has not been loaded Check the user program.
correctly from the memory module with the
GET statement.
The cam variable data has not been transferred Check the user program.
correctly to the buffer by the "PUT xx, yy BUF
zz" statement.
9380 ECL error 3

With the ECL statement "ERROR 3” a class 3 error has been triggered in the ECL user
the user.
Cause Remedy

2TxtDosi106
9383 ECL COM

COM1/2 has not been reserved for the COM statement or COMX statement.
Cause Remedy
The parameter P0.21 (COM2) or P0.26 (COM1) Adapt the parameters (RESET after parameter
is not set to COM ECL. acceptance is required!).
9386 Pos overflow

An overflow is occurring in the conversion INK <-> units. The value range of a 32-bit two's
complement number is between:
+ 231-1 = + 2 147 483 647
and
- 231 = - 2 147 483 648
Cause Remedy
The error occurs while sending or receiving the Check the parameters e.g. P0.13
parameters in the PMC-2. The values for "Softlimit_Pos" 999 999.999 units.
parameter P0.13 "Softlimit_Pos" or P0.14 P3.00 "Auflösung_Geb_0" 4096.0000 incr/unit
"Softlimit_Neg" or P0.15 "O_Punkt_Offset" are -> calculate value in increments
too great. -> 999 999.999 units * 4096.0000 incr/unit = 4
095 999 995.904 incr
-> value is too high
Elimination:
reduce resolution, e.g. 409.6000 incr/unit
reduce P0.13 "Softlimit_Pos" e.g. 99 999.999
units.
Error occurs during normal operation. Reset system variables in the user program in
The value range (I32) is exceeded when good time.
converting a system variable. This occurs
mostly when a system variable is displayed in
EPAS-3, in BE-1, BE-7, BE-8 or during transfer
via an interface.
9390 PLC PT function

An illegal statement is to be used in a PLC program part.
Cause Remedy
The statement HOME, POS, POSG, SYN or Check the user program.
SYNG is used in a PLC program part.

2TxtDosi106
9416 Target window timeout

The target window is not reached during a positioning.
Cause Remedy
The target window in the parameter P1.03 Increase the parameter P1.03 "Zielfenster".
"Zielfenster" has been selected too small.
The parameterization of the control circuits Check the parameters.
(parameter group 2 and P4.10 - P4.13) is not
correct.
There is a mechanical blockage. Check the mechanism.
9426 Heat sink temperature too high

The heat sink temperature is too high (level 2).
Cause Remedy
The output stage is overloaded. Check the motor / actuator combination.
Check the calculation of the motor and
actuator.
Run the line slower.
Ventilation is insufficient or the ambient Check the ventilation of the switch cabinet
temperature is too high. (filter may be dirty).
Check the function of the air conditioning unit.
Hardware defect: the temperature sensor is Replace the PMC-2.
defective.
9427 Inner temperature high

The PMC-2 inner temperature is too high.
Cause Remedy
defective.
9430 Bleeder I²T

The bleeder resistance is overloaded.
Cause Remedy
The drive is wrongly dimensioned. Check the drive rating.

2TxtDosi106
9481 ECL error 4

A class 4 error with the ECL statement "ERROR 4” has been triggered in the ECL user
the user.
Cause Remedy
9522 Phase failure

Failure of a phase (or two) of the mains connection.
Cause Remedy
Wiring defect: not all phases are connected or Check the wiring.
the mains contactor is not correctly wired.
External fuse has responded. Check fuses.
9524 Intermediate circuit voltage too low

The intermediate circuit voltage is too low.
Cause Remedy
The mains voltage is too low. Check the mains voltage.
With intermediate circuits wired in parallel a Look for the PMC-2 with the error and
PMC-2 has a class 1 or 2 error. eliminate the error.
9526 Heat sink temperature too high

The heat sink temperature is too high (level 1).
Cause Remedy
The output stage is overloaded. Check the motor / actuator combination.
Check the calculation of the motor and
actuator.
Run the line slower.
defective.

2TxtDosi106
9528 Motor I²T

The motor is overloaded or the wattage supplied to the motor is too high.
Upon the occurrence of motor I²T the motor current is limited to the motor's rated current.
The motor I²t monitoring is performed with the aid of an integrator.
Cause Remedy
The holding brake is not released (broken Check the brake or wiring.
cable, voltage outside of the range 22...33 V).
The lubrication system is defective. Check the lubrication.
Blunt tool. Check or replace the tool
The motor is vibrating. Check the parameters (parameter group 2 and
P4.10 - P4.13).
The suspended axis is too heavy or. the Check the drive rating and counterbalance.
counterbalance is defective.
Mechanism stiff or blocked. Check the traversing range.
The motor is overloaded. Check the drive rating.
Run the line slower or accelerate more slowly.
The motor is demagnetized. Replace the motor.
9529 Output stages I²T rpm

The output stage is overloaded or the output stage wattage is too high.
When output stages I²T occur the motor current is limited to the PMC-2 device's rated current.
Monitoring of the output stages I²t is performed with the aid of an integrator, which is determined
by the following equations.
Cause Remedy
The output stage is overloaded (where rpm Check the drive rating.
<50).
For further causes and remedies see 9528
motor I²t.
9582 ECL error 5

With the ECL statement "ERROR 5” a class 5 error (warning) has been triggered in the
ECL user
program. This error does not lead to the program part error, because it was triggered by the user.
Cause Remedy

2TxtDosi106
9584 EEPROM ANA-1

The EEPROM on the ANA-1 module does not contain any offset balancing data.
Cause Remedy
The EEPROM on the ANA-1 module is defective Send ANA-1 in for checking.
or deleted.
9587 BE timeout
The PMC-2 expects an operator control device to be connected, but cannot connect to it.
Cause Remedy
No operator control device should be Change parameter P0.21 "COM2_Anwendung"
connected. or P0.26 "COM1_Anwendung".
Wiring defect: no connecting cable is plugged Make the connection to the operator control
into the operator control device or the cable is device, check the cable.
defective.
Hardware defect: the operator control device is Replace the operator control device.
defective.
9588 Control voltage low

The control voltage (24 V DC) is too low.
Cause Remedy
Control voltage too low. Check the control voltage (22...33 V DC).
9589 Communication module

An error in connection with the communication module has occurred.
Cause Remedy
See documentation (Elau) process coupling. See documentation (Elau) process coupling.
9592 EG sequence error

The drive did not become synchronous by the synchronous end point (S5.04
"E_SYN_Ende").
Cause Remedy
The reference velocity is too fast. Check the reference velocity.
The path to synchronization is too short. Check the starting point.
Increase the acceleration.

2TxtDosi106
9596 Axis pos timeout

A timeout has occurred in the internal calculation of the POS statement. The reason for
this is a PMC-2 processor overload.
Cause Remedy
AXIS VEL, AXIS ACC, AXIS DEC or AXIS POS Compose AXIS statement again.
statement has been composed and the internal Reduce the system load.
calculations for the POS statement were not
able to be terminated in good time.
9700 EMERGENCY STOP
Cause Remedy
Safety circuit is broken. Safety switch on the agitator hopper is broken
or other additional safety switches (optional)
on the filler are broken.
Connection in plug X1/6-7 is disconnected Use wiring diagram for troubleshooting.
(external EMERGENCY STOP).
9701 Cross-feed auger faulty
Cause Remedy
The motor of the cross-feed auger on the Check the cross-feed auger for smooth
displayed filler is overloaded. operation.
Check the mechanical components for damage.
The protective motor switch hat triggered. Check the protective motor switch.
Voltage connection (400 V) has no contact. Check the voltage.
Error message on the frequency converter. See operating instructions of the manufacturer.
9702 Agitator faulty
Cause Remedy
The motor of the agitator on the displayed filler Check the agitator for smooth operation.
is overloaded. Check the mechanical components for damage.
The protective motor switch hat triggered. Check the protective motor switch.
Voltage connection (400 V) has no contact. Check the voltage.
Error message on the frequency converter. See operating instructions of the manufacturer.

2TxtDosi106
9703 Protective motor switch
Cause Remedy
Protective motor switch for drive of the Check the protective motor switch and
cross-feed auger and agitator in the filler has servomotor.
triggered. Check the voltages on the servomotors.
Then render the protective motor switch
operable again.
9704 Closure does not open
Cause Remedy
The closure motor on the displayed filler is Check the closure for smooth operation.
overloaded. Check the mechanical components for damage.
Only in case of a closure with a servomotor. The electricity supply plug is not plugged in.
The current supply plug of the electricity Check the servomotor's brake.
supply is not plugged in.
For pneumatic closure only. Check the closure for smooth operation.
The initiator is not being reached in the preset Check the pneumatics.
time. Check the initiator.
9705 Cycle too short
Cause Remedy
The dosing time is too short. Check and correct the input.
Reduce the machine cycle. Increase the dosing
auger speed, however this can cause a change
in the filling precision.
9707 No material/empty message
Cause Remedy
There is too little product in the displayed Top off the product. Check the product feed to
filler. the product distributor.
Initiator for the product scan is defective, Check the initiator.
unplugged or incorrectly set. Readjust the sensitivity of the initiator.
"Calibrated filling" is not possible, if there is a
product empty message.

2TxtDosi106
9708 Closure's advance switch-off time is too long
Cause Remedy
The advance switch-off time is too long. Check and correct the input.
The advance switch-off time is too long for the To eliminate the delay when closing the
current dosing time. closure, a lead time can be defined that is
usually between 0 and 60 ms.
9710 Address in the secure memory area
Cause Remedy
Error in the memory. Switch off the displayed filler and switch it
The program has errors. back on again (on the operator control and
Profibus transfer is faulty. display terminal).
9711 Data loss in the RAM, transfer again
Cause Remedy
Data loss in the format data memory. Transfer the format data again (in the operator
The last production/filler data are stored in the control and display terminal).
control unit.
The memory duration is roughly 7 days.
9712 Max. top-off volume exceeded
Cause Remedy
Only for use as a top-off filler: Increase the preset filling weight of the main
The top-off volume of the top-off filler is filler (in the operator control and display
exceeded. terminal).
No top-off filling is taking place. Check the top-off filler.
9713 Transfer the value < = 0
Cause Remedy
Error in the memory. Switch off the displayed filler and switch it
The program has errors. back on again (on the operator control and
Profibus transfer is faulty. display terminal).
Check the data entered.

2TxtDosi106
9714 Weight too low or no new value
Cause Remedy
Only for use as a top-off filler: Increase the preset filling weight of the main
The top-off volume of the top-off filler is filler (in the operator control and display
exceeded. terminal).
No top-off filling is taking place. Check the top-off filler.
9715 No calibrated filling, product is missing
Cause Remedy
There is too little product in the displayed Top off the product.
filler. The calibrated filling could not be Check the product feed to the product
performed. distributor.
Initiator for the product scan is defective, Check the initiator.
unplugged or incorrectly set. Readjust the sensitivity of the initiator.
9716 Weight regulation at the stop
Cause Remedy
The regulating range of the filler is exhausted, Perform a recalibration.
because the product has changed too much.
Dosing auger dirty. Clean the auger.
9717 Closure is closing during dosing
Cause Remedy
The initiator on the closure is free during Check the mechanism.
dosing. Check the wiring and initiator.
9718 Profibus faulty
Cause Remedy
No bus connection to the filler. Check the Profibus wiring/operability.

2TxtDosi106
9719 Voltage for outputs is missing
Cause Remedy
Supply voltage missing. Check the voltage. See wiring diagram.
9720 Fuse for outputs defective
Cause Remedy
Fuse in the infeed terminal of the I/O modules Check outputs for short circuit, replace fuse
is defective. with same type.
9721 Motor temperature of agitator
Cause Remedy
Thermal contact in the agitator motor has Check the agitator for smooth operation.
triggered. Clean the cooling ribs and vents of the motor.
Replace motor, if defective.
9722 Motor temperature of cross-feed auger
Cause Remedy
Thermal contact in the cross-feed auger motor Check the cross-feed auger for smooth
has triggered. operation.
Clean the cooling ribs and vents of the motor.
Replace motor, if defective.
9723 Agitator hopper open
Cause Remedy
Safety switch on the agitator hopper is open. Close the agitator hopper.
Check the wiring and safety switch.

2TxtDosi106
9724 Wrong operating mode
Cause Remedy
Function not possible in the set operating Change the operating mode.
mode.

2TxtDosi106
10037 Battery low

The buffer battery of the servo control device is discharged.
Cause Remedy
The battery voltage is too low. Change the battery with the aid of the
10038 Power fail

A voltage drop has occurred on the NvRam and on the real-time clock (RTC). The NvRam
is deleted and the system time is not correct.
Cause Remedy
The system has been switched off for too long Re-initialize the retain area and the clock.
and the battery voltage is insufficient. Change the battery with the aid of the
10100 I2T Motor

The motor is overloaded or the power transmitted to the motor is too high. The integra
tor (see control configuration l2t) increased to 100 %.
Cause Remedy
The holding brake is not bled (broken cable, Check brake and wiring.
voltage outside the range of 24 V +/-10 %).
Defective lubricating system. Check lubrication.
Blunt tool. Check and/or exchange tool.
Motor oscillates. Check the controller parameters.
Pendant axis too heavy or weight balancing Check drive settings and weight balancing, run
defective. plant at slower speed or accelerate more
slowly.
Motor is demagnetized. Exchange motor.
10101 Amplifier power-off due to excess temperature

The cooling body of the PacDrive servo amplifier is too hot.
Cause Remedy
Insufficient ventilation or too high ambient Check equipment ventilation and ventilation
temperature. openings (if applicable), check control cabinet
ventilation, check function of the air
conditioning system.
End stage or mains rectifier are overloaded. Check motor/actuator combination, check
calculation of motor and actuator.
Hardware error: Temperature sensor is Exchange device.
defective.

2TxtDiag105
10102 Motor - power-off due to excess temperature

The internal motor temperature (temperature switch in the motor) is too high for at least
2 seconds (approx. 130 °C).
Cause Remedy
Wiring error: Temperature switch in the motor Check wiring.
winding is connected incorrectly.
Wiring error: Shield of motor cable is applied Check shield clamp at the bottom of the MC-4
incorrectly. motor controller and in the terminal box of the
SM motor.
The holding brake is not bled. Bleed brake.
Motor is overloaded. Run plant more slowly.
Check drive design. Possibly use a bigger motor for this
application.
Commutation error, i.e. encoder is not adjusted Adjust and/or trim encoder.
or trimmed.
Hardware fault: Defective temperature switch Exchange motor.
in motor winding.
10103 Power-off due to cooling error

The internal temperature of the device is too high. For PS-5, the fan is switched on when
the temperature is higher than 55 °C and switched off again when the temperature is
lower than 40 °C.
Cause Remedy
Insufficient ventilation or too high ambient Check equipment ventilation and ventilation
temperature. openings (if applicable), check control cabinet
ventilation.
Hardware error: Defective temperature sensor. Exchange device.
10104 Power-off due to control voltage error

Control voltage incorrect.
Cause Remedy
Control voltage is too low or temporarily fell Check 24 V control voltage.
below 24V DC.

2TxtDiag105
10105 Feedback error (track monitoring)

A hardware encoder error occurred. It is necessary to reset the device that triggered the
error.
Cause Remedy
Wiring error: Encoder cable at encoder or at Check encoder cable and exchange if
servo amplifier or PacDrive controller is pulled necessary, check mass connection (shield).
off or defective.
Encoder voltage is not applied or incorrect. Check encoder voltage.
Hardware error: Encoder is defective. Exchange encoder.
10106 Communication error DC controller

An internal system error has occurred.
Cause Remedy
EMC errors. Reset PacDrive system (PacDrive controller and
servo amplifier).
Hardware error: Servo amplifier is defective. Exchange servo amplifier.
10107 Excess current

The current flowing the output stage of the servo amplifier or in the DC circuit of the
power supply is too high. Unlike diagnosis messages 120 "Overload power-off of output
state" and 146 "DC circuit overloaded", shutdown occurs immediately after the peak cur
rent is exceeded. For PS-5 the diagnosis message 146 "DC circuit overloaded" is also
reported as diagnosis message 107 "Excess current".
Cause Remedy
Wiring error servo amplifier: Motor cable is Check wiring.
connected incorrectly or has a short circuit.
Servo amplifier: The current regulator Parameterize.
parameters are incorrect.
Hardware error servo amplifier: short circuit in Exchange motor.
the motor.
Power supply devices PS-4/PS-5: Too many Use an additional power supply and distribute
consumers are connected (ServoDrive SCL, the power supply for the consumers. The
Intelligent Servo Module iSH). existing arrangement of devices may be made
adequate by adjusting one of the applications
(e.g. decreasing acceleration).

