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:

[email protected]

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

Chapter 1:

Important Information

1

1 | Important Information

1/8

Contents

Bosch Packaging Technology

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

717079MS5025W | Version 1.0 | en T

2/8

1 | Important Information

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

1 | Important Information

3/8

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_01_Zielgruppe (7.1)

1 | Important Information

4/8

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.

717079MS5025W | Version 1.0 | en S_01_Hinweise (7.1)

Bosch Packaging Technology

1 | Important Information

5/8

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 materials

Corrosive substances

Fire

Explosive substances

Crushing - hands

Explosive atmosphere

Crash

Laser radiation

X-ray radiation

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_01_Hinweise (7.1)

6/8

1 | Important Information

Declaration of conformity

717079MS5025W | Version 1.0 | en CE_Konformitaet

Bosch Packaging Technology

Type of machine:

Customer

Order/machine no.

KWE 5000 LM

PT Eastern Pearl Flour Mills / Indonesia

717079MS5025W

Version

Date

Chapter

New pages

Changed pages

Scope of supply

Changed by

1.0

06.02.2012

1 - 10

all

‐

all

srw2wa2

1 | Important Information

Bosch Packaging Technology

Version overview

7/8

717079MS5025W | Version 1.0 | en S_01_Version (2)

8/8

1 | Important Information

Notes 1.

717079MS5025W | Version 1.0 | en S_Notiz

Bosch Packaging Technology

Basic Safety Information

Chapter 2:

Basic Safety Information

2

2 | Basic Safety Information

1 / 12

Contents

Bosch Packaging Technology

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 regulations

4

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 devices

8

Measures for electrical welding work

9

Dust explosion

10

Notes

11

717079MS5025W | Version 1.0 | en T

2 / 12

2 | Basic Safety Information

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

2 | Basic Safety Information

3 / 12

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_02_Gewaehrl (7)

2 | Basic Safety Information

4 / 12

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.

717079MS5025W | Version 1.0 | en S_02_Hinw-Betreiber (7)

Bosch Packaging Technology

2 | Basic Safety Information

5 / 12

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. Serious bodily injury can occur. 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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_02_Masch-Bedieng (7)

2 | Basic Safety Information

6 / 12

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.

717079MS5025W | Version 1.0 | en S_02_Schutzeinrichtg (7)

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.

Bosch Packaging Technology

2 | Basic Safety Information

7 / 12

Measures prior to working on the machine 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! 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! Serious bodily injury can occur. 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. Serious bodily injury can occur.

Bosch Packaging Technology

u

Prior to working on the machine the strike button EMERGENCY STOP must be actuated without fail.

u

Secure the machine against being switched On.

717079MS5025W | Version 1.0 | en S_02_Maßn-vor-Arbeit (7)

2 | Basic Safety Information

8 / 12

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).

717079MS5025W | Version 1.0 | en S_02_Maßn-vor-Elektrik (7.1)

u

Secure the machine against being switched On.

u

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

Bosch Packaging Technology

2 | Basic Safety Information

9 / 12

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. Serious bodily injury can occur. 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.).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_02_Maßn-bei-Schweissen (7)

2 | Basic Safety Information

10 / 12

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.

717079MS5025W | Version 1.0 | en S_02_Staubex_PKM (7)

u

Check electrical devices at regular intervals!

u

Ground statically rechargeable objects!

u

Keep the machine clean as required!

Bosch Packaging Technology

2 | Basic Safety Information

11 / 12

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

12 / 12

2 | Basic Safety Information

Notes 2.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology

Transport, Installation and Connections

Chapter 3:

Transport, Installation and Connections

3

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 substances

6

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

Bosch Packaging Technology

10

717079MS5025W | Version 1.0 | en T

2 / 10

3 | Transport, Installation and Connections

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

3 | Transport, Installation and Connections

3 / 10

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_03_Transport (7)

3 | Transport, Installation and Connections

4 / 10

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:

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).

1

2

4

3

717079MS5025W | Version 1.0 | en 108589 (1)

Bosch Packaging Technology

3 | Transport, Installation and Connections

5 / 10

Installation and connection of checkweigher 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).

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.

4.

Remove two screws (3) from the bores (4) and screw in at the front side of the belt carrier (1).

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 and rear.

6

7

5

1 2

3

4

 The belts may not be offset with regard to height and must not contact one another.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108589 (1)

6 / 10

3 | Transport, Installation and Connections

Installation and connection of checkweigher 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.

 The guard cover (4) may not touch the cable (3) between plug and clamping point.

2 1 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.

717079MS5025W | Version 1.0 | en 108589 (1)

Bosch Packaging Technology

3 | Transport, Installation and Connections

7 / 10

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. Serious bodily injury can occur. 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_03_Abbau-Lagerg-Entsrg (7.1)

3 | Transport, Installation and Connections

8 / 10

Transport drawing Checkweigher KWE 5000 LM Weight

approx. 250 kg

Infeed belt (transport separately)

Transport fork (fork length 1100 mm)

717079MS5025W | Version 1.0 | en 8108255484

Bosch Packaging Technology

3 | Transport, Installation and Connections

9 / 10

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)

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en FVS3201 (1)

10 / 10

3 | Transport, Installation and Connections

Notes 5.

717079MS5025W | Version 1.0 | en S_Notiz

Bosch Packaging Technology

Description of the Machine

Chapter 4:

Description of the Machine

4

4 | Description of the Machine

1 / 20

Contents

Bosch Packaging Technology

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 output

13

Converting the regulating increment from grams into time i.e. pulses

13

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

717079MS5025W | Version 1.0 | en T

2 / 20

4 | Description of the Machine

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

4 | Description of the Machine

3 / 20

Structure and operating method

3

6

10

7

9

8

5

2

1

4

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”.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107131 (2)

4 | Description of the Machine

4 / 20

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).

717079MS5025W | Version 1.0 | en 107700 (1)

Bosch Packaging Technology

4 | Description of the Machine

5 / 20

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107701 (1)

6 / 20

4 | Description of the Machine

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

4 | Description of the Machine

7 / 20

Installation layout drawing 8-108-255-586

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 8108255586

8 / 20

4 | Description of the Machine

This page is empty on purpose!

717079MS5025W | Version 1.0 | en 8108255586

Bosch Packaging Technology

4 | Description of the Machine

9 / 20

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103536 (1)

4 | Description of the Machine

10 / 20

Classification (division into weight ranges) checkweigher ”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.

Nominal weight

Weight limits

Rejection

TU2

TU1

Rejection

TO1

TO2

Weight

ACCEPT RANGE

717079MS5025W | Version 1.0 | en 103536 (1)

Bosch Packaging Technology

4 | Description of the Machine

11 / 20

Classification (division into weight ranges) checkweigher ”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.

Nominal weight

Weight limits

Rejection

G1

G2

Rejection

G3

G4

Weight

ACCEPT RANGE G = weight limit

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103238 (1.1)

12 / 20

4 | Description of the Machine

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.

717079MS5025W | Version 1.0 | en 071456 (5)

Bosch Packaging Technology

4 | Description of the Machine

13 / 20

Control checkweigher Test whether the computed regulating increment will be output Setpoint filling volume Deviation - <

> + Deviation <‐k*S

Regulating increment

+k*S>

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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 071456 (5)

14 / 20

4 | Description of the Machine

Control checkweigher 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.

717079MS5025W | Version 1.0 | en 071456 (5)

Bosch Packaging Technology

4 | Description of the Machine

15 / 20

Control checkweigher 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:

Bosch Packaging Technology

u

for the current article, or

u

in the article data memory.

717079MS5025W | Version 1.0 | en 071456 (5)

4 | Description of the Machine

16 / 20

Structure of the auger filler Modular groups

1 3

2 4

8

5

6

7

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

717079MS5025W | Version 1.0 | en 101188 (1)

Bosch Packaging Technology

4 | Description of the Machine

17 / 20

Structure of the auger filler Modular groups

12

9 14

10

15

11 16 13 Item 9

Designation 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

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 101188 (1)

4 | Description of the Machine

18 / 20

Structure of the auger filler Description

1

4 2

5

3

6

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).

717079MS5025W | Version 1.0 | en 101190 (1)

Bosch Packaging Technology

4 | Description of the Machine

19 / 20

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

20 / 20

4 | Description of the Machine

Notes 6.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology

Operation

Chapter 5:

Operation

5

5 | Operation

1 / 68

Contents

Bosch Packaging Technology

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

717079MS5025W | Version 1.0 | en T

5 | Operation

2 / 68

717079MS5025W | Version 1.0 | en T

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 Bosch Packaging Technology

5 | Operation

3 / 68

Safety instructions

INFORMATION All work and activities may be carried out by trained and duly authorized persons only.

WARNING The machine presents a danger, if it is operated improperly or if it is not in a correct condition. Serious bodily injury can occur.

Bosch Packaging Technology

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.

717079MS5025W | Version 1.0 | en S_05_Sicherheit (7)

4 / 68

5 | Operation

Position of operator

717079MS5025W | Version 1.0 | en 108590 (1)

Bosch Packaging Technology

5 | Operation

5 / 68

Control elements

1

2

Item 1

2

Element

Assignment

Function

Operating and display terminal (touchscreen)

depends on menu called up

Commands are entered by tapping the relevant button.

Main switch

MAIN SWITCH



Never use sharp objects to tap the buttons!

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108591 (1)

6 / 68

5 | Operation

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!

717079MS5025W | Version 1.0 | en 107463 (2)

Bosch Packaging Technology

5 | Operation

7 / 68

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107464 (1)

5 | Operation

8 / 68

Auger filler startup Control System INFORMATION Operation is carried out at the operating and display terminal. This may be

717079MS5025W | Version 1.0 | en 101192 (1)

u

an individual device

u

a checkweigher with dosing option, or

u

a machine control system with appropriate option.

Bosch Packaging Technology

5 | Operation

9 / 68

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 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).

3

1

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.

 Set maximum 0.2 bar at the pressure

2

5

4

controller (5). Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 101193 (1)

5 | Operation

10 / 68

Switching off checkweigher Requirement u u

The upstream machine is switched off to avoid infeed backup 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.

717079MS5025W | Version 1.0 | en 107465 (1)

Bosch Packaging Technology

5 | Operation

11 / 68

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 090907 (6)

5 | Operation

12 / 68

Control and display terminal Start screen - basic structure 1

2

3

Item

Designation

Function

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.

717079MS5025W | Version 1.0 | en 099269 (6)

Bosch Packaging Technology

5 | Operation

13 / 68

Control and display terminal 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 099269 (6)

5 | Operation

14 / 68

Control and display terminal Text and number input Button

Function Dialog window for input of numbers. 1 1.

Admissible input range (min. - max.)

Dialog window for text input.

717079MS5025W | Version 1.0 | en 099269 (6)

Bosch Packaging Technology

5 | Operation

15 / 68

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107704 (1)

5 | Operation

16 / 68

Information area Weight display 1

2

3

4

Item 1

Description 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.

717079MS5025W | Version 1.0 | en 107705 (1)

Bosch Packaging Technology

5 | Operation

17 / 68

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 display of the password level (1 - 4).

1

If an incorrect password is entered: u

The user is not logged in.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107706 (1)

5 | Operation

18 / 68

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.

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

1

The password is changed. 2 3

717079MS5025W | Version 1.0 | en 107706 (1)

Bosch Packaging Technology

5 | Operation

19 / 68

User and passwords Reset all passwords Requirement: Setup engineer 2 must be logged in. Procedure 1.

Press screen button User.

2.

Press screen button Reset passwords.

4

 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107706 (1)

5 | Operation

20 / 68

Basic functions Function u

Basic functions for machine operation.

1

2

3

4

5

6

7

8

9

10

4.

Item

Designation

Function

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

717079MS5025W | Version 1.0 | en 108596 (1)

Go to Online Help.

Bosch Packaging Technology

5 | Operation

21 / 68

Checkweigher Basic data

1 6

2 3

4 5

Item

Designation

Function

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107708 (2)

5 | Operation

22 / 68

Checkweigher Parameter input - package

1

5

2

6

8

3

4

Item

7

Designation

Function

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.

717079MS5025W | Version 1.0 | en 107709 (2)

Bosch Packaging Technology

5 | Operation

23 / 68

Checkweigher Zero point

1

4

2

5

3

Item

Designation

Function

1

Maximally admissible zero point difference.

Input.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107710 (1)

5 | Operation

24 / 68

Checkweigher Ejector

2

1

3

4

5

6

7

8

9

10

11

12

Item

Designation

Function

1

Ejector.

Selection.

2

Distance between the ejector light barrier and ejector.

Input.

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 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.

717079MS5025W | Version 1.0 | en 108592 (1)

On/Off.

Display.

Bosch Packaging Technology

5 | Operation

25 / 68

Checkweigher Calibrating

1

2

Item

Designation

Function

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.

4.

Press screen button (2). Following the message "Ready measuring calibration weight": Emplace calibration weight and press screen button (2) once again.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107712 (1)

5 | Operation

26 / 68

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.

717079MS5025W | Version 1.0 | en 107712 (1)

Bosch Packaging Technology

5 | Operation

27 / 68

Checkweigher Random samples

1

1

3 2 4

 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. Item

Designation

Function

1

Random sampling size. Number of packages per random sample.

Input.

2

Interval with cyclic random sampling: n = number of packages (target unit count). t = time (time target).

Selection.

3

Target unit count.

Input.

4

Time target.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107713 (2)

5 | Operation

28 / 68

Checkweigher Shift start/shift end

1

2

Item 1

Designation 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.

717079MS5025W | Version 1.0 | en 107714 (1)

Bosch Packaging Technology

5 | Operation

29 / 68

Checkweigher Parameter display - statistics

1

8

2

9

3

10

14

4

Item

5

11

6

12

7

13

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.

13

Standard deviation.

14

Count of rejected packages.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108102 (2)

5 | Operation

30 / 68

Checkweigher Histogram

1

2

Item 1

2

Designation 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.

Print statistics data.

717079MS5025W | Version 1.0 | en 107716 (2)

Bosch Packaging Technology

5 | Operation

31 / 68

Checkweigher Last 60 weights

1

2

Item

3

4

5

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107717 (1)

5 | Operation

32 / 68

Checkweigher Last 100 tare changes

1

2

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.

