BS350 en

BS350
350 Operating System V2.400 Release | 2014-09

English
3 608 870 B05
Online help
2/201 Bosch Rexroth AG | Tightening Technology
Title 350 Operating System
Type of Documentation Online help
Purpose of Documentation This documentation describes the Rexroth Tightening System 350.
Record of Revision Version Status Comments

Version for Rexroth Tightening System 350 and Operating
BS350 V2.200 Release 04.2010
System BS350 V2.200
BS350 V2.200 Release 06.2011
System BS350 V2.200
BS350 V2.200 Release 12.2011 System BS350 V2.200
Minor editorial changes
BS350 V2.200 Release 01.2012 System BS350 V2.200
Amended by the "Nutrunner docking" functionality.
BS350 V2.300 Release 05.2013
System BS350 V2.300
3 608 878 302_AG/EN 11.2013
System BS350 V2.300 SP1
3 608 878 302_AH/EN 9.2014
System BS350 V2.400
Copyright © Bosch Rexroth AG, 2014

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

Electric Drives and Controls
Postfach 1161
D-71534 Murrhardt, Germany
Fornsbacher Str. 92
D-71540 Murrhardt, Germany
Phone: +49 (0)71 92 22 208
Fax: +49 (0)71 92 22 181
schraubtechnik@boschrexroth.de
www.boschrexroth.com
Note Original documentation. This documentation is available as a PDF file.

Translation of the original operating instructions. The original instructions were written in German.
BS350 | V2.400 Release/2014-09

Tightening Technology | Bosch Rexroth AG 3/201
Contents
1 About this documentation 5 4.1.2 Recommended filter intervals
(gradient parameters) . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1.3 Overview of commissioning steps . . . . . . . . . . . . . . 35
1.1 Overview of this documentation . . . . . . . . . . .6
4.2 Assembling the tightening cell . . . . . . . . . . . 37
1.2 Validity of the documentation . . . . . . . . . . . . .7 4.2.1 Assembling the tightening spindle . . . . . . . . . . . . . . 37
1.3 Additional documentation . . . . . . . . . . . . . . . . .7 4.2.2 Assembling the ErgoSpin hand-held nutrunner . . . 37
1.4 Representation of information . . . . . . . . . . . . .7 4.2.3 Assembling the CS351 compact system . . . . . . . . 37
1.4.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2.4 Assembling the modular system. . . . . . . . . . . . . . . . 37
1.4.2 Symbols and identifications . . . . . . . . . . . . . . . . . . . . . 8 4.2.5 Interface modules (IM). . . . . . . . . . . . . . . . . . . . . . . . 37
1.4.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2.6 Setting up the connections. . . . . . . . . . . . . . . . . . . . 39
1.4.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 4.2.7 Motor-breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2.8 Switching on the tightening cell . . . . . . . . . . . . . . . . 44
2 Safety Instructions 13 4.3 Connecting the PC for programming . . . . . . 46
4.3.1 Connecting the PC . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3.2 Installing the operating system BS350 on the PC . 47
2.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . 14 4.3.3 Starting the BS350 . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1.1 Using and communicating the safety instructions . .14 4.3.4 Setting up the programming interface . . . . . . . . . . . 48
2.1.2 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . .15 4.3.5 Logging in to the tightening system
2.1.3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . .16 (password entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.1.4 Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . .16 4.4 Sending and saving . . . . . . . . . . . . . . . . . . . . . 50
2.1.5 Maintenance and repair instructions . . . . . . . . . . . . .17 4.4.1 Sending files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1.6 Disposal instructions. . . . . . . . . . . . . . . . . . . . . . . . . .17 4.4.2 Saving data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.4.3 Data backup with the backup function . . . . . . . . . . 54
2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 4.5 Operating the compact system . . . . . . . . . . . 54
2.2.2 Application areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 4.5.1 General information on the configuration . . . . . . . . 54
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.5.2 Online configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Personnel qualifications . . . . . . . . . . . . . . . . 18 4.5.3 Offline configuration: . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5.4 Defining a tightening program . . . . . . . . . . . . . . . . . 74
2.5 General safety instructions . . . . . . . . . . . . . . 19
4.5.5 Configuration SE/CS PLC assignment table . . . . . 77
2.6 Product- and technology-dependent 4.5.6 Setting the time on the tightening controller . . . . . . 77
safety instructions for Rexroth tightening 4.5.7 Synchronizing date and time with an external clock 78
system 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.5.8 Sequence test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.6.1 Protection against accidental contact with 4.6 Operating the Modular System . . . . . . . . . . . 81
electrical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 4.6.1 General information on the configuration . . . . . . . . 81
2.6.2 Protective extra-low voltage for protection against 4.6.2 Online configuration of the KE . . . . . . . . . . . . . . . . . 82
electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 4.6.3 KE configuration offline . . . . . . . . . . . . . . . . . . . . . . . 93
2.6.3 Protection against dangerous movements . . . . . . . .22 4.6.4 Configuring the tightening channels . . . . . . . . . . . . 94
2.6.4 Protection against magnetic and electromagnetic 4.6.5 Defining the tightening program. . . . . . . . . . . . . . . . 97
fields during operation and assembly . . . . . . . . . . . .24 4.6.6 Defining a tightening application . . . . . . . . . . . . . . . 97
2.6.5 Protection against accidental contact with 4.6.7 SE PLC assignment table. . . . . . . . . . . . . . . . . . . . . 99
hot parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 4.6.8 KE PLC assignment table . . . . . . . . . . . . . . . . . . . . 100
2.6.6 Protection during handling and assembly . . . . . . . . .25 4.6.9 Setting the KE time . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.6.7 Protection when handling batteries . . . . . . . . . . . . . .25 4.6.10 Sequence test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.6.8 Protection against pressurized lines . . . . . . . . . . . . .26
4.7 Saved ("automatic") channel configuration . .
101
3 Scope of delivery and system 4.7.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
requirement 27 4.7.2 Modular system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.7.3 Configuring the tightening channel . . . . . . . . . . . . 108
3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . 28 4.7.4 Configuring the optional additional module
barcode scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2 System requirements . . . . . . . . . . . . . . . . . . . 28 4.7.5 Nutrunner test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.8 Commissioning the CC-ErgoSpin
4 Basic commissioning 31 hand-held nutrunner and its special
features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 4.8.1 Commissioning the CC-ErgoSpin hand-held
4.1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . .32 nutrunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
BS350 | V2.200 Release/2010-04