2TxtDiag105
10108 Excess voltage

The DC circuit voltage is too high (for 400 V AC devices greater than 860 V DC; for 230 V
AC devices greater than 430 V DC)
Cause Remedy
Wiring error: Bleeder not connected. Connect bleeder.
Brake energy fed back to the DC-circuit is too Brake more slowly, check dimensioning of
high, which results in increased voltage. bleeder; use additional bleeder (bleeder
module BM-4) for 400 V AC devices.
Mains voltage too high. Check mains power supply.
Hardware error: Bleeder transistor is defective. Exchange bleeder transistor.
10109 Undervoltage
The DC circuit voltage is too low.
Cause Remedy
The mains voltage is too low. Check mains voltage (see Technical Data).
Parallel connected DC links, error in one servo Find servo amplifier with error and clear error.
amplifier.
10110 Phase error (power supply)

Failure of a phase (or two phase of the mains supply of the servo amplifier. The warning
131 "Phase failure of power supply warning" must have been pending beforehand for 10
s.
Cause Remedy
Wiring error: Not all phases connected Check wiring.
correctly or mains contactor wired incorrectly.
External fuse reacted. Check fuses.
10111 Excessive following error

A very serious following error has occurred that is bigger than the 8-fold value of the Fol
lowingLimit.
Cause Remedy
Usually this error occurs only in combination Check cam data.
with CAM functions (e.g. MultiCam).
The axis should be run with revolution control. Set parameter Pos_P_Gain to "0".

2TxtDiag105
10112 Communication error real-time bus

The device (SERCOS slave) did not receive a valid telegram of the real time bus
(SERCOS). This diagnosis signal is not reported in the system, because, in the case of an
error, the SERCOS slave (e.g. power amplifier MC-4) cannot report the diagnosis code
via SERCOS bus to the control system (e.g. C400). In this case, the diagnosis code 506
Multiple SERCOS cycle error (MASTER) is reported.
Cause Remedy
Intensity of optical fiber signal from Set intensity according to configuration.
predecessor too low or too high.
Hardware error: Optical fiber defective or Exchange optical fiber; it may be sufficient to
signal too weak. exchange optical fiber guide.
Due to aging. Exchange device.
10113 Braking resistor defective

The device recognized a defect of the braking resistor (bleeder resistor).
Cause Remedy
Wiring: Short circuit in brake resistor or feeder. Check brake resistor and feeder.
Wrong dimensioning of brake resistor (too low Check brake resistor dimensioning (see also
Ohm Project
value). Manual and Technical Data).
Hardware error: Braking resistor (bleeder) Measure bleeder resistor and, if necessary,
defective. exchange bleeder.
Hardware error: Device with internal braking Exchange device.
resistor defective.
10114 Reading error EEPROM

The electronic device type plate cannot be read from the EEPROM. In the rating plate the
device type, serial number, adjustment values etc. are stored.
Cause Remedy
Hardware error: EEPROM is defective. Please contact the customer service, exchange
servo amplifier.
10115 Gate-power failure

The voltage supply of the end stage of the servo amplifier is not available.
Cause Remedy
Hardware error: Servo amplifier defective. Exchange servo amplifier.

2TxtDiag105
10116 Commutation error

Commutation cannot be detected.
Cause Remedy
Motor is turning during MC-4 boot of power Make sure that the motor is standing when
amplifier MC-4. booting the
servo amplifier.
Wiring error: Encoder cable not connected or Check wiring.
defective.
10117 Reading error encoder EEPROM

It is not possible to read the electronic motor rating plate from the encoder EEPROM.
Cause Remedy
Wiring error: Encoder cable is incorrect. Check wiring.
Hardware error: Encoder defective. Exchange motor and/or encoder.
10118 Error on serial interface to encoder

Data transmission to the encoder is disturbed.
Cause Remedy
Wiring error: Encoder cable defective. Check encoder cable and exchange it if
necessary.
Check mass connection (shield). Check bridge in encoder cable
connector.
Encoder voltage is not applied or incorrect. Check encoder voltage.
Hardware error: Encoder is defective. Exchange motor and/or encoder.
10119 Short or ground circuit in output stage

The system checks for a short circuit (phase short circuit) of the motor cables or the mo
tor.
Cause Remedy
Wiring error: Short circuit in motor cable. Exchange motor cable.
Hardware error: Short circuit in motor (phase Exchange motor.
to phase or phase to casing).
Hardware error: End stage in servo amplifier is Exchange servo amplifier.
defective.

2TxtDiag105
10120 Overload power-off output stage

Output stage is overloaded. Unlike diagnosis messages 107 "Excess current", shutdown
does not occur immediately when voltage limit has been exceeded. The high thermal
load of the device over a certain time interval is considered.
Cause Remedy
Output stage is overloaded. Check combination of motor / positioning
controller, check calculation of motor and
positioning controller, drive system at lower
speed.
Motor brake is not opened. Check wiring of motor brake (protection
against polarity reversal, cable break, ....).
Hardware error: Servo amplifier is defective. Replace servo amplifier.
10121 Bleeder temperature too high

Bleeder is overloaded.
Cause Remedy
Drive is dimensioned wrongly. Check drive dimensioning.
Hardware error: Bleeder or control is defective. Please contact the customer service.
10122 Max. motor speed reached

The current motor speed is higher than the rated motor speed.
Cause Remedy
Error occurs when using a motor SH-055 with a Use Firmware version starting from V00.22.00
rated speed bigger than 6000 rpm. in the power amplifier MC-4.
Error occurs in CAM function (e.g. MultiCAM9 Check cam data and program.
due to wrong cam or profile data.
Jumps occurred in the master encoder. Check master encoder.
The error occurs in a CAM function due to an Check program.
incorrect position manipulation (e.g. Setpos1()
function).
Hardware error: Commutation error, i.e. the Please contact the customer service.
motor encoder (SinCos) is not adjusted and/or
trimmed.

2TxtDiag105
10123 Error "Inverter Enable"

The "Inverter Enable" input became LOW while the drive was "in regulation" (DeviceState
>= 16#20). If the drive is shut down via HW_Enable or ControllerEnable, the regulation is
active until the drive is stationary and then the brake is activated (BrakeCouplingTime).
Cause Remedy
Wiring error. Check wiring of the "Inverter Enable" input.
Switching error: "Inverter Enable" input was set Check addressing of "Inverter Enable" input.
to LOW.
Ext. diagnosis = Wrong Mode: xx Check parameter InverterEnableMode and
The set mode in the parameter adjust if necessary, check iSH hardware
InverterEnableMode does not correspond with configuration and, if necessary, plug in or pull
the real devices. off iSH-DIS1.
10124 Power-off due to overload

The power-off due to overload (overload function) detected an excess torque. This dia
gnosis signal can be switch off via function OverloadErrorOff() switched back on via
function OverloadErrorOn() (standard behavior!).
Cause Remedy
A case of overload occurs with active overload Mechanics are tight or blocked, check driving
function. range.
10125 "2t Motor" warning

Motor is overloaded. Integrator (parameter I2t) has already increased to 80 %. This can
result in an error 100 "I2T motor".
Cause Remedy
Warning of control device. -
10126 Amplifier excess temperature warning

The cooling body of MC-4/SCL/PS-4 gets too hot. This can result in an error 101 "Ampli
fier - power-off due to excess temperature".
Cause Remedy

2TxtDiag105
10127 Excess temperature motor warning

Internal motor temperature (temperature switch inside the motor) is too high (approx.
130°C). If the temperature switching the motor reports a too high temperature for at
least 2 seconds, the error 102 "Motor - power-off due to excess temp." is triggered.
Cause Remedy
10128 Cooling error warning

Internal temperature of the device is too high. For SCL, the internal power supply can be
overloaded as well. This can result in an error 103 "Power-off due to cooling error".
Cause Remedy
Warning of control system. -
10129 Power-off overload output stage warning

End stage is overloaded. This can result in an error 120 "Overload power-off output
stage".
Cause Remedy
Warning of the control device. -
10130 Bleeder temperature rising

Bleeder is overloaded. This can result in an error 121 "Bleeder temperature too high".
Cause Remedy
10131 Phase failure of power supply warning

Failure of one phase (or two) of the mains connection of the servo amplifier. If this war
ning exists for 10s, this leads to an error 110 "Phase error (power supply)"
Cause Remedy

2TxtDiag105
10132 Following error

A positioning following error greater than the parameter "FollowingLimit" occurred in the
position regulator of the servo amplifier.
Cause Remedy
The contouring error monitoring is too Increase object parameter FollowingLimit.
intolerant.
Acceleration is too high. Reduce acceleration.
Following error is a result of the diagnosis Mechanics are tight or blocked, check driving
message 100 "I2T motor". range.
Incorrect parameterization. Check regulator parameters and J_Load.
The current feed forward is switched off. Wiring error: Cores in the motor or encoder
cable are switched, check cable connection
and/or cable.
Wiring error: Wrong encoder connector or Check encoder connector and motor
motor connector connected maybe from connector, check connector cable and motor
neighboring actuator). cable.
Wiring error: Holding brake not lifted. Check holding brake.
No mains voltage. Check mains voltage at the servo amplifier.
An encoder with a wrong bar code was Check encoder.
installed.
Hardware error: Coupling to the position Check encoder coupling.
encoder is loose.
Hardware error: Encoder signal gives jumps. Check driving range.
The axis should be operated with velocity Set parameter Pos_P_Gain to 0.
control.
10133 Speed-dependent power reduction

From a speed of < 75 RPM (112.5 RPM SM 070), the maximum motor current is limited
to 70% of peak current. This is a safety measure to protect the output stage of the servo
amplifier when driving on block. In versions V00.11.00 or higher, this message is not
generated until the set current is really limited to 70% of peak current.
Cause Remedy
Axis is driven to block. Check driving range of the axis.
10134 External 24 V power supply too low

Control voltage (24 V DC) is too low.
Cause Remedy
Control voltage too low. Check control voltage (see also Technical Data
of the device).

2TxtDiag105
10135 Undervoltage warning

The system tries to start the drive, but the DC-circuit voltage is too low.
Cause Remedy
Hardware enable and software enable are Check mains voltage (see also Technical Data
there, but the mains voltage is too low. of the device); the mains contactor may not be
connected.
Parallel connected DC links, one servo Search the servo amplifier with error and clear
amplifier has an error. error.
10136 "Inverter Enable" warning

Attempt to start the drive, but inverter enable is still LOW.
Cause Remedy
Hardware enable and software enable are Switch on "inverter enable".
there, but "inverter enable" is still LOW.
10137 Motorless
When changing the power amplifier MC-4 from motorless to normal operation, the sys
tem reports a motor error that occurred in the meantime.
Cause Remedy
A motor error occurred. The MC-4 can only be freed from this state if
you carry out a hardware reset on the MC-4 or
you set the MC-4 back to motorless.
The MC-4 was not switched off when The MC-4 can only be freed from this state if
connecting a motor to an MC-4 that was you carry out a hardware reset on the MC-4 or
parameterized to motorless. After that, the you set the MC-4 back to motorless.
MC-4 was changed to normal operation.
10138 Inadmissible motor

An inadmissible motor is connected to the MotorController.
Cause Remedy
An SM 070 60 010 is connected to the MC-4 / Use a "bigger" motor (e.g. SM 070 60 020) or a
22 A. "smaller" MotorController (e.g. MC-4 / 10 A).
An SM 070 60 010, SM 070 60 020 or SM 100 Use a "bigger" motor (z. B. SM 100 40 050) or a
50 030 is connected to an MC-4 / 50 A. "smaller" MotorController (z. B. MC-4 / 10 A).

2TxtDiag105
10139 Error in DC-circuit charge

The error message is generated if the mains voltage is applied and the DC circuit voltage
is not reached after switching on the mains phases. The phase monitoring (MC-4: Pha
seCheck, PS-4: PhaseCheckMode) does not influence this error check. This check pre
vents a thermal destruction of the internal brake resistor.
Cause Remedy
The following sequence leads to the diagnosis Prevent drop of mains voltage while the drive is
message: in regulation. Switch off regulation or the end
1. The parameter DC_LowCheck is "off". stage of the MotorController when switching
2. The mains voltage drops and the drive off the mains contactor (parameter
remains in regulation. (If DC_LowCheck is "on", ControllerEnable or input enable on the
diagnosis message 109 "Undervoltage" MotorController).
appears. This leads to a reaction B and the
drive does not stay in regulation.)
3. The mains voltage is increases (drive still in
regulation!) while e.g. a load is pressing on the
axis (energy consumption on the shaft!). This
consumes so much energy that the DC circuit
cannot be loaded.
Short circuit or ground fault in DC voltage Check wiring.
wiring.
10140 Stop time limit

The stop time limit was exceeded when ramping down the motor in a controlled way.
When switching off the Enable or HW_Enable or if an error with reaction B (best possible
shutdown) occurs or by user-driven shutdown, the ramping down time is determined by
the parameter StopTimeLim. If the drive still is not standing at the end of this ramping
down time, the brake is actuated and the error message stop time limit is triggered.
When the BrakeCouplingTime is completed, the drive is switched to a torque free state.
Cause Remedy
The load on the drive is too great to be able to Check the parameter StopTimeLim.
observe the
set stop time limit.
Encoder in the motor is defective (or Exchange motor.
commutation not ok).
10141 Reading error EncoderPosition

An error occurred when reading the matching position from the motor encoder. In Mo
torController Firmware version 00.20.00 and higher, this diagnosis message is replaced
by diagnosis message 170 "Reading error DrvEncPosition".
Cause Remedy
The function DrvEncSetPosition() was called up Call up the function DrvEncSetPosition() again.
and could not be processed correctly.
Encoder in the motor is defective. Exchange motor.

2TxtDiag105
10142 Board power-off due to overtemperature

The board temperature inside the housing is too high.
Cause Remedy
Ventilation is inadequate or the ambient Check the control cabinet ventilation system,
temperature is too high. check air conditioning unit (if available) for
proper function.
Hardware error: The temperature sensor is Exchange the device.
defective.
10143 Encoder temperature warning

The temperature inside the encoder is too high.
Cause Remedy
Ventilation is inadequate or the ambient Check equipment ventilation and ventilation
temperature is too high. openings (if applicable), check control cabinet
ventilation, check function of the air
conditioning system (if applicable).
Hardware error: The temperature sensor is Exchange the device.
defective.
10144 DC bus short circuit

A short circuit has occurred in the DC bus of the power supplies PS-4/PS-5. For the PS-5
a ground circuit may have occurred.
Cause Remedy
Wiring error: the connecting cables of the Check cables and exchange, if necessary.
power supply via the terminal boxes to the
ServoDrives are incorrectly connected or short
circuited.
10145 DC bus ground circuit

A ground circuit has occurred in the power supply PS-4.
Cause Remedy
Wiring error: the connecting cables of the Check cables and exchange, if necessary.
power supply via the terminal boxes to the
ServoDrives are incorrectly connected or
ground circuited.

2TxtDiag105
10146 DC bus overload

The DC circuit is overloaded. In this case, unlike diagnosis message 107 "overcurrent",
switch-off does not occur as soon as the current threshold has been exceeded. The
thermal overload of the device is observed over a specific period of time.
Cause Remedy
Too many loads (e.g. ServoDrive SCL) are Maybe the existent device constellation is
connected to the DC bus. sufficient when adapting the application (e.g.
lower acceleration). Use another power supply
PS-4 and divide the supply of the loads.
10147 24 V power supply overload

The 24 V supply available at the output of the PS-4/PS-5 power supplies is overloaded. If
the diagnosis message occurs at the (load >100%) and the load continues to increase to
>130%, then the 24 V for the 24 V for the subordinate iSH and DB-5 is switched off which
means that the iSH cannot be reached via SERCOS any longer. The PS5 remains accessi
ble in the SERCOS loop, because in this case, the PS-5 recloses the loop.
Cause Remedy
Wiring error: a short circuit has occurred. Check wiring of the 24 V supply of the power
supply via the terminal boxes to the
ServoDrives.
Too many consumers (ServoDrive SCL, Use another power supply PS-4 and divide the
Intelligent Servo Module iSH) are connected. supply of the consumers.
10148 Internal voltage error 15 V

The device-internal 15 V voltage is too low.
Cause Remedy
The device is defective. Exchange the device.
10149 Internal voltage error 12 V

The device-internal 12 V voltage is too low.
Cause Remedy
The device is defective. Exchange the device.

2TxtDiag105
10150 Phase L1 failure

The L1 phase of the mains connection to the device has failed or is too low. Via the Pha
seCheckMode parameter the diagnosis message can be switched off.
Cause Remedy
Wiring error. Check the phase connection. Check wiring of
the mains contactor.
The mains contactor is defective. Exchange mains contactor.

The phase L2 of the mains connection of the device has failed or is too low. The Pha
seCheckMode parameter can switch off the diagnosis message.
Cause Remedy
Wiring error. Check the connection of the phase. Check
wiring of mains contactor.
Mains contactor defective. Exchange mains contactor.

The phase L3 of the mains connection of the device has failed or is too low. The Pha
seCheckMode parameter can switch off the diagnosis message.
Cause Remedy
Wiring error. Check the connection of the phase. Check
wiring of mains contactor.
10153 DC bus discharge failure

DC bus was not discharged properly.
Cause Remedy
Too much braking energy is being fed from the Decelerate the drives before discharging (at a
connected SCL back into the DC bus. reduced rate of speed if necessary) and then
start the discharge procedure. Incorrect
shutdown sequence.
Phase voltage has been present for too long Allow the mains contractor to release before
(see also 159 "DC bus not discharged activating the discharge.
warning").
The bleeder (responsible for the discharge) Decelerate the drives before discharging (at a
reaches maximum load when the discharge reduced rate of speed if necessary) and then
begins. start the discharge procedure.