2

Scroll page by page.

717079MS5025W | Version 1.0 | en 107718 (1)

Bosch Packaging Technology

5 | Operation

33 / 68

Checkweigher Manual random samplings

Item

1

6

2

7

3

8

4

9

5

10

11

12

Designation

Function

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).

8

Count of rejected packages.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107719 (2)

5 | Operation

34 / 68

Checkweigher Manual random samplings

Item 9

1

6

2

7

3

8

4

9

5

10

11

12

Designation

Function

Standard deviation.

Display.

10

Mean value.

11

Number of manual samplings subject to the defaulted number of packages (pass-packages/random sampling size).

Input.

12

Start manual random sampling

Start.

717079MS5025W | Version 1.0 | en 107719 (2)

Bosch Packaging Technology

5 | Operation

35 / 68

Checkweigher Cyclical random samples

Item

1

6

2

7

3

8

4

9

5

10

11

Designation

Function

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).

8

Count of rejected packages.

9

Standard deviation.

10

Mean value.

11

Number of cyclical samplings subject to the defaulted number of packages (pass-packages/random sampling size).

Bosch Packaging Technology

Input.

717079MS5025W | Version 1.0 | en 107720 (2)

5 | Operation

36 / 68

Checkweigher Conveyor belts

1

2

3

4

Item

Designation

Function

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.

717079MS5025W | Version 1.0 | en 107721 (1)

Bosch Packaging Technology

5 | Operation

37 / 68

Checkweigher Size management

1

2

3

4

5

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107722 (1)

5 | Operation

38 / 68

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. The size name is shown against a blue background.

2.

Press screen button.

3.

Confirm size name Ļ. The selected size is active.

717079MS5025W | Version 1.0 | en 107723 (2)

Bosch Packaging Technology

5 | Operation

39 / 68

Checkweigher Delete size Delete one size 1.

Press size which you wish to delete. The size name is shown against a blue background.

2.

Press screen button.

3.

Confirm delete command Ļ. The size selected is deleted.

Delete all formats 1.

Press screen button. Caution!

 There is no second query "Are you sure you wish to delete?"! 2.

Press clear all formats. All sizes are deleted.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107724 (1)

5 | Operation

40 / 68

Checkweigher Setup

1

4

7

2

5

8

13

3

6

9

14

Item

Designation

1

10

11 7

12

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).

717079MS5025W | Version 1.0 | en 095949 (7)

Bosch Packaging Technology

5 | Operation

41 / 68

Checkweigher Setup

1

4

7

10

11 7

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).

12

 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 095949 (7)

5 | Operation

42 / 68

Checkweigher Adjust the network connection (option)

1 3

2

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.

717079MS5025W | Version 1.0 | en 095949 (7)

Bosch Packaging Technology

5 | Operation

43 / 68

Checkweigher Regulation auger filler - parameter input

1

5

2

6

9

10

Item

3

7

11

4

8

12

Designation

Function

1

Overfilling: shifting the reference point towards the nominal weight. Modification is possible during operation.

Input.

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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 100041 (6)

5 | Operation

44 / 68

Checkweigher Regulation auger filler - parameter input

1

5

2

6

9

10

3

7

11

4

8

12

Item

Designation

Function

9

Regulation.

On/Off.

10

Number of packages per multipack (option).

Input.

11

Increase regulating increment.

12

Reduce regulating increment.

717079MS5025W | Version 1.0 | en 100041 (6)

Bosch Packaging Technology

5 | Operation

45 / 68

Checkweigher Regulation auger filler - parameter display

1

2

3

Item

Designation

4

Function

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 099286 (4)

5 | Operation

46 / 68

Checkweigher Metal detector ‐ basic screen

1

5

2

4

3

Item

Designation

Function

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.

717079MS5025W | Version 1.0 | en 108593 (1)

Display.

Bosch Packaging Technology

5 | Operation

47 / 68

Checkweigher Metal detector ‐ statistic

1

2

Item

3

4

Designation

1

A list of statistics including value, date and time is displayed.

2

Scroll page by page.

3

Scroll line by line.

4

Delete statistics data.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108593 (1)

5 | Operation

48 / 68

Checkweigher Metal detector ‐ inputs

4

1

5 2 6 3

Item 1

Designation

Function

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.

717079MS5025W | Version 1.0 | en 108593 (1)

On/off.

Bosch Packaging Technology

5 | Operation

49 / 68

Checkweigher Metal detector ‐ inputs

4

1

5 2 6 3

Item 4

Designation

Function

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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108593 (1)

5 | Operation

50 / 68

Filling auger Basic data

2 1

5

3 6 4

7

Item

Designation

Function

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).

717079MS5025W | Version 1.0 | en 103225 (2)

Bosch Packaging Technology

5 | Operation

51 / 68

Filling auger Operating modes

6

1

7

8

2

3

4

5

Item

Designation

Function

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103226 (2)

5 | Operation

52 / 68

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

Item 1

Designation

Function

Trigger single dosing. For checking of function and weight.

Start.

717079MS5025W | Version 1.0 | en 103226 (2)

Bosch Packaging Technology

5 | Operation

53 / 68

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

Item 1

2

Designation

Function

Start emptying (continuous operation of the auger).

Start.

 Place a sufficiently large container under the opening. 2

Speed.

Bosch Packaging Technology

Input.

717079MS5025W | Version 1.0 | en 103226 (2)

5 | Operation

54 / 68

Filling auger Operating modes ‐ calibrated filling

Function u

To adjust the filler to the product. The pulse/weight factor is calculated and displayed.

2

1 3

4

Item

Designation

Function

1

Standard revolutions target value (see data Input. sheet).

2

Start calibrated filling. 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.

Start.

 Change the value of the standard revolutions (1) until the standard weight is achieved. 3

Standard weight.

Input.

4

Standard weight factor

Display.

717079MS5025W | Version 1.0 | en 103226 (2)

Bosch Packaging Technology

5 | Operation

55 / 68

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103226 (2)

5 | Operation

56 / 68

Filling auger Operating modes ‐ turn filling auger backwards

Function u

Turn filling auger backwards,

u

Withdraw filling auger by turning.

1

Item 1

Designation

Function

Turning filling auger backwards. One revolution is performed for each actuation.

Start.

717079MS5025W | Version 1.0 | en 103226 (2)

Bosch Packaging Technology

5 | Operation

57 / 68

Filling auger Filling auger

1

6 7

2

8

3

9

4

10

5

Item

Designation

Function

1

Preset fill weight parameter.

Input.

2

Dosing screw rotational speed.

3

Revolution/weight factor of the last calibration dosing.

4

Revolution/weight factor current.

5

Percentage of regulation.

6

Ramp time acceleration.

7

Ramp time brakes.

8

Relation foreign mass to motor mass.

9

Positioning accuracy.

10

Display.

Input.

Programmed cams of servo motors.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103227 (2)

5 | Operation

58 / 68

Filling auger Cross-feed auger

1

3

2

4

Item

5

Designation

Function

1

Cross-feed scroll.

On/Off.

2

Regulation.

3

Revolution speed crossfeed scroll.

4

Setpoint product level in chute if with option measuring probe.

5

Response time sensor until start of crossfeed scroll.

717079MS5025W | Version 1.0 | en 103228 (2)

Input.

Bosch Packaging Technology

5 | Operation

59 / 68

Filling auger Agitator

1

2

Item

3

Designation

Function

1

Agitator.

On/Off.

2

Agitator revolution speed.

Input.

3

Agitator slow-down-to-stop time.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103229 (2)

5 | Operation

60 / 68

Filling auger Closure

1

Item 1

Designation

Function

Closure pre-switch-off time.

Input.

717079MS5025W | Version 1.0 | en 103230 (2)

Bosch Packaging Technology

5 | Operation

61 / 68

Filling auger Product sensor

2 1 3

4

Item 1

Designation

Function

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103232 (2)

5 | Operation

62 / 68

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

Item 1

Designation

Function

Dosing data for size parts.

Input.

717079MS5025W | Version 1.0 | en 101372 (3)

Bosch Packaging Technology

5 | Operation

63 / 68

Menu tree

Basic screen

1 Password administration

Conveyor belts

Log on/Log off

Parameter input

Basic data

Target tare weight

1

Nominal output

3

Parameter display

3 Package

1 Statistics

4 Zero point

Change password

4 Delete size

1 Last 100 tare changes.

3

1 Man. random samplings

Random samples

Shift start/ shift end

Change size

Last 60 weights

Adjusting weigher

1

1

3

4 Password administration On / Off

Create size

Histogram

Ejector

Reset password

3

1

4

4

Format administration

1

2 Cycl. random samplings

1 Conveyor belts

Post-feed time On / Off

3

Enter post-feed time

3

1 Password level 1 - operator 1 2 Password level 2 - operator 2 3 Password level 3 - setup engineer 1 4 Password level 4 - setup engineer 2

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107726 (1)

64 / 68

5 | Operation

This page is empty on purpose!

717079MS5025W | Version 1.0 | en 107726 (1)

Bosch Packaging Technology

5 | Operation

65 / 68

Menu tree

Basic screen

1 Setup

Filler (FVS)

1

Cleaning the touchscreen

Netweigher (FIW)

2 2

Basic data

Language

Information

Online help for current menu screen

Single dosing

4 Regulation auger filler parameter input

Special function

3

Operating modes

2 3

Dosing unit control

1 Electr. designation plate Interface single weight

Regulation auger filler parameter display

1

Run empty

Dosing scroll

2

3 Calibration dosing

Cross-feed scroll

4

3 Race auger filler backwards

Agitator

4

2

3

Network connection

Closure

General settings

Enter regulating increment

3

4 Adjust weighing curve

1 Display regulating increment

3 Time + date

3 Product sensor

3 Metal detector

1 Password level 1 - operator 1 2 Password level 2 - operator 2

Dosing data

3 Password level 3 - setup engineer 1 4 Password level 4 - setup engineer 2

For Bosch Service Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107727 (1)

66 / 68

5 | Operation

This page is empty on purpose!

717079MS5025W | Version 1.0 | en 107727 (1)

Bosch Packaging Technology

5 | Operation

67 / 68

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

68 / 68

5 | Operation

Notes 5.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology

Troubleshooting

Chapter 6:

Troubleshooting

6

6 | Troubleshooting

1 / 126

Contents

Bosch Packaging Technology

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

717079MS5025W | Version 1.0 | en T

6 | Troubleshooting

2 / 126

717079MS5025W | Version 1.0 | en T

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

9173

Error encoder_2:

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 Bosch Packaging Technology

6 | Troubleshooting

Bosch Packaging Technology

3 / 126

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

9243

Error encoder_0:

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

9271

Error encoder_1:

34

9272

Error encoder_2:

35

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 717079MS5025W | Version 1.0 | en T

6 | Troubleshooting

4 / 126

717079MS5025W | Version 1.0 | en 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

Bosch Packaging Technology

6 | Troubleshooting

Bosch Packaging Technology

5 / 126

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 717079MS5025W | Version 1.0 | en T

6 | Troubleshooting

6 / 126

717079MS5025W | Version 1.0 | en 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

10151

Phase L2 failure

68

10152

Phase L3 failure

68

10153

DC bus discharge failure

68

10154

Phase L1 warning

69

10155

Phase L2 warning

69

10156

Phase L3 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

10166

SERCOS: C2D manufacturer-specific error

71

10167

SERCOS: C3D operation status

71

10168

SERCOS: C3D manufacturer-specific error

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 power-off

74

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

Bosch Packaging Technology

6 | Troubleshooting

Bosch Packaging Technology

7 / 126

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

717079MS5025W | Version 1.0 | en T

6 | Troubleshooting

8 / 126

717079MS5025W | Version 1.0 | en 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

10401

IEC diagnosis message class3

90

10402

IEC diagnosis message class4

91

10403

IEC diagnosis message class5

91

10404

IEC diagnosis message class6

91

10405

IEC diagnosis message class7

91

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 Bosch Packaging Technology

6 | Troubleshooting

Bosch Packaging Technology

9 / 126

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

717079MS5025W | Version 1.0 | en T

6 | Troubleshooting

10 / 126

10810

Error reading directory entry

10811

Error writing directory entry

116

10812

Lost cluster/block found

116

10813

Device not found

117

10814

Initialization of failed

117

10815

Error using function with

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

717079MS5025W | Version 1.0 | en T

116

125

Bosch Packaging Technology

6 | Troubleshooting

11 / 126

Safety information

INFORMATION All work and activities may be carried out by trained and duly authorized persons only. All work with electric devices may be carried out by trained and duly authorized persons only.

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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_06_Sicherheit (7)

6 | Troubleshooting

12 / 126

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 is not switched On.

Switch On the checkweigher at the operating and display terminal of the machine.

Defective fuse.

Replace defective fuse.

Signal from upstream machine is missing (if installed by customer).

Check signal from upstream machine.

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 motor.

Excessive belt tension.

The discharge runs too slowly / low‐power.

Cylinder / air nozzle has insufficient compressed air supply.

The checkweigher does not switch On after service work.

717079MS5025W | Version 1.0 | en 037369 (7.1)

Check air pressure. Check compressed air line for absence of leaks and bends.

Bosch Packaging Technology

6 | Troubleshooting

13 / 126

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 times in succession.

Increase the cumulative error on the control 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 from the stored serial number.

Install the correct weighing cell. 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 adjusted.

Perform an adjusting procedure as described in the operating instructions.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108107 (1)

6 | Troubleshooting

14 / 126

407

Communication weighing cell master distorted

Cause

Remedy

The weighing cell control unit cannot communicate with the weighing cell.

Check the connection cable between the 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 completed successfully because there was too much agitation.

Reduce 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 tolerance range.

Check input and correct if necessary.

412

Adjusting weight input error.

Cause

Remedy

The adjusting weight input is outside the tolerance range.

Check input and correct if necessary.

413

Operating values inconsistent

Cause

Remedy

Operating values could not be transferred from the master to the weighing module.

Check Profibus connection.

The weigher control system has failed (does not respond).

Check the operability of the weigher coupler.

717079MS5025W | Version 1.0 | en 108107 (1)

Bosch Packaging Technology

6 | Troubleshooting

414

15 / 126

Fail pack not ejected

Cause

Remedy

Ejector countercheck has detected a non-ejected fail pack.