4/201 Bosch Rexroth AG | Tightening Technology
4.8.2 Special features of the CC-ErgoSpin hand-held 5.8.7 Interface Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 160
nutrunner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5.9 Complete error list . . . . . . . . . . . . . . . . . . . . . 161
4.9 Special characteristics of Nexo portable 5.9.1 Servo amplifier (error code 100 - 199) . . . . . . . . . 161
radio nutrunner operation . . . . . . . . . . . . . . .120 5.9.2 Measurement transducer (error codes 200 - 299) 163
5.9.3 ErgoSpin hand-held nutrunner
5 Troubleshooting 123 (error codes 300 - 399). . . . . . . . . . . . . . . . . . . . . . 165
5.9.4 CAN bus (error codes 500 - 699) . . . . . . . . . . . . . 166
5.9.5 ARCNET (error codes 700 - 799) . . . . . . . . . . . . . 169
5.1 Error codes and classes . . . . . . . . . . . . . . . .124 5.9.6 Interface module (error codes 800 - 899) . . . . . . . 173
5.1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 5.9.7 Update CAN components
5.1.2 Error code assignment table. . . . . . . . . . . . . . . . . . 124 (error codes 900 - 999). . . . . . . . . . . . . . . . . . . . . . 174
5.1.3 Error classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 5.9.8 Control unit (error codes 1000 - 1051) . . . . . . . . . 175
5.2 Reset function . . . . . . . . . . . . . . . . . . . . . . . . .125 5.9.9 Channel configuration (error codes 1100 - 1161) 177
5.9.10 PLC assignment table (error codes 1180 - 1182) 180
5.3 LED displays and operating elements . . . .126
5.9.11 Change engineering units
5.3.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
(error codes 1190 - 1191) . . . . . . . . . . . . . . . . . . . 180
5.3.2 LTU350 servo amplifier . . . . . . . . . . . . . . . . . . . . . . 127
5.9.12 Sequence control (error codes 1200 - 1244). . . . 180
5.3.3 LTS350D and LTE350D servo amplifiers . . . . . . . 127
5.9.13 Control unit (error codes 1301 - 1319) . . . . . . . . . 183
5.3.4 VM power supply module . . . . . . . . . . . . . . . . . . . . 128
5.9.14 Communication unit (error codes 2000 - 2099) . . 183
5.3.5 SE352 and SE352M control units. . . . . . . . . . . . . 129
5.9.15 Sequence control (error codes 2101 - 2199). . . . 187
5.3.6 LT35x servo amplifiers. . . . . . . . . . . . . . . . . . . . . . . 129
5.9.16 Configuration (error codes 2200 - 2700) . . . . . . . 189
5.3.7 KE communication unit . . . . . . . . . . . . . . . . . . . . . . 129
5.9.17 Internal controller (error codes 2800 - 2843) . . . . 192
5.3.8 LED display in operating state . . . . . . . . . . . . . . . . 130
5.9.18 Data output (error codes 2899 - 2907) . . . . . . . . . 193
5.4 Error recognition on interface modules . .132 5.9.19 Time zone (error codes 2910 - 2913) . . . . . . . . . . 194
5.4.1 LEDs on the interface modules . . . . . . . . . . . . . . . 132 5.9.20 Firmware download (error code 2915 - 2916) . . . 194
5.4.2 Examples of errors on interface modules. . . . . . . . 137 5.9.21 Hardware error (error code 3000 - 3002) . . . . . . . 194
5.5 Error recognition and acknowledgement 5.9.22 Open protocol error (error codes 3050 - 3053) . . 195
on the TFT display . . . . . . . . . . . . . . . . . . . . . .141 5.9.23 CAQTNG errors (error codes 3070 - 3074). . . . . 195
5.9.24 PLC error (error codes 3100 - 3148) . . . . . . . . . . 195
5.6 Error recognition and acknowledgement
5.9.25 Errors Rexroth XML (error code 3204 - 3211) . . . 198
with the BS350 operating program . . . . . .142
5.9.26 Job functionality (error code 3250 - 3252) . . . . . . 198
5.6.1 Error lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.9.27 System error (error codes 3700 - 3800) . . . . . . . . 198
5.6.2 Sequence test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6.3 Transducer test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.6.4 Tightening channel info . . . . . . . . . . . . . . . . . . . . . . 145 6 Service and Sales 199
5.6.5 KE info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.6.6 Tightening cell info. . . . . . . . . . . . . . . . . . . . . . . . . . 146 6.1 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.6.7 KE mass storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.6.8 SE, CS/KE I/O interface . . . . . . . . . . . . . . . . . . . . . 151 6.2 Sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5.6.9 SE/KE Arcnet bus . . . . . . . . . . . . . . . . . . . . . . . . . . 153 6.3 Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5.6.10 CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.6.11 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.6.12 Field bus data CS/KE . . . . . . . . . . . . . . . . . . . . . . . 155
5.6.13 Field bus status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.6.14 ... FF3/FF4 (internal sequence trace) . . . . . . . . . . . 156
5.7 Description of selected errors . . . . . . . . . . .156
5.7.1 Error code 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.7.2 Error code 102/206 . . . . . . . . . . . . . . . . . . . . . . . . 157
5.7.3 Error code 204/205 . . . . . . . . . . . . . . . . . . . . . . . . 157
5.7.4 Error code 712/713 . . . . . . . . . . . . . . . . . . . . . . . . 157
5.7.5 Error code 1111 . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.7.6 Error code 1206/1209 . . . . . . . . . . . . . . . . . . . . . . 158
5.7.7 Error code 1221 . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.7.8 Error code 23xx/24xx. . . . . . . . . . . . . . . . . . . . . . . . 158
5.8 Replacing defective components . . . . . . . .159
5.8.1 VM350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.8.2 LT35x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.8.3 LTU350/1 (for ErgoSpin hand-held nutrunner). . . 159
5.8.4 LTS350D/LTE350D . . . . . . . . . . . . . . . . . . . . . . . . 159
5.8.5 SE/CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.8.6 KE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
BS350 | V2.200 Release/2010-04

1 About this
documentation
This chapter contains general information on the present documentation.
• Overview of this documentation (page 6)

• Validity of the documentation (page 7)
• Additional documentation (page 7)
• Representation of information (page 7)
6/201 Bosch Rexroth AG | Tightening Technology BS3503 608 878 202
1.1 Overview of this documentation

This documentation describes the tightening system in the following chapters:
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 sys-
tems. Information on the intended use of Rexroth tightening systems.
3 Scope of delivery and system require- This chapter contains information on the scope of delivery and the system requirements for
ment the Rexroth BS350 operating system.
4 Basic commissioning All steps required for commissioning a tightening system, e.g. setting up interfaces and tigh-
tening channel configuration.
5 Troubleshooting This chapter describes errors which can occur when working with the Rexroth Tightening
System 350 and provides troubleshooting advice.
6 Service and Sales Options for contacting Rexroth, sources for additional information on the tightening system.
BS350 | V2.400 Release/2014-09