2TxtDiag105
10154 Phase L1 warning

The phase L1 of the mains connection of the device has failed. If the warning persists for
10 s or longer, the system issues the error message 150 "Phase L1 failure".
Cause Remedy

Cause Remedy

Cause Remedy
10157 DC bus overload warning

The load of the DC bus is at 80 %. This is displayed by the DC_BusOverload parameter. If
the load reached 100 %, error message 146 "DC bus overload" is triggered.
Cause Remedy
10158 24 V supply overload warning

The load of the 24 V supply for the devices SCL, iSH, PS-4 and PS-5 is at 80 %. If the
load reaches 100 %, error message 147 "24 V supply overload" is triggered.
Cause Remedy

2TxtDiag105
10159 DC bus no discharge warning

An attempt was made to discharge the DC bus, but the mains voltage is still present. If
the DC bus voltage does not decrease to 25 V within 200 ms of this warning appearing,
the error message 153 "DC bus discharge failure" is triggered.
Cause Remedy
Wiring error: the mains contractor is controlled Check the wiring.
incorrectly.
10160 Undervoltage power stage driver

The supply voltage of the power stage driver is too low.
Cause Remedy
Hardware error: the device is defective. Exchange the device.
10161 Overtemperature board warning

The temperature of the board in the inside of the housing is too high. If the temperature
continues to rise, diagnosis message 142 "Board power-off due to overtemperature" is
triggered.
Cause Remedy
10162 Wiring error O_0

There is a wiring error at pin 1 of the sensor/actor connector to the SCL.
Cause Remedy
The output is short circuited or overloaded. Check the wiring of the output.
Hardware error: the output function block is Exchange the device.
defective.
10163 SERCOS: C1D error

A SERCOS warning in diagnosis class 1 (C1D) has occurred. The extended diagnosis con
tains a data word that provides information on the exact cause.
Cause Remedy

2TxtDiag105
10164 SERCOS: C1D manufacturer-specific error

A manufacturer-specific SERCOS error in diagnosis class 1 (C1D) has occurred. The
extended diagnosis contains a data word that provides information on the exact cause.
For detailed information of the single bits, refer to the operating instructions of the
SERCOS device manufacturer.
Cause Remedy
10165 SERCOS: C2D warning

A SERCOS warning in diagnosis class 2 (C2D) has occurred. The extended diagnosis con
tains a data word that provides information on the exact cause.
Cause Remedy

Cause Remedy
10167 SERCOS: C3D operation status

A SERCOS operation status in diagnosis class 3 (C3D) has changed. The extended dia
gnosis contains a data word that provides information on the exact cause.
Cause Remedy

Cause Remedy

2TxtDiag105
10169 Single SERCOS error (SLAVE)

A temporary signal error on the SERCOS bus has been detected. The MDT data may now
be incorrect due to this fault. In this case, the data of the last cycle is reused.
Cause Remedy
Temporary errors can have the following Check the intensity setting in the PacDrive
causes: Signal distortion, loss of more than 10 Controller and on the servo amplifier. Check
signal edges (fiberoptic break), failure of fiberoptic conductor.
master synchronous telegram (MST), failure of
master data telegram (MDT), signal over
SERCOS fiberoptic conductor incorrect.
EMC problems. Check wiring.
SCL-055 motors are connected to the PacDrive Check the connection of the SCL-055 motors in
-Controller. The SCL-055 motors in the the PacDrive-PD-8 Box. Simply placing jumpers
PacDrive PD-8 Box is connected incorrectly. on the desired terminals will not resolve the
problem. Slaves must not be inserted into the
following SERCOS slot. Also observe the
notices in the operating instructions "SCL" and
"PS-4 and PD-8".
10170 DrvEncPosition reading error

The error message is triggered when an error occurs as the position is being read from or
written to the electronic type plate of the motor. Writing to the position occurs by using
the function DrvEncSetPosition(). This diagnosis message replaces the diagnosis mes
sage 141 "Reading error EncoderPosition" in MotorController firmware version 00.20.00
or higher.
Cause Remedy
The DrvEncSetPosition() was called and could Call the DrvEncSetPosition() function again.
not be processed properly.
Encoder in the motor is defective. Exchange the motor.
10171 Encoder communication warning

An error occurred in reading the encoder via the serial interface.
Cause Remedy
Wiring error: the encoder cable is incorrect. Check wiring.
Hardware error: The encoder is defective. Exchange motor or encoder.

2TxtDiag105
10172 Extebded diagnosis message

This diagnosis message is only intended for ELAU internal use. To view the diagnosis
message in the message, logger, FilterType 15 must be selected via Setfilter.
Cause Remedy
10173 Feedback message (track monitoring)

This diagnosis message is only intended for ELAU internal use. To view the diagnosis
message in the message, logger, FilterType 15 must be selected via Setfilter.
Cause Remedy
10174 Excess current warning

In the power supply PS-4 the warning "Excess current warning" will be triggered in hard
ware code xx3xxx if a DC bus current of more than 50 A is present for at least 1 ms. The
error message 107 "Excess current" will be generated if the DC bus current reaches 55 A.
Cause Remedy
Too many consumers (e.g. ServoDrive SCL) are Use an additional power supply PS-4 and
connected to the DC bus. distribute the power supply of the consumers.
The existing arrangement of devices may be
made adequate by adjusting one of the
applications (e.g. decreasing acceleration).
10175 Bleeder overload

If a bleeder of 86 % (MC-4 and PS-4) or 90 % (PS-5) is reached, the message "Bleeder
overload" can be triggered.
Cause Remedy
The braking energy of the motor that is fed into Brake at a slower rate. Check the dimensioning
the DC bus is too high and therefore results in of the bleeder. Use additional bleeder module
voltage build-up. (BM-4) with 400 V AC devices.
10176 Reserved
This diagnosis code is reserved.
Cause Remedy

2TxtDiag105
10177 Power-Board-excess temperature power-off

The temperature of the power board inside the housing is too high.
Cause Remedy
Insufficient ventilation or ambient temperature Check the control cabinet ventilation. Check
is too high. the air conditioning device (if available) for
proper function.
Hardware error: the temperature sensor is Exchange the device.
defective.
10178 Device error

An internal error has occurred.
Cause Remedy
Device error. Please contact the service department.
Device defective. Exchange the device.
10179 Warning braking resistance overloaded

The bleeder-I2t has reached a value of 80 % for the PS-5. At 100 % Bleeder, the bleeder
is deactivated with further message. Once the DC bus voltage exceeds 850 V, an error
message 108 "Excess current" is generated.
Cause Remedy
The braking energy of the motor that is fed into Brake at a slower rate. Check the dimensioning
the DC bus is too high and therefore results in of the bleeder. Use additional bleeder module.
voltage build-up.
10180 Warning power board excess temperature power-off

The temperature of the power board inside the housing is too high. If the temperature
continues to increase, the diagnosis message 177 "Power board excess temperature
power-off" will be triggered.
Cause Remedy

2TxtDiag105
10181 Warning fan defective

An error of the fan has occurred.
Cause Remedy
The fan is blocked. CAUTION: Rotating fan. Risk of injuries. Open
the main switch. Secure main switch against
switching back on. Remove blocking objects.
Clean fan.
The fan is defective. Exchange the device.
10182 External 24 V supply too high

The control voltage (24 V DC) is too high.
Cause Remedy
Control voltage is too high. Check the control voltage (see also Technical
Data of the device).
10200 Faulty log. address of the parameter

The object or parameter to be accessed does not exit in the control configuration. In the
external diagnosis in the message logger, the logic address is displayed.
Cause Remedy
The IEC program addresses an object or Check program. Please contact the application
parameter which does not exist in the control department.
configuration.
Following error of diagnosis message 209 "last See diagnosis message 209 "last boot failed".
boot failed". The configuration file of the Retransmit the configuration file to the control.
control is corrupted.
10201 Faulty parameter type code

The type code of a parameter is wrong.
Cause Remedy
Software error. Please contact the service department.
10202 Faulty configuration file

The configuration file can no longer be read.
Cause Remedy

2TxtDiag105
10203 Faulty parameter file

The parameter file cannot be read. In the Controller-Firmware version 00.16.30, the file
name of the temporary parameter file in the message logger is displayed in the external
diagnosis.
Cause Remedy
There is no parameter file in the PacDrive Retransmit the parameter file with EPAS-4.
controller or parameter file is faulty.
10204 IEC program cannot be loaded

The IEC program cannot be loaded. In DiagExtCode or in the message logger in external
diagnosis, more information for error localization are stored. Observe the previous error
message (e.g. 312 "parameter relocation failed"). This is a following error.
Cause Remedy
There is no IEC program in the PacDrive Retransmit with EPAS-4 IEC program.
controller or the IEC program is defective or
incompatible.
IEC program code, IEC data range or IEC retain Adjust project.
range in the PacDrive controller too large.
The settings under “Number of data segments“ Increase number of data segments.
EPAS-4 Project/Options/Compilation options is
less than 2 (DiagExtCode = ret xhhhhhhhh).
10205 Illegal parameter value

The parameter has an illegal value. Use the parameter DiagExtCode in the control confi
guration or the message logger to detect the logic address of the parameter with the
illegal value. Thus it can be allocated to the control configuration.
Cause Remedy
External diagnosis: BaudRate=<invalid value>. Enter valid value for BaudRate.
l=0Bxx0004; i.e. a too high or too low value for Enter valid value for Acceleration.
"acceleration" was entered in the virtual
encoder.
l=03xx0025; i.e. J_Load in the control Enter valid value for J_Load.
configuration is too high.
l=01000004;i.e. IP_Gateway in the control Observe conventions of IP address
configuration does not match IP_SubNetMask. nomenclature.

2TxtDiag105
10206 Faulty ObjType of Log Adr

There is not object with the type code. Use the configuration object "DiagExtCode" in the
control configuration or the message logger to detect the logic address of the parameter
with the illegal value. Thus it can be allocated to the control configuration. See diagnosis
message 209 "last boot failed".
Cause Remedy
Software error. Contact the customer service.
10207 Hardware module does not exist

A hardware module that does not exist in the real system was entered in the control con
figuration. Use the configuration object DiagExtCode in the control configuration or the
message logger to detect the type of the hardware module.
Cause Remedy
An analog input or physical encoder that does Check control configuration.
not exist
was entered in the control configuration.
Hardware error: Hardware module not Exchange PacDrive controller or optional
recognized or module.
defective.
10208 Too many real axes in config

The number of exes in the control configuration is too high.
Cause Remedy
The number of axes for the cycle time is too Check cycle time.
high.
The number of axis per PacDrive controller is Check type plate for PacDrive controller type.
limited.

2TxtDiag105
10209 Last boot failed

During the last booting process, a PacDrive controller voltage drop or a PacDrive con
troller rest or a serious error occurred. With the DiagExtCode, the problem can be locali
zed in detail. When booting, the PacDrive controller protocols the individual phases in
the NvRam. If a serious error occurs in the process (err LED permanently ON), the next
boot will boot only with the basic configuration and the diagnosis message 209 is be
generated. For minimal booting of the PacDrive controller, the configuration and the pa
rameters of the control configuration are set to default values!
Cause Remedy
Procedure. Read out and evaluate EPAS-4 connection with
TCP/IP default address or serial, read out and
evaluate message logger (important
DiagExtCode!). The DiagExtCode can be used
to read which phase of the boot procedure was
executed correctly last time.
The function SysReset() was called, although Use the GetPacDriveBootState() function to
the boot procedure of the PacDrive controller make sure that the PacDrive controller has
was not yet complete. stopped the boot procedure before you use the
SysReset() function.
DiagExtCode = 19: programming error, i.d. the Overwrite the IEC program on the PacDrive
IEC program file is incorrect. controller by transferring the IEC project
(dummy) with the default configuration. Check
your program and send an error-free project to
the PacDrive controller.
DiagExtCode is not 19. Please contact the service department.
The PacDrive controller was booted twice in Check control voltage (see also Technical
quick succession. This may have been caused Data).
by pressing the reset button twice or a drop in
the control voltage.
Insufficient RAM in the PacDrive controller for Reduce configuration. RamDiskSize must be
the project (DiagExtCode=out of memory). decreased. Reduce number of tasks. Apply a
PacDrive controller that has more RAM.
A PacDrive controller version 00.15.00 or Use a PacDrive controller that has at least 32
higher is being used. The user data area was MB RAM or firmware versions < V00.15.00.
increased from2 MB to 3.7 MB starting from
this version. If the PacDrive controller has less
than 32 MB RAM, the PacDrive controller in
minimal boot mode.

2TxtDiag105
10210 Boot failed

The diagnosis message is used to differentiate from the message 209 "Last boot failed"
for minimal boot (boot not complete). In such a case the last boot failed.
Cause Remedy
If this diagnosis message appears, the minimal Exchange the PacDrive controller MAx-4 with a
boot is also in error. However, this is caused by device that has newer hardware or use an older
having insufficient RAM in the PacDrive firmware version in the PacDrive controller
controller MAx-4 (RAM<32 MB). MAx-4 (lower than V00.15.03).
10211 Invalid configuration

A configuration error has occurred.
Cause Remedy
Cause, firmware V00.20.00:The connector Check the "Connector" parameter in the control
parameter is set for the "Bottom / 1" configuration.
connector, but there is no expansion module
present in the PacDrive controller (C600 or
P600).
Cause, firmware V00.16.41: This diagnosis Check the control configuration.
message will be triggered if there are two field
busses configured in PacDrive controller C600
or P600 that cannot be connected at the same
time. Can Layer 2 and DeviceNet Slave are
configured; or CANopen Master and DeviceNet
Slave are configured; or PROFIBUS DP Master
and PROFIBUS DP Slave are configured.
10300 Division error

A division by 0 was attempted in the IEC program. NOTICE The division by "0" is defined
for REAL and LREAL and therefore does not generate the diagnosis message 300 "Di
vision error".
Cause Remedy
In an IEC division function the divisor was zero. Avoid division by 0 in the IEC program. Check
numerical range.
10301 Coprocessor segment overflow

A system error has occurred.
Cause Remedy
A system error has occurred. Please contact the service department.

2TxtDiag105
10302 Stack error

Cause Remedy
10303 General protection error

Cause Remedy
10304 Coprocessor error

Cause Remedy
10305 Memory limit exceeded

Cause Remedy
10306 Arithmetic overflow

Cause Remedy
10307 Double execution error

Cause Remedy

2TxtDiag105
10308 Invalid task state segment

Cause Remedy
10309 No memory segment

Cause Remedy
10310 Faulty memory segment adjustment

Cause Remedy
10311 Coprocessor division error

Cause Remedy
10312 Parameter relocation failed

Cause Remedy
Program not matching active configuration. Retransmit the project.

2TxtDiag105
10313 Serious cycle time overflow

The serious cycle time error of an IEC task is triggered if the 10-fold cycle time is excee
ded (see Task Configuration). The task moves to error state. This state can only be
quitted by an IEC task reset (online > reset PacDrive controller). The cycle time monito
ring of the IEC tasks refers to the object parameter Load, which is shown in the IEC Task
expansion object in the control configuration.
Cause Remedy
Call of a parameter or system component Increase interval time in the task configuration.
which takes "very long" to process. Time
interval too short.
10314 Defective program file

Cause Remedy
The check sum of the program is incorrect. Retransmit the program.
10315 Library function not implemented

The program used an interface library which is not or not fully supported in the actual
PacDrive controller (function name see DiagExtCode).
Cause Remedy
Firmware in PacDrive controller too old. Update firmware in PacDrive controller. Maybe
use older library version.

2TxtDiag105
10316 Faulty NvRam CRC

The NvRam lost the data. This means that the data were deleted from the message logger
and the IEC variable values are deleted.
Cause Remedy
Object in message logger: "MAX4" PacDrive Reboot the PacDrive controller. Now the error
controller was not switched on for more than 7 must not reappear.
days (control voltage!).
Object in the message logger: "PN4" The Reboot the PacDrive controller. Now the error
internal or external battery on the optional must not reappear.
module PN-4 is empty and the PacDrive
controller was not switched on for more than 7
days (control voltage!).
Object in message logger: "MAX4" External Exchange PacDrive controller.
diagnosis in the message logger: Nvram
damaged The NvRam of the PacDrive controller
is defective.
Object in message logger: "PN4" External Exchange optional module PN-4.
diagnosis in the message logger: Nvram
damaged The NvRam of the optional module
PN-4 is defective.
Hardware error: The buffer capacitor is Exchange PacDrive controller.
defective.
10317 Cycle time overflow

A cycle time error was detected. It is triggered if the cycle time is exceeded by more
than a system cycle (a standard cycle is 250 μs or 1 ms for C200). The "actual cycle time"
/ "cycle time from the task configuration" in ms can be found in DiagExtCode.
Cause Remedy
10318 Profile to be calculated was deleted

The system tried to calculate a profile (e.g. CamMasterStart() ), that is just being deleted
by the function ProfilDelete(). In DiagExtCode the profile ID is shown in hexadecimal
code (e.g. Prof=10010000).
Cause Remedy
Program error: The profile to be calculated was Check program.
deleted too early or the wrong profile was
deleted.
Program error: Asynchronously running high Synchronize FastTask to real time process.
priority FastTasks were used.