Check the ejector and sensor of the ejector 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 completed successfully because there was too much agitation.

Reduce agitation.

418

Input weighing belt length = 0

Cause

Remedy

The value 0 has been entered as the weighing belt length.

Increase the value on the control and display terminal.

419

No adjusting process with calibration dongle

Cause

Remedy

An attempt has been made to adjust with a dongle inserted.

Pull off the dongle to adjust.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108107 (1)

6 | Troubleshooting

16 / 126

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 not be completed.

Check at the operating and display terminal if 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 performance.

Increase the value at the control and display terminal.

428

Profibus connection PMC2 disturbed!

Cause

Remedy

Profibus connection between weigher and dosing unit is disturbed.

Check Profibus connection. Switch the weigher on and off.

717079MS5025W | Version 1.0 | en 108107 (1)

Bosch Packaging Technology

6 | Troubleshooting

429

17 / 126

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. Initialization of dosing unit is missing.

Check dosing unit.

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 machine is missing.

Check the downstream machine.

453

Only possible when belts are running

Cause

Remedy

Belts are not switched on. Function cannot be executed.

Switch on belts. 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108107 (1)

6 | Troubleshooting

18 / 126

461

Pass package missing in counter-check

Cause

Remedy

A weighed package was removed from the outfeed belt.

Do not remove any weighed packages from the outfeed belt.

462

Unexpected package in counter-check

Cause

Remedy

An unweighed package was put onto the outfeed belt.

Do not put any unweighed packages onto the outfeed belt.

600

Fault initialization printer

Cause

Remedy

Initialization of the printer could not be completed.

Switch off weigher and check connecting cable to the printer.

601

Printer interface reception disturbed

Cause

Remedy

The signal exchange to the printer interface is disturbed.

Switch off weigher and check connecting cable to the printer.

602

Printer interface sending disturbed

Cause

Remedy

The signal exchange to the printer interface is disturbed.

Switch off weigher and check connecting cable 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.

717079MS5025W | Version 1.0 | en 108107 (1)

Bosch Packaging Technology

6 | Troubleshooting

613

19 / 126

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 disturbed.

Check power supply the module.

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. Function cannot be executed.

Switch Off machine. Execute function when machine is standing still.

651

External stop

Cause

Remedy

The machine was stopped by the downstream machine. The downstream machine is switched Off. Fault at downstream machine.

Inform operating personnel of the downstream machine. Switch on downstream machine or eliminate fault.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108107 (1)

6 | Troubleshooting

20 / 126

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 adjusted incorrectly.

Clean sensor. 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.

717079MS5025W | Version 1.0 | en 108107 (1)

Bosch Packaging Technology

6 | Troubleshooting

7300

21 / 126

Belts are blocking

Cause

Remedy

The belt is mechanically blocked.

Attention: danger of crushing! Check if mechanically moving parts can easily be moved.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108107 (1)

6 | Troubleshooting

22 / 126

Auger filler faults Faults without fault message Fault

Possible cause

Remedy

The auger filler does not start up after servicing or changeover work.

1 The agitator hopper is not closed. Safety switch (1) is defective. The auger filler stops or is not filling any longer.

Close the agitator hopper. Check the safety switch (1) and replace it as necessary.

The gate valve does not open.

Check the drive and valve. Check the initiator in the gate housing.

Foreign body in the agitator hopper.

Open the agitator hopper and remove any foreign bodies as necessary.

Encrusted product has built up on the filling auger.

Open the agitator hopper and clean the filling auger.

Fluctuations in volume in the product.

Check the uniformity of the product.

The filling weight is fluctuating too intensively.

The quality of the product is changing. Compare size parts with data sheet.

Ensure uniform quality of the product. Perform trial weighings more frequently.

The cross-feed auger does not start.

The fill level sensor signals full.

Check the fill level sensor.

The pouring volume is constantly diminishing.

717079MS5025W | Version 1.0 | en 101194 (1)

Bosch Packaging Technology

6 | Troubleshooting

23 / 126

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 108530 (1)

6 | Troubleshooting

24 / 126

Troubleshooting filling auger

9110

A job timeout A job timeout has occurred.

Cause

Remedy

Internal problem with the data interchange between the positioning and actuator parts.

Encoder cable on SINCOS encoder not plugged in correctly or is defective. Please get in touch with our customer service department.

In versions < V20.01.04 the AXIS SINCOS SET <no.> statement has led to this error.

If AXIS SINCOS SET <no.> statement is needed, 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 to phase or phase to casing).

Replace motor or send in for repair.

Hardware defect: the output stage in the PMC-2 is defective.

Replace the PMC-2 or send it in for repair.

9131

Bleeder defective The bleeder resistance (brake resistance) is being checked for operability.

Cause

Remedy

Wiring: the brake resistance is not connected to the PMC-2.

Connect the brake resistance (terminals 2 and 3).

Wiring: the brake resistance or supply line has a short circuit.

Check the brake resistance and supply line.

A mains voltage drop has occurred.

Check the mains voltage.

Mains voltage too high.

Check the mains voltage.

The brake resistance is wrongly dimensioned (ohm value too low).

Check the brake resistance rating.

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.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9148

25 / 126

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 defective.

Replace the MEM module.

9149

No MEM parameters No valid parameters are stored on the memory module.

Cause

Remedy

No parameters are stored on the memory module.

Send parameters to PMC-2.

Hardware defect: the memory module is defective.

Replace the MEM module.

The PMC-2 firmware version has been replaced and the PMC-2 was unable to convert the old parameters.

Change parameters to EPAS-3 and send to PMC-2.

9163

Incompatible EPROMs There are incompatible EPROMs in the in PMC-2.

Cause

Remedy

You have replaced EPROMs yourself. When you did so, you plugged in incompatible EPROMs.

Plug 2 compatible EPROM sets into the PMC-2.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

26 / 126

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 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.

Plug the encoder cable into the encoder.

EPROMs have been replaced that are not compatible.

With "incompatible EPROMs”, under certain circumstances this error is reported, although the diagnostic message E163 would have to be triggered (OV change!).

EPROMs have been replaced that are not correctly plugged in.

Check whether the EPROMs are inserted in the 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 actuator part.

Please get in touch with our customer service department.

Errors can occur when changing over from 8 to 16 bit VECON (FPGA) (software version V0X.XX.XX -> V10.XX.XX).

Please get in touch with our customer service department.

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 being available.

Load cam data into the function buffer BUF.

A fatal software error has occurred in the actuator part.

Please get in touch with our customer service 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 performed on optional modules that are not available in the PMC-2.

Adapt the wiring table (parameters) to the optional module and transfer it to the PMC-2.

The optional module is not correctly plugged in.

Check the code of the optional module in the 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 defective.

If the code of the optional module in the system variables S9.14 "A_POS_OPT_X19" is not correct, replace the optional module or send it in for repair.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9171

27 / 126

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 correct.

Check the encoder voltage (see also encoder documents).

The parameter P1.05 "Lagegeber" = 1, but no optional module is plugged in.

Change the parameters or plug in the optional module.

The value in parameter P3.04 "Inkr_Geber_1" is not a number for base 2 with a SinCos encoder as position encoder.

Enter a valid value (4096, 8192, 16384, 32768 or 65536).

Hardware defect: the encoder is defective.

Replace the encoder.

9173

Error encoder_2: A hardware encoder error has occurred on encoder 2 (reference encoder).

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 correct.

Check the encoder voltage (see also encoder documents).

The value in parameter P3.10 "Inkr_Geber_2" is not a number for base 2 with a SinCos encoder as position encoder.

Enter a valid value (4096, 8192, 16384, 32768 or 65536).

Hardware defect: the encoder is defective.

Replace the encoder.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

28 / 126

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 brief voltage drop in the 24 V DC.

Check the 24 V control voltage (22...33 V DC).

Wiring defect: there is a short circuit in the encoder cable of an encoder.

Check the encoder cable and replace it, if necessary.

Hardware defect: the power unit in the PMC-2 is defective.

Please get in touch with our customer service 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 program.

See ECL user program or description relating 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 motor are entered incorrectly in the parameter set.

Check 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 correctly plugged in or is defective.

Check the encoder cable and replace it, if necessary.

The SinCos position encoder has moved upon being switched on (power On or reset).

The SinCos encoder must stop upon being switched on (< approx. 1 rpm).

Hardware defect: the SinCos encoder is defective.

Replace the encoder.

Hardware defect: SCI-1 optional module defective.

Replace the module.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9198

29 / 126

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 correctly plugged in or is defective.

Check the encoder cable and replace it, if necessary.

This error also occurs on the SCI-1 optional module with incremental encoder as the reference encoder, if the parameter P1.07 "Check reference encoder" is on "Yes" and no encoder is plugged into the PMC-2.

Plug the encoder cable into the PMC-2 or check the plug bridge (X12.1 pin 8 to pin 10 for incremental encoder).

Hardware defect: the SinCos encoder is defective.

Replace the encoder.

Hardware defect: SCI-1 optional module defective.

Replace the module.

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 the PMC-2.

Check and change the parameter set.

Hardware defect: the memory module is defective.

Replace the memory module.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

30 / 126

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.

Hardware defect: the memory module is defective.

Replace the memory module.

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 connected or has a short circuit.

Check the wiring.

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 or SinCos) is not balanced or calibrated.

Balance or calibrate the encoder.

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 resistance) not connected.

Connect the brake resistance (terminals 2 and 3).

The motor's braking energy fed back into the intermediate circuit of the motor is too high, which causes an increase in the voltage.

Decelerate slower. Check the dimensioning of the brake resistance (bleeder resistance).

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 defective.

Replace PMC-2 or send it in for repair.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9225

31 / 126

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 missing (X5.1).

Connect 24 V.

Wiring defect: the temperature switch in the motor winding is not correctly connected.

Check the wiring.

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.

Commutation defect, i.e. the encoder (resolver or SinCos) is not balanced or calibrated.

Balance or calibrate the encoder.

Wiring defect: the temperature switch in the motor winding is defective.

Replace the motor or send it in for repair.

Hardware defect: the input for the temperature encoder on the PMC-2 is defective.

Replace PMC-2 or send it in for repair.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

32 / 126

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 encoder is broken.

Check the mechanical connection to the position encoder.

Hardware defect: the holding brake of the motor is defective.

Check the holding brake.

9242

Encoder jump

A jump-like change in position has been determined on the encoder. Important information: this message (and E242) can be switched off via S1.21 "E_Geber_Stillstand". Cause

Remedy

An encoder overflow (max. encoder range exceeded) has occurred on an absolute value encoder (SSI) in an absolute system (P0.12) that has been preselected as a position encoder.

Check the maximum traversing range and resolution.

Wiring defect: the encoder cable is defective.

Replace the encoder cable.

Hardware defect: the encoder is defective.

Replace the encoder.

9243

Error encoder_0:

An error has occurred on the resolver. Important information: 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 not correctly plugged in.

Plug in the encoder cable. Check the encoder cable.

Hardware defect: the resolver in the motor is defective.

Replace the motor.

Hardware defect: the resolver input on the PMC-2 is defective.

Replace the PMC-2.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9247

33 / 126

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.

Hardware defect: the memory module is defective.

Replace the memory module.

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 formula.

Adapt the parameters.

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 "PMC_Variant", but the parameter P1.05 "Lagegeber" is not entered on "1".

Change parameter P1.05 "Lagegeber" to "1" or P0.24 "PMC_Variant" to "Standard".

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

34 / 126

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 account of wrong data.

Check the cam data and program.

Jumps have occurred in the reference encoder.

Check the reference encoder.

The error is occurring on the electrical transmission or electrical cam on account of a wrong AXIS SETPOSG statement.

Check the program.

Commutation defect, i.e. the encoder (resolver or SinCos) is not balanced or calibrated.

Balance or calibrate the encoder.

Parameter P0.02 "A_max" is so high that fast automatic control with the preset P4.02 "Max_Strom" is not possible.

Check parameter P0.02 "A_max". Check the drive rating.

The rotational direction parameter is not correctly entered.

Check the parameter P3.08 "Geber_Richt_1" 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 correctly entered.

Check the parameters. Motor actuator combination correct?

9271

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 correct.

Check the encoder voltage (see also encoder documents).

The parameter P1.05 "Lagegeber" = 1, but no optional module is plugged in.

Change the parameters or plug in the optional module.

The value in parameter P3.04 "Inkr_Geber_1" is not a number for base 2 with a SinCos encoder as position encoder.

Enter a valid value (4096, 8192, 16384, 32768 or 65536).

Hardware defect: the encoder is defective.

Replace the encoder.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9272

35 / 126

Error encoder_2: A hardware encoder error has occurred on encoder 2 (reference encoder).

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 correct.

Check the encoder voltage (see also encoder documents).

The value in parameter P3.10 "Inkr_Geber_2" is not a number for base 2 with a SinCos encoder as position encoder.

Enter a valid value (4096, 8192, 16384, 32768 or 65536).

Hardware defect: the encoder is defective.

Replace the encoder.

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", P0.06 "Man_schnell" or P0.09 "V_Referenz" is greater than the parameter P0.01 "V_max".

Check the parameters.

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

An error has been triggered by the user program.

See ECL user program or description relating to the ECL user program.

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 with the electrical cam disk.

Check your cam data.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

36 / 126

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 range.

Put the drive out of the limit switch range and possibly check the parameters.

The parameter P0.11 "End_Schalter" is wrongly set.

Check parameter P0.11 "End_Schalter" (break or make contact!).

The reference switch was not found on the reference run.

Check the parameter P0.10 "Ref_Schalter" (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 range.

Put the drive out of the limit switch range and possibly check the parameters.

The parameter P0.11 "End_Schalter" is wrongly set.

Check parameter P0.11 "End_Schalter" (break or make contact!).

The reference switch was not found on the reference run.

Check the parameter P0.10 "Ref_Schalter" (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 negative software limit switch.

Check the ECL program.

A traversing order should cross the negative software limit switch.

Check the ECL program.

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 positive software limit switch.

Check the ECL program.

A traversing order should cross the positive software limit switch.

Check the ECL program.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9305

37 / 126

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 diagnostic message E528 "Motor I²t".

In the system variables S4.02 "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 resolver cable interchanged.