BS3503 608 878 202 Tightening Technology | Bosch Rexroth AG 7/201
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 or V2.400 of the Tightening System 350 are highlighted accor-
dingly.
The Tightening System 350 contains customer-specific data protocols that may not be used by all custo-
mers for legal reasons. Therefore, they are no general part of the scope of delivery of the Tightening Sys-
tem 350. 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 nutrun-
ner. Please find information on the Rexroth Nexo portable radio nutrunner in the "Nexo" documentation.
Some chapters of this documentation contain references to the Nexo portable radio 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.
You can find current documentation for project planning, as well as related documents, in the media
directory at:
www.boschrexroth.com/various/utilities/mediadirectory/index.jsp?publication=NET
 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 ap-
plicable in your country.
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 in-
jury or damage to equipment. The measures described to avoid these hazards must be observed.
Safety instructions are set out as follows:
SIGNAL WORD
Type of DANGER
Consequences
 Precautions
• Safety sign (warning triangle): draws attention to the danger

• Signal word: identifies the degree of the danger (type of risk)
• Type of danger: identifies the type or source of the danger
• Consequences: describes what occurs when the safety instructions are not observed
• Precautions: states how the danger 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:
BS350 | V2.400 Release/2014-09

Table 1–1: Warning symbols used

Symbol Meaning
This 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 cur-
rents. Observe all safety instructions that follow this symbol to avoid possible injuries or death.
The safety instructions describe the following types of risk. The type of risk describes the risk if the cor-
responding safety instruction is not observed. The signal words have the following meanings:
DANGER
Death or serious bodily harm will result.
WARNING
Death or serious bodily harm could result.
CAUTION
Bodily harm or damage to equipment could result.
NOTE
Damage to equipment could result.
If this information is not observed, the operating procedure may be impaired.
1.4.2 Symbols and identifications
Table 1–2: Identifications used in the documentation

Symbol: Explanation
 Prerequisite
Ensure that the stipulated prerequisite is met before continuing with the next step.
 Step
This symbol indicates an individual step.
1. Sequence
2. Complete the specified steps in the stipulated sequence.
3.
BS350 | V2.400 Release/2014-09

Table 1–2: Identifications used in the documentation

Symbol: Explanation
 Result
This symbol indicates the result of an action.
Example Examples are in a gray field and clarify 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. In the PDF, click this area to go directly to the
reference.
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.
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 applica-
tion blocks (FO1 ... FO8) if they do not access the tightening channels simultaneously. Up to 40 tigh-
tening 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 by the latest data
if more storage is required.
Tightening process The tightening process describes the entire tightening procedure including the various individually pa-
rameterized tightening program steps (such as "finding", "screwing in" "tightening", etc.) until the tar-
get 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 com-
plete tightening spindle, controller, servo amplifier, and connector cable.
Tightening program The tightening program coordinates the tightening process/sequence. It is divided into various tigh-
tening steps, where tightening parameters are set.
Tightening position The tightening position is the defined location where the tightening is performed using a tightening
channel and a tightening program.
BS350 | V2.400 Release/2014-09

Tightening system A tightening system is a complete system with all tightening channels that are needed to carry out the
defined tightening case.
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 inclu-
des 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 an auxiliary variable to measure the angle of turn for a target or monitoring fun-
ction. The function monitoring of the angle is started as soon as the torque measured at the bolt rea-
ches the value specified as torque threshold for the first time. Afterwards, the torque threshold has no
more influence on the tightening process, except for correcting the angle.
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)
BS350 | V2.400 Release/2014-09

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.
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 tigh-
tening 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 variable (e.g. gradient) of a tightening step that must be
maintained within specific limits, in order for a tightening process to be performed safely. Exceeding
the limits can lead to the tightening step being 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 tor-
que. 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 pa-
rameter (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 determines more parameters for the tightening step. Additional functions influ-
ence the tightening process (e.g. start-up suppression, speed setting) but 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.
BS350 | V2.400 Release/2014-09

1.4.4 Abbreviations
The following abbreviations are used in this documentation:
Table 1–3: Abbreviations for the components in the tightening system

Abbreviation Explanation
BT356 Card rack field system 350 for max. 6 tightening channels
BS350 350 Operating System
CS Compact system
ES ErgoSpin hand-held nutrunner
HMI Human Machine Interface
IL Integrated logic
IM Interface module
IM24V 24 V interface module
IMdev DeviceNet interface module
IMenip EtherNet/IP interface module
IMmtcp ModbusTCP interface module
IMpdp PROFIBUS DP interface module
IMpnio PROFINET IO 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
BS350 | V2.400 Release/2014-09

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 14)

• Intended use (page 17)
• Improper use (page 18)
• Personnel qualifications (page 18)
• General safety instructions (page 19)
• Product- and technology-dependent safety instructions for Rexroth tightening sys-
tem 350 (page 20)
14/201 Bosch Rexroth AG | Tightening Technology BS350
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 tigh-
tening 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 Euro-
pean 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 war-
nings stated here, or improper interventions in the safety equipment can cause damage to equip-
ment, injury, electric shock, and even, in extreme cases, death.
 Observe the safety instructions.
BS350 | V2.400 Release/2014-09

BS350 Tightening Technology | Bosch Rexroth AG 15/201
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 documenta-
tion 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 transporta-
tion, 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 compo-
nents 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 com-
ponents. 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 manu-
facturer and system installer must implement the required measures, modifications, and expansi-
ons.
• Commissioning of the supplied components is prohibited until it has been determined that the ma-
chine or system in which they are installed corresponds to country-specific provisions, safety regula-
tions, and standards for the specific application.
• Operation is only permitted in accordance with the national EMC regulations for the respective
application.
BS350 | V2.400 Release/2014-09

• 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 correspon-
ding 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 ac-
cordance 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 equip-
ment 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.
BS350 | V2.400 Release/2014-09

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 techno-
logy. 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.
As the manufacturer, Bosch Rexroth does not grant any warranty, assume any liability, or provide com-
pensation for damages caused by improper use of the products. The user is solely responsible for risks
caused by improper use of the products.
Before using any product from Bosch Rexroth, the following prerequisites must be fulfilled to ensure in-
tended 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.
2.2.2 Application areas
The Rexroth tightening system is a system used to perform, document, and analyze tightenings in accor-
dance with freely programmable sequences.
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 com-
pensation 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.
BS350 | V2.400 Release/2014-09