2TxtDiag105
10319 TPEdge inaccurate at 4 ms

The touchprobe measurement is inaccurate at the entered CycleTime of 4ms.
Cause Remedy
A CycleTime of 4ms is entered in the control Set CycleTime to 1 or 2 ms, if possible. Update
configuration and the PacDrive controller PacDrive controller hardware. Contact the
hardware does not correctly support the customer service.
touchprobe measurement at this CycleTime.
10320 Array access error(check)

Check.lib detected an array access error in the IEC user program. The component calls
and their interlacing can be traced back using the function call hierarchy of the message
logger.
Cause Remedy
The limits of the array were violated when Check the IEC user program.
accessing an array in the IEC program.
10321 Division by 0 (check)

Check.lib detected a division by 0 in the IEC user program. The component calls and
their interlacing can be traced back using the function call hierarchy of the message log
ger.
Cause Remedy
The IEC user program attempted a division by Intercept division by 0 in the IEC program.
0. Check number range.
10322 IEC task exception processing

If the IEC-Task detects a serious error (e.g. faulty access via pointer), the diagnosis mes
sage is generated. The component calls and their interlacing can be traced back using
the function call hierarchy of the message logger.
Cause Remedy
10323 Max. string length exceeded

Check.lib detected a violation of the maximum string length (255) in the IEC user pro
gram. The component calls and their interlacing can be traced back using the function
call hierarchy of the message logger.
Cause Remedy
The maximum string length was exceeded in Check IEC user program.
the IEC user program.

2TxtDiag105
10324 UPS internal error

There is an internal error in the UPS.
Cause Remedy
UPS battery is empty. Recharge battery.
Power supply of UPS is ok, but the UPS input With correct power supply, the input “ON/OFF“
“ON/OFF“ is OFF. must be ON in order for the UPS function to be
available.
A UPS object is entered in the control Connect UPS or adjust control configuration.
configuration, but no UPS is connected.
An internal error occurred in the UPS. Check UPS.
Ext. diagnosis: "PIC fail" or "State=5". An Please contact the service department.
internal error of the PIC Controllers has
occurred.
10325 Corrupt file

A problem (no data or CRC error) occurred when reading the retain file. The retain file is
read from the flash disk when booting the PacController if the parameter Enable of the
UPS expansion object is set to “external / 1“.
Cause Remedy
A UPS object is entered in the control Connect UPS or adjust control configuration.
configuration, but no UPS is connected.
Function of UPS not ok. Check function of UPS.
10326 Function not available

A function that is not supported by the system was called up. Further information on
object type and instance are shown in the message logger. The DiagExtCode contains
further information on the cause of the error.
Cause Remedy
The hardware of the PacDrive controllers does Check the hardware version on the type plate
not support this function. and using the parameter MAx4Type.
10327 Invalid PositionSource

The CamTrack in the PositionSource parameter contains an invalid value.
Cause Remedy
The symbolic name of a logical encoder or an Check the value in the PositionSource
axis (MC-4 or SCL)was not specified in the parameter.
PositionSource.

2TxtDiag105
10328 Invalid destination

The CamTrack in the Destination parameter contains an invalid value.
Cause Remedy
The Destination parameter was specified either Check the value in the Destination parameter.
without the symbolic name of an output group
or with "none".
10329 Invalid BitNumber

The CamTrack in the Bitno parameter contains an invalid value.
Cause Remedy
An invalid bit number was specified in the Check the value in the Bitno parameter.
Bitno parameter.
10330 Bad master parameter data

The message will be triggered if the system is unable to process the master positioning
job of an axis even though no errors were detected by the job parameter area checks
(e.g. error in the precalculation of the generator data). An extended diagnosis message
as "GT=XXX,MJId=YYY" is generated. XXX indicated the generator type while YYY indica
ted the Master-JobId of the job that caused the problem.
Cause Remedy
Internal calculation error. Contact the customer service department.
10331 Licensing
This diagnosis message will be triggered by the license server of the PAC Driver con
troller (e.g. C600) if a function block is used without a sufficient number of points. The
331 "Licensing" error (can be acknowledged) will be triggered first so as to notify the
user that the remaining run time of the system is only six hours. Then all functions can be
used without restrictions until the evaluation phase of six hours has elapsed. When this
time period has elapsed, a higher priority error that cannot be acknowledged is trigge
red. After a few minutes (about 5 min.), the SERCOS bus is shut down, making any
further use of the affected control impossible.
Cause Remedy
The number of license points on the compact Check the number of required license points on
flash card of the PacDrive controller is not the Licensing parameter in the control
sufficient. configuration.

2TxtDiag105
10332 Licensing
This diagnosis message will be triggered by the license server of the PAC Driver con
troller (e.g. C600) if a function block is used without a sufficient number of points. The
331 "Licensing" error (can be acknowledged) will be triggered first so as to notify the
user that the remaining run time of the system is only six hours. Then all functions can be
used without restrictions until the evaluation phase of six hours has elapsed. When this
time period has elapsed, a higher priority error that cannot be acknowledged is trigge
red. After a few minutes (about 5 min.), the SERCOS bus is shut down, making any
further use of the affected control impossible.
Cause Remedy
The number of license points on the compact Check he number of required license points
flash card of the PacDrive controller is not based on the Licensing parameter in the
sufficient. control configuration.
10333 Fatal error receiving encoder data

V00.22.00 or higher: in the encoder network, a fatal error occurred while distributing the
encoder positions.
Cause Remedy
Multiple initialization of object (SYN_DIN, Please contact the service department.
SYN_DOUT).
Synchronization was lost while the object Please contact the service department.
(SYN_DIN, SYN_DOUT) was activated.
The number of data sets (xxx) that was not Please contact the service department.
received sequentially exceeds the limit
specified in DataCycleErrorLimit.
Due to an internal error, the system was unable Please contact the service department.
to send a telegram for 5 cycles.
10334 Error receiving encoder data (warning)

V00.22.00 or higher: in the encoder network, an error occurred while distributing the en
coder positions.
Cause Remedy
xxx data sets were not received sequentially. If Please contact the service department.
more data sets were not received sequentially,
as specified in the DataCycleErrorLimit,
diagnosis message 333 "Fatal error receiving
encoder data".
10335 Fatal synchronization error

In the encoder network, a fatal error occurred while synchronizing the controller system
clocks.
Cause Remedy

2TxtDiag105
Initialization of the synchronization master or Check SlaveIPAddress parameter of the sync.

synchronization slave failed. module in the synchronization master control
configuration.
The IP address (SlaveIPAddress) of the sync. Check SlaveIPAddress parameter of the sync.
module is assigned twice. module in the synchronization master control
configuration.
The SERCOS loop is not in phase 4. "Ramp up" the SERCOS bus to phase 4.
The set MasterID is already being used by Change the MasterID.
another synchronization master that is in the
same network.
The synchronization master protocol version Use compatible software versions of the
does not match the synchronization slave controls. Please contact the service
protocol version. department.
The synchronization master failed to respond to Check the Ethernet connection to the
a ping. synchronization master.
The IP address (SlaveIPAddress) of the Check the SlaveIPAddress of the
synchronization module is assigned twice. synchronization module parameter in the
synchronization master control configuration.
SlaveCycleTime is not a multiple of the Adjust the SlaveCycleTime parameter or the
SERCOS cycle time. SERCOS cycle time.
The addresses synchronization slave is not Check the configuration of the synchronization
properly configured or is not responding. slave (e.g. same CycleTime). Check the TCP/IP
connection synchronization master to
synchronization slave.
The SERCOS cycle time differs on Adjust the CycleTime parameter of the
synchronization master and synchronization synchronization master or the synchronization
slave or the synchronization slave configuration slave.
cannot be sent.
The addresses synchronization slave is in an Acknowledge the error in the synchronization
error state. slave.
External diagnosis: "No DataOut" Check control configuration. Activate sync.
Encoder output if necessary (Enable
parameter).
No sync. Module and no sync. encoder input Check the control configuration. Activate the
has been configured or activated. sync. module or sync. encoder input (sync.
module Enable parameter or sync. encoder
input Enable parameter).
The synchronization slaves are unable to Check Ethernet connection. Optimize the IEC
synchronize the synchronization master. No project to reduce the CPU load.
sync. encoder output is configured or
activated. The Ethernet (see SyncQuality
parameter) and / or The CPU load (see
AvailableLoad parameter) is too high.
The number of sequential synchronization Check Ethernet connection. Optimize the IEC
telegrams (xxx) which were not received project to reduce the CPU load. Increase the
exceeded the number specified in SlaveCycleErrorLimit.
SlaveCycleErrorLimit. The Ethernet see
SyncQuality parameter) and / or the CPU load
see AvailableLoadparameter) is too high.
The sync. encoder outputs are unable to Check the DiagCode parameter of the sync.
configure the sync. encoder inputs or a data module to receive more detailed information
error has occurred while the system is running. about the source of the error.

2TxtDiag105
Not all sync. encoder outputs and sync. Check the DiagCode parameter of the sync.
encoder inputs are ready to exchange data. module to receive more detailed information
about the source of the error.
The SlaveIPAddress parameter is not set. Please contact the service department.
Internal error code. Please contact the service department.
10336 Synchronization error (warning)

V00.22.00 or higher: in the encoder network, an error occurred while synchronizing the
controller system clocks.
Cause Remedy
More than half of the synchronization telegrams Please contact the service department.
(xxx) specified in SlaveCycleErrorLimit have
not been received sequentially. If more than
half of the synchronization telegrams have not
been received sequentially, the 335 diagnosis
message "Fatal synchronization error" will be
triggered.
10337 Insufficient system memory to create DynIECData

V00.22.00 or higher: the dynamic memory area, which was specified with the DynIECDa
taSize parameter, could not be reserved due to insufficient memory (RAM). During IEC
program start, a check will be performed to determine if there is at least 4 MB of availa
ble memory after the dynamic memory area is reserved.
Cause Remedy
The dynamic memory area to be reserved is too Reduce the value of the DynIECDataSize
high. parameter.

2TxtDiag105
10338 UPS accu error

The battery is not sufficiently charged.
Cause Remedy
The PacDrive controller has been switched off Switch on the PacDrive controller. The battery
for too long. will be charged automatically when the
PacDrive controller is on.
The UPS has been operating in the battery Check the supply voltage. Maybe switch on the
mode (state = 3) for an extended period. PacDrive controller. The battery will be charged
automatically when the PacDrive controller is
on.
The battery capacity is insufficient due to Please contact the service department.
aging.
10339 UPS active - system temperature too high

The temperature in the PacDrive controller is too high.
Cause Remedy
Ambient temperature too high. Observe the Technical Data of the PacDrive
controller (see operating instructions).
10340 Outside limits (check)

TODO
Cause Remedy
- -
10400 IEC diagnosis message class2

The IEC program triggered a diagnosis message with the function DiagMsgWrite().
Cause Remedy
The error was caused by the IEC program. See description of your IEC program. It is
possible to output an additional error text
using the function DiagMsgWrite().

Cause Remedy

2TxtDiag105

Cause Remedy

Cause Remedy

Cause Remedy

Cause Remedy
10406 IEC diagnosis message class 1

TODO
Cause Remedy
- -

2TxtDiag105
10407 IEC diagnosis message class 8

TODO
Cause Remedy
- -
10500 Duplication of SERCOS slave address

During bootup of the SERCOS bus in phase 3, the addresses of the found SERCOS slaves
are checked. Thereby, duplication of addresses is detected. This function, however, must
also be supported by the SERCOS slaves. ELAU slaves (MC-4, SCL and PS-4) support this
function for version V00.15.00 and higher.
Cause Remedy
A SERCOS slave address was issued twice to Determine duplication of addresses in the
the SERCOS slaves. parameter DiagExtCode. Check and adjust the
parameter RealTimeBusAdr in the control
configuration.
A SERCOS slave address was issued several Check the rotary switch settings at the
times in the control configuration. SERCOS slaves.
10501 SERCOS slave not found

A SERCOS slave (MC-4, PS-4, SCL) entered in the control configuration cannot be found
in the SERCOS bus.
Cause Remedy
SERCOS slave does not exist in the SERCOS Integrate SERCOS slave in SERCOS bus or
bus. remove SERCOS slave from the control
configuration or parameterize as virtual device.
controller. The connection of the SCL-055 the PacDrive PD-8 Box. It is not sufficient to
motors in the PacDrive PD-8 Box is incorrect. place the jumpers on the desired terminals. No
slave may be place on the following SERCOS
slot. Observe the notices in operating manuals
"SCL" and "PS-4 and PD-8".

2TxtDiag105
10502 Loop not closed

The SERCOS loop is not closed. A longer interruption (>100 ms) of the loop has occur
red. Via the LED "bus err" and the parameter LoopStatus it can be detected where the
interruption exists. When the interruption is cleared and the SERCOS bus has entered at
least phase 2, the source of error can be limited by using the SERCOS firmware assistant
in the data view system diagnosis > SERCOS configuration and SERCOS topology.
Cause Remedy
Signal via SERCOS optical waveguide incorrect. Check intensity setting in the PacDrive
controller and at the PacDrive servo amplifier.
Check wiring (see parameter LoopStatus).
A device in the SERCOS loop is switched off or Check voltage supply (24 V) of the device.
was reset. Switch the device on.
10503 error in parameter channel

A transmission error occurred in the SERCOS bus during operation. Additional informa
tion is recorded in DiagExtCode.
Cause Remedy
SERCOS slaves (MC-4) with a firmware version For SERCOS slaves (MC-4) with a firmware
smaller than V00.15.00 are in the loop that are version smaller than V00.15.00, that are not
not addressed as real devices. This causes addressed as real devices, the SERCOS
during phase run-up of the SERCOS bus a address must be adjusted to 0 at the device.
serious error including abortion of the phase
run-up.
EMC problem. Check electric environment.
HW problem of a SERCOS slave (e.g. power Please contact the service department.
amplifier MC-4) or the SERCOS master (e.g.
PacDrive controller MAx-4).

2TxtDiag105
10504 Read cycle overflow

Actual speed is possibly incorrect. The transfer of the actual position of the axis (servo
amplifiers) to the PacDrive controller was carried out too late. The actual values of the
next SERCOS cycle were already entered. The actual speed provided for the IEC program
is possibly incorrect.
Cause Remedy
SERCOS bus is overloaded. Increase CycleTime parameter in the control
configuration.
One or several SERCOS slaves were switched Switch on SERCOS slave.
off and therefore no longer supply data on the
SERCOS-Bus.
10505 Simple SERCOS cycle error (MASTER)

A checksum error on the SERCOS bus was detected. The data (target and actual posi
tion) of the last cycle are used again.
Cause Remedy
Signal via SERCOS fiberoptic cable incorrect. Check intensity setting in PacDrive controller
and at the PacDrive servo amplifier. Check
fiberoptic cable.
EMC problems. Check wiring.

2TxtDiag105
10506 Multiple SERCOS error (MASTER)

An error during receipt of data on the SERCOS bus in two consecutive cycles has been
detected. The SERCOS bus was shut down. For firmware versions smaller than
V00.15.00, the PacDrive controllers must be reset to restart the SERCOS bus. CAUTION
Position loss caused by severe SERCOS bus error! Material damage may occur!
Cause Remedy
Diagnosis message can only be acknowledged The acknowledgability of the diagnosis
when reinitialization and reference of the message can be switched off via function
system by the IEC program is secured. DiagNoQuitSet(). Possibly use functions
SysReset() or PrgResetAndStart().
A drop of the control voltage (24 V DC) has Check control voltage (see also Technical Data
occurred. Possibly the diagnosis message 134 of the device).
"External 24 V supply too low" is still entered in
the message logger (if it still could be
transferred via SERCOS bus).
SERCOS slaves (MC-4) with a firmware version For SERCOS slaves (MC-4) with a firmware
smaller than V00.15.00 are in the loop that are version smaller than V00.15.00, that are not
not addressed as real devices. This causes addressed as real devices, the SERCOS
during phase run-up of the SERCOS bus a address must be adjusted to 0 at the device.
serious error including abortion of the phase
run-up.
10507 Write cycle error

The transfer of the target position to the SERCOS bus was carried out too late. The last
target position was possibly transferred twice. For drive, this causes a speed jump (see
parameter RTPWriteRes).
Cause Remedy
SERCOS bus is overloaded. Increase the CycleTime parameter in the
control configuration.
The real time process is overloaded. Reduce number of objects with real-time jobs
(e.g. virtual
axes, virtual encoders, logic encoders, sum
encoders, ... ).
One or several SERCOS slaves were switched Switch on SERCOS slaves.
off and no longer supply data on the SERCOS
bus.

2TxtDiag105
10508 SERCOS boot error

Cause Remedy
In the control configuration, virtual SERCOS Check RealTimeBusAdr parameter of the
slaves are entered although the slaves are SERCOS slaves in the control configuration.
physically connected to the SERCOS bus.
There are more SERCOS slaves in the loop than Check the number of SERCOS slaves in the
entered in the control configuration. control configuration. Check the
RealTimeBusAdr parameter of the SERCOS
slaves in the control configuration. Possibly
remove SERCOS slaves from the loop or set
address at the device to 0.
In case of a bad connection, it is possible that Check the intensity setting for the SERCOS
no loop interruption is detected. The transfer interface. Check the wiring of the SERCOS bus.
quality at the BUS can be so bad that no
telegrams can be transferred. A run-up from
phase 0 is aborted without diagnosis message.
According to the message logger, the change
from phase 0 to phase 1 was aborted with the
internal error code 483.
A synchronization error has occurred during Please contact the service department.
phase run-up.
The phase run-up of the SERCOS bus took too Please contact the service department.
long. The diagnosis message is triggered during
bootup of the control.
10509 Wrong FW version

The firmware version of the SERCOS slave is incorrect.
Cause Remedy
The firmware version of the SERCOS slave Update PacDrive controller firmware or install
(MC-4, SCL, PS-4, ...) is higher than the an "older" firmware version on the SERCOS
firmware version of the PacDrive controller in slave.
the first 4 digits.
The SERCOS slave is in boot loader mode. The Pull off programming cable from SERCOS
version of the bootloader is displayed in the slave. Reset SERCOS slave. Acknowledge
message logger under ext. diagnosis. diagnosis message. The SERCOS bus runs up in
Furthermore, with the help of the information phase 4.
about object and entity in the message logger,
the SERCOS slave can be determined.