Check the cable connection or cable.

Wiring defect: wrong encoder plug or motor plug inserted (possibly by the adjacent actuator).

Check the encoder plug and motor plug. Check the encoder cable and motor cable.

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 graduations has been installed.

Check the encoder.

Hardware defect: the coupling is too loose.

Check the encoder coupling.

Hardware defect: encoder signal is delivering jumps.

Check the traversing range.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

38 / 126

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 24.8 days (without a reset or power OFF) in operation. This leads to an internal time overflow.

Trigger a reset on the PMC-2 or an acknowledgment. Intercept this suitably in the ECL program -> 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 was performed, was not completed with VELEND 0.

Check the ECL program.

The positioning order on which blending was performed is not available in good time.

Check the ECL program.

9335

Invalid reference run mode The selected reference run mode is unknown.

Cause

Remedy

A wrong value has been entered in the parameter P0.08 "Referenz_Modus".

Enter the valid reference run mode in parameter P0.08.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9336

39 / 126

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 track is missing.

Replace the encoder cable.

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.

9337

Replace the encoder.

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 "Inkr_Geber_1" is incorrectly entered.

Enter the parameter correctly.

Wiring defect: the position encoder cable is defective.

Check the encoder cable.

Hardware defect: the encoder is defective.

Replace the encoder.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

40 / 126

9346

MEM R/W error Error during read or write access to the MEM module.

Cause

Remedy

Hardware defect: the memory module is defective.

Replace the memory module.

9350

BCD format error A BCD conversion is not possible.

Cause

Remedy

The number to be converted is not a BCD notation or the binary number is greater than 8 decimal places or the number is negative.

Check the numerical range.

Wiring defect: the BCD-value is read in via I/O wiring. In doing so, for example, the conductors have got mixed up.

Check the wiring.

9351

Variable number An illegal variable number has been used.

Cause

Remedy

For example, it is verified for the PUT statement whether the source index + quantity > 10000 and whether the target index + quantity > 3999.

Check the numerical range.

9352

Variable range The value cannot be represented by the variable.

Cause

Remedy

For example, AXIS SETPOSG on an encoder that is not present.

Check the value range.

For a VARIO CAM statement (e.g. SYNG) Y_NORM * Auflösung_NormGeber > 3276800.

Change Y-scaling in the cam file.

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.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9354

41 / 126

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 is already populated (multiple calls).

Check the user program.

A program location number has been used that is greater than 8.

Check the user program.

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 transfer of the program (EPAS-3 or MEM --> PMC).

Comply with the chronological order.

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 BASIC soft PMC-2.

Install a valid Elau BASIC soft program.

9359

VEL <= 0 The preset velocity is zero or negative.

Cause

Remedy

In the user program (VEL or VELEND statement) a velocity is preselected that is zero or negative.

Check the user program.

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 statement) a velocity is preselected that is greater than the maximum velocity in the parameter P0.01 "V_max".

Check the user program.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

42 / 126

9361

ACC <= 0 The preset acceleration is zero or negative.

Cause

Remedy

In the user program (ACC statement) an acceleration is preselected that is zero or negative.

Check the user program.

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 maximum acceleration in the parameter P0.02 "A_max".

Check the user program.

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 to the PMC-2.

Transfer the cam variable file to the PMC-2.

The cam variable data has not been loaded correctly from the memory module with the GET statement.

Check the user program.

The cam variable data has not been transferred correctly to the buffer by the "PUT xx, yy BUF zz" statement.

Check the user program.

9380

ECL error 3 With the ECL statement "ERROR 3” a class 3 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 program.

See ECL user program or description relating to the ECL user program.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9383

43 / 126

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) is not set to COM ECL.

Adapt the parameters (RESET after parameter 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 parameters in the PMC-2. The values for parameter P0.13 "Softlimit_Pos" or P0.14 "Softlimit_Neg" or P0.15 "O_Punkt_Offset" are too great.

Check the parameters e.g. P0.13 "Softlimit_Pos" 999 999.999 units. P3.00 "Auflösung_Geb_0" 4096.0000 incr/unit -> calculate value in increments -> 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. The value range (I32) is exceeded when 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.

Reset system variables in the user program in good time.

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 SYNG is used in a PLC program part.

Check the user program.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

44 / 126

9416

Target window timeout The target window is not reached during a positioning.

Cause

Remedy

The target window in the parameter P1.03 "Zielfenster" has been selected too small.

Increase the parameter P1.03 "Zielfenster".

The parameterization of the control circuits (parameter group 2 and P4.10 - P4.13) is not correct.

Check the parameters.

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 temperature is too high.

Check the ventilation of the switch cabinet (filter may be dirty). Check the function of the air conditioning unit.

Hardware defect: the temperature sensor is defective.

Replace the PMC-2.

9427

Inner temperature high The PMC-2 inner temperature is too high.

Cause

Remedy

Ventilation is insufficient or the ambient temperature is too high.

Check the ventilation of the switch cabinet (filter may be dirty). Check the function of the air conditioning unit.

Hardware defect: the temperature sensor is defective.

Replace the PMC-2.

9430

Bleeder I²T The bleeder resistance is overloaded.

Cause

Remedy

The drive is wrongly dimensioned.

Check the drive rating.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9481

45 / 126

ECL error 4 A class 4 error with the ECL statement "ERROR 4” 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 program.

See ECL user program or description relating to the ECL user program.

9522

Phase failure Failure of a phase (or two) of the mains connection.

Cause

Remedy

Wiring defect: not all phases are connected or the mains contactor is not correctly wired.

Check the wiring.

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 PMC-2 has a class 1 or 2 error.

Look for the PMC-2 with the error and 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.

Ventilation is insufficient or the ambient temperature is too high.

Check the ventilation of the switch cabinet (filter may be dirty). Check the function of the air conditioning unit.

Hardware defect: the temperature sensor is defective.

Replace the PMC-2.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

46 / 126

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 cable, voltage outside of the range 22...33 V).

Check the brake or wiring.

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 counterbalance is defective.

Check the drive rating and counterbalance.

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 <50).

Check the drive rating.

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

An error has been triggered by the user program.

See ECL user program or description relating to the ECL user program.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9584

47 / 126

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 or deleted.

Send ANA-1 in for checking.

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 connected.

Change parameter P0.21 "COM2_Anwendung" or P0.26 "COM1_Anwendung".

Wiring defect: no connecting cable is plugged into the operator control device or the cable is defective.

Make the connection to the operator control device, check the cable.

Hardware defect: the operator control device is defective.

Replace the operator control device.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

48 / 126

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 statement has been composed and the internal calculations for the POS statement were not able to be terminated in good time.

Compose AXIS statement again. Reduce the system load.

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 (external EMERGENCY STOP).

Use wiring diagram for troubleshooting.

9701

Cross-feed auger faulty

Cause

Remedy

The motor of the cross-feed auger on the displayed filler is overloaded.

Check the cross-feed auger for smooth 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 is overloaded.

Check the agitator for smooth 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.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9703

49 / 126

Protective motor switch

Cause

Remedy

Protective motor switch for drive of the cross-feed auger and agitator in the filler has triggered.

Check the protective motor switch and servomotor. 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 overloaded.

Check the closure for smooth operation. Check the mechanical components for damage.

Only in case of a closure with a servomotor. The current supply plug of the electricity supply is not plugged in.

The electricity supply plug is not plugged in. Check the servomotor's brake.

For pneumatic closure only. The initiator is not being reached in the preset time.

Check the closure for smooth operation. Check the pneumatics. 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 filler.

Top off the product. Check the product feed to the product distributor.

Initiator for the product scan is defective, unplugged or incorrectly set.

Check the initiator. Readjust the sensitivity of the initiator. "Calibrated filling" is not possible, if there is a product empty message.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

50 / 126

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 current dosing time.

To eliminate the delay when closing the 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. The program has errors. Profibus transfer is faulty.

Switch off the displayed filler and switch it back on again (on the operator control and display terminal).

9711

Data loss in the RAM, transfer again

Cause

Remedy

Data loss in the format data memory. The last production/filler data are stored in the control unit. The memory duration is roughly 7 days.

Transfer the format data again (in the operator control and display terminal).

9712

Max. top-off volume exceeded

Cause

Remedy

Only for use as a top-off filler: The top-off volume of the top-off filler is exceeded. No top-off filling is taking place.

Increase the preset filling weight of the main filler (in the operator control and display terminal). Check the top-off filler.

9713

Transfer the value < = 0

Cause

Remedy

Error in the memory. The program has errors. Profibus transfer is faulty.

Switch off the displayed filler and switch it back on again (on the operator control and display terminal). Check the data entered.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9714

51 / 126

Weight too low or no new value

Cause

Remedy

Only for use as a top-off filler: The top-off volume of the top-off filler is exceeded. No top-off filling is taking place.

Increase the preset filling weight of the main filler (in the operator control and display terminal). Check the top-off filler.

9715

No calibrated filling, product is missing

Cause

Remedy

There is too little product in the displayed filler. The calibrated filling could not be performed.

Top off the product. Check the product feed to the product distributor.

Initiator for the product scan is defective, unplugged or incorrectly set.

Check the initiator. Readjust the sensitivity of the initiator.

9716

Weight regulation at the stop

Cause

Remedy

The regulating range of the filler is exhausted, because the product has changed too much.

Perform a recalibration.

Dosing auger dirty.

Clean the auger.

9717

Closure is closing during dosing

Cause

Remedy

The initiator on the closure is free during dosing.

Check the mechanism. Check the wiring and initiator.

9718

Profibus faulty

Cause

Remedy

No bus connection to the filler.

Check the Profibus wiring/operability.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

52 / 126

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 is defective.

Check outputs for short circuit, replace fuse with same type.

9721

Motor temperature of agitator

Cause

Remedy

Thermal contact in the agitator motor has triggered.

Check the agitator for smooth operation. 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 has triggered.

Check the cross-feed auger for smooth 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.

717079MS5025W | Version 1.0 | en 2TxtDosi106

Bosch Packaging Technology

6 | Troubleshooting

9724

53 / 126

Wrong operating mode

Cause

Remedy

Function not possible in the set operating mode.

Change the operating mode.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDosi106

6 | Troubleshooting

54 / 126

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 operating instructions.

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 and the battery voltage is insufficient.

Re-initialize the retain area and the clock. Change the battery with the aid of the operating instructions.

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, voltage outside the range of 24 V +/-10 %).

Check brake and wiring.

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 defective.

Check drive settings and weight balancing, run 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 temperature.

Check equipment ventilation and ventilation 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 defective.

Exchange device.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10102

55 / 126

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 winding is connected incorrectly.

Check wiring.

Wiring error: Shield of motor cable is applied incorrectly.

Check shield clamp at the bottom of the MC-4 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 in motor winding.

10103

Exchange motor.

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 temperature.

Check equipment ventilation and ventilation 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 below 24V DC.

Check 24 V control voltage.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

56 / 126

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 servo amplifier or PacDrive controller is pulled off or defective.

Check encoder cable and exchange if necessary, check mass connection (shield).

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 connected incorrectly or has a short circuit.

Check wiring.

Servo amplifier: The current regulator parameters are incorrect.

Parameterize.

Hardware error servo amplifier: short circuit in the motor.

Exchange motor.

Power supply devices PS-4/PS-5: Too many consumers are connected (ServoDrive SCL, Intelligent Servo Module iSH).

Use an additional power supply and distribute the power supply for the consumers. The existing arrangement of devices may be made adequate by adjusting one of the applications (e.g. decreasing acceleration).

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10108

57 / 126

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 high, which results in increased voltage.

Brake more slowly, check dimensioning of 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 amplifier.

Find servo amplifier with error and clear error.

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 correctly or mains contactor wired incorrectly.

Check wiring.

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 with CAM functions (e.g. MultiCam).

Check cam data.

The axis should be run with revolution control.

Set parameter Pos_P_Gain to "0".

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

58 / 126

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 predecessor too low or too high.

Set intensity according to configuration.

Hardware error: Optical fiber defective or signal too weak.

Exchange optical fiber; it may be sufficient to 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 Ohm value).

Check brake resistor dimensioning (see also Project Manual and Technical Data).

Hardware error: Braking resistor (bleeder) defective.

Measure bleeder resistor and, if necessary, exchange bleeder.

Hardware error: Device with internal braking resistor defective.

Exchange device.

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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10116

59 / 126

Commutation error

Commutation cannot be detected. Cause

Remedy

Motor is turning during MC-4 boot of power amplifier MC-4.

Make sure that the motor is standing when booting the servo amplifier.

Wiring error: Encoder cable not connected or defective.

Check wiring.

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 to phase or phase to casing).

Exchange motor.

Hardware error: End stage in servo amplifier is defective.

Exchange servo amplifier.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

60 / 126

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 rated speed bigger than 6000 rpm.

Use Firmware version starting from V00.22.00 in the power amplifier MC-4.

Error occurs in CAM function (e.g. MultiCAM9 due to wrong cam or profile data.

Check cam data and program.

Jumps occurred in the master encoder.

Check master encoder.

The error occurs in a CAM function due to an incorrect position manipulation (e.g. Setpos1() function).

Check program.

Hardware error: Commutation error, i.e. the motor encoder (SinCos) is not adjusted and/or trimmed.

Please contact the customer service.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10123

61 / 126

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 The set mode in the parameter InverterEnableMode does not correspond with the real devices.

10124

Check parameter InverterEnableMode and adjust if necessary, check iSH hardware configuration and, if necessary, plug in or pull off iSH-DIS1.

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 function.

Mechanics are tight or blocked, check driving 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

Warning of control device.

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

62 / 126

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

Warning of control device.

-

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

Warning of the control device.

-

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

Warning of the control device.

-

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10132

63 / 126

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 intolerant.

Increase object parameter FollowingLimit.

Acceleration is too high.

Reduce acceleration.

Following error is a result of the diagnosis message 100 "I2T motor".

Mechanics are tight or blocked, check driving 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 motor connector connected maybe from neighboring actuator).

Check encoder connector and motor connector, check connector cable and motor 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 installed.

Check encoder.

Hardware error: Coupling to the position encoder is loose.

Check encoder coupling.

Hardware error: Encoder signal gives jumps.

Check driving range.

The axis should be operated with velocity control.

