operating system 350 - bosch rexroth

Operating System 350

Version ALEN

Online help3 608 870 B05/03.2019

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The data specified serve to describe the product.

Instructions on use, if any, only constitute application

examples and suggestions. Catalog specifications are

no warranted properties. The information given does

not release the user from the obligation of own

judgment and verification. Our products are subject to

a natural process of wear and aging.

© This document, as well as the data, specifications,

and other information set forth in it, are the exclusive

property of Bosch Rexroth AG. It may not be

reproduced or given to third parties without its consent.

The title page shows an exemplary configuration. The

supplied product may therefore vary from the

illustration.

Translation of the original operating instructions. The

original instructions were written in German.

3/243 Bosch Rexroth AG | Tightening Technology

Title Operating System 350

Type of Documentation Online help

Purpose of Documentation This documentation describes the Rexroth Tightening System 350.

Copyright © Bosch Rexroth AG, 2019

Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

Validity The specified data is for product description purposes only and may not be deemed to be guaran-teed properties unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the products.

Published by Bosch Rexroth AG

Postfach 1161D-71534 Murrhardt, Germany

Fornsbacher Str. 92D-71540 Murrhardt, Germany

Phone: +49 (0)71 92 22 208Fax: +49 (0)71 92 22 181

www.boschrexroth.com

Note Original documentation. This documentation is available as a PDF file.

Record of Revision Version Status Comments

3 608 870 B05_AA/EN 04.2009 Version for Rexroth Tightening System 350 and Operating System BS350 V2.100

3 608 870 B05_AB/EN 04.2010 Version for Rexroth Tightening System 350 and Operating System BS350 V2.100 and V2.200

3 608 870 B05_AC/EN 06.2011 Version for Rexroth Tightening System 350 and Operating System BS350 V2.100 and V2.200

3 608 870 B05_AD/EN 12.2011 Version for Rexroth Tightening System 350 and Operating System BS350 V2.100 and V2.200

Editorial revision

3 608 870 B05_AE/EN 01.2012 Version for Rexroth Tightening System 350 and Operating System BS350 V2.100 and V2.200

Amended by the "Nutrunner docking" functionality.

3 608 870 B05_AF/EN 05.2013 Version for Rexroth Tightening System 350 and Operating System BS350 V2.300

3 608 870 B05_AG/EN 11.2013 Version for Rexroth Tightening System 350 and Operating System BS350 V2.300 SP1

3 608 870 B05_AH/EN 9.2014 Version for Rexroth Tightening System 350 and Operating System BS350 V2.400

3 608 870 B05_AI/EN 12.2015 Version for Rexroth Tightening System 350 and Operating System BS350 V2.400

Editorial revision

3 608 870 B05_AJ/EN 01.2016 Version for Rexroth Tightening System 350 and Operating System BS350 V2.500

3 608 870 B05_AK/EN 03.2018 Version for Rexroth Tightening System 350 and Operating System BS350 V2.600

3 608 870 B05_AL/EN 03.2019 Version for Rexroth Tightening System 350 and Operating System BS350 BS350 V2.700

BS350 | 3 608 870 B05/2019-03

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Contents1 About this documentation 7

1.1 Overview of this documentation . . . . . . . . . . .81.2 Validity of the documentation . . . . . . . . . . . . .81.3 Additional documentation . . . . . . . . . . . . . . . . .81.4 Representation of information . . . . . . . . . . . . .91.4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.4.2 Symbols and representations . . . . . . . . . . . . . . . . . . . . 101.4.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.4.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 Safety instructions 15

2.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . 162.1.1 Using and communicating the safety instructions . . . . 162.1.2 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.1.3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . 182.1.4 Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 182.1.5 Maintenance and repair instructions. . . . . . . . . . . . . . . 192.1.6 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2.2 Application areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . 202.4 Personnel qualifications . . . . . . . . . . . . . . . . 212.5 General safety instructions . . . . . . . . . . . . . . 222.6 Product- and technology-dependent safety

instructions for Rexroth tightening system 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.1 Protection against accidental contact with electrical parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.2 Protective extra-low voltage for protection against electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.6.3 Protection against dangerous movements . . . . . . . . . . 252.6.4 Protection against magnetic and electromagnetic fields

during operation and assembly. . . . . . . . . . . . . . . . . . . 282.6.5 Protection against accidental contact with

hot parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.6.6 Protection during handling and assembly. . . . . . . . . . . 292.6.7 Protection when handling batteries . . . . . . . . . . . . . . . 292.6.8 Protection against pressurized lines . . . . . . . . . . . . . . . 30

3 Scope of delivery and system requirement 31

3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . 323.2 System requirements . . . . . . . . . . . . . . . . . . . 32

4 Basic commissioning 33

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344.1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .344.1.2 Recommended filter intervals

(gradient parameters) . . . . . . . . . . . . . . . . . . . . . . . . . .364.1.3 Overview of commissioning steps . . . . . . . . . . . . . . . .38

4.2 Assembling the tightening cell . . . . . . . . . . .404.2.1 Assembling the tightening spindle . . . . . . . . . . . . . . . .404.2.2 Assembling the ErgoSpin hand-held nutrunner . . . . . .404.2.3 Assembling the CS351 compact system. . . . . . . . . . . .404.2.4 Assembling the modular system . . . . . . . . . . . . . . . . . .404.2.5 Interface modules (IM) . . . . . . . . . . . . . . . . . . . . . . . . .424.2.6 Setting up the connections . . . . . . . . . . . . . . . . . . . . . .434.2.7 Motor-breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494.2.8 Switching on the tightening cell . . . . . . . . . . . . . . . . . .49

4.3 Connecting the PC for programming . . . . . .514.3.1 Connecting the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . .514.3.2 Installing the operating system BS350 on

the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524.3.3 Starting the BS350 . . . . . . . . . . . . . . . . . . . . . . . . . . . .534.3.4 Setting up the programming interface. . . . . . . . . . . . . .544.3.5 Logging in to the tightening system (password entry) .56

4.4 Sending and saving . . . . . . . . . . . . . . . . . . . . .574.4.1 Sending files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .574.4.2 Saving data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584.4.3 Data backup with the backup function . . . . . . . . . . . . .604.4.4 Automatic data backup with backup/restore function .60

4.5 Operating the compact system . . . . . . . . . . .644.5.1 General information on the configuration. . . . . . . . . . .644.5.2 Online configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .654.5.3 Offline configuration: . . . . . . . . . . . . . . . . . . . . . . . . . .914.5.4 Defining a tightening program . . . . . . . . . . . . . . . . . . .924.5.5 Configuration SE/CS PLC assignment table . . . . . . . .954.5.6 Setting the time on the tightening controller. . . . . . . . .964.5.7 Synchronizing date and time with an external

clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .964.5.8 Sequence test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

4.6 Operating the Modular System . . . . . . . . . .1004.6.1 General information on the configuration. . . . . . . . . .1004.6.2 Online configuration of the KE. . . . . . . . . . . . . . . . . . 1014.6.3 KE configuration offline . . . . . . . . . . . . . . . . . . . . . . . 1184.6.4 Configuring the tightening channels. . . . . . . . . . . . . . 1194.6.5 Defining the tightening program. . . . . . . . . . . . . . . . . 1214.6.6 Defining a tightening application . . . . . . . . . . . . . . . .1214.6.7 SE PLC assignment table . . . . . . . . . . . . . . . . . . . . . . 1234.6.8 KE PLC assignment table . . . . . . . . . . . . . . . . . . . . . .1244.6.9 Setting the KE time. . . . . . . . . . . . . . . . . . . . . . . . . . . 1254.6.10 Sequence test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

4.7 Saved ("automatic") channelconfiguration . . . . . . . . . . . . . . . . . . . . . . . . . .126

4.7.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1274.7.2 Modular system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1284.7.3 Configuring the tightening channel . . . . . . . . . . . . . .1324.7.4 Configuring the optional additional module

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barcode scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1374.7.5 Nutrunner test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

4.8 Special operating features of the hand-held nutrunner ErgoSpin/CC-ErgoSpin . . . . . . . . . . . . . . . . .141

4.8.1 Special features of ErgoSpin with open flat output drive with mechanical safety catch . . . . . . . . .141

4.8.2 Special features of ErgoSpin with open flat output drive without safety catch . . . . . . . . . . . . . . . .141

4.8.3 Special features of ErgoSpin with angle compensation . .145

4.8.4 Special features for CC-ErgoSpin and commissioning of the CC-CS351 compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

4.9 Special characteristics of Nexo cordless Wi-Fi nutrunner operation . . . . . . . . . . . . . . .151

5 Troubleshooting 153

5.1 Error codes and classes . . . . . . . . . . . . . . . .1545.1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1545.1.2 Error code assignment table . . . . . . . . . . . . . . . . . . . .1545.1.3 Error classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

5.2 Reset function . . . . . . . . . . . . . . . . . . . . . . . . .1555.3 LED displays and operating elements . . . .1565.3.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1565.3.2 LTU350 servo amplifier . . . . . . . . . . . . . . . . . . . . . . .1575.3.3 LTS350D and LTE350D servo amplifiers . . . . . . . . .1575.3.4 VM power supply module. . . . . . . . . . . . . . . . . . . . . .1585.3.5 SE352 and SE352M control units . . . . . . . . . . . . . . . .1595.3.6 LT35x servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . .1595.3.7 KE communication unit . . . . . . . . . . . . . . . . . . . . . . .1605.3.8 LED display in operating state . . . . . . . . . . . . . . . . . .160

5.4 Error recognition on interface modules . .1635.4.1 LEDs on the interface modules . . . . . . . . . . . . . . . . . .1635.4.2 Examples of errors on interface modules . . . . . . . . . .170

5.5 Error recognition and acknowledgement at the TFT display . . . . . . . . . . . . . . . . . . . . . .174

5.6 Error recognition and acknowledgement with the BS350 operating program . . . . . .175

5.6.1 Error lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1755.6.2 Sequence test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1775.6.3 Transducer test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1785.6.4 Tightening channel info . . . . . . . . . . . . . . . . . . . . . . .1785.6.5 KE info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1795.6.6 Tightening cell info . . . . . . . . . . . . . . . . . . . . . . . . . . .1795.6.7 KE mass storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1825.6.8 SE, CS/KE I/O interface . . . . . . . . . . . . . . . . . . . . . . .1825.6.9 SE/KE Arcnet bus . . . . . . . . . . . . . . . . . . . . . . . . . . . .1855.6.10 CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1855.6.11 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1865.6.12 Field bus data CS/KE . . . . . . . . . . . . . . . . . . . . . . . . .1865.6.13 Field bus status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1875.6.14 ... FF3/FF4 (internal sequence trace) . . . . . . . . . . . . .1875.6.15 Logging configuration in the BS350. . . . . . . . . . . . . .188

5.7 Description of selected errors . . . . . . . . . . .1895.7.1 Error code 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

5.7.2 Error code 102/206 . . . . . . . . . . . . . . . . . . . . . . . . . . 1895.7.3 Error code 204/205 . . . . . . . . . . . . . . . . . . . . . . . . . . 1905.7.4 Error code 712/713 . . . . . . . . . . . . . . . . . . . . . . . . . . 1905.7.5 Error code 1111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1905.7.6 Error code 1206/1209 . . . . . . . . . . . . . . . . . . . . . . . . 1915.7.7 Error code 1221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1915.7.8 Error code 23xx/24xx . . . . . . . . . . . . . . . . . . . . . . . . 191

5.8 Replacing defective components . . . . . . . . 1925.8.1 VM350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1925.8.2 LT35x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1925.8.3 LTU350/1 (for ErgoSpin hand-held nutrunner) . . . . 1925.8.4 LTS350D/LTE350D . . . . . . . . . . . . . . . . . . . . . . . . . 1925.8.5 SE/CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1935.8.6 KE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1935.8.7 Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

5.9 Complete error list . . . . . . . . . . . . . . . . . . . . . 1945.9.1 Servo amplifier (error code 100 - 199) . . . . . . . . . . . 1955.9.2 Measurement transducer

(error codes 200 - 299) . . . . . . . . . . . . . . . . . . . . . . . 1975.9.3 ErgoSpin hand-held nutrunner

(error code 300 - 383) . . . . . . . . . . . . . . . . . . . . . . . . 1985.9.4 CAN bus (error codes 500 - 699) . . . . . . . . . . . . . . . 2005.9.5 ARCNET (error codes 700 - 799) . . . . . . . . . . . . . . . 2045.9.6 Interface module (error codes 800 - 899) . . . . . . . . . 2085.9.7 Update CAN components

(error code 900 - 999) . . . . . . . . . . . . . . . . . . . . . . . . 2095.9.8 Control unit (error codes 1000 - 1057) . . . . . . . . . . . 2105.9.9 Channel configuration

(error code 1100 - 1167) . . . . . . . . . . . . . . . . . . . . . . 2135.9.10 PLC assignment table

(error codes 1180 - 1182) . . . . . . . . . . . . . . . . . . . . . 2165.9.11 Change engineering units

(error codes 1190 - 1191) . . . . . . . . . . . . . . . . . . . . . 2175.9.12 Sequence control (error codes 1200 - 1246) . . . . . . . 2175.9.13 Communication unit (error codes 2000 - 2099) . . . . 2205.9.14 Driver error (error codes 1301 - 1322) . . . . . . . . . . . 2245.9.15 Sequence control (error codes 2100 - 2199) . . . . . . . 2255.9.16 Configuration (error codes 2200 - 2700). . . . . . . . . . 2285.9.17 Internal controller (error codes 2800 - 2850) . . . . . . 2305.9.18 Data output (error codes 2897 - 2909). . . . . . . . . . . . 2325.9.19 Time zone (error codes 2910 - 2913) . . . . . . . . . . . . 2325.9.20 Firmware download (error code 2915 - 2916). . . . . . 2335.9.21 Auto backup/restore (error codes 2917 - 2937). . . . . 2335.9.22 Hardware error (error codes 3000 - 3008). . . . . . . . . 2335.9.23 Open protocol error (error codes 3050 - 3060) . . . . . 2345.9.24 CAQTNG errors (error codes 3070 - 3074) . . . . . . . 2355.9.25 PLC error (error codes 3100 - 3148) . . . . . . . . . . . . . 2355.9.26 VW-XML error (error codes 3200 - 3215) . . . . . . . . 2385.9.27 Job functionality (error codes 3250 - 3256) . . . . . . . 2385.9.28 Integrated logic (error codes 3270 - 3279) . . . . . . . . 2395.9.29 System error (error codes 3700 - 3800). . . . . . . . . . . 239

6 Service and sales 241

6.1 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2416.2 Sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2426.3 Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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1 About this documentation

This chapter contains general information on the present documentation.

• Overview of this documentation (page 8)• Validity of the documentation (page 8)• Additional documentation (page 8)• Representation of information (page 11)

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1.1 Overview of this documentation

This documentation describes the tightening system in the following chapters:

1.2 Validity of the documentation

All information in this document refers to software versions from V2.100 in the Tightening System 350. Functions available from V2.200, V2.300, V2.400, V2.500, V2.600 or V2.700 of the Tightening System 350 are highlighted accordingly.

The Tightening System 350 contains customer-specific data protocols that may not be used by all customers for legal reasons. Therefore, they are no general part of the scope of delivery of the Tightening System350. The receivers of these customer-specific data protocols are not provided by Bosch Rexroth.

All information in this document refer to Rexroth tightening spindles and the ErgoSpin hand-held nutrunner. Please find information on the Rexroth Nexo cordless Wi-Fi nutrunner in the "Nexo" documentation. Some chapters of this documentation contain references to the Nexo cordless Wi-Fi nutrunner.

1.3 Additional documentation

Please also observe the current instructions for all tightening system components, as well as the documentation of the machine or system manufacturer and the product catalog of Rexroth Tightening System 350 available in the media directory.

You can find current documentation for project planning, as well as related documents, in the media directory at: http://www.boschrexroth.com/mediadirectory

Please also observe the generally applicable, legal or otherwise binding regulations of European or national legislation and the rules for the prevention of accidents and for environmental protection applicable in your country.

Chapter Title Contents

1 About this documentation Validity of this document, abbreviations, designations used, glossary.

2 Safety instructions Safety precautions on how to avoid hazardous situations when using Rexroth tightening systems. Information on the intended use of Rexroth tightening systems.

3 Scope of delivery and system requirement

Information on the scope of delivery and the system requirements for the operating systemRexroth BS350.

4 Basic commissioning All steps required for commissioning a tightening system, e.g. setting up interfaces and tightening channel configuration.

5 Troubleshooting Troubleshooting by means of hardware and software, error hierarchy with error code tables, system test options

6 Service and sales Options for contacting Rexroth, sources for additional information on the tightening system.

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1.4 Representation of information

This section shows how the data, e.g. safety instructions, and symbols are represented in the present documentation.

1.4.1 Safety instructions

In this documentation, safety instructions precede an instruction when there is the danger of personal injury or damage to equipment. The hazard avoidance measures described must be observed.

Safety instructions are structured as follows:

• Safety sign (warning triangle): draws attention to the danger

• Signal word: identifies the degree of the risk (hazard class)

• Type of danger: identifies the type or source of the danger

• Consequences: describes what occurs when the safety instructions are not complied with

• Precautions: states how the risk can be avoided

Warning symbols (e.g. dangerous electric voltage) warn of dangers and consequential damages or denote prohibitions. This documentation uses the following warning symbols:

SIGNAL WORD

Type of DANGERConsequences Precautions

Table 1–1: Warning symbols used

Symbol MeaningThis warning symbol cautions against dangers to your health. Observe all safety instructions that follow this symbol to avoid possible injuries or death.

This warning symbol cautions against dangers to your health caused by electric voltages or currents. Observe all safety instructions that follow this symbol to avoid possible injuries or death.

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The safety instructions describe the following types of risk. The type of risk describes the risk if the corresponding safety instruction is not observed. The signal words have the following meanings:

1.4.2 Symbols and representations

DANGER

Death or serious bodily harm will result.

WARNING

Death or serious bodily harm may result.

CAUTION

Bodily harm or damage to equipment may result.

NOTICE

Damage to equipment may result.

If this information is not observed, the operating procedure may be impaired.

Table 1–2: Symbols and representations used in the documentation

Symbol Explanation

Prerequisite

Ensure that the stipulated prerequisite is met before proceeding to the next step.

Step

This symbol indicates an individual step.

1.

2.

3.

Sequence of steps

Take the steps specified while following the order specified.

Result

This symbol indicates the result of a step.

Example Examples are in a gray field and illustrate the previously stated information.

A tip provides additional information that is not decisive for working with the tightening system, but is important and useful.

Blue text References to other sections are shown in blue. Click the reference in the PDF to jump directly to the referenced target.

Bold text Special text is shown in bold. This includes operating elements, screen displays, or important text passages.

<n> Angled brackets mark a variable value that you need to replace with a specific value in the respective case.

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1.4.3 Designations

Application block A maximum of 48 applications/tightening applications can be programmed in one communication unit (KE). Up to 8 tightening applications may be controlled simultaneously via the eight available application blocks (FO1 ... FO8) if they do not access the tightening channels simultaneously. Up to 40 tightening positions can be coordinated within a tightening application.

CF350 The CF350 mass storage device is a compact flash card (CF card) for the X6C1 slot of the compact system (CS351) and the communication unit (KE).

DMS Strain gauges. Measuring device that changes its electrical resistance even with slight deformation and is thus used as a strain gauge sensor.

Torque filter factor Additional parameter for determining the gradient.

KE Communication unit. Used to control several control units and simultaneously also for communication with the partner controllers.

Ring memory Limited storage is available in the ring memory. The oldest data will be overwritten with the latest data if more storage space is required.

Tightening process The tightening process describes the entire tightening procedure including the various individually parameterized tightening program steps (such as "finding", "driving in" "tightening", etc.) until the target function is reached (torque, angle, etc.).

Tightening application Within a tightening application (also called application), 1 to a maximum of 40 tightening channels are coordinated.

Tightening controller A tightening controller is either a compact system or a tightening controller in a modular system with several tightening units.

Tightening channel A tightening channel comprises the necessary components for a tightening. This includes the complete tightening spindle, controller, servo amplifier, and connection cable.

Tightening program The tightening program coordinates the tightening process/sequence. It is divided into various tightening steps, where tightening parameters are set.

Tightening position The tightening position is the defined location where tightening is performed using a tightening channel and a tightening program.

Tightening system A tightening system is a complete system with all tightening channels that are needed to carry out the defined tightening case.

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Tightening cell A tightening cell is designated as the installed hardware for at least one tightening channel and at least one data interface for communication with the operating program or the partner controller. This includes the corresponding tightening programs and tightening applications.

1 Tightening position

2 Tightening channel

3 Tightening cell

4 Program

5 Data interface

Torque threshold The torque threshold is a parameter to help measure the angle of turn for a target or monitoring function. The monitoring function of the angle is started as soon as the measured torque for the bolt reaches the value for the torque threshold for the first time. Afterwards, the torque threshold has no more influence on the tightening process, except for angle correction.

SE Control unit. Each Compact System consists of a single control unit.

Chord angle The chord angle is an additional parameter for determining the gradient.

Controller Controllers are

- tightening controller (SE or compact system)

- communication unit (KE)

Yield point process This process uses the gradient calculation in the measurement transducer. The bolt is tightened until its yield point (elastic limit to plastic deformation) is reached.

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System stick A USB stick included in the scope of delivery that, amongst others, contains the installation program for the operating system BS350, as well as the firmware and documentation.

Monitoring function The monitoring function keeps track that the upper and lower limits are complied with during the tightening process by checking a monitoring parameter (e.g. gradient).

If the monitoring function has switching capabilities, the tightening step will be terminated immediately if a limit is exceeded. If it is has no switching capabilities, the step result changes to NOK, even if the target parameter has been reached.

Monitoring parameter The monitoring parameter is the measured quality (e.g. gradient) of a tightening step that must be kept within specific limits in order for a tightening process to be performed safely. If the limits are violated, the tightening step may be terminated.

Angle correction The angle correction is an additional parameter to measure the angle of turn. Since the angle of turn is never measured directly on a bolt, but above the output drive, there is a small deviation between the measured angle and the angle on the bolt as a result of the torsion of the output drive due to the torque. This deviation can be avoided with an angle correction at the end of the tightening process (never during tightening!). The angle value measured at the end of tightening after falling below the torque threshold is then used as the target or last monitoring parameter (the torsion of the output drive has then reset itself).

Target function The target function controls the process sequence of the tightening step by monitoring the target parameter (e.g. torque) and ends the step if the parameter value has reached its target value.

Target parameter The target parameter is the measured variable (e.g. torque) of a tightening step, which must reach a specific value (target value) for a tightening process to be performed successfully. The tightening step is terminated once the target value has been reached.

Additional function The additional function defines further parameters for the tightening step. Although they have an effect on the tightening process (e.g. start-up suppression, speed setting), additional functions cannot interrupt it. They do not carry out an OK/NOK evaluation.

Additional parameters Additional parameters are the parameter values in a tightening step, which influence the tightening process (e.g. target speed, torque threshold), but which cannot interrupt the tightening process.

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1.4.4 Abbreviations

The following abbreviations are used in this documentation:

Table 1–3: Abbreviations for the components in the tightening system

Abbreviation ExplanationBT356 Subrack system 350 for max. 6 tightening channels

BS350 Operating System 350

CS Compact System

ES ErgoSpin hand-held nutrunner

HMI Human-machine interface

IL Integrated logic

IM Interface module

IM24V 24V interface module

IMdev DeviceNet interface module

IMecat IMecat interface module

IMenip EtherNet/IP interface module

IMenip2 EtherNet/IP interface module

IMmtcp ModbusTCP interface module

IMpdp PROFIBUSDP interface module

IMpnio PROFINETIO interface module

IMpnio2 PROFINETIO interface module

KE350 System 350 communication unit without DVI interface

KE350G IL System 350 communication unit with DVI interface and integrated logic

LT35x Size-dependent servo amplifiers for System 350 stationary tightening technology

LTS350D Servo amplifier for tightening spindle

LTU350/1 Servo amplifier for System 350 ErgoSpin

LTE350D Servo amplifier for System 350 ErgoSpin

MC/DMC Measurement transducer

NK350 System 350 network coupler

NK350S System 350 network coupler with external power supply

SB356 System 350 system box for max. 6 tightening channels

SE352 System 350 controller for two-channel operation

SE352M System 350 controller for two-channel operation with slot for B module

PLC Programmable logic controller

VM350 System 350 power supply module

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2 Safety instructions

This chapter describes the general safety requirements for working with the Rexroth tightening system. It contains important information that is necessary for the safe use of the Rexroth tightening system.

• About this chapter (page 16)• Intended use (page 19)• Improper use (page 20)• Personnel qualifications (page 21)• General safety instructions (page 22)• Product- and technology-dependent safety instructions for Rexroth tightening

system 350 (page 23)


2.1 About this chapter

2.1.1 Using and communicating the safety instructions

Read all supplied documents carefully before installing any components or commissioning the Rexroth tightening system. Read these safety instructions and all other user information each time before working with the Rexroth tightening system. If you do not have a copy of the user information for the Rexroth tightening system and components, please contact your Bosch Rexroth sales representative. Request that documents be immediately sent to the person responsible for safe operation of the Rexroth tightening system.

If the Rexroth tightening system and components are sold, lent, or otherwise passed on within the European Union (EU), these safety instructions must also be included in the language of one country of the European Union.

WARNING

Risk of injury!Improper use of the Rexroth tightening system and components, non-compliance with the safety warnings stated here, or improper interventions in the safety equipment can cause damage to equipment, injury, electric shock, and even, in extreme cases, death. Observe the safety instructions.

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2.1.2 Instructions for use

To prevent injury and/or damage to equipment, read the following instructions before commissioning the Rexroth tightening system and components. These safety instructions must be observed at all times.

• Bosch Rexroth AG does not assume any liability for damages resulting from non-compliance with the safety warnings in this documentation and in the documentation of all the Rexroth tightening system components.

• Read the operating, maintenance, and safety instructions prior to commissioning. If the documentation in the available language is not clearly understood, please contact the supplier and inform him of this.

• The prerequisites for correct, safe operation of the Rexroth tightening system are: proper transportation, storage, assembly, and installation, as well as careful operation and maintenance.

– Check the product for visible defects, for example cracks in the housing or missing screws and seals.

– Before commissioning, make sure that all the connection gaskets and plugs are installed correctly to ensure that they are leakproof and fluids and foreign bodies are prevented from penetrating the product.

– Make sure that all electrical connections are either used or covered. Commission the product only if it is installed completely.

– Only use Rexroth products within the performance range specified in the respective technical data.

– Do not expose Rexroth products to any mechanical loads under any circumstances. Never use Rexroth products as a handle or step. Do not place any objects on Rexroth products.

• Only use accessories and spare parts that are approved by the manufacturer.

• Observe the safety regulations of the country in which the Rexroth tightening system and components are used.

• Rexroth tightening system components are designed for installation in machines used in industrial applications.

• Always observe the ambient conditions specified in the product documentation of the respective component.

– Let new components acclimate for several hours before commissioning. Otherwise, water may condense, e.g. in the control housings.

– Make sure that all electrical connections are either used or covered. Commission the component only if it is installed completely.

• Safety-relevant applications are only permitted if they are clearly and explicitly stated in the planning documents. If this is not the case, they are excluded. Safety-relevant applications are all applications that may result in injury to personnel or damage to equipment.

• In the respective product documentation, information is provided regarding use of the supplied components. These are application examples and suggestions only.The machine manufacturer and system installer must check that

– the supplied components and specifications made in the respective documentation are suitable for the application on hand, and that they

– correspond to the safety regulations and standards valid for that application. The machine manufacturer and system installer must implement the required measures, modifications, and expansions.

• Commissioning of the supplied components is prohibited until it has been determined that the machine or system in which they are installed corresponds to country-specific provisions, safety regulations, and standards for the specific application.

• Operation is only permitted in accordance with the national EMC regulations for the respective application.

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• For instructions on EMC installations, refer to the documentation for the respective component. The manufacturer of the system or machine is responsible for maintaining the limit values required by national regulations.

• The technical data, connection conditions, and installation conditions can be found in the corresponding product documentation and must be complied with at all times.

• The Compact System CS351 is not designed to be directly connected to the public low-voltage power supply, but is only intended for use in industrial environments (emission classA).

Country-specific regulations that the user must observe• European countries:

– Corresponding EN European standards

• United States of America (USA):

– National Electrical Code (NEC),

– National Electrical Manufacturers Association (NEMA), as well as regional building codes

• Canada

– Canadian Standards Association (CSA)

• Other countries:

– International Organization for Standardization (ISO)

– International Electrotechnical Commission (IEC)

2.1.3 Operating instructions

Observe the regulations for accident prevention and environmental protection for the country where the product is used and at the workplace.

Only allow persons who are authorized by the operator to access the system's direct operating area. This is also valid when the system is standing still.

In case of an emergency, fault or any other anomalies, switch the system off and protect it against being switched on again.

Only operate the control and power electronics for Rexroth tightening technology in a grounded network. Operation in non-grounded networks (IT network) is not permitted, as clearance and creepage distances in the system may be overloaded. Here, protective grounding is the permissible protective measure in accordance with EN 50178. The inlet cables to the control and power electronics must be equipped with a protective conductor (PE).

Make sure that there is potential equalization between the workpiece and nutrunner, as well as its carrier plate, so that potential equalization is ensured for all system components.

Protect the system from short circuits in the connector cables with a fuse provided by the customer.

2.1.4 Cleaning instructions

Observe the following notes in order to guarantee the IP protection classes of the components (IP54 when assembled):

Cover all openings in Rexroth tightening system components with the appropriate protective equipment in order to prevent detergents from penetrating the system.

Never use solvents or aggressive detergents.

Do not use a high-pressure cleaner for cleaning.

Also observe the cleaning instructions in the operating instructions for the respective system component.

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2.1.5 Maintenance and repair instructions

Perform the prescribed maintenance work at the intervals specified in the operating instructions for the respective system component.

Make sure that no lines, connectors or components are disconnected as long as the system is under pressure and voltage.

After the system is switched off, protect it from being switched on again.

2.1.6 Disposal instructions

Dispose of Rexroth products in accordance with the currently applicable regulations in your country.

2.2 Intended use

2.2.1 Introduction

Bosch Rexroth products are developed and manufactured in accordance with the latest state of technology. They are checked for safe function before delivery.

The products may only be used as intended. If they are not used as intended, this may result in situations that cause injuries and damage to equipment.

Before using any product from Bosch Rexroth, the following prerequisites must be fulfilled to ensure intended use:

Anyone who deals with our products in any manner must read and understand the appropriate safety instructions and information on intended use.

If dealing with hardware products, they must be kept in their original state, i.e. no modifications may be made to them. Software products may not be decompiled and the source code may not be changed.

Damaged or faulty products may not be installed or commissioned.

Before commissioning, ensure that the current firmware version (release or SP) is installed on the controllers.

Make sure that the products have been installed in accordance with the specifications listed in the respective documentation.

NOTICE

Stable tool qualityRecommendation To ensure stable tool quality, a machine capability test (MCT) should be carried out at regular

intervals. If individual components are changed, an MCT must be carried out in any case The MCT should comply with VDE/VDI2645 Sheet 2. Bosch Rexroth Service provides this service (see page 241)

As the manufacturer, Bosch Rexroth does not grant any warranty, assume any liability, or provide compensation for damages caused by improper use of the products. The user is solely responsible for risks caused by improper use of the products.

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2.2.2 Application areas

The Rexroth tightening system is a system used to perform, document, and analyze tightenings in accordance with freely programmable sequences.

2.3 Improper use

Use of the Rexroth tightening system and components for any application not listed herein, or under operating conditions other than those described in the respective documentation and technical information, is considered improper use.

The Rexroth tightening system and components may not be used:

• If subjected to operating conditions that do not fulfill the specified ambient conditions. Operation is forbidden e.g. under water, at high air humidity, under extreme temperature fluctuations, or under extreme maximum temperatures.

• If used in applications that have not been explicitly approved by Bosch Rexroth. Always observe the safety instructions in the respective documentation.

See the associated documentation for information on the application areas for the respective components.

As the manufacturer, Bosch Rexroth does not grant any warranty, assume any liability, or provide compensation for damages caused by improper programming or configuration of the tightening system.The user is solely responsible for risks caused by programming and configuration of the tightening system.

Only accessories and add-on units that have been approved for use in Rexroth tightening systems may be used therein. Non-approved components may neither be added nor connected to the system. The same applies to cables and lines which belong to the Rexroth tightening system. Otherwise, functional and system safety is jeopardized.

The Compact System CS351 is not designed to be directly connected to the public low-voltage power supply, but is only intended for use in industrial environments (emission classA).

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2.4 Personnel qualifications

Rexroth tightening systems may only be used by trained and qualified personnel. That means:

• Only appropriately trained and qualified personnel are permitted to work with or near the Rexroth tightening system. Personnel are qualified if sufficiently familiar with assembly, installation, and operation of the Rexroth tightening system and components, as well as all warnings and precautionary measures in accordance with this documentation and the documentation of the respective component.

• Personnel must also be trained, instructed, or authorized to switch electrical circuits and devices on and off in accordance with the accepted rules of safety and current technology, ground them, and mark them according to the job requirements. Personnel must have appropriate safety equipment and be trained in first aid.

• Persons who assemble, operate, disassemble, or maintain Rexroth products must not consume any alcohol, drugs, or pharmaceuticals that may affect their ability to respond.

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2.5 General safety instructions

This chapter describes general safety instructions for accident prevention. These safety instructions warn of general dangers that may e.g. result from the use or disposal of the product (or components thereof).

DANGER

High voltage and high operating current! Danger to life or risk of serious injury due to electric shock!

DANGER

Dangerous movements! Danger to life, risk of serious injury, or damage to equipment due to unintended motor movements!

WARNING

High voltage due to improper connection! Danger to life or risk of serious injury due to electric shock!

WARNING

Health risk for persons with pacemakers, metal implants, and hearing aids in the immediate vicinity of electrical equipment!

CAUTION

Hot surfaces possible on device housing! Risk of injury! Risk of burns!

CAUTION

Risk of injury due to improper handling! Injury due to crushing, shearing, cutting, impact, or improper handling of pressurized lines!

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2.6 Product- and technology-dependent safety instructions for Rexroth tightening system 350

2.6.1 Protection against accidental contact with electrical parts

Contacting parts with voltages greater than 50 V can be dangerous to persons and lead to electric shock. When electrical devices are operated, specific parts of these devices are under a dangerous voltage.

This section only applies to devices and components with voltages above 50 V.

DANGER

High voltage!Danger to life, risk of injury due to electric shock, or risk of serious injury! This device may only be operated, maintained and/or repaired by personnel trained and qualified

to work on or with electrical devices. Observe the general construction and safety regulations for working with high-voltage systems. Firmly connect the protective conductor to all electrical devices according to the connection

diagram before switching the system on. Operation, even briefly for measuring or testing purposes, is only permitted if the protective

conductor is firmly connected to the components at the intended points. Disconnect the device from the mains or voltage source before accessing electrical parts with

voltages greater than 50 V. Protect it against being switched on again. After switching off the power supply, wait 10 seconds for the system to discharge before opening

the housing or starting repair/maintenance work. For electrical drive and filter components:

After switching off, take the specified discharging time for the respective components into account before accessing the devices. To eliminate the risk of contact, measure the voltage of the condensers before starting work.

Do not touch the electrical connection points of the components when the device is switched on.

Before switching on, attach the provided covers and protective devices (protection against accidental contact) to the devices. Also, before switching on, securely cover and protect live parts to prevent accidental contact.

Do not touch the electrical connection points of the components when the device is switched on. A residual-current-operated protective device (RCD) cannot be used for multi-channel tightening

systems! Protection against accidental contact must be ensured by other means, for example via an overload protection device corresponding to the relevant standards.

Prevent accidental contact with electrical parts in installed devices by means of an external housing such as a switch cabinet.

Before using the system or starting service/maintenance work, make sure you read and understand these operating instructions.

European countries: Corresponding to EN 50178/1998, paragraph 5.3.2.3.USA: See National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA), as well as regional building codes. The operator must comply with all of the above points at all times.

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For electrical drive and filter components:

Safety warning sticker

Safety warning stickers on the compact system (CS), card rack field (BT), and system box (SB) indicate the risk of electric shock (sticker location, see figure 2–1).

Fig. 2–1: Safety warning sticker on compact system (CS), card rack field (BT), and system box (SB)

On the Compact System, the safety warning sticker is visible when the cover is open. On the system box, the sticker is visible when the door is open.

Fig. 2–2: Safety warning sticker on Compact System (CS)

DANGER

Risk of injury!Risk of injury due to electric shock! Before switching on, connect the electrical equipment and the housings of all electric devices

and motors to the protective conductor at the grounding points, or ground them. Even prior to quick tests.

Before commissioning, even for testing purposes, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that may cause an electric shock.

Ensure that PE connections are not affected by mechanical, chemical, or electrochemical influences.

For multi-channel tightening systems: Always connect the protective conductor for the electrical equipment to the power supply

permanently. The leakage current is greater than 3.5 mA. Use a copper wire diameter of 10 mm2 or greater for the entire protective conductor!

For compact systems:No separate 10 mm2 copper cross-section is necessary for the protective conductor. The leakage current is less than 3.5 mA.

Ensure that the compact system is connected to protected mains supplies and grounded via the mains connection.

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Fig. 2–3: Safety warning sticker on card rack (BT) and system box (SB)

2.6.2 Protective extra-low voltage for protection against electric shock

All connections and terminals with voltages of 5 to 50 V on Rexroth products are protective extra-low voltages which are designed to be safe to touch in accordance with the product standards.

2.6.3 Protection against dangerous movements

Dangerous movements can be caused by improper actuation of connected motors. Causes can be any of the following:

• Careless or improper wiring

• Errors while operating the components

• Incorrect input of parameters prior to commissioning

• Error in the measurement transducer or signal transducer

• Defective components

• Software errors

These errors can occur immediately after the system has been switched on or after operating for an indefinite time.

WARNING

Dangerous voltage inside device!Danger to life, risk of injury due to electric shock! Switch the device off. Disconnect the device from the mains supply.

Compact System (CS): Before opening the device or starting maintenance work, wait at least 90 seconds for the device

to discharge.

Card rack (BT) and system box (SB): Before opening the device or starting maintenance work, wait at least 10 seconds for the device

to discharge. Before starting maintenance work, make sure you read and understand these operating

instructions.

WARNING

High voltage due to improper connection!Danger to life, risk of injury due to electric shock! Only devices, electrical components, and cables with protective extra-low voltage (PELV) may be

connected to connections and terminals with voltages of 0 to 50 V. Only connect voltages and electric circuits that are safely isolated from dangerous voltages. Safe

isolation is obtained by means of isolating transformers, safe optocouplers, or battery operation disconnected from the mains.

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The monitoring devices in the drive components almost completely eliminate malfunctions in the connected drives. However, in view of personal safety, especially that involving risk of injury and/or damage to equipment, this alone is not sufficient. Until the installed monitoring devices become fully effective, faulty drive movements, whose magnitude depends on the controller type and the operating condition, must be anticipated.

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DANGER

Dangerous movements!Danger to life, risk of serious injury or damage to equipment! Ensure personal safety, either by means of monitoring devices or by superior measures directly

on the system. The measures depend on the specific system conditions and are determined based on a risk and

error analysis. The safety regulations applicable to the system must be taken into consideration. Unintended machine movements or other malfunctions may occur when the safety equipment is switched off, bypassed, or not activated.

Preventing accidents, injury, and/or damage to equipment: Do not enter the machine's and machine parts' area of travel. Possible measures to prevent

unintended entry of persons include:

– Protective barriers

– Protective enclosures

– Protective covers

– Photocells Barriers and covers must be rigid enough to withstand the maximum possible momentum. The emergency OFF switch must be easily accessible in the immediate vicinity. Check the

function of the emergency OFF system before commissioning. If the emergency OFF switch malfunctions, do not operate the device.

Protection against unintended start-up by means of an emergency OFF circuit. Safely bring the drives to a standstill before accessing or entering the danger zone. Additionally secure vertical axes from falling or dropping after the motor is switched off by:

– Mechanical lock on the vertical axis

– External braking/catching/clamping device

– Sufficient weight compensation of the axis Switch electrical equipment to a de-energized state at the mains and protect it against being

switched on again during:

– Maintenance and repair

– Cleaning

– Long disruptions in operation Avoid operating high-frequency, remote-controlled, or radio devices in the vicinity of the device

electronics and cables. If this cannot be avoided, check the device and the system for malfunctions in all working positions. In some cases, a special EMC inspection of the entire system may be necessary.

In the following cases, install a torque support at the ErgoSpin hand-held nutrunner:

– ESM as of 10 Nm

– ESA or ESV as of 40 Nm Use a torque support if tightenings with higher torques are to be performed with a hand-held

tightening spindle.

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2.6.4 Protection against magnetic and electromagnetic fields during operation and assembly

Magnetic and electromagnetic fields that surround live conductors and the permanent magnets of motors can pose a serious risk to persons with pacemakers, metal implants, or hearing aids.

2.6.5 Protection against accidental contact with hot parts

DANGER

Health risk for persons with pacemakers, metal implants, and hearing aids in the immediate vicinity of electrical equipment!Magnetic and electromagnetic fields may interfere with and impair the function of pacemakers or hearing aids as well as of metal implants. This may lead to a health risk for the persons concerned. Persons with pacemakers and metal implants are prohibited from entering the following areas:

– Areas in which electrical devices and parts are assembled, operated, or commissioned

– Areas in which motor parts with permanent magnets are stored, repaired, or assembled If persons with pacemakers need to enter these types of areas, a physician must first be

consulted. The interference resistance of current or future pacemaker versions varies greatly. For this reason, no generally applicable rules exist.

Persons with metal implants, metal shrapnel in the body, or hearing aids must consult a physician before entering these types of areas, as adverse health effects must be expected in these areas.

CAUTION

Hot surfaces possible on motor housings and gearboxes!Risk of injury! Risk of burns! Do not touch device housing surfaces at heat sources! Risk of burns! Do not touch housing surfaces of motors and gearboxes! Risk of burns! Depending on the operating conditions, temperatures during or after operation may exceed

60 °C (140 °F). After switching off the motors, allow them to cool down sufficiently before accessing them. Wear protective gloves or do not work near hot surfaces. For specific applications, the manufacturer must undertake measures on the end product, the

machine, or the system to prevent burn injuries during the end use. These measures must be in accordance with the safety regulations. Examples of possible measures are: safety warnings, a separating safety device (shielding or locking), and technical documentation.

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2.6.6 Protection during handling and assembly

Under unfavorable conditions, handling or assembling specific parts in an unsuitable manner could cause injuries.

2.6.7 Protection when handling batteries

Batteries consist of active chemicals surrounded by a rigid housing. Improper handling can thus result in injuries or damage to equipment.

CAUTION

Risk of injury due to improper handling!Injury due to crushing, shearing, cutting, impact! Observe the general construction and safety regulations for handling and assembly. Use suitable assembly and transport equipment. Prevent trapping and crushing injuries by means of suitable provisions. Only use suitable tools. Use special tools if stipulated. Use lifting equipment and tools properly. If necessary, use suitable protective equipment (for example, protective goggles, safety shoes,

protective gloves). Do not stand under suspended loads. Any fluids that have leaked onto the floor must be wiped up immediately to prevent slip hazards. Lay cables and lines in accordance with the permissible bending radiuses so that they cannot be

damaged and no one can trip over them.

CAUTION

Risk of injury due to improper handling!The improper handling of batteries may lead to chemical burns or explosions that can again lead to injuries. Never attempt to reactivate dead batteries by heating or other methods (risk of explosion and

chemical burns)! The batteries must never be recharged, as this could cause them to leak or explode. Do not incinerate batteries. Do not take batteries apart. Do not damage the electrical components installed in the devices.

Environmental protection and disposal: In the context of legal regulations, the batteries contained in this product are to be considered hazardous materials when transported on land, by sea, or by air (risk of explosion). Dispose of used batteries separately from other waste. Observe the national regulations of the country where the product is installed.

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2.6.8 Protection against pressurized lines

According to the specifications in the planning documents, liquid-cooled and forced-air-cooled motors and drive controllers, as well as forced-air-driven leads, may be supplied with external, pressurized media such as compressed air, hydraulic fluid, coolant, and coolant lubricant. In this case, incorrect handling of external supply systems, supply lines, or connections may lead to injuries or damage to equipment.

CAUTION

Risk of injury due to improper handling of pressurized lines!The improper handling of pressurized lines may cause explosions that can again lead to injuries. Never attempt to disconnect, open, or cut pressurized lines (risk of explosion). Observe the operating instructions from the respective manufacturer. Discharge the pressure and medium from lines before disassembly. Use suitable protective equipment (for example, protective goggles, safety shoes, protective

gloves). Any fluids that have leaked onto the floor must be wiped up immediately.

Environmental protection and disposal: The media used to operate this product may be harmful to the environment. Dispose of toxic media separately from other waste. Observe the national regulations of the country where the product is installed.

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3 Scope of delivery and system requirement

This chapter contains information on the scope of delivery and the system requirements for the Rexroth BS350 operating system.

• Scope of delivery (page 32)• System requirements (page 32)


3.1 Scope of delivery

The Rexroth BS350 operating program as of V2.100 is delivered on the Bosch Rexroth system stick. The program can be used to operate the following versions of the Tightening System 350:

• CS351 Compact System with ErgoSpin hand-held nutrunner, portable nutrunner or tightening spindle

• Modular system 350 with ErgoSpin hand-held nutrunner, portable nutrunner and/or tightening spindle

3.2 System requirements

The relevant minimum and recommended requirements with regard to processor power, required working memory as well as free hard drive memory are contained in the information of the respective operating system manufacturer.

• System requirements for version 2.700

The workstation computer (PC) runs one of the following operating systems and the hardware requirements of the operating system have to be met, e.g. regarding CPU output:

– Windows 7 (32 bits or 64 bits)


Additional system requirements are:

• Ethernet (TCP/IP) or USB for connection to the tightening system

• Graphics resolution 800x600 (1024x768 recommended)

• Recommended: a mouse or other compatible device

• The following TCP/IP ports must be enabled:

– TCP input and output at port 7072

– UDP output at port 7073

– UDP input at ports 7073 to 7079

If several programs have to be active at the same time on the operating computer, we recommend a correspondingly higher system performance (processor and working memory) as compared to the information of the respective operating system manufacturer.

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4 Basic commissioning

This document explains how to commission the Rexroth Tightening System 350 with the sequence test. This includes commissioning the CS351 compact system with ErgoSpin hand-held nutrunner or a tightening spindle, as well as commissioning the modular system with a tightening spindle. Commissioning primarily consists of system construction, setting up the programming interface (Ethernet or USB), configuration of the tightening channel, and creating tightening programs with the BS350 operating system. The connection of the tightening cell to a partner controller (PLC) is not the subject of this chapter.For information on the integrated logic, see in the "Project planning" documentation of the Rexroth Tightening System 350.

• Overview (page 34)• Assembling the tightening cell (page 40)• Connecting the PC for programming (page 51)• Sending and saving (page 57)• Operating the compact system (page 64)• Operating the Modular System (page 100)• Saved ("automatic") channel configuration (page 126)• Special operating features of the hand-held nutrunner ErgoSpin/CC-ErgoSpin

(page 141)• Special characteristics of Nexo cordless Wi-Fi nutrunner operation (page 151)


4.1 Overview

4.1.1 General instructions

Firmware is installed on all components at the time of delivery.

When exchanging these components or purchasing complementary ones, please observe the compatibility of the firmware versions1)! In the BS350, the current firmware updates for the components used are displayed under System test Info tightening cell Firmware.

For further information, see chapter Troubleshooting from page 153.

Commissioning a tightening cell with BT or SB is very similar. In this documentation a tightening cell with BT will be shown for illustrative purposes.

Special information on the SB will be given in the description only if the steps for commissioning differ between the BT and SB. Otherwise the same procedure will apply.

CAUTION

Incorrect connections and open slotsIncorrect cable connections and open slots may lead to damages to the system and injuries. Always connect all cables correctly and completely before switching the system on. Close all free slots with dummy plates.

1) The firmware for BS350 and the CS351, KE, and SE must have the same release version.

Before commissioning, check if a new service pack is available in the download section at www.boschrexroth.com/tightening. Bosch Rexroth recommends installing new service packs prior to commissioning as they rectify all known errors. Additionally, find the following in the download section:

• Service packs for older versions (if available)

• Current firmware updates

• Further information on upgrading/downgrading different versions in the Rexroth Tightening System 350.

NOTICE

Danger to system safetyA firmware download or a backup/restore during operation endangers system safety. Before downloading firmware or performing a backup/restore, ensure that the tightening system

is not in operation.

A description on how to use the firmware updates and service packs can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

BS350 | 3 608 870 B05/2019-03

http://www.boschrexroth.com/schraubtechnik



Information on commissioning of the ErgoSpin hand-held nutrunner and the tightening spindle

CAUTION

Risk of property damage and personal injury due to incorrect motor alignmentIf the output drive is blocked during first start-up of the ErgoSpin hand-held nutrunner or the tightening spindle, the function of the tightening channel may be compromised and increased heating of the motor, reduced performance and reversed spin direction during the next tightening operation may occur. Additionally, a system error class 3 (error code 122) is returned. In current-controlled systems, this may also lead to incorrect evaluation of results. Make sure that the output drive can freely rotate after switching on the tightening channel, restart

of the servo amplifier and after connection of the ErgoSpin hand-held nutrunner or the tightening spindle. Completion of motor alignment is indicated by brief vibration (1 s) of the ErgoSpin hand-held nutrunner or the tightening spindle.

If nutrunner docking is activated, the motor is realigned after each docking operation. Make sure that the output drive can freely rotate after docking.

BS350 | 3 608 870 B05/2019-03


4.1.2 Recommended filter intervals (gradient parameters)

In the start step of a tightening program, the calculation of the gradient values is parameterized using gradient parameters. This is particularly important with yield-point controlled tightening processes. One of these gradient parameters is the so-called filter interval that is used to improve suppression of output drive-specific interferences in the gradient signal. The filter interval leads to an extended smoothing of the gradient graph, but also delays gradient evaluation.

Information on the gradient parameters in general and on the filter interval in particular can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

The filter interval depends on the mechanical output drive component. Table 4–1 shows the filter intervals for different output drives recommended by Rexroth.

Table 4–1: Recommended filter intervals

Designation Code Order number Filter interval [°]1 x 2 x

Offset output drive BG 4 VNK1A156 0 608 800 501 40 –Offset output drive BG 4 VNK1C156 0 608 800 502 40 –Offset output drive BG 5 VNK3C281 0 608 800 543 40 –Offset output drive BG 5 VNK3C350 0 608 800 545 40 –Offset output drive BG 3 VNL3C418 0 608 800 548 40 –Offset output drive BG 3 VN1A102 0 608 800 592 32,72 –Offset output drive BG 3 VN2A152 0 608 800 594 32,72 –Offset output drive BG 3 VN2B152 0 608 800 595 32,72 –Offset output drive BG 3 VN1C102 0 608 800 602 32,72 –Offset output drive BG 3 VN2C152 0 608 800 603 32,72 –Offset output drive BG 2 2VNA82 0 608 800 607 36 –Offset output drive BG 2 2VNB82 0 608 800 608 36 –Feed output drive BG 4 4S1 0 608 800 609 21,18 42,35Feed output drive BG 3 3S1 0 608 800 610 14.4 28.8Feed output drive BG 3 3S2 0 608 800 611 14.4 28.8Feed output drive BG 2 2S1 0 608 800 612 18,95 37,89Feed output drive BG 2 2S2 0 608 800 619 18,95 37,89Offset output drive BG 3 VNS2A152 0 608 800 629 36 –Offset output drive BG 3 VNS2B152 0 608 800 630 36 –Offset output drive BG 3 VNS2C152 0 608 800 631 36 –Offset output drive BG 3 with measurement transducer

3VMC017 0 608 801 001 32,72 –

Offset output drive BG 3 with measurement transducer

3VMC035 0 608 801 002 32,72 –


3VMC060 0 608 801 003 32,72 –


4VMC150 0 608 801 004 40 –


4VMC210 0 608 801 005 22.5 45


4VMC360 0 608 801 006 22.5 45


3VMC017-SD 0 608 801 012 32,72 –


3VMC017-QC 0 608 801 018 32,72 –


3VMC060-SP 0 608 801 023 32,72 –


3VMC060-QC 0 608 801 020 32,72 –


4VMC150-SD 0 608 801 015 40 –


4VMC150-QC 0 608 801 021 40 –


4VMC210-SD 0 608 801 016 22.5 45


4VMC210-QC 0 608 801 022 22.5 45

BS350 | 3 608 870 B05/2019-03



4VMC360-SD 0 608 801 017 22.5 45

Offset output drive BG 4 VNK2A181 0 608 800 632 40 –Offset output drive BG 4 VNK2A251 0 608 800 633 40 –Offset output drive BG 4 VNK2B181 0 608 800 634 40 –Offset output drive BG 4 VNK2B251 0 608 800 635 40 –Offset output drive BG 4 VNK2C181 0 608 800 636 40 –Offset output drive BG 4 VNK2C251 0 608 800 637 40 –Offset output drive BG 4 VNL2A319 0 608 800 639 40 –Offset output drive BG 4 VNL2C319 0 608 800 643 40 –Offset output drive BG 4 VUK2D242 0 608 PE0 588 22.5 45Offset output drive BG 4 VUK2D186 0 608 800 644 22.5 45Offset output drive BG 4 VUL2D290 0 608 800 645 22.5 45Angle head BG 2 2W1 0 608 810 001 25,71 51,43Angle head BG 2 2W2 0 608 810 002 25,71 51,43Angle head BG 2 2W3 0 608 810 003 25,71 51,43Angle head BG 3 3W4 0 608 810 007 25,71 51,43Angle head BG 3 3W5 0 608 810 008 25,71 51,43Angle head BG 3 3W6 0 608 810 009 25,71 51,43Angle head BG 4 4W3 0 608 810 013 22.5 45,0Angle head BG 4 4W4 0 608 810 014 24.0 48.0Angle head W1H 0 608 810 035 16,36 32,72Angle head WH2 0 608 810 040 25,71 51,43Angle head WH3 0 608 810 029 22.5 45,0Angle head WH4 0 608 810 031 13,33 26,66Angle head BG 2 2W011 0 608 810 041 16,36 32,72Angle head BG 3 3W027 0 608 810 042 16,36 32,72Angle head BG 3 3W050 0 608 810 043 16,36 32,72Angle head BG 3 3W090 0 608 810 044 14.4 28.8Angle head BG 4 4W130 0 608 810 045 16,36 32,72Angle head BG 4 4W230 0 608 810 046 14.4 28.8Angle head BG 3 with measurement transducer

3WMC090 0 608 PE2 378 14.4 28.8

Angle head BG 4 with measurement transducer

4WMC220 0 608 PE2 373 14.4 28.8

Offset output drive BG 5 VUK3D316 0 608 PE0 017 22.5 45Offset output drive BG 5 VUK3D384 0 608 PE0 180 22.5 45ErgoSpin ESA005S 0 608 841 018 15,65 31,30ErgoSpin ESA005G 0 608 841 028 15,65 31,30ErgoSpin ESA013S 0 608 841 019 15,65 31,30ErgoSpin ESA013G 0 608 841 029 15,65 31,30ErgoSpin ESA030S 0 608 841 020 27,69 35,38ErgoSpin ESA030G 0 608 841 030 27,69 35,38ErgoSpin ESA040S 0 608 841 021 13,85 27,69ErgoSpin ESA040G 0 608 841 031 13,85 27,69ErgoSpin ESA056S 0 608 841 022 16,36 32,72ErgoSpin ESA056G 0 608 841 032 16,36 32,72ErgoSpin ESA065S 0 608 841 023 13,33 26,66ErgoSpin ESA065G 0 608 841 033 13,33 26,66ErgoSpin ESA075S 0 608 841 024 14.4 28.8ErgoSpin ESA075G 0 608 841 034 14.4 28.8ErgoSpin ESA100S 0 608 841 025 13,33 26,66ErgoSpin ESA150S 0 608 841 026 15,65 31,3ErgoSpin ESA220S 0 608 841 027 13,33 26,66ErgoSpin ESA005S-G 0 608 841 204 15,65 31,30ErgoSpin ESA005G-G 0 608 841 224 15,65 31,30ErgoSpin ESA013S-G 0 608 841 205 15,65 31,30ErgoSpin ESA013G-G 0 608 841 225 15,65 31,30ErgoSpin ESA030S-G 0 608 841 206 27,69 35,38ErgoSpin ESA030G-G 0 608 841 226 27,69 35,38ErgoSpin ESA040S-G 0 608 841 207 13,85 27,69ErgoSpin ESA040G-G 0 608 841 227 13,85 27,69ErgoSpin ESA056S-G 0 608 841 208 16,36 32,72ErgoSpin ESA056G-G 0 608 841 228 16,36 32,72



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4.1.3 Overview of commissioning steps

The following sections give an overview of the commissioning steps for:

• Compact system CS351 (page 38)

• Modular system 350 (page 39)

4.1.3.1 Compact system CS351

ErgoSpin ESA065S-G 0 608 841 209 13,33 26,66ErgoSpin ESA065G-G 0 608 841 229 13,33 26,66ErgoSpin ESA075S-G 0 608 841 210 14.4 28.8ErgoSpin ESA075G-G 0 608 841 230 14.4 28.8ErgoSpin ESA100S-G 0 608 841 211 13,33 26,66ErgoSpin ESA150S-G 0 608 841 212 15,65 31,3ErgoSpin ESA220S-G 0 608 841 213 13,33 26,66



Please find information on the commissioning of the Nexo cordless Wi-Fi nutrunner and on the definition of tightening programs in the "Nexo" documentation.

Assembling the tightening spindle (see page 39) or the ErgoSpin hand-held nutrunner (see page 40)

Assembling the compact system (see page 40)

Inserting the interface modules (see page 42)

Connecting the tightening spindle (see page 43) or the ErgoSpin hand-held nutrunner (see page 43) to the compact system

Mains connection of the CS351 compact system (see page 44)

Switching on the tightening cell (see page 49)

Connecting the PC (see page 51)

Installing the BS350 operating system (see page 52)

Starting the BS350, setting up the programming interface, password entry (see page 53) to (page 56)

Configuring the tightening channel (see page 65) and (page 91)

Fig. 4–1: Overview of commissioning steps for compact system CS351

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4.1.3.2 Modular system 350

Configuring the PLC assignment table (see page 95)

Defining the tightening program (see page 92)

Sending/saving data (see page 58)

Sequence test (see page 97)

Operating the ErgoSpin hand-held nutrunner (see page 141)

Fig. 4–1: Overview of commissioning steps for compact system CS351

For commissioning of a tightening channel with the ErgoSpin hand-held nutrunner, see Special operating features of the hand-held nutrunner ErgoSpin/CC-ErgoSpin (page 141).

Assembling the tightening spindle (see page 39) or the ErgoSpin hand-held nutrunner (see page 40)

Inserting the control and power electronics in the BT/SB (see page 40)

Inserting the interface modules (see page 103)

Assigning the BT addresses1

Inserting the NK350(S) network couplers1

Combining multiple BT/SB1

Setting up the connections (see page 43)

Switching on the tightening cell (see page 49)

Connecting the PC (see page 51)

Installing the BS350 operating system (see page 52)

Starting the BS350, password entry (see page 53)

Configuring the tightening channels (see page 119)

Fig. 4–2: Overview of commissioning steps for the modular system

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4.2 Assembling the tightening cell

4.2.1 Assembling the tightening spindle

4.2.2 Assembling the ErgoSpin hand-held nutrunner

4.2.3 Assembling the CS351 compact system

4.2.4 Assembling the modular system

The system box SB356 or the card rack field BT356 are required in the modular system to support the control and power electronics.

Defining a tightening program (see page 92)

Sending/saving data (see page 57)

Sending the KE PLC assignment table (see page 124)

Setting the KE time (see page 125)

Sequence test (see page 125)

1 Only for multi-channel operation with more than one card rack field or system box. See section "Combination of multiple card rack fields and system boxes" in the "Project planning documentation of the Rexroth Tightening System 350

Fig. 4–2: Overview of commissioning steps for the modular system

Detailed information on the assembly of the tightening spindle can be found in the installation instructions "Rexroth Tightening Spindle".

The specific tightening torques set out in the respective operating instructions must be observed when bolting the components together.

Detailed information on assembling and commissioning the ErgoSpin hand-held nutrunner can be found in the "ErgoSpin" operating instructions.

Detailed information on assembling and commissioning the CS351 compact system can be found in the "CS351" operating instructions.

The Compact System CS351 is not designed to be directly connected to the public low-voltage power supply, but is only intended for use in industrial environments (emission classA).

BS350 | 3 608 870 B05/2019-03


Detailed information on assembling and commissioning the SB356 system box can be found in the "SB356" operating instructions.

Detailed information on assembling and commissioning the BT356 card rack field can be found in the "BT356" operating instructions.

BS350 | 3 608 870 B05/2019-03


4.2.5 Interface modules (IM)

Data communication (data services) and control signal exchange with the partner controller are implemented by interface modules (IM).

Fig. 4–3: Possible interfaces A, B1 and B2 on CS351/SE352M/KE350(G IL)

To insert the interface modules:

Slide the interface module into the top and bottom guide rails of the respective slot as far as it will go and then secure the same using the corresponding knurled bolts at the front.

Slots in CS351/SE352M/KE350G IL

Detailed information on admissible interface module can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

.

17

9

1

24C5 C4

C2

C3

C1

16

8 X7E1X3U1

X3U2 XDN1

X6C1

X3C1

XDVIX3U4

X3U3

ResetB2B1

A

NOKOK FG

RexrothCS351

Reset

B1B11

X3U1X3U2

X3U3

2

B1 B2

R eset

X3C1

X3U4

XDVI

X7E1

K E 350G IL

X3U1X3U2

X3U3

A

R UN/S TOPE R R OR

1 2 3

2 2 3

1

Interface AInterface B1Interface B2

123

Detailed information on the data communication can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

Detailed information on the control signal exchange can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

NOTICE

Open slotsOpen slots may lead to system damages. Close all free slots with dummy plates.

Interface modules do not always have to be used. In this case, close the empty slots using dummy plates.

BS350 | 3 608 870 B05/2019-03


4.2.6 Setting up the connections

4.2.6.1 Tightening spindle

The tightening spindle is connected to the compact system (CS) or to the servo amplifier LT35x or LTS350D via a connection cable. The total length of the connection cable depends on the type of the tightening system:

• When connecting to a system box or card rack field: up to 100 m

• When connecting to the compact system: up to 50 m

Connecting the tightening spindle:

1. Plug the connecting line plug for the tightening spindle to the socket of the EC-motor.

2. Use the union nut to secure the plug to the socket of the EC motor.

3. Insert the connection cable angle plug as follows:

– on the compact system (CS) into the XDS2 interface

– on the servo amplifier LT35x or LTS350D into theXDS2 interface

4. Align the angle plug with the compact system respectively with the servo amplifier in the desired outlet direction.

5. Secure the angle plug at the compact system or the servo amplifier by fully tightening the union nut.

4.2.6.2 ErgoSpin hand-held nutrunner

The ErgoSpin hand-held nutrunner is connected to the compact system (CS) or to the LTU350/1 and/or LTE350Dpower section via a connection cable. The total length of the connection cable depends on the type of the tightening system:

• When connecting to a system box or card rack field: up to 100 m

• When connecting to the compact system: up to 50 m

NOTICE

Overvoltage!Damage of electrical components. Connect the voltage-free connectors of the card rack field (BT), system box (SB) or compact

system (CS).

The length of the connection cable for certain components may be limited. You must therefore observe the length specification if stickers with limitations are attached to the components.

Fit appropriate strain relief devices to prevent kinks in the cable.

The length of the connection cable for certain components may be limited. You must therefore observe the length specification if stickers with limitations are attached to the components.

BS350 | 3 608 870 B05/2019-03


To connect the ErgoSpin hand-held nutrunner:

1. Insert the ErgoSpin connection cable in the plug on the handle of the hand-held nutrunner (use the guide grooves and catches) and tighten the union nut firmly by hand.

2. Insert the connection cable plug as follows:

– on the compact system (CS) into the XDS1 interface

– on the LTU350/1 in theXDS1 interface

– on the LTE350D in theXDS1 interface

3. Align the angle plug with the compact system respectively with the servo amplifier in the desired outlet direction.

4. Secure the plug at the compact system or the servo amplifier by fully tightening the union nut.

4.2.6.3 CS351 compact system mains connection

The compact system is delivered with an EU mains connection and mains connection plug with screw terminals. The mains connection cable can be unscrewed at the connection plug and assembled as desired.

The mains connection interface (X1N) is located outside the front cover (see Figure 4–4).

Fig. 4–4: X1N mains connection interface on the compact system

Always use angle plugs on the servo amplifier with the system box (SB) so the system box door can be closed.

NOTICE

Use of non-original partsDamages to the compact system Only use mains connection cables from Bosch Rexroth. You can find suitable cables in Bosch Rexroth's delivery program. Please also observe the local

regulations.

XDS1QO

X1N

CS351E-D CS351S-D

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The connection assignment of the X1N mains connection interface is shown in Figure 4–5 and explained in more detail in Table 4–2.

Fig. 4–5: X1N connections

Table 4–2: Pin assignment for X1N interface

Pin Signal Description/function Voltage/currentPE PE Leading PE wire PE potential

1 L1 L1 mains connection 230 V~ / 5 A, 120 V~ / 10 A

2 N Neutral mains connection 230 V~ / 5 A, 120 V~ / 10 A

3 n.c. - -

1 2

PE 3

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4.2.6.4 BT356 mains connection

The mains connection is implemented via the mains connection terminals on the X1N1 interface (see Figure 4–6 and Table 4–3).

The connection assignment can be found on the field next to the terminals.

Depending on the power consumption, the card rack mains connection can be

• 1-phase (1 x 230 V~ ±10 %)

or

• 3-phase (3 x 230 V~ ±10 %)

.

1. Insert the PE wire (minimum cross section 10 mm2 Cu) into the PE connection terminal and secure the same with the bolt.

2. Insert the L1, L2, L3 connection cables (cross section4 mm2 Cu) into the corresponding connection terminals and secure each with the bolt.

Fig. 4–6: X1N1 interface mains connection terminals on the BT356

Table 4–3: Description of the X1N1 interface

Terminal Description Voltage/currentL1 Phase 1 230 V~ / 6.3 A

L2 Phase 2 230 V~ / 6.3 A

L3 Phase 3 230 V~ / 6.3 A

PE PE wire 10 mm2

230 V N

L1 L2 L3

A≥10mm2

3 x 230 V

PE

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4.2.6.5 SB356 system box mains connection

The mains connection is implemented via the screw terminals on the mains switch (see Figure 4–7 and Table 4–4).

The cable fitting (Ø 8 mm – 13 mm) is located in the system box base.

The SB356 mains connection must be 3-phase (4 x 2.5 mm2) and include a PE wire. To avoid short circuits and ground leakage, a 3-phase fuse (16 A) must be provided.

Fig. 4–7: SB356 mains connection terminals

Voltage selection The voltage selection terminals in the SB356 allow for operating the system box in a voltage range of 380 V to 500 V.

The system box is set to 400 V at the time of delivery (see Figure 4–8).

The X1N4 interface partitions represent a logical separation of the 3 possible connection groups (G1 to G3) (see Figure 4–8).

Table 4–4: Description of the mains connection terminals on the SB356

Signal Description/function Voltage/currentPE PE wire PE potential

1L1 L1 mains connection 380 – 500 V~ / 4.6 – 3.5 A



1L1 3L2 5L3 PE

NOTICE

Damages caused by varying voltagesVarying mains voltages will damage the control and power electronics. All three mains phases must be connected with the same voltage value!

NOTICE

Varying assignment of mains connectionsDamages to the control and power electronics Only use the voltage selection terminals from the G1, G2, and G3 groups for the mains

connection. Do not assign the device connection.

BS350 | 3 608 870 B05/2019-03


Fig. 4–8: X1N4 voltage selection terminals with connection groups G1, G2, and G3

NOTICE

Varying assignment of connections within a groupDevice destruction Only the connections of one group may be used. Do not simultaneously assign varying groups.

NOTICE

Incorrect wiringDamages to the control and power electronics Always feed the mains connection through the upper terminal strip (see Table 4–5) The lower terminal strip must remain fully wired.

Table 4–5: Voltage selection terminals

Pin Signal Description Voltage/current1 PE PE wire PE potential

G1 2 L1 L1 mains connection 380 V~ – 415 V~ / 4.6 A

3 L2 L2 mains connection 380 V~ – 415 V~ / 4.6 A


G2 5 L1 L1 mains connection 440 V~ – 480 V~ / 3.9 A



G3 8 L1 L1 mains connection 500 V~ / 3.5 A

9 L2 L2 mains connection 500 V~ / 3.5 A

10 L3 L3 mains connection 500 V~ / 3.5 A

G4 11 L1 L1 device connection 230 V~ / 7.5 A

12 L2 L2 device connection 230 V~ / 7.5 A

13 L3 L3 device connection 230 V~ / 7.5 A

}.1

.2

.1

.2

.1

.2

.3

.4

1

.1

.2

.1

.2

.1

.2

.1

.2

.1

.2

.1

.2

.1

.2

2 3 4 5 6 7 8 9 10

.1

.2

.1

.2

.1

.2

11 12 13

G1 G2 G3 G4

Terminal strips for mains connection Device connection

BS350 | 3 608 870 B05/2019-03


4.2.7 Motor-breaker

Information on the Motor-breaker topic is contained.

4.2.8 Switching on the tightening cell

4.2.8.1 Compact system

LED displays

Fig. 4–9: LED on the front

NOTICE

OvervoltageComponents may be damaged The CS on/off switch may only be switched on once all the cables have been connected and

checked for proper fit.

Table 4–6: LED modes

LED Display DiagnosisOff No power supply or low-voltage power supply

available

Blue Power supply and low-voltage power supply available

Green Ready for operation

Green, flashing Sequence control active, not ready for operation, no system error

Red, flashing System error

OK/NOK Green Tightening case evaluation: OK

Red, flashing Tightening case evaluation: NOK

Off Motor contactor not operated

Green Motor contactor operated

Red/green, flashing Servo amplifier initialization

Red Motor contactor error

FG Green Servo amplifier release

Off No servo amplifier release

RUN/STOP

(only for CS... IL)

Green IndraLogic running

Red IndraLogic stopped

ERROR

(only for CS... IL)

Red, flashing IndraLogic error

BS350 | 3 608 870 B05/2019-03


4.2.8.2 Modular system

LED displays

Tables 4–7 to 4–9 show the LED displays for the VM, SE, LT, and KE during the starting/run-up phase, when they are ready for operation, and in tightening operation.

Starting/run-up phase

Ready for operation

Tightening operation

NOTICE

OvervoltageControl and power electronics can be damaged. The BT voltage supply or the SB on/off switch (below the door) may only be switched on after all

modules have been fully inserted and secured with knurled bolts and all cables have been connected and checked for proper fit.

Information on the operating states can be found in the project planning manual for the respective component.

Table 4–7: Starting/run-up phase

VM SE LT KEGreen (static) Red (static) Green/red

flashingRed (static)

Red (static) Off Red (static)4

Table 4–8: Ready for operation

VM SE LT KEGreen (static) Green (static):

Ready for operation

Green (static): Ready for operation


Red (flashing): error

Red (static): error Red (static): error

Green/red flashing: logon to CAN bus

Red (flashing): no tightening took place beforehand.

Off Off4

Table 4–9: Tightening operation

VM SE LT KEGreen (static) Green (static):

Ready for operation


Green (static)

Red (flashing): error

Red (static): error

Green (flashing): emergency STOP chain interrupted1

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4.3 Connecting the PC for programming

4.3.1 Connecting the PC

The tightening system is programmed via a connected PC with installed BS350 operating system. The following interfaces may be used to connect the PC:

Fig. 4–10: USB and Ethernet interfaces for the compact system (CS351) and KE350(G IL)

Red (flashing): tightening NOK

Off, when the motor is not triggered

Off

Green (static): tightening OK

Green (static) in tightening operation

Red (flickering): data traffic on control bus

Off:

– during the tightening

– after play at the start switch

Green (flickering): data traffic on data bus

1 with LTU only if emergency OFF function is configured

Table 4–9: Tightening operation

VM SE LT KE

4

For detailed information on LED displays for other (e.g. malfunctioning) operating states, see chapter Troubleshooting from page 153.

117

9

1

24C5 C4

C2

C3

C1

16

8 X7E1X3U1

X3U2 XDN1

X6C1

X3C1

XDVIX3U4

ResetB2B1

A

NOKOK FG

RexrothCS351

B1 B2

R eset

X3C1

X3U4

XDVI

X7E1

K E 350G IL

X3U1X3U2

X3U3

A

R UN/S TOPE R R OR

USB interface X3U3

1

Ethernet interface X7E1

2

2

1

12

The front door of the SB may remain open during commissioning to feed the programming cable/Ethernet cable through.

The compact systems CS351x-D NK (as of version V2.200 of the Rexroth Tightening System 350) are programmed via the communication unit (KE) of the modular system.

BS350 | 3 608 870 B05/2019-03


4.3.1.1 Connecting to the USB programming interface

The connection must be made using the USB350 programming cable.

4.3.1.2 Connecting to the Ethernet interface

In order to operate the tightening system via Ethernet, the PC has to be equipped with an Ethernet interface card for network operation.

4.3.2 Installing the operating system BS350 on the PC

The Rexroth BS350 operating program as of V2.100 is delivered on the Bosch Rexroth system stick. The program can be used to operate the following versions of the Tightening System 350:

• CS351 Compact System with ErgoSpin hand-held nutrunner, portable nutrunner or tightening spindle

• Modular system 350 with ErgoSpin hand-held nutrunner, portable nutrunner and/or tightening spindle

The user is guided through the installation with an installation program.


The relevant minimum and recommended requirements with regard to processor power, required working memory as well as free hard drive memory are contained in the information of the respective operating system manufacturer.

• System requirements for version 2.700

The workstation computer (PC) runs one of the following operating systems and the hardware requirements of the operating system have to be met, e.g. regarding CPU output:




• Ethernet (TCP/IP) or USB for connection to the tightening system

• Graphics resolution 800x600 (1024x768 recommended)

• Recommended: a mouse or other compatible device

• The following TCP/IP ports must be enabled:

– TCP input and output at port 7072

– UDP output at port 7073

– UDP input at ports 7073 to 7079

Detailed information on the set-up of the Ethernet interfaces can be found in the "Project planning" documentation of the Rexroth Tightening System350!

If several programs have to be active at the same time on the operating computer, we recommend a correspondingly higher system performance (processor and working memory) as compared to the information of the respective operating system manufacturer.

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Installing the BS350 operating system

To install the BS350:

1. Connect the system stick to your computer.

2. Open the file start.htm in the root directory of the system stick.

Your HTML-browser will start.

3. Click the hyperlink Installation.

4. Use the mouse (or compatible device) to click the entry for the desired software version.

The installation program will start.

5. Select the desired language and confirm with OK.

6. In the BS350 V2.700 settings dialog, select the option BS350 started once, i.e. the BS350 cannot be started more than once on the PC.

7. Install both USB drivers.

Read the instructions on installing the USB drivers to ensure that you install them correctly. You must observe all of the steps in the dialog during the installation.

8. You can download the current firmware via the support pages in the Internet.

After successful installation the BS350 icon will appear on the desktop.

Downward compatibility

Version 2.700 to V2.600

4.3.3 Starting the BS350

Double click the BS350 icon to start the operating program.

The USB drivers and installation instructions are included on the system stick in the following directory: \Miscellaneous\Additional Drivers\FTDI USB Driver

Version 2.700 of the BS350 operating system (BS350 V2.700 release) is downward compatible with version 2.600 as regards:

• Firmware update, refer to the

The BS350 V2.700 release supports firmware updates from V2.600 to V2.700 and firmware downgrades from V2.700 to V2.600 for the components SE, CS and KE.

• Downgrade of components SE, CS and KE with firmware version 2.700 to firmware versions < 2.700

• Via the menu items Firmware update, Delete configurations and HMI configuration of the BS350 2.700, the control components with firmware version V2.700 can be updated to operational firmware versions < 2.700.

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4.3.4 Setting up the programming interface

4.3.4.1 USB interface

The USB interface drivers must be installed separately. The necessary files and instructions for this can be found on the USB stick provided with the tightening system (hereafter referred to as the "system stick").

To select the USB interface:

1. Make sure that the PC is connected to the compact system via the USB cable (interface X3U3 at the front).

2. Click PC Interface in the BS350 operating system.

3. Select the USB interface.

4. Click OK to accept the setting.

5. Click System test Tightening channel info to test the connection.

4.3.4.2 Ethernet interface

In order to operate the tightening system via Ethernet, the PC has to be equipped with an Ethernet interface card for network operation.

The Ethernet interface in the compact system has the following settings by default:

• IP address: 192.168.1.1

• Subnet mask: 255.255.255.0

• Host name: cell

The rest of the settings are either 0.0.0.0 or empty.

If the connection is not established, you can reset all connection parameters without closing the BS350. Proceed as follows:

Disconnect the USB cable from the interface.

Reinsert the USB cable in the interface.

Go to the PC/PC interface window and click the Reset button.

If the connection is not established, you can reset all connection parameters and close any open connections, without closing the BS350. Proceed as follows:

Go to the PC/PC interface window and click the Reset button.

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To change the IP address (CS compact system):1. Make sure that the PC and tightening cell are connected to the Ethernet.

If you cannot use the Ethernet connection with the current IP address, additionally establish a direct connection via USB (see page 54).

2. In the BS350 operating system, click System Tightening channel configuration.

3. Double click the line CS to view the interfaces.

4. Double click the line X7E1.

The compact system - X7E1 parameter dialog will appear (see page 75).

5. Enter the desired data to configure the Ethernet interface.

6. Click Accept to accept the data and close the parameter dialog.

7. Click Data Send to send the modified data to the controller.

To change the IP address (KE Modular System)1. Make sure that the PC and tightening cell are connected to the Ethernet.

If you cannot use the Ethernet connection with the current IP address, additionally establish a direct connection via USB (see page 54).

2. In the BS350 operating system, click System KE configuration.

3. Double click the line X7E1.

The compact system - X7E1 parameter dialog will appear (see page 75).

4. Enter the desired data to configure the Ethernet interface.

5. Click Accept to accept the data and close the parameter dialog.

6. Click Data Send to send the modified data to the controller.

To select the Ethernet interface:

1. Click PC Interface.

2. Select the Ethernet interface.

3. Enter the new IP address at Tightening cell.

4. Click OK to accept the settings.

5. Click System test Tightening channel info to test the connection.

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4.3.5 Logging in to the tightening system (password entry)

In order to be able to change tightening programs and configurations, the user must be logged in to the tightening system using his user name and password.

To log in to the tightening system:

1. Click the symbol or

click Administration Log ON/OFF or

press the [F3] button on the keyboard.

2. Enter the password Robert and confirm with OK.

Fig. 4–11: User name Bosch, password Robert

The status Log ON is shown in the status bar.

Period of the active connection

If you access the KE communication unit or the CS351 compact system using the BS350 operating system, the connection is automatically disconnected after 15 minutes.

In the following cases, the connection is not cancelled automatically:

• You are currently active, i.e. you exchange data with the hardware (retrieve or transmit data). This includes e. g.:

– Transmission of channel configurations, tightening programs or applications to the hardware

– Logon to the system, see figure 4–11

– Reading of available tightening programs or -applications from the hardware

– Query of diagnosis data

• You have opened one of the following views in the BS350:

– Actual value …

– Graph …

– Graph Save …

– Graph Overlay …

In these cases, the connection is not automatically disconnected after 15 minutes as between the BS350 and KE/CS351 keep alive messages are transmitted on a permanent basis. This is also the case if no configuration or tightening results data is transmitted.

The user does not have to be logged in to the system to query configurations, results, error lists, etc.

As of Rexroth Tightening System 350 version V2.600, selection between the standard authorization concept and a new authorization concept is possible. Depending on the selection, additional settings can be made. Refer to.

Information on the password change can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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4.4 Sending and saving

4.4.1 Sending files

Prerequisites for sending files:

• a connection of the PC to the tightening controller with set-up interfaces (see Setting up the programming interface (page 54))

Prerequisites for sending files:

• In single-channel operation: a connection between the PC and CS with set-up interfaces

• In multi-channel operation: a connection between the PC and KE with set-up interfacesand

• password entry in the BS350 (see Logging in to the tightening system (password entry) (page 56))

The following files, among others, can be sent to the controller:

• to SE/CS:

– One or more tightening programs for this tightening controller

– Tightening channel configuration

– SE/CS PLC assignment table

• to KE:

– One or more tightening applications

– KE configuration

– KE PLC assignment table

– One or more tightening programs for one or more SEs

– The tightening channel configuration to one or more SEs

– PLC assignment table to one or more SEs

The data is sent by:

• Data Send ... or

• Data Send to ... or

4.4.1.1 Send ...

Single-channel operation (CS)

Files loaded online can be edited and then sent to the tightening controller using Data Send ... . Amongst others, these files include:

• Tightening program

• Tightening channel configuration

• SE/CS PLC assignment table

Multi-channel operation (KE)

Files loaded online have to be sent to the KE after editing. Amongst others, these files include:



• KE PLC assignment table

The KE forwards tightening programs and tightening channel configurations to the SEs.

Files created offline cannot be sent using Data Send ... or . For this purpose, use Data Send to ... or .

Files created offline for the KE cannot be sent to a tightening channel using Data Send or . For this purpose, use Data Send to ... or .

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4.4.1.2 Send to …

Single-channel operation (CS)

Files loaded online or created offline can be sent to the tightening controller with Data Send to ... . Amongst others, these files include:

• One tightening program or several tightening programs simultaneously


• SE/CS PLC assignment table

Multi-channel operation (KE)

Files loaded online or created offline have to be sent to one/several SEs or the KE. Amongst others, these files include:

• One or more tightening programs to one or more SEs

• The tightening channel configuration to one or more SEs

• The SE PLC assignment table to one or more SEs

• One or more tightening applications to the KE

4.4.2 Saving data

File Save

An open and modified file is saved with the same name using File Save.

File Save as ...

Use File Save as ... to save the open file to the data carrier (e.g. hard disk). Amongst others, these files include:


• Tightening application

• Tightening jobs

• CS, SE, or KE configuration

• PLC assignment table for the SE/CS or KE

• Graph

File Save tightening cell

The contents of a tightening cell are saved in several individual files using File Save tightening cell.

These files can be opened separately using BS350 (File Open ...) and, if needed, be sent back individually to the controller.

In the dialog for saving the content of a tightening cell, the following information can be entered:

• Directory path

• Tightening channel selection (only one channel is available with the compact system)

• Selection of the data to be saved

Select Save to initiate the saving procedure. The saved data is stored in the selected directory in a folder for each SE with the identification "Ch x.y channel name" or in a folder for the KE with the identification "KE". The file name extension is based on Table 4–10.

Exit the dialog using Close.

File name extensions

The following table gives an overview of the file name extensions when they are saved.

The KE configuration and KE PLC assignment table cannot be sent using Data Send to ... or clicking ! For this purpose, use Data Send ... or .

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Table 4–10: Files with file name extensions

Files File name extensionTightening program *.prgAll tightening programs *.prxTightening application *.fopAll tightening applications *.foxTightening job CS *.jobAll tightening jobs CS *.jbxTightening job KE *.kjbAll tightening jobs KE *.kjxTightening job SE *.sjbAll tightening jobs SE *.sjxGraphs *.crvTightening channel configuration *.scgKE configuration *.kcgPLC assignment table SE / CS *.sioPLC assignment table KE *.kioPLC assignment table IL export data *.expQuality code *.qtbHMI configuration *.sdcCS field bus data *.sdfKE field bus data *.kdfGraph memory configuration *.scvResults storage configuration *.sreResults storage display *.sdtOK/NOK counter configurations *.cntAuto Backup / Restore configuration *.cbrPrinter 1/2 configurations *.dcgPLC (3964R) 1/2 configurations *.dcgFTP configurations *.dcgID code configurations *.dcgIPM Protocol configuration *.dcg and*.ipmPLUS Protocol configuration *.dcg and*.plsOpen Protocol configuration *.dcg HTTP Protocol configuration *.dcgQDA Protocol configuration *.dcg and*.qdaPFCS-2Port configuration *.dcgVW-XML 2.x configuration *.dcgIntegra-XML configuration *.cbr Log book files *.lbkStatus IPM *.xmlStatus PLUS *.pluNexo configuration *.nexoTrace sequence *.trace

The .dcg files can only be stored or loaded in the respective menu under System Tightening cell data.

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4.4.3 Data backup with the backup function

When the operating computer is connected to the controller, the data backup is performed using Data Backup ... . All of the configuration data and tightening programs in the controller are stored in the backup file.

It is not possible to display the individual data (e.g. PLC table) in a created backup file, i.e. the backup file serves as a so-called "collective file". It is only possible to save the data in separate files using Data Save tightening cell.

4.4.4 Automatic data backup with backup/restore function

The automatic data backup with backup/restore function is configured in the System Auto Backup/Restore menu item.

Fig. 4–12: Parameters dialog for configuration of the backup/restore function

More detailed information regarding the data backup can be found in the "Project planning" documentation of the Rexroth Tightening System 350!

As of version V2.600 of the Rexroth Tightening System 350, automatic backup/restore is possible. I.e. all components must have firmware version 2.600 or higher.

For using the automatic backup/restore function, a CF350 (memory card) has to be inserted in the compact system (CS) or the communication unit (KE) and the control unit (SE). Otherwise, an error (error class 3) is returned at the components without CF350.For systems using data output that applies this CF350 as buffer, the 1 GByte CF350 is recommended.

2

4

3

1

5

6

78

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Auto backup/restore function

Configuration and firmware of the components are stored on the CF350 of the respective component according to the settings in the Auto backup/restore dialog. If the configuration or firmware changes, this data is updated on the CF350. If the CF350 is connected to a different component with the same type number, a restore process is carried out if the Auto restore checkbox is enabled. Otherwise, the restore function can also be started manually with the Start restore manually button.

1 When logging off

2 Time 1

3 Time 2

4 Time 3

5 By "Backup" PLC signal

6 Auto restore

7 Start restore manually

8 Start backup manually

Table 4–11: Settings in the Backup/Restore function configuration

Element DescriptionWhen logging off If the When logging off option is enabled, the backup function is

started automatically after the user is logged off from the BS350 Tightening System.

Time 1Time 2Time 3

If the option Time 1, Time 2 or Time 3 is enabled, the automatic backup is started automatically after the selected time(s). If a user is logged in at the tightening system, the automatic backup function is started if the user is logged off.

By "Backup" PLC signal If the By "Backup" PLC signal option is enabled, the automatic backup function is started if the Backup PLC signal changes from 0 to 1. If a user is logged in at the tightening system, the automatic backup function is started if the user is logged off.

Auto restore If the Auto restore option is enabled, the stored backup is loaded automatically after replacement of a defective component.

Start restore manually The Start restore manually button enables manual starting of the restore function.

Start backup manually The Start backup manually button enables manual starting of the backup function.

The backup/restore process may take a few seconds up to several minutes depending on various factors:

• Is saving/backup of the firmware required or has it already been saved or is available?

• How many parameters (e.g. tightening programs, applications, jobs, etc.) are programmed/configured?

• How often are automatic backups carried out during the tightening process?

To monitor/control the sequence of the automatic backup/restore, we recommend using the PLC signals for auto backup/restore, see section PLC signals from page 125.

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4.4.4.1 Sequence of the automatic backup process

If a backup is initiated by reaching of the set time or the Backup PLC signal, the system checks whether a user is logged on. If a user is logged on, the start of the backup is delayed until the user has logged off.

If a backup is running, the following error message is displayed on logging in at the operating system or at the TFT display of the CS351: "Automatic backup or restore in progress. This process will be canceled by logging on. Continue logging on?". If the message is confirmed with "YES", the running backup is canceled. The old backup data remains changed.

If another backup is initiated while a backup process is already running (e.g. by means of a Backup PLC signal or logging off of a user), it is not started.

If the tightening cell is switched off at the time a backup is to be started, the backup is not resumed after the tightening cell is switched on. If the tightening cell is switched off while a backup is running, the backup is resumed completely on restarting of the tightening system.

If a component is replaced by an incorrect component after previous backup, no backup is created of this component if the backup is started again. The BackupF PLC signal is set. A backup is only possible if the backup on a component was either deleted or a new backup is created by means of the trigger conditions of Start auto backup. Alternatively, a backup can also be started with the Start backup manually button. Afterwards, the BackupF PLC signal is reset.

Start backup manually

If no options are enabled under Start auto backup, the backup can be started with the Start backup manually button.

4.4.4.2 Sequence of the automatic restore process

If the Auto restore option is enabled, the stored backup is loaded automatically after replacement of a defective component.

In a multi-channel system, this is controlled by the communication unit. When the system is booting, the type numbers of the (replaced) components are checked for compliance while the serial number is deviating. Only in this case, the restore process is initiated for this component. If the type numbers of the components are deviating, an error (error class 3) is returned.

Start restore manually

If the Auto restore option is not activated, the restore process can be started in BS350 based on the backup data stored in the components of the tightening cell.

The restore process is carried out for all components without plausibility check. Only the state at the time of the last backup can be restored.

The tightening cell is also in operation while the backup is running and tightening processes can be realized. The backup is running in the background. General impact on the times cannot be excluded even with a low-priority sequence.

The tightening cell is not in operation while the restore process is running and tightening processes cannot be realized.

Auto restore should never by canceled. In case of cancelation, error 2935 “Restore was interrupted. Data could be corrupt. Repeat restore.” will be entered.

By repeating the Auto restore (e.g. via BS350), the system can be brought back into the status of the currently saved backups.

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Special case: Restore after replacement of the KE communication unit

When changing the KE in a multi-channel system, a new CF350 may also be installed with the new KE. To prevent automatic restore of a backup not fitting the tightening cell, the contents of the backup are checked for plausibility. The automatic restore is only executed if at least one component is recognized by the KE. This means, at least one component with the related serial number must exist in the tightening cell and the administration structure of the automatic backup (CF350) on the KE.

4.4.4.3 Deleting of backup data on tightening cell components

No longer required backup data stored on the components of a tightening cell can be deleted by means of Data Delete SE/CS or Data Delete KE.

4.4.4.4 Status of the automatic backup

In BS350, the status of the backup of every channel of a tightening cell can be checked. With menu item System test Tightening cell info Auto backup/restore, the status of the backup is displayed.

If the ACTUAL state does not correspond to the TARGET state of the automatic backup, the corresponding line will be marked in red in the Auto Backup/ Restore diagnosis and the tool tip TARGET / ACTUAL difference in the Auto Backup / Restore in the administration structure will be output.

There may be different causes:

• Firmware file *.bfw not available

• Firmware file *.bfw is not suitable for the current firmware

• Backup file *.chl or *.cel not available

• Backup file *.chl or *.cel is not suitable for the component and/or the channel slot

To remove the TARGET/ACTUAL difference in the Auto Backup/Restore in the administration structure, an automatic backup needs to be carried out.

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4.5 Operating the compact system

4.5.1 General information on the configuration

The configuration of a tightening channel with BS350 includes logical linkage and parameter assignment of all electronic and mechanical components involved in the tightening channel. The configuration window (see Figure 4–13) opens when the following menu items have been selected:

• System Tightening channel configuration in online mode (see page 65) and/or

• File New Tightening channel configuration in offline mode (see page 91).

Layout of the configuration window

The configuration window of the BS350 displays (see Figure 4–13, from left to right):

• Component selection

• Configuration of the tightening channel as logically linked components subdivided into four columns (from left to right):

– Name

– Symbol

– Parameter

– Notes

– Global parameters

Fig. 4–13: Layout of the tightening channel configuration window

The configuration has to be sent to the corresponding tightening channel upon creation. The same is compared to the actual configuration (actual equipment) of the tightening channel. After the configuration has been sent, errors (e.g. configuration conflicts) will be displayed in the configuration window.

Global parameters Configuration fields Component selection

Name Symbol Parameter Notes

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4.5.2 Online configuration

The advantage of online configuration is that configuration and parameter assignment of components with an electronic nameplate are automatically recognized.

4.5.2.1 Loading the tightening channel configuration

The PC and tightening channel must be connected before the online configuration can be loaded (see Connecting the PC for programming (page 51)).

To load the current configuration of the tightening channel:

Click System Tightening channel configuration or .

System components with an electronic nameplate are automatically recognized by the BS350 and listed with the appropriate information, e.g.:

• ErgoSpin

• EC-motor

• Measurement transducer

• Interface Modules

• Part no.

• Firmware version

• Battery monitoring

• Monitoring of the compact flash card

To check the configuration of the interfaces:

1. Double click the field

All the available interfaces are displayed. The X3C1 serial interface and the X7E1 Ethernet interface are permanently installed. The other interfaces are not equipped1).

All the interface fields are closed by double clicking again.

For detailed information concerning troubleshooting, see chapter Troubleshooting from page 153.

Configuration of a tightening channel with ErgoSpin SlimLine and ErgoSpin GripLine is implemented automatically. You do not have to supplement the configuration. For further information on the automatic configuration of an ErgoSpin tightening channel, see Configuring the tightening channel (page 132).

1) For possible interface assignments and parameterizations, see Setting up additional interfaces (page 76).

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Fig. 4–14: View of the interfaces in the compact system

4.5.2.2 Completing the tightening channel configuration

To delete a component:

Click the appropriate symbol in the configuration sequence and press the [Del] button to delete the component.

To add a component:

Add a permitted component (displayed in black) (see page 91).

A distinction is made between two cases:

– If the new component is to be added to an empty field then select the empty symbol field in the configuration sequence and add a permitted component (=displayed in black) from the component selection into the configuration sequence.

– If the new component is to be inserted between two components, then select the component in the configuration sequence in front of which you wish to insert a new element. Then, insert a component permitted (=displayed in black) within the configuration sequence.

Configuration with standard version

If the tightening channel only contains mechanical components, e.g. an additional drive component on the ErgoSpinVarioLine, they are inserted in the configuration sequence, but not parameterized. They are therefore highlighted in red and the message Check component ______ Set parameters is displayed.

The same applies for a compact system with tightening spindle (see 4–15). Here, the EC-motor and the measurement transducer are recognized automatically due to their electronical nameplates, whereas the mechanical components, e.g. planetary gearbox and straight output drive, have to be parameterized manually.

NOTICE

Incorrect channel configurationAn incorrectly configured ErgoSpin VarioLine or pistolgrip nutrunner may result in faulty tightenings. When working with the ErgoSpin VarioLine or pistolgrip nutrunner, always check that the

components stored on the hand-held nutrunner correspond to the actually equipped components and, if necessary, correct the configuration with the operating program.

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Fig. 4–15: Compact system CS351S-G with configured tightening channel

Using the compact system (CS), the transducer function motor current ("Off", "Primary", "Redundancy") can be configured, whereas the following restrictions apply:

ErgoSpin configuration with adapter, straight output drive or angle head1. Double click the field highlighted in red to open the associated parameter dialog.

Figure 4–16 shows the dialog Adapter after double clicking the red field in line A.

Table 4–12: Compact system CS351 - Setting the transducer function motor current

Transducer function via motor current

CS351E-D/IL CS351E-G/IL CS351E-G+ CS351E-D NK

CS351S-D/ILCS351S-G/ILCS351S-D NK

CC-CS351E-D

Off - x -

Primary1

1 The compact system can be used for current-controlled tightenings. That means that the motor current can be used for the primary measurement ("Primary").

- x x

Redundancy2

2 With the compact system, the motor current can be used for the redundancy measurement.

x x -

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Fig. 4–16: Completing the configuration with the special component entry window

2. Select the component to be used from the Code drop-down list (note the sizes).

3. A serial number does not need to be entered for mechanical components.

4. Efficiency is used to calculate the torque of the output drive. Nominal efficiency is automatically entered for the corresponding component by the BS350, but it can be adjusted up or down as needed (e.g. if there are signs of wear). The values in the grayed-out windows cannot be modified.

5. Click Accept to accept the component data into the program. The data are then displayed in white.

The assignment of parameters is aborted and any modifications are rejected by selecting Cancel.

6. If necessary, set the missing parameters for further components.

Alternatively, you can also delete the component (see above). You then add another, side-by-side component such as an angle head or adapter on tightening spindle output drives, for the ErgoSpinVarioLine. Also set the missing parameters for this component as described above.

Compare all the values in the parameter fields to the data on the name plates for accuracy. To correct these values, double click the respective parameter field, then correct and transfer the data to the configuration.

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ErgoSpin configuration without standard version

Additional, special mechanical components can be added to the ErgoSpin ESM and ESV hand-held nutrunners. After you have added them, the components can be selected from the database or freely configured.

1. If necessary, delete an existing component.

2. Add a new component.

3. Double click the field highlighted in red to open the associated parameter dialog.

4. Figure 4–17 shows the Special component dialog after double clicking the line SO.

Fig. 4–17: Completing the configuration with the special component entry window

5. Enter the order number for the special component into the Order number list field.

A serial number does not need to be entered for mechanical components.

Enter the efficiency of the special component into the Efficiency list field.

6. Enter the transmission for the special component into the Transmission list field.

For monitoring purposes, you can also enter the maximum permissible torque for the special component.

7. Click Accept to accept the planetary gearbox data in the program. The data are then displayed in white.

The assignment of parameters is aborted and any modifications are rejected by selecting Cancel.

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Channelconfiguration of open

flat output drives

BS350 allows for simple configuration of the ErgoSpin hand-held nutrunner with open flat output drives.

Using the Flat output drive (F) parameter dialog (the symbol is shown in Figure 4–18) select the output drive spin direction and reverse spin direction. Depending on these two settings, the alignment spin direction of the motor is adjusted accordingly. In this way, you can use flat output drives with counterclockwise spin direction and flat output drives with clockwise spin direction."Referencing

Fig. 4–18: Channel configuration: Symbol flat output drive (F)

Table 4–13 describes the parameters that you can set in the Flat output drive (F) parameter dialog.

Table 4–13: Parameter for setting the flat output drive (F)

Parameter DescriptionCode With flat output drives, there is no selection option. The component is displayed

with the corresponding serial number as soon as you accept the configuration.

Order number Component order number

Serial number Component serial number

Efficiency Specification of efficiency in percent [%]

– Value range: 0% … 100%

Transmission Specification of the transmission

– Value range: 0 … 1.000

Max. torque Maximum torque up to which the flat output drive may be used

Reverse spin direction Specification of an option for a reverse spin direction

– ActivatedSelect this option if the drive spin direction of the flat output drive does not correspond to the output drive spin direction of the flat output drive.

– Deactivated

Select this option if the drive spin direction of the flat output drive corresponds to the output drive spin direction of the flat output drive.

Output drive spin direction Specification of the mechanically defined spin direction / tightening direction (spin direction not running towards the safety catch) of the flat output drive

Value range:

– Counterclockwise

– Clockwise

Cycle counter Cycles that have already been run through on the flat output drive.

– Presetting: 0

Open flat key program-controlled This parameter is available for flat output drives without safety catch as of Rexroth Tightening System V2.400.

Activate this option for configuration of the open flat output drive without safety catch. After sending, the system is restarted.

Precise motor screw reduction ratio

This parameter is available for flat output drives without safety catch as of Rexroth Tightening System V2.400.

Specification of the accuracy for the reduction ratio of the motor screw. For open position accuracy, the value should be entered with 12 decimal places. See also table 4–14.

Change component Click on this button in case of a component change to save the serial number and the number of cycles of the new component.

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Parameter "Precise motor screw reduction ratio"

Reduction ratio calculation:

ITotal = IErgoSpin * IAngle head * IFlat output drive + Ix ...

Configuration example

4.5.2.3 Setting the global parameters

General The unit (Nm, Ftlb, Inlb, kpm, kgfm, and kgm) selected in the Unit torque list applies for the tightening program and tightening channel and is used for tightening results data, graph displays, etc. The values Spindle overload and Per. torque in the Spindle limits field are adapted to the selected unit.

Operating mode The 1-channel option is permanently activated with compact systems.

Channel configuration

The Automatic radio button is only active if there is a channel configuration with a hand-held nutrunner ErgoSpin, with a DMC measurement transducer or offset output drive with integrated measurement transducer VMC...-SD/-QC/-SP. In this case, you can choose between automatic and manual channel configuration.

If the automatic channel configuration is not possible for system components, error code 1113 will be displayed.

A change in the hand-held nutrunner or tightening spindle is automatically recognized and accepted by the automatic configuration, making the tightening system immediately ready for operation. Serial number monitoring is inactive if the automatic configuration is active.

Table 4–14: Hand-held nutrunner components reduction ratio

ErgoSpin Varioline Reduction ratio Angle head Reduction ratioESV005/012 27.9230769230769 WH013 1.095238095

ESV025 17.4705882352941 WH040 1.733333333

ESV050 36.6230769230769 WH056 1.157894737

ESV073 24.4152249134948 WH065 1.35

ESV146 52.02 WH075 1.5625

WH100 1.421052632

WH150 1.095238095

WH220 1.588235294

The total reduction ratio factor for angular measurement of the tightening system is usually determined automatically by the system according to the connected spindle components of the tightening channel configuration. The information of "Precise motor screw reduction ratio" > 0.0 overwrites this total reduction ratio factor for angular measurement of the tightening system!

The reduction ratio factors for torque measurement are not affected.

Reverse spin direction No No Yes

Output drive spin direction

Clockwise Clockwise Clockwise

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If the Manual option is active, system components with an electronic name plate of the tightening channel are recognized, but mechanical components (e.g. gearbox or straight output drive) must be configured manually.

The option Serial number monitoring is used to detect the exchange of an electronic component.

If a component is exchanged, the serial number of the connected system component deviates from the number stored in the channel configuration and a system error is generated.

Additional function With the additional function Hand-held nutrunner it is possible to switch on the hand-held nutrunner function in a tightening spindle configuration in which no hand-held nutrunner was inserted.

In this operating mode, recognition of play on the start switch by the user is active (see Nutrunner start (page 139)).

The threshold from which an evaluation is performed corresponds to the entry in the field Play on start switch, evaluation from in the start step. The default value is 5% of the tightening spindle's nominal torque.

Tightening programs 0, 1, 2, 3, and 99 are automatically transferred from the ErgoSpin hand-held nutrunner to the tightening controller with the additional function Use tightening programs from hand-held nutrunner (program 99 and 0 to 3).

Attention: The corresponding programs on the tightening controller are overwritten by the BS350 or TFT display after the error message has been acknowledged (error code 382).

Nutrunner docking is configured with the additional function Nutrunner docking, see Nutrunner docking configuration (page 90).

Additional function for angle compensation, see Special features of ErgoSpin with angle compensation (page 145):

• By means of Activate angle compensation, the function can be activated or deactivated. If no valid license is available, the license is already in use or Angle correction demo period is not activated, the checkbox cannot be enabled.

• Via Angle compensation demo period, the 30-day demo period can be activated. The angle compensation function can now be enabled via Activate angle compensation.

With the additional function Socket tray coding, the type of coding for the socket tray is defined:

• Bit pattern

Every bit represents a slot in the socket tray. With bit coding, more than 1 slot can be displayed. At 3, for example, bit 1 and 2 are set, i.e. slot 1 and 2 in the socket tray are selected.

• Decimal

Defines the socket tray slot. For example 3 represents slot 3 in the socket tray.

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Tool As of version V2.600 of the Rexroth Tightening System 350, the Tool option is supported. Via Tool, you can configure the maintenance interval for tightening spindle and ErgoSpin and make settings for ErgoSpin SlimLine/GripLine for a new angle head. Click the Options button to start the configuration. The button is active if a measurement transducer DMC, VMC...-SD/-QC/-SP, 3WMC090 / 4WMC220 or ErgoSpin has been configured. The ErgoSpin hand-held nutrunner options/ DMC options/ VMC options/ WMC options dialog is displayed:

Table 4–15: ErgoSpin hand-held nutrunner options/ DMC options/ VMC options/ WMC options dialog

Element DescriptionInfo hand-held nutrunner (for ErgoSpin) / Info tightening spindle (for DMC, VMC...-SD/-QC/-SP and 3WMC090/ 4WMC220)

– ID number: Number to identify the hand-held nutrunner or the tightening spindle.

– Comment: For entry of a comment, a max. of 400 characters is available.

– MCT protocol document ID: Here, you can save a comment for the MCT protocol document identification.

Maintenance interval monitoring

– Options / settings: Opens the Maintenance settings dialog. In this dialog, at least one of the following options Next maintenance after cycles and/or Next maintenance by date can be selected to define performance of the next maintenance:

– Write protection: The checkbox can only be selected if your are logged in as system administrator. If the write protection is active, users can only change the values for the maintenance information.

– Next maintenance after cycles: Fixed with: User is free to determine after which number of tightening cycles the maintenance is to be performed.Load-dependent with: The tightening cycles for the maintenance are automatically determined by the system in a load-dependent manner. Information: Here, you can define the number of tightening cycles before the maintenance information is to be provided.Remaining tightening cycles: Here, the remaining tightening cycles until the maintenance are displayed.

– Next maintenance by date: Maintenance on: Here, the date for the next maintenance is set.Information, upcoming maintenance: Here, it can be defined when information on the upcoming maintenance is to be provided.

– Confirm maintenance: If you want to confirm the maintenance, you have to activate the Confirm maintenance checkbox.

– The settings are accepted by means of OK. You can exit the dialog without changes using Cancel. To accept the settings made, the channel configuration has to be sent to the controller.

– The settings for the maintenance interval will be displayed above the button.

– If in active monitoring/information, the limit set for the next maintenance/information is reached, the controller will set the MntTool/InfoTool PLC output signal and enter a class 5 system error. The PLC signal is reset if one of the following events occurs:

– Maintenance is deactivated.

– The maintenance is confirmed and the settings are adjusted accordingly.

Exchanging the angle head (only for ErgoSpin SlimeLine/GripLine)

– new serial number: Number of the next output drive to be used. By default, the serial number of the last angle head exchanged is displayed.

– Number of cycles: Cycles that have already been run by the angle head to be used. By default, 0 is entered.

– The settings are accepted by means of OK. If no entries have been made, a warning diagnosis with corresponding information will be shown when you try to accept the settings.

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Spindle limits The displayed parameters for Per. torque, Max. speed and Spindle overload are calculated on the basis of the spindle data. They serve for plausibility checks of tightening programs. These values may not be exceeded when assigning parameters to a tightening program! Settings at this point are not possible.

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4.5.2.4 Setting up installed interfaces

Serial interfaces X3C1

This serial interface is intended to connect a printer or scanner.

Open the associated parameters dialog by double clicking the parameter field in line X3C1 (see Figure 4–14).

Fig. 4–19: Parameter dialog X3C1

You can make the following settings in the Set up serial interface group:

• Baud rate (300, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200)

The presetting is 115200 Baud. Use this value, if the partner controller allows so. Otherwise, delays during results output may occur, which limits the availability of the system.

• Data bits (7, 8)

• Parity (none, odd, even)

• Stop bits (0, 1, 2) and

• Protocol (none, X-On/X-Off, RTS/CTS).

Click Accept to store these data in the program.


The installed Ethernet interface is used for tightening results output and for programming the tightening controller.

The associated parameter dialog is opened by double clicking the parameter field in line X7E1 (see Figure 4–14):

Fig. 4–20: Parameter dialog X7E1

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You can make the following settings in the Ethernet interface setup group:

• IP address: Assigned by the network administrator; identifies the participant in the data exchange.

• Subnet mask: Assigned by the network administrator; contains information on the network configuration (address range).

• Host name: Name by which the Ethernet participant (here the compact system/the KE of the tightening system) can be addressed.

• DNS: Assignment of logical participant names to unique IP addresses.

• Domain name: The domain name is the same for all the participants in an Ethernet, the full logical name of a participant is Hostname@Domainname.

• Gateway: Establishes the external connection.


Click Accept to store the data in the program.

4.5.2.5 Setting up additional interfaces

Type A interface modules

This interface is intended for inserting type A interface modules from Rexroth. A tightening system is controlled by this interface.

Open the associated parameter dialog by double clicking the parameter field in line A (see Figure 4–14).

In the Select interface module field, select the desired module from the drop-down list and set its parameters.

General parameters for all interfaces

Physical interface The physical characteristics of the interface depend on the field bus module used. They can only be partially configured via the operating system.

Number of I points / Number of O points

This parameter determines how many control signals should be processed via the field bus interface.

Receive data / Send data

Setting of the remaining data width. These settings depend on the set scope of the I/O points. If the maximum available bandwidths are exceeded, the settings will be automatically corrected to correspond to the maximum data width. Make sure that the receipt range for ID codes is also set here.

The allocation of the data buffer is shown in tables in the “Project planning” documentation of the Rexroth Tightening System 350.

Receive IL data / Send IL data

Only with KE350G IL and CS351x-IL: Setting of the remaining data width. These settings depend on the set scope of the I/O points. If the maximum available bandwidths are exceeded, the settings will be automatically corrected to correspond to the maximum data width.

Detailed information on the data exchange via Ethernet can be found in the "Project planning" documentation of the Rexroth Tightening System 350!

This setting only reserves the memory space for the logical control signals (1 bit per input or output). Control signal assignment is implemented using the PLC assignment table.

The indicated value ranges are maximum values that can only be fully used if the other parameters have not been set to the maximum value.

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IMpdp You can make the following settings in the Set Profibus DP interface group:

No settings can be made in the Configured ranges field: The grayed out fields cannot be edited. The parameters displayed in this field depend on the selected number of I/O points.

A participant profile in form of a GDS file (Generic Station Description - master data file) is required for commissioning of the IMpdp interface module. The GSD file (*.gsd) allows the software to recognize the adjustable parameters and their value ranges.

After setting all parameters, create the master data file by clicking Create GSD file. Save the file and import it into the field bus configurator.

Click Accept to take over this data in the configuration for the tightening channel in the BS350.

Table 4–16: Settings in BS350 for IMpdp - Setting the Profibus DP interface

Element DescriptionStation address Address of the IMpdp in the PROFIBUS network. The address is assigned during

field bus planning. The address section is from 2 to 123. The field bus master (partner controller) is usually assigned the address 0 or 1.

Number of I points Number of control signals to be processed via the PROFIBUS interface. Value range 16 to 64 input signals (2 to 8 bytes)

Number of O points Number of control signals to be processed via the PROFIBUS interface. Value range 16 to 64 output signals (2 to 8 bytes)

Receive data Memory location for receiving the ID code, max. 64 bytes

Send data Memory location for sending results, max. 198 bytes at 2 bytes for O points

Receive IL data Memory location for receiving IL data, max. 198 bytes at 2 bytes for I pointsThese data are processed using the IL function block ControlFieldbus.

Send IL data Memory location for sending of IL data, max. 198 bytes at 2 bytes for O pointsThese data are processed using the IL function block ControlFieldbus.

Example If 16I was selected as the number of I points and 32O as the number of O points, 16 inputs (= 2 bytes) and 32 outputs (= 4 bytes) will also be available in the field bus configurator.

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IMdev You can make the following settings in the Set up DeviceNet interface group:


A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMdev interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the software.

After setting all parameters, create the EDS file by clicking Create EDS file. Save the file and import it into the field bus configurator.


Table 4–17: Settings in BS350 for IMdev - Setting the DeviceNet interface

Element DescriptionMAC ID Media Access Code Identifier - Interface module address, address range 0 to 63

Baud rate Transmission rate of 125, 250, 500 kbit/s; in addition, the auto detection function can be selected

Number of I points Number of control signals to be processed via the DeviceNet interface: Value range 16 to 64 input signals (2 to 8 bytes)

Number of O points Number of control signals to be processed via the DeviceNet interface: Value range 16 to 64 output signals (2 to 8 bytes)



Receive IL data Memory location for receiving IL data, max. 254 bytes at 2 bytes for I points

These data are processed using the IL function block ControlFieldbus.

Send IL data Memory location for sending of IL data, max. 254 bytes at 2 bytes for O points



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IMpnio This parameter dialog contains three index cards that may be selected in the group Set Profinet IO interface:

• I/O and data

• Configuration

• Station information

Index card: I/O and data

Input and output range mapping

In IMpnio, the cyclical process data between tightening system and communication partner is mapped within max. 64 I/O modules.

The I/O modules are mapped within the Profinet configurator.

Case 1 The total data width is less than/equal to 64 bytes, i.e. mapping is realized exclusively in 1-byte modules.

Case 2 If the data width it exceeds 64 bytes, it must be allocated to larger I/O modules. Starting with the output modules, the highest module width is "filled" first, followed by the respectively next lower applicable modules. Available are 4-word modules (quad words), 2-word modules (double words), 1-word modules (single word) and 1-byte modules.

Table 4–18: Settings in BS350 for IMpnio - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the PROFINET interface. Value range

0 to 64 input signals (0 to 8 bytes)

Number of O points Number of control signals to be processed via the PROFINET interface. Value range 0 to 64 output signals (0 to 8 bytes)



Receive IL data Memory location for receiving IL data, max. 256 bytes at 0 bytes for I pointsThese data are processed using the IL function block ControlFieldbus.



Example Data width in tightening system of 32 bytes I and 32 bytes O:

• A data width of 32 bytes in the input range of the tightening system correspond to the same width in the output range of the PLC.

• A data width of 32 bytes in the output range of the tightening system correspond to the same width in the input range of the PLC.

Respectively, the following applies for the number and mapping of I/O modules in the PLC

• Setting of O modules: 32 x 1-byte module

• Setting of I modules: 32 x 1-byte module





• Setting of O modules: 6x 4-wordk module + 1x 2-word module + 1x 1-byte-module

• Setting of I modules: 12x 4-wordk module + 1x 2-word module

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The number of configured I/O modules at the communication partner (PLC) must correspond to the setting in "Tightening channel configuration" / "KE configuration" in the BS350 because, otherwise, data cannot be exchanged between the communication partner (PLC) and the tightening system.


Index card: Configuration

The following settings can be made in this index card:

• Get configuration via DHCP

or

• Use the following configuration: If you select this item, you can enter the following parameters:

– IP address: Assigned by the network administrator; identifies the participant in the data exchange

– Subnet mask: Assigned by the network administrator; contains information on the network configuration (address range)

– Gateway: Establishes the external connection

• Host name: Name by which the Ethernet participant (here the KE of the tightening system) can be addressed.

Index card: Station information

The station can be additionally assigned several attributes.

The Station name field is grayed out and cannot be changed.

The following entries can be made in this index card:

• Additional information 1 - max 32 ASCII characters




Create GSDML file button

If the IMpnio interface module is commissioned with the configuration program for PROFINET, this configurator requires the participant profile in form of a GSDML (Generic Station Description Markup Language - master data file) file. The GSDML file (*.gsd) contains access points for the configuration of the communication partner (PLC) and is generated independently from the parameters set in BS350 (e.g. configured number of I points).

Click Create GSDML file to generate a GSDML file. Save the file and import it into the field bus configurator.

The Station name has to be set by the master PLC using the Naming function.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio interface module without errors, the station name at IMpnio and in the configuration program of the IMpnio communication partner have to be identical.

The station name which the communication partner has assigned to the IMpnio can be checked under the IMpnio "station information" (A-module) in "Tightening channel configuration" or "KE configuration".

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ProfiNet master settings

Click Accept to transfer the data to the configuration for the tightening channel in the BS350.

As of version V2.500 of the Rexroth Tightening System 350, the GSDML file version "GSDML-V2.3-Bosch_Rexroth_AG-Schraubsystem_350-20150226.xml" is generated. In the configuration tool of the communication partner, the access point (DAP; Device Access Point) corresponding to the access point of the firmware version of the applied IMpnio interface module has to be selected.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio interface module without errors, observe the following information:

1. To read the firmware version of the applied IMpnio interface module in BS350, click in the BS350 menu bar on System test and then on Field bus... status.

2. In the configuration tool of the communication partner, select the access point (DAP; Device Access Point) corresponding to the firmware version of the applied IMpnio interface module or lower. Choose between the following options:

– "IMpnio Firmware V1.07"



Example with DAP version identical to the firmware version of the interface module, e.g. DAP "IMpnio Firmware V1.18" and firmware version V1.18 of the interface module:

Selection correct.

Example with DAP version higher than the firmware version of the interface module, e.g. DAP "IMpnio Firmware V1.18" and firmware version V1.07 of the interface module:

A partner controller error may occur.

For firmware version V1.07 of the interface module, use DAP "IMpnio Firmware V1.07".

3. Configure the communication partner. Please proceed in the following order:

a. Configure the outputs first.

b. Then configure the inputs.

The ProfiNet cycle time during communication with the tightening system must not fall below 4ms.

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IMpnio2 IMpnio2 is supported as of version V2.500 of the Rexroth Tightening System 350.

This parameter dialog contains three index cards that may be selected in the group Set Profinet IO interface:

• I/O and data

• Configuration




In IMpnio, the cyclical process data between tightening system and communication partner IMpnio2 is mapped within max. 64 I/O modules.

The I/O modules are mapped within the Profinet configurator. Starting with the output modules, the highest module width is "filled" first, followed by the respectively next lower applicable modules.



Table 4–19: Settings in BS350 for IMpnio2 - I/O and data














• Setting of O modules: 6 x 8-byte module + 1 x 4-byte module + 1 x 1-byte module

• Setting of I modules: 12 x 8-byte module + 1 x 4-byte module

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or














If the IMpnio2 interface module is commissioned with the configuration program for PROFINET, this configurator requires the participant profile in form of a GSDML (Generic Station Description Markup Language - master data file) file. The GSDML file (*.gsd) contains access points for the configuration of the communication partner (PLC) and is generated independently from the parameters set in BS350 (e.g. configured number of I points).


The parameters IP address, Subnet mask, Gateway displayed here or under System test Field bus status ... always correspond to the currently used value. If the network connection is lost, e.g. if the Ethernet line is disconnected at the interface module, these values are invalid or 0.0.0.0. This also applies for permanently assigned IP parameters.

The Station name has to be set by the master PLC using the Naming function.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio2 interface module without errors, the station name at IMpnio2 and in the configuration program of the IMpnio2 communication partner have to be identical.

The station name which the communication partner has assigned to the IMpnio2 can be checked under the IMpnio2 "station information" (O module) in "Tightening channel configuration" or "KE configuration".

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As of version V2.500 of the Rexroth Tightening System 350, the GSDML file version "GSDML-V2.32-Bosch_Rexroth_AG-Schraubsystem_350_IMpnio2-20161221.xml" is generated. In the configuration tool of the communication partner, the access point (DAP; Device Access Point) corresponding to the access point of the firmware version of the applied IMpnio2 interface module has to be selected.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio2 interface module without errors, observe the following information:

1. To read the firmware version of the applied IMpnio2 interface module in BS350, click in the BS350 menu bar on System test and then on Field bus... status.

2. In the configuration tool of the communication partner, select the access point (DAP; Device Access Point) corresponding to the firmware version of the applied IMpnio2 interface module.





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IMenip This parameter dialog consists of two index cards that can be selected in the Setup EtherNet/IP interface group:

• I/O and data

• Configuration






or






Create ESD file button

A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMenip interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the software.

After setting all parameters, create the EDS file by clicking Create EDS file.


Table 4–20: Settings in BS350 for IMenip - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherNet/IP interface: Value

range 16 to 64 input signals (2 to 8 bytes)

Number of O points Number of control signals to be processed via the EtherNet/IP interface: Value range 16 to 64 output signals (2 to 8 bytes)








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Configuration settings in the "RSLogix 5000" software for IMenip

Configuration of the IMenip interface module (EtherNet/IP) in the "RSLogix 5000" software of the company Rockwell is realized using the following parameters:

• General parameters

– Superior instance: X_1788_ENBT

– Name: IMenip

• Connection parameter input (32 bit):

– Assembly instance: 100

– Size: 1

Ensure that in the PLC partner control of the company Rockwell, you adjust the value of this parameter of the configuration of the IMenip interface module. In order to ensure smooth communication, the following parameters must in this case correspond to each other:

– Connection parameter input size in the "RSLogix 5000"

– Configured ranges O points + send in the BS350

Generally, the following applies:

Connection parameter input size=configured ranges O points + send

• Connection parameter output (32 bit):


– Size: 1


– Connection parameter output size in the "RSLogix 5000"

– Configured ranges I points + receive in the BS350


Connection parameter output size=configured ranges I points + receive

• Connection parameter configuration (8 bit):


– Size: 0

Examples of the configuration of the connection parameters input size and output size in the "RSLogix 5000" software:

• If the parameter Configured ranges O points + send is set to the value 256 bytes, the connection parameter Input size must be set to the following values, depending on the communication format:

– Communication format SINT (8 bit per size): 256

– Communication format INT (16 bit per size): 128

– Communication format DINT (32 bit per size): 64

• If the parameter Configured ranges I points+receive is set to the value 256 bytes, the connection parameter output size must be set to the following values, depending on the communication format:



Communication format DINT (32 bit per size): 64

The software "RSLogix 5000" of the company Rockwell is not able to read the EDS file of the Tightening System 350. For this reason, the IMenip interface module (EtherNet/IP) must be set up as general Ethernet module (type: ETHERNET MODULE | Description: General Ethernet modules). Detailed information on the correct configuration is contained in section „Configuration settings in the "RSLogix 5000" software for IMenip“ on page 86.

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IMenip2 IMenip2 is supported as of version V2.600 of the Rexroth Tightening System 350.

This parameter dialog consists of two index cards that can be selected in the Setup EtherNet/IP interface group:

• I/O and data

• Configuration




You can select configuration either via DHCP = Dynamic Host Configuration Protocol or via specification of the IP address with subnet mask and gateway.


A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMenip2 interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the project planning software.



Table 4–21: Settings in BS350 for IMenip2 - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherNet/IP interface: Value


Number of O points Number of control signals to be processed via the EtherNet/IP interface: Value range 16 to 64 output signals (2 to 8 bytes)







The IP parameters (IP address, Subnet mask and Gateway) under System test Field bus status and in the channel or KE configuration at IMenip2 always correspond to the currently applied value. If the network connection is lost, e.g. if the Ethernet line is disconnected at the interface module, these values are invalid or 0.0.0.0.


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IMmtcp This parameter dialog consists of two index cards that can be selected in the Set ModbusTCP interface group:

• I/O and data

• Configuration






or






Table 4–22: Settings in BS350 for IMmtcp - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the ModbusTCP interface: Value


Number of O points Number of control signals to be processed via the ModbusTCP interface: Value range 16 to 64 output signals (2 to 8 bytes)







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IMecat IMecat is supported as of version V2.500 of the Rexroth Tightening System 350:

This parameter dialog consists of two index cards that can be selected in the Set up EtherCat interface group:

• I/O and data

• Device information



Index card: Device information

In this index card, the Device ID is set.

Create description file button

A participant profile in form of a description file (*.xml) is required to commission the IMecat interface module. The description file enables the software to recognize the variable parameters and their value ranges.

Click Create description file to generate a description file. Save the file and import it into the field bus configurator.


Type B interface modules (B1 and B2)

This interface is intended for the use of type B interface modules from Rexroth.

• IM24V for reading 24 V I/O signals in and out (e. g. for actuating lamps and buttons)

Open the associated parameter dialog by double clicking the parameter field in line B1 or B2 (see Figure 4–14).

In the Select interface module field (see Figure 4–21), select the desired module from the drop-down list and set its parameters.

Table 4–23: Settings in BS350 for IMcat - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherCat interface. Value range


Number of O points Number of control signals to be processed via the EtherCat interface. Value range 16 to 64 output signals (2 to 8 bytes)







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IM24V

Fig. 4–21: IM24V parameter dialog


4.5.2.6 Nutrunner docking configuration

The "Nutrunner docking" function can be used to change the tightening tool (ErgoSpin hand-held nutrunner or Rexroth tightening spindle) during normal operation without long waiting times.

Initial commissioning to configure the function Nutrunner docking:

1. Set the Tightening channel configuration to Automatic.

2. Activate the additional function nutrunner docking via the respective option Nutrunner docking.

3. Carry out the following so that the system detects the Rexroth tightening spindle when it is connected:

Configure the Rexroth tightening spindle via the BS350 for the first time.

When the Tightening channel configuration is sent to the controller, the spindle configuration is also stored in the measurement transducer on the Rexroth tightening spindle.

When the tightening tool is connected again, the system imports the configuration from the Rexroth tightening spindle.

4.5.2.7 Sending/saving data

The tightening channel configuration must be sent to the tightening controller. It can also be stored as a file on the PC (see Sending and saving (page 57)).

The typical time required for docking is 3 to 4 seconds. In case of unfavorable boundary conditions, this time may be extended. For example, excessive connection cycles at connector or socket contacts may lead to extended docking times.

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4.5.3 Offline configuration:

In addition to the online configuration, the BS350 also allows for channel configurations to be generated even if no tightening channel is connected. This may be helpful if, e.g., the channel configuration to be generated is known before commissioning and can be done as preparatory work.

To generate a new configuration file in offline mode

In BS350 click File New Tightening channel configuration.

When generating a channel configuration offline, all the electronic and mechanical components have to be added to the configuration file manually.

To add a component manually:

Click the empty symbol field and then select a permitted component from the component selection (see Figure 4–22)

The global parameters are set in accordance with the online configuration (see Configuration example (page 71)).

Fig. 4–22: Offline configuration of a tightening channel

The configuration of the tightening channel can be stored as a file on the PC (see Sending and saving (page 57)). It must be sent to the tightening controller before commissioning the tightening channel.

Only those components permitted in the configuration sequence are highlighted for selection, those not allowed are grayed out! This ensures that the linked components in the configuration sequence are plausible.

Permitted component Empty symbol field

Tightening channel configurations created offline which contain either an ErgoSpin hand-held nutrunner of type VarioLine (ESV) or of type pistol grip nutrunner (ESM) are not accepted by the tightening controller.

In this context, see the information in section „Channel configuration created offline with an ErgoSpin VarioLine (ESV) or pistol grip nutrunner (ESM)“ on page 132.

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4.5.4 Defining a tightening program

The tightening program coordinates the tightening process or sequence. It is divided into various tightening steps, where tightening parameters are set.

Basic commissioning is carried out with small-scale tightening programs. They consist of a:

• Start step

• Single tightening step

• End step

The following describes how to generate programs for tightening and loosening a bolt.

4.5.4.1 Tightening program for tightening a bolt

The tightening program for tightening a bolt starts the nutrunner clockwise. The following example shows all the steps this requires.

To generate a new tightening program:

1. In BS350 click File New Tightening programs.

2. Select a program number, e.g. 1.

3. Assign a name to the tightening program, such as Tightening test by overwriting the existing program name n.a. (not available). (if program number 0 is selected, "n.a." is not displayed).

4. Click Program info and enter a comment for the tightening program in the Program info dialog.

5. Confirm your comment with OK.

The Program info dialog closes and the text Program info is underlined. Move the mouse over the button and the comment is displayed as a tooltip.

6. Select the end step and click the symbol .

A single tightening step is added before the end step (see Figure 4–23).

Programs from the machine capability examination are already included on the device at the time of delivery. You can use these programs as the basis for your own tightening programs.


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Fig. 4–23: Tightening program for the sequence test

7. Double click the new tightening step symbol.

The parameter dialog for the tightening step appears (see Figure 4–23).

8. Enter the following data:

Name: e.g. Tightening step

Target function, e.g. Angle, value: 360 [°]

Additional functions, e.g. Speed, value: 60 [rpm]

9. Click Accept to store these data in the tightening program.

4.5.4.2 Loosening program for loosening the bolt

The loosening program for loosening a tightened bolt starts the tightening spindle counterclockwise. In the BS350 this program must be stored in program space no. 99 because program no. 99 is always started with PLC signal Ccw or if the Loosen button is clicked in the sequence test (see page 97).

The following entered data have to be adapted to the respective tightening channel configuration. Spindle overload and max. speed, which can be read in the Spindle limits field in the configuration window of the tightening channel, must not be exceeded.

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To generate a loosening program:

1. In BS350 click File New Tightening programs.

2. Select a program number, e.g. 99.

3. Assign a name to the tightening program, such as Loosening program, by overwriting the existing program name n.a. (not available).

4. Click Program info and enter a comment for the tightening program in the Program info dialog.


The Program info dialog closes and the text Program info is underlined. Move the mouse over the button and the comment is displayed as a tooltip.

6. Select the end step and click the symbol .

A single tightening step is added before the end step (see Figure 4–24).

Fig. 4–24: Loosening program for the sequence test

7. Double click the new tightening step symbol.

The parameter dialog for the tightening step appears (see Figure 4–24).

8. Enter the following data:

Name, e.g. Loosen

Target function, e.g. Angle, value: 200 [°]

Additional functions, e.g. Speed, value: -100 rpm.

The following entered data have to be adapted to the respective tightening channel configuration. The max. speed, which can be seen in the Spindle limits field in the configuration window of the tightening channel (see Figure 4–16), must not be exceeded.

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9. Click Accept to store these data in the tightening program.


Tightening programs have to be sent to the tightening controller before they can be used. They can also be stored as files on the PC (see Sending and saving (page 57)).

4.5.5 Configuration SE/CS PLC assignment table

The PLC assignment table defines the assignment of the control signals to the tightening controller's physical interfaces. The tightening controller can be integrated into a system sequence with these control signals. The following number of inputs and outputs are available on the interfaces:

A maximum of 256 input and output signals can be used.

With automatic channel configuration, the PLC assignment table is created in accordance with the presettings when the compact system is commissioned with the ErgoSpin. It can be loaded from the compact system by selecting System SE/CS PLC assignment table.

Send the preset PLC assignment table to the tightening controller; it can also be stored as a file on the PC (see Sending and saving (page 57)).

Always enter a negative speed value for counterclockwise rotation.

Table 4–24: Number of inputs and outputs

System component Number of inputs/outputs SE Number of inputs/outputs CSErgoSpin 4/0 4/0

IMpdp – 16 to 64/16 to 64

IMdev – 16 to 64/16 to 64

IMpnio, IMpnio2 – 0 to 64/0 to 64

IMenip, IMenip2 – 16 to 64/16 to 64

IMmtcp – 16 to 64/16 to 64

IMecat – 16 to 64/16 to 64

IM24V 5/6 10/13

HMI – 8/0

HVO – 8/8

IL – 32/32

OP – 33/24

XML – 22/25

Information on the configuration of the PLC assignment table can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

The detailed description of the control signals can be found in the "Project planning" documentation of the Rexroth Tightening System350.

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4.5.6 Setting the time on the tightening controller

The time on the tightening controller can be set if the controller is connected to the BS350. Set the time via System System time. Table 4–25 shows the possibilities for setting the time of the tightening controller.

The time is logged, e. g. in the course of the tightening results output, enabling times to be assigned to the tightening results data.

4.5.7 Synchronizing date and time with an external clock

The date and time can be manually set in the BS350. Additionally, the clock can be set automatically via a so-called timeserver. In this case, the clock is synchronized with the timeserver clock whenever the system is booted and periodically thereafter.

To indicate a timeserver:

1. In the BS350 operating system, click System Tightening channel configuration

2. Double click the parameter field for the compact system.

The parameter dialog Rexroth BS350 - Compact system appears.

Fig. 4–25: Configuration of time synchronization with an NTP server

3. Enter the name (or IP address) of the timeserver in the NTP server address field.

4. Assign the synchronization interval in the Sync interval field.

5. Click Accept to accept the settings.

Table 4–25: Setting the system time

Element DescriptionDate and time These values can be changed by directly entering numbers or by clicking the plus

or minus button. The plus or minus button changes the field that the cursor is currently in.

System time / PC time – System time: Makes it possible to set the system time.

– PC time: Shows the current PC time and takes it over in the entry fields. This time cannot be changed.

Set system time Transfer modified setting to the tightening cell.

This button is only active if no synchronization with an external clock is taking place.Time zone Selection of the desired time zone, which is calculated from Greenwich Mean Time

(GMT) and a time shift factor.

You can also set whether the clock should automatically be changed for daylight savings time (summer time) and winter time.

All tightening system outputs, e.g. printer or FTP, use the local time for the tightening system, taking the time zone and, if necessary, the automatic daylight savings time change into consideration. This also applies to outputs in the BS350 like actual values or curves. The settings of the operating system are, however, not used! This is why there may be deviations between the PC time and the BS350 outputs.

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4.5.8 Sequence test

4.5.8.1 Sequence test via theBS350

The generated tightening programs can be started directly from the BS350 with a sequence test.

To start the sequence test:

1. Make sure that you are logged in to the tightening system (see page 56).

2. Click System test Sequence test or .

The control panel shown in Figure 4–26 opens.

The sequence test is stopped by selecting this button again.

Fig. 4–26: Control panel in sequence test mode

CAUTION

Incorrect fixingIncorrect fixing of the nutrunner or workpiece may lead to injuries and may damage to the device. Make sure that the nutrunner and workpiece are fixed securely and tightly or that you have a good

grip on the hand-held nutrunner before starting the sequence test! Follow the safety instructions in the "ErgoSpin" operating instructions.

1 Channel selection

2 Program selection

3 System status displays

4 Loosen button

5 Start button

6 Stop button

7 Reset button

8 Standard input field

9 Wait after start... input field

1 2 3 4 5 6 7 8 9

The Wait after start... waiting time is only necessary in connection with an ErgoSpin hand-held nutrunner in manual operation. The waiting time is a timeout time. If the hand-held nutrunner is not started within that time, the sequence test will be canceled.

If the sequence test is used in connection with a tightening spindle, it will be canceled after expiry of the waiting time if the spindle could not be started due to an error. Recommended setting: 5 seconds.

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To start the tightening program to tighten the bolt:

1. In the program selection, select the program number to be tested, e.g. 1: Tightening test.

2. Click Start.

3. Within the time set in the Wait after start... input field, press the start button at the ErgoSpin.

To start the loosening program:

Click Loosen to start the loosening program (program 99, Ccw) independently of the program selection.

Further functions• Stop stops the running program prematurely.

• Reset acknowledges class 3 errors.

• Standard indicates the number of times the selected tightening program can be started in a row.

• As of version V2.400: Wait after start... specifies the time before the sequence test is executed. Values from 15 to 500 seconds are valid. As the time is determined at the operating system, it is subject to tolerance.

The system status displays are activated by selecting Start, Stop or Loosen.

The system status display to the left indicates the hardware's system status:

• Green: Tightening channel is ready for operation

• Red: System error

The system status display to the right provides information about the last tightening job:

• Green: The last tightening result is OK

• Red: The last tightening result is NOK

• Gray: Invalid status, i.e. tightening channel is not yet ready for operation again or no tightening job has been performed yet

After a successful sequence test, both system status displays on the control panel and on the tightening controller emit a static green light.

4.5.8.2 Sequence test via the TFT display of the CS351E-G or CS351S-G

The generated tightening programs can also be started via the TFT display (System test Sequence test). Here, the functions Loosen, Start, Stop, Reset are identical to those in BS350.

For detailed information on LED displays for other (e.g. malfunctioning) operating states, see chapter Troubleshooting from page 153.

For sequence tests using the TFT display of the CS351E-G, please observe the notes in the "ErgoSpin" operating instructions.

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1 2 3 4 5

Fig. 4–27: Sequence test via the TFT display

1 Program selection

2 Loosen button

3 Start button

4 Stop button

5 Reset button

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4.6 Operating the Modular System

Multiple tightening channels are usually operated in the modular system. The KE controls the control units of the tightening channels.

4.6.1 General information on the configuration

The KE configuration includes setting the parameters of all the components in the KE. The configuration window (see Figure 4–28) opens when the following menu items have been selected:

• System KE configuration in online mode (see page 101) and/or

• File New KE configuration in offline mode (see page 118).

Layout of the configuration window

The configuration window in the BS350 displays the following (see Figure 4–28, from left to right):

• The front view of the KE

• The KE configuration with its available interfaces subdivided into 4 columns:

– Name

– Symbol

– Parameter

– Notes

Fig. 4–28: Configuration loaded online using the KE350G as an example

The configuration has to be sent to the corresponding tightening channel upon creation. The same is compared to the actual configuration (actual equipment) of the tightening channel. After the configuration has been sent, errors (e.g. configuration conflicts) will be displayed in the configuration window.

Symbol

Configuration fieldsKE front view

Name Parameter Note

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4.6.2 Online configuration of the KE

In the online configuration, slots equipped with an IM are highlighted in red in the configuration window; the inserted IM is referred to in the Notes field by IMxxx module is new! The parameters still have to be set.

4.6.2.1 Loading the KE configuration

The PC and KE must be connected before the online configuration can be loaded (see Connecting the PC (page 51)).

Below is a description of the configuration and parameter assignment of the KE with the following components:

• KE350

• IM in the slots A, B1, and B2

Use System KE configuration to load the current KE configuration.

The configuration window displays the following (see Figure 4–28):

• KE with part no., firmware version, and NTP status1)

• The permanently installed X7E1 interface with:

– IP address

– Subnet mask

– Host name

– DNS

– Domain name

– Gateway

• The permanently installed X3C1 interface with:

– Interface type (RS232)

– Baud rate, data bits, stop bits

– Parity

– Protocol

• the IM to be parameterized in A, B1, and B2

For detailed information concerning troubleshooting, see chapter Troubleshooting from page 153.

1) NTP = Network Time Protocol. Using the NTP server, the KE time can be set at regular intervals. For this, the tightening system must be connected to a network via Ethernet. More information on Ethernet connection and time synchronization using the NTP server can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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4.6.2.2 Setting up installed interfaces


The installed Ethernet interface is used for tightening results output and for programming the tightening controller.

The associated parameter dialog is opened by double clicking the parameter field in line X7E1 (see Figure 4–28):

Fig. 4–29: Parameter dialog X7E1

You can make the following settings in the Ethernet interface setup group:

• IP address: Assigned by the network administrator; identifies the participant in the data exchange.

• Subnet mask: Assigned by the network administrator; contains information on the network configuration (address range).

• Host name: Name by which the Ethernet participant (here the compact system (CS)) can be addressed.

• DNS: Assignment of logical participant names to unique IP addresses.

• Domain name: The domain name is the same for all the participants in an Ethernet, the full logical name of a participant is Hostname@Domainname.

• Gateway: Establishes the external connection.


X3C1 interface

The X3C1 serial interface is designed to connect data collection devices, barcode readers, etc., or as output interfaces for tightening results data. Open the associated parameter dialog by double clicking one of the fields in line X3C1 (see Figure 4–28):

Detailed information on the data exchange via Ethernet can be found in the "Project planning" documentation of the Rexroth Tightening System 350!

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Fig. 4–30: Parameter dialog X3C1

You can make the following settings in the Set up serial interface group:

• Baud rate (300, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200)

The standard value is 115200 Baud. Use this value, if the partner controller allows so. Otherwise, delays during results output may occur, which limits the availability of the system.

• Data bits (7, 8)

• Parity (none, odd, even)

• Stop bits (0, 1, 2) and

• Protocol (none, X-On/X-Off, RTS/CTS).


4.6.2.3 Setting up additional interfaces

Type A interface

This interface is intended for inserting type A interface modules from Rexroth. A tightening system is controlled by this interface.

Open the associated parameter dialog by double clicking the parameter field in line A (see Figure 4–28).

In the Select interface module field, select the desired module from the drop-down list and set its parameters.

General parameters for all interfaces

Physical interface The physical characteristics of the interface depend on the field bus module used. They can only be partially configured via the operating system.

Number of I points / Number of O points

This parameter determines how many control signals should be processed via the field bus interface.

Receive data / Send data

Setting of the remaining data width. These settings depend on the set scope of the I/O points. If the maximum available bandwidths are exceeded, the settings will be automatically corrected to correspond to the maximum data width. Make sure that the receipt range for ID codes is also set here.

The allocation of the data buffer is shown in tables in the “Project planning” documentation of the Rexroth Tightening System 350.

Receive IL data / Send IL data

Only with KE350G IL and CS351x-IL: Setting of the remaining data width. These settings depend on the set scope of the I/O points. If the maximum available bandwidths are exceeded, the settings will be automatically corrected to correspond to the maximum data width.

This setting only reserves the memory space for the logical control signals (1 bit per input or output). Control signal assignment is implemented using the PLC assignment table.

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IMpdp You can make the following settings in the Set up Profibus DP interface group:


A participant profile in form of a GDS file (Generic Station Description - master data file) is required for commissioning of the IMpdp interface module. The GSD file (*.gsd) allows the software to recognize the adjustable parameters and their value ranges.

After setting all parameters, create the master data file by clicking Create GSD file. Save the file and import it into the field bus configurator.


The indicated value ranges are maximum values that can only be fully used if the other parameters have not been set to the maximum value.

Table 4–26: Settings in BS350 for IMpdp - I/O and data

Element DescriptionStation address Address of the IMpdp in the PROFIBUS network. The address is assigned during

field bus planning. The address section is from 2 to 123. The field bus master (partner controller) is usually assigned the address 0 or 1.

Number of I points Number of control signals to be processed via the PROFIBUS interface. Value range 16 to 512 input signals (2 to 64 bytes)

Number of O points Number of control signals to be processed via the PROFIBUS interface. Value range 16 to 512 output signals (2 to 64 bytes)

Receive data Memory location for receiving the ID code, max. 198 bytes at 2 bytes for I points







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IMdev You can make the following settings in the Set up DeviceNet interface group:


A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMdev interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the software.

After setting all parameters, create the EDS file by clicking Create EDS file. Save the file and import it into the field bus configurator.


Table 4–27: Settings in BS350 for IMdev - I/O and data

Element DescriptionMAC ID Media Access Code Identifier - Interface module address, address range 0 to 63

Baud rate Transmission rate of 125, 250, 500 kbit/s; in addition, the auto detection function can be selected

Number of I points Number of control signals to be processed via the DeviceNet interface: Value range 16 to 512 input signals (2 to 64 bytes)

Number of O points Number of control signals to be processed via the DeviceNet interface: Value range 16 to 512 output signals (2 to 64 bytes)








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IMpnio This parameter dialog contains three index cards that may be selected in the group Profinet IO Set up interface:

• I/O and data

• Configuration




In IMpnio, the cyclical process data between tightening system and communication partner is mapped within max. 64 I/O modules.

The I/O modules are mapped within the Profinet configurator.

Case 1 The total data width is less than/equal to 64 bytes, i.e. mapping is realized exclusively in 1-byte modules.

Case 2 If the data width it exceeds 64 bytes, it must be allocated to larger I/O modules. Starting with the output modules, the highest module width is "filled" first, followed by the respectively next lower applicable modules. Available are 4-word modules (quad words), 2-word modules (double words), 1-word modules (single word) and 1-byte module.

Table 4–28: Settings in BS350 for IMpnio - I/O and data














• Setting of O modules: 32 x 1-byte module

• Setting of I modules: 32 x 1-byte module





• Setting of O modules: 6x 4-wordk module + 1x 2-word module + 1x 1-byte-module

• Setting of I modules: 12x 4-wordk module + 1x 2-word module

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or















If the IMpnio interface module is commissioned with the configuration program for PROFINET, this configurator requires the participant profile in form of a GSDML (Generic Station Description Markup Language - master data file) file. The GSDML file (*.gsd) contains access points for the configuration of the communication partner (PLC) and is generated independently from the parameters set in BS350 (e.g. configured number of I points).


To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio interface module without errors, the station name at IMpnio and in the configuration program of the IMpnio communication partner have to be identical.

The station name which the communication partner has assigned to the IMpnio can be checked under the IMpnio "station information" (A-module) in "Tightening channel configuration" or "KE configuration".

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As of version V2.500 of the Rexroth Tightening System 350, the GSDML file version "GSDML-V2.3-Bosch_Rexroth_AG-Schraubsystem_350-20150226.xml" is generated. In the configuration tool of the communication partner, the access point (DAP; Device Access Point) corresponding to the access point of the firmware version of the applied IMpnio interface module has to be selected.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio interface module without errors, observe the following information:

1. To read the firmware version of the applied IMpnio interface module in BS350, click in the BS350 menu bar on System test and then on Field bus... status.

2. In the configuration tool of the communication partner, select the access point (DAP; Device Access Point) corresponding to the firmware version of the applied IMpnio interface module or lower. Choose between the following options:




Example with DAP version identical to the firmware version of the interface module, e.g. DAP "IMpnio Firmware V1.18" and firmware version V1.18 of the interface module:

Selection correct.

Example with DAP version higher than the firmware version of the interface module, e.g. DAP "IMpnio Firmware V1.18" and firmware version V1.07 of the interface module:

A partner controller error may occur.

For firmware version V1.07 of the interface module, use DAP "IMpnio Firmware V1.07".





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IMpnio2 IMpnio2 is supported as of version V2.500 of the Rexroth Tightening System 350.

This parameter dialog contains three index cards that may be selected in the group Profinet IO Set up interface:

• I/O and data

• Configuration





In IMpnio, the cyclical process data between tightening system and communication partner IMpnio2 is mapped within max. 64 I/O modules.

The I/O modules are mapped within the Profinet configurator. Starting with the output modules, the highest module width is "filled" first, followed by the respectively next lower applicable modules.


Table 4–29: Settings in BS350 for IMpnio2 - I/O and data














• O module setting: 6 x 8-byte module + 1 x 4-byte module + 1 x 1-byte module

• I module setting: 12 x 8-byte module + 1 x 4-byte module

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or














If the IMpnio2 interface module is commissioned with the configuration program for PROFINET, this configurator requires the participant profile in form of a GSDML (Generic Station Description Markup Language - master data file) file. The GSDML file (*.gsd) contains access points for the configuration of the communication partner (PLC) and is generated independently from the parameters set in BS350 (e.g. configured number of I points).


The parameters IP address, Subnet mask, Gateway displayed here or under System test Field bus status ... always correspond to the currently used value. If the network connection is lost, e.g. if the Ethernet line is disconnected at the interface module, these values are invalid or 0.0.0.0. This also applies for permanently assigned IP parameters.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio2 interface module without errors, the station name at IMpnio2 and in the configuration program of the IMpnio2 communication partner have to be identical.

The station name which the communication partner has assigned to the IMpnio2 can be checked under the IMpnio2 "station information" (O module) in "Tightening channel configuration" or "KE configuration".

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As of version V2.500 of the Rexroth Tightening System 350, the GSDML file version "GSDML-V2.32-Bosch_Rexroth_AG-Schraubsystem_350_IMpnio2-20161221.xml" is generated. In the configuration tool of the communication partner, the access point (DAP; Device Access Point) corresponding to the access point of the firmware version of the applied IMpnio2 interface module has to be selected.

To ensure communication of the Rexroth Tightening System 350 with the communication partner via the IMpnio2 interface module without errors, observe the following information:

1. To read the firmware version of the applied IMpnio2 interface module in BS350, click in the BS350 menu bar on System test and then on Field bus... status.

2. In the configuration tool of the communication partner, select the access point (DAP; Device Access Point) corresponding to the firmware version of the applied IMpnio2 interface module.





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IMenip This parameter dialog consists of two index cards that can be selected in the Setup EtherNet/IP interface group:

• I/O and data

• Configuration




The following settings can be made in this window:


or







A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMenip interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the software.



Table 4–30: Settings in BS350 for IMenip - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherNet/IP interface. Value


Number of O points Number of control signals to be processed via the EtherNet/IP interface. Value range 16 to 512 output signals (2 to 64 bytes)








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Configuration settings in the "RSLogix 5000" software for IMenip

Configuration of the IMenip interface module (EtherNet/IP) in the "RSLogix 5000" software of the company Rockwell is realized using the following parameters:

• General parameters

– Superior instance: X_1788_ENBT

– Name: IMenip

• Connection parameter input (32 bit):


– Size: 1


– Connection parameter input size in the "RSLogix 5000"

– Configured ranges O points + send in the BS350


Connection parameter input size=configured ranges O points + send

• Connection parameter output (32 bit):


– Size: 1


– Connection parameter output size in the "RSLogix 5000"

– Configured ranges I points + receive in the BS350


Connection parameter output size=configured ranges I points + receive

• Connection parameter configuration (8 bit):


– Size: 0

Examples of the configuration of the connection parameters input size and output size in the "RSLogix 5000" software:

• If the parameter Configured ranges O points + send is set to the value 256 bytes, the connection parameter Input size must be set to the following values, depending on the communication format:



– Communication format DINT (32 bit per size): 64

• If the parameter Configured ranges I points+receive is set to the value 256 bytes, the connection parameter output size must be set to the following values, depending on the communication format:



Communication format DINT (32 bit per size): 64

The software "RSLogix 5000" of the company Rockwell is not able to read the EDS file of the Tightening System 350. For this reason, the IMenip interface module (EtherNet/IP) must be set up as general Ethernet module (type: ETHERNET MODULE | Description: General Ethernet modules). Detailed information on the correct configuration is contained in section „Configuration settings in the "RSLogix 5000" software for IMenip“ on page 86.

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IMenip2 IMenip2 is supported as of version V2.600 of the Rexroth Tightening System 350.

This parameter dialog consists of two index cards that can be selected in the Setup EtherNet/IP interface group:

• I/O and data

• Configuration




You can select configuration either via DHCP = Dynamic Host Configuration Protocol or via specification of the IP address with subnet mask and gateway.


A participant profile in form of an EDS (electronic data sheet) file is required to commission the IMenip2 interface module. The EDS file (*.eds) enables recognition of variable parameters and their value ranges in the project planning software.



Table 4–31: Settings in BS350 for IMenip2 - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherNet/IP interface. Value


Number of O points Number of control signals to be processed via the EtherNet/IP interface. Value range 16 to 512 output signals (2 to 64 bytes)







The IP parameters (IP address, Subnet mask and Gateway) under System test Field bus status and in the channel or KE configuration at IMenip2 always correspond to the currently applied value. If the network connection is lost, e.g. if the Ethernet line is disconnected at the interface module, these values are invalid or 0.0.0.0.


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IMmtcp This parameter dialog consists of two index cards that can be selected in the Set ModbusTCP interface group:

• I/O and data

• Configuration






or






Table 4–32: Settings in BS350 for IMmtcp - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the ModbusTCP interface. Value


Number of O points Number of control signals to be processed via the ModbusTCP interface. Value range 16 to 512 output signals (2 to 64 bytes)







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IMecat IMecat is supported as of version V2.500 of the Rexroth Tightening System 350:

This parameter dialog consists of two index cards that can be selected in the Set up EtherCat interface group:

• I/O and data

• Device information



Index card: Device information

In this index card, the Device ID can be set.

Create description file button

A participant profile in form of a description file (*.xml) is required to commission the IMecat interface module. The description file enables the software to recognize the variable parameters and their value ranges.

Click Create description file to generate a description file. Save the file and import it into the field bus configurator.


Type B interfaces (B1 and B2)

This interface is intended for inserting type B interface modules from Rexroth:

• IM24V for reading 24 V I/O signals in and out (e.g. for actuating lamps and buttons).

Open the associated parameter dialog by double clicking the parameter field in line B1 or B2 (see Figure 4–28).

In the Code list, select the desired module from the drop-down list and set its parameters.

Table 4–33: Settings in BS350 for IMcat - I/O and data

Element DescriptionNumber of I points Number of control signals to be processed via the EtherCat interface. Value range


Number of O points Number of control signals to be processed via the EtherCat interface. Value range 16 to 512 output signals (2 to 64 bytes)







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IM24V

Fig. 4–31: IM24V parameter dialog












The created configuration has to be sent to the KE. It can also be stored as a file on the PC (see Sending and saving (page 57)).


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4.6.3 KE configuration offline

If the configuration of the KE is already known before commissioning, it can be generated in offline mode. For this purpose, select File New KE configuration in the BS350 menu bar. The following window will appear:

Fig. 4–32: KE configuration offline using the KE350 as an example

The KE and its interfaces have to be configured and parameterized completely. To do this, double click the respective line and configure according to Setting up installed interfaces (page 102).

The created KE configuration can be stored as a file on the PC (see Sending and saving (page 57)).

The configuration must be sent to the KE before commissioning.

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4.6.4 Configuring the tightening channels

To configure the tightening channels, select System Tightening channel configuration and then select a tightening channel.

If the tightening channels all have the same configuration, only one tightening channel has to be configured. The configuration can then be sent to all tightening channels involved in the tightening application or stored as a file on the PC (see Sending and saving (page 57)).

Tightening channel configuration of the control unit in single-channel operation

The control unit controls and monitors the tightening process of up to two independent tightening channels per control unit. If you want to operate the control unit in single-channel operation, proceed as follows:

1. Open the tightening channel configuration.

– Online configuration: System Tightening channel configuration

– Offline configuration: File New Tightening channel configuration

2. Change the Operating mode of the first tightening channel from 2 channels (default) to 1 channel.

The Operating mode option is not displayed for the second tightening channel.

The control unit is configured for the single-channel operation.

4.6.4.1 Configuration of servo amplifiers with transducer function

Depending on the code, servo amplifiers can be configured to serve as primary transducers or redundant transducers.

Depending on the servo amplifier selected, the following transducer functions can be implemented:

• With the servo amplifiers LTE350D and LTU350/1 only "Redundancy" is possible.

• For the servo amplifiers LTS350D, LT353, LT354 and LT355 "Redundancy" is preset. Primary" is possible.

• With the servo amplifier LTU350/1S neither "Primary" nor "Redundancy" is possible.

If after its delivery, the control unit is operated directly next to a KE for the first time, the following scenario occurs: the control unit is automatically converted to single-channel operation.

As a consequence of non-compliance with the following information an error may occur and both, the tightening channel and the entire tightening controller may be disturbed.

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4.6.4.2 Tightening channel configuration with BG5+

By using the power reserves of the servo amplifier LT355 and/or LTS350 and the EC motor EC305 in the Tightening System 350, the spindle limits of a stationary spindle of size 5 can be expanded as follows:

nmax, motor = 12,500 rpm (previously 10,000 rpm)

Tmax, motor = 9.5 Nm

An overview of the hardware requirements can be found in the “Project planning” documentation of the Rexroth Tightening System 350.

Offline tightening channel configuration with expanded limits is possible if an EC motor (EC305?) is selected. Additionally, an adjusted system box SB356 with an increased intermediate circuit voltage is required.

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4.6.5 Defining the tightening program

Proceed as listed in section Defining the tightening program (page 121) to generate a tightening program for tightening and loosening a bolt. The generated tightening program has to be sent to all the tightening channels involved in the tightening application. It can also be stored as a file on the PC (see Sending and saving (page 57)).

Then test the function of the tightening program in each tightening channel with a sequence test (see Sequence test (page 125)).

4.6.6 Defining a tightening application

1to 40 tightening positions can be coordinated within a tightening application.

Basic commissioning is carried out with a small-scale tightening application. It consists of a:

• Start step

and

• End step

The following describes how to generate a tightening application for tightening and loosening bolts.

4.6.6.1 Tightening application for tightening bolts

The tightening application for tightening bolts simultaneously starts the selected tightening spindles clockwise along with the corresponding tightening program. The following example shows all the steps this requires.


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Example 1. To generate a tightening application, select File New Tightening applications in the BS350 menu bar.

2. Select an application number, e.g. 1 and assign a name to the tightening application, e.g. Test application, by overwriting the existing program name “n.a." (not available). (If program number 0 is selected, "n.a." is not displayed).

3. Click Application info and enter a comment for the tightening application in the Application info dialog.


The Application info dialog closes and the text Application info is underlined. Move the mouse over the button and the comment is displayed as a tooltip.

Fig. 4–33: Tightening application for the sequence test

5. Double click the start step symbol 1, A. The start step dialog opens.

6. Assign a Step name, e.g. start step.

7. Enter the name of the first tightening position in the field Name of tightening position e.g. tightening position 1.

8. From the Channel selection list select the channel that is to be used in the tightening application e.g. 0.1.

9. Select the tightening program (program no.) to be executed in the application from the Program selection list.

10. Click Insert, to insert these data into the Assignment table.

11. Repeat steps 7-10 until the desired number of tightening positions is reached.

The tightening channels transferred to the Assignment table field are started simultaneously with the assigned tightening program in application 1.

12. If you wish to delete an entry from the Assignment table, select the entry, then click Delete.

13. If you want to change an entry, first select the entry in the assignment table and then click Change. The entry may then be edited in the fields Name of tightening position, Channel selection and Program selection.

14. Select Accept to save these data to the tightening application.

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The created tightening application has to be sent to the KE. It can also be stored as a file on the PC (see Sending and saving (page 57)).

4.6.6.4 Loosening tightened bolts

Already tightened bolts are loosened with program no. 99 (Ccw). The tightening application only defines the tightening channels in which program no. 99 is executed.

Activating Loosen in the sequence test (see Sequence test via theBS350 (page 97)) always simultaneously starts loosening program no. 99 in all the tightening channels. Proceed according to Defining a tightening program (page 92) to create and send a loosening program.

4.6.7 SE PLC assignment table

For information on the SE PLC assignment table, see Configuration SE/CS PLC assignment table (page 95).


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4.6.8 KE PLC assignment table

The PLC assignment table defines the assignment of the control signals to the KE's physical interfaces (Arcnet, fast inputs/outputs, module slots). The KE can be integrated into a system sequence with these control signals. A total of 512 control signals can be configured via all PLC cards.

Basic commissioning takes place with a sequence test and therefore specific programming of this PLC assignment table is not necessary. However, a predefined PLC assignment table has to be sent to the KE to make it ready for operation.

A connection between the PC and KE is required to load the predefined PLC assignment table in online mode (see Connecting the PC for programming (page 51)).

Use SystemKE PLC assignment table to load the current KE PLC assignment table.

To create a PLC assignment table in offline mode, select File New KE PLC assignment table. The following dialog opens:

Fig. 4–34: Create KE PLC assignment table offline

There are two options for loading the KE configuration:

• Select From KE because the respective configuration file has been sent and is present in the KE. The current PLC assignment table for the KE is then loaded.

• Select From file and assign the respective configuration file (file name extension: *.kcg). The current PLC assignment table for the KE is then loaded.

Send this PLC assignment table to the KE; it can also be stored as a file on the PC (see Sending and saving (page 57)).

Table 4–34: Number of inputs and outputs

System component Number of inputs/outputs KEIMpdp 16 to 512/16 to 512

IMdev 16 to 512/16 to 512

IMpnio, IMpnio2 0 to 512/0 to 512

IMenip, IMenip2 16 to 512/16 to 512

IMmtcp 16 to 512/16 to 512

IMecat 16 to 512/16 to 512

IM24V 10/13

IL 256/256

XML 649/675

Information on the configuration of the PLC assignment table can be found in the "Project planning" documentation of the Rexroth Tightening System 350. Related examples can be found as well as in the "Project planning" documentation of the Rexroth Tightening System 350.

The detailed description of the control signals can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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4.6.9 Setting the KE time

The time for the KE can be set when it is connected to the BS350. This will automatically set the time of the connected SEs.

The KE time is logged, e.g. in the course of the tightening results output, enabling times to be assigned to the tightening results data. To set the KE time, select System System time. The following dialog opens:

Fig. 4–35: Setting the KE time

The time zone must be selected from the list (for Germany: see time zone in Figure 4–35). The time will automatically change to summer or winter time by activating the option underneath the list.

The option PC time displays the PC time and date. Set system time once synchronizes the KE clock to the PC clock.

The option System time displays the saved KE time and the saved KE date. To make a change, click the desired digit field and press or

Information on the time synchronization of the tightening system using the NTP server can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

4.6.10 Sequence test

The differences from the sequence test of a tightening program in the BS350 (see Sequence test (page 97)) are described here.

To carry out the sequence test for a tightening application, proceed as described in Sequence test (page 97).

Tightening spindles clockwise

To start the tightening application to tighten the bolts, select:

• KE in the channel selection

• the application number in the application selection, e.g. 1: Test application.

• When Start is selected, the tightening application is started.

Tightening spindles counterclockwise

When Loosen is selected, the loosening program (Ccw, no. 99) will be started simultaneously in all the tightening channels in the selected tightening application.

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4.7 Saved ("automatic") channel configuration

The online-configuration of the tightening channel is implemented semi-automatically, i.e. all components with electronic nameplate are configured and parameterized automatically. Mechanical components are not equipped with such an electronic nameplate. However, in the BS350, these components have to be configured and parameterized manually. Furthermore, manual re-configuration of the tightening channel is also required after the tightening spindle or the ErgoSpin hand-held nutrunner has been replaced.

The saved ("automatic") channel configuration eliminates the manual re-configuration step upon nutrunner replacement. This function works as follows: Upon initial online- or offline configuration of the tightening channel, the configuration files are saved directly to the hand-held nutrunner

• For a tightening channel with ErgoSpin hand-held nutrunner,

• directly to the extension memory of the initial measurement transducer of the tightening channel for a tightening channel with tightening

spindle. This way, a complete hand-held nutrunner respectively spindle configuration can be stored. Previously saved configurations are overwritten.

When loading the saved configuration, the channel configuration is calculated automatically, e.g.maximum spindle torque or maximum speed.

Saved ("automatic") channel configuration

For tightening spindles, the following prerequisites have to be met to be able to save a created channel configuration:

The measurement transducer 1 is of the DMC type.

The value of the Channel configuration option is "Automatic".

Proceed as follows to send the configuration data to the tightening controller and the tightening spindle:

Initiate saving the configuration data via Data Send to ... or .

When the spindle configuration is sent, it is additionally saved to the DMC. In this, an old configuration will be overwritten.

Loading channel configuration

The following is required for reading in the saved configuration:

The value of the Channel configuration option is "Automatic".

The hand-held nutrunner is detected automatically and the data are imported into the tightening channel configuration. With a Varioline hand-held nutrunner, a configuration has to be stored to the device once. Then, it is detected automatically, too. No further user intervention is required.

This function is supported as of version V2.200 of the Rexroth Tightening System 350.

If there are two measurement transducers, the configuration is saved to the transducer that is only connected to one CAN line (MC1).

Other measurement transducers are not supported for this function. There will be no error messages either.

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With tightening spindles, the tightening controller first tries using a configuration saved to the DMC. This means that the tightening controller reads the saved configuration when a tightening spindle with saved channel configuration is used. The read configuration is compared to the electronic tightening components detected (e.g. measurement transducer).

• If the saved spindle components and the spindle components detected are identical, the saved configuration is accepted automatically. There is no need for manual reconfiguration with the BS350 operating system.

• If the saved tightening channel configuration and the spindle components detected automatically differ, the channel has to be re-configured in the operating system BS350 and the data have to be sent to the controller.

However, if the tightening channel is designed with tightening spindle without saved configuration or if the saved data are invalid, the channel has to be re-configured in the operating system BS350 . Afterwards, the data have to be sent to the controller. Additionally, the error message 1111 "Channel configuration missing" is issued. This procedure is identical to the behavior known from previous versions when there was no configuration saved to the controller.

Deleting channel configuration

Use Data Delete SE/CS Configuration in the BS350, to delete the saved channel and spindle configuration data on the tightening controller. Furthermore, this function deletes the spindle configuration data in the extended memory of the DMC of the tightening spindle.

4.7.1 Compact system

All hand-held nutrunners are recognized automatically (with the exception of VarioLine). As a result, an operating system is not always required to configure and program the tightening channel, depending on the compact system used:

• With the CS351E-G or CS351E-G IL compact system, you can use the TFT- display instead.

• With the CS351E-D or CS351E-DIL Compact System, a BS350 operating system is required.

NOTICE

Incorrect channel configurationBy replacing mechanical components or components with integrated measurement transducer (DMC, VMC, WMC), the saved channel configuration may deviate from the actual configuration. Thus, erroneous tightenings may be the result. After having replaced mechanical components or components with integrated measurement

transducer, always re-configure the tightening channel. Use the operating program BS350. Finally, save this new configuration to the hand-held nutrunner or tightening spindle, see Saved ("automatic") channel configuration on page 126.

NOTICE

Adaptes spindle component efficiencyThe efficiency of the spindle components were partially optimized in the BS350 V2.300 data base. If the channel configurations created wit these spindle components are sent to the tightening controller, the physical torques of the bolt may change slightly with respect to the "old" channel configuration, data base < V2.300.

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4.7.2 Modular system

The following describes the special features for commissioning a tightening channel that consists of individual components (LTU350/1, LTS350D/LTE350D, SE, VM) and an ErgoSpin.

4.7.2.1 Interfaces and displays on the LTU350/1 servo amplifier

The following interfaces and displays are integrated in the LTU350/1:

Fig. 4–36: Interfaces and displays on the LTU350/1

LC display The LC display allows for displaying the result values (torque, angle, gradient, time) and error codes. Texts are shown in 4 lines, each with 8 characters. The display is permanently backlit. For more information on the LC display, see in the "Project planning" documentation of the Rexroth Tightening System 350.

LED displays Three LEDs are located on the front plate of the servo amplifier and provide information on the following operating states:

Reset button Press this button to reset the servo amplifier.

XDS1 The ErgoSpin connection cable is connected to the XDS1 interface.

LC display

LED displaysReset button

ErgoSpin connection at the XDS1 interface

Table 4–35: LED display on the LTU350/1

LED displayBTB Green

RedReady for operation

System error

MS GreenRed

Ready for operation

Motor contactor error

FG GreenOff

Servo amplifier releaseNo servo amplifier release

Reset button Reset

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4.7.2.2 Interfaces and displays on the LTS350D/LTE350D servo amplifier

The following interfaces and displays are integrated in the LTS350D/LTE350D:

Fig. 4–37: Interfaces and displays on the LTS350D/LTE350D

LC display The LC display allows for displaying the result values (torque, angle, gradient, time) and error codes. Texts are shown in 4 lines, each with 8 characters. The display is permanently backlit. More information on the LC display can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

LED displays Three LEDs are located on the front plate of the servo amplifier and provide information on the following operating states:

Reset button Press this button to reset the servo amplifier.

XDS1 The ErgoSpin connection cable is connected to the XDS1 interface.

LED displays

Reset button

LTE350D: XDS1 interface for hand-held nutrunner ErgoSpin

LC display

LTS350D: XDS2 interface fortightening spindle

XDN3 interface for interrupting the motor release

Table 4–36: LED display on the LTE350D

LED displayBTB Off

GreenGreen, flashing

No power supply or LTS/LTE is in download modeReady for operationNot ready for operation, but no system error; emergency OFF has been triggered

FG GreenOff

Servo amplifier releaseNo servo amplifier release

Error LED Red System error

Reset button Reset

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4.7.2.3 Motor contactor control and fuses

Motor contactor control

Information on the position and locations of the PIN plug on the LTU350/1 can be found in Table 4–37 and Figure 4–38.

Find information on the position and location of switch S2 at the LTS350D/LTE350D in Table 4–38 and Figure 4–39.

Fig. 4–38: PIN plug

CAUTION

Incorrect setting on the LTU350/1 An incorrect setting of the PIN plug can endanger operating personnel.The position of the PIN plug determines the availability of the emergency OFF function. The setting must be made application-specific in the LTU350/1 and in the BS350. The motor contactor control is implemented via the start switch on the ErgoSpin and is thus

independent of the position of the PIN plug. The emergency OFF is thus guaranteed if the start switch is released.

In position 2, the emergency-OFF is additionally involved in the motor contactor control via the VM350.

Incorrect setting on the LTS350D/LTE350D An incorrect setting of the S2 switch can endanger operating personnel.LT350D: The position of the S2 switch determines the availability of the emergency OFF function. The S2 switch determines the function of the motor-breaker VM350 according to table 9. The

selected position of switch S2 has to match "motor-breaker VM350" in the channel configuration LTE350D to ensure the servo amplifier is operational (on delivery S2 = 0).

Table 4–37: Positions of the PIN plug in the LTU350/1

PIN plug in position:

Explanation

1 Operation of ErgoSpin as hand-held nutrunner without emergency-OFF via power supply module VM350 (condition on delivery)

2 Operation of ErgoSpin as tightening spindle with motor-breaker via VM350 power supply module

Channel configuration in BS350: Motor-breaker VM350 active

Table 4–38: Positions of switch S2 in the LTS350D/LTE350D

Position Explanation

1 Emergency OFF VM350 active

LTS350D: Switch S2 has to be in position 1, to ensure the servo amplifier is operational (on delivery S2 = 1).

0 Motor-breaker VM350 active

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Fig. 4–39: Switch S2

Fuses The intermediate circuit of the servo amplifier is protected by two safety fuses. If these fuses blow (melt), the BTB LED changes from green to red. In this state, operation is no longer possible.

These safety fuses are located on the rear of the servo amplifier and must be replaced in the case described above (for removal, see Figure 4–40).

Fig. 4–40: Removal of the safety fuses

Recommended fuse: 3 608 875 374, 12 A, 500 V DC, 10,3 x 38 mm

Manufacturer: Ferraz Shawmut

Order number: 6JX12

More detailed information on motor breaker circuits can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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4.7.2.4 Motor release interruption at the LTS350D/LTE350D

At the XDN3 interface, see figure 4–41, the motor release can be interrupted via a potential-free opening contact.

PIN 1 and 2 are equipped with a jumper at the factory to ensure that the motor is ready for operation.

Fig. 4–41: Interface XDN3

4.7.2.5 Inserting and connecting the modules

Proceed as follows to insert and connect the modules:

• Insert components in accordance with chapter Assembling the modular system (page 40)

• Insert the available interface modules in accordance with chapter Interface modules (IM) (page 42)

• Insert the socket for the hand-held nutrunner connection cable in the correct position in the plug on the nutrunner handle and tighten the union nut connection by hand

• Insert the plug for the nutrunner connection cable in socket XDS1 (Figure 4–36) on the LTU350/1 servo amplifier and/or LTS350D/LTE350D and tighten the union nut connection by hand

• Establish the other required connections in accordance with Setting up the connections (page 43)

• Switch on the power supply for the BT or on/off switch on the SB

• Connect the PC for programming in accordance with chapter Connecting the PC for programming (page 51) (not necessary if commissioning a complete package).

4.7.3 Configuring the tightening channel

The standard configuration of the ErgoSpin tightening channel is automatically configured during commissioning. No configuration changes are required for basic commissioning. The configuration can also be implemented manually at System Tightening channel configuration (see Offline configuration: (page 91)), if you are using deviating versions, additional components, or working in offline mode.

Channel configuration created offline with an ErgoSpin VarioLine (ESV) or pistol grip nutrunner (ESM)

For reasons of securing the tightening system, the following restriction applies to tightening channel configurations created offline which contain an ErgoSpin of type VarioLine (ESV) or of type pistol grip nutrunner (ESM): the tightening controller does not accept this tightening channel configurations. The tightening channel configuration can be sent to the tightening controller (Data Send … or Data Send to …), it is, however, not accepted.

Table 4–39: Positions of the PIN plug in the LTS350D/LTE350D

PIN plug in position:

Explanation

1 Motor-breaker Out

2 Motor-breaker In

General information on sending files can be found at Sending and saving (page 57).

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If such tightening channel configuration has been sent to the tightening controller, the BS350 outputs the following message:

The values stored on the hand-held nutrunner (MFU factor, ident number, comment, test intervals, output drive data) are not overwritten by sending.

Proceed as follows in order to change tightening channel configurations containing an ErgoSpin hand-held nutrunner of type VarioLine (ESV) or of type pistol grip nutrunner (ESM):

1. Load the tightening channel configuration from the tightening controller.

– Compact system: see „Loading the tightening channel configuration“ from page 65

– Modular system: see „Loading the KE configuration“ from page 101.

2. Adjust the tightening channel configuration.

– Compact system: see „Completing the tightening channel configuration“ from page 66

– Modular system: see „Configuring the tightening channels“ from page 119.

3. Send the changed tightening channel configuration to the tightening controller, see „Sending and saving“ from page 57

The tightening channel configuration on the tightening controller has been changed.

4.7.3.1 Storing the tightening programs

The ErgoSpin hand-held nutrunners are supplied from the factory without tightening programs.

Proceed as follows for initial commissioning:

1. Create the tightening programs in the operating system BS350.

2. Send the created tightening programs to the control unit.

ErgoSpin with stored tightening programs

For initial commissioning of an ErgoSpin hand-held nutrunner on which tightening programs have already been stored at the factory, proceed as follows:

Activate the additional functionality Use tightening programs from hand-held nutrunner (program 99 and 0..3) (see Additional function (page 72)).

In order to allow for tightenings, send the configuration to the control unit.

The tightening programs on ErgoSpin hand-held nutrunners supplied from the factory can be deleted.

If deviating tightening programs (0 to 3, 99) are already on the tightening controller, they will be overwritten after acknowledgement of error message code 382, if the additional function Use tightening programs from hand-held nutrunner (program 99 and 0 to 3) (see Additional function (page 72)) is activated.

NOTICE

Loss of dataTightening programs can be deleted in the hand-held nutrunner, if the tightening programs in the SE need to be deleted with Data Delete SE/CS .... Before deleting, deactivate the additional function Use tightening programs from hand-held

nutrunner (program 99 and 0...3) and send it to the tightening channel.

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4.7.3.2 Automatic configuration of the tightening channel

Automatic initial commissioning

Automatic commissioning is active if there is no existing channel configuration. Here, the components recognized by the tightening controller are transferred to the channel configuration without querying the user and configured with a default value (SE, IM, LTU).

The PLC assignment table is generated automatically. To call up the configuration of the tightening

channel, select System Tightening channel configuration or .

Automatic channel configuration

Automatic channel configuration is active if the Automatic option is selected under Channel in the global parameters (see Channel configuration (page 71)). Automatic channel configuration allows for example to replace the ErgoSpin during operation (plug & run). The ErgoSpin data are then transferred to the channel configuration without querying the user. All other components must be manually configured.

4.7.3.3 SE/CS PLC assignment table

Control unit (SE) The PLC assignment table defines the assignment of the control signals to the tightening controller's physical interfaces of the tightening controller (Arcnet, fast inputs/outputs, module slots) of the SE352(M).

Programming the IM24V interface module in the type B1/B2 slot Load the assignment table via System SE/CS PLC assignment table.

To ensure simple program selection, assign the signals in the Inputs group as follows:

• Prog0 to B1/B2 0.0

• Prog1 to B1/B2 0.1

Send the changed PLC assignment table to the SE.

To initialize other processes with the tightening sequence evaluation, assign the signals in the Outputs group as follows:

• Ok to B1/B2 0.0

• Nok to B1/B2 0.1

Compact system (CS) The assignment is largely specified for the compact system and does not need to be changed for basic commissioning. You can, however, optionally specify the input signal for the tool button on the hand-held nutrunner.

For this, proceed as follows:

1. Load the assignment table via System SE/CS PLC assignment table.

2. Click the ErgoSpin 0.3 input.

3. Click << to remove the existing signal.

4. Click the desired input signal (e.g. ResRs).

5. Click the ErgoSpin 0.3 input.

6. Click >> to assign the signal.

The ResRs signal is displayed for the ErgoSpin 0.3 input (see Figure 4–43)

Automatic commissioning can be forced during later operation by simultaneously deleting the channel configuration and PLC assignment table.In doing so, the output drive components for the ESV and ESM are deleted automatically.

The PLC assignment table is generated automatically during automatic commissioning.

For information on offline configuration, see chapter Configuration SE/CS PLC assignment table (page 95)

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4.7.3.4 Selecting tightening programs

As described in section Storing the tightening programs (page 133), up to five tightening programs (0 to 3, 99) can be stored in the ErgoSpin hand-held nutrunner ex factory (see Figure 4–42). A copy of the programs is stored on the tightening controller when the tightening controller is switched on or reset, as well as when the hand-held nutrunner is connected.

• Program 0: MCT (machine capability test 1)) Tightening with approx. 80% of the working range

• Program 1: Tightening at the lower limit (with approx. 0 %) of the working range

• Program 2: Tightening with approx. 30 % of the working range

• Program 3: Tightening with approx. 80 % of the working range

• Program 99 (Ccw): Loosen bolted connections

Fig. 4–42: Selecting the tightening program in the BS350

Program selection can be implemented via 24V signals (IM24V interface module), a field bus (IMpdp or IMdev interface module) or, with the CS351E-G, directly via the TFT.

If no program is selected via one of these interfaces, program 0 is selected as standard. Loosening program 99 is set via a CW/CCW reversal switch.

If the tightening programs stored in the ErgoSpin are to be automatically loaded in the tightening controller (e.g. when the ErgoSpin is exchanged), the additional function Use tightening programs from hand-held nutrunner (program 99 and 0 to 3) must be activated in the channel configuration (see also Additional function (page 72) and Chapter Storing the tightening programs (page 133)).

In the BS350, the Data ErgoSpin tightening programs menu item can be used to compare varying tightening programs in the tightening controller and hand-held nutrunner. Different programs are highlighted in red (see Figure 4–43):

1) The machine capability examination is always implemented with an external, independent measuring system. This measuring system provides the reference value. During the MCE, the measurement results from the tightening system and the results from the reference measuring system are adjusted using the MCE factor, if the results deviate from each other slightly.

The PLC assignment table must be configured for this accordingly.

If deviating tightening programs (0 to 3, 99) are already on the tightening controller, they will be overwritten after acknowledgement of error message code 382, if the additional function Use tightening programs from hand-held nutrunner (program 99 and 0..3) (see Additional function (page 72)) is activated.

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Fig. 4–43: Tightening program comparison

The changed program is assigned to the tightening controller or ErgoSpin with the arrow buttons >> and <<. You must then send this assignment to the tightening system using Send.

Tightening programs ErgoSpin or Tightening programs SE/CS opens the tightening programs from the ErgoSpin or the tightening controller for editing.

4.7.3.5 Changing tightening programs

The parameters of the tightening program can be changed in the BS350 operating system or via the TFT-display. You must then send the tightening program to the tightening controller.

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4.7.4 Configuring the optional additional module barcode scanner

The Configuring the tightening channel does not differ between ErgoSpin hand-held nutrunners with or without optional additional module "barcode scanner". The only distinctive feature is that hand-held nutrunners with barcode scanners have a PE number.

The barcode scanner within the hand-held nutrunner can be selected as ID code source and can be configured manually. The barcode scanner settings can be modified using the following:

• CS/KE: System Tightening cell data Scanner Scanner in the hand-held nutrunner

• SE352M: System SE data Scanner Scanner in the hand-held nutrunner

The following setting options are available:

• Activate or deactivate barcode scanner

• Valid (permitted) barcode types, the length of the same, and whether the corresponding barcode type is active

There are several options for the length of the corresponding barcode:

– Entry of a fixed length, e.g. „12“

– Entry of 2 fixed lengths, e.g. „4;8“

– Entry of a length range, e.g. „3–9“

– No length restriction, i.e. "all" or ""

• Barcode-specific options, such as the "Security Level"

• Time-dependent parameters, i.e.

– Activation time

– Release time

– Signal time

– Delay during continuous operation

Table 4–40 shows the as-delivered-state of this time-dependent parameters.

After configuration of the barcode scanner within the ErgoSpin hand-held nutrunner, there are the following options:

• Updating the configuration data

• Sending the configuration data to the hand-held nutrunner

The optional barcode scanner for the versions SlimLine, GripLine, and VarioLine of the ErgoSpin hand-held nutrunner is available as of V2.200 of the Rexroth Tightening System 350.

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Table 4–40: Barcode scanner within ErgoSpin: Timing parameter

Timing parameter

Explanation Standard value [s]

Value range [s] Modification step [s]

Special value [s]

Activation time laser

Maximum illumination time until automatic deactivation of the laser

– 0,5…25,5 0,1 0: Continuous operation

Release time The scanner can be released using the PLC signal EnScan. The duration is set using this parameter.

– 1…99 1 0: Scanner is released as long is the PLC-signal is present.

1…99 If the PLC-signal is present, the scanner is released from the set time.

Time acoustic signal decode

Duration of the acoustic signal upon recognizing a barcode

– 0,1…9,9 0,1

Delay during continuous operation

Only relevant if scanner in continuous operation (laser always activated)

Waiting time upon recognizing a barcode until the next barcode is recognized.

– 0,5…9,9 0,1

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4.7.5 Nutrunner test

Fig. 4–44: ErgoSpin, SlimLine type

4.7.5.1 Nutrunner start

The ErgoSpin is started by actuating the start switch (1) (see Figure 4–44).

Releasing the start switch (1) aborts the tightening process. The aborted tightening process is evaluated by the tightening controller:

• If the torque threshold for play on the start switch (default value: 5 % of the nominal torque of the hand-held nutrunner) was not exceeded, the tightening is not evaluated. This process is interpreted as "Play at start switch" and ignored (i.e. OK = 0 and NOK = 0, both LEDs are off).

• If the torque threshold was exceeded, the tightening is evaluated as faulty (NOK) and the red LEDs are illuminated (see Acknowledging a faulty tightening process (page 140)).

4.7.5.2 CW/CCW reversal switch

The direction of rotation for the nutrunner can be changed to tighten and loosen bolts. The direction is changed using the CW/CCW reversal switch (2) on the hand-held nutrunner (see Figure 4–44).

1 Start switch

2 CW/CCW reversal switch

3 Tool button

4 Socket for the ErgoSpin connection cable

1

23

4

Press the start switch (1) on the hand-held nutrunner and hold until the hand-held nutrunner automatically switches off.

The direction of rotation for the nutrunner is determined by the algebraic sign for the speed in the tightening program. The description in this section applies in case a positive speed is set in the tightening program. With a negative speed, the description for clockwise/counterclockwise revolution has inverse effects.

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The setting for the direction of rotation of the nutrunner is visible on the CW/CCW reversal switch (2)

• Switch position towards right : Clockwise rotation, program in accordance with the selected program (basic setting: program 0)

• Switch position towards left : Counterclockwise rotation, program 99, cannot be changed.

If you make a change during a tightening process, it will only take effect in the next tightening process.

4.7.5.3 Acknowledging a faulty tightening process

If the PLC assignment table stores the PLC signal NokAck on the tool button (3) (see Figure 4–44), faulty tightenings must be acknowledged by actuating the tool button.

A faulty tightening process is indicated by illumination of the red LEDs on the hand-held nutrunner.

Acknowledgement of a faulty tightening process (NokAck) via the tool button is already configured after commissioning.

After the compact system has been switched on, the tool button must be pressed before you can start the first tightening.

For information on how to change the function of the tool button (3) using the PLC assignment table (control signals), see SE/CS PLC assignment table (page 134).

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4.8 Special operating features of the hand-held nutrunner ErgoSpin/CC-ErgoSpin

This section describes commissioning and the special features for operating an ErgoSpin hand-held nutrunner.

4.8.1 Special features of ErgoSpin with open flat output drive with mechanical safety catch

In order to ensure perfect current feed of the motor, the motor of the ErgoSpin hand-held nutrunner is adjusted after every switch-on of the Rexroth Tightening System. The alignment process takes one motor rotation. This corresponds to an angle of turn at the output drive of 8° to 15°.

4.8.2 Special features of ErgoSpin with open flat output drive without safety catch

This section describes special features for the configuration of ErgoSpin VarioLine with open flat output drive without safety catch. Flat output drives without safety catch are applied if bolts are also to be loosened. For example, for fitting brake lines.

For flat output drives without safety catch, the controller must ensure precise running in open position by means of internal angle measurement. The operating sequences are to be stored and executed by the tightening controller.

On "opening" the flat output drive, the nutrunner automatically runs to open position of the flat output drive from every position. The flat output drive is "opened" in tightening direction (clockwise). Before opening, the flat output drive has to be removed from the tightening position. If the user is still at the tightening position when "opening", undesired loosening of tightening is prevented by opening in tightening position.

The tightening/loosening sequence (Prgx/Prg99) and opening of the flat output drive ("opening" program) is realized alternatively by operating the start button at the hand-held nutrunner.

For referencing the open position, teaching of the tightening system is required. This is required after switching on the system or if the position is insufficient due to accumulated inaccuracies.

The open position is referenced in tightening direction in the teach-in process.

To recognize potential manipulation at the flat output drive outside of a tightening operation, the position of the flat output drive (angle measurement) is continuously measured by the tightening system.

NOTICE

Damage to the flat output driveWhen open flat output drives with mechanical safety catch are in zero position, i. e. when they are open, they can only be moved in output drive spin direction. If the output drive direction of an open flat output drive with mechanical safety catch does not comply with the alignment spin direction of the hand-held nutrunner, the flat output drive may be damaged. Always use the latest firmware (for version V2.400 as of version 1V08) of the servo amplifier

(LTU350/1 or CS351) that is adjusted to the flat output drive.

In the Rexroth Tightening System 350 the alignment spin direction is directly adjusted by specifying the output drive spin direction and the reverse spin direction, see Channel configuration of open flat output drives on page 70.

This application is supported as of BS350 V2.400.

For application, the special firmware esfw-22B2.mhx for ErgoSpin is required.

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4.8.2.1 Commissioning

Tightening channel configuration

The flat output drive without safety catch is configured in the open flat output drive channel configuration. See Channel configuration of open flat output drives (page 70).

For configuration, activate the option Open flat key program-controlled. After sending, the system is restarted.

Calculation and specification of the Precise motor screw reduction ratio:

For positioning accuracy, the total motor screw reduction ratio (IG) should be entered with 12 decimal places.

PLC signals Referencing and open position of flat output drives without safety catch is realized via the PLC output signals GO_Rdy and GO_Open.

As of version V2.500 of the Rexroth Tightening System 350, the PLC input signal GO_SetRef is available for the reference point of the open position.

Tightening programs For opening and referencing the flat output drive, new target functions were added to the extended tightening step in the tightening program. Refer to the "Project planning" documentation of the Rexroth Tightening System 350:

• Target function GO Ref

The open position of the flat output drive of the nutrunner is calibrated in the teach-in process.

• Target function GO Open

The nutrunner is rotating in tightening direction until the open position of the flat output drive is reached. This requires referencing of the flat output drive.

4.8.2.2 Open position referencing

After switching on the system, referencing of the flat output drive in open position is required. Without referencing, the "open" function GO Open of the flat output drive is canceled with error 1245.

Referencing is required:

• On controller reset / switching on

• After removal and connection of hand-held nutrunners

• If the open position cannot be set precisely on opening

The partner controller sets the reference run program via the program selection. More information on the LC display can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

Application of the new tightening functions GO_Ref and GO_Open without activation of the Program-controlled flat key opening option leads to error 1213 "Sequence control error".

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Fig. 4–45: Flat output drive referencing via tool button

The operator presses the start switch once or several times. This way, the program is started for referencing until the flat key is in open position.

By pressing the tool button at the nutrunner for at least 5 seconds, the open position is assigned to the internal angle counter in the controller. Referencing is indicated to the user by means of a blink code. Running light: 3x red 500ms on -> yell 500ms on -> green 500ms on

Fig. 4–46: Flat output drive referencing via tool PLC signal

Referencing of the open position is controlled via the PLC input signal GO_SetRef.

Program with target function GO Ref

selected

Referencing programwith target function

GO Ref

Tool button pushed for 5 s

Cw / CCw=1

ToolBn=1

GO_Open=1 GO_Rdy=1

GO_Open=0 GO_Rdy=0

Start

Program with target function GO Ref

selected

Referencing programwith target function

GO Ref

GO_SetRef=1

Cw / CCw=1

GO_Open=1 GO_Rdy=1

GO_Open=0 GO_Rdy=0

Start

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Example: Tightening process with opening the flat output drive in tightening direction

ErgoSpin with open flat output drive without safety catch:

– If the flat output drive is to be opened after tightening the bolt with OK evaluation or NOK evaluation, the opening program has to be linked to the tightening program / loosening program.

Cancellation of the link:

– At any time by reversing the spin direction at the spin direction selector switch of the hand-held nutrunner.

Interruption of the link:

– In case of a system error. After correction of the system error, the program link can be resumed.

Setting ofCw/Ccw reversal

switch

Loosen programselected

Loosen program 99

Tightening program selected

Start switchpushed

Start switchpushed

Tightening program in accordance with selected program

Start switch pushedagain

Start switch pushedagain

Open flat output drivein accordance with

program with target function: GO Open

CCwSel=1

Go_Open=1

CCwSel=0

Go_Open=0

Go_Open=1

Open flat output drive in accordance with

program with target function: GO Open

Go_Open=0

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4.8.3 Special features of ErgoSpin with angle compensation

The angle compensation function is applied to compensate the hand-held nutrunner motion by the user.

If the hand-held nutrunner is moved in or against tightening direction during the tightening process (see Figure 4–47), this rotary motion is recorded and compensated by the drive of the hand-held nutrunner, provided the "Angle compensation" function is activated.

Fig. 4–47: Tool motion compensation in/against the spin direction

The angle compensation function is only available for ErgoSpin hand-held nutrunners with gray start switch.

This function is available as of version V2.500 of the Rexroth Tightening System 350 and requires CPU card hardware version rev. 02.xx.xx or higher in the controller (menu System test Tightening cell info CPU carte rev.).

Tightening direction

Compensation ofthe tool motion

Tool motion

Tool motion

If the maximum angular speed is exceeded, a system error of error class 3 (error code 373) is returned.

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Angle compensation is activated by means of a license available on a license stick. Each license stick contains exactly one license for one tightening channel. For licensing, the license stick can be inserted into the following slots:

• At the control unit (SE), the license stick is inserted in the respective channel for the nutrunner in slot X3U1 or X3U2 and the channel is assigned in the channel configuration.

• At the CS351 compact system, the license stick is inserted into slot X3U1 or X3U2.

On switching on the system, the availability of valid licenses is checked. An overview of the licenses per channel can be accessed in menu System test Tightening cell info Licenses. If the system recognizes, that a license cannot be read, a buffer period (up to 10 days) is activated. This buffer period is displayed in menu System test Tightening cell info Licenses. During this period, the function has to be deactivated or a valid license inserted.

Free demo period Angle compensation can be tested for up to 30 days without a license. It can only be activated once for each channel at each controller. It is activated by means of the channel configuration:

• Online: System Tightening channel configuration CS or SE

The additional function enables activation or deactivation of the 30-day demo period with the Angle compensation demo period checkbox. The checkbox cannot be enabled if the demo period was already activated or has expired. The license overview shows the remaining runtime. If the period has expired, a respective error message (FC 3007) is returned.

If the angle head output drive axis is not aligned with the tightening axis, an angle head compensation error occurs. A deviation of 15° leads to an error of approx. 1.5°.

Fig. 4–48: Angle head output drive axis of the ErgoSpin hand-held nutrunner and tightening axis

Tightening axis

Angle head output drive axis

Only connect the license stick in de-energized condition.

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4.8.3.1 Activating angle compensation

Angle compensation is configured in the BS350 in channel configuration:

• Online: System Tightening channel configuration CS or SE

The additional function enables activation or deactivation of the angular compensation with the Activate angle compensation checkbox. This requires a valid license stick inserted in the respective slot X3U1 or X3U2. Alternatively, the function Angle compensation demo period can be enabled to obtain a temporary license for 30 days. Otherwise, the function cannot be activated.

4.8.3.2 Configuring angle compensation

It is configured via the BS350 operating system. The ErgoSpin configuration view was extended by the parameter Angle head rotation. The angle head can be adjusted in steps of 15° between 0° and 345°. Select the respective entry.

Fig. 4–49: Angle head rotation

Angle compensation is only admissible for ESA types, ESV types with standard angle head and ESM types without additional output drives.

NOTICE

Accuracy of angle compensationThe position of the angle head has an effect on the accuracy of the angle compensation. For this reason, the relative angle head position to the nutrunner has to be configured. Reconfigure the position if the angle head is adjusted.

345°

90°

75°

60°

45°30°

15°0°

Tool button

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4.8.3.3 Function and accuracy check of the nutrunner

Recommendation: Check the function and accuracy of the ErgoSpin hand-held nutrunner by means of a rotation of 90° to the tightening axis. For the test, create a tightening program with a speed of 0, angle of turn tolerance window for the output drive of 88° - 92° and a tightening time of approx. 5 seconds.

After start-up of the tightening program, the hand-held nutrunner is moved by 90° in the direction of the tightening axis.

Fig. 4–50: Function and accuracy check of the ErgoSpin hand-held nutrunner

The test result is illustrated in the graph display.

4.8.3.4 Error messages

The following system errors may occur:

• System error e.g. shock error (error code 373, 529 and 1246)

• Error codes 350, 351 and 352

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4.8.4 Special features for CC-ErgoSpin and commissioning of the CC-CS351 compact system

4.8.4.1 Commissioning

CC-ErgoSpin hand-held nutrunner

The CC-ErgoSpin can only be used with servo amplifier firmware version 01V08 or higher. Make sure that servo amplifier firmware version 01V08 or higher is installed.

The software "350CsFw-2350.elx" or higher must be installed on the standard CS351 compact system intended for operation of the CC-ErgoSpin.

Configuration

The CC-ErgoSpin channel is configured and parameterized using the "BS350 operating system (V2.300 SP1 or higher).

The CC-ErgoSpin does not provide the setting option "Redundancy factor". The CC-ErgoSpin is exclusively set using the "MCE factor". The "MCE factor" can be adjusted in the range 0.500 to 2.000. The nutrunner torque derived from power supply was adjusted to a MCE factor of 1,000 using a reference measuring system at the factory.

CC-CS351 compact system

The control software "350CsFw-2350.elx" or higher is required for operating the CC-CS351. This software is already installed when the CC-CD351 is delivered.

4.8.4.2 Special features of the CC-ErgoSpin hand-held nutrunner

When the nutrunner is started, it requires an increased amount of current for mass acceleration. As the CC-ErgoSpin detects the torque indirectly using the present motor current, this current peak may cause the system to reach the programmed target torque early and to terminate or cancel the tightening sequence.

To avoid the abortion of the tightening sequence, use the function "Start-up suppression". Refer to the "Project planning" documentation of the Rexroth Tightening System 350. The "start-up suppression" is the time in ms after the tightening step has been started during which the tightening process is not evaluated. Therefore, the current peak during nutrunner start-up is not included in the evaluation.

The step start-up is only monitored if the speed is increased as compared to the previous step (positive speed change).

The CC-ErgoSpin and CC-CS351 can be connected as of version V2.300 SP1 of the BS350.

CC-ErgoSpin hand-held nutrunners cannot be operated with the LTE350D servo amplifier.

CAUTION

Risk of damage to persons and property due to improper handling!If the nutrunner is started on a bolt that is already tightened, the bolt may be torn off or the nutrunner may turn around the bolt at a certain angle. This angle depends on the set speed and the duration of the "start-up suppression". Depending on the tightening case the nutrunner turning around the bolt may injure the operator (e.g. crushing). Bear this in mind when setting the "start-up suppression". It is advisable to use the function "start-up test". To ensure the tightening is of a high quality, it is advisable to carry out a tightening case analysis

for every tightening case. For more information on this, please read the chapters "Tightening processes" and "Working with the System".

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Other deviations of the CC version in the BS350 standard operating system

Fig. 4–51: CC-CS351 configuration

• With the CC-CS351, module slot A is not displayed in the tightening channel configuration.

Interface modules in slot A are not supported by the channel configuration. For this reason, all field bus functions are disabled.

• With the CC-CS351, the "motor current transducer function" is set to primary and cannot be adjusted.

The auto configuration sets the transducer function to "primary transducer" for the servo amplifier and to "off" for the hand-held nutrunner. This cannot be changed. This is automatically done for unconfigured systems following a restart.

• The CC-ErgoSpin does not support the function "transducer test".

The "standard" ErgoSpin executes the transducer test outside of the tightening. The ErgoSpin reads measured values from the measurement transducer.

The CC-ErgoSpin records measured values via the motor current when turning the spindle. For operator safety reasons, this is not possible in the transducer test.

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4.9 Special characteristics of Nexo cordless Wi-Fi nutrunner operation

This section describes the characteristics of the operation of the Nexo cordless Wi-Fi nutrunner.

Configuration files• *.ini configuration file:

The configuration file contains the IP address of the Nexo cordless Wi-Fi nutrunner to be connected as well as the field bus assignment (PLC) as default setting. All cordless Wi-Fi nutrunners are configured identically. Configuration is carried out using the BS350.

• Sys350_Fieldbus_Nexo.zip zip file

The zip file is an IndraWorks archive. Supported IndraWorks versions (10, 11, 12).

The zip file contains the IL program for the Nexo protocol conversion. The file can be found in the directory Miscellaneous IL-Examples on the system stick.

Nexo configuration in BS350

Online configuration Click on Extras Nexo configuration.

Offline configuration Click on File New Nexo configuration.

After starting, the Nexo configuration view is displayed. By default, the entry New Nexo with the IP address 0.0.0.0 is displayed.

Fig. 4–52: Nexo configuration

The Nexo cordless Wi-Fi nutrunner can be connected from V2.300 of the Rexroth Tightening System 350. Please find information on the Rexroth Nexo cordless Wi-Fi nutrunner in the "Nexo" documentation.

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Saving a configuration file

Click on File Save to save a configuration file.

Opening a configuration file

Click on File Open to open the respective *.nexo configuration file.

Sending a configuration file

Click on Data Send to transfer the configuration file to the KE controller component or the CS351 connected via PC Interface. The Send option is only active if the user is logged on to the controller component.

Before sending, the BS350 checks the electronic name plate to determine whether it is an IL component and carries out the download depending on whether a IL component is available.

If the file contains invalid entries, an error message is displayed and the sending process is canceled.

The configuration file can be found under the CS/KE controller in the directory CoDeSys or on the local operating computer.

Table 4–41: Nexo configuration

Element Description IP address Preset IP address: 0.0.0.0

Double click on the IP address to open the default web browser providing the IP address or the DNS name of the cordless Wi-Fi nutrunner.

Channel Definition of the node ID

Send NXC file With this button, the NXC file is transmitted to the controller. The button is only active if the user is logged on to the controller component.

Before sending, the BS350 checks the electronic name plate to determine whether it is an IL component and carries out the download depending on whether a IL component is available.

Click on the button to add new entries.

– NameDefault setting: New Nexo. Enter the name.

This function can also be accessed via New in the context menu.

Press this button to delete a selected entry.

This function can also be accessed via Delete in the context menu.

Click on the button to change the name of the Nexo cordless Wi-Fi nutrunner.

This function can also be accessed via Edit in the context menu.

Moves the selected entry up.

This function can also be accessed via Up in the context menu.

Moves the selected entry down.

This function can also be accessed via Down in the context menu.

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5 Troubleshooting

This chapter describes errors which can occur when working with the Rexroth Tightening System 350 and provides troubleshooting advice.

• Error codes and classes (page 154)• Reset function (page 155)• LED displays and operating elements (page 156)• Error recognition on interface modules (page 163)• Error recognition and acknowledgement at the TFT display (page 174)• Error recognition and acknowledgement with the BS350 operating program

(page 175)• Description of selected errors (page 189)• Replacing defective components (page 192)• Complete error list (page 194)


5.1 Error codes and classes

All information in this document refers to software versions from V2.300 in the Tightening System 350.

5.1.1 Overview

Errors in the tightening System 350 are displayed via:

• The LEDs on the control and power electronics (compact system, VM power supply module, SE control unit, LT35x, LTU350/1 servo amplifier or LTS350D/LTE350D)

• the LEDs of the interface modules

• The BS350 operating program

• The display on the LTU350/1, LTS350D/LTE350D and on the compact system

• Control signals

• The ErgoSpin hand-held nutrunner

All errors that occur must always be acknowledged after the remedy of their cause, in order to bring the tightening system back into working order. The acknowledgement takes place via:

• The reset button on the control and power electronics components (compact system, VM, SE352(M), LT35x, LTU350/1, LTS350D/LTE350D, KE350(G IL))

• The error lists in the BS350 (Acknowledgement button)

• The compact system TFT (Acknowledge button)

• Switching off/on the entire tightening system (Note: after switching off the tightening system, a waiting period of approx. 30 seconds is to be observed before it is switched on again!)

• Control signals

• Self-acknowledgement by the Tightening System 350 (only for error class 4).

5.1.2 Error code assignment table

A list with error codes and the relevant error texts are supplied in PDF with the BS350. All error codes can also be found in the error list (see Complete error list from page 194).

The error code assignment table is divided as follows:


Table 5–1: Description of the error code assignment table

Column heading DescriptionError code Unique error number

English Error text, some entries with information on the components affected, e.g.:

– KE: Communication unit

– LT: Servo amplifier

– CAN: CAN bus (measurement transducer)

– MSEN1: Measurement transducer, transducer system 1

Error class Classification (see Error classes (page 155))

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5.1.3 Error classes

Errors in the Tightening System 350 are divided into the following classes:

5.2 Reset function

Errors are signalized via the LED on the control and power electronics. In principle, the measures indicated in section Overview (page 154) are available. Errors can be acknowledged on each component via the reset button on the following hardware components:

• Compact system

• SE352 or SE352M

• KE350 or KE350G IL

• VM350

• LT35x

• LTU350/1

• LTS350D/LTE350D

A software reset and a hardware reset is possible for control electronics components (compact system, SE and KE).

A software reset is generated if the reset button is briefly pressed (< 1 second). The control electronics are reset when the button is released.

A hardware reset is generated if the reset button is pressed for a long period (> 3 seconds). The control electronics (compact system or SE352...) and power electronics (compact system, LT35x or LTU350/1 or LTS350D/LTE350D) are reset when the button is released.

Pressing and releasing the reset button on the servo amplifiers (LT35x, LTU350/1 and LTS350D/LTE350D) will acknowledge all CAN bus errors on a tightening channel without resetting the control unit. The tightening system is then quickly ready for operation again.

Table 5–2: Error classes

Error class Error type Remedy 1 This error class indicates the occurrence of a

serious error; the tightening system is no longer ready for operation, i.e. a tightening job is not possible. This error can be caused by e. g.:

– missing configuration

– Failure of hardware components

The tightening system can only be made ready for operation with the help of the user, e.g. by:

– sending the correct configuration

– power off/on

– reset

– replacement of hardware components

2 Currently not used -

3 This error class indicates a malfunction in the tightening system. Before the error is acknowledged, it is temporarily not ready for operation.

Acknowledgement of the error via the electronic interfaces:

– PLC signals

– BS350 error list

– TFT on the compact system

4 This error class indicates a malfunction in the tightening system; however, the error is acknowledged by the tightening system itself after the remedy of the cause, e.g.:

– temperature error

– error motor-breaker circuit

Self-acknowledgement of the error by the tightening system.

5*

* Errors of error class 5 are not displayed at the communication partner for the Open Protocol, the so-called "Open Interface".

System message (no error), e.g.:

– Test interval ErgoSpin reached

Remedy not required

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Switching the control and power electronics on and off will acknowledge all tightening channel errors.

5.3 LED displays and operating elements

5.3.1 Compact system

LED display

Fig. 5–1: LEDs at the front

NOTICE

Damages caused by restarting the system too fastRestarting the system too fast causes damages to the control and power electronics. If you switch off the control and power electronics and restart the same just once, you

have to wait 10 seconds before switching them on again. If you switch off the control and power electronics and restart the same numerous

times, you have to wait 30 seconds before switching them on again.

Table 5–3: LED modes

LED Color DescriptionOff No power supply or low-voltage power supply available

Blue Power supply and low-voltage power supply available


Green, flashing Not ready for operation, but no system error


OK/NOKGreen Tightening case evaluation: OK

Red, flashing Tightening case evaluation: NOK

Off Motor contactor not operated

Green Motor contactor operated

Red/green, flashing Servo amplifier initialization


FGGreen Servo amplifier release

Off No servo amplifier release

RUN/STOP *

* Only for CS351 with IL

Green PLC program is running

Red PLC program is stopped

Off No PLC program is included in the tightening system

ERROR * Red, flashing Integrated logic error

IL RUN/STOP ERROR

CS351 without CS351 with IL

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5.3.2 LTU350 servo amplifier

On the front panel of the LTU350/1, there are four LEDs to display the operating state and a reset button which, when pressed, initiates error acknowledgement and a restart of the SE:

The BTB-LED describes the following modes:

• Constant green light: No error, LTU350/1 ready for operation

• Green flashing: LTU350/1 not ready for operation, but no system error; emergency OFF has been triggered

• Constant red light: System error, LTU350/1 not ready for operation

• Constant orange light: VM power supply module not ready for operation

5.3.3 LTS350D and LTE350D servo amplifiers

On the front panel of the LTS350D/LTE350D, there are four LEDs to display the operating state and a reset button which, when pressed, initiates error acknowledgement and a restart of the SE.


• Constant green light: No error, LTS350D/LTE350D ready for operation

• Green flashing: LTS350D/LTE350D not ready for operation, but no system error; emergency OFF has been triggered

Table 5–4: Displays and operating elements on the LTU350/1

LED Color DescriptionBTB-LED Off No power supply or LTU is in download mode


Green, flashing Not ready for operation, but no system error; Emergency OFF has been triggered

Red System error

Orange VM power supply module not ready for operation

MS-LED Off Motor contactor open



FG-LED Off No servo amplifier release

Green Servo amplifier release

Button Reset

Table 5–5: Displays and operating elements on the LTS350D/LTE350D

LED Color DescriptionBTB-LED Off No power supply or LTS/LTE is in download mode


Green, flashing Not ready for operation, but no system error; Emergency OFF has been triggered

FG-LED Off No servo amplifier release

Green Servo amplifier release

Error LED Red System error

Button Reset

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5.3.4 VM power supply module

On the front panel of the VM, there are six LEDs to display the operating state, as well as a reset button for error acknowledgement, see also VM350 instruction:

Readiness for operation is indicated by the constantly lit green BTB-LEDs.

Temperature and voltage errors can be acknowledged by:

• pressing the reset button on the front panel of the VM

• or switching the entire system on and off.

Table 5–6: Displays and operating elements on the VM

LED Color DescriptionBTB-LED Green Ready for operation

LED Red Mains voltage error

LED Red Intermediate circuit voltage error

LED Red Temperature error

LED Red Internal voltage error

LED Green External 24 V available

Button Reset

INT

EXT

The reset circuit of the VM is error-dominant, i.e. if an error is present, a ready-for-operation mode cannot be forced, even when pressing the reset button constantly.

NOTICE

Damages to components and partsIf the reset button on the VM is pressed during a tightening process, the spindles run out. In an extreme case, this can lead to the bolt heads being torn off. Do not press the reset button during a tightening process!

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5.3.5 SE352 and SE352M control units

LEDs and reset button

There are four LEDs on the front panel of the control unit. They indicate the operating state of tightening channels 1 and 2.

The reset button can be used to reset the hardware.

1 Possible causes: sequence test, nutrunner in bypass

5.3.6 LT35x servo amplifiers

On the front panel of the LT, there are two LEDs to display the operating state and a reset button which, when pressed, initiates a restart of the SE and the LT:


• Constant green light: No error, LT ready for operation

• Green flashing: No error, LT not ready for operation, possible cause:

– Interruption of the emergency OFF signal (emergency OFF has been triggered)

• Constant red light: System error, LT not ready for operation

• Constant orange light (red and green lit constantly at the same time): abort tightening and switch off the LT (sleep mode) as VM is not ready for operation.

Table 5–7: LEDs and reset button on the SE

1 2 Color DescriptionLED Red, flashing System error


Green, flashing Not ready for operation1), but no system error;

4LED Red, flashing Tightening result NOK

Green Tightening result OK

Button Reset

Color DescriptionBTB-LED Green Ready for operation

Green, flashing Not ready for operation

Red LT system error

LED Orange VM not ready for operation

Green Motor is triggered

Button Reset

If the emergency OFF signal is interrupted during a tightening, e.g. by the emergency OFF, the tightening spindle is decelerated actively and tightening is stopped and an error message is sent to the SE. Depending on the tightening process state, a class 4 or a class 3 error is generated. As soon as the emergency OFF signal is present and the contactor is operated, a class 4 error is automatically acknowledged in the LT and the SE. If it is not automatically acknowledged in the LT, the SE must be switched off and switched on again (e.g, with reset on the LT). Class 3 errors can be acknowledged via the ResF control signal or via the error lists in the BS350. Then, a new tightening can be started.

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5.3.7 KE communication unit

On the front panel of the KE, there are two LEDs to display the operating state, as well as a restart button, which, when pressed, initiates a restart of the KE:


Constant green light: No error, KE ready for operation

• Green flashing: No error, KE not ready for operation, possible causes:

– Initialization of the KE during ramp-up

– Sequence test mode selected in the BS350 (see Sequence test (page 177))

– Automatic restore is executed.

• Red flashing: System error, KE not ready for operation

• Constant orange light (red and green lit constantly at the same time): KE not ready for operation, possible causes:

– Specified waiting period before restart not observed

– Firmware faulty.

5.3.8 LED display in operating state

LED displays of the compact system, LTU350/1, LTS350D/LTE350D, VM, SE, LT, and KE when ready for operation are listed in the following tables.

Color DescriptionBTB-LED Green Ready for operation

Green, flashing Not ready for operation


LED Orange Not ready for operation

Red/green, flashing

Data traffic active

Button Restart

Table 5–8: LED displays in operating state

CS351 (when used with ErgoSpin)On

Green (static)

– Green (static) during tightening (servo amplifier or ErgoSpin active)

– Off in waiting mode (no tightening)

FG– Green (static) during tightening (servo amplifier or ErgoSpin active), release

servo amplifier

– Off in waiting mode (no tightening), no release of servo amplifier

Table 5–9: LTU350/1 ready for operation

LTU350/1 (when used with ErgoSpin)Green (static)

– Green (static) during tightening (LTU350/1 or ErgoSpin active)


– Green (static) during tightening (LTU350/1 or ErgoSpin active)


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LED display – other operating states

Other operating states of the VM, SE, LT, and KE components are listed in the following tables.

Table 5–10: LTS350D/LTE350D ready for operation

LTS/LTE (when used with ErgoSpin)Green (static)

– Green (static) during tightening (LTS350D/LTE350D or ErgoSpin active)


Table 5–11: VM, SE, LT and KE ready for operation

VM SE LT KEGreen (static) Green (static) Green (static) Green (static)

Off Green (static)depending on the result of the tightening

– Green (static)

– Off, when the motor is not triggered

Off

Off

4

Information on additional operating states of CS351 and LTU350/1 or LTS350D/LTE350D can be found under Compact system (page 156) and under LTU350 servo amplifier (page 157).

Table 5–12: Display of various operating states via LEDs

States Possible operating state

Error cause Measure

VM350

VM not ready for operation

Undervoltage or overvoltage error

Restore correct input voltage

VM not ready for operation

Temperature error establish permissible ambient tem-perature

SE

Ready for operation NOK tightening check e.g. program parametersand/or tightening case

Sequence testDeselection of tighteningspindles (bypass)

-

Spindle bypass

-Spindle selection and deselection possible under BS350

Configuration error, channel not ready for operation

Incorrect configuration of the tightening channel

Check and correct configuration under BS350

Condition when switched on or starting

Condition when switched on Wait until the tightening system is ready

System error Pinpointing of errors via BS350, SE error list

Restart via KE

KE

4

*

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* With NOK tightening** Data transfer LED flashes during data transfer

Key:

: LED green

: LED red

: Static LED display or off

: LED flashes

Sequence test - -

Condition when switched on or starting

Initialization not yet completed

Wait until initialization is complete

System error Pinpointing of errors via BS350 - KE error list

LT

Motor is triggered No error -

Not ready for operation Emergency OFF signal at the VM is missing

Activation 24V to X4 on VM

System error Pinpointing of errors via BS350, SE/KE error list

Remedy error and reset on LT or acknowledge via BS350

Sleep mode VM not ready for operation Get VM ready for operation

Table 5–12: Display of various operating states via LEDs

States Possible operating state

Error cause Measure

**

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5.4 Error recognition on interface modules

The LEDs at the IMenip, IMenip2, IMmtcp, IMpnio, IMpnio2, IMpdp, IMdev and IMecat interface modules support error recognition during communication via these interfaces. The IM24V interface module does not have an LED.

5.4.1 LEDs on the interface modules

The LEDs at the front of the interface modules display the respective network status.

IMenip

Fig. 5–2: IMenip LED display

Detailed information on the interface modules type IMenip, IMenip2, IMmtcp, IMpnio, IMpnio2, IMpdp, IMdev, IMecat and IM24V can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

1 LED NS (network status)

2 Ethernet interface

3 LINK LED (connection/activity)

4 MS LED (module status)

5 Bolts

Table 5–13: NS

LED display MeaningOff No voltage, not initialized or invalid IP address

Green Online, one or more connections to master established (CIP class 1 or 3), ready for operation

Flashing green Online, no connection to master established

Red Double IP address or blocking error

Flashing red Timeout reached in one or more connections (CIP class1 or 3)

Table 5–14: LINK

LED display MeaningOff No connection, no activity

Green Connection established, ready for operation

Flashing green Connection/activity

41 32

5NS MS

LINK

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IMenip2

Fig. 5–3: IMenip2 LED display

Table 5–15: MS

LED display MeaningOff No voltage or not initialized

Green Module controlled by a scanner during operation

Flashing green Not configured or scanner in idle mode

Red Error (exception error or blocking error)

Flashing red Self-acknowledging error



3 Port 1: LINK LED (connection/activity)


Table 5–16: NS

LED display MeaningOff No voltage or invalid IP address

Green Online, one or more connections to master established (CIP class 1 or 3), ready for operation

Flashing green Online, no connection to master established


Flashing red Timeout reached in one or more connections (CIP class1 or 3)

Table 5–17: LINK


Green Connection (100 Mbits/s) established

Flashing green Activity (100 Mbits/s)

Yellow Connection (10 Mbits/s) established

Flashing yellow Activity (10 Mbits/s)

Table 5–18: MS

LED display MeaningOff No voltage

Green Module controlled by a scanner during operation

Flashing green Not configured or scanner in idle mode

Red Error (exception error or blocking error)

Flashing red Self-acknowledging error. Used configuration deviating from saved configuration.

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IMmtcp

Fig. 5–4: IMmtcp LED display


2 Modbus interface



5 Bolts

Table 5–19: NS

LED display MeaningOff No voltage, not initialized or incorrect/missing IP address

Green Module is active or in idle mode

Flashing green Waiting for connection setup


Flashing red Timeout reached for an active process

Table 5–20: LINK


Green Connection established

Flashing green Connection established, activity

Table 5–21: MS


Green Module ready for operation

Red Exception error, module in "EXCEPTION" status, or blocking error

Flashing red Error (but not an exception error), module continues running in restricted mode

41 32

5NS MS

LINK

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IMpnio

Fig. 5–5: IMpnio LED display


2 PROFINET interface



5 Bolts

Table 5–22: NS

LED display MeaningOff No voltage, not initialized, or no connection to the IO controller

Green Online (RUN), connection established to IO controller, IO controller during operation

Flashing green Online (STOP), connection established to IO controller, IO controller in idle mode

Table 5–23: LINK

LED display MeaningOff No connection, no communication

Green Connection established, no communication

Flashing green Connection established, communication running

Table 5–24: MS

LED display MeaningOff No voltage or not initialized, module in "SETUP" or "NW_INIT" status

Green Module ready for operation, module not in "NW_INIT" status

Flashing green (flashes once)

Diagnostic events available

Flashing green (flashes twice)

Network configuration with module identification running

Red Exception error, module in "EXCEPTION" status

Flashing red (flashes once)

Configuration error

Flashing red (flashes twice)

Error in the IP address or IP address not assigned

Flashing red (flashes three times)

Error in station name or station name not assigned

Flashing red (flashes four times)

Severe internal error

41 32

5NS MS

LINK

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IMpnio2

Fig. 5–6: IMpnio2 LED display



3 Profinet interface (port 1)

4 Profinet interface (port 2)



Table 5–25: NS

LED display MeaningOff No voltage, not initialized, or no connection to the IO controller

Green Online (RUN), connection established to IO controller, IO controller during operation

Flashing green 1x Online (STOP), connection established to IO controller, IO controller in idle mode, IRT synchronization not completed

Flashing green Network configuration with module identification running

Red Exception error (this display is not combined with the red LED MS)

Flashing red (flashes once)

Error in station name or station name not assigned

Flashing red (flashes twice)

Error in the IP address or IP address not assigned

Flashing red (flashes three times)

Severe internal error

Table 5–26: LINK

LED display MeaningOff No connection, no communication

Green Connection established, no communication

Flashing green Connection established, communication running

Table 5–27: MS

LED display MeaningOff No voltage or not initialized, module in "SETUP" or "NW_INIT" status

Green Module ready for operation, module not in "NW_INIT" status

Flashing green (flashes once)

Diagnostic events available

Red Exception error, module in "EXCEPTION" status

Flashing red/green alternating

Firmware update. Do not switch off the module.

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IMpdp

Fig. 5–7: IMpdp LED display

IMdev

Fig. 5–8: IMdev LED display

1 LED OP (operation mode)

2 Interface

3 LED ST (status)

4 Bolts

Table 5–28: OP

LED display MeaningOff No connection to master or no voltage

Green Online, connection to master established, data exchange takes place

Flashing green Online, connection to master established, no data exchange

Flashing red (1 Hz) Parameterization error

Flashing red (2 Hz) PROFIBUS configuration error

Table 5–29: ST



Flashing green Ready for operation, diagnoses available

Red Exception error


2 Interface


4 Bolts

5

5

69

1

1 3

2

4

1 3

2

4NS MS

1 2 3 4 5

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IMecat

Fig. 5–9: IMecat LED display

Table 5–30: NS

LED display MeaningOff After the device has been started and during the test for double MAC IDs; no power or

connection in the network

Green Network available, connection to master established, data exchange takes place

Flashing green (1 Hz) Network available, but no connection to master established; device waits for the master to set up a connection

Red Error in the interface module, critical connection error, device has detected a network error (double MAC ID or bus off)

Flashing red (1 Hz) Communication has failed, severe communication error

Table 5–31: MS

LED display MeaningOff No voltage


Flashing green (1 Hz) Missing or incomplete configuration

Red The IMdev interface module can only be made ready for operation through measures performed by the user.

Flashing red (1 Hz) Error has been self-acknowledged after the IMdev interface module has remedied the cause of the same.

1 Run LED

2 Error LED

3 Interface

4 Interface

Table 5–32: Run LED

LED display MeaningOff Device in status "INIT" (or no voltage)

green, steady light Device in status "OPERATIONAL"

green, flashing Device in status "PRE-OPERATIONAL"

green, single flashing Device in status "SAFE-OPERATIONAL"

red, static Error

Table 5–33: Error LED

LED display MeaningOff No error (or no voltage)

red, flashing Incorrect configuration

red, double flashing Watchdog timeout - timeout of Sync Manager

red, static Exception error, module in "EXCEPTION" status

If the run and error LEDs change their color to red, please contact Rexroth Service.

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5.4.2 Examples of errors on interface modules

If the programmed KE or SE configuration is not identical to the actual configuration (actual equipment), a so-called configuration conflict exists.

Taking the KE as an example, various configuration conflicts are described, which can be similarly applied to the SE.

In the BS350, the error codes created, amongst others, by configuration conflicts are retrieved via:

• System test SE/CS error list …

• System test KE error list …

• System test Tightening cell error list ... (all SE and KE)

The current configuration of the KE is loaded by selecting the System KE configuration menu (Fig. 5–10). A faulty slot is highlighted red in the KE configuration window.

Fig. 5–10: IMpdp module removed

KE configuration errors are also entered into the KE error list, which can be queried in the System test KE error list ... menu (Fig. 5–11).

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Fig. 5–11: KE error list

The configuration conflict is remedied by creating agreement between the programmed configuration and the actual configuration of the KE.

Example Error code 2208

The IMpdp interface module configured and parameterized in the BS350 is not inserted into the KE on a type A slot. The KE configuration window shows the error message highlighted red Module IMpdp removed! (Fig. 5–10, 5–12) and the error code 2208 in the error list:

Remedy:

The missing IMpdp interface module must be inserted into the KE and then the restart button of the KE must be pressed. Or the KE must be re-configured in the BS350 at System KE configuration (without IMpdp). To do this, double-click line A in the configuration window and select none as interface module (Fig. 5–12):

The configuration conflicts listed in the following can occur in all interface modules and slots of the KE!

Table 5–34: Example error code 2208

Error code Error text Error class2208 Module in <A> removed 1

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Fig. 5–12: KE configuration: IMpdp module removed

Select Accept to take over this data into the program. Then, the new configuration file must be sent to

the KE with Data Send or by selecting .

After it has been sent successfully, the error message highlighted red disappears.


The IMpdp interface module not yet configured in the KE is inserted into the previously unoccupied type A slot of the KE. The Module in <A> new error message appears highlighted red in the KE configuration window (Fig. 5–13) and the error code 2205 appears in the error list:

Remedy:

Or the KE must be re-configured in the BS350 at System KE configuration (Figure 5–13). For this, double-click line A in the configuration window and parameterize the IMpdp interface module:

If already configured interface modules are missing on the type B1 and B2 slots, the following error codes are displayed in the error list:


Error code Error text Error class2208 Module in <A> removed 1


Error code Error text Error class2205 Module in <A> new 1

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Fig. 5–13: KE configuration: New module

Selecting Accept, these data are transferred to the program. Then, the new configuration file must be sent

to the KE using Data Send ... or by selecting .

After it has been sent successfully, the error message highlighted red disappears.


The IMpdp interface module is inserted into the KE into the type A slot, on which, however, the IMpnio interface module is configured. The Module in <A> changed error message appears highlighted in red in the KE configuration window and the error code 2211 appears in the error list:

Remedy:

The KE must be re-configured in the BS350 at System KE configuration. The further procedure is identical to the procedure in the example for error code 2205.

If you insert interface modules not yet configured into type A and B1 slots, the following error codes are displayed in the error list:

Table 5–37: Example error codes 2203 and 2205

Error code Error text Error class2203 Module in <B1> new 1

2205 Module in <A> new 1


Error code Error text Error class2211 Module in <A> changed 1

If other interface modules than the ones configured in the BS350 are inserted into the type A and B1 slots, the following error codes are displayed in the error list:

Table 5–39: Example error codes 2209 and 2211

Error code Error text Error class2209 Module in <B1> changed 1

2211 Module in <A> changed 1

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5.5 Error recognition and acknowledgement at the TFT display

You can display the error list on the TFT display with the CS351E-G (IL) and with the CS351S-G (IL). You can find the error lists under:

• System Test Error List

The error list configuration is described using the following example:

Fig. 5–14: CS error list

In the second line of an error entry, the respective error text is output. You can scroll up and down through the error display with the arrow keys on the right-hand edge of the screen.

Class 3 errors can be acknowledged directly via the TFT display: To do this, log in using the button

and then press the Acknowledge button.

Class 1 errors cannot be acknowledged via the TFT display.

A non-acknowledged error is indicated by inverse representation of error code and error class.

In the Error list menu item you can select whether all or only the non-acknowledged errors of the KE should be displayed.

1 Consecutive error number

2 Time

3 Date

4 Error message in clear text

5 Error code

6 Error class

1 2 3 4 5 6

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5.6 Error recognition and acknowledgement with the BS350 operating program

The System test menu is activated when the operating computer and the tightening system are connected and offers a series of diagnosis options. These are described briefly in Table 5–40.

5.6.1 Error lists

In order to quickly and simply pinpoint the cause of an error, the respective data from the tightening system are written in error lists. The tightening system thus demonstrably logs hardware and software errors, configuration errors, malfunctions etc.

Three error lists are available in the BS350. You can find them under:

• System test SE/CS error list …

• System test KE error list … (Fig. 5–15)

• System test Tightening cell error list ... (SE, KE, CS)

Figure 5–15 shows the contents and the configuration of the KE error list.

Table 5–40: Brief description of the diagnosis options

Diagnosis option Brief descriptionSequence test Functional test via BS350 (without PLC), see Sequence test (page 177)

Transducer test Diagnosis of the transducer signals, see Transducer test (page 178)

Tightening channel info General information on the tightening channel, see Tightening channel info (page 178)

KE info General information on the KE, see KE info (page 179)

Tightening cell info Information on the tightening cell (see Tightening cell info (page 179)) concerning:

– Firmware

– Cycle counter

– OK/NOK counter

– Temperature

– Language packs

– Units

– As of version V2.500: Licenses (full license and demo license)

– As of version V2.600: Auto backup/restore

Mass storage ... CF350 mass storage diagnosis, see KE mass storage (page 182)

SE/CS I/O interface … Monitoring of the SE and CS I/O signals, see SE, CS/KE I/O interface (page 182)

KE I/O interface ... Monitoring of the KE I/O signals, see SE, CS/KE I/O interface (page 182)

SE Arcnet bus ... Diagnosis data on the Arcnet SE status and participants, see SE/KE Arcnet bus (page 185)

KE Arcnet bus ... Diagnosis data on the Arcnet KE status and participants, see SE/KE Arcnet bus (page 185)

CAN bus ... Diagnosis data on the CAN bus status and participants, see CAN bus (page 185)

EtherNet ... Test functions for the Ethernet connection, see Ethernet (page 186)

CS field bus data ... Diagnosis data on the field bus in the SE, see Field bus data CS/KE (page 186)

KE field bus data … Diagnosis data on the field bus in the KE, see Field bus data CS/KE (page 186)

Field bus status ... Field bus diagnosis data, see Field bus status (page 187)

Status IPM ... For diagnosis data on the Rexroth IPM Protocol, refer to the "Project planning" documentation of the Rexroth Tightening System 350

Status PLUS For diagnosis data on Rexroth PLUS, refer to the "Project planning" documentation of the Rexroth Tightening System 350

Diagnosis Text protocol for diagnosis of Open Protocol, IPM, HTTP, QDA, PFCS-2Port, PLUS

ID code Data for ID code source

SE/CS error list … Documentation of errors that occurred in the SE/CS, see Error lists (page 175)

KE error list ... Documentation of errors that occurred in the KE, see Error lists (page 175)

Tightening cell error list ... Documentation of errors that occurred in the tightening cell, see Error lists (page 175)

... Description of the sequence trace, see ... FF3/FF4 (internal sequence trace) (page 187)

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No separate explanation for the SE/CS error list and the Tightening cell error list is given here as they are self-explanatory. The SE/CS error list documents the errors in the tightening channel and Tightening cell error list documents the errors within the tightening cell.

Fig. 5–15: Example: KE error list

The following data are listed on the Error list index card:

• l. No.: Consecutive number of the error

• Time/date Indicates date and time of the error.

• Description: Describes the error type

• Code: Error code (internal)

• Class: Error class

• Acknowledged: With class 1 and 4 errors, this indicates whether the error still exists, (0 = errors exists, not acknowledged). With class 3 and 5 errors, this indicates whether an error was confirmed (= acknowledged) (1 = acknowledged, 0 = not acknowledged).

Using Request, the error list is updated if the operating computer and the KE (or SE) are connected (no permanent, automatic update is implemented).

Using Delete, the error list in the respective KE (SE or tightening cell) is deleted via BS350

Using Acknowledge, class 3 and 5 errors are confirmed 1).

In the Error frequency index card (Fig. 5–16), all errors from the respective error list are output sorted according to their frequency.

1 Errors of error class 5 are not displayed at the communication partner for the Open Protocol, the so-called "Open Interface".

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Fig. 5–16: KE error frequency

Underneath the Error frequency list, the error time, number of errors, as well as the error frequency, absolute and in percent, are displayed.

Error list and Error frequency can be sorted via the selection of any column, increasing or decreasing; the selection of the respective column heading starts the sorting; the repeated selection reverses the sorting, increasing or decreasing.

Preset sorting: The

• Error list is sorted as increasing, according to the time (last error at the top) (Fig. 5–15)

• Error frequency is sorted as increasing, according to the number of errors (most frequent error at the top) (Fig. 5–16).

5.6.2 Sequence test

Using the sequence test, see Sequence test via theBS350 on page 97, individual programs or applications are started manually (without control e.g. via a PLC).

As soon as the control bar is activated, the selected KE/SE switches to test mode. As an indication of this, the LED display on the front side of the KE/SE flashes green. In test mode, starting via the control signals of a tightening program or an application is not possible. For normal operation, the test mode must be deactivated again by switching off the sequence test on the PC (LED display of the KE/SE stops flashing).

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5.6.3 Transducer test

Fig. 5–17: Information on MC1 and MC2

With this function, the MC1 and/or MC2 measurement transducers of the selected channel or the ErgoSpin hand-held nutrunner series can be tested (nominal torque, deviation from the zero point, calibration value, and actual values (torque, maximum torque value, angle)). Using Update, the actual values are constantly updated.

5.6.4 Tightening channel info

Fig. 5–18: Information on the tightening channel

Select one of the options (right in Fig. 5–18) to receive information about the selected components (SE, LT, MC) of the tightening channel e.g. type number, firmware, temperature etc. For MC1 or MC2, an Error list can be additionally called up.

Example The transducer test should be used to test the transfer of the measurement transducer signals to the tightening cell. To do this, select System test Transducer test and press the button Update . As soon as a torque is generated at the spindle (e.g. with a socket wrench, torque wrench), the actual transducer values are displayed.

Pressing the Update button puts the tightening channel in the operating state "not ready for operation"!

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5.6.5 KE info

Fig. 5–19: Information on KE

Here, you receive information on the KE components, e. g. type number, firmware, temperature, etc.

5.6.6 Tightening cell info

Information on the entire tightening cell are displayed here (firmware, cycle counter, OK/NOK counter, temperature, language packs, units, backup).

5.6.6.1 Firmware

Fig. 5–20: Current firmware versions within the tightening cell

The current firmware version of all components within the tightening cell is displayed here.

To ensure correct functioning, BS350 must have the same or a higher version than SE/CS and KE. The LT, MC1, and MC2 components can have a firmware version that is different to that of the KE, SE, and CS.

The firmware versions for the above-mentioned components, as well as the service packs and other information can be found at:

• www.boschrexroth.com/tightening

In the BS350, use the Data Firmware update... function to install the firmware to all components.

More information on the installation of firmware updates and service packs on the electronic components can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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5.6.6.2 Cycle counter

Fig. 5–21: Cycle counter within the tightening cell

The number of KE tightening cycles and tightening channels and their components is listed in an overview here.

5.6.6.3 OK/NOK counter

Fig. 5–22: OK/NOK counter within the tightening cell

The counter status of the OK/NOK counters can be viewed here. The affected tightening channel is displayed in Channel. In Program or CntSel0-5, the tightening program or the PLC signal is displayed to which the counter value is assigned. Sum OK indicates the actual value and the set default value for the maximum of OK evaluations. A C next to the actual value indicates that the counter is blocked by a counter value change (PLC signal Ch y.x CntNOK = "high"). A triangle indicates the count direction of the counter. Sum NOK displays values, default values and counter directions according to the NOK values.

5.6.6.4 Temperature

Fig. 5–23: General information on the temperature of the tightening cell

The temperature of all active components of the entire tightening cell is displayed here. The "temperature error" message can be defined further here.

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5.6.6.5 Language packs

Fig. 5–24: Language packs used within the tightening cell

The activated language packs are displayed under language packs.

The language packs and the active languages of KE, SE, and CS are set at System HMI KE configuration and System HMI SE/CS configuration.

5.6.6.6 Tightening cell units

Fig. 5–25: Units used within the tightening cell

The current settings for the torque measurement unit and the gradient calculated from the same are displayed here for:

• the tightening channel configuration (e.g. Nm, Nm/°)

• the tightening program (e.g. Nm, Nm/°).

In the channel configuration, the torque measurement unit is set under System Tightening channel configuration. The tightening programs can be converted to another measurement unit under Edit Convert units.

To avoid unit conflicts, the measurement units shown must be identical within a tightening channel.

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The tightening results are calculated and output with the measurement units indicated in the respective channels.

Below right in the window, a calculation aid is provided to convert the torque into other measurement units.

5.6.7 KE mass storage

The CF350 mass storage can only be diagnosed once the mass storage is inserted in the KE350 or KE350G IL. More information on mass storage diagnosis options can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

5.6.8 SE, CS/KE I/O interface

As an example, the CS/KE I/O interface diagnosis option is described in the following, based on the respective control signals of the CS/KE. The diagnosis option is similarly available with the SE I/O interface for SEs with the respective control signals.

Fig. 5–26: KE I/O signals

With System test KE I/O interface..., a window is opened that displays the input and output signals of the KE (Fig. 5–26). This function is used to monitor the signal exchange between the KE and a partner controller, e.g. a PLC. The interface assignment, the logical as well as physical assignment, and the value of the input and output signals of the KE are indicated.

Check the Update checkbox to constantly receive current data.

Select Request to have the respective current data transferred once.

The times required for writing and reading on the CF350 memory module will increase, if the data volume on the memory module increases. Ageing of the memory module and fragmentation of the file system can result in a slower access as well.

The detailed description of the control signals as well as sequence examples and timing diagrams can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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1 For the sequence test, see Sequence test (page 177).

5.6.8.1 Analysis of an operating state (during a tightening process) via KE I/O signals

Fig. 5–27: KE I/O signals during a tightening process

Description:

• Input signals:

– Tightening cell was activated by the partner controller (FC En = 1)

– Application 1 was selected by the partner controller (FO1 Seq0 = 1)

– Application 1 was started by the partner controller (FO1 Cw = 1)

• Output signals:

– KE is ready for operation (KE Rdy = 1)

– No error in the tightening cell (FC NF = 1)

– Application 1 is active (FO InCy = 1)

– Selection of Application 1 confirmed by KE (FO1 Ack0 = 1).

Example You wish to check whether the control signals specified in the PLC assignment tables and sent to the tightening system actually "arrive" in the tightening system. For this, check the 5–26 Update checkbox shown in Fig.. To test the output signals of the tightening cell, activate the input signals via the PLC or the sequence test1) (e.g. start of a tightening program). If this functions correctly, the respective values switch from 0 to 1.

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5.6.8.2 Analysis of an operating state (after the end of a tightening process) via KE I/O signals

Fig. 5–28: KE I/O signals after the end of a tightening process

Description:

• Input signals:

– Tightening cell was activated by the partner controller (FC En = 1)

– Application 1 was selected by the partner controller (FO1 Seq0 = 1)

• Output signals:

– KE is ready for operation (KE Rdy = 1)

– No error in the tightening cell (FC NF = 1)

– The tightening process is complete (FO CyCmp = 1)

– The tightening process was evaluated with OK (FO Ok = 1)

– Selection of Application 1 confirmed by KE (FO1 Ack0 = 1).

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5.6.9 SE/KE Arcnet bus

Via the SE (or KE) Arcnet bus, control and data signals of the SE (or KE) are sent and received.

Fig. 5–29: Arcnet bus (using SE as an example)

Diagnosis data on the status, participant, network coupler, and test function of the SE (or KE) control Arcnet (SARC) and data Arcnet (DARC) are displayed. Using the diagnosis counter, errors in the SE (or KE) Arcnet bus can be displayed. Delete diagnosis counter sets the counter values to 0.

In the Arcnet participant index card, all participants on the SE (or KE) Arcnet bus are displayed.

5.6.10 CAN bus

The CAN bus is used for communication between control unit, servo amplifier, and measurement transducer.

Fig. 5–30: CAN bus status

Diagnosis data on status and participants in the CAN bus are displayed. Delete diagnosis counter sets the counter values to 0. By selecting Participant, the participants in the CAN bus are determined and information on their registration is given to the controller.

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5.6.11 Ethernet

Fig. 5–31: Ethernet test

To test the connection to the Ethernet, comprehensive functions are available.

5.6.12 Field bus data CS/KE

Fig. 5–32: Field bus data

In this window, the current data traffic via field bus can be viewed. The display can be switched between Clear text and Hexadecimal. By default, the diagnosis window opens with the clear text display of the Send range. On the receipt range index card, the ID code data receipt is displayed in clear text or hexadecimal.

Detailed related information can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

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5.6.13 Field bus status

Fig. 5–33: Field bus status

In this window, the current status of the field bus is displayed. This includes the display of the component type, IP address, subnet mask, gateway, host name, serial number, firmware version, status, error code, exception code, and received data in the value column and hexadecimal in the alternative display column.

Press the F5 button on the keyboard to update the display.

5.6.14 ... FF3/FF4 (internal sequence trace)

Fig. 5–34: Sequence trace FF3

For internal purposes, the KE (FF3) Sequence trace window is called up, which supplies the trace code and description.

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5.6.15 Logging configuration in the BS350

As of version V2.700 of the Rexroth Tightening System 350, settings for the logging can be made.

1. In the operating system, select Extras Options.

2. Select the Logging configuration index card.

Table 5–41: Options - Logging configuration index card

Element DescriptionCard rack field Select the channels for the logging.

Select all Using the button, all available channels are logged.

Deselect all Using the button, all previously selected channels are deselected again.

Reset configuration Click this button to reset the changes you made.

Configuration of file Using the button, you select the logging configuration file which is then sent to the selected channels by means of Send configuration.

Send configuration Using the button, the configuration is sent to the tightening controller.

Restart Press this button to restart the selected channels. The completed change will only take effect afterwards.

Close Click this button to close the Options view.

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5.7 Description of selected errors

Some error examples are described in more detail below.

5.7.1 Error code 100

Contactors are installed in every servo amplifier LT35x, LTU350/1 and LTS350D/LTE350D, to ensure motor release interruption. During operation, these contactors disconnect the EC motor from the servo amplifier and, thus, reduce the risk for the operating personnel.

If the emergency OFF signal is interrupted during tightening (e.g. by emergency OFF), the above error message is generated.

Remedy: Close emergency OFF circuit, so that the 24 V are re-supplied to the PS input (VM: Terminal XDN2).

If a start signal is set (e.g. FO1 Cw) and 24 V are not present at the PS input, or if the PS signal is interrupted during tightening (e.g. by activating the emergency-off), other class 4 and/or class 3 errors are generated along with the error code 100, depending on the status of the tightening process. See also the note in LT35x servo amplifiers (page 159).

Remedy:

• Close emergency OFF circuit, so that the 24 V are re-supplied to the PS input (VM: Terminal XDN2).

• LT reset, to switch off the SE and switch it on again

• Acknowledge class 3 errors via the ResF control signal or via the error lists in the BS350 (see Complete error list (page 194))

5.7.2 Error code 102/206

These errors can have several causes, e.g.:

• Temperature error

• Power supply error

• Defective connection lines or components

Table 5–42: Error code 100

Error code Error text Error class100 LT: Personnel safety missing 4


Table 5–43: Error codes 102 and 206

Error code Error text Error class102 Temperature error motor 4

206 MSEN 1: Supply error 1

The SE cannot recognize whether the connection line or the component itself is defective (here: LT and measurement transducer 1).

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Remedy:

• Observe permissible ambient temperature (note: Check the temperature of the active components in a tightening cell under system test tightening cell info temperature(see Temperature (page 180))

• Select appropriate power supply

• Change defective connection lines and/or components

• Possible cycle time problem, or the nutrunner has reached its performance limit

5.7.3 Error code 204/205

The measurement system (measurement transducer) of the nutrunner is overloaded. A possible cause is e.g. the tightening of an already-tightened bolt with very high speed. Due to the physical properties, the tightening spindle cannot immediately come to a complete standstill, so that during the decrease in speed, the torque increases further for a short time.

Remedy: Decrease speed at the final tightening.

5.7.4 Error code 712/713

The KE no longer communicates with the Arcnet bus or the KE was restarted. After a restart, the KE reboots, so that during the boot phase, the controllers (SE) cannot find a KE. Code 1221 frequently follows error code 712/713.

Remedy: Check the correct position of the KE in the card rack field or the system box. If several card rack fields (BT) or system boxes (SB) are coupled, check if the Arcnet bus lines are connected correctly. Wait until the start phase of the KE is completed.


There is no channel configuration available.

Remedy: The available components must be configured in the BS350; this configuration then has to be sent to the respective channel.


Error code Error text Error class204 MSEN 1: Overload (positive) 3

205 MSEN 1: Overload (negative) 3

For an overload of a redundancy measurement transducer (MSEN 2), the error codes 224/225 are valid respectively.


Error code Error text Error class712 No KE found 4

713 No KE found 4

The cause of error code 712/713 can be pinpointed further by determining all participants in the SE/KE Arcnet bus (see under SE/KE Arcnet bus (page 185)).


Error code Error text Error class1111 Channel configuration missing 4

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5.7.6 Error code 1206/1209

The programmed torque/speed value is greater than the maximum permissible value, which can be checked from the channel configuration and/or from the technical data in the current product catalog.

Remedy: Do not exceed the maximum permissible torque/speed value when programming!


Error code 1221 follows as a result of code 712/713: If the KE does not communicate to the Arcnet bus, it is also unable to transfer results.

Remedy: Remedy errors 712/713.

5.7.8 Error code 23xx/24xx

The LT was reset and subsequently, the SE reboots. The KE now reports e.g. code 2401 for channel 0.1. This means that the KE does not find this channel during the start phase of the SE 0.1.

Remedy: Restart the entire tightening system or restart the KE.


Error code Error text Error class1206 Torque plausibility error 3

1209 Speed plausibility error 3


Error code Error text Error class1221 Error while transferring result to KE 3

Table 5–49: Error codes 23xx and 24xx

Error code Error text Error class23xx Control x.y has logged off from data Arcnet 1

24xx Control x.y has logged off from control Arcnet 1

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5.8 Replacing defective components

For safety reasons, the LT35x/LTU350/1/LTS350D/LTE350D and VM must only be pulled out 10 seconds after the power supply voltage of the card rack field has been switched off, at the earliest.

The following sections provide information on whether hardware and/or software settings must be performed in the BS350 after the replacement of certain components.

5.8.1 VM350

Hardware setting: No

Software setting: No

5.8.2 LT35x

Hardware setting:Yes

• Check jumper setting: Position emergency OFF (emergency OFF) or works setting

5.8.3 LTU350/1 (for ErgoSpin hand-held nutrunner)


• Check protection class plug: only position 2 permissible

• Check protection class plug: Only permissible on slot A

5.8.4 LTS350D/LTE350D


• Check protection class plug: only position 2 permissible

• Check protection class plug: Only permissible on slot A

WARNING

Improper execution of service workIn the event that service works are executed improperly, persons can be injured, components damaged, and the safety of the tightening system jeopardized. Ensure that service works are always implemented by qualified personnel having the required

expert knowledge and tools to implement the necessary works. Rexroth recommends the Rexroth Service for the aforementioned. Service by qualified personnel is particularly essential with safety-relevant works and works on safety-relevant systems.

If you use the components in an existing system as a replacement or an extension, you must install the firmware that is used in the system.



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5.8.5 SE/CS


• Activation of the battery to buffer the actual values in case of a power supply failure.

Software setting:

• Perform "Restore" incl. firmware with BS350 (prior to this, a data backup incl. firmware must be implemented using the backup function). During "Restore", the system checks whether the same firmware is available, after that, the tightening parameters are rewritten. Afterwards, the SE/CS is functional again.

5.8.6 KE


• Activation of the battery to buffer the actual values, time, and error lists in case of a power supply failure.

Software setting:

• Perform "Restore" incl. firmware with BS350 (prior to this, a data backup incl. firmware must be implemented using the backup function). During "Restore", the system checks whether the same firmware is available, after that, the tightening parameters are rewritten. Then, the KE is functional again.

5.8.7 Interface Modules

5.8.7.1 IM24V


• Check jumper setting: setting of internal or external voltage supply for the outputs



The MCE factors at stationary spindles are also stored on backup. Previously determined MCE factors can be overwritten by means of restore - to a different spindle than the one, the backup was created with. Check the MCE factors after restore.

The detailed description of the data storage strategies can be found in the "Project planning" documentation of the Rexroth Tightening System 350.


The detailed description of the data storage strategies can be found in the "Project planning" documentation of the Rexroth Tightening System 350.

Configuration/parameterization must be performed during commissioning at KE configuration/Tightening channel!

The configuration/parameterization of the interface module is saved in the KE/SE so that a software setting is not necessary after a replacement.

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5.8.7.2 IMenip, IMmtcp, IMpnio, IMpdp, IMecat

Hardware setting: No


5.8.7.3 IMdev


• Check jumper setting (Bus power detection): setting in position on or off to check the DeviceNet voltage


5.9 Complete error list

The following tables include possible error codes that possibly appear during the tightening process. As not all codes are assigned or some are used for internal purposes only, the list is incomplete.

WARNING

Improper execution of service workIn the event that service works are executed improperly, persons can be injured, components damaged, and the safety of the tightening system jeopardized. Ensure that service works are always implemented by qualified personnel having the required

expert knowledge and tools to implement the necessary works. Rexroth recommends the Rexroth Service for the aforementioned. Service by qualified personnel is particularly essential with safety-relevant works and works on safety-relevant systems.

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5.9.1 Servo amplifier (error code 100 - 199)

Table 5–50: Servo amplifier (error code 100 - 199)

Error code

Error class

Message Possible cause/consequence Suggested solution

100 4 LT: Emergency OFF has been triggered No motor release

– LTE350D signal not activated

– LTS350D signal not activated

– VM350 PS signal not activated (can only occur when LTU350/1 or LTE350D is in switch position 1)

– LTU350/1 (no current firmware)

– Servo amplifier defective

Switch- emergency OFF signal

Ensure that current firmware is used

Replace component

101 4 LT temperature error Adjust tightening and break time (cycle time)

or

Exchange the servo amplifier

Check fan function

Check ambient temperature

102 4 Temperature error motor Adjust tightening and break time (cycle time)


Check connecting cable/plug-in connector

In connection with errors 111, 1148:

Replace EC motor

103 1 LT: Incompatibility of boot loader/firmware Ensure compatibility of boot loader with firmware

104 1 LT: Protection class error

105 1 LT: Motor contactor does not open! Servo amplifier or connection line for tightening spindle defective


or

Replace connection line for tightening spindle

106 1 LT: Overload Tightening spindle blocked or supply voltage too high

Check tightening spindle

Check supply voltage

107 1 VM: error Check the power supply

Check the intermediate circuit voltage

Check the internal power supply

Check motor-breaker connection

replace VM, if necessary

108 4 Motor/LT configuration error or emergency OFF

Configuration "Emergency OFF VM350 active" and servo amplifier switch position do not correspond

Correct motor and servo amplifier combination or switch position.

109 1 LT: CRC error flash Servo amplifier defective Replace defective component or have the same repaired

110 1 LT: Offset error current measurement Replace servo amplifier or have it repaired

111 4 Motor cable disconnected Check connecting cable/plug-in connector

In connection with errors 102, 1148:

Replace EC motor

112 1 LT: CAN bus error Loose cable connection (plug-in contacts) or ErgoSpin LTU350 defective (batch 883, 884)

Exchange LTU350

Replace spindle connecting line

Replace ErgoSpin

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113 1 LT: RAM error Reboot

If error reoccurs:

Replace servo amplifier or have it repaired

114 1 LT: Driver supply error Replace servo amplifier or have it repaired

115 1 Motor identifier change Install EC motor suitable for size

116 1 LT: CAN job log file error Find and replace faulty component

117 4 LT: CAN bus monitoring error

118 4 LT: CAN bus monitoring error Keep-alive request by the control unit to the servo amplifier outside the admissible time window during the tightening.

Reboot

If error reoccurs:

Find and replace faulty component (cable, servo amplifier, ErgoSpin)

In combination with error 561:

Check jump target 1A in program

119 3 LT: Motor release missing Play at ErgoSpin start switch

Error with switch S2 setting (LTU350/1) Check switch

Check start switch position ErgoSpin in case of use as spindle (must be operated)

Replace servo amplifier or have it repaired

120 1 LT: Defective encoder index track

121 1 LT: Download programming error Check firmware version

Reload firmware if necessary

122 3 Spindle blocked Rotor shaft damaged or defective Replace defective component or have the same repaired

Check rotability of output drive

123 3

from V2.400

4

LT: Align motor Motor blocked or adjustment error Check rotability of output drive

Perform a reset

Find and replace possibly defective component

124 4 LT: Plausibility error motor-breaker loop 2 Check motor-breaker loop (CS351)

Replace component

125 4 LT: Plausibility error motor-breaker loop 1 Check motor-breaker loop (CS351)

Replace component

126 4 LT: Intermediate circuit under-voltage (FI residual-current-operated protected device, fuses)

Check fuses and FI residual-current-operated protected device

No start-up if VM350 is supplied with external 24 V and the power supply is switched off

127 4 LT: End step error (power, temperature, driver)

Reboot device

Replace component

128 4 LT: Motor contactor does not close CS351, LTU350/1 Perform a reset

If error still occurs:

Replace component

or

Replace connection line for tightening spindle

Table 5–50: Servo amplifier (error code 100 - 199)

Error code

Error class


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5.9.2 Measurement transducer (error codes 200 - 299)

Table 5–51: Measurement transducer (error codes 200 - 299)

Error code

Error class


200 3 MSEN 1: Zero point error Measurement transducer defective

Deformed tightening spindle Replace defective component or have

the same repaired

Check freedom of movement of the tightening spindle

201 3 MSEN 1: Calibration error Measurement transducer defective


the same repaired


202 1 MSEN 1: Transducer system error Measurement transducer defective Replace defective component or have the same repaired

203 4 MSEN 1: Temperature error Reduce cycle time


204 3 MSEN 1: Overload (positive) Check tightening program and adjust

Check working range of the tightening spindle

205 3 MSEN 1: Overload (negative) Check tightening program and adjust


206 1 MSEN 1: Supply error Measurement transducer or measurement transducer cable defective

Replace defective component or have the same repaired



208 1 MSEN 1: CRC error Measurement transducer defective Replace defective component or have the same repaired




212 1 MSEN 1: SRAM error Measurement transducer defective Replace defective component or have the same repaired

213 1 MSEN 1: Flash error Measurement transducer defective Replace defective component or have the same repaired


216 1 MSEN 1: Wrong transducer identification Check configuration

Correct channel configuration

220 3 MSEN 2: Zero point error Measurement transducer defective


the same repaired


221 3 MSEN 2: Calibration error Measurement transducer defective


the same repaired


222 1 MSEN 2: Transducer system error Measurement transducer defective Replace defective component or have the same repaired

223 4 MSEN 2: Temperature error Reduce cycle time


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5.9.3 ErgoSpin hand-held nutrunner (error code 300 - 383)

224 3 MSEN 2: Overload (positive) Check tightening program and adjust


225 3 MSEN 2: Overload (negative) Check tightening program and adjust










232 1 MSEN 2: SRAM error Measurement transducer defective Replace defective component or have the same repaired



Table 5–51: Measurement transducer (error codes 200 - 299)

Error code

Error class


Table 5–52: ErgoSpin hand-held nutrunner (error code 300 - 383)

Error code

Error class


300 3 Hand-held nutrunner does not support torque redundancy

Deselect torque redundancy in the operating system

301 3 Hand-held nutrunner does not support angle redundancy

Deselect angle redundancy in the operating system

350 3 ErgoSpin: Zero point error ErgoSpin defective or deformed Replace defective component or have the same repaired

Check freedom of movement of the spindle

351 3 ErgoSpin: Calibration error ErgoSpin defective or deformed Replace defective component or have the same repaired

Check freedom of movement of the spindle

352 1 ErgoSpin: Transducer system error ErgoSpin or connection cable defective In connection with errors 1001, 355, 371:

Replace connection cable

Replace ErgoSpin

353 3 ErgoSpin: Temperature warning level Temperature warning level for handle, motor, or torque converter

Adjust tightening and break time (cycle time)


354 4 ErgoSpin: Temperature error Temperature of handle, motor, or torque converter

Adjust tightening and break time (cycle time)


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355 3 ErgoSpin: Overload Target angle possibly set without torque monitoring

Check tightening program and adjust, if necessary

After tightening, do not use the tightening tool as "spanner" for tightening The evaluation defined after tightening is kept.

Depending on target and nutrunner size, a bolt tightened and defined as OK can be manipulated without affecting the tightening result.

In connection with errors 1001, 355, 371:


356 1 ErgoSpin: Machine body supply Control electronics in the handle defective Replace ErgoSpin

357 1 ErgoSpin: Torque converter supply EPLD error (control electronics): During system boot, the red LED at the ErgoSpin handle does not light up

Replace ErgoSpin or have it repaired

358 1 ErgoSpin: Option module supply Error in the option module Replace ErgoSpin

359 1 ErgoSpin: Input voltage error Control electronics in the handle defective Replace ErgoSpin

360 1 ErgoSpin: CRC boot loader error Boot loader missing Replace ErgoSpin

361 1 ErgoSpin: CRC firmware error Corrupt ErgoSpin firmware Reload firmware

362 1 ErgoSpin: CRC configuration error Corrupt ErgoSpin parameter table Replace ErgoSpin

363 1 ErgoSpin: Calibration table error Corrupt ErgoSpin calibration table Replace ErgoSpin

364 1 ErgoSpin: Machine body access error Defective electronics Replace ErgoSpin

365 1 ErgoSpin: Torque converter access error Defective electronics Replace ErgoSpin

366 1 ErgoSpin: Option module access error Defective electronics Replace ErgoSpin

367 1 ErgoSpin: Memory extension access error Defective electronics Replace ErgoSpin

368 1 ErgoSpin: Display element error Display elements/electronics defective or firmware not up to date

Visually check the display elements

Replace ErgoSpin

Update firmware (install version V0.97AO for ErgoSpin)

369 1 ErgoSpin: Operating element error Display elements/electronics defective or firmware not up to date

Check the operating elements

Replace ErgoSpin

Update firmware (firmware update to 1.00A2.mhx)

370 3 ErgoSpin: Cycle counter overflow Cycle counter restarts with 1

Check maintenance interval

371 3 ErgoSpin: Error counter overflow Too many error entries, e.g. caused by Transducer overload error

MtP repair plant

372 1 ErgoSpin: Invalid combination of modules MtP repair plant

Converter and standard machine are not compatible

373 3 ErgoSpin: Angle compensation measuring range overload

380 5* ErgoSpin: Maintenance interval reached The set limit for the next maintenance of the ErgoSpin hand-held nutrunner has been reached

Provide for ErgoSpin maintenance, e.g. by Rexroth Service


Error code

Error class


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5.9.4 CAN bus (error codes 500 - 699)

381 3 ErgoSpin: Tightening program too large for storing in hand-held nutrunner

Reduce the number of used tightening steps in the tightening program with the operating system and send the tightening program to the ErgoSpin once again

Deactivate "use tightening programs from hand-held nutrunner" in tightening channel configuration

382 3 ErgoSpin: Hand-held nutrunner and SE programs different

Different tightening programs on the ErgoSpin and the controller

Synchronize the control unit tightening program with ErgoSpin or deactivate using tightening programs from ErgoSpin

383 5* ErgoSpin: Planning maintenance The set limit for planning the next maintenance of the ErgoSpin hand-held nutrunner has been reached

Planning maintenance, e.g. by Rexroth Service



Error code

Error class


Table 5–53: CAN bus (error codes 500 -699)

Error code

Error class


500 1 CAN SW driver error Find and replace faulty component

501 1 CAN controller error Find and replace faulty component

502 1 No CAN component found Motor or MWG not connected Check correct positioning of motor line and transducer line


Check jump target 1A in tightening program

503 1 No CAN component log-in Find and replace faulty component

Install servo amplifier

504 1 No CAN component log-in In connection with 505, 506: Control unit board defective

Find and replace faulty component

505 4 CAN bus out of order LTU350 defective (batch 883, 884) or loose cable connection (plug-in contacts) or ErgoSpin defective

In connection with 504, 506: Control unit board defective

Exchange LTU350

Check cables that they are connected correctly and securely


Replace ErgoSpin


Check jump target 1A in tightening program

Check E120 connection cables that they are connected correctly and securely

506 1 CAN bus out of order LTU350 defective (batch 883, 884) or loose cable connection (plug-in contacts) or ErgoSpin defective

In connection with 504, 505: Control unit board defective

Exchange LTU350

Check cables that they are connected correctly and securely


Replace ErgoSpin

507 1 General error transducer 1 Replace primary measurement transducer

508 1 General error transducer 2 Replace redundancy measurement transducer

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510 3 CAN bus not ready CAN bus in "failure" condition Reboot

If error reoccurs:

Find and replace faulty component (cable, servo amplifier, ErgoSpin)

511 3 Primary/redundancy transducer assignment error

Adjust channel configuration

Check measurement transducer cable

512 3 Primary transducer not ready Replace defective components, e. g. measurement transducer

513 3 Redundancy transducer not ready Replace defective components, e. g. measurement transducer

514 3 LT tightening job error Replace defective components, e. g. measurement transducer

515 3 Tran 1 tightening job error Replace defective components, e. g. measurement transducer

516 3 Tran 2 tightening job error Replace defective components, e. g. measurement transducer

517 3 Zero point error transducer 1 Tightening spindle deformed or component outside the calibration

Check the zero point using the "Transducer test" diagnosis

If OK:

Adjust process for deformed tightening spindle.

If NOK:

Recalibrate or replace component

518 3 Calibration error transducer 1 Component outside of the calibration Recalibrate or replace component

519 3 Zero point error transducer 2 Tightening spindle deformed or component outside the calibration

Check the zero point using the "Transducer test" diagnosis

If OK:

Adjust process for deformed tightening spindle.

If NOK:

Recalibrate or replace component

520 3 Calibration error transducer 2 Component outside of the calibration Recalibrate or replace component

521 3 Tightening job log file error Acknowledge in BS350

Replace defective component

522 1 Start tightening error Restart system

If error reoccurs:


523 1 End tightening error Restart system

If error reoccurs:


524 3 Tightening job log file error Acknowledge in BS350


525 1 Unknown CAN component type Find and replace faulty component

526 4 Unknown CAN message Different firmware versions Ensure compliant firmware versions

527 4 General CAN job log file error Unknown job log file error due to different firmware versions

Ensure compliant firmware versions

528 1 Unknown error CAN Inform qualified personnel, e. g. the Rexroth Service

529 1 Angle overflow angle compensation Primary


Error code

Error class


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530 3 No primary transducer data Measurement transducer very likely defective

Perform tightening channel reset and then continue tightening

Replace defective component, if necessary, e.g. measurement transducer

531 3 No redundancy transducer data Measurement transducer very likely defective



532 3 Job log file error primary transducer Too much data from primary measurement transducer



533 3 Job log file error redundancy transducer Too much data from redundancy measurement transducer



534 3 Job log file error primary transducer Too many timeouts from primary measurement transducer



535 3 Job log file error redundancy transducer Too much data from redundancy measurement transducer



536 3 Timeout tightening program System utilization Acknowledge error

537 3 Timeout tightening program

538 3 Angle overflow primary transducer More than 180 rotations Optimize tightening process

539 3 Angle overflow redundancy transducer More than 180 rotations Optimize tightening process

540 1 Firmware LT missing Load firmware

541 1 Transducer 1 firmware missing

542 3 Transducer 2 firmware missing

545 4 LT job log file error Service response during tightening Inform qualified personnel, e. g. the Rexroth Service

546 3 Job log file error transducer 1


550 4 LT job log file error Service response without request Possible, in connection with FC109 after error acknowledgement at the power supply module

Inform qualified personnel, e. g. the Rexroth Service



555 4 LT job log file error Serial number different from last request Inform qualified personnel, e. g. the Rexroth Service




Error code

Error class


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560 4 LT job log file error No service mode response on request:

In connection with errors 560, 1123, 1145, there is an error that is described in the TIe151 (timing problem emergency-off) - motor board failure

Check cable connections for correct positioning

Connection problem: Replace motor connection line or transducer line



565 4 LT job log file error Device responds with error code Inform qualified personnel, e. g. the Rexroth Service



570 4 LT job log file error Error while writing values Inform qualified personnel, e. g. the Rexroth Service



575 4 LT job log file error Inform qualified personnel, e. g. the Rexroth Service



580 4 LT job log file error Inform qualified personnel, e. g. the Rexroth Service



585 4 LT: Login error Inform qualified personnel, e. g. the Rexroth Service

586 1 Tran1: Login error


590 4 LT: Double login Inform qualified personnel, e. g. the Rexroth Service

591 1 Tran1: Double login

592 1 Tran2: Double login

595 4 LT: No login permission Inform qualified personnel, e. g. the Rexroth Service

596 3 Tran1: No login permission
















Error code

Error class


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5.9.5 ARCNET (error codes 700 - 799)









635 4 LT: No measurement values in S mode Inform qualified personnel, e. g. the Rexroth Service

636 3 Tran1: No measurement values in S mode

637 3 Tran2: No measurement values in S mode


Error code

Error class


Table 5–54: ARCNET (error codes 700 -799)

Error code

Error class


700/701

1 Initialization error Arcnet Arcnet data Find and replace defective component, e. g. network coupler

702/703

1 Error Arcnet SW driver Arcnet data Find and replace defective component, e. g. network coupler

704/705

1 Error Arcnet controller Arcnet data Find and replace defective component, e. g. network coupler

706/707

1 Error Arcnet SW driver Arcnet data

(Unused semaphore error) Find and replace defective component,

e. g. network coupler

708/709

1 Error Arcnet SW driver Arcnet data

(Semaphore error Int. RAM) Find and replace defective component,

e. g. network coupler

710/711

1 Double Arcnet address Arcnet data

Double assignment of node ID Find and replace defective component,

e.g. control unit or communication unit

Check address selection switches for identical addresses

712/713

4 No KE found Arcnet data Wait for communication unit to be ready for operation after reset

In single-channel operation:

Adjust configuration

714/715

1 Error Arcnet SW driver Arcnet data Reboot communication unit

or

Reduce communication unit load

716/717

4 Data Arcnet failure Arcnet data Check plug-in connection and line routing

If a channel is marked with -1:

Replace supply module

718/719

4 No Arcnet participants Arcnet data

In single-channel operation, the option "single operation without KE" is not selected in the configuration (no checkmark)

Check connection to Arcnet participant

In single-channel operation:

Adjust configuration

BS350 | 3 608 870 B05/2019-03


720/721

3 Transmission error Arcnet data Find and replace defective component, e. g. network coupler

Check connection to the Arcnet participant (flat ribbon cable, connector)

If a master/slave networking is concerned:

Check NK350S network coupler

Check the NK350 voltage supply on the power supply module

Check flat ribbon cable and connector of the Arcnet cable

Check grounding of the rack

Check driver component on controller

722/723

1 Controller has logged off Arcnet data

After controller restart / reset

No action required

724/725

1 Invalid Arcnet address Arcnet data Find and replace defective component, e.g. power supply module or control unit

Check switch position at the rack

Check flat ribbon cable between back plane and NK350(S)


726/727

3 Error Arcnet SW driver Arcnet data Find and replace defective component, e.g. power supply module or control unit

If error occurs permanently after reboot:

Exchange controller

728/729

1 Error Arcnet controller Arcnet data

(Unused error during verification) Find and replace defective

component, e.g. power supply module or control unit


Exchange controller

730/731

1 Error Arcnet controller Arcnet data

(Unused error during RAM test) Find and replace defective



Exchange controller

732/733

1 Double error while sending Arcnet data

Defective control unit Find and replace defective









Error code

Error class


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734/735

3 Transmission aborted Arcnet data Find and replace defective component, e.g. power supply module or control unit







736/737

3 Unknown message Arcnet data Find and replace defective component, e.g. power supply module or control unit






738/739

3 Arcnet not ready Arcnet data Find and replace defective component, e.g. power supply module or control unit

Check connection to the Arcnet participant (flat ribbon cable, connector)






If no hardware problem was identified, this could be a software problem:

Load current software patch

740/741

3 Arcnet pack too long Arcnet data

Data amount per data packet too large Check lines and network couplers






742/743

3 Transmission error (FBE) Arcnet data

– No receipt buffer available (control unit entry, if the communication unit has no buffer and vise versa)

– System utilization

– Failures on Arcnet

Acknowledge in BS350

Troubleshoot any errors that follow

744 3 Sending canceled (data bus / EXCNAK) Arcnet data

Transmission attempts on controller level (hardware) exceeded

Check whether all control unit/ communication units can be contacted

Reboot component, if necessary


Error code

Error class


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745 3 Sending canceled (control bus / EXCNAK)

746 3 Data Arcnet package (RX) too long 3

747 3 Control Arcnet package (RX) too long

748 3 Data package (RX) with 0 bytes at data Arcnet

749 3 Data package (RX) with 0 bytes at control Arcnet

750 3 Arcnet job log file error Arcnet data

Query of service messages between components defective or interrupted (service job log file error)

Check lines and network couplers




751 3 Arcnet job log file error Arcnet control

Query of service messages between components defective or interrupted (timeout during service query)






Query of service messages between components defective or interrupted (read parameter error)






Query of service messages between components defective or interrupted (write parameter error)






Query of service messages between components defective or interrupted (verification error)






Query of service messages between components defective or interrupted (command execution error)





757 3 Block transfer error Arcnet control Find and replace defective component, e. g. network coupler






Error code

Error class


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5.9.6 Interface module (error codes 800 - 899)

758 3 Timeout block transfer Arcnet data Check Arcnet counters RECON, NNID, and TX error.

If the values of these counters are high or increase even without tightening, then one or more network couplers could be defective

– Find and replace defective component, e. g. network coupler





759 3 Timeout block transfer Arcnet control Check Arcnet counters RECON, NNID, and TX error.

If the values of these counters are high or increase even without tightening, then one or more network couplers could be defective

– Find and replace defective component, e. g. network coupler





760 3 Block transfer error Arcnet data Find and replace defective component, e. g. network coupler





761 4 NK350 supply voltage missing! Arcnet control

– Rack with KE350 and NK350S not switched on

– Bus cable interrupted

– NK350S defective

Check rack

Check network connections

Check NK350S

check the voltage rate to the bus plug, if necessary

The pin assignment at the bus plug (XDAcx) can be found in the NK350S project planning manual


Error code

Error class


Table 5–55: Interface module (error codes 800 -899)

Error code

Error class


800 1 Unknown module in <A> Module is not supported Use Rexroth modules

Check correct installation

801 4 Driver error in <A> Driver error in module Check module in slot

Implement system reset

Replace module

802 1 Driver number in <A> invalid Driver number incorrect Implement system reset

Use Rexroth modules

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5.9.7 Update CAN components (error code 900 - 999)

803 1 Invalid number of I/O in <A> Check field bus configuration

Configuration of PLC assignment table

804 1 Driver exception in <A> Exception in module driver Check module in slot

Implement system reset

805 1 Field bus configuration error Module reports configuration error Check field bus configuration

806 4 Field bus <-> Master interrupted Ensure master connection

807 1 Firmware download to HMS module failed Check firmware version

Reload firmware

820 3 IMpdp: Number of send/receive errors Not enough storage space reserved on module

Check field bus configuration

835 4 IMdev: DeviceNet master not available Ensure master connection

836 3 IMdev: Serial number error Read in error of serial number Implement system reset

Replace module

890 4 IM24V: 24 V power supply missing External voltage supply missing Ensure voltage supply

891 4 IM24V: Fuse has been triggered 24 V fuse has been triggered externally Check power supply

Replace IM24V, if necessary

892 4 IM24V: Short circuit or overload Short circuit or overload of outputs Remove overload

Replace IM24V, if necessary

894 1 FPGA version is not supported by IM24V! Check FPGA version

Table 5–55: Interface module (error codes 800 -899)

Error code

Error class


Table 5–56: Update CAN components (error code 900 - 999)

Error code

Error class


900 1 FW download LT error Firmware files defective (buffer overflow) Download suitable firmware files from the internet

901 1 FW download transducer 1 error


905 1 FW file LT error Firmware files defective (CRC error in hex file)

Download suitable firmware files from the internet



910 1 FW download LT error Firmware files defective (timeout) Download suitable firmware files from the internet



915 1 FW file LT error Firmware files defective (line length data error)




920 1 FW file LT error Firmware files defective (no ASCII characters)




925 1 FW download LT error Firmware files defective (wrong device firmware)




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5.9.8 Control unit (error codes 1000 - 1057)

930 1 FW download LT error Firmware files defective (wrong HW revision)




935 1 FW download LT error Firmware files defective (flash write error) Download suitable firmware files from the internet



940 1 FW download LT error Firmware files defective (delete error) Download suitable firmware files from the internet



945 1 FW file LT error Firmware files defective (data read or write error)




950 1 FW file LT error Firmware files defective (CRC entire file error).




955 1 Error FW file format LT Firmware files defective (unknown record) Download suitable firmware files from the internet



960 1 Firmware and FPGA0 version incompatible

Update firmware version (or FPGA0 version)

961 1 Firmware and FPGA1 version incompatible

Update firmware version (or FPGA1 version)

962 1 Firmware and 1st MENMON version incompatible

Update only possible with special software

Send in controller

963 1 Firmware and 2nd MENMON version incompatible

Update via operating system

964 1 Internal error: FPGA or MENMON string in brcversion.c too long


965 1 Cannot read FPGA version.

Table 5–56: Update CAN components (error code 900 - 999)

Error code

Error class


Table 5–57: Control unit (error codes 1000 - 1057)

Error code

Error class


1000 3 Faulty error list See also error code 936 Acknowledge error and delete from the error list, if necessary

Check battery on controller


1001 3 Error list overflow Too many error entries in error list In connection with errors 1001, 355, 371:


1002 1 Error flash management Exchange controller

1003 1 File access error Exchange controller

1004 1 Delete file error Exchange controller

1005 1 Write file error Exchange controller

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1006 1 Unknown HW identifier Exchange controller

1007 1 SE initialization error Exchange controller

1008 1 Internal error serial interface Exchange controller

1009 1 Internal error serial interface Exchange controller

1010 3 KE / SE / CS temperature warning level Ambient temperature (e. g. in the control cabinet) exceeds the admissible maximum value for the temperature

Ensure that the ambient temperature according to the specifications (technical data) is complied with, e.g. by means of suitable cooling

1011 4 KE / SE / CS temperature error Ambient temperature (e. g. in the control cabinet) exceeds the admissible maximum value for the temperature

Ensure that the ambient temperature according to the specifications (technical data) is complied with, e.g. by means of suitable cooling

1012 3 Battery empty / not inserted F376 separation paper

Battery empty Remove separation paper

Insert new battery

Switch off battery monitoring

1013 1 Printer initialization Initialization error on printer output Check interface

Switch tightening system on/off.

1014 1 Serial server error Switch tightening system on/off.

1015 3 Error while compressing data

1016 3 Error while decompressing data

1017 4 Incompatible KE FW Check firmware version, adjust, if necessary

1018 3 BS350 program < V1.250 Operating system version not up to date, firmware versions are not compatible

Use firmware versions that are compatible with the operating system

1019 3 CRC error results storage Delete ErgoSpin configuration and then generate new one

Delete available data in the ErgoSpin

Check battery

1020 3 Number of graph points outside of the stipulated range

Check tightening program

Check configuration of graph memory

1021 3 Graph resolution outside of the stipulated range


Check configuration of graph memory

1022 1 Power supply error

1023 3 Error number of graphs for saving on SE Check operating system version and adjust, if necessary

Check firmware versions and adjust, if necessary

1024 3 CRC error graph memory After battery change:

Acknowledge error

Check battery

Data Delete SE/CS Stored graphs data

1025 3 Signature error in configuration saving to SE

Generate new configuration


1026 3 CRC error in configuration of saving to SE Re-create graph memory configuration on the controller

After battery change:

Acknowledge error

Re-create graph memory configuration on the controller


Error code

Error class


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1027 3 CRC error in graph memory administration After battery change:

Acknowledge error

Data Delete SE/CS Stored graphs configuration

1028 3 Signature error in graph memory administration

Data Delete SE/CS Stored graphs configuration

1029 3 Data consistency error flash SRAM (configuration/administration)


Check battery

1030 3 Results storage cannot be initialized in SRAM


Check battery

If the error reoccurs, the SRAM is probably defective:


1031 3 CRC error flash channel name SE Inconsistency in the file system. Switch tightening system on/off.

Re-configure tightening system, if necessary

If more flash errors occur, the flash is probably defective:


1032 3 Graph memory problem on SE Graph memory test across allocated range

Generate new graph memory configuration

If the error reoccurs.


1033 3 CRC error log book Exchanging the battery

Flash defective

After battery change:

Acknowledge error

1034 3 Redundancy transducer for graph memory missing

Check configuration of graph memory and compare with spindle configuration

1035 3 Timeout during access to the results storage in SRAM

Switch controller off/on

1036 1 Start signal configuration error This error is no longer used in the firmware Inform qualified personnel, e. g. the Rexroth Service

1037 1 Program selection via HMI not configured incompletely

Not all program selection bits assigned in tightening controller (PLC)

Correct PLC assignment table, i.e. assign all program bits to the HMI

1038 4 Language pack configuration error Update language packs

1039 3 Restart with watch dog! Inform qualified personnel, e. g. the Rexroth Service

1040 4 Permissible temperature too low Switch off device and acclimatize

1041 4 Emergency OFF at start tightening! Check motor-breaker loop

1042 4 Tightening aborted due to Emergency-OFF!

Check motor-breaker loop

1043 3 POST messages cannot be read. POST test (hardware test) on the component is possibly deactivated.


1044 1 POST NAND flash test failed. NAND memory defective Replace defective component

1045 3 POST- SDRAM test failed. SDRAM memory defective Replace defective component


Error code

Error class


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5.9.9 Channel configuration (error code 1100 - 1167)

1046 3 POST- RTC test- Check system time. Check battery

Reset time

1047 1 POST- EEPROM test failed. Hardware defective (memory) Replace defective component

1048 3 POST- ETHER0 test failed. Replace defective component

1049 3 POST- TOUCH test failed. Touch possibly disconnected Check touch in the firmware


1050 3 No KE version identifier received Incorrect firmware version

No version string contained Use right compatible firmware version

1051 5 Error list has been re-created Error list has been deleted (time of deletion has been documented)

No action required as system error; the entry is used for documentation purposes.

1055 1 Cannot generate diagnosis structure in memory

Memory issues Switch tightening system on/off

1056 5 Note: Logging activated! Logging has already been activated. Inform qualified personnel, e.g. the Rexroth Service if error diagnosis is no longer to be carried out.

1057 5 Note: Active path file for debugging available!


Error code

Error class


Table 5–58: Channel configuration (error code 1100 - 1167)

Error code

Error class


1100 1 Channel configuration error Incorrect control unit configuration Check control unit configuration and generate new one, if necessary

1101 4 Power electronics not available – The servo amplifier is defective

– The servo amplifier is not recognized Install servo amplifier


Exchange card rack field or system box

1102 1 Automatic restart due to change to single/2-channel operation

Function as note for the customer (an control unit directly next to a communication unit is automatically brought into single-channel operation)

1103 1 Channel configuration error Incorrect control unit configuration Check control unit configuration and generate new one

Replace control unit, if necessary

1104 4 Channel configuration error Incorrect control unit configuration Check control unit configuration and generate new one

Replace control unit, if necessary

1105 1 Channel configuration data error The transmission values i with regard to torque and/or angle are not plausible

Check and correct the transmission values i of the mechanical components in the channel configuration

1106 1 Channel configuration data error The efficiency values eta are wrong or not plausible

Check and correct the efficiency values eta of the mechanical components in the channel configuration

1109 3 Channel configuration reading error Delete configuration and then generate new one



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1110 1 Channel configuration error Incorrect control unit configuration Delete configuration and then generate new one



1111 4 Channel configuration missing New ErgoSpin, channel configuration missing or incorrect control unit configuration



Correct channel configuration

1112 1 BS350 channel configuration error The format code sent by the BS350 as part of the configuration files is not accepted by the firmware

Ensure that the BS350 version is compatible with the firmware version

1113 3 Spindle: Automatic configuration is not supported by measurement transducer

Auto configuration was deactivated, transducer does not have a memory device to store the spindle configuration.

Use new DMC measurement transducer.

1114 1 Electronic nameplate controller missing Send in device

1115 1 Read signature error from channel configuration

Generate a new configuration and delete the old one in advance, if applicable


1116 1 CRC error while reading from channel configuration

Generate a new configuration and delete the old one in advance, if applicable


1117 3 Q code flash signature error Delete Q code table and then generate new one


1118 1 Q Code CRC - Flash error Delete Q code table and then generate new one


1119 1 Electronic nameplate module missing No FBLOCK found in module Send in device

1120 1 New LT added Hardware configuration was changed Check channel configuration and correct, if necessary. As of version V2.700 of the Rexroth Tightening System, FC 1120 is no longer displayed. An identified conflict in the transducer assignment will be automatically remedied.

1121 1 New transducer 1 added Hardware configuration was changed Check channel configuration and correct, if necessary

1122 1 New transducer 2 added Hardware configuration was changed Check channel configuration and correct, if necessary

1123 4 LT missing – In connection with error codes 560:

Possible timing problem "emergency-off" (description see Technical Information TIe_151)

– In connection with error codes 1124, 1125, 504, 560, 532:

Possible error at power supply module VM310 (coupler relay PS damaged)

Check transducer

Check cables and connections and replace, if necessary



Error code

Error class


BS350 | 3 608 870 B05/2019-03


1124 4 Transducer 1 missing – In connection with error codes 560, 1123:

Possible timing problem (description see Technical Information TIe_151)

– In connection with error codes 1125, 504, 560, 532:


Check transducer



1125 4 Transducer 2 missing – In connection with error codes 560, 1123:

Possible timing problem (description see Technical Information TIe_151)

– In connection with error codes 1124, 504, 560, 532:


Check transducer



1126 1 LT type has been changed New component does not correspond to the previous configuration

Correct configuration

Install suitable component

1127 1 Transducer 1 type has been changed New component does not correspond to the previous configuration



1128 1 Transducer 2 type has been changed New component does not correspond to the previous configuration



1129 1 LT serial no. has been changed In the configuration, the "Serial number monitoring" option is activated and a component has been exchanged

Update the serial number in the configuration

1130 1 Serial no. transducer 1 has been changed In the configuration, the "Serial number monitoring" option is activated and a component has been exchanged


1131 1 Serial no. transducer 2 has been changed In the configuration, the "Serial number monitoring" option is activated and a component has been exchanged


1132 1 New hand-held nutrunner added New component does not correspond to the previous configuration



1133 4 Hand-held nutrunner removed Connect hand-held nutrunner

1134 4 Hand-held nutrunner has been modified New component does not correspond to the previous configuration



1135 1 Controller is new Correct configuration

Install correct component

1136 4 Controller has been removed Inform qualified personnel, e. g. the Rexroth Service

1137 1 Controller has been changed Correct configuration


1138 1 Serial no. controller has been changed Check configuration



1145 1 LT for motor check is missing Install suitable component

1146 1 Motor EC30X is new Correct configuration


1147 4 Motor EC30X has been removed Connect tightening spindle

1148 1 Motor EC30X has been changed Check configuration




Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.10 PLC assignment table (error codes 1180 - 1182)

1149 4 LT unknown Inform qualified personnel, e. g. the Rexroth Service

1150 4 ErgoSpin is not supported by this controller!


1152 4 New output drive added Correct configuration


1153 4 Output drive removed Check channel configuration and correct, if necessary

1154 4 Output drive has been modified Check channel configuration and correct, if necessary

1155 1 Output drive serial no. has been changed Check channel configuration and correct, if necessary

1156 1 Output drive transmission has been changed

Check channel configuration (output drive transmission) and correct, if necessary

1157 1 Hand-held nutrunner serial no. has been changed

An identical hand-held nutrunner with different serial number has been connected

Check channel configuration and correct, if necessary

1158 5 Electronic nameplate display unit missing Send in device

1159 1 Configuration error motor-breaker servo amplifier

Configuration and position of jumper do not correspond

Check jumper position in servo amplifier

1160 1 LT: Motor-breaker jumper not inserted or defective

Check jumper position in servo amplifier

1161 1 CC-ErgoSpin or flat output drive is not supported by LT-FW -> FW update

Incorrect combination of controller firmware and servo amplifier firmware


1162 1 CC-ErgoSpin is not supported! Please update controller firmware

Update firmware

1163 4 Function is not supported! Please update ErgoSpin firmware

When using ErgoSpin hand-held nutrunners with open flat output drive without safety catch, a special firmware is required. See Special features of ErgoSpin with open flat output drive without safety catch (page 141)

Carry out a special firmware update to esfw-22B2.mhx

1166 5 Spindle: Planning maintenance The set limit for planning the next maintenance of the tightening spindle has been reached

Planning maintenance, e.g. by Rexroth Service

1167 5 Spindle: Maintenance necessary! The set limit for the next maintenance of the tightening spindle has been reached

Provide for tightening spindle maintenance, e.g. by Rexroth Service


Error code

Error class


Table 5–59: PLC assignment table (error codes 1180 - 1182)

Error code

Error class


1180 1 PLC table too large Adjust PLC assignment table

1181 1 Transmission error: PLC signal No longer used in the firmware Inform qualified personnel, e. g. the Rexroth Service

1182 1 Transmission error: PLC signal image No longer used in the firmware Inform qualified personnel, e. g. the Rexroth Service

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5.9.11 Change engineering units (error codes 1190 - 1191)

5.9.12 Sequence control (error codes 1200 - 1246)

Table 5–60: Change engineering units (error codes 1190 - 1191)

Error code

Error class


1190 1 Conflict of units programs/configuration Check units in the spindle configuration and the tightening programs and correct, if necessary

1191 3 Conflict of units tightening programs/tightening programs

Check units in the spindle configuration and the tightening programs and correct, if necessary

Table 5–61: Sequence control (error codes 1200 - 1246)

Error code

Error class


1200 1 Sequence control error Undefined status in sequence control Inform qualified personnel, e. g. the Rexroth Service

1201 1 Tightening program administration error 1202 3 CRC error tightening program Delete all tightening programs and

then generate new ones

1203 3 Tightening program not available Check PLC program selection and correct, if necessary

or

Generate tightening program

3 Tightening program BMW RPA mode not available

1204 3 Unknown command The firmware version is not compatible with the available tightening programs

BS300 V1.500 Rel. access to SE with V1.400:

– Programs can be converted without error message and returned to the control unit (without warning from BS)

– Error code 1204 appears with first start

Generate a tightening program compatible with the firmware and BS

1205 3 Primary transducer missing Check measurement transducer cable

or

Connect measurement transducer

1206 3 Torque plausibility error Permissible torque exceeded Correct values in tightening program



1209 3 Speed plausibility error Permissible speed exceeded Correct values in tightening program

1210 3 Gradient evaluation using the LT as primary transducer not possible

Connect measurement transducer as primary measurement transducer

Deselect gradient monitoring

1211 1 Internal memory error Memory cannot be requested Inform qualified personnel, e. g. the Rexroth Service

Update firmware, if necessary

1212 3 Torque plausibility error Check threshold torque for angle counting, gradient, stick slip

Correct values in tightening program

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1213 1 Sequence control error Error in tightening program Check tightening program

Flat output drive without safety catch: Using the GO Ref or GO Open target function without correct flat output drive configuration.

Check flat output drive configuration, see Channel configuration of open flat output drives (page 70)

1214 3 Results output error Check connection cables

If the error occurs again:

Switch the complete system off/on.

1215 3 Torque redundancy error Set tolerance value exceeded Check measurement transducer and adapter

Re-calibrate measurement transducer, if necessary

or

Check tolerance values, reset, if necessary

or

Enter correction factor

1216 3 Angle redundancy error Set tolerance value exceeded Check measurement transducer and adapter

Re-calibrate measurement transducer, if necessary

or

Check tolerance values, reset, if necessary

1217 3 Torque threshold redundancy error Torque thresholdRed > maximum permissible spindle torque

In the tightening program, set the torque thresholdRed to a value smaller than the admissible torque

1218 3 Redundancy suppression time error Redundancy suppression time Start-up suppression time

In the tightening program, set the redundancy suppression time to a value greater than the start-up suppression time

1219 3 Speed error – Wrong spindle configuration entry

– Gear transmission

– Connection cable union nuts loose

– Problem on one of the plug-in connections e. g. contacts bent, cable pulled out

– Connection cable for tightening spindle defective

– Motor defective

– Angle of turn transducer on rotor shaft damaged/defective

– in connection with LTU350/1 (channel ready - speed error after start)

– Can occur in connection with motor OFF

Check spindle configuration on gearbox transmission

Check union nuts

Check cables and contacts

Check connection cable for tightening spindle

Send hand-held nutrunner to Murrhardt for inspection

Check fuses in LTU350/1, replace LTU350/1, if necessary, and send to Murrhardt for inspection

Reduce moment of inertia e.g. BG5 VUK with ErgoStart

1220 3 Redundancy transducer missing Connect redundancy measurement transducer

or

Adjust channel configuration

1221 3 Error while transferring result to KE Check Arcnet counters RECON, NNID, and TX error.

If these are high or increase even without tightening, then one or more network couplers could be defective


Error code

Error class


BS350 | 3 608 870 B05/2019-03


1222 3 Reference to preliminary step is missing (relative torque monitoring)

Adjust tightening program

1223 3 Started program is 0>No>98 Check PLC program selection and correct, if necessary

1224 3 Plausibility error Correct values in tightening program

1225 3 Torque plausibility Permissible torque exceeded Correct values in tightening program

1226 3 T angle threshold plausibility Correct values in tightening program

1227 3 T gradient threshold plausibility Correct values in tightening program

1228 3 Plausibility: Torque graph threshold Correct values in tightening program

1229 3 Gradient filtering error Adjust filter interval in the start step according to the table (see documentation)

1230 3 Tightening program incomplete Check tightening program and create a new one, if necessary

1231 3 Spin direction change for relative torque monitoring

The step with the relative torque monitoring and its previous step must have the same direction of rotation

1232 3 Selected OK/NOK counter is not 0>No>98

Check PLC program/counter record selection and correct, if necessary

1233 3 Error while initializing the docu buffers – Software error

– Possibly, there are further error entries

– The tightening program is possibly not compliant with the firmware version


1234 3 Angle overflow error (default values) Check default value settings

1235 3 Sequence control: Angle redundancy value error

1236 3 Sequence control: Torque redundancy value error

1237 3 Sequence control: coastdown monitoring redundancy error

Safety shutdown with redundancy evaluation in costdown


1238 3 Sequence control: No measurement values

1239 3 Sequence control: CAN access error – No measurement values

– Request of the CAN component failed Acknowledge error

1240 3 Sequence control: Intit ZF input plausibility error

Error in tightening program Generate new target function Input

1241 3 Sequence control: ZF input plausibility error

Error in tightening program Generate new target function Input

1242 3 Sequence control: Minimum plausibility test error

Tightening program error:

– Plausibility error for threshold value lower torque


1243 3 Maximum permissible number of tightening steps reached!

Reduce number of tightening steps to max. number


Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.13 Communication unit (error codes 2000 - 2099)

1244 5 Sum counter blocked Sum counter is not reset.

If the FC has been entered in the error list, only the time stamp will be adjusted the next time the FC occurs. If a different FC occurs in between, FC 1244 will be entered in the error list once again.

1245 3 ZF GO Open: Open position referencing (ZF GO Ref) not executed

– Flat output drive open position was not executed or the hand-held nutrunner was changed.

– Potential program link is canceled.

refer to the "Project planning" documentation of the Rexroth Tightening System 350

1246 3 ErgoSpin: No measurement values for angle compensation

– Angle compensation was activated in the channel configuration, however, no values from the nutrunner are received by the SE during tightening.

Replace ErgoSpin against ErgoSpin with gray start switch or deactivate angle compensation in the configuration.


Error code

Error class


Table 5–62: Communication unit (error codes 2000 - 2099)

Error code

Error class


2000 3 Faulty error list Delete error list

2001 3 Error list overflow This error occurs if approx. 120 non-acknowledged errors already exist and a new error overwrites the existing non-acknowledged errors

Delete error list

2002 1 Error flash management Access to the internal flash is disturbed, the flash module may be defective


2003 1 File access error Internal file system inconsistent Switch off/on. Replace if error reoccurs

Otherwise:



Otherwise:



Otherwise:


2006 1 Unknown HW identifier Replace component or have it repaired

2007 1 SE initialization error Switch controller off/on

Otherwise:


2008 1 Internal error serial interface Switch component on/off

Otherwise:


BS350 | 3 608 870 B05/2019-03


2009 1 Internal error serial interface Switch component on/off

Otherwise:


2010 3 KE / SE / CS temperature warning level Adjust tightening and break time (cycle time)

Or:

Check fan function


Check fan and replace, if necessary

2011 4 KE / SE / CS temperature error Adjust tightening and break time (cycle time)

Or:

Check fan function


Check fan and replace, if necessary

2012 1 Printer initialization Switch component on/off

2013 1 Internal memory error Switch component on/off

2014 1 Initialization error TCP/IP Switch component on/off

2015 1 Internal error TCP server Switch component on/off

2016 1 Internal error serial server Switch component on/off

2017 1 Internal error RK512 server Switch component on/off

2018 3 No access to RK512 data element Ensure that the PLC is writing in the correct data element

Check cable connection between PLC and controller

Switch component on/off

2019 3 RK512: Neg. acknowledgment by PLC Job log file error between PLC and RK512 Adjust PLC

Check PLC-controller cable connection


2020 3 CRC error settings PLC 3964R Re-create settings for PLC 3964R

2021 3 ID code device not ready Check and correct ID code source in tightening cell data.

2022 3 CRC error settings ID code Re-select ID code device.

2023 3 Results output: CF card warning level FTP data transmission is not working properly

Check FTP connection

Correctly set FTP data transmission

Perform a reset

2024 4 Results output: CF card full Check FTP connection


Release storage space on mass storage

2025 3 Error while compressing data If error occurs several times:


2026 3 Error while decompressing data If error occurs several times:


2027 3 ID code cannot be read Check FTP ID code in file

Check the length of the ID code and adjust, if necessary

2028 3 Results output: CF card access error Mass storage available?

Check / format mass storage


Error code

Error class


BS350 | 3 608 870 B05/2019-03


2029 4 FTP results output: Transfer list error Delete transfer list and restart component

or


2030 1 FTP results output: Internal error Inform qualified personnel, e. g. the Rexroth Service

2031 3 FTP results output: Server access error Check FTP connection


2032 3 FTP results output: CRC error settings Re-create settings for FTP


2033 4 FTP results output: Read transfer list error Delete transfer list and restart component

or


2034 4 Incompatible SE FW KE and SE have different firmware versions

Adjust firmware versions of components

2035 3 Q code flash signature error Delete table for Q code and then generate new one

2036 1 Q Code CRC - Flash error Delete table for Q code and then generate new one

2037 4 FTP results output: Write transfer list error Delete transfer list and restart component

or


2038 3 FTP results output: Create transfer list error

Delete transfer list and restart component

or


2039 4 FTP results output: Delete transfer list error

Delete transfer list and restart component

or


2040 3 FTP results output: Error App. res. file creation


2041 3 FTP results output: SE res. file creation error


2042 3 FTP results output: Read results file error Check / format mass storage

2043 4 FTP results output: ATA directory does not exist

Install mass storage

2044 4 Error: Create directory Check / format mass storage

2045 3 Error: Create file ID Code Inform qualified personnel, e. g. the Rexroth Service

2046 3 FTP results output: FTP server write access error

Check FTP connection


Correct FTP server settings

2047 3 Error: Close FTP connection Communication problem with FTP server Reset the controller

2048 3 Error: Login FTP server Correct FTP server settings

2049 3 Error: FTP directory access Correct FTP server settings

2050 3 Application of BS350 > V1.250


Error code

Error class


BS350 | 3 608 870 B05/2019-03


2051 3 IP address not found by server Check FTP connection

Check Ethernet connecting cable and replace, if necessary


2052 1 Too many SE connected to KE More than 40 tightening channels logged in to one KE

Reduce number of channels

2053 1 DARC and SARC status different Inform qualified personnel, e. g. the Rexroth Service

2054 3 KE storage administration: SE has not yet registered itself

Restart KE

2055 3 ID code file or directory wrong The set-up of the file name of the ID code file received via FTP does not comply with the specification


2056 3 The SE could not be found in the channel administration

Restart KE

2057 3 CRC error flash channel name KE Re-assign channel name

2058 3 CRC error log book flash KE Inform qualified personnel, e. g. the Rexroth Service

2059 1 Only one controller permitted in conjunction with KE312

Reduce number of channels

2060 1 Start signal configuration error

2061 3 Error: During generation of the rundown data base

2062 4 Error: During deletion of the rundown data base

2063 1 Error: FSH client software driver

2064 4 Error: No FSH server confirmation

2065 1 Error: Insufficient memory for FSH client

2066 1 Error: Open/close FSH connection

2067 1 CntRes PLC signal configuration error

2068 4 Permissible temperature too low Reboot controllers

2069 4 Check file system compact flash card (chkdsk)

Check disk was triggered automatically Note for user

Replace mass storage, if necessary


2070 3 KE350 must be plugged into the "KE" slot in rack 0!

Incorrect KE slot or rack number

2071 3 Rack coupler next to KE must be equipped with NK350S

Install NK350S next to KE in the rack

2072 3 CRC results data record after transmission from SE -> KE defective.

Data transmission error Check data-Arcnet cable and replace, if necessary

2073 3 Data output error: Ethernet connection interrupted/cable missing.

Check Ethernet connection

2074 3 Results data record not (completely) received


Acknowledge error

If error reoccurs, reboot controller


Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.14 Driver error (error codes 1301 - 1322)

2075 3 No storage space defined for channel results data record.

Rack address changed during operation Switch system off and on again.


2076 3 Results were refused by KE due to incorrect format identification

Incompatibility between KE and SE firmware

Update firmware versions.


2077 5 FTP results output: Watchdog

2090 3 Error on writing of the IPM data set into the FIFO file system

During transmission of a IPM data set from the IPMConnectionmanager, the data set could not be written into the FIFO file system.

Insufficient resources (file handles).

Check file system for errors.

System off / on

2091 3 Result listing task has been closed (Watchdog)

Result listing task has crashed (Watchdog)

Off / on.

Restart with BS350 IPM-RTP

2092 3 IPM client task has been closed (Watchdog)

IPM client task has crashed (Watchdog) Off / on.


2093 3 Logon to ResultServer failed Logon to ResultServer failed. Off / on.


2094 3 Error reading message from the ResultServer message queue

Reading message from the ResultServer message queue failed.

Off / on.


2095 3 Error reading IPM configuration An error occurred during reading of the IPM configuration.

Generate new configuration.

Check file system.

2096 4 Error reading the CF card CF card not available / defective Use new CF card.

2097 3 Configuration files V2.500 and < V2.500 available


Error code

Error class


Table 5–63: Driver error (error codes 1301 - 1322)

Error code

Error class


1301 1 No response from internal BS350 Driver

Driver for display of BS350 contents not working.

Switch system off/on

1302 1 No response from internal printer Driver

Driver for printer output stopped working. Switch system off/on

1303 1 No response from internal RK512 Driver

Driver for RK512 output stopped working. Switch system off/on

1304 5 No response from internal PFCS Driver

Driver for PFCS output stopped working. Switch system off/on

1305 1 No response from internal FTP client Driver for FTP output stopped working. Switch system off/on

1306 1 No response from internal OpenProtocol driver

Driver for OpenProtocol output stopped working.


1307 1 No response from internal Arcnet Driver

Driver for Arcnet transmission stopped working.


1308 1 No response from internal Arcnetdata transfer driver

Sending of results from SE -> KE. This is a SE error that may be caused by an issue with KE data output. This leads to a delay in the SE sequence and a timeout is reported.

Driver for Arcnet data transmission stopped working.


1309 1 No response from internal IPM driver Driver for IPM output stopped working. Switch system off/on

1310 1 ResultServer asynchronous error Driver for data output coordination stopped working.


BS350 | 3 608 870 B05/2019-03


5.9.15 Sequence control (error codes 2100 - 2199)

1311 1 ResultServer confirmation error Driver for data output coordination stopped working.


1312 1 No response from internal data service (unknown device)

Data service stopped working. Switch system off/on

1313 1 No response from internal IndraLogic driver

Opening of the "TighteningResults" block is monitored. If it was opened 1x in the IL application, it must be opened after tightening (at least 1x after generation of the evaluation). After CyCmp, the data of the block can be used. Opening the block is part of tightening.

IL data output stopped working.


1314 1 No response from internal job driver Job driver stopped working. Switch system off/on

1315 1 No response from internal PLUS Driver

Driver for PLUS communication stopped working.


1316 1 No response from internal XML driver Driver for XML output stopped working. Switch system off/on

1317 1 No response from internal CAQTNG Driver

Driver for CAQTNG output stopped working.


1318 1 No response from internal Ethernet data output

Ethernet driver stopped working. Switch system off/on

1319 1 No response from backup/restore process

Backup / restore process stopped working.


1320 1 No response from QDA driver QDA driver stopped working. Switch system off/on

1321 1 No response from HTTP(Json) Process

Driver for HTTP(Json) stopped working. Switch system off/on

1322 1 No response from PFCS2P Process

Driver for PFCS2P stopped working. Switch system off/on

Table 5–63: Driver error (error codes 1301 - 1322)

Error code

Error class



Error code

Error class


2100 2 Sequence control error

2101 1 Application administration error Internal software error Reboot tightening system.

2102 3 CRC error application Delete application and then generate new one.

2103 3 Application administration error

2104 3 Unknown command A program version has been started which is not compatible with the firmware.

Generate application compatible with the firmware version.

or

Update KE firmware to the program version.

2105 3 Timeout sequence end KE If Arcnet counters (RECON, NNID, and TXError) are high or also increase without active tightening:

– At least one network coupler is defective.

Check application timeout time.

Check Arcnet counters RECON, NNID, and TX error.

Replace network coupler, if necessary.

or

Find and replace faulty component.

2106 3 CW & CCW simultaneously Too short period ( 200 ms) between the Cw and Ccw signals for an application block (FOx).

Correct direction of rotation control.

Increase period between signals.

2107 3 Application already running Adjust application number control.

BS350 | 3 608 870 B05/2019-03


2108 3 Appl.: Channel in use Adjust application number control.

or

Adjust channel selection.

2109 1 Internal error application Synchronization stage error Delete application and then generate new one.

2110 3 No program acknowledgment SE – If it occurs repeatedly on numerous channels simultaneously (on KE350G IL), interval time of the PLC task too short

– Possible result: Download abort of a PLC program

Check PLC table: Are the program bits (ProgX) and program acknowledge bits (AckX) correctly applied?

Increase interval time of PLC task in the IndraLogic task configuration window (e.g. 100 ms).

In the case of download abort of a PLC program: Check connection, delete PLC project on target system, and integrate new project with longer PLC task interval.

While tightening the system:

– Activate/deactivate or reset tightening channels not participating in a tightening.

When there are no tightenings in the system:

Activate, deactivate or reset non-participating tightening channels.

2111 3 Channel not ready Check SE.

Get it ready for operation.

2112 3 No results from tightening channel – If it occurs repeatedly on numerous channels simultaneously (on KE350G IL), interval time of the PLC task too short




Application was started and immediately closed before the channels were initiated. Signal FOx Cw/Ccw must be longer present.

2113 3 Application not defined Non-programmed application was selected

Adjust application number control.

or

Program application.

2114 3 Unknown control unit Sync/RW point Program application correctly.

2115 3 Spindle failure after start signal – If it occurs repeatedly on numerous channels simultaneously (on KE350G IL), interval time of the PLC task too short


Check Ccw, Cw and En signals on internal Arcnet and assign, if necessary.



2116 3 Transmission error app.: result through the RK512

Check communication partner, ensure connection.

2117 3 Sync. or rework point on KE known and SE is not defined

Program application on SE correctly.

2118 3 Data element error while outputting results using RK512

Check configuration of the PLC data elements (PLC setting firmware).

Check settings on the PLC side.


Error code

Error class


BS350 | 3 608 870 B05/2019-03


2119 3 Transmission error: Single channel result via RK512

Check communication partner

Inform qualified personnel, e.g. the Rexroth Service

2120 3 Send error: Application result through the FTP


2121 3 Send error: Single channel result through the FTP


2122 3 Started application is 0>No>47 Check PLC application selection and correct, if necessary.

2123 3 Application not available Adjust application number control.

or

Program application.

2124 3 Sync/RW is available twice on SE Programming error on the SE Check SE programming and correct, if necessary.

2125 1 Result administration timeout Data output process does not respond Check communication partners and connections.

Restart controller.

2126 3 Result reset not successful on all channels Arcnet Check functional safety of the application channels

2127 3 Access error (timeout) while editing the application results

Internal software error Reboot system.

2128 3 Access error while editing the application results


2129 3 Cannot initialize application information for results data sets


2130 3 Channel is already used (PLC driver monitoring)

2192 3 PFCS: Number of tightening processes to be sent exceeds the sending buffer size

2193 3 CRC error in the configuration Check ID code configuration serially and reload.

2194 3 CRC error in the configuration Check PFCS configuration and reload.

2195 4 Set RTS signal for PFCS interface This error indicates the condition of an external PFCS service (not firmware).

Note: The error is no longer used in later firmware versions.


2196 4 Reset RTS signal of PFCS interface With old firmware versions:

– Entry with the information that the drive has been re-initialized for the PFCS interface.

Update firmware.

2197 4 Timeout PFCS data output Check PFCS receiver (main computer, PLC, etc.)

2198 4 PFCS response error Check cable connection.

Check interface settings and adjust, if necessary.

2199 4 PFCS transmission attempts exceeded Check cable connections.

Check interface settings and adjust, if necessary.

Check PFCS receiver.


Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.16 Configuration (error codes 2200 - 2700)

Table 5–65: Configuration (error codes 2200 - 2700)

Error code

Error class


2200 1 unknown module in <B1> Check module and replace, if necessary

2201 1 unknown module in <B2> Check module and replace, if necessary

2202 1 unknown module in <A> Check module and replace, if necessary

2203 1 Module in <B1> new Check configuration and adjust, if necessary

2204 1 Module in <B2> new Check configuration and adjust, if necessary

2205 1 Module in <A> new Check configuration and adjust, if necessary

2206 1 Module in <B1> removed Check configuration and adjust, if necessary

2207 1 Module in <B2> removed Check configuration and adjust, if necessary

2208 1 Module in <A> removed Check configuration and adjust, if necessary

2209 1 Module in <B1> changed Check configuration and adjust, if necessary

2210 1 Module in <B2> changed Check configuration and adjust, if necessary

2211 1 Module in <A> changed Check configuration and adjust, if necessary

2212 1 Serial no. in <B1> changed Serial number configuration error in module B1

Check configuration in BS and confirm, if necessary

2213 1 Serial no. in <B2> changed Check configuration in BS and confirm, if necessary

2214 1 Serial no. in <A> changed Check configuration in BS and confirm, if necessary

2215 3 Battery empty / not inserted Remove isolating strips from below the battery

or

Check battery jumper

or

Replace battery

2216 3 No real time clock buffer Battery is empty Replace battery

2217 3 Error real time clock Program real time

2218 1 Compact flash card missing Format mass storage

or

Use recommended mass storage

2219 1 Error file system mass storage Check mass storage and format, if necessary.

2220 1 Initialization error PLC card PLC card has not been recognized by the system

Check / replace PLC card


2221 1 PLC assignment table error Active PLC assignment table does not correspond to the hardware configuration.

System/PLC assignment table for SE or KE:

Update PLC assignment table

BS350 | 3 608 870 B05/2019-03


2222 3 Could not find printer configuration The printer configuration is invalid. Check configuration and create a new one, if necessary.


2223 3 CRC error in printer configuration Configure printer setting

2224 3 Signature error in printer configuration Configure printer setting

2225 3 CRC error spindle bypass Recreate spindle bypass.

2226 1 PLC assignment table: Error in number of I/O signals

Adjust PLC assignment table for KE

2227 1 PLC assignment table: Modules equipped differently

Adjust PLC assignment table to actual configuration

2228 3 Internal error Ethernet driver Inform qualified personnel, e. g. the Rexroth Service

2229 3 Internal error Ethernet driver Inform qualified personnel, e. g. the Rexroth Service

2230 1 PLC table: Restore error PLC assignment table could not be read in. Reasons:

– Problem with flash access

– Hardware defective

Re-create PLC table


2231 1 PLC table: save error Re-create PLC table


2240 4 Cell configuration missing Signature for the cell configuration is missing.

Re-create the cell configuration and send it to the controller.

2241 4 CRC error cell configuration CRC error while reading the cell configuration

Re-create the cell configuration and send it to the controller.

2242 1 Cell configuration error Incorrect cell configuration Re-create the cell configuration and send it to the controller.

2243 3 Cell/BS350 configuration error This error code is no longer used.

2300 3 Receiving message from ResultServer failed

Connection to ResultServer no longer functions

Restart PLUS or controller

2301 3 Logon to ResultServer failed Connection to result structure failed. The error can only occur after start of PLUS.

Restart PLUS or controller

2302 3 Error reading PLUS configuration There is no PLUS configuration available. Provide PLUS configuration in proper directory. To do so, either generate and save a new configuration in BS350 or open available configuration in BS350 (e.g. configuration generated offline or saved in backup) and save afterwards.

2303 3 ResultServer task has been closed (Watchdog timeout)

Permitted timeout time exceeded. Restart defective controller

2310 3 Error reading QDA configuration Error has to be acknowledged. Check/correct the BS350 configuration

2311 3 QDA ResultServer task has been closed (Watchdog timeout)

No response from ResultServer process. Restart system

2312 3 QDA file uploader task has been closed (Watchdog timeout)

Watchdog timeout. Restart system

2313 3 QDA logon to ResultServer failed Internal system error. Restart system

2314 3 QDA receiving message from ResultServer failed

Internal system error. Restart system

2315 3 Cannot generate the QDA results file in the FIFO file system

Check/format the CF card.

Restart the QDA service.


Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.17 Internal controller (error codes 2800 - 2850)

2316 3 QDA data error - Corrupt FIFO data Check/format the CF card.


2317 4 QDA error reading the CF card (file system corrupted? loss of data!)

File system corrupted? Loss of data! Check/format the CF card.


2318 4 QDA error starting a kernel task Internal system error. Restart system

2350 3 Certificate not found (FTP/TLS) Error while loading a certificate Upload a valid certificate in the QDA configuration. (Certificates are not contained in the backup and will thus be lost in case of device exchange.)

2351 3 Private key for certificate not found (FTP/TLS)

Error while loading a private key Upload a valid certificate in the QDA configuration. (Certificates are not contained in the backup and will thus be lost in case of device exchange.)

2600 1 Controller %s has logged off from data Arcnet

Note: Was replaced by 26xx, 27xx error codes in accordance with V1.250 SP1

This messages is a not for the user that one controller has logged off (e.g. due to reset).

If error occurs without external influence:

check component

2700 1 Controller %s has logged off from controller Arcnet

Note: Was replaced by 26xx, 27xx error codes after V1.250 SP1

This messages is a not for the user that one controller has logged off (e.g. due to reset).

If error occurs without external influence:

check component


Error code

Error class


Table 5–66: Internal controller (error codes 2800 - 2850)

Error code

Error class


2800 1 No memory available for ring buffer RAM range is not available. Switch tightening system on/off.

If error reoccurs:

Check battery.

2801 3 SE results buffer, results data record too great

Switch system off/on, software error

2802 3 CRC checksum in SE results buffer incorrect


2810 3 Internal error, communication channel cannot be opened ("SALOpen")


Software error, switch system off/on.

2811 3 Internal error, timeout no data exchange possible ("SALCall")



2812 3 Internal error, timeout send process failed ("SALSend")



2813 3 Message overflow on the data bus (queue)



2815 3 "ResultServer SDR" error Inform qualified personnel, e.g. the Rexroth Service


2816 1 Initialization of ResultServer failed Starting the ResultServer (results manager) has failed.



BS350 | 3 608 870 B05/2019-03


2830 3 Internal PFCS synchronization on (re-)start failed



2831 3 Cannot send the internal PFCS trigger message



2832 3 Cannot send the results in PFCS driver (internal)


2833 3 PFCS database (CF card) cannot be created

CF card missing/unformatted Check CF card.

2834 3 Cannot access PFCS database directory (CF card)

CF card missing/unformatted Check CF card.

2835 3 PFCS interface not ready for data output Output interface not ready/available, used otherwise


Check output driver settings.

2836 1 Cannot access PFCS driver on CF card CF card available? Inform qualified personnel, e.g. the Rexroth Service

Format or replace CF card as necessary.

2837 3 Internal error PFCS driver Inform qualified personnel, e.g. the Rexroth Service

Software error, switch system on/off

2838 3 CRC - PFCS configuration error Configuration file defective Turn system off and on again.

Reconfigure driver.

2840 3 BS350 error display driver(0) Error in firmware responsible for communication with display in BS350 (channel 1).

No update in BS 350 (instance 0), driver not running correctly


Switch system off/on.

2841 3 BS350 error display driver(1) Error in firmware responsible for communication with display in BS350 (channel 2).

No update in BS 350 (instance 1), driver not running correctly



2842 3 Timeout message processing BS350 display(0)

Error in firmware responsible for communication with display in BS350 (channel 1).

Data could not be sent.


Check BS350 condition.


2843 3 Timeout message processing BS350 display(1)

Error in firmware responsible for communication with display in BS350 (channel 2).

Data could not be sent.


Check BS350 condition.


2844 3/5 * Error on generation/sending of HTTP data set

HTTP data set could not be generated or sent to server.


Check connection to server.

2850 3 IntegraXML: Data on CF card in invalid format (old data of V2.600?)

Old firmware V2.600 data available Delete old data on CF card.

* 5 if "Stop in case of error in generated JSON data set" is selected in the HTTP configuration.

Table 5–66: Internal controller (error codes 2800 - 2850)

Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.18 Data output (error codes 2897 - 2909)

5.9.19 Time zone (error codes 2910 - 2913)

Table 5–67: Data output (error codes 2897 - 2909)

Error code

Error class


2897 1 Refresh of field bus / IDCode Event Mechanism failed (reboot necessary)

Refresh IDCode Event Handler failed Switch system off/on.

2898 3 Multi telegram no. Rx non-consecutive Switch system off/on.


2899 3 Timeout of field bus - MultiTelegramm output

Request of MultiTelegramm data or Acknowledge not within the defined TimeOut time

Communication partner not connected.

Incorrect TimeOut time -- increase timeout time in field bus configuration view. Handshake procedure of communication partner too slow

2900 3 HMI error texts for field bus output not available

Send HMI configuration to component.

2901 1 Field bus data configuration error Incorrect configuration of data PROFIBUS

Correct field bus data configuration.

2902 3 Field bus data configuration error (number of tightening positions)

Incorrect configuration of data PROFIBUS

Correct field bus data configuration.

2903 3 Cannot save field bus configuration in flash


2904 3 IDS_SYSERR_2904 Inform qualified personnel, e. g. the Rexroth Service

2905 3 No field bus module available for field bus configuration

Equip field bus module.

2906 3 CRC error field bus configuration Delete configuration and generate new one.

2907 3 Output on field bus failed No connection to PLC or PLC not in mode “RUN”.

Check PLC, check field bus cable.

2908 3 Command sequence at field bus - MultiTelegram data output incorrect

Incorrect command sequence in MultiTelegramm mode.

MultiTelegramm - Check sequence for PLC

2909 3 Command sequence at field bus - MultiTelegram IDCode incorrect

Table 5–68: Time zone (error codes 2910 - 2913)

Error code

Error class


2910 3 Access error on time zone The software reports an error as it has not been possible to determine the time zone.


2911 3 Incorrect time zone setting Check the time zone with the BS, set again, if necessary.

2912 3 Ambient variable for time zone cannot be set

The error can be generated in the tightening system by the software.


2913 3 Month in real time clock not plausible Format error in NTP server If the internal software error reoccurs:

Reset time.


BS350 | 3 608 870 B05/2019-03


5.9.20 Firmware download (error code 2915 - 2916)

5.9.21 Auto backup/restore (error codes 2917 - 2937)

5.9.22 Hardware error (error codes 3000 - 3008)

Table 5–69: Firmware download (error code 2915 - 2916)

Error code

Error class


2915 3 FW download: Firmware does not correspond to the system hardware

Firmware does not correspond to addressed hardware component

Select suitable firmware files.

Update firmware.

2916 1 FPGA missing! Perform update! Update firmware version.

Table 5–70: Auto backup/restore (error codes 2917 - 2936)

Error code

Error class


2917 3 Restore could not be completed. Reset or deactivation of the component during restore

Initiate auto restore again or via BS350 or trigger.

2919 1 Last firmware download incomplete. Please repeat download

Reset or OFF/ON during firmware download

Repeat firmware download

2923 1 Mass storage for automatic backup/restore not available

Mass storage not available Insert mass storage into component

2926 3 TTNR between backup and controller not identical

Controller replaced by incorrect TTNR Use controller with correct TTNR.

2929 3 Tightening cell backup and mass storage medium backup not identical!

The KE350 was replaced but not the mass storage

Insert the mass storage fitting the tightening cell.

2932 3 No/incorrect backup data available Auto restore was triggered, however, no/incorrect backup data are available

Initiate auto backup again via BS350 or trigger or insert the correct mass storage.

2933 3 Error when copying the backup data Data storage access problems Repetition of auto backup/restore

2934 3 Restore: Error when unpacking the file Data storage access problems Repetition of auto restore

2935 3 Restore was interrupted Reset or deactivation of the component during restore

Initiate auto restore again or via BS350 or trigger.

2936 3 Error during auto backup/restore of a component, see auto backup/restore diagnosis

Mass storage missing, backup data missing

Insert mass storage into component. Create backup data via auto backup.

2937 3 Processing timeout during backup / restore

Timeout message processing Backup/restore RTP

Restart controller.

Table 5–71: Hardware error (error codes 3000 - 3008)

Error code

Error class


3000 1 Internal flash error Access to internal flash not possible Inform qualified personnel, e. g. the Rexroth Service

3001 1 External flash error Check CF card.

3002 3 Battery empty / not inserted The battery must be replaced and/or equipped.

Before you switch the controller off, we recommend the following:

Backup necessary documentation files using the operating system, e.g.:

– Results storage

– Tightening and result graphs

Equip battery.

Replace battery.

3003 5 Log messages are lost

BS350 | 3 608 870 B05/2019-03


5.9.23 Open protocol error (error codes 3050 - 3060)

3004 3 Faulty license! Connect valid license stick Cannot read license file or USB stick serial number does not match the license serial number.

Deactivate the additional function "Angle compensation" or insert a valid license stick.

3005 3 Faulty license! 10 days buffer period is activated

The buffer period of 10 days is activated if licensing cannot be read although a valid license stick was connected and not removed.

Connect a valid license stick within 10 days.

3006 3 Buffer period expired! Connect valid license stick

The buffer period of 10 days has expired. Deactivate the additional function "Angle compensation" or insert a valid license stick.

3007 3 Demo period expired! Connect valid license stick

The demo period of 30 days has expired. Deactivate the additional function "Angle compensation" or insert a valid license stick.

3008 4 License stick missing/not detected (CPU card rev. <02.xx.xx?)

Hardware version in controller too old. Use controller with CPU rev. 02.xx.xx as of manufacturing date of mid 2012.

Table 5–71: Hardware error (error codes 3000 - 3008)

Error code

Error class


Table 5–72: Open protocol error (error codes 3050 - 3060)

Error code

Error class


3050 1 Selection of programs via "OpenProtocol" is not fully configured

Check configuration.

3051 1 Selection of the application via "OpenProtocol" is not fully configured


3052 3 OpenProtocol: CF card for saving results not available

Insert CF card.

3053 3 Faulty Open Protocol configuration file Generate new configuration.

3054 5 No connection to Open Protocol Slave

3055 5 OpenProtocol: Tool disable not successful.

3060 1 PLC module HVO incompletely configured

Data transmission not possible Check system settings and communication partner settings. Check network connection independent from protocol.

BS350 | 3 608 870 B05/2019-03


5.9.24 CAQTNG errors (error codes 3070 - 3074)

5.9.25 PLC error (error codes 3100 - 3148)

Table 5–73: CAQTNG errors (error codes 3070 - 3074)

Error code

Error class


3070 3 No connection to CAQTNG communication partner

The CAQTNG server is not available in order to output the tightening result data after a tightening has been completed.


3071 5 No connection to CAQTNG communication partner

The CAQTNG server is not available in order to output the tightening result data after a tightening has been completed.


3072 5 Warning: CAQTNG message buffer full The tightening result data cannot be transmitted to the CAQTNG server fast enough.

Check network connection and/or CAQTNG server.

3073 3 Error: CAQTNG message buffer full The tightening result data cannot be transmitted to the CAQTNG server fast enough.

Check network connection and/or CAQTNG server.

3074 5 CAQTNG acknowledge not OK No or incomplete communication partner acknowledgement

Compare settings of both communication partners.

Table 5–74: PLC error (error codes 3100 - 3148)

Error code

Error class


3100 3 PLC error: Task monitoring failed, PLC in stop mode!

Software watchdog of IEC task has expired

Acknowledge error in BS error list. Increase task cycle time or shorten program.

Note: Synchronous file access functions can be time consuming.

3101 5* PLC error: Hardware monitoring failed Hardware watchdog expired. Global software error

Increase watchdog time.

Deactivate watchdog.

3102 5* PLC error: bus error Field bus error Acknowledge error in BS error list. Invalid address was accessed in IEC program. More information in stack trace.

3103 3 PLC error: Check sum error. PLC in stop mode!

Check sum error after program download Acknowledge error in BS error list. Try download again. Could have been caused by defective data transfer or corrupt file system.

3104 5* PLC error: field bus error Field bus error: at least one configured IO driver could not be loaded

Acknowledge error in BS error list. Check the runtime system configuration (file Rts3S.cfg or registry) whether all drivers are available in controller file system.

3105 5* PLC error: I/O update failed I/O update error

– pfStartReadInputs, CalllOltfFunctionReadInput, pfDoneReadInputs or

– Output of a field bus driver failed

Acknowledge error in BS error list. Check used IO drivers.

Check whether configured and non-configured IOs are used in the project and that the address test is off.

Switch on address test.

3106 5* PLC error: Cycle time exceeded Cycle time exceeded Acknowledge error in BS error list. Does not occur in current runtime versions.

3107 3 PLC error: Retain variables could not be floated. PLC stopped!

Boot project was not loaded as retain variables could not be reset

Cold reset. Reduce number of retain variables. Reload boot project.

3108 3 PLC error: Boot project was not loaded. PLC in stop mode!

Boot project was not loaded. File system could be defective

Regenerate and load boot project.

BS350 | 3 608 870 B05/2019-03


3109 5* PLC error: Task could not be completed Acknowledge error in BS error list. Reset or reset (origin), reload boot project.

3110 3 PLC error: Maximum charge volume exceeded. PLC in stop mode!

Charge volume exceeded Acknowledge error in BS error list. Reduce size of PLC program, adjust variable list.

3111 1 PLC error: SRAM battery empty. Reset remanent variables. PLC stopped!

SRAM battery empty Replace battery.

3121 5* PLC error: Invalid instructions Non-permissible instructions Acknowledge error in BS error list.

PLC program error. Send archive file to Bosch Rexroth.

3122 5* PLC error: Access violation Access violation Acknowledge error in BS error list.

Check use of pointers.

3123 5* PLC error: Privileged instructions Privileged instructions Acknowledge error in BS error list.


3124 5* PLC error: Page error Page error Acknowledge error in BS error list.


3125 5* PLC error: Stack overflow Stack overflow Acknowledge error in BS error list.


3126 5* PLC error: Invalid disposition Invalid disposition Acknowledge error in BS error list.


3127 5* PLC error: Invalid access identification Invalid handle Acknowledge error in BS error list.


3128 5* PLC error: Access to protected page Protected page Acknowledge error in BS error list.


3129 5* PLC error: Double error Double error Acknowledge error in BS error list.


3130 5* PLC error: Invalid instructions Transmission error in IndraLogic Check instructions.

3131 5 PLC error: Access to odd address Incorrect alignment of data types Acknowledge error in BS error list.

Check use of pointers.

3132 5* PLC error: Array limit exceeded Array limit exceeded Acknowledge error in BS error list.

Check use of arrays.

Use checkbounds function.

3133 5* PLC error: Division by zero Division by zero Acknowledge error in BS error list.

Use CheckDivZero function.

3134 5* PLC error: Overflow Memory overflow Acknowledge error in BS error list.


3135 5* PLC error: Unavoidable exception Unavoidable exception Acknowledge error in BS error list.


3136 5* PLC error: Floating decimal point: General error

Floating decimal point: General error Acknowledge error in BS error list.



Error code

Error class


BS350 | 3 608 870 B05/2019-03


3137 5* PLC error: Floating decimal point: Non-normalized operand

Floating decimal point: Non-normalized operand

Acknowledge error in BS error list.


3138 5* PLC error: Floating decimal point: Division by zero

Floating decimal point: Division by zero Acknowledge error in BS error list.


3139 5* PLC error: Floating decimal point: Inaccurate result

Floating decimal point: Inaccurate result Acknowledge error in BS error list.


3140 5* PLC error: Floating decimal point: Invalid instructions

Floating decimal point: Invalid instructions Acknowledge error in BS error list.


3141 5* PLC error: Floating decimal point: Overflow

Floating decimal point: Overflow Acknowledge error in BS error list.


3142 5* PLC error: Floating decimal point: Stack check failed

Floating decimal point: Stack check failed Acknowledge error in BS error list.


3143 5* PLC error: Floating decimal point: Underflow

Floating decimal point: Underflow Acknowledge error in BS error list.


3144 5 PLC error: Undefined

3145 3 PLC error: Initialization data output IL Internal error of FW; access to the results data from the PLC program not possible

Restart controller,

3146 3 PLC error: Initialization IL device Error during controller boot process; ID transfer and data access from the PLC program impossible

Restart controller,

3147 3 PLC error: Data access Internal error FW; access to the results data from the PLC program not possible

Restart controller,

3148 3 Field bus data configuration error, send/transmit IL data too large

You have set more than 256 bytes. Reduce the set width to maximally 256 bytes.



Error code

Error class


BS350 | 3 608 870 B05/2019-03


5.9.26 VW-XML error (error codes 3200 - 3215)

5.9.27 Job functionality (error codes 3250 - 3256)

Table 5–75: VW-XML error (error codes 3200 - 3215)

Error code

Error class


3200 5* XML error serialization port A Incomplete or invalid response data Save the contents of the mass storage with BS350 and send it to the Bosch Rexroth service.

Reboot the tightening controller.

3201 5* XML error parsing port A Master PC sent an invalid VW-XML stream to the tightening controller

Inform the manufacturer/operator of the master PC.

3202 5* XML error serialization port B Incomplete or invalid dispatch data Save the contents of the mass storage with BS350 and send it to the Bosch Rexroth service.

Reboot the tightening controller.

3203 5* XML error parsing port B Master PC sent an invalid VW-XML stream to the tightening controller

Inform the manufacturer/operator of the master PC.

3204 1 Error PLC assignment table XML The PLC signals have been incorrectly assigned to the "XML" PLC module.

Check and correct configuration.

3205 5 XML inconsistent tightening program

3206 5 Connection to XML communication partner port B cannot be established

Either the network or the master PC is not available.

Check network and master PC.

3207 3 XML archiving: CF card not found Files for local buffering cannot be saved Equip memory module CF350 (compact flash card; CF card).

3208 3 XML archiving: Error access directory Files for local buffering cannot be saved Check memory module CF350 (compact flash card; CF card).

3209 5 XML archiving: Storage warning

3210 3 XML archiving: No storage space – Check archive server.

3211 3 XML archiving: Faulty file Faulty archive file Check memory module CF350 (compact flash card; CF card).

3212 1 XML driver initialization error XML driver failed. Restart system.

3213 3 Too much memory required by XML driver.

3214 5 GRS only possible with deactivated group (set TOL VAL 0 of the GRP)

Master PC has not deleted enable of the group.

Before selecting the group once again, delete the group enable by means of TOLVAL0.

3215 5 PRS only possible with deactivated channel (set TOL VAL 0 of the KNR)

Master PC has not deleted enable of the channel.

Before selecting the program once again, remove the enable of the channel by means of TOLVAL0.

* As of version 2.600 of the Rexroth Tightening System 350.

Table 5–76: Job functionality (error codes 3250 - 3256)

Error code

Error class


3250 3 JobNo not available. Job with this number does not exist. Generate job or use different job.

3251 1 Error performing Job Init Software error or transfer error. Generate job or use different job.

3252 3 Error performing Job sequence Software error or transfer error. Generate job or use different job.

3253 3 Job ILBridge-FB: Incorrect AckNo applied for acknowledgement.

BS350 | 3 608 870 B05/2019-03


5.9.28 Integrated logic (error codes 3270 - 3279)

5.9.29 System error (error codes 3700 - 3800)

3254 3 Controller model does not support FB ILBridge.

3255 3 Started job is >249

3256 3 Job version and firmware version incompatible.

Table 5–76: Job functionality (error codes 3250 - 3256)

Error code

Error class


Table 5–77: Job functionality error (error codes 3250 - 3252)

Error code

Error class


3270 3 Error code from IL Application_01










Table 5–78: System error (error codes 3700 - 3800)

Error code

Error class


3700 1 Stack monitoring missing Inform qualified personnel, e.g. the Rexroth Service

3800 1 Exception handle missing Inform qualified personnel, e.g. the Rexroth Service

BS350 | 3 608 870 B05/2019-03


BS350 | 3 608 870 B05/2019-03

6 Service and sales

6.1 Service

We are always the right partner when it comes to system know-how.

For any problem: Service from Rexroth

• You can reach us around the clock at:

+49 9352 40 50 60

• Or contact us by email:

– Field Service & Training Joining Technology

[email protected]

– Repair & Spare Parts Joining Technology

[email protected]

Worldwide service

Our global service network can be reached at any time in over 40 countries. You can find detailed information on our service locations in Germany and worldwide on the Internet at:

www.boschrexroth.com/service

Information preparation

We will be able to help you quickly and efficiently if you have the following information ready:

• Detailed description of the malfunction and conditions

• Information on the name plate of the affected product, particularly the material and serial numbers

• Telephone/fax numbers and email address where we can reach you if we have any questions.

www.boschrexroth.com/service


6.2 Sales

Bosch Rexroth AG

Postfach 116171534 Murrhardt, Germany

Fornsbacher Str. 9271540 Murrhardt, Germany

You can contact us

• By telephone

+49 71 92 22 208

• By fax

+49 71 92 22 181

• By email

[email protected]

6.3 Internet

Information on Rexroth's tightening technology can be found on the Internet at

www.boschrexroth.com/tightening

Additional information on service, repairs, and training, as well as the current addresses of our sales offices can be found at


If you are located outside of Germany, please contact your nearest Rexroth partner.

BS350 | 3 608 870 B05/2019-03

www.boschrexroth.com/schraubtechnik


Bosch Rexroth AG Postfach 1161 71534 Murrhardt, GermanyFornsbacher Str. 92 71540 Murrhardt, Germanywww.boschrexroth.com/tightening

BS350EN | 2019-03-AL© Bosch Rexroth AG 2019Subject to revisions!

Contact:

FOR BARCODE

06113609929910

operating system 350 - bosch rexroth

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