2TxtDiag105
10510 RTB interrupt missing

The interrupt of the SERCOM bus has not arrived for at least double the cycle time. This
diagnosis message typically occurs in conjunction with further diagnosis messages (504
Read cycle overflow ... 507 Write cycle error).
Cause Remedy
The problem occurs when switching off the Check wiring or wiring diagram.
plant. The 24V control voltage of the SERCOS
slave is lifted faster than the 24V control
voltage of the PacDrive controller.
Wiring error: The fiberoptic cable of the Exchange fiberoptic cable.
SERCOS bus is damaged.
A SERCOS slave has failed. Check SERCOS slave.
10511 CPU time overflow

The real time process is overloaded (CycleLoad >95 %). In the parameter DiagExtCode
parameter the measured load is displayed with 'Load = xxx%' whereby xxx represents the
load %. NOCTICE: After fault detection the processing of the real and target values for
the encoder, generators and axis in the real time process are not carried out any longer.
Therefore, the "Target and actual values" parameters of the axis do not display valid va
lues.
Cause Remedy
Too many objects entered in the control Increase the CycleTime parameter of the
configuration. SERCOS-Interfaces in the control configuration.
10512 SERCOS wrong device type

During run-up of the SERCOS bus in phase 2, a type check is performed regarding the
type of found SERCOS slave (MC-4, SCL, PS-4, ...) and the type entered in the control
configuration. If they do not correspond, the SERCOS bus phase run-up is aborted. In the
extended diagnosis the SERCOS address and the found type are entered. Multiple
addressing can exist, too. In case of multiple addressing, at least two SERCOS slaves
have identical addresses.
Cause Remedy
The SERCOS slave address (RealTimeBusAdr) Check if the address setting on the SERCOS
on the SERCOS slave (MC-4, SCL, PS-4, ...) slave that is displayed in the diagnosis
was not set correctly. message. Check if the address setting on the
SERCOS slave matches the address setting in
the control configuration (RealTimeBusAdr).
The SERCOS address (RealTimeBusAdr) has Check the RealTimeBusAdr parameter of the
not been specified correctly in the control device displayed in the diagnosis message.
configuration.

2TxtDiag105
10513 Download result

An error has occurred during the program-controlled firmware download. Find more in
formation on the error in the ext. diagnosis.
Cause Remedy
An incorrect device type is indicated in the Adjust the configuration file.
configuration file (e.g. a PS-4 firmware for a
MC-4). This diagnosis message is generated for
each SERCOS slave.
The "Download Mode" in the configuration file Check firmware version of the SERCOS slave.
is specified as "upgrade" (or "downgrade") and Adjust configuration file, if necessary.
the current firmware version is higher (or
lower) than the firmware version that is to be
programmed.
10514 Error download configuration file

TODO
Cause Remedy
- -
10516 SERCOS wrong device position

While starting up, the SERCOS bus at the end of phase 3, the assignment of the SCLs to
the PS-4 systems is checked. All SCLs that have been assigned a specific PS-4 power
supply in the control configuration, must be physically connected with that PS-4. If an
assignment error occurs, the diagnosis message 516 "SERCOS wrong device position"
will be generated. The message appears for the affected SCL. The DiagExtCode displays
the name of the PS-4 that actually should be assigned to the SCL.
Cause Remedy
The address of the integrated servo drive SCL Check the address settings on the SCL.
have been incorrectly set via the rotary switch
on the device.
The address of the PS-4 power supply/power Check the address settings on the PS-4.
supplies has been set incorrectly via the rotary
switch on the device.
The RealTimeBusAdrcontrol parameter in the Check the RealTimeBusAdr parameter in the
control configuration contains incorrectly control configuration.
specified PS-4 and/or SLC addresses.

2TxtDiag105
10517 Multiple use RealTimeBusAdr

A SERCOS address ( RealTimeBusAdr) has been assigned more than once in the control
configuration. A check is performed while preparing the SERCOS phase 1. The boot pro
cedure of the SERCOS bus is cancelled. The DiagExtCode parameter and the ext. diagno
sis in the message logger display the address that has been assigned more than once.
Cause Remedy
A SERCOS address has been assigned more Check the RealTimeBusAdr parameter in the
than once in the RealTimeBusAdr parameter in control configuration.
the control configuration.
10518 Too many real SERCOS slaves

The number of real SERCOS slaves is too high. Ext. diagnosis: HW <maximum number
SERCOS slaves on the controller>/<number of configured SERCOS slaves>.
Cause Remedy
Limited by the controller type. Check the PacDrive controller type referring to
the type plate.
The number of SERCOS slaves (MC-4, PS-4, Check the cycle time. Check the baud rate.
SCL) for the cycle time is too high.
Limited by the hardware configuration Check the PacDrive controller type by referring
(licensing). to the type plate.
10600 Serial interface disturbed

During data exchange with the SinCos master encoder via a serial interface of the enco
der, a fault has occurred. CAUTION: InitPosition and EncoderPosition could be wrong!
Damage caused by not referenced machine is possible! Reset the PacDrive controller,
after you have cleared the error.
Cause Remedy
Wiring error: The encoder cable is connected Check and, if necessary, exchange encoder
incorrectly or defective. cable. Reset the PacDrive controller.
PacDrive controller is overloaded. Increase the priority of the system task. Reset
the PacDrive controller.
Hardware error: SinCos encoder is defective. Exchange encoder. Reset the PacDrive
controller.
Hardware error: SinCos encoder interface in Exchange control.
the control is defective.

2TxtDiag105
10601 Encoder track error

No analog data received from the SinCos master encoder. CAUTION: Hardware encoder
error! Loss of position of master encoder! Acknowledge diagnosis message only when
reinitialization or reference of the system by the IEC program has been secured. Possibly
use functions SysReset() or PrgResetAndStart().
Cause Remedy
Wiring error: The encoder cable is connected Check and, if necessary, exchange encoder
incorrectly or defective. cable.
Hardware error: SinCos encoder defective. Exchange encoder.
Hardware error: SinCos encoder interface in Exchange control.
the control defective.
10700 CAN layer2 driver error

The driver for the CAN module could not be started.
Cause Remedy
No CAN module in the PacDrive controller. Order CAN module and install it.
I/O address or interrupt set incorrectly. Check I/O address. Check interrupt setting.
Hardware error: CAN module defective. Exchange CAN module.
Hardware error: Control defective. Exchange control.
10701 CAN Layer 2 Init error

Initialization failed.
Cause Remedy
CAN module overloaded; command messages Exchange module.
could not be processed fast enough. Hardware
error: CAN module defective.
10702 CAN Layer 2 1 error occurred

A send or receive error occurred.
Cause Remedy
Two nodes are using the same identifier or Check identifier or COB-ID.
COB-ID.
Temporarily disturbed connection to receiver. Check bus wiring and environment.
Dominant signal level due to external
disturbance, critical bus time setting (Baud
rate) or bus length, bus error.

2TxtDiag105
10703 CAN Layer 2 error reaches warning limit

The number of send or receive errors set in the warning limit register have occurred.
Cause Remedy
10704 CAN Layer 2 switched passive

128 send or receive errors occurred. In passive mode, no more CAN messages are ack
nowledged and no error messages are sent on the bus.
Cause Remedy
10705 CAN system error

A system error of the CAN module occurred. The kind of error is further specified in ext.
diagnosis.
Cause Remedy
The control firmware could not pick the Please contact the service department.
command or state messages fast enough from
the CAN module, which resulted in a buffer
overflow and the loss of XXX messages.
The control firmware could not pick the layer2 Please contact the service department.
messages fast enough from the CAN module,
which resulted in a buffer overflow and the loss
of XXX messages.
CPU on CAN module could not read data fast Please contact the service department.
enough from CAN bus, which resulted in a loss
of messages.
CPU on CAN module could not read CAN Please contact the service department.
messages for CAL/CANopen fast enough from
the bus. In layer 2 no messages are defined for
CAL/CANopen! This error must not occur with
CAN layer 2 module.
CPU on CAN module could not send CAN Please contact the service department.
messages for CAL/CANopen fast enough. In
layer 2 no messages are defined for
CAL/CANopen! This error must not occur with
CAN layer 2 module.
Unspecified event error of the CAN module. Please contact the service department.
Default branch event error evaluation. Should
not occur.

2TxtDiag105
10706 CAN Layer 2 under warning limit

The number of send or receive errors is lower than the number set in the warning limit
register. Sending and receiving is working again.
Cause Remedy
10707 CAN Layer 2 switched active

Number of send or receive errors below 128. The CAN module is working in active mode
again. Sending and receiving is working again.
Cause Remedy
10720 No module found

Module ID could not be found or it was not possible to update the field bus firmware. An
iSH-DIO8 was configured and activated at the iSH (Enable = TRUE), but not found during
the SERCOS phase run-up.
Cause Remedy
The firmware file on the flash disk (or on the Check if the valid firmware file is available.
hard disk of the P600) does not exist or is
incorrect.
Optional module does not exist. Install module or send control/drive for
modification.
An optional module that does not exist was Check the control configuration.
entered in the control configuration.
A phys. master encoder (SinCos encoder) is Attach the incremental encoder cable to the
entered in the control configuration at the BT-4/ENC1 connector. Check encoder cable.
BT-4/ENC1, but no phys. master encoder at the Check I/O address.
connector BT-4/ENC1.
Hardware error: Module defective. Exchange module.

2TxtDiag105
10721 Module not ready

After initialization by the control, the module does not react.
Cause Remedy
Module defective. Exchange module in the control.
Watchdog monitoring of the (PROFIBUS-) Exchange module in the control.
module is activated. The module does not react
within the preset monitoring time (see
standard configuration).
FPGA could not be programmed. The module is Exchange module in the control.
not ready.
The FPGA firmware file does not match the Copy correct FPGA firmware via FTP to control
FPGA pinout. This could damage the module. flash disk and restart control.
The FPGA could not be programmed. The Copy correct FPGA firmware via FTP to control
firmware does not match the module. flash disk and restart control.
The FPGA firmware file could not be opened. Exchange flash disk.
Flash disk may be defective.
The header in the firmware file was incorrect. Copy correct FPGA firmware via FTP to control
flash disk and restart control.
The size of the FPGA file was wrong. Copy correct FPGA firmware via FTP to control
No FPGA firmware file found on the flash disk. Copy correct FPGA firmware via FTP to control
The time of the RealTimeClock of the optional This is a problem of a very early hardware
module PN-4 could not be set. Diagnosis version of the PN-4. To clear fault, the PN-4
message cannot be acknowledged. module must be exchanged. The problem does
not exist any longer for hardware code 030033
an higher. Workaround: The diagnosis message
can be made acknowledgeable via IEC function
DiagNoQuitReset().
10722 No cyclic telegrams

The exchange of cyclic data was interrupted. NOTICE: In case the connection is inter
rupted between the PROFIBUS DP slave and the PROFIBUS DP master connection, no
error is shown if the master switched off the call monitoring in the slave. This means that
the diagnosis code 722 is not triggered.
Cause Remedy
Master interrupts sending of cyclic data. Check the master.
Cable problem. Check the wiring.
Duplicate slave address in the network. Check the configuration.

2TxtDiag105
10723 No Profibus configuration data

This diagnosis message occurs only in the boot phase of the PacDrive controller or in the
bus release. No configuration file on the flash disk of the PacDrive controller was found.
A DiagExtCode may be generated.
Cause Remedy
Communication problems. Retransmit control configuration.
Duplicate slave address in the network. Check the configuration.
Hardware error: Flash disk defective. Exchange flash disk.
10724 No I/O range

See diagnosis message 204 "IEC program cannot be loaded". The field bus server(s)
found no IEC I/O range. The I/O range is made available when loading the IEC program.
Following error for diagnosis 204 "IEC program cannot be loaded".
Cause Remedy
Libraries in the project were changed or Reset the Controller (EPAS-4: Online > Reset
exchange. This program may occurred in PacDrive controller).
Controller versions smaller than V00.16.20.
A project with a different setting of Match the settings of the MaxNumOfPOUs
MaxNumOfPOUs was transmitted to EPAS-4 in against your EPAS-4 installations. Reset the
the file "EPAS-4.ini". Controller (EPAS-4: Online > Reset PacDrive
controller).
Faulty project. Retransmit the project by firstly executing in
EPAS-4 "Project > Clear all" and then "Project >
Transmit all". Then Retransmit the project to
the Controller and reset the Controller (EPAS-4:
Online > Reset PacDrive controller).
10725 Module firmware replaced

This message indicates that the firmware of a field bus module was exchanged.
Cause Remedy
10726 Module firmware invalid

This message indicates that the firmware of a field bus module is invalid.
Cause Remedy
The firmware download for a field bus module Repeat firmware download.
via the Controller was not successful.

2TxtDiag105
10730 Faulty master parameter data

The master and/or slave data of the configuration file are faulty. The error code entered
after "Err=" is equivalent to the error code of the parameter ErrorCode.
Cause Remedy
Communication problems when transmitting Retransmit the control configuration.
the control configuration from EPAS-4 to the
control.
Hardware error: Control or flash disk defective. Exchange control.
10731 Automatic bus deactivation

The Auto Clear bit in the master is set and at least one slave is not exchanging cyclic I/O
data. The error code entered after "Err=" is equivalent to the error code of the parameter
ErrorCode.
Cause Remedy
Slave was switched off. Reactivate slave.
Faulty configuration of at least one slave. Check configuration.
Wiring error: Cable problem in the bus. Check cable.
Wiring error: Faulty bus topology. Check terminals, stubs.
10732 No reply from slave

Slave with the bus address indicated after "Sl=" is not exchanging cyclic I/O data. The
error code entered after "Err=" is equivalent to the error code of the parameter Er
rorCode. If the parameter activation is set to "false", this diagnosis message is not trigge
red for V00.20.00 and higher of the Controller.
Cause Remedy
Slave was switched off. Reactivate slave.
Faulty configuration of at least one slave. Check configuration.
Wiring error: Cable problem in PROFIBUS-DP. Check cable.

2TxtDiag105
10733 Serious bus error

No further bus communication possible due to a serious bus error. CAUTION: No data
exchange with bus terminals BT-4/ENC1! Position loss of master encoder connected to
bus terminals BT-4/ENC1! Acknowledge diagnosis message only when reinitialization or
referencing of the system by the IEC program has been secured. Possibly use functions
SysReset() or PrgResetAndStart().
Cause Remedy
EMC problem. Check wiring and EMC protection.
A synchronization error occurred. The Check bridging cable between the control and
touchprobes to BT-4/DIO1 are not working. the optional module PN-4 (in the control).
A communication error occurred in PacNet. Check PacNet loop and all modules in the loop.
This can have several reasons: PacNet loop not
closed, PacNet terminal connector missing,
failure of a module connected to PacNet (no
voltage supply).
10734 Bus short circuit recognized

The number of bus short circuits given after "count=" was recognized.
Cause Remedy
Faulty slave. Check slave device.
EMC problem. Check wiring.
Wiring error: Cable defective. Check wiring.
10735 Bus telegrams ignored
Cause Remedy
Wiring error: Cable defective. Check wiring.
10736 No I/O data exchange with slave

Slave with the bus address given after "Sl=" exchanges no cyclic I/O data.
Cause Remedy
Faulty slave configuration. Check configuration by using slave
documentation.

2TxtDiag105
10737 Duplication of IEC addresses

The IEC start addresses for the input or output range were allocated twice.
Cause Remedy
Faulty slave configuration. Check configuration. Adjust addresses manually
or select "Addresses automatic" in the
properties dialog of the Profibus master object
in the control configuration.
10738 Conf. IO data > admissible IO range

IO data size exceeded.
Cause Remedy
Faulty slave configuration. Reduce IO data of the slave.
10739 Duplicate Profibus addresses

The Profibus address Adr=xxx was allocated twice within the master configuration.
Cause Remedy
Faulty configuration of the slave. Check configuration. Adjust addresses manually
or select "Addresses automatic" in the
properties dialog of the Profibus master object
in the control configuration.
10750 CanOpen node does not exist

The bus is checked for existing nodes using the default Sdo index 0x1000. This diagnosis
message is triggered if the configuration contains nodes that were not recognized.
Cause Remedy
Node not switched on or not yet ready at the Check configuration.
time of checking; node permits no Sdo access
to Index 0x1000; wrong or faulty electrical
connection; node addresses set incorrectly.
Electrical connection wrong or defective. Check wiring.
10751 CanOpen node not configured

The bus is checked for existing nodes using the default Sdo index 0x1000. This diagnosis
message is triggered if the configuration contains nodes that were not recognized.
Cause Remedy
Node not configured. Switch off node or configure node.