Set parameter Pos_P_Gain to 0.

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).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

64 / 126

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 there, but the mains voltage is too low.

Check mains voltage (see also Technical Data of the device); the mains contactor may not be connected.

Parallel connected DC links, one servo amplifier has an error.

Search the servo amplifier with error and clear error.

10136

"Inverter Enable" warning

Attempt to start the drive, but inverter enable is still LOW. Cause

Remedy

Hardware enable and software enable are there, but "inverter enable" is still LOW.

Switch on "inverter enable".

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 connecting a motor to an MC-4 that was parameterized to motorless. After that, the MC-4 was changed to normal operation.

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.

10138

Inadmissible motor

An inadmissible motor is connected to the MotorController. Cause

Remedy

An SM 070 60 010 is connected to the MC-4 / 22 A.

Use a "bigger" motor (e.g. SM 070 60 020) or a "smaller" MotorController (e.g. MC-4 / 10 A).

An SM 070 60 010, SM 070 60 020 or SM 100 50 030 is connected to an MC-4 / 50 A.

Use a "bigger" motor (z. B. SM 100 40 050) or a "smaller" MotorController (z. B. MC-4 / 10 A).

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10139

65 / 126

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 message: 1. The parameter DC_LowCheck is "off". 2. The mains voltage drops and the drive remains in regulation. (If DC_LowCheck is "on", diagnosis message 109 "Undervoltage" 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.

Prevent drop of mains voltage while the drive is in regulation. Switch off regulation or the end stage of the MotorController when switching off the mains contactor (parameter ControllerEnable or input enable on the MotorController).

Short circuit or ground fault in DC voltage wiring.

Check 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 observe the set stop time limit.

Check the parameter StopTimeLim.

Encoder in the motor is defective (or commutation not ok).

Exchange motor.

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.

Bosch Packaging Technology

Exchange motor.

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

66 / 126

10142

Board power-off due to overtemperature

The board temperature inside the housing is too high. Cause

Remedy

Ventilation is inadequate or the ambient temperature is too high.

Check the control cabinet ventilation system, check air conditioning unit (if available) for proper function.

Hardware error: The temperature sensor is defective.

Exchange the device.

10143

Encoder temperature warning

The temperature inside the encoder is too high. Cause

Remedy

Ventilation is inadequate or the ambient temperature is too high.

Check equipment ventilation and ventilation openings (if applicable), check control cabinet ventilation, check function of the air conditioning system (if applicable).

Hardware error: The temperature sensor is defective.

Exchange the device.

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 power supply via the terminal boxes to the ServoDrives are incorrectly connected or short circuited.

Check cables and exchange, if necessary.

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 power supply via the terminal boxes to the ServoDrives are incorrectly connected or ground circuited.

Check cables and exchange, if necessary.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10146

67 / 126

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 connected to the DC bus.

Maybe the existent device constellation is 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, Intelligent Servo Module iSH) are connected.

Use another power supply PS-4 and divide the 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

68 / 126

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.

External fuse reacted.

Check fuses.

The mains contactor is defective.

Exchange mains contactor.

10151

Phase L2 failure

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.

External fuse reacted.

Check fuses.

Mains contactor defective.

Exchange mains contactor.

10152

Phase L3 failure

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.

External fuse reacted.

Check fuses.

10153

DC bus discharge failure

DC bus was not discharged properly. Cause

Remedy

Too much braking energy is being fed from the connected SCL back into the DC bus.

Decelerate the drives before discharging (at a reduced rate of speed if necessary) and then start the discharge procedure. Incorrect shutdown sequence.

Phase voltage has been present for too long (see also 159 "DC bus not discharged warning").

Allow the mains contractor to release before activating the discharge.

The bleeder (responsible for the discharge) reaches maximum load when the discharge begins.

Decelerate the drives before discharging (at a reduced rate of speed if necessary) and then start the discharge procedure.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10154

69 / 126

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

Warning of the control device.

-

10155

Phase L2 warning

The phase L2 of the mains connection of the device has failed. If the warning persists for 10 s or longer, the system issues the error message 151 "Phase L2 failure". Cause

Remedy

Warning of the control device.

-

10156

Phase L3 warning

The phase L2 of the mains connection of the device has failed. If the warning persists for 10 s or longer, the system issues the error message 152 "Phase L3 failure". Cause

Remedy

Warning of the control device.

-

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

Warning of the control device.

-

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

Warning of the control device.

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

70 / 126

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 incorrectly.

Check the wiring.

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

Warning of the control device.

-

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 defective.

Exchange the device.

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

Warning of the control device.

-

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10164

71 / 126

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

Warning of the control device.

-

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

Warning of the control device.

-

10166

SERCOS: C2D manufacturer-specific error

A manufacturer-specific SERCOS error in diagnosis class 2 (C2D) 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

Warning of the control device.

-

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

Warning of the control device.

-

10168

SERCOS: C3D manufacturer-specific error

A manufacturer-specific SERCOS error in diagnosis class 3 (C3D) 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

Warning of the control device.

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

72 / 126

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 causes: Signal distortion, loss of more than 10 signal edges (fiberoptic break), failure of master synchronous telegram (MST), failure of master data telegram (MDT), signal over SERCOS fiberoptic conductor incorrect.

Check the intensity setting in the PacDrive Controller and on the servo amplifier. Check fiberoptic conductor.

EMC problems.

Check wiring.

SCL-055 motors are connected to the PacDrive -Controller. The SCL-055 motors in the PacDrive PD-8 Box is connected incorrectly.

Check the connection of the SCL-055 motors in the PacDrive-PD-8 Box. Simply placing jumpers 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 not be processed properly.

Call the DrvEncSetPosition() function again.

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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10172

73 / 126

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

Warning of the control device.

-

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

Warning of the control device.

-

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 connected to the DC bus.

Use an additional power supply PS-4 and 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 the DC bus is too high and therefore results in voltage build-up.

Brake at a slower rate. Check the dimensioning of the bleeder. Use additional bleeder module (BM-4) with 400 V AC devices.

10176

Reserved

This diagnosis code is reserved. Cause

Remedy

Warning of the control device.

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

74 / 126

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 is too high.

Check the control cabinet ventilation. Check the air conditioning device (if available) for proper function.

Hardware error: the temperature sensor is defective.

Exchange the device.

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 the DC bus is too high and therefore results in voltage build-up.

Brake at a slower rate. Check the dimensioning of the bleeder. Use additional bleeder module.

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

Warning of the control device.

-

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10181

75 / 126

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 parameter which does not exist in the control configuration.

Check program. Please contact the application department.

Following error of diagnosis message 209 "last boot failed". The configuration file of the control is corrupted.

See diagnosis message 209 "last boot failed". Retransmit the configuration file to the control.

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

Warning of the control device.

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

76 / 126

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 controller or parameter file is faulty.

Retransmit the parameter file with EPAS-4.

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 controller or the IEC program is defective or incompatible.

Retransmit with EPAS-4 IEC program.

IEC program code, IEC data range or IEC retain range in the PacDrive controller too large.

Adjust project.

The settings under “Number of data segments“ EPAS-4 Project/Options/Compilation options is less than 2 (DiagExtCode = ret xhhhhhhhh).

Increase number of data segments.

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=.

Enter valid value for BaudRate.

l=0Bxx0004; i.e. a too high or too low value for "acceleration" was entered in the virtual encoder.

Enter valid value for Acceleration.

l=03xx0025; i.e. J_Load in the control configuration is too high.

Enter valid value for J_Load.

l=01000004;i.e. IP_Gateway in the control configuration does not match IP_SubNetMask.

Observe conventions of IP address nomenclature.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10206

77 / 126

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 not exist was entered in the control configuration.

Check control configuration.

Hardware error: Hardware module not recognized or defective.

Exchange PacDrive controller or optional module.

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 high.

Check cycle time.

The number of axis per PacDrive controller is limited.

Check type plate for PacDrive controller type.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

78 / 126

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 the boot procedure of the PacDrive controller was not yet complete.

Use the GetPacDriveBootState() function to make sure that the PacDrive controller has stopped the boot procedure before you use the SysReset() function.

DiagExtCode = 19: programming error, i.d. the IEC program file is incorrect.

Overwrite the IEC program on the PacDrive 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 quick succession. This may have been caused by pressing the reset button twice or a drop in the control voltage.

Check control voltage (see also Technical Data).

Insufficient RAM in the PacDrive controller for the project (DiagExtCode=out of memory).

Reduce configuration. RamDiskSize must be decreased. Reduce number of tasks. Apply a PacDrive controller that has more RAM.

A PacDrive controller version 00.15.00 or higher is being used. The user data area was 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.

Use a PacDrive controller that has at least 32 MB RAM or firmware versions < V00.15.00.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10210

79 / 126

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 boot is also in error. However, this is caused by having insufficient RAM in the PacDrive controller MAx-4 (RAM<32 MB).

Exchange the PacDrive controller MAx-4 with a device that has newer hardware or use an older firmware version in the PacDrive controller MAx-4 (lower than V00.15.03).

10211

Invalid configuration

A configuration error has occurred. Cause

Remedy

Cause, firmware V00.20.00:The connector parameter is set for the "Bottom / 1" connector, but there is no expansion module present in the PacDrive controller (C600 or P600).

Check the "Connector" parameter in the control configuration.

Cause, firmware V00.16.41: This diagnosis 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.

Check the control configuration.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

80 / 126

10302

Stack error

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10303

General protection error

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10304

Coprocessor error

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10305

Memory limit exceeded

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10306

Arithmetic overflow

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10307

Double execution error

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10308

81 / 126

Invalid task state segment

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10309

No memory segment

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10310

Faulty memory segment adjustment

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10311

Coprocessor division error

A system error has occurred. Cause

Remedy

A system error has occurred.

Please contact the service department.

10312

Parameter relocation failed

A system error has occurred. Cause

Remedy

Program not matching active configuration.

Retransmit the project.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

82 / 126

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 which takes "very long" to process. Time interval too short.

Increase interval time in the task configuration.

10314

Defective program file

A system error has occurred. 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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10316

83 / 126

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 controller was not switched on for more than 7 days (control voltage!).

Reboot the PacDrive controller. Now the error must not reappear.

Object in the message logger: "PN4" The internal or external battery on the optional module PN-4 is empty and the PacDrive controller was not switched on for more than 7 days (control voltage!).

Reboot the PacDrive controller. Now the error must not reappear.

Object in message logger: "MAX4" External diagnosis in the message logger: Nvram damaged The NvRam of the PacDrive controller is defective.

Exchange PacDrive controller.

Object in message logger: "PN4" External diagnosis in the message logger: Nvram damaged The NvRam of the optional module PN-4 is defective.

Exchange optional module PN-4.

Hardware error: The buffer capacitor is defective.

Exchange PacDrive controller.

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

Warning of the control device.

-

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 deleted too early or the wrong profile was deleted.

Check program.

Program error: Asynchronously running high priority FastTasks were used.

Synchronize FastTask to real time process.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

84 / 126

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 configuration and the PacDrive controller hardware does not correctly support the touchprobe measurement at this CycleTime.

Set CycleTime to 1 or 2 ms, if possible. Update PacDrive controller hardware. Contact the customer service.

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 accessing an array in the IEC program.

Check the IEC user 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 0.

Intercept division by 0 in the IEC program. 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

Warning of the control device.

-

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 the IEC user program.

Check IEC user program.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10324

85 / 126

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 “ON/OFF“ is OFF.

With correct power supply, the input “ON/OFF“ must be ON in order for the UPS function to be available.

A UPS object is entered in the control configuration, but no UPS is connected.

Connect UPS or adjust control configuration.

An internal error occurred in the UPS.

Check UPS.

Ext. diagnosis: "PIC fail" or "State=5". An internal error of the PIC Controllers has occurred.

Please contact the service department.

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 configuration, but no UPS is connected.

Connect UPS or adjust control configuration.

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 not support this function.

Check the hardware version on the type plate 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 axis (MC-4 or SCL)was not specified in the PositionSource.

Check the value in the PositionSource parameter.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

86 / 126

10328

Invalid destination

The CamTrack in the Destination parameter contains an invalid value. Cause

Remedy

The Destination parameter was specified either without the symbolic name of an output group or with "none".

Check the value in the Destination parameter.

10329

Invalid BitNumber

The CamTrack in the Bitno parameter contains an invalid value. Cause

Remedy

An invalid bit number was specified in the Bitno parameter.

Check the value in the 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 flash card of the PacDrive controller is not sufficient.

Check the number of required license points on the Licensing parameter in the control configuration.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10332

87 / 126

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 flash card of the PacDrive controller is not sufficient.

Check he number of required license points based on the Licensing parameter in the 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, SYN_DOUT).

Please contact the service department.

Synchronization was lost while the object (SYN_DIN, SYN_DOUT) was activated.

Please contact the service department.

The number of data sets (xxx) that was not received sequentially exceeds the limit specified in DataCycleErrorLimit.

Please contact the service department.

Due to an internal error, the system was unable to send a telegram for 5 cycles.

Please contact the service department.

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 more data sets were not received sequentially, as specified in the DataCycleErrorLimit, diagnosis message 333 "Fatal error receiving encoder data".

Please contact the service department.

10335

Fatal synchronization error

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

Bosch Packaging Technology

Remedy

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

88 / 126

Initialization of the synchronization master or synchronization slave failed.

Check SlaveIPAddress parameter of the sync. module in the synchronization master control configuration.

The IP address (SlaveIPAddress) of the sync. module is assigned twice.

Check SlaveIPAddress parameter of the sync. 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 another synchronization master that is in the same network.

Change the MasterID.

The synchronization master protocol version does not match the synchronization slave protocol version.

Use compatible software versions of the controls. Please contact the service department.

The synchronization master failed to respond to Check the Ethernet connection to the a ping. synchronization master. The IP address (SlaveIPAddress) of the synchronization module is assigned twice.

Check the SlaveIPAddress of the synchronization module parameter in the synchronization master control configuration.

SlaveCycleTime is not a multiple of the SERCOS cycle time.

Adjust the SlaveCycleTime parameter or the SERCOS cycle time.

The addresses synchronization slave is not properly configured or is not responding.

Check the configuration of the synchronization slave (e.g. same CycleTime). Check the TCP/IP connection synchronization master to synchronization slave.