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 class A).
2.3 Improper use

Use of the Rexroth tightening system and components for any application not listed herein, or under ope-
rating 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, in case of 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.
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 tigh-
tening 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 measu-
res 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.
BS350 | V2.400 Release/2014-09

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, cut-
ting, impact, or improper handling of pressurized lines!
BS350 | V2.400 Release/2014-09

2.6 Product- and technology-dependent safety instructions for

Rexroth tightening system 350
2.6.1 Protection against accidental contact with electrical parts
This section only applies to devices and components with voltages above 50 V.
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.
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 dia-
gram before switching the system on.
 Operation, even briefly for measuring or testing purposes, is only permitted if the protective con-
ductor 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 acci-
dental 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 under-
stand 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.
BS350 | V2.400 Release/2014-09

For electrical drive and filter components:
DANGER
High housing voltage and high leakage current!
Danger to life, 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.
For multi-channel tightening systems:
 Always connect the protective conductor for the electrical equipment to the power supply perma-
nently. 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 for ErgoSpin:
A 10 mm2 copper wire diameter is not required for the protective conductor. The leakage current
is less than 3.5 mA.
Safety warning sticker

Safety warning stickers on the compact system (CS), card rack (BT), and system box (SB) indicate the
risk of electric shock (sticker location, see Fig. 2–1).
Fig. 2–1: Safety warning sticker on Compact System (CS), card rack (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)
Fig. 2–3: Safety warning sticker on card rack (BT) and system box (SB)
BS350 | V2.400 Release/2014-09

WARNING
Dangerous voltage inside device!
 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.
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 vol-
tages which are designed to be safe to touch in accordance with the product standards.
WARNING
High voltage due to improper connection!
 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.
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 inde-
finite time.
The monitoring devices in the drive components almost completely eliminate malfunctions in the connec-
ted 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.
BS350 | V2.400 Release/2014-09

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 unin-
tended 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 func-
tion of the emergency OFF system before commissioning. If the emergency OFF switch malfunc-
tions, 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 malfunc-
tions 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.
BS350 | V2.400 Release/2014-09

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.
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 hea-
ring 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 consul-
ted. 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.
2.6.5 Protection against accidental contact with hot parts
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.
BS350 | V2.400 Release/2014-09

2.6.6 Protection during handling and assembly
Under unfavorable conditions, handling or assembling specific parts in an unsuitable manner could cause
injuries.
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.
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!
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 ex-
plosion). Dispose of used batteries separately from other waste. Observe the national regulations of the
country where the product is installed.
BS350 | V2.400 Release/2014-09

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 en-
vironment. Dispose of toxic media separately from other waste. Observe the national regulations of the
country where the product is installed.
BS350 | V2.400 Release/2014-09

3 Scope of delivery and
system requirement
This chapter contains information on the scope of delivery and the system require-
ments for the Rexroth BS350 operating system.
• Scope of delivery (page 28)

• System requirements (page 28)
3.1 Scope of delivery

The Rexroth BS350 operating program in versions V2.1, V2.2, V2.3 and V2.4 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 V2.100
The workstation computer (PC) runs one of the following operating systems:
– Windows 2000
– Windows XP Service Pack 3
The workstation computer (PC) runs one of the following operating systems and the hardware requi-
rements of the operating system have to be met, e.g. regarding CPU output:
– Windows Vista (32 bits version)
– Windows 7 (32 bits or 64 bits)
The installation has been tested successfully with the "Windows Vista Business N 32 bit edition".

– 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
If several programs have to be active at the same time on the operating computer, we recommend a cor-
respondingly higher system performance (processor and working memory) as compared to the informati-
on of the respective operating system manufacturer.
BS350 | V2.400 Release/2014-09

Under Windows XP with SP2 or SP3, problems may result with the firewall if the BS350 user does not
have any administrator rights. In this case, the administrator should enable port 7072 for TCP/IP and port
7073 for UDP for the BS350.
BS350 | V2.400 Release/2014-09

BS350 | V2.400 Release/2014-09

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 sys-
tem construction, setting up the programming interface (Ethernet or USB), configura-
tion 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.
Information on the integrated logic is contained in the "Project planning" documenta-
tion of the Rexroth Tightening System 350.
• Overview (page 32)

• Assembling the tightening cell (page 37)
• Connecting the PC for programming (page 46)
• Sending and saving (page 50)
• Operating the compact system (page 54)
• Operating the Modular System (page 81)
• Saved ("automatic") channel configuration (page 101)
• Nutrunner docking configuration (page 72)
• Special characteristics of Nexo portable radio nutrunner operation (page 120)
4.1 Overview
4.1.1 General instructions
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 slots
Incorrect 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.
Firmware is installed on all components at the time of delivery.

When exchanging these components or purchasing complementary ones, please observe the compati-
bility 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 more information, see chapter Troubleshooting from page 123.
Before commissioning, check if a new service pack is available in the download section2) at
www.boschrexroth.com/schraubtechnik. 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.
NOTE
Danger to system safety
A 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.
1) The firmware for BS350 and the CS351, KE, and SE must have the same release version. It is per-
missible for the LT35x, LTU350/1, tightening spindle components, and ErgoSpin to have different
firmware versions than the tightening controller.
2) www.boschrexroth.com/business_units/brc/en/information_en/software_en/download_se_en/in-
dex.jsp
BS350 | V2.400 Release/2014-09

A description on how to use the firmware updates and service packs can be found in the "Project plan-
ning" documentation of the Rexroth Tightening System 350.
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 gra-
dient 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 [˚]
1x 2x
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 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 42.35
Offset 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 drive 3VMC017 0 608 801 001 32.72 –
Offset drive 3VMC035 0 608 801 002 32.72 –
Offset drive 3VMC060 0 608 801 003 32.72 –
Offset drive 4VMC150 0 608 801 004 40 –
Offset drive 4VMC210 0 608 801 005 22.5 45
Offset drive 4VMC360 0 608 801 006 22.5 45
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 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 45
Offset output drive BG 4 VUK2D186 0 608 800 644 22.5 45
Offset output drive BG 4 VUL2D290 0 608 800 645 22.5 45
Angle head BG 2 2W1 0 608 810 001 25.71 51.43
Angle head BG 2 2W2 0 608 810 002 25.71 51.43
Angle head BG 2 2W3 0 608 810 003 25.71 51.43
Angle head BG 3 3W4 0 608 810 007 25.71 51.43
Angle head BG 3 3W5 0 608 810 008 25.71 51.43
Angle head BG 3 3W6 0 608 810 009 25.71 51.43
BS350 | V2.400 Release/2014-09