2TxtDiag105
10752 No CanOpen EDS file

No CANopen description file COPMAX4.EDS found on the flash disk of the control.
Cause Remedy
Description file was not transmitted to the Description file transmitted via FTP to the
control or was deleted. control.
10753 Init of CanOpen module failed

An error occurred during the initialization phase of the CANopenmodule.
Cause Remedy
10754 CanOpen error message

A CANopen node sent an error message to the bus.
Cause Remedy
Node reports an error. See description of triggering node.
10755 CanOpen node guarding error

The CANopen master can monitor the individual CANopen slave nodes. The state of the
node is checked in a configurable interval (Guard Time). If no reply is received within a
configured time (Guard Time * Life Time Factor), the diagnosis message is triggered. Af
ter receipt of the first monitoring request, the CANopen slave also checks the time bet
ween the monitoring requests (Guard Time * Life Time Factor). In this case no ext. dia
gnosis is shown.
Cause Remedy
CANopen node did not process reset or no Check wiring.
configuration was sent. Electrical bus
connection distorted or faulty.
10756 CanOpen DPM access time overflow

At least one input application object could not be read.
Cause Remedy
Software error; module overloaded. Please contact the service department.

2TxtDiag105
10757 CanOpen config error

An error occurred when configuring the individual CANopen slaves.
Cause Remedy
CANopen node cannot be addressed via Sdo Check electrical connection. Please contact the
access (node e.g. still in boot phase); node service department.
does not exist; electrical bus connection
distorted or interrupted; mapping of
application object not allowed (application
object does not exist or cannot be mapped);
writing access to index not allowed for this
node. Electrical bus connection distorted or
faulty.
10758 Size of application object not supported

The CANopen master makes available the described application objects. This diagnosis
message is triggered if application objects with an unavailable size are configured in the
configuration of a CANopen node.
Cause Remedy
Configuration error. Check configuration.
10759 Max. no. of application objects limit reached

The CANopen master provides the number of application objects described in the opera
ting manual. This diagnosis message triggered if more application objects than available
are configured in the CANopen master configuration.
Cause Remedy
Configuration error. Check configuration.
10770 Overflow of optional module ranges

An overlapping of the IO ranges of the optional modules was recognized. The number
code of the type key of the overlapping modules is shown in DiagExtCode.
Cause Remedy
The IO ranges of the optional modules were not Check setting of IO ranges against the
set duly in the control. respective operating manuals of the optional
modules.

2TxtDiag105
10771 Duplicate IRQ config. of optional modules

Duplicate interrupt use by optional modules detected. The interrupt that is used twice is
shown in DiagExtCode.
Cause Remedy
The interrupts of the optional modules were Check setting of interrupts against the
not set duly in the control. respective operating manuals of the optional
modules.
10780 Frequency > 1 MHz

Output velocity in increments was too high. CAUTION: Velocity in increments too high.
Position loss at incremental encoder output!
Cause Remedy
Velocity of encoder to be simulated is too high. Reduce encoder velocity.
The Resolution and/or FeedConstant Check parameters.
parameters are not entered correctly.
Connector of incremental encoder was Switch off device. Connect or disconnect
connected or unconnected while device was connector. Switch on device. device is
switched on (control voltage on!). switched on. Modifications at the wiring can
cause equipment damage. Switch off voltage
supply of the equipment before connectors are
connected or disconnected. CAUTION!
10781 No connection with encoder

The bridge in the connector of the encoder cable on the control is not recognized. This
monitoring is active for the MAx-4 optional module for the connection of an incremental
encoder . The monitoring of the SinCos encoder is active at the controllers Cx00 and
P600.
Cause Remedy
Wiring error: Encoder cable disconnected from Connect encoder cable.
control.
Wiring error: Encoder cable defective. Check encoder cable and exchange, if
necessary.

2TxtDiag105
10782 Track error

A hardware error has occurred at the incremental encoder input (BT-4/ENC1 or incre
mental encoder module INC-4). CAUTION: Hardware encoder error! Position loss of
master encoder! Acknowledge diagnosis message only after reinitialization or referencing
of the system is secured by the IEC program. Possibly use functions SysReset() or Pr
gResetAndStart().
Cause Remedy
Wiring error: Encoder cable at the encoder or Check encoder cable and exchange, if
at the encoder input disconnected or defective. necessary. Check mass connection (shield).
Encoder or encoder supply or encoder By default, monitoring can be switched off
stimulation not yet ready for operation. using the
parameter CheckOff. When the encoder or
encoder
simulation is ready, the monitoring can be
activated in the
IEC program.
Encoder defective. Exchange encoder.
10785 Hardware defective

There is a hardware defect.
Cause Remedy
Ext. diagnosis = PIIX Error. Exchange control.
Ext. diagnosis = EEPROM damag. Exchange optional module PN-4.
Ext. diagnosis = EEPROM S xxxx. Exchange optional module PN-4.
Ext. diagnosis = RTC is damaged. The time of Exchange PN-4 module.
the RealTimeClock of the optional module PN-4
could not be set. This is a problem of a very
early hardware version of the PN-4. The
problem is cleared for hardware for hardware
code 030033 and higher.
Ext. diagnosis = Ref PowerFail. Check the supply voltage.
10786 Asynchronous to SERCOS-Bus

TODO
Cause Remedy
- -
10787 Configuration error

A configuration error has occurred.
Cause Remedy
A non-configured module at the PacNet was Check the configuration of the module in the
found. The module cannot be used. control configuration.

2TxtDiag105
No module at the PacNet was found. Switch on control voltage at the module.
The module with the bus address xx repeatedly Check the module address on the module.
give no response. This may be caused by a Check the module address in the control
power failure or a defective module. The configuration. Check the power supply of the
module cannot be used. module. Maybe exchange the module.
The supply voltage for outputs 0-7 of the Check supply voltage of the outputs. The
BT-4/DIO1 or iSH-DIO8 is not available or too message can be disabled with the
low. These outputs cannot be used. The DiagPF0_7Enable parameter.
diagnosis message is only triggered by the
iSH-DIO8 in case of PowerSupply = "Extern /
TRUE".
The mains voltage for outputs 0-7 of the Check power supply of the outputs. The
BT-4/DIO1 missing or too low. Those outputs message can be switch off via the parameter
cannot be used. DiagPF8_15Enable.
No "c2_xpxx.bin" file was found on the flash of Install the valid FPGA firmware file
the C200. xpxx is in accordance with the FPGA "c2_xpxx.bin" with the matching pinout to the
firmware version. The Controller C200 cannot flash disk of the C200. During installation of a
be used. The pinout of the Controller C200 firmware version to the Controller C200, the
must match the pinout of the FPGA firmware. firmware assistant automatically copies the
The pinout of the FPGA firmware is the number firmware file "c2_xpxx.bin" to the flash of the
represented by p in the xpxx of the FPGA C200.
firmware version. The pinout of the control can
be read in the ControllerType1 parameter and
is indicated by P in FPGA=pyxxxx.
No file "c2_xpxx.bin" was found on the flash of Attach the valid FPGA firmware file
the C200. xpxx is in accordance with the FPGA "c2_xpxx.bin" with the appropriate pinout to
firmware version. The Controller C200 cannot the flash disk of the C200. During attachment
be used. The pinout of the Controller C200 of a firmware version to the Controller C200,
must match the pinout of the FPGA firmware. the firmware assistant copies automatically the
The pinout of the FPGA firmware corresponds firmware file "c2_xpxx.bin" to the flash of the
to the number at position p in xpxx of the FPGA C200.
firmware version. The pinout of the control can
be read off in the parameter ControllerType1
under FPGA=pyxxxx at position p.
The current firmware of the controller (C400, Attach the appropriate firmware version with
C600 or P600) does not match the hardware of the firmware assistant to the Controller.
the Controller.
A FPGA version on the Controller (C200, C400, Install a valid FPGA firmware file to the
C600 or P600) was found that is not marked as Controller (C200, C400 and C600 -> flash disk;
beta test version. The pinout of the FPGA P600 -> hard disk).
firmware corresponds to the number at
position p in zpxx of the FPGA firmware
version. The pinout of the control can be read
in the ControllerType1 parameter for C200 by
FPGA=pyzpxx) and is indicated by the p. The
highest bit at position z marks a beta test
version.
The PROFIBUS address is larger than the max. Check the PROFIBUS configuration.
permitted bus address.
The sum of the measuring inputs and puls Check the configuration (parameter IO0_Mode
counters are higher than two for the iSH-DIO8. ... IO7_Mode).

2TxtDiag105
10788 Connection error

There is a connection error.
Cause Remedy
There is a short circuit or an overload at the Check the connections of the output.
output in question. The diagnosis message is
only triggered by the SH-DIO8 only for
PowerSupply = "Intern / FALSE".
The output has not connection or is used very Check the connections of the output. It may be
little. sensible to switch off this diagnosis message.
The external power supply of the digital Check the power supply of the digital outputs.
outputs was not connected. The supply of the Check the DiagMask parameter.
digital outputs is checked, if at least one bit is
set to 1 in the DiagMask parameter of the
output group object.
The power supply of the encoder is too low. Check the power supply of the encoder. Check
Short circuit of the power supply (pin 5 and 9) the encoder cable.
to the connected encoder or defective bus
terminal BT4/ENC1. Parameter
EncPowerSupply = "Extern / TRUE": There is no
or not enough power at the X5 plug connector
or there is a short circuit at the power supply
(pin 5 and 9) of the connected encoder.
A SinCos encoder (physical encoder) was Connect the SinCos encoder cable to the
entered in the control configuration, but no BT-4/ENC1 X2 or X3 connector. Check encoder
SinCos encoder is recognized at the X2 or X3 cable.
connector of the BT-4/ENC1.
The connected encoder type is not supported Check the assignment of encoder connectors.
by the system.
10789 Simple bus error

A simple bus error occurred.
Cause Remedy
The module with bus address xx did not reply Check the wiring of the module.
once. Transmission is disturbed.
PacNet-Warning. An RX clock is missing. Check the wiring of the module.

2TxtDiag105
10790 Module error

A module error occurred.
Cause Remedy
An error in the communication between Please contact the service department.
iSH-DIO8 and iSH occurred.
An error during the synchronization with the Please contact the service department.
SERCOS cycle occurred.
The iSH , at which the iSH-DIO8 was Check control configuration.
configured, is deactivated (RealTimeBusAdr =
200 ... 299) and the iSHDIO8 is activated
(Enable = TRUE).
Internal error. Please contact the service department.
10800 Insufficient memory

As soon as the free main memory exceeds drops below 512000 bytes, the diagnosis mes
sage 800 is generated. The problem can be narrowed down further by using the DiagEx
tCode parameter in the control configuration or the message logger.
Cause Remedy
Insufficient memory (RAM) for the project Reduce control configuration, reduce
(DiagExtCode = free<512000). RamDiskSize,
reduce number of tasks, maybe use control
with
bigger RAM.
10801 Error reading FAT
Cause Remedy
There was a fault in the file system of the flash Repair file system. Replace flash disk. Please
disk. contact the service department.
10802 Error writing FAT
Cause Remedy
An error in the file system of the flash disk Repair file system. Replace flash disk. Please
occurred. contact the service department.

2TxtDiag105
10803 Inconsistency of FATs
Cause Remedy
10804 Corrupt cluster detected
Cause Remedy
10805 Corrupt file name detected
Cause Remedy
10806 Corrupt file size detected
Cause Remedy
10807 Multiple cluster/block detected
Cause Remedy

2TxtDiag105
10808 Corrupt directory name detected
Cause Remedy
10809 Circularly linked clusters/blocks detected
Cause Remedy
10810 Error reading directory entry
Cause Remedy
10811 Error writing directory entry
Cause Remedy
10812 Lost cluster/block found
Cause Remedy

2TxtDiag105
10813 Device <ide0:> not found
Cause Remedy
10814 Initialization of <ide0:> failed
Cause Remedy
10815 Error using function with <ide0:>
Cause Remedy
10816 Bootrom.sys
Cause Remedy
10817 No device name
Cause Remedy

2TxtDiag105
10818 File not found
Cause Remedy
10819 File open error
Cause Remedy
10820 File read error
Cause Remedy
10821 File not continuously saved
Cause Remedy
10822 Cluster read error
Cause Remedy

2TxtDiag105
10823 Contents of files different
Cause Remedy
10824 No file name
Cause Remedy
10825 Invalid directory size
Cause Remedy
10826 Error during PIC-FW update

An error occurred during a firmware exchange for the PIC Controller (on C400, C600 or
P600). The PacDrive controller is in bootloader mode and is attempting to exchange the
firmware again. The firmware (such as file "c6p_0511.bin") is on the flash disk (C400 and
C600) or the hard disk (P600). When the firmware has been exchanged, the controller
will be reset (Reset). The PacDrive controller P600 has not automatic reset. A note ap
pears on the display. After the real-time system successfully starts up, the firmware file is
deleted automatically.
Cause Remedy
The PacDrive controller attempts to exchange If this attempt also fails, contact the service
the firmware again. department.
Transfer the firmware file to the flash disk If this attempt also fails, contact the service
(C400 and C600) or to the hard disk (P600). department.
Transfer the correct firmware file to the flash If this attempt also fails, contact the service
disk (C400 and C600) or the hard disk (P600). department.
Checking hardware dependencies. The Use the PIC update file that matches the device
message appears if PIC update files are found (hardware).
that have an incorrect hardware code. The
index outputs the required HW index.

2TxtDiag105
10827 Power-Off due to hardware monitoring

The hardware provides an internal "error logger" that logs all the causes for error-
dependent control deactivations. The next time the control is started up the error is
analyzed and the cause of the error can be output in the message logger. In addition, a
more specific message is displayed (055 "Debug message cause by hardware monitor"),
that can be enabled by the MsgFilter parameter and through the EPAS-4 message logger.
This message is intended to be a debug message and outputs the exact cause of the de
activation.
Cause Remedy
The DiagExtCode defines the error further (high Please contact the service department.
or low voltage, high or low temperature, fan
error, temperature sensor error).
10828 Library active

TODO
Cause Remedy
- -
10900 Software error (suspend Task)
Cause Remedy
During operation of the PacDrive system, this Please contact the service department.
error should not occur.
10901 Software error (invalid opcode)
Cause Remedy

2TxtDiag105
10902 Software error (page fault)
Cause Remedy
An old firmware < V00.10.00 was loaded on a Retransmit the project from EPAS-4.
PacDrive controller and the project on the
PacDrive controller flash disk was created for a
firmware >= 00.10.00. The error occurs when
booting and MAX4 is entered at Object in the
message logger.
IECPRG is entered at Object in the message Find faulty point in the program and correct
logger. The IEC task stated at Instance in the application program.
message logger recognized a serious error.
Possible errors are e.g.
disregard of array limits, incorrect use of
pointers or the address operator (ADR).
10903 Software error (class 2)
Cause Remedy
During operation of the PacDrive system this Please contact the service department.
10904 Software error (class 1)
Cause Remedy
During operation of the PacDrive system this Please contact the service department.
11000 Reference run: initiator not found

During the reference run of the servo axis no initiator was found.
Cause Remedy
Drive is decoupled or dismantled from the Mount and adjust drive and motor.
motor.
Initiator or wiring defective or missing. Check initiator and wiring and replace, if
necessary. Repeat reference run.
Travel limit for the reference run is too short to Check defaults in the operation. Repeat
find initiator. reference run.

2TxtDiag105
11001 Reference run: no torque found

During the reference run of the servo axis no resistance as reference point was found.
Cause Remedy
Drive is decoupled or dismounted from the Mount and adjust drive and motor.
motor.
The mechanic limit for the reference run (e.g. Check and repair limit. Repeat reference run.
stop or screw head) is missing.
The travel limit for the reference run is too Check defaults in the operation. Repeat
short to run to the limit. reference run.
11002 Warmstart: outside window

A warmstart is only possible when the drive position is inside a window around the
target position. The current actual position is outside the window, however, and
collisions with other drives/components can result from this.
Cause Remedy
The drive was adjusted manually. Manually readjust the drive back to the valid
section and repeat the reference run. If the
reference run fails again, reset the Controller
and thus force a reference run.
11011 Reference run: initiator not found

During the reference run of the servo axis no initiator was found.
Cause Remedy
Drive is decoupled or dismounted from the Mount and adjust drive and motor.
motor.
Initiator or wiring is defective or missing. Check initiator and wiring and replace, if
necessary. Repeat reference run.
The travel limit for the reference run is too Check defaults in the operation. Repeat
short to run to the limit. reference run.
11019 Cam definition higher than period

A cam must always defined for a period (normally 360°). But the cam definition of the
drive is higher than the period and therefore invalid.
Cause Remedy
Input error during input of cam definition. Check and correct defaults of cam definition.

2TxtDiag105
11020 Movement profile missing

A movement profile shall be loaded from the flash or RAM disk. But the file with the cam
data is missing.
Cause Remedy
Movement profile is not saved on flash disk. Please contact the service department.
Program error, movement profile was not Please contact the service department.
generated or not deposited on RAM disk.
11021 Error monitor mains contactor

The mains contactor that activates the power supply of the drive was not energized.
Cause Remedy
Mains contactor defective. Exchange mains contactor.
11022 Error monitor "Inverter Enable"

The "Inverter Enable" inputs of the servo controller are not activated even though the
Controller receives a release signal.
Cause Remedy
Activation "Inverter Enable" defective. Check wiring and activation of the "Inverter
Enable" inputs.
"Inverter Enable" relays defective. Exchange control device.
Control device defective. Exchange control device.
11023 Error monitor Hardware Enable

The Hardware Enable inputs are not activated even though the Controller receives a re
lease signal.
Cause Remedy
Activation Hardware Enable defective. Check wiring and activation of the Hardware
Enable inputs.
Hardware Enable relay defective. Exchange control device.