The SERCOS cycle time differs on synchronization master and synchronization slave or the synchronization slave configuration cannot be sent.

Adjust the CycleTime parameter of the synchronization master or the synchronization slave.

The addresses synchronization slave is in an error state.

Acknowledge the error in the synchronization slave.

External diagnosis: "No DataOut"

Check control configuration. Activate sync. Encoder output if necessary (Enable parameter).

No sync. Module and no sync. encoder input has been configured or activated.

Check the control configuration. Activate the sync. module or sync. encoder input (sync. module Enable parameter or sync. encoder input Enable parameter).

The synchronization slaves are unable to synchronize the synchronization master. No sync. encoder output is configured or activated. The Ethernet (see SyncQuality parameter) and / or The CPU load (see AvailableLoad parameter) is too high.

Check Ethernet connection. Optimize the IEC project to reduce the CPU load.

The number of sequential synchronization telegrams (xxx) which were not received exceeded the number specified in SlaveCycleErrorLimit. The Ethernet see SyncQuality parameter) and / or the CPU load see AvailableLoadparameter) is too high.

Check Ethernet connection. Optimize the IEC project to reduce the CPU load. Increase the SlaveCycleErrorLimit.

The sync. encoder outputs are unable to configure the sync. encoder inputs or a data error has occurred while the system is running.

Check the DiagCode parameter of the sync. module to receive more detailed information about the source of the error.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

89 / 126

Not all sync. encoder outputs and sync. encoder inputs are ready to exchange data.

Check the DiagCode parameter of the sync. 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 high.

Reduce the value of the DynIECDataSize parameter.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

90 / 126

10338

UPS accu error

The battery is not sufficiently charged. Cause

Remedy

The PacDrive controller has been switched off for too long.

Switch on the PacDrive controller. The battery will be charged automatically when the PacDrive controller is on.

The UPS has been operating in the battery mode (state = 3) for an extended period.

Check the supply voltage. Maybe switch on the PacDrive controller. The battery will be charged automatically when the PacDrive controller is on.

The battery capacity is insufficient due to aging.

Please contact the service department.

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().

10401

IEC diagnosis message class3

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().

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10402

91 / 126

IEC diagnosis message class4

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().

10403

IEC diagnosis message class5

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().

10404

IEC diagnosis message class6

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().

10405

IEC diagnosis message class7

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().

10406

IEC diagnosis message class 1

TODO Cause

Remedy

-

-

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

92 / 126

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 the SERCOS slaves.

Determine duplication of addresses in the parameter DiagExtCode. Check and adjust the parameter RealTimeBusAdr in the control configuration.

A SERCOS slave address was issued several times in the control configuration.

Check the rotary switch settings at the 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 bus.

Integrate SERCOS slave in SERCOS bus or remove SERCOS slave from the control configuration or parameterize as virtual device.

SCL-055 motors are connected to the PacDrive controller. The connection of the SCL-055 motors in the PacDrive PD-8 Box is incorrect.

Check the connection of the SCL-055 motors in the PacDrive PD-8 Box. It is not sufficient to 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".

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10502

93 / 126

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 was reset.

Check voltage supply (24 V) of the device. Switch the device on.

SCL-055 motors are connected to the PacDrive controller. The connection of the SCL-055 motors in the PacDrive PD-8 Box is incorrect.

Check the connection of the SCL-055 motors in the PacDrive PD-8 Box. It is not sufficient to 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".

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 smaller than V00.15.00 are in the loop that are not addressed as real devices. This causes during phase run-up of the SERCOS bus a serious error including abortion of the phase run-up.

For SERCOS slaves (MC-4) with a firmware version smaller than V00.15.00, that are not addressed as real devices, the SERCOS address must be adjusted to 0 at the device.

EMC problem.

Check electric environment.

HW problem of a SERCOS slave (e.g. power amplifier MC-4) or the SERCOS master (e.g. PacDrive controller MAx-4).

Please contact the service department.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

94 / 126

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 off and therefore no longer supply data on the SERCOS-Bus.

Switch on SERCOS slave.

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.

SCL-055 motors are connected to the PacDrive controller. The connection of the SCL-055 motors in the PacDrive PD-8 Box is incorrect.

Check the connection of the SCL-055 motors in the PacDrive PD-8 Box. It is not sufficient to 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".

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10506

95 / 126

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 when reinitialization and reference of the system by the IEC program is secured.

The acknowledgability of the diagnosis message can be switched off via function DiagNoQuitSet(). Possibly use functions SysReset() or PrgResetAndStart().

A drop of the control voltage (24 V DC) has occurred. Possibly the diagnosis message 134 "External 24 V supply too low" is still entered in the message logger (if it still could be transferred via SERCOS bus).

Check control voltage (see also Technical Data of the device).

SERCOS slaves (MC-4) with a firmware version smaller than V00.15.00 are in the loop that are not addressed as real devices. This causes during phase run-up of the SERCOS bus a serious error including abortion of the phase run-up.

For SERCOS slaves (MC-4) with a firmware version smaller than V00.15.00, that are not addressed as real devices, the SERCOS address must be adjusted to 0 at the device.

SCL-055 motors are connected to the PacDrive controller. The connection of the SCL-055 motors in the PacDrive PD-8 Box is incorrect.

Check the connection of the SCL-055 motors in the PacDrive PD-8 Box. It is not sufficient to 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".

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 off and no longer supply data on the SERCOS bus.

Switch on SERCOS slaves.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

96 / 126

10508

SERCOS boot error

A system error has occurred. Cause

Remedy

In the control configuration, virtual SERCOS slaves are entered although the slaves are physically connected to the SERCOS bus.

Check RealTimeBusAdr parameter of the SERCOS slaves in the control configuration.

There are more SERCOS slaves in the loop than entered in the control configuration.

Check the number of SERCOS slaves in the 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.

SCL-055 motors are connected to the PacDrive controller. The connection of the SCL-055 motors in the PacDrive PD-8 Box is incorrect.

Check the connection of the SCL-055 motors in the PacDrive PD-8 Box. It is not sufficient to 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".

In case of a bad connection, it is possible that no loop interruption is detected. The transfer 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.

Check the intensity setting for the SERCOS interface. Check the wiring of the SERCOS bus.

A synchronization error has occurred during phase run-up.

Please contact the service department.

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 (MC-4, SCL, PS-4, ...) is higher than the firmware version of the PacDrive controller in the first 4 digits.

Update PacDrive controller firmware or install an "older" firmware version on the SERCOS slave.

The SERCOS slave is in boot loader mode. The version of the bootloader is displayed in the message logger under ext. diagnosis. Furthermore, with the help of the information about object and entity in the message logger, the SERCOS slave can be determined.

Pull off programming cable from SERCOS slave. Reset SERCOS slave. Acknowledge diagnosis message. The SERCOS bus runs up in phase 4.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10510

97 / 126

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 plant. The 24V control voltage of the SERCOS slave is lifted faster than the 24V control voltage of the PacDrive controller.

Check wiring or wiring diagram.

Wiring error: The fiberoptic cable of the SERCOS bus is damaged.

Exchange fiberoptic cable.

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 configuration.

Increase the CycleTime parameter of the 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) on the SERCOS slave (MC-4, SCL, PS-4, ...) was not set correctly.

Check if the address setting on the SERCOS slave that is displayed in the diagnosis message. Check if the address setting on the SERCOS slave matches the address setting in the control configuration (RealTimeBusAdr).

The SERCOS address (RealTimeBusAdr) has not been specified correctly in the control configuration.

Check the RealTimeBusAdr parameter of the device displayed in the diagnosis message.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

98 / 126

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 configuration file (e.g. a PS-4 firmware for a MC-4). This diagnosis message is generated for each SERCOS slave.

Adjust the configuration file.

The "Download Mode" in the configuration file is specified as "upgrade" (or "downgrade") and the current firmware version is higher (or lower) than the firmware version that is to be programmed.

Check firmware version of the SERCOS slave. Adjust configuration file, if necessary.

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 have been incorrectly set via the rotary switch on the device.

Check the address settings on the SCL.

The address of the PS-4 power supply/power supplies has been set incorrectly via the rotary switch on the device.

Check the address settings on the PS-4.

The RealTimeBusAdrcontrol parameter in the control configuration contains incorrectly specified PS-4 and/or SLC addresses.

Check the RealTimeBusAdr parameter in the control configuration.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10517

99 / 126

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 than once in the RealTimeBusAdr parameter in the control configuration.

Check the RealTimeBusAdr parameter in 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>/. 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, SCL) for the cycle time is too high.

Check the cycle time. Check the baud rate.

Limited by the hardware configuration (licensing).

Check the PacDrive controller type by referring 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 incorrectly or defective.

Check and, if necessary, exchange encoder 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 the control is defective.

Exchange control.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

100 / 126

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 incorrectly or defective.

Check and, if necessary, exchange encoder cable.

Hardware error: SinCos encoder defective.

Exchange encoder.

Hardware error: SinCos encoder interface in the control defective.

Exchange control.

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 could not be processed fast enough. Hardware error: CAN module defective.

Exchange module.

10702

CAN Layer 2 1 error occurred

A send or receive error occurred. Cause

Remedy

Two nodes are using the same identifier or COB-ID.

Check identifier or COB-ID.

Temporarily disturbed connection to receiver. Dominant signal level due to external disturbance, critical bus time setting (Baud rate) or bus length, bus error.

Check bus wiring and environment.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10703

101 / 126

CAN Layer 2 error reaches warning limit

The number of send or receive errors set in the warning limit register have occurred. Cause

Remedy

Warning of the control device.

-

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

Warning of the control device.

-

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 command or state messages fast enough from the CAN module, which resulted in a buffer overflow and the loss of XXX messages.

Please contact the service department.

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 enough from CAN bus, which resulted in a loss of messages.

Please contact the service department.

CPU on CAN module could not read CAN 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.

Please contact the service department.

CPU on CAN module could not send CAN 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.

Please contact the service department.

Unspecified event error of the CAN module. Default branch event error evaluation. Should not occur.

Please contact the service department.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

102 / 126

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

Warning of the control device.

-

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

Warning of the control device.

-

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 hard disk of the P600) does not exist or is incorrect.

Check if the valid firmware file is available.

Optional module does not exist.

Install module or send control/drive for modification.

An optional module that does not exist was entered in the control configuration.

Check the control configuration.

A phys. master encoder (SinCos encoder) is entered in the control configuration at the BT-4/ENC1, but no phys. master encoder at the connector BT-4/ENC1.

Attach the incremental encoder cable to the BT-4/ENC1 connector. Check encoder cable. Check I/O address.

Hardware error: Module defective.

Exchange module.

Hardware error: Control defective.

Exchange control.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10721

103 / 126

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 not ready.

Exchange module in the control.

The FPGA firmware file does not match the FPGA pinout. This could damage the module.

Copy correct FPGA firmware via FTP to control flash disk and restart control.

The FPGA could not be programmed. The firmware does not match the module.

Copy correct FPGA firmware via FTP to control flash disk and restart control.

The FPGA firmware file could not be opened. Flash disk may be defective.

Exchange flash disk.

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 flash disk and restart control.

No FPGA firmware file found on the flash disk.

Copy correct FPGA firmware via FTP to control flash disk and restart control.

The time of the RealTimeClock of the optional module PN-4 could not be set. Diagnosis message cannot be acknowledged.

This is a problem of a very early hardware version of the PN-4. To clear fault, the PN-4 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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

104 / 126

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.

Hardware error: Control defective.

Exchange control.

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 exchange. This program may occurred in Controller versions smaller than V00.16.20.

Reset the Controller (EPAS-4: Online > Reset PacDrive controller).

A project with a different setting of MaxNumOfPOUs was transmitted to EPAS-4 in the file "EPAS-4.ini".

Match the settings of the MaxNumOfPOUs against your EPAS-4 installations. Reset the 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

Warning of the control device.

-

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 via the Controller was not successful.

Repeat firmware download.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10730

105 / 126

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 the control configuration from EPAS-4 to the control.

Retransmit the control configuration.

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.

Wiring error: Faulty bus topology.

Check terminals, stubs.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

106 / 126

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

Wiring error: Faulty bus topology.

Check terminals, stubs.

EMC problem.

Check wiring and EMC protection.

A synchronization error occurred. The touchprobes to BT-4/DIO1 are not working.

Check bridging cable between the control and the optional module PN-4 (in the control).

A communication error occurred in PacNet. This can have several reasons: PacNet loop not closed, PacNet terminal connector missing, failure of a module connected to PacNet (no voltage supply).

Check PacNet loop and all modules in the loop.

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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10737

107 / 126

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 time of checking; node permits no Sdo access to Index 0x1000; wrong or faulty electrical connection; node addresses set incorrectly.

Check configuration.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

108 / 126

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 control or was deleted.

Description file transmitted via FTP to the control.

10753

Init of CanOpen module failed

An error occurred during the initialization phase of the CANopenmodule. Cause

Remedy

Software error.

Please contact the service department.

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 configuration was sent. Electrical bus connection distorted or faulty.

Check wiring.

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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10757

109 / 126

CanOpen config error

An error occurred when configuring the individual CANopen slaves. Cause

Remedy

CANopen node cannot be addressed via Sdo access (node e.g. still in boot phase); node 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.

Check electrical connection. Please contact the service department.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

110 / 126

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 not set duly in the control.

Check setting of interrupts against the 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 parameters are not entered correctly.

Check parameters.

Connector of incremental encoder was connected or unconnected while device was switched on (control voltage on!).

Switch off device. Connect or disconnect connector. Switch on device. device is 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 control.

Connect encoder cable.

Wiring error: Encoder cable defective.

Check encoder cable and exchange, if necessary.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10782

111 / 126

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 stimulation not yet ready for operation.

By default, monitoring can be switched off 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 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.

Exchange PN-4 module.

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 found. The module cannot be used.

Check the configuration of the module in the control configuration.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

112 / 126

6 | Troubleshooting

No module at the PacNet was found.

Switch on control voltage at the module.

The module with the bus address xx repeatedly give no response. This may be caused by a power failure or a defective module. The module cannot be used.

Check the module address on the module. Check the module address in the control configuration. Check the power supply of the module. Maybe exchange the module.