Table 4–1: Recommended filter intervals

Designation Code Order number Filter interval [˚]
1x 2x
Angle head BG 4 4W3 0 608 810 013 22.5 45.0
Angle head BG 4 4W4 0 608 810 014 24.0 48.0
Angle head BG 4 4W130 0 608 810 045 16.36 32.72
Angle head BG 4 4W220 0 608 810 046 14.4 28.8
Angle head W1H 0 608 810 035 16.36 32.72
Angle head WH2 0 608 810 040 25.71 51.43
Angle head WH3 0 608 810 029 22.5 45.0
Angle head WH4 0 608 810 031 13.33 26.66
Angle head BG 2 2W011 0 608 810 041 16.36 32.72
Angle head BG 3 3W027 0 608 810 042 16.36 32.72
Angle head BG 3 3W050 0 608 810 043 16.36 32.72
Angle head BG 3 3W090 0 608 810 044 14.4 28.8
Angle head BG 4 4W150 0 608 810 045 16.36 32.72
Angle head BG 4 4W250 0 608 810 046 14.4 28.8
ErgoSpin ESA013S 0 608 841 019 15.65 31.30
ErgoSpin ESA013G 0 608 841 029 15.65 31.30
ErgoSpin ESA030S 0 608 841 020 27.69 35.38
ErgoSpin ESA030G 0 608 841 030 27.69 35.38
ErgoSpin ESA040S 0 608 841 021 13.85 27.69
ErgoSpin ESA040G 0 608 841 031 13.85 27.69
ErgoSpin ESA056S 0 608 841 022 16.36 32.72
ErgoSpin ESA056G 0 608 841 032 16.36 32.72
ErgoSpin ESA065S 0 608 841 023 13.33 26.66
ErgoSpin ESA065G 0 608 841 033 13.33 26.66
ErgoSpin ESA075S 0 608 841 024 14.4 28.8
ErgoSpin ESA075G 0 608 841 034 14.4 28.8
ErgoSpin ESA100S 0 608 841 025 13.33 26.66
ErgoSpin ESA150S 0 608 841 026 15.65 31.3
ErgoSpin ESA220S 0 608 841 027 13.33 26.66
BS350 | V2.400 Release/2014-09

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

• CS351 compact system (page 35)
• Modular system 350 (page 36)
Please find information on the commissioning of the Nexo portable radio nutrunner and on the definition
of tightening programs in the "Nexo" documentation.
4.1.3.1 CS351 compact system
Assembling the tightening spindle (see page 37) or the ErgoSpin hand-held nutrunner (see page 37)
Assembling the compact system (see page 37)
Inserting the interface modules (see page 37)
Connecting the tightening spindle (see page 39) or the ErgoSpin hand-held nutrunner (see page 39) to the
compact system
Mains connection of the CS351 compact system (see page 40)
Switching on the tightening cell (see page 44)
Connecting the PC (see page 46)
Installing the BS350 operating system (see page 47)
Starting the BS350, setting up the programming interface, password entry (see page 48) to (page 49)
Configuring the tightening channel (see page 55) and (page 73)
Configuring the PLC assignment table (see page 77)
Defining the tightening program (see page 74)
Sending/saving data (see page 51)
Sequence test (see page 78)
Operating the ErgoSpin hand-held nutrunner (see page 72)

Fig. 4–1: Overview of commissioning steps for compact system CS351
To commission a tightening channel with the ErgoSpin hand-held nutrunner, see Nutrunner docking con-
figuration (page 72).
BS350 | V2.400 Release/2014-09

4.1.3.2 Modular system 350
Assembling the tightening spindle (see page 37) or the ErgoSpin hand-held nutrunner (see page 37)
Inserting the control and power electronics in the BT/SB (see page 37)
Inserting the interface modules (see page 84)
Assigning the BT addresses1?1 (see page 37)
Inserting the NK350(S) network couplers1 (see page 37)
Combinating multiple BT/SB1 (see page 37)
Setting up the connections (see page 39)
Switching on the tightening cell (see page 44)
Connecting the PC (see page 46)
Installing the BS350 operating system (see page 47)
Starting the BS350, password entry (see page 48)
Configuring the tightening channels (see page 94)
Defining a tightening program (see page 74)
Sending/saving data (see page 50)
Sending the KE PLC assignment table (see page 100)
Setting the KE time (see page 100)
Sequence test (see page 101)

Fig. 4–2: Overview of commissioning steps for the modular system
1 Only for multi-channel operation with more than one card rack field or system box
BS350 | V2.400 Release/2014-09

4.2 Assembling the tightening cell

4.2.1 Assembling the tightening spindle
Detailed information on the assembly of the tightening spindle is contained in the installation instructions
"Rexroth Tightening Spindle" (3 608 870 0D0).
The specific tightening torques set out in the respective operating instructions must be observed when
bolting the components together.
4.2.2 Assembling the ErgoSpin hand-held nutrunner
Detailed information on assembling and commissioning the ErgoSpin hand-held nutrunner can be found
in the "ErgoSpin" operating instructions (3 609 929 965).
4.2.3 Assembling the CS351 compact system
Detailed information on assembling and commissioning the CS351 compact system can be found in the
"CS351" operating instructions (3 609 929 B45).
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).
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.
Detailed information on assembling and commissioning the SB356 system box can be found in the
"SB356" operating instructions (3 609 929 B67).
Detailed information on assembling and commissioning the BT356 card rack field can be found in the
"BT356" operating instructions (3 609 929 B68).
4.2.5 Interface modules (IM)
Data communication (data services) and control signal exchange with the partner controller are imple-
mented by interface modules (IM).
BS350 | V2.400 Release/2014-09

Rexroth
CS351
X3U3
OK NOK FG
2 2 3
X3U4 XDVI
A 1 8 C1 C2
9
17
16
24 C3
X7E1
C5 C4
X3U1
X6C1
B1 B2
X3C1 X3U2 XDN1
B1 R UN/S T O P
1 2 E R R OR
B1 B2 Reset R es et
Reset
X 3C 1
1
A
1 2 3
X 3U4
X 7E 1 X 3U1 X 3U2 X 3U3
X 3U1 X 3U2 X 3U3
X DV I
1 Interface A
2 Interface B1
3 Interface B2 K E 350G IL
Fig. 4–3: IM interfaces A, B1 and B2 on CS351/SE352M/KE350(G IL)
Detailed information on the data communication is contained in the "Project planning" documentation of
the Rexroth Tightening System 350.
Detailed information on the control signal exchange is contained in the "Project planning" documentation
of the Rexroth Tightening System 350.
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.
NOTE
Open slots
Open slots may lead to system damages.
 Close all free slots with dummy plates.
Slots in CS351/SE352M/KE350G IL
Table 4–2 lists the permissible interface modules for the individual slots.
Table 4–2: Permissible interface modules