2TxtDiag105
11024 DC voltage too low

The DC voltage is too low.
Cause Remedy
The mains voltage is too low. Check mains voltage (see Technical Data).
Mains contactor is not activated. Exchange mains contactor.
Parallel connected DC links, error in one servo Find servo amplifier with error and clear error.
amplifier.
Software error, drive was released before DC Please contact the service department.
voltage could be built up.
11025 Controller not ready

The Controller is not ready but is to be released anyway.
Cause Remedy
Software error, the drive was released although Please contact the service department.
the Controller was not ready.
15000 Warmstart not finished

The warmstart of the drive was not completed yet.
Cause Remedy

2TxtDiag105
Notes

S_Notiz_2s
Notes
6.

S_Notiz_2s
Change of Size / Product
7
Chapter 7: Change of Size / Product
7 | Change of Size / Product 1 / 22
Contents
Preparations for a size change or product change 3
Measures prior to switching back On following a size 3
change or product change
Size changing 4
Introduction 4
Sequence 5
Auger filler size change 6

Remove the filling auger and connection 6
Installing the filling auger and connection 7
Gate closure basic setting 8
Size setting table - auger filler 13
Size data sheet with option auger filler FVS 17
Production data sheet 18
Operation data sheet with option filler 20
Notes 21

T
2 / 22 7 | Change of Size / Product

S_Leer
Safety instructions
INFORMATION
Preparations for a size change or product change

u Cordon off a wide area around the working area.
u Appoint a responsible person who will operate the machine from a location at which the
machine can be shut down at any time
Measures prior to switching back On following a size change or product change

u After a changeover, machines with size-dependent, isolating guard devices must not be put
back into operation until the guard devices have been adapted to the new size.

S_07_Sicherheit (7)
Size changing
Introduction
INFORMATION
Before beginning the size change / product change ensure that all size
parts pertaining to the size sets are clean and in good condition.
WARNING
Danger due to crushing, shearing, cutting and impact.

u Before working on the machine press the EMERGENCY STOP

button.

099440 (2)
Size changing
Sequence
INFORMATION
The settings of the machine have been carried out with great care and
in compliance with the contractual conditions.
Preparing for a size change
Procedure Comment
1. Remove the product completely from the machine.

2. Clean the entire machine.
3. Prepare the tools and size set.
Before beginning the size change ensure that the size sets
are clean and in good condition.

099526 (1)
Auger filler size change
Remove the filling auger and connection
WARNING

machine.
All work on the machine during operation may have fatal
consequences, peril of loss of life.
u For cleaning the machine must be at a complete standstill.
1. Run the auger filler empty.

2. Switch Off the control unit for auger fillers.
3. Switch Off the machine.
4. Unscrew the four clamping screws, e.g. (1)

on the agitator hopper (2).
5. Open the agitator hopper shell.
6. Loosen the four screws on the clamping 3

piece (3) and push the clamping piece up.
7. Separate the filling auger (4) and shaft (5)
in the agitator hopper.
8. Remove the filling auger and connection
(6).

101195 (1)
Installing the filling auger and connection
1. Clean the connection between filler 4

auger (1) and shaft (2) from remnants.
2. Insert the filler auger (1) into the filling
connection (5).
3. Insert the filling connection (5) into the
agitator hopper.
3
Take heed of the fixing pins.
4. Hook the filling auger (1) with the fixing
pin (2) into the shaft (3) and slide the
clamping piece (4) over it.
2 1
Turn the butt of the clamping piece relative
to the butt of the two shaft ends through
90. 5
5. Tighten the four screws on the clamping
piece.
6. Close the agitator hopper shell (6) and

tighten the clamping screws (7).
Avoid torsion.

101196 (1)
Gate closure basic setting
1
2
Basic setting
1. Retract the cylinder (2) fully.
2. Screw the joint head (1) into the cylinder (2) until the lever (3) no longer moves when the
hinge joint (4) is moved within the slot (5).
Stroke setting
The highest position for the lever is when the cylinder (2) is retracted and the lowest position
when the cylinder (2) is extended.
1. The stroke can be modified by shifting the hinge (4) in the slot (5). After adjusting the
hinge (4) tighten it again.

034900 (4.2)L
Setting the gate (open)

2
For example, after a size changeover or removal
of the size tube.
The cylinder of the closure drive must be
pressureless.
1. Retract the pressureless cylinder fully.
2. Loosen the nuts (1) and (2).
3
3. Slacken nuts (3).
4. Screw the lift rods (4) fully into the 4
hinge (7).
5. Tighten the nuts (1) slightly.
6. With the nuts (3) adjust the lift rods (4)
until the two gates (5) are externally flush
1 6
with the size tube (6).
7. Tighten the nuts (2) and (3).
8. Relieve the lift rods (4).
7
9. Tighten nuts (1).

060935 (3.2)L
Setting the gate (closed)

Extend the pressureless cylinder (1) fully.
1. Loosen the nuts (2) on the hinge.
2. Adjust the lever (3) and hinge (4) so that
both gates (5) are positioned centrically
under the filling tube and a gap (x) of 0.5 to
0.7 mm is created.
3. Tighten nuts (2).
4. Check the gap (x).
5
X

060935 (3.2)L
Check the gate for smooth operation

1. Open both gates (1) fully by hand.
2. Release both gates (1).
The closure must close of its own accord.
If not:
3. Remove the nuts (2) to eliminate the
tension.
4. Retighten the nuts (2).
Adjusting the lift rod guides

1. Align the two lift rod guides (3) roughly
with the center of the lift rods. 3
2. Tighten the tensioning strap (4) on the size
tube.
3. Check for smooth operation again.

060935 (3.2)L
1
2
Adjusting the proximity sensor

1. Adjust the proximity sensor (1) so that the LED lights up when the gate plates (2) are roughly
half open.

034901 (4.2)L
Size setting table - auger filler
Date 01.02.2012
Type of machine: FVS 3201

Customer PT Eastern Pearl Flour Mills
Order No. 717078MS3822W
Size number
Memory location 500 g 1000 g
Product designation Flour Flour
Original product yes yes
Power (Cycles / min.) 65 50
Weight 500 g 1000 g
Volume with 500g 940 cm³ 940 cm³
Filler configuration
Auger dimensions Ø56x65St. Ø56x65St.
8108342929 8108342929
Retainer wire on auger no no
Spiral, welded on yes yes
Connection- 59 mm 59 mm 8108341137
Nozzle- 59 mm 59 mm 8108341922
Add. Spiral / Blade F 35X55 r65 F 35X55 r65
No. of agitators, bottom / top 2/1 2/1
Pressing disk- 25 mm 25 mm
Distance sleeve height M6 M6
Filler data
Fill quantity in PF max. weight [g] - -
Calibration factor(s) - -
Range 1, mainfiller (MF) + postfiller (PF)
Acceleration/braking [ms] 50/50 50/50
Auger speed [revs/min] 1700 1700
Calibration revs. [xx,xx] 6,1 12,6
Calibration weight [g] 500,0 1000,0
Calib. factor (unregulated) [revs/g] 0,012200 0,012600
Range 2, only postfiller
Auger speed [revs/min] - -
Calibration revs. [xx,xx] - -
Calibration weight [g] - -
Calib. factor (unregulated) [revs/g] - -
Range 3, only postfiller
Auger speed [revs/min] - -
Calibration revs. [xx,xx] - -
Calibration weight [g] - -
Calib. factor (unregulated) [revs/g] - -

Formateinstelltabelle_FVS_717078

Size number
Agitator
Speed [%] 60 60
Agitator mode free free
Slow-to-stop time [ms] 1000 1000
Feed auger speed [%] 40 70
Feed auger free free
Feed auger speed regulation blocked blocked
Reaction time sensor [ms] 500 500
Dosing time max. [ms] 458 620
Dosing time (required) [%] [ms] 272 500
Power uptake (servo) [%] 1,8 V/50% 1,3 V/40%
Product level in duct
Cap. initiator (from bottom) [mm] - -
Level sensor with vibrating rod max. 10 mm
above
agitator
Parameter, servo motor
Y5, foreign mass [%] 80 80
Y6, Positioning accuracy [%] - -
Closure data
Closure type Pusher Pusher
closure closure
Closure earlier closing [ms] 30 30
Distance [º]
Enabling dosing auger [º]
Rotation direction (left/right) leftright leftright
Weight accuracy
Setpoint S≤2,8 S≤4,0
Actual - -
Output
Setpoint 65/min 50/min
Actual - -

Formateinstelltabelle_FVS_717078
Size setting table - auger filler
Date

Size number
Memory location
Product designation
Original product
Power (Cycles / min.)
Weight
Volume with 500g
Filler configuration
Auger dimensions
Retainer wire on auger
Spiral, welded on
Connection-
Nozzle-
Add. Spiral / Blade
No. of agitators, bottom / top
Pressing disk-
Distance sleeve height
Filler data
Fill quantity in PF max. weight [g]
Calibration factor(s)
Range 1, mainfiller (MF) + postfiller (PF)
Acceleration/braking [ms]
Auger speed [revs/min]
Calibration revs. [xx,xx]
Calibration weight [g]
Calib. factor (unregulated) [revs/g]

Formateinstelltabelle_FVS3201

Size number
Agitator
Speed [%]
Agitator mode
Slow-to-stop time [ms]
Feed auger speed [%]
Feed auger
Feed auger speed regulation
Reaction time sensor [ms]
Dosing time max. [ms]
Dosing time (required) [%] [ms]
Power uptake (servo) [%]
Parameter, servo motor
Y5, foreign mass [%]
Y6, Positioning accuracy [%]
Closure data
Closure type
Closure earlier closing [ms]
Distance [º]
Enabling dosing auger [º]
Rotation direction (left/right)
Weight accuracy
Setpoint
Actual
Output
Setpoint
Actual

Formateinstelltabelle_FVS3201
Size data sheet with option auger filler FVS
Master copy - Please make a copy prior to filling out.

Order/machine no.
Size name (30 digit, alphanumeric)
Designation Input/input value Unit/text

Checkweigher
Classification per Default FPR
Package length mm in direction of travel
Output Packages/minute
Nominal weight grams
Tare weight grams
Overweight limit grams
Weight limit TO1/G3 grams
Underweight limit grams
Weight limit TU1/G2 grams
Operating mode rejector 1 default text
Operating mode rejector 2 default text
Auger filler FVS
Dosing weight grams
Filling auger r.p.m. 1/min
Agitator OnOff
Agitator r.p.m. %
Agitator slow‐down‐to‐stop‐time ms
Cross‐feed auger OnOff
Cross‐feed auger regulator OnOff
Cross‐feed auger r.p.m. %
Calibration revolutions set value rotations
Calibration weight grams
Mode during start with calibration weight

with last regulating factor
Filler control (option)
Control On Off
Overfill grams
Min. regulator step grams
Number of packages for data logging (sampling) units
Number of packages between filling unit and KWE (blocked cycles) units
Startup operation according to time s
Startup interlock units
Number of packages per multi‐unit pack (option) units

103233 (2)
Production data sheet
Order/machine no.

Zero point Automatic zero point On Off
Machine stop in case On Off
of zero point failure
Maximally admissible grams
zero point difference
Maximum zero point grams
deviation
Number of zero point amount
faults

Ejector control Ejector no.
Distance sensor ejector mm
Dead time ejector ms
Number for stop after (max. 9999): amount
serial fault
Push time of ejector ms
Ejector operating Eject packages On Off no.
modes: (underweight/overweight/
faults)
Ejector overweights On Off
Ejector underweights On Off
Ejector switched off On Off
Eject good packages On Off

103235 (1)
Production data sheet
Order/machine no.

Sampling Manual sampling amount
Cyclical sampling amount
u Break unit setting amount
u Break time setting minutes

Belt inputs Release On Off
slow‐down-to‐stop‐time
Slow‐down-to‐stop‐time seconds

Filler control Startup operation seconds
Startup interlock amount

Network connection IP address -
Subnet mask -
Default gateway -
DNS -

103235 (1)
Operation data sheet with option filler
Order/machine no.

Basic data Ramp time ms
acceleration
Ramp time brakes ms
Mass load to mass %
motor
Please do not
modify the
ex‐works values
Positioning accuracy %
Please do not
modify the
ex‐works values
Programmed cams of %
servo motors

Filler setting: Response time fill level (normal 200): ms
Cross‐feed auger sensor
Nominal height fill %
level

Filler setting: Closure Closure pre‐switch‐off ms
time

103236 (1)
Notes

S_Notiz_2s
Notes
2.

S_Notiz_2s
Maintenance
8
Chapter 8: Maintenance
8 | Maintenance 1 / 26
Contents
Measures prior to maintenance work 3
Procedures prior to renewed Power On following 3
maintenance
work
Information on maintenance 4
Lubrication 4
Information on cleaning 5
Work instructions 5
Composition of the cleansers and disinfectants 5
Cleaning plan checkweigher 6
Cleaning plan auger filler 7
Information on cleaning 8
Schedule for checkweigher cleaning 8
Clean filter housing and filter cartridge 9
Overview ‐ cleaning auger filler 10
Cleaning crossfeed auger 11
Clean the dust filter 12
Clean sensors 13
Clean the agitator, filling auger and filling pipe connection 14
Clean the drive chain of the agitator drive 17
Electrical devices 18
Maintenance plan checkweigher 19
Maintenance plan auger filler 20
Information for maintenance 21

Adjust/replace belts 21
Drain water from the filter housing 23
Tension the drive chain of the agitator drive 24
Lubricant change at the drive motor 25
Notes 26

T
2 / 26 8 | Maintenance

S_Leer
Safety instructions
INFORMATION
Measures prior to maintenance work

u Switch Off the machine in accordance with these operating instructions and secure it against
being unexpectedly switched back On.
u Lock the main command devices and withdraw the key and/or attach a warning sign to the
main switch.
u Cordon off a large area around the repair zone.
Procedures prior to renewed Power On following maintenance

work
u Check the safety devices.

S_08_Sicherheit (7)
Information on maintenance
INFORMATION
Lack of cleaning and inadequate maintenance and upkeep will cut

short the service life of the machine.
Service the machine regularly and in accordance with the instructions,
make sure you keep the workplace clean.
u Comply with setting, maintenance and servicing jobs and intervals that are described in the
operating instructions including the specifications on the replacement of parts.
u Workshop equipment appropriate for the work is absolutely necessary for the performance of
maintenance measures.
u Clean the machine, in particular the connections and screwed fittings prior to starting
maintenance procedures.
u Do not use any corrosive cleaning agents.
Lubrication
INFORMATION
Use only lubricants approved for the appropriate sector (e.g.

pharmaceutical or foodstuffs sector).
u Observe manufacturer instructions for lubrication (Chapter 10) for the sub-supplied parts.
u A warranty for high aging stability must be provided for all lubricants.
Ensure that the lubricant type and quality are adhered to when topping up lubricants.
u Use lubricant types in compliance with the maintenance or lubrication plan. If using different
lubricants please reconcile this with the supplier of the lubricant.
Hydraulic-type lubricating nipples

Lubricate all lubricating nipples as laid down in the maintenance and lubrication plans.
u The lubricating nipples must be cleaned prior to lubrication with a grease gun.
u Normally, lubricating with a grease gun is sufficient. If a high-pressure press is used, the
pressure may not exceed 1000kPa (10bar / 145psi).

S_08_Hinweise (7.1)
Information on cleaning
WARNING
Moving masses and revolving or hot components inside the machine.

There exists the risk of serious bodily injury during work at the
running machine!

Work instructions
u Perform cleaning and any disinfection of the machine in conformity with the works cleaning
schedule.
u For cleaning use only suction air (no blowing air).
If blowing air is used there is a danger that dirt particles will penetrate sensitive components
such as bearings, bushes or electrical components and cause damage.
u Do not clean the machine with water!
u After the cleaning process examine all piping and hoses for leaks, loose connections, abrasion
points and damage! Immediately eliminate any defects that are ascertained.
u Do not use solvents!
u For normal contamination use commonly available non-combustible cleaning agents.
u In case the machine is heavily soiled (such as due to very sticky media) the components must
be disassembled and cleaned. After cleaning, dry the components completely, then lubricate
and refit.
Composition of the cleansers and disinfectants
CAUTION
Wrong cleansers and disinfectants may constitute a health hazard

and lead to damage of the machine.
u Check whether the cleansers and disinfectants may be used

without risk to personnel and machine.
Heed the manufacturer's information!
u If in doubt, contact the Bosch Service Department, stating the
name/brand of the agent as well as its chemical composition.
New agents should be tested prior to use.