The supply voltage for outputs 0-7 of the BT-4/DIO1 or iSH-DIO8 is not available or too low. These outputs cannot be used. The diagnosis message is only triggered by the iSH-DIO8 in case of PowerSupply = "Extern / TRUE".

Check supply voltage of the outputs. The message can be disabled with the DiagPF0_7Enable parameter.

The mains voltage for outputs 0-7 of the BT-4/DIO1 missing or too low. Those outputs cannot be used.

Check power supply of the outputs. The message can be switch off via the parameter DiagPF8_15Enable.

No "c2_xpxx.bin" file was found on the flash of the C200. xpxx is in accordance with the FPGA firmware version. The Controller C200 cannot be used. The pinout of the Controller C200 must match the pinout of the FPGA firmware. The pinout of the FPGA firmware is the number represented by p in the xpxx of the FPGA firmware version. The pinout of the control can be read in the ControllerType1 parameter and is indicated by P in FPGA=pyxxxx.

Install the valid FPGA firmware file "c2_xpxx.bin" with the matching pinout to the flash disk of the C200. During installation of a firmware version to the Controller C200, the firmware assistant automatically copies the firmware file "c2_xpxx.bin" to the flash of the C200.

No file "c2_xpxx.bin" was found on the flash of the C200. xpxx is in accordance with the FPGA firmware version. The Controller C200 cannot be used. The pinout of the Controller C200 must match the pinout of the FPGA firmware. The pinout of the FPGA firmware corresponds to the number at position p in xpxx of the FPGA firmware version. The pinout of the control can be read off in the parameter ControllerType1 under FPGA=pyxxxx at position p.

Attach the valid FPGA firmware file "c2_xpxx.bin" with the appropriate pinout to the flash disk of the C200. During attachment of a firmware version to the Controller C200, the firmware assistant copies automatically the firmware file "c2_xpxx.bin" to the flash of the C200.

The current firmware of the controller (C400, C600 or P600) does not match the hardware of the Controller.

Attach the appropriate firmware version with the firmware assistant to the Controller.

A FPGA version on the Controller (C200, C400, C600 or P600) was found that is not marked as beta test version. The pinout of the FPGA 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.

Install a valid FPGA firmware file to the Controller (C200, C400 and C600 -> flash disk; P600 -> hard disk).

The PROFIBUS address is larger than the max. permitted bus address.

Check the PROFIBUS configuration.

The sum of the measuring inputs and puls counters are higher than two for the iSH-DIO8.

Check the configuration (parameter IO0_Mode ... IO7_Mode).

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10788

113 / 126

Connection error

There is a connection error. Cause

Remedy

There is a short circuit or an overload at the output in question. The diagnosis message is only triggered by the SH-DIO8 only for PowerSupply = "Intern / FALSE".

Check the connections of the output.

The output has not connection or is used very little.

Check the connections of the output. It may be sensible to switch off this diagnosis message.

The external power supply of the digital outputs was not connected. The supply of the digital outputs is checked, if at least one bit is set to 1 in the DiagMask parameter of the output group object.

Check the power supply of the digital outputs. Check the DiagMask parameter.

The power supply of the encoder is too low. Short circuit of the power supply (pin 5 and 9) 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.

Check the power supply of the encoder. Check the encoder cable.

A SinCos encoder (physical encoder) was entered in the control configuration, but no SinCos encoder is recognized at the X2 or X3 connector of the BT-4/ENC1.

Connect the SinCos encoder cable to the BT-4/ENC1 X2 or X3 connector. Check encoder cable.

The connected encoder type is not supported by the system.

Check the assignment of encoder connectors.

10789

Simple bus error

A simple bus error occurred. Cause

Remedy

The module with bus address xx did not reply once. Transmission is disturbed.

Check the wiring of the module.

PacNet-Warning. An RX clock is missing.

Check the wiring of the module.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

114 / 126

10790

Module error

A module error occurred. Cause

Remedy

An error in the communication between iSH-DIO8 and iSH occurred.

Please contact the service department.

An error during the synchronization with the SERCOS cycle occurred.

Please contact the service department.

The iSH , at which the iSH-DIO8 was configured, is deactivated (RealTimeBusAdr = 200 ... 299) and the iSHDIO8 is activated (Enable = TRUE).

Check control configuration.

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 (DiagExtCode = free<512000).

Reduce control configuration, reduce 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 disk.

Repair file system. Replace flash disk. Please contact the service department.

10802

Error writing FAT

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10803

115 / 126

Inconsistency of FATs

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10804

Corrupt cluster detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10805

Corrupt file name detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10806

Corrupt file size detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10807

Multiple cluster/block detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

116 / 126

10808

Corrupt directory name detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10809

Circularly linked clusters/blocks detected

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10810

Error reading directory entry

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10811

Error writing directory entry

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10812

Lost cluster/block found

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10813

117 / 126

Device not found

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10814

Initialization of failed

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10815

Error using function with

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10816

Bootrom.sys

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10817

No device name

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

118 / 126

10818

File not found

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10819

File open error

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10820

File read error

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10821

File not continuously saved

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10822

Cluster read error

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10823

119 / 126

Contents of files different

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10824

No file name

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

10825

Invalid directory size

Cause

Remedy

An error in the file system of the flash disk occurred.

Repair file system. Replace flash disk. Please contact the service department.

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 the firmware again.

If this attempt also fails, contact the service department.

Transfer the firmware file to the flash disk (C400 and C600) or to the hard disk (P600).

If this attempt also fails, contact the service department.

Transfer the correct firmware file to the flash disk (C400 and C600) or the hard disk (P600).

If this attempt also fails, contact the service department.

Checking hardware dependencies. The message appears if PIC update files are found that have an incorrect hardware code. The index outputs the required HW index.

Use the PIC update file that matches the device (hardware).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

120 / 126

10827

Power-Off due to hardware monitoring

The hardware provides an internal "error logger" that logs all the causes for errordependent 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 error should not occur.

Please contact the service department.

10901

Software error (invalid opcode)

Cause

Remedy

During operation of the PacDrive system, this error should not occur.

Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

10902

121 / 126

Software error (page fault)

Cause

Remedy

During operation of the PacDrive system, this error should not occur.

Please contact the service department.

An old firmware < V00.10.00 was loaded on a 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.

Retransmit the project from EPAS-4.

IECPRG is entered at Object in the message logger. The IEC task stated at Instance in the message logger recognized a serious error. Possible errors are e.g. disregard of array limits, incorrect use of pointers or the address operator (ADR).

Find faulty point in the program and correct application program.

10903

Software error (class 2)

Cause

Remedy

During operation of the PacDrive system this error should not occur.

Please contact the service department.

10904

Software error (class 1)

Cause

Remedy

During operation of the PacDrive system this error should not occur.

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 motor.

Mount and adjust drive and 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 find initiator.

Check defaults in the operation. Repeat reference run.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

122 / 126

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 motor.

Mount and adjust drive and motor.

The mechanic limit for the reference run (e.g. stop or screw head) is missing.

Check and repair limit. Repeat reference run.

The travel limit for the reference run is too short to run to the limit.

Check defaults in the operation. Repeat 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 motor.

Mount and adjust drive and 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 short to run to the limit.

Check defaults in the operation. Repeat 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.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

11020

123 / 126

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 generated or not deposited on RAM disk.

Please contact the service department.

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.

Software error.

Please contact the service department.

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.

Control device defective.

Exchange control device.

Hardware Enable relay defective.

Exchange control device.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 2TxtDiag105

6 | Troubleshooting

124 / 126

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 amplifier.

Find servo amplifier with error and clear error.

Control device defective.

Exchange control device.

Software error, drive was released before DC voltage could be built up.

Please contact the service department.

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

Software error.

Please contact the service department.

717079MS5025W | Version 1.0 | en 2TxtDiag105

Bosch Packaging Technology

6 | Troubleshooting

125 / 126

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

126 / 126

6 | Troubleshooting

Notes 6.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology

Change of Size / Product

Chapter 7:

Change of Size / Product

7

7 | Change of Size / Product

1 / 22

Contents

Bosch Packaging Technology

Safety instructions

3

Preparations for a size change or product change

3

Measures prior to switching back On following a size change or product change

3

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

717079MS5025W | Version 1.0 | en T

2 / 22

7 | Change of Size / Product

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

7 | Change of Size / Product

3 / 22

Safety instructions

INFORMATION All work and activities may be carried out by trained and duly authorized persons only. All work with electric devices may be carried out by trained and duly authorized persons only.

Preparations for a size change or product change u

Cordon off a wide area around the working area.

u

Inform the operating personnel and appoint a supervisor.

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.

u

Check the fault-free functional sequence of the machine (collision-free operation).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_07_Sicherheit (7)

7 | Change of Size / Product

4 / 22

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. Serious bodily injury can occur. u

717079MS5025W | Version 1.0 | en 099440 (2)

Before working on the machine press the EMERGENCY STOP button.

Bosch Packaging Technology

7 | Change of Size / Product

5 / 22

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 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.

Bosch Packaging Technology

Comment

717079MS5025W | Version 1.0 | en 099526 (1)

7 | Change of Size / Product

6 / 22

Auger filler size change Remove the filling auger and connection WARNING Moving masses and revolving or hot components inside the 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.

2

1

6.

Loosen the four screws on the clamping 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).

3

5 4

6

717079MS5025W | Version 1.0 | en 101195 (1)

Bosch Packaging Technology

7 | Change of Size / Product

7 / 22

Auger filler size change Installing the filling auger and connection 1.

Clean the connection between filler 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.

 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.

 Turn the butt of the clamping piece relative

4

3

2

1

to the butt of the two shaft ends through 90. 5.

Tighten the four screws on the clamping piece.

6.

Close the agitator hopper shell (6) and tighten the clamping screws (7).

5

 Avoid torsion. 6

7

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 101196 (1)

8 / 22

7 | Change of Size / Product

Auger filler size change Gate closure basic setting

1 2

3

4

5

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.

717079MS5025W | Version 1.0 | en 034900 (4.2)L

Bosch Packaging Technology

7 | Change of Size / Product

9 / 22

Auger filler size change Gate closure basic setting 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.

Slacken nuts (3).

4.

Screw the lift rods (4) fully into the 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 with the size tube (6).

7.

Tighten the nuts (2) and (3).

8.

Relieve the lift rods (4).

9.

Tighten nuts (1).

3 4

1

6

7

5

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 060935 (3.2)L

7 | Change of Size / Product

10 / 22

Auger filler size change Gate closure basic setting

1

4 3

2

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).

X

717079MS5025W | Version 1.0 | en 060935 (3.2)L

5

Bosch Packaging Technology

7 | Change of Size / Product

11 / 22

Auger filler size change Gate closure basic setting 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). 4

Adjusting the lift rod guides 1.

Align the two lift rod guides (3) roughly with the center of the lift rods.

2.

Tighten the tensioning strap (4) on the size tube.

3.

Check for smooth operation again.

3

2

1

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 060935 (3.2)L

12 / 22

7 | Change of Size / Product

Auger filler size change Gate closure basic setting

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.

717079MS5025W | Version 1.0 | en 034901 (4.2)L

Bosch Packaging Technology

7 | Change of Size / Product

13 / 22

Size setting table - auger filler Date

01.02.2012

Type of machine: Customer

FVS 3201 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

500 g

1000 g

940 cm³

940 cm³

Ø56x65St. 8108342929 no yes 59 mm 59 mm F 35X55 r65 2/1 25 mm M6

Ø56x65St. 8108342929 no yes 59 mm 59 mm F 35X55 r65 2/1 25 mm M6

-

-

50/50 1700 6,1 500,0 0,012200

50/50 1700 12,6 1000,0 0,012600

-

-

-

-

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

8108341137 8108341922

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] 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]

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en Formateinstelltabelle_FVS_717078

7 | Change of Size / Product

14 / 22

Type of machine: Customer

FVS 3201 PT Eastern Pearl Flour Mills

Order No.

717078MS3822W

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) [%]

60 free 1000 40 free blocked 500 458 272 1,8 V/50%

60 free 1000 70 free blocked 500 620 500 1,3 V/40%

max.

10 mm above agitator

80 -

80 -

Pusher closure 30

Pusher closure 30

leftright

leftright

Setpoint Actual

S≤2,8 -

S≤4,0 -

Setpoint Actual

65/min -

50/min -

Product level in duct Cap. initiator (from bottom) [mm] Level sensor with vibrating rod

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

Output

717079MS5025W | Version 1.0 | en Formateinstelltabelle_FVS_717078

Bosch Packaging Technology

7 | Change of Size / Product

15 / 22

Size setting table - auger filler Date Type of machine: Customer

FVS 3201 PT Eastern Pearl Flour Mills

Order No.

717078MS3822W

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]

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en Formateinstelltabelle_FVS3201

7 | Change of Size / Product

16 / 22

Type of machine: Customer

FVS 3201 PT Eastern Pearl Flour Mills

Order No.

717078MS3822W

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

717079MS5025W | Version 1.0 | en Formateinstelltabelle_FVS3201

Bosch Packaging Technology

7 | Change of Size / Product

17 / 22

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

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 103233 (2)

7 | Change of Size / Product

18 / 22

Production data sheet Order/machine no.

Zero point

Designation

Input/input value

Automatic zero point

 On

 Off

Machine stop in case of zero point failure

 On

 Off

Maximally admissible zero point difference

grams

Maximum zero point deviation

grams

Number of zero point faults

amount

Designation Ejector control

Input/input value

no.

Distance sensor ejector

mm

Dead time ejector

ms (max. 9999):

Push time of ejector

717079MS5025W | Version 1.0 | en 103235 (1)

Unit/text

Ejector

Number for stop after serial fault

Ejector operating modes:

Unit/text

amount ms

Eject packages (underweight/overweight/ faults)

 On

 Off

Ejector overweights

 On

 Off

Ejector underweights

 On

 Off

Ejector switched off

 On

 Off

Eject good packages

 On

 Off

no.

Bosch Packaging Technology

7 | Change of Size / Product

19 / 22

Production data sheet Order/machine no.