Slot Interface module Available/can be used in
CS3511?1 SE352M KE350(G IL)
A IMpdp, IMdev, IMpnio, IMenip, IMmtcp x x
B1/B2 IM24V x x x
1 Not available for CS351x-D NK
Interface modules do not always have to be used. In this case, close the empty slots using dummy plates.
BS350 | V2.400 Release/2014-09

4.2.6 Setting up the connections
NOTE
Overvoltage
Damage to electronic parts
 Disconnect voltage to the BT/SB, before 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 with 230 V: up to 25 m
Fit appropriate strain relief devices to prevent kinks in the cable.
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 out-
let direction.
5. Use the union nut to secure the angle plug to the compact system respectively the servo amplifier.
Always use angle plugs on the LT35x or LTS350D with the system box (SB) so the system box door can
be closed.
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
LTE350D power 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
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 connection 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 the XDS1 interface
– on the LTE350D in the XDS1 interface
3. Tighten the union nut connection firmly by hand.
BS350 | V2.400 Release/2014-09

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.
NOTE
Use of non-original parts
Damages 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.
The mains connection interface (X1N) is located outside the front cover (see Figure 4–4).
QO XDS1
X1N
CS351E-D CS351S-D
Fig. 4–4: X1N mains connection interface on the compact system
The connection assignment of the X1N mains connection interface is shown in Figure 4–5 and explained
in more detail in Table 4–3.
1 2
PE 3
Fig. 4–5: X1N connections
Table 4–3: Pin assignment for X1N interface

Pin Signal Description/function Voltage/current
PE 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. - -
BS350 | V2.400 Release/2014-09

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 4–4).
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.
L1 L2 L3 PE
3 x 230 V
A≥
230 V N 10mm2
Fig. 4–6: X1N1 interface mains connection terminals on the BT356
Table 4–4: Description of the X1N1 interface

Terminal Description Voltage/current
L1 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
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 4–5).
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 cir-
cuits and ground leakage, a 3-phase fuse (16 A) must be provided.
BS350 | V2.400 Release/2014-09

1L1 3L2 5L3 PE
Fig. 4–7: SB356 mains connection terminals
Table 4–5: Description of the mains connection terminals on the SB356

Signal Description/function Voltage/current
PE PE wire PE potential
1L1 L1 mains connection 380 – 500 V~ / 4.6 – 3.5 A
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).
NOTE
Damages caused by varying voltages
Varying mains voltages will damage the control and power electronics.
 All three mains phases must be connected with the same voltage value!
NOTE
Varying assignment of mains connections
Damages 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.
NOTE
Varying assignment of connections within a group
Device destruction
 Only the connections of one group may be used.
 Do not simultaneously assign varying groups.
BS350 | V2.400 Release/2014-09

NOTE
Incorrect wiring
Damages to the control and power electronics
 Always feed the mains connection through the upper terminal strip (see Table 4–6)
 The lower terminal strip must remain fully wired.
Terminal strips for mains connection Device connection
.1 .3 .1 .1 .1 .1 .1 .1 .1 .1 .1 .1 .1 .1
}
1 2 3 4 5 6 7 8 9 10 11 12 13
.2 .4 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2
G1 G2 G3 G4
Fig. 4–8: X1N4 voltage selection terminals with connection groups G1, G2, and G3
Table 4–6: Voltage selection terminals

Pin Signal Description Voltage/current
1 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
4.2.7 Motor-breaker
Information on the Motor-breaker topic is contained in the "Project planning" documentation of the Rex-
roth Tightening System 350.
BS350 | V2.400 Release/2014-09

4.2.8 Switching on the tightening cell
4.2.8.1 Compact system
NOTE
Overvoltage
Components 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.
LED displays
Fig. 4–9: LED on the front
Table 4–7: LED modes

LED Display Diagnosis
Off 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 Green IndraLogic running
(only for Red IndraLogic stopped
CS... IL)
ERROR Red, flashing IndraLogic error
(only for
CS... IL)
4.2.8.2 Modular system
NOTE
Overvoltage
Control 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 con-
nected and checked for proper fit.
BS350 | V2.400 Release/2014-09

LED displays
Tables 4–8 to 4–10 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.
Information on the operating states can be found in the project planning manual for the respective com-
ponent.
Starting/run-up
Table 4–8: Starting/run-up phase
phase
VM SE LT KE
Green (static) Red (static) Green/red Red (static)
flashing
Red (static) Off Red (static)
Ready for operation

Table 4–9: Ready for operation
VM SE LT KE
Green (static) Green (static): Green (static): Green (static):
Ready for Ready for Ready for
operation operation operation
Red (flashing): Red (static): error Red (static):
error error
Green/red
flashing:
logon to CAN bus
Red (flashing): Off Off
no tightening
took place be-
forehand.
Tightening operation
Table 4–10: Tightening operation
VM SE LT KE
Green (static) Green (static): Green (static): Green (static)
Ready for Ready for
operation operation
Red (flashing): Red (static):
error error
Green (flashing):
emergency
STOP chain in-
terrupted1?1
Red (flashing): Off, when the Off
tightening NOK motor is not
triggered
Green (static): Green (static) in Red (flickering):
tightening OK tightening data traffic on
operation control bus
Off: Green (flicker-
– during the ing): data traffic
tightening on data bus
– after play at the
start switch
1 with LTU only if emergency OFF function is configured
BS350 | V2.400 Release/2014-09

For detailed information on LED displays for other (e.g. malfunctioning) operating states, see chapter
Troubleshooting from page 123.
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:
Rexroth
CS351
1
OK NOK FG
B1 B2
R UN/S T O P
X3U4 XDVI
A 1 8 C1 C2
E R R OR
1 9
17
16
24 C3
X7E1 R es et
C5 C4
X3U1
X6C1 2
X 3C 1
X3C1 X3U2 XDN1
A
B1 B2 Reset
X 3U4
X 7E 1 X 3U1 X 3U2 X 3U3
1
2 X DV I
1 USB interface X3U3

2 Ethernet interface X7E1 K E 350G IL
Fig. 4–10: USB and Ethernet interfaces for the compact system (CS351) and KE350(G IL)
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.
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 inter-
face card for network operation.
BS350 | V2.400 Release/2014-09