S_08_Trockenreinigung (7)
717079MS5025W | Version 1.0 | en
107833 (1)
Cleaning plan checkweigher
6 / 26
Item Maintenance point Job description Description Service interval *) Personnel Info page
10 000
5 000
1 000
2 000
160
500
40
8
Cleaning
1 Weighing work area Removing packaging material Use suction air! ¬ Page 8
residues
1.1 Cover Cleaning Do not use alcohol or aggressive ¬

cleaning agents!
Clean with ”Antistatic plastic
cleaner and polish”.
2 Sensors Cleaning With fine brush or soft lint‐free ¬ Page 8
cloth
Pneumatic system
3 Filter housing and filter cartridge Cleaning Housing must be Page 9
unpressurized
before opening!
Cleanse housing and filter
Overall machine
4 Rollers Cleaning If necessary ¬ Page 8
5 Belts Cleaning If necessary ¬ Page 8
*) in operating hours = cleaning ¬ = Operating staff

= checking / replacing = Skilled staff
= lubricating
8 | Maintenance
Cleaning plan auger filler
8 | Maintenance
Item Maintenance point Job description Description Service interval*) Personnel Info page
10 000
5 000
1 000
2 000
160
500
40
8
Cleaning
1 Overall machine Remove filling material residues Vacuum air ¬ Page 10
2 Crossfeed scroll Cleaning ¬ Page 11
3 Dust filter Cleaning ¬ Page 12
4 Sensor Clean active surfaces With soft lint‐free cloth Page 13
5 Agitator hopper Cleaning ¬ Page 14
6 Agitator, filling auger and filling
pipe connection
Electrical devices
7 Motor frequency converter Clean dirty cooling ribs Chapter 2
Dust explosion! page 18

= lubricating
717079MS5025W | Version 1.0 | en
108594 (1)
7 / 26
Schedule for checkweigher cleaning
INFORMATION
Use only lint-free cloth and solvent-free cleansers. Use suction air in
case of dust deposits!
Clean lenses and mirror of the light-barrier (7) with a fine brush or
lint-free cloth.
3 1 2 5 4
The position numbers refer to the cleaning plan.

107133 (1)
WARNING
The pneumatic systems are pressurized.

If incorrectly disassembled the systems can explode and cause
serious accidents.
u Depressurize the pneumatic system (see package maker).
Clean filter housing and filter cartridge
INFORMATION
Use water, soap suds or similar neutral cleansers for cleaning plastic
containers and caps.
1. Unscrew the filter housing (1).

2. Rinse filter housing with water.
3. Unscrew the filter cartridge (2).
4. Rinse filter cartridge.
5. Blow-dry filter cartridge from the inside to the
outside. 2 1
6. Mount the filter cartridge (2) and the filter

housing (1).

107836 (1)
Overview ‐ cleaning auger filler
INFORMATION
Neutral cleaning agents and disinfectants, e.g. “P 3 - Sterile” from the

company Henkel are allowed.
Acids and lyes are not allowed!
Clean all parts in contact with product with a

u vacuum cleaner
u cloth
u brush or paintbrush.
Wet cleaning is not recommended because moisture makes dry products biologically unstable.
If wet cleaning is performed despite this, dry the parts completely.
2 1
Item Designation Item Designation
1 Crossfeed scroll 5 Agitator

2 Dust filter 6 Dosing scroll
3 Sensor 7 Dosing nozzle
4 Filling hopper

101198 (1)
Cleaning crossfeed auger
WARNING

1 3 4
Procedure Notice
1. Slacken screws (1). Four screws.

2. Turn and remove lid (2).
3. Slacken screw (3) at crossfeed auger. One screw.
4. Pull out crossfeed auger (4) with shaft.
5. Clean crossfeed auger.
6. Insert crossfeed auger (4) with shaft.
7. Locate and fasten screw (3) at crossfeed auger. One screw.
8. Locate lid (2) and turn into position.
9. Fasten screws (1). Four screws.

101199 (1)
Clean the dust filter
Procedure Notice
1. Slacken screw (1) at hose clip (2). 1 screw.

2. Remove dust filter (3) and clean. Shake off the dirt, vacuum.
3. Put dust filter (3) onto connection piece (4).
4. Tighten screw (1) at hose clip (2). 1 screw.

101200 (1)
Clean sensors
WARNING

Procedure Notice
1. Slacken clamping screws at agitator hopper. Four screws.

2. Open the shell of the agitator hopper.
3. Clean sensor rod (1) from remnants. Clean with fine brush or with a
soft lint-free cloth.
4. Clean inspection glass (2) (option) from remnants.
5. Close the agitator hopper shell and tighten the clamping Avoid torsion.
screws.

101201 (1)
Clean the agitator, filling auger and filling pipe connection
WARNING

1. Run the auger filler empty.

2. Switch Off the control unit for auger fillers.
3. Switch Off the machine.
4. Unscrew the four clamping screws, e.g. (1)

on the agitator hopper (2).
5. Open the agitator hopper shell.
6. Loosen the four screws on the clamping 3

piece (3) and push the clamping piece up.
7. Separate the filling auger (4) and shaft (5)
in the agitator hopper.
8. Remove the filling auger and
connection (6).

101202 (1)
INFORMATION
The displayed graphic of the agitator serves as an example.
9. Slacken three screws e.g. (1). 1

10. Remove the agitator (2).
11. Clean the agitator hopper with soft lint-free

cloth.
12. Clean the agitator, filling auger and filling

pipe connection.
13. Insert the agitator holder into the 1

agitator (1).
14. Fasten the three screws e.g. (2).

101202 (1)
15. Clean the connection between filler 4

auger (1) and shaft (2) from remnants.
16. Insert the filler auger (1) into the filling
connection (5).
17. Insert the filling connection (5) into the
agitator hopper.
3
Take heed of the fixing pins.
18. Hook the filling auger (1) with the fixing
pin (2) into the shaft (3) and slide the
clamping piece (4) over it.
2 1
Turn the butt of the clamping piece relative
to the butt of the two shaft ends through
90. 5
19. Tighten the four screws on the clamping
piece.
20. Close the agitator hopper shell (6) and

tighten the clamping screws (7).
Avoid torsion.

101202 (1)
Clean the drive chain of the agitator drive
Procedure Notice
1. Slacken screw (1). 1 screw.

2. Lift off the cover plate (2)
3. Clean contaminated drive chain (3). With wire brush or with
petroleum.
4. After cleaning lubricate the chain links with some drops of
oil.
5. Apply cover plate (2).
6. Fasten screw (1). 1 screw.

108595 (1)
Electrical devices
DANGER
There is a risk of fire and explosion at the machine.
See chapter 2 ”Processing of dusty materials”.
u The following measures must be observed without fail.
Carry out maintenance every 8 hours!
Item Measure
1 Keep motor frequency converter free of dust.

u Layers of dust must be removed!
2 Keep plug connections free of dust.
3 Visual inspection:
u Remove any other contamination.

101374 (1)
Maintenance plan checkweigher
8 | Maintenance
Item Maintenance point Job description Description Service interval *) Personnel Info page
10 000
5 000
1 000
2 000
160
500
40
8
Drives and gears
1 3-phase motor In normal conditions -
maintenance-free
2 Belts Check belt tension As delivered condition ¬ Page 21
2.1 Replace belt If necessary
Pneumatic system
3 Maintenance unit Drain water from the filter Housing must be ¬ Page 23
housing unpressurized
before opening!
Electrical devices
4 Control cabinet and terminal
boxes
4.1 Electric screw and clamp Check all electric screw and Every 24 months at the latest!
connections clamp connections for firm Switch Off the main
seating switch and secure it
against being
switched back On.
Overall machine
5 Fastening elements Check for firm seating Once after 160 hrs if the machine
is new
= lubricating
717079MS5025W | Version 1.0 | en
19 / 26
107837 (1)
717079MS5025W | Version 1.0 | en
101197 (2)
Maintenance plan auger filler
20 / 26
Item Maintenance point Job description Description Service interval*) Personnel Info page
10 000
5 000
1 000
2 000
160
500
40
8
Overall machine
1 Fastening elements Check firm seating Especially of moving parts
Electrical devices
2 Control cabinet and terminal Check all electric screw and Every 24 months at the latest!
boxes clamp connections for firm Switch Off the main
seating switch and secure it
against being
switched back On.
Drives and gears
3 Drive chain of agitator drive Lubricate and check tension A few drops of Shell Omala Page 24
oil 320
4 Drive motor - agitator and Esso Synthetic low-viscosity Page 25
crossfeed auger grease S 420
= lubricating
8 | Maintenance
Information for maintenance
Adjust/replace belts
WARNING
The machine is equipped with rotating components.

Long hair worn open, loose clothing, jewelry or similar can be seized
and drawn in by rotating components. Extremely serious injuries can
be caused by this.
u Wear tight-fitting clothing. Protect long hair, e.g. with a hair net.
Take off any jewelry.
Adjust belt tension

The belt tension is set ex-works and should
not be changed.
Depending on load strain the tension might change
after a longer period of operation. Tension is
adjusted by shifting the axis (1) in the desired
bearing point.
u Requirement: belts must run during setup
operation.
u Slacken lock nut (2) on the right and left side
of the belt.
u Slowly turn clamping (3) and check belt
movement. Belt must run straight and parallel.
u Tighten lock nut (2).
The belt tension is adjusted correctly if 2
neither slack nor excessive load occur.
3
Adjust lateral setting
1
u Requirement: belts must run during setup
operation.
u Slacken lock nut (2) on the belt side to be
adjusted.
u Slowly turn clamping nut (3) and check belt
movement. Belt must run straight and parallel.
u Tighten lock nut (2).

108135 (3)
Adjust/replace belts
Replace belt in case of excessive wear

u Slacken screws (1) and remove belt body.
u Slacken lock nut (2) and slacken the belt 5
tension with the clamping nut (3).
u Unscrew screw (4). 7
u Unscrew screws (5).
u Remove side panel (6).
6
u Pull belt (7) off toward the front.
u Install new belt.
u Mount by following the reverse order of steps.
1
u Readjust belt tension (see page 21).

108135 (3)
WARNING
The pneumatic systems are pressurized.

If incorrectly disassembled the systems can explode and cause
serious accidents.
u Depressurize the pneumatic system (see package maker).
Drain water from the filter housing
The compressed air system must be

unpressurized.
The pressure gauge (1) must display 0 bar.
1. Open valve (2). 1
2. Drain water from filter housing (3).

3
3. Close valve (2).

107839 (1)
Tension the drive chain of the agitator drive
INFORMATION
Check the tension of the drive chain (1) once a month.
1
3
5 4
10 mm
Procedure Notice
1. Slacken screw (1). 1 screw.

2. Lift off the cover plate (2).
3. Slacken the four screws, e.g. (3) at the slotted holes in the
motor plate (4).
4. Slide the motor plate (4) smoothly in the direction of the The chain is correctly
arrow to tension the drive chain (5). tensioned when it can be
pressed inwards by approx. 10
mm.
5. Retighten the four screws (3) on the motor plate (4).
6. Apply cover plate (2).
7. Fasten screw (1). 1 screw.

101203 (2)
Lubricant change at the drive motor
WARNING
Peril of loss of life - do not touch any lines, leads or components

that carry a live voltage.
The consequence can be very serious injuries or death.
u The entire machine must be separated from mains prior to

working on electric installations:
Switch Off the main switch (after switching Off the main
switch, excepted electrical circuits can still carry live voltage
- see wiring diagram).
Disconnect mains plug (if present).
u Secure the machine against being switched back on.
u Reliably establish the absence of any voltage with a suitable test
instrument.
2 1
Procedure Notice
1. Change the lubricant every 10 000 operating hours using See operating instructions
the synthetic liquid grease Esso S 420. drive motors crossfeed
auger (1)/ agitator (2).

101203 (2)
Notes
2.

S_Notiz
Appendix
9
Chapter 9: Appendix
9 | Appendix 1/4
Contents
Note 3
Notes 4

T
2/4 9 | Appendix

S_Leer
9 | Appendix 3/4
Note
INFORMATION
Chapter 9 of these Operating Instructions is void.

S_ohne_Inhalt (7.1)
4/4 9 | Appendix
Notes
3.

S_Notiz
Operation and
maintenance-relevant Purchase
Parts (OEM) 10
Chapter 10: Operation and maintenance-relevant Purchase Parts (OEM)
10 | Operation and maintenance-relevant Purchase Parts (OEM) 1/6
Contents
Overview 4
GEARS, MOTORS, DRIVE ELEMENTS 4
PROCESSING / FILTER 4
SENSORS, LIMIT SWITCHES 4
CONTROL/REGULATING DEVICES, COMPUTER SYSTEMS 4
SUBSUPPLIED EQUIPMENT 4
CHECK SETTING HELPS, COMPUTER, ETC. 4
Notes 5

T
2/6 10 | Operation and maintenance-relevant Purchase Parts (OEM)

S_Leer
Documents for purchase parts on CD-ROM
INFORMATION
The documents for operation and maintenance-relevant purchase parts

are gathered as listed below on the attached CD-ROM as PDF-files.
They do not exist in a printed version.

S_10_OEM_CD (7)-en
717079MS5025W | Version 1.0 | en
t_Kap10_717078_en
Overview
4/6
Machine / Type Machine No. / Order No. Customer as per
KWE 5000 LM 717079MS5025W PT Eastern Pearl Flour 21.12.2011
Mills
Designation Benennung Manufacturer / supplier Bosch No.

GEARS, MOTORS, DRIVE ELEMENTS
THREE‐PHASE GEAR MOTOR DREHSTROM‐GETRIEBEMOTOR IGK 65‐60;I=7 GROSSCHOPP AG 8 108 174 269 10.1
THREE‐PHASE GEAR MOTOR DREHSTROM‐GETRIEBEMOT. IGK 65‐60;I=12 GROSSCHOPP AG 8 108 174 272 10.1
10 | Operation and maintenance-relevant Purchase Parts (OEM)

AC‐SERVOMOTOR AC‐SERVOM.SH140/20200/0/1/00/00/00/00 SCHNEIDER ELECTRIC GMBH 8 108 150 282 10.2
PROCESSING / FILTER
FILTER / PRESSURE REGULATOR FILTER‐DRUCKREGELVENTIL NL2 G1/4 BOSCH REXROTH AG 0 821 300 300 10.3
SENSORS, LIMIT SWITCHES

PHOTOELECTRIC REFLEX SWITCH REFLEXIONS‐LICHTSCHRANKE WL160‐F440 SICK AG 8 108 166 183 10.4
POINT LEVEL SENSOR WITH VIBRATING ROD VIBRATIONSGRENZSCHALTER VEGAVIB 63 VEGA GRIESHABER KG 8 108 175 354 10.5
CONTROL/REGULATING DEVICES, COMPUTER SYSTEMS

SERVO CONTROL UNIT SERVO‐STEUERGERAET MC‐4/11/10/400 ELAU AG 8 108 171 684 10.6
FREQUENCY CONVERTER E82EV371K2C FREQUENZUMRICHTER E82EV371K2C LENZE VERTRIEB GMBH 8 108 171 427 10.7
CONTROLLER MULTIACHSCO. C200/A2 PROFIBUS‐DP/CAN SCHNEIDER ELECTRIC GMBH 8 108 174 329 10.8
TOUCH PANEL TOUCH PANEL TP104AT/781060 SÜTRON ELECTRONIC GMBH 8 108 174 604 10.9
SUBSUPPLIED EQUIPMENT
METAL DETECTOR UNICON‐D 1100/200/250/150 GENIUS+ S+S SEPARATION & SORTING 8 108 255 350 10.10
CHECK SETTING HELPS, COMPUTER, ETC.

WEIGHING CELL WAEGEZELLE DIGITAL 1‐FIT/1SB30/5KG HOTTINGER BALDWIN 8 108 150 280 10.11
Notes

S_Notiz_2s
6/6 10 | Operation and maintenance-relevant Purchase Parts (OEM)
Notes
4.

S_Notiz_2s

KWE 5000 LM - FVS 3201 Manual PDF

Uploaded by

Copyright:

Available Formats

KWE 5000 LM - FVS 3201 Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KWE 5000 LM - FVS 3201 Manual PDF

Uploaded by

Copyright:

Available Formats

Instruction Manual

PT Eastern Pearl Flour Mills

Translation of the original instructions

Customer Overall order no.

Type of machine: Designation Order/machine no.

Declaration of conformity : Chapter 1 - Important Information

Robert Bosch GmbH

Robert Bosch GmbH 2012

Information for these operating instructions 4

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

This page is empty on purpose!

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

These operating instructions are intended for:

The following documentations are supplied in addition to these operating instructions:

Spare parts list

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

Information for these operating instructions

Safety instructions and their significance

Refers to direct and imminent danger which if not heeded might

Refers to a potentially dangerous situation which if not heeded

Refers to a potentially harmful situation which if not heeded might

Refers to user suggestions and other especially useful information.

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

Information for these operating instructions

Danger symbols in safety instructions

Symbol Significance Symbol Significance

Danger in general Hot surface

Voltage / Current Suspended load

Health-impairing or irritating Corrosive substances

Fire Explosive substances

Crushing - hands Explosive atmosphere

Crash Laser radiation

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

Warranty and liability 3

Information for the plant operator 4

Operator control of the machine 5

Measures prior to working on the machine 7

Measures prior to working on electrical/electronic 8

Measures for electrical welding work 9

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

This page is empty on purpose!

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

Warranty and liability

Illustrations and drawings

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en

Information for the plant operator

Inspection in compliance with the accident prevention regulations

717079MS5025W | Version 1.0 | en Bosch Packaging Technology

Operator control of the machine

Moving masses and revolving or hot components inside the

u Do not climb on the machine.

During the machine's reference/synchronous run, movements of the

u Keep a sufficient safety distance to the machine during the

Hot surfaces on heated machine parts.

Machines with heat-sealing devices

Fire hazard due to overheating of machine parts.

Bosch Packaging Technology 717079MS5025W | Version 1.0 | en