Designation Sampling

Belt inputs

Input/input value

Manual sampling

amount

Cyclical sampling

amount

u

Break unit setting

amount

u

Break time setting

minutes

Designation

Input/input value

Release slow‐down-to‐stop‐time

 On

Designation

Bosch Packaging Technology

seconds

Input/input value

Unit/text

Startup operation

seconds

Startup interlock

amount

Designation Network connection

Unit/text

 Off

Slow‐down-to‐stop‐time

Filler control

Unit/text

Input/input value

Unit/text

IP address

-

Subnet mask

-

Default gateway

-

DNS

-

717079MS5025W | Version 1.0 | en 103235 (1)

7 | Change of Size / Product

20 / 22

Operation data sheet with option filler Order/machine no.

Designation Basic data

Input/input value

Unit/text

Ramp time acceleration

ms

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

Designation Filler setting: Cross‐feed auger

717079MS5025W | Version 1.0 | en 103236 (1)

Input/input value

Unit/text

Response time fill level (normal 200): sensor

ms

Nominal height fill level

%

Designation Filler setting: Closure

%

Closure pre‐switch‐off time

Input/input value

Unit/text ms

Bosch Packaging Technology

7 | Change of Size / Product

21 / 22

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

22 / 22

7 | Change of Size / Product

Notes 2.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology

Maintenance

Chapter 8:

Maintenance

8

8 | Maintenance

1 / 26

Contents

Bosch Packaging Technology

Safety instructions

3

Measures prior to maintenance work

3

Procedures prior to renewed Power On following maintenance work

3

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

717079MS5025W | Version 1.0 | en T

2 / 26

8 | Maintenance

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

8 | Maintenance

3 / 26

Safety instructions

INFORMATION All work and activities may be carried out by trained and duly authorized persons only. All work with electric devices may be carried out by trained and duly authorized persons only.

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.

u

Inform the operating personnel and appoint a supervisor.

Procedures prior to renewed Power On following maintenance work u

Check the safety devices.

u

Check the fault-free functional sequence of the machine (collision-free operation).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_08_Sicherheit (7)

8 | Maintenance

4 / 26

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).

717079MS5025W | Version 1.0 | en S_08_Hinweise (7.1)

Bosch Packaging Technology

8 | Maintenance

5 / 26

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! u

For cleaning the machine must be at a complete standstill.

u

Secure the machine against being switched On.

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_08_Trockenreinigung (7)

Info page

10 000

Personnel 5 000



2 000

Use suction air!

1 000

Removing packaging material residues

500

Service interval *)

40

Description

160

Job description

8

Item Maintenance point

6 / 26

717079MS5025W | Version 1.0 | en 107833 (1)

Cleaning plan checkweigher

Cleaning 1

Weighing work area

¬



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 cloth

Cleaning

Housing must be unpressurized before opening! Cleanse housing and filter

Page 8

¬



¬

Page 8

­

Page 9

Pneumatic system 3

Filter housing and filter cartridge



Overall machine 4

Rollers

Cleaning

If necessary

¬

Page 8

5

Belts

Cleaning

If necessary

¬

Page 8

*)

in operating hours

= cleaning = checking / replacing  = lubricating  

¬ = Operating staff ­ = Skilled staff

8 | Maintenance

Bosch Packaging Technology

Info page

10 000

Personnel 5 000

2 000

500

Vacuum air

1 000

Service interval*)

40

Description

160

Job description

8

Item Maintenance point

8 | Maintenance

Bosch Packaging Technology

Cleaning plan auger filler

Cleaning 1

Overall machine

Remove filling material residues



¬

Page 10

2

Crossfeed scroll

Cleaning



¬

Page 11

3

Dust filter

Cleaning



¬

Page 12

4

Sensor

Clean active surfaces

­

Page 13

5

Agitator hopper

Cleaning



¬

Page 14

6

Agitator, filling auger and filling pipe connection 

­

Chapter 2 page 18

With soft lint‐free cloth



Electrical devices 7

Motor frequency converter

Clean dirty cooling ribs Dust explosion! *)

in operating hours

= cleaning = checking / replacing  = lubricating  

¬ = Operating staff ­ = Skilled staff

7 / 26

717079MS5025W | Version 1.0 | en 108594 (1)

8 | Maintenance

8 / 26

Information on cleaning 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.

717079MS5025W | Version 1.0 | en 107133 (1)

Bosch Packaging Technology

8 | Maintenance

9 / 26

Information on cleaning 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.

6.

2

1

Mount the filter cartridge (2) and the filter housing (1).

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107836 (1)

8 | Maintenance

10 / 26

Information on cleaning 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

3

4 5 6 7

Item

Designation

Item

Designation

1

Crossfeed scroll

5

Agitator

2

Dust filter

6

Dosing scroll

3

Sensor

7

Dosing nozzle

4

Filling hopper

717079MS5025W | Version 1.0 | en 101198 (1)

Bosch Packaging Technology

8 | Maintenance

11 / 26

Information on cleaning Cleaning crossfeed auger WARNING Moving masses and revolving or hot components inside the machine. All work on the machine during operation may have fatal consequences, peril of loss of life. u

1

For cleaning the machine must be at a complete standstill.

3

4

2

Procedure

Notice

1.

Slacken screws (1).

Four screws.

2.

Turn and remove lid (2).

3.

Slacken screw (3) at crossfeed auger.

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.

8.

Locate lid (2) and turn into position.

9.

Fasten screws (1).

Bosch Packaging Technology

One screw.

One screw.

Four screws.

717079MS5025W | Version 1.0 | en 101199 (1)

8 | Maintenance

12 / 26

Information on cleaning Clean the dust filter

3

2

1

4

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).

717079MS5025W | Version 1.0 | en 101200 (1)

1 screw.

Bosch Packaging Technology

8 | Maintenance

13 / 26

Information on cleaning Clean sensors WARNING Moving masses and revolving or hot components inside the 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

2

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.

4.

Clean inspection glass (2) (option) from remnants.

5.

Close the agitator hopper shell and tighten the clamping screws.

Bosch Packaging Technology

Clean with fine brush or with a soft lint-free cloth. Avoid torsion.

717079MS5025W | Version 1.0 | en 101201 (1)

8 | Maintenance

14 / 26

Information on cleaning Clean the agitator, filling auger and filling pipe connection WARNING Moving masses and revolving or hot components inside the 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.

2

1

6.

Loosen the four screws on the clamping 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).

3

5 4

6

717079MS5025W | Version 1.0 | en 101202 (1)

Bosch Packaging Technology

8 | Maintenance

15 / 26

Information on cleaning Clean the agitator, filling auger and filling pipe connection INFORMATION The displayed graphic of the agitator serves as an example.

9.

Slacken three screws e.g. (1).

1

10. Remove the agitator (2).

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 agitator (1).

1

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

2

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 101202 (1)

8 | Maintenance

16 / 26

Information on cleaning Clean the agitator, filling auger and filling pipe connection

15. Clean the connection between filler auger (1) and shaft (2) from remnants.

4

16. Insert the filler auger (1) into the filling connection (5). 17. Insert the filling connection (5) into the agitator hopper.

 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.

 Turn the butt of the clamping piece relative

3

2

1

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. 6

7

717079MS5025W | Version 1.0 | en 101202 (1)

Bosch Packaging Technology

8 | Maintenance

17 / 26

Information on cleaning Clean the drive chain of the agitator drive

1

2

3

Procedure

Notice

1.

Slacken screw (1).

1 screw.

2.

Lift off the cover plate (2)

3.

Clean contaminated drive chain (3).

4.

After cleaning lubricate the chain links with some drops of oil.

5.

Apply cover plate (2).

6.

Fasten screw (1).

Bosch Packaging Technology

With wire brush or with petroleum.

1 screw.

717079MS5025W | Version 1.0 | en 108595 (1)

8 | Maintenance

18 / 26

Information on cleaning 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 1

Measure 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.

1

2

717079MS5025W | Version 1.0 | en 101374 (1)

Bosch Packaging Technology

Info page

10 000

Personnel 5 000

2 000

500

1 000

Service interval *)

40

Description

160

Job description

8

Item Maintenance point

8 | Maintenance

Bosch Packaging Technology

Maintenance plan checkweigher

Drives and gears 1

3-phase motor

In normal conditions maintenance-free

2

Belts

Check belt tension

As delivered condition

Replace belt

If necessary

2.1



­

-

¬

Page 21

­

Pneumatic system 3

Maintenance unit

Drain water from the filter housing

¬



Housing must be unpressurized before opening!

Page 23

Electrical devices 4

Control cabinet and terminal boxes

4.1

Electric screw and clamp connections

Check all electric screw and clamp connections for firm seating

Every 24 months at the latest! Switch Off the main switch and secure it against being switched back On.

Check for firm seating

Once after 160 hrs if the machine is new



­

Overall machine 5

Fastening elements

*)

in operating hours





= cleaning = checking / replacing  = lubricating  

­ ¬ = Operating staff ­ = Skilled staff

19 / 26

717079MS5025W | Version 1.0 | en 107837 (1)

A few drops of Shell Omala oil 320

Info page

10 000

Lubricate and check tension

Personnel 5 000

Every 24 months at the latest! Switch Off the main switch and secure it against being switched back On.

2 000

Check all electric screw and clamp connections for firm seating

500

Especially of moving parts

1 000

Check firm seating

Service interval*)

40

Description

160

Job description

8

Item Maintenance point

20 / 26

717079MS5025W | Version 1.0 | en 101197 (2)

Maintenance plan auger filler

Overall machine 1

Fastening elements

­



Electrical devices 2

Control cabinet and terminal boxes

­



Drives and gears 3

Drive chain of agitator drive

4

Drive motor - agitator and crossfeed auger





Esso Synthetic low-viscosity grease S 420 *)

in operating hours



= cleaning = checking / replacing  = lubricating  

­

Page 24

­

Page 25

¬ = Operating staff ­ = Skilled staff

8 | Maintenance

Bosch Packaging Technology

8 | Maintenance

21 / 26

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 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).

Bosch Packaging Technology

1

717079MS5025W | Version 1.0 | en 108135 (3)

8 | Maintenance

22 / 26

Information for maintenance 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 tension with the clamping nut (3).

5

u

Unscrew screw (4).

7

u

Unscrew screws (5).

u

Remove side panel (6).

u

Pull belt (7) off toward the front.

u

Install new belt.

u

Mount by following the reverse order of steps.

u

Readjust belt tension (see page 21).

6

1

4 2 3

717079MS5025W | Version 1.0 | en 108135 (3)

Bosch Packaging Technology

8 | Maintenance

23 / 26

Information for maintenance 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).

2.

Drain water from filter housing (3).

3.

Close valve (2).

1 3

2

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 107839 (1)

8 | Maintenance

24 / 26

Information for maintenance Tension the drive chain of the agitator drive INFORMATION Check the tension of the drive chain (1) once a month.

1 3

2

4

10 mm

5

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 arrow to tension the drive chain (5).

5.

Retighten the four screws (3) on the motor plate (4).

6.

Apply cover plate (2).

7.

Fasten screw (1).

717079MS5025W | Version 1.0 | en 101203 (2)

The chain is correctly tensioned when it can be pressed inwards by approx. 10 mm.

1 screw. Bosch Packaging Technology

8 | Maintenance

25 / 26

Information for maintenance 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.

See operating instructions drive motors crossfeed auger (1)/ agitator (2).

Change the lubricant every 10 000 operating hours using the synthetic liquid grease Esso S 420.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en 101203 (2)

26 / 26

8 | Maintenance

Notes 2.

717079MS5025W | Version 1.0 | en S_Notiz

Bosch Packaging Technology

Appendix

Chapter 9:

Appendix

9

9 | Appendix

1/4

Contents

Bosch Packaging Technology

Note

3

Notes

4

717079MS5025W | Version 1.0 | en T

2/4

9 | Appendix

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

9 | Appendix

3/4

Note INFORMATION Chapter 9 of these Operating Instructions is void.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_ohne_Inhalt (7.1)

4/4

9 | Appendix

Notes 3.

717079MS5025W | Version 1.0 | en S_Notiz

Bosch Packaging Technology

Operation and maintenance-relevant Purchase Parts (OEM)

Chapter 10: Operation and maintenance-relevant Purchase Parts (OEM)

10

10 | Operation and maintenance-relevant Purchase Parts (OEM)

1/6

Contents

Bosch Packaging Technology

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

717079MS5025W | Version 1.0 | en T

2/6

10 | Operation and maintenance-relevant Purchase Parts (OEM)

This page is empty on purpose!

717079MS5025W | Version 1.0 | en S_Leer

Bosch Packaging Technology

10 | Operation and maintenance-relevant Purchase Parts (OEM)

3/6

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.

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_10_OEM_CD (7)-en

4/6

717079MS5025W | Version 1.0 | en t_Kap10_717078_en

Overview Machine / Type

Machine No. / Order No.

Customer

as per

KWE 5000 LM

717079MS5025W

PT Eastern Pearl Flour Mills

21.12.2011

Designation

Benennung

Manufacturer / supplier

Bosch No.

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

AC‐SERVOMOTOR

AC‐SERVOM.SH140/20200/0/1/00/00/00/00

SCHNEIDER ELECTRIC GMBH

8 108 150 282

10.2

FILTER‐DRUCKREGELVENTIL NL2 G1/4

BOSCH REXROTH AG

0 821 300 300

10.3

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

GEARS, MOTORS, DRIVE ELEMENTS

FILTER / PRESSURE REGULATOR

SENSORS, LIMIT SWITCHES

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

UNICON‐D 1100/200/250/150 GENIUS+

S+S SEPARATION & SORTING

8 108 255 350

10.10

HOTTINGER BALDWIN

8 108 150 280

10.11

SUBSUPPLIED EQUIPMENT Bosch Packaging Technology

METAL DETECTOR

CHECK SETTING HELPS, COMPUTER, ETC. WEIGHING CELL

WAEGEZELLE DIGITAL 1‐FIT/1SB30/5KG

10 | Operation and maintenance-relevant Purchase Parts (OEM)

PROCESSING / FILTER

10 | Operation and maintenance-relevant Purchase Parts (OEM)

5/6

Notes

Bosch Packaging Technology

717079MS5025W | Version 1.0 | en S_Notiz_2s

6/6

10 | Operation and maintenance-relevant Purchase Parts (OEM)

Notes 4.

717079MS5025W | Version 1.0 | en S_Notiz_2s

Bosch Packaging Technology