4.3.2 Installing the operating system BS350 on the PC
This section describes the installation of the BS350 operating system version 2.400 on the PC.
Requirements
• 1 USB 1.1 interface to connect the USB cable
• Recommended: a mouse or other compatible device
Additional system requirements are:

The workstation computer (PC) runs one of the following operating systems and the hardware require-
ments of the operating system have to be met, e.g. regarding CPU output:
• Windows XP Service Pack 3
• Windows Vista (32 bits version)
• Windows 7 (32 bits or 64 bits)
BS350 installation
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 V2.400 settings dialog, select the option BS350 started once, i.e. BS350 can only
be started 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.
The USB drivers and installation instructions are included on the system stick in the following directory:
\Miscellaneous\Additional Drivers\FTDI USB Driver
After successful installation the BS350 icon will appear on the desktop.
Downward The following version 2.300 configurations can be adopted on the file level:
compatibility • Tightening programs (including tightening programs with ErgoSpin)
• Applications
• Quality code assignment table
• Results storage
• Graph memory
• OK/NOK counter
• Channel configuration
• PLC assignment table
BS350 V2.400 is able to load the V2.300 .prx files offline. It can also load the FW V2.300 tightening pro-
grams or saved files (V2.300) and send them to FW V2.300.
BS350 | V2.400 Release/2014-09

4.3.3 Starting the BS350
Double click the BS350 icon to start the operating program.
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).
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.
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 inter-
face card for network operation.
If the connection is not established, you can reset all connection parameters and close any open connec-
tions, without closing the BS350. Proceed as follows:
 Go to the PC/PC interface window and click the Reset button.
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
• Gateway 0.0.0.0
The rest of the settings are either 0.0.0.0 or empty.
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 48).
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 to open the associated parameters dialog.
 The compact system - X7E1 parameter dialog will appear (see page 64).
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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 48).
2. In the BS350 operating system, click System → KE configuration
3. Double click the line X7E1 to open the associated parameters dialog.
 The compact system - X7E1 parameter dialog will appear (see page 64).
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.
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.
The user does not have to be logged in to the system to query configurations, results, error lists, etc.
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.
Information on the password change is contained in the "Project planning" documentation of the Rexroth
Tightening System 350.
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Period of the active connection

If you access the KE communication unit or the CS351 compact system using the BS350 operating sys-
tem, the connection is automatically disconnected after 15 minutes.
In the following cases, the connection is not cancelled automatically:
• If you are currently active, i.e. you exchange data with the hardware (data query or transmission). 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 result data is transmitted.
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 pro-
gramming interface (page 48))
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 interfaces
and
• password entry in the BS350 (see Logging in to the tightening system (password entry) (page 49))
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
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4.4.1.1 Send ...
Single-channel Files loaded online can be edited and then sent to the tightening controller using Data → Send ... .
operation (CS) Amongst others, these files include:
• Tightening program
• Tightening channel configuration
• SE/CS PLC assignment table
Files created offline cannot be sent using Data → Send ... or . For this purpose, use Data → Send
to ... or .
Multi-channel Files loaded online have to be sent to the KE after editing. Amongst others, these files include:
operation (KE) • Tightening program
• KE PLC assignment table
The KE forwards tightening programs and tightening channel configurations to the SEs.
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 .
4.4.1.2 Send to …
Single-channel Files loaded online or created offline can be sent to the tightening controller with Data → Send to ... .
operation (CS) Amongst others, these files include:
• One tightening program or several tightening programs simultaneously
• SE/CS PLC assignment table
Multi-channel Files loaded online or created offline have to be sent to one/several SEs or the KE. Amongst others, these
operation (KE) 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
The KE configuration and KE PLC assignment table cannot be sent using Data → Send to ... or clicking
! For this purpose, use Data → Send ... or .
4.4.2 Saving data
Use File → Save as ... to save the open file to the data carrier (e.g. hard disk). Amongst others, these files
include:
• Tightening program
• Tightening application
• CS, SE, or KE configuration
• PLC assignment table for the SE/CS or KE
The following table gives an overview of the file name extensions when they are saved.
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Table 4–11: Files with file name extensions

Files File name extension
Tightening programs *.prg
All tightening programs *.prx
Tightening applications *.fop
All tightening applications *.fox
Graph *.crv
Tightening channel configurations *.scg
KE configurations *.kcg
PLC assignment tables for SE/CS *.sio
PLC tables for KE *.kio
PLC assignment table IL export data *.exp
Quality code assignment table for SE or KE *.qtb
HMI configuration *.sdc
Field bus DP data for CS *.sdp
Field bus DP data for KE *.kdp
Graph memory configuration *.scv
Results storage configuration *.sre
Results storage display *.sdt
OK/NOK counter configurations *.cnt
Printer 1/2 configurations *.dcg
PLC (3964R) 1/2 configurations *.dcg
FTP configurations *.dcg
ID code configurations *.dcg
The .dcg files can only be stored or loaded in the respective menu under System → Tightening cell data.
An open and modified file is saved with the same name using File → Save.
The contents of a tightening cell are saved in several individual files using File → Save tightening cell
• Compact system: see figure 4–12
• Modular system: Depending on the selection made in CS selection or KE selection and SE/CS-NK
selection, see figure 4–13
These files can be opened separately using BS350 (File → Open ...) and, if needed, be sent back indi-
vidually to the controller.
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Fig. 4–12: Save tightening cell on the compact system
Fig. 4–13: Save tightening cell on the modular system
The following settings can be specified in this dialog:

• 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 4–11.
All tightening programs from the tightening controller are saved as a *.prx file for each SE. All KE tighten-
ing applications are saved as a *.fox file. All jobs of the compact systems are saved as *.job files and jobs
of the communication unit as *kjb files.
Exit the dialog using Close.
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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.
More detailed information regarding the data backup is contained in the "Project planning" documenta-
tion of the Rexroth Tightening System 350!
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 4–14) opens when the following menu items have been selected:
• System → Tightening channel configuration in online mode (see page 55) and/or
• File → New → Tightening channel configuration in offline mode (see page 73).
Layout of the The configuration window of the BS350 displays (see Figure 4–14, from left to right):
configuration window • 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
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Component selection Configuration fields Global parameters
Name Symbol Parameter Notes
Fig. 4–14: Layout of the 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.
For detailed information concerning troubleshooting, see chapter Troubleshooting from page 123.
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.
Configuration of a tightening channel with ErgoSpin SlimLine and ErgoSpin GripLine is implemented au-
tomatically. 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 108).
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 46)).
To load the current configuration of the tightening channel:
 Click System → Tightening channel configuration or .
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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 inter-
face are permanently installed. The other interfaces are not equipped1).
 The interface fields are closed by double clicking again.
Fig. 4–15: View of the interfaces in the compact system
4.5.2.2 Completing the tightening channel configuration
NOTE
Incorrect channel configuration
An 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 compo-
nents stored on the hand-held nutrunner correspond to the actually equipped components and, if
necessary, correct the configuration with the operating program.
1) For possible interface assignments and parameterizations, see Setting up additional interfaces
(page 65).
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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 73).
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 com-
ponent 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
ErgoSpin VarioLine, 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 holds true for a compact system with tightening spindle (see Figure 4–16). 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 param-
eterized manually.
Fig. 4–16: Compact system CS351S-G with configured tightening channel
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Using the compact system (CS), the transducer function motor current ("Off", "Primary", "Redundancy")
can be configured, whereas the following restrictions apply (see Figure 4–17):
• The compact system (CS) cannot be used for current-controlled tightenings. That means that the mo-
tor current cannot be used for the primary measurement ("Primary").
The corresponding option in the channel configuration is deactivated.
• With the compact system for the ErgoSpin hand-held nutrunner (CS351E...), the motor current can
be used for the redundancy measurement. In compact systems for tightening spindles (CS351S...),
this function is, however, also deactivated.
CS351E… CS351S…
"Redundancy" is possible, Neither "Redundancy" nor
"Primary" not "Primary" is possible
Fig. 4–17: CS351 compact system: Setting the transducer function motor current
ErgoSpin configuration with adapter, straight output drive or angle head

1. Double click the field highlighted in red to open the associated parameter dialog.
Figure 4–18 e.g. shows the dialog Adapter after double clicking the red field in line A.
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Fig. 4–18: Complete 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 en-
tered 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.
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.
Alternatively, you can also delete the component (see above). You then add another, side-by-side com-
ponent such as an angle head or adapter on tightening spindle output drives, for the ErgoSpin VarioLine.
Also set the missing parameters for this component as described above.
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.
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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 4–19 shows the e.g, the Special component dialog after double clicking the line SO.
Fig. 4–19: 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.
Configuration 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°.
NOTE
Damage to the flat output drive
Only for software version V2.200 SP1 and lower:
When 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 firmware of the servo amplifier (LTU350/1 or CS351) that is adjusted to the flat
output drive.
A special software with orientation to the right is available on request.
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In the Rexroth Tightening System350 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 61.
Table 4–12 shows the necessary special firmware depending on the software version of the 350 operat-
ing system and the alignment and drive direction of rotation of the ErgoSpin hand-held nutrunner.
Table 4–12: Special firmware necessary for changing the drive direction of open flat output drives with mechanical safety catch
Software version BS350 operating Alignment and drive spin direction of the ErgoSpin
system hand-held nutrunner
Clockwise Counterclockwise
BS350 V2.000 … V2.200 Special firmware: Standard, i. e. no special firmware
– LTU350/ V1.111 necessary
– CS351-E V1.201
From BS350 V2.200 SP1 Standard firmware:
– LTE350D: from 01V03
– CS351/LT: from version 2.2 FT3
Channel configura- From version 2.200 SP1 the BS350 allows for simple configuration of the ErgoSpin hand-held nutrunner
tion of open flat with open flat output drives. Using the Flat output drive (F) parameter dialog (the symbol is shown in
output drives Figure 4–20) select the output drive spin direction and, if necessary, 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.
Fig. 4–20: 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 Description
Code 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
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Table 4–13: Parameter for setting the flat output drive (F)
Parameter Description
Reverse spin direction Specification of an option for a reverse spin direction
Value range:
– Yes
Select 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.
– No
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 specified output drive spin direction 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
Configuration
example Table 4–14:
Example
Reverse spin direction No No Yes

Output drive spin Clockwise Clockwise Clockwise
direction
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 Spindle
overload and Perm. torque in the Spindle limits field is adapted to the selected unit.
Operating mode The 1-channel option is permanently activated with compact systems.
Channel The Automatic radio button is only active if there is a channel configuration with a hand-held nutrunner.
configuration In this case, you can choose between automatic and manual channel configuration.
With automatic channel configuration, system components with an electronic nameplate are automatical-
ly taken over in the configuration window and configured with the basic settings. A change in the hand-
held nutrunner is also 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.
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.
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In this operating mode, recognition of play on the start switch by the user is active (see Nutrunner start
(page 116)).
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 72).
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. For
example, for 3 slots, bit 1 and 2 are set. This means 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.
Spindle limits The displayed parameters for Perm. 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.
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 4–15).
Fig. 4–21: Parameter dialog X3C1
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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.
Ethernet interface X7E1

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 4–15):
Fig. 4–22: Parameter dialog X7E1
You can make the following settings in the Set up Ethernet interface 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 configu-
ration (address range).
• Host name: Name by which the Ethernet participant (here the compact system/the KE of the tight-
ening 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.
Detailed information on the data exchange via Ethernet is contained in the "Project planning" documen-
tation of the Rexroth Tightening System 350!
 Click Accept to store the data in the program.
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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 con-
trolled by this interface. It enables cyclical data exchange via the following interface modules:
• IMpdp
• IMdev
• IMpnio
• IMenip
• IMmtcp
Open the associated parameter dialog by double clicking the parameter field in line A (see Figure 4–15).
 In the Select interface module field (see Figure 4–23), select the desired module from the drop-
down list and set its parameters.
IMpdp
Fig. 4–23: Parameter dialog IMpdp
You can make the following settings in the Set up Profibus DP interface group:
• Station address: Address of the IMpdp in the PROFIBUS network, address range 2 to 123
• Number of I points: Number of control signals to be processed via the PROFIBUS interface: Value
range 16 to 64 input signals
• Number of O points: Number of control signals to be processed via the PROFIBUS interface: Value
range 16 to 64 output signals
• Receive data: Memory location for receiving the ID code, max. 64 bytes
• Send data Memory location for sending results, max. 198 bytes
• Receive IL data: Memory location for receiving IL data, max. 64 bytes
• Send IL data: Memory location for sending IL data, max. 198 bytes
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.
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After all the parameters have been set, create a GSD file with the button Create GSD file. Save the file
(*.gsd) and import it into the PROFIBUS configurator.
Detailed information on the data exchange via PROFIBUS is contained in the "Project planning" docu-
mentation of the Rexroth Tightening System 350!
 Click Accept to take over this data in the configuration for the tightening channel in the BS350.
IMdev
Fig. 4–24: Parameter dialog IMdev
You can make the following settings in the Set up DeviceNet interface