REXRTOH ECODRIVE DKC01.1/DKC11.1 Drive Controllers

REXRTOH ECODRV DKC01.1/DKC11.1 series drive controllers

The official troubleshooting guide for Bosch Rexroth ECODRV DKC01.1/DCC11.1 series drive controllers revolves around four categories of diagnostic messages (error/warning/command/status), with detailed definitions of the causes, troubleshooting steps, and solutions for each diagnostic message. It covers 23 types of error messages (such as F218 radiator overheating shutdown), 22 types of warning messages (such as E250 radiator overheating warning), 33 types of command messages (such as C100 communication phase 3 transition check), and 16 types of status messages (such as A100 torque mode). It also provides replacement processes for drives, motors, and cables, as well as global customer service contact information, providing core guidance for maintenance personnel to quickly locate faults and efficiently repair.

Diagnostic message system

（1） Message classification and structure

Classification rules: Divided into four categories based on their functions, distinguished by specific letters starting with them. The priority order is: error message>warning message>command message>status message.

Structure composition: Each diagnostic message contains a "diagnostic number+diagnostic text", for example, "F2/28 excessive output error". The number is displayed alternately on the H1 screen, and the complete text can be viewed for parameter S-0-0095.

（2） Detailed Explanation of Core Diagnostic Messages (Table Summary)

The message type represents the core cause of the message and key solutions

Error message (starting with F) F218 radiator overheating shutdown environment temperature>45 ℃, radiator dirty, fan failure cooling cleaning/driver replacement

F219 motor overheating shutdown motor overload, temperature monitoring line fault inspection load/repair circuit

F226 undervoltage error, power interruption, abnormal power supply check, power supply logic/restore power supply

F229 encoder quadrant error encoder cable damage, insulation interference replacement cable/separation of power line and encoder line

F860 power level short circuit overcurrent motor cable short circuit, drive power level fault check cable/replace driver

Warning message (starting with E) E250 radiator overheating warning Internal fan failure, insufficient heat dissipation in control cabinet Replace driver/install air conditioner

E251 motor overheating warning, continuous torque exceeding allowable value, inspection of motor installation/operating conditions

E254 did not return to zero absolute positioning command, did not execute return to zero, executed return to zero operation/selected relative positioning

E256 torque limit=0 parameter setting error, analog channel overload adjustment parameter S-0-0092/reducing analog voltage

Command message (starting with C/D) C101 communication parameter invalid parameter mode switch, invalid parameter connection DriveTop software correction parameter

C600 Drive Control Zero Return Command Activated but Drive Not Enabled Enable Drive Restart Command

D903 inertia detection failed due to low acceleration and excessive load inertia, increasing torque limit/improving positioning speed

Status message (starting with A/J) A100 torque mode drive operates in torque control mode and switches to speed/position mode as required

A203 position mode driver works in position control mode (stepper interface) to confirm that the command signal matches the parameters

The AF drive enable signal has been applied, and the drive is ready to operate normally without intervention

Key troubleshooting points

（1） High frequency fault classification and handling

Temperature related faults

Common reasons: excessive environmental temperature, blocked heat dissipation channels, fan failure, and excessive energy feedback.

Handling principle: Warning types (E250/E251/E252) need to be processed within 30 minutes; Shutdown type (F218/F219/F220) requires root cause investigation before restarting.

Encoder related faults

Core requirement: The amplitude of the encoder signal should be between 12.0-18.0V (F822 fault diagnosis standard).

Wiring specification: The encoder cable should be arranged separately from the power line, and the shielding layer should be reliably grounded.

Parameter related faults

Attention: Executing 'Load Default Parameters' (C800) will overwrite all existing parameters and positioning blocks, and backup is required in advance.

Common problem: Torque limit of 0 (E256) and feed rate of 0 (E255) will cause the drive to be inactive, and the parameters need to be reset to>0.

（2） Safety operation standards

Electrical safety: Before disassembly, disconnect the main power supply and take measures to prevent accidental closing. The discharge time of the capacitor should be ≥ 1 minute to avoid high-voltage electric shock.

Parameter operation: After modifying key parameters (such as travel limit and torque limit), it is necessary to verify the operating status of the equipment to prevent mechanical impact.

Replacement specification: When replacing the driver/motor/cable, the replacement part model must be exactly the same as the original equipment. After replacing the motor, the absolute position (absolute encoder type) must be reconstructed.

Component replacement process

（1） Replacement steps (universal framework)

Power off preparation: Turn off the main power supply, set up anti misoperation signs, and wait for the capacitor to discharge for ≥ 1 minute.

Disassembly operation: Separate the relevant cables (power line/encoder line/control line), remove the fixing screws, and remove the faulty components.

Install new components: Fix the new parts and reproduce the connection according to the wiring diagram (ensuring polarity/pin correspondence). The encoder cable should be firmly fixed.

Parameter loading: After replacing the driver, the backup parameter file needs to be loaded (or C700 basic loading needs to be performed), and after replacing the motor, absolute position calibration needs to be performed.

Test run: After powering on, check for no fault codes and conduct a trial run to verify that the function is normal.

（2） Key points for replacing different components

Key precautions and special requirements for replacing components

Drive (DKC) loads the original parameter file and confirms that the firmware version matches the discharge time of ≥ 1 minute

The motor (MKD/MDD) covers the temperature monitoring line of the motor, and the reconstruction of the absolute position joint requires protection (against coolant/oil contamination)

Replace the cable (power/feedback) according to its original length/specifications, and ensure that the shielding layer is reliably grounded to avoid parallel wiring with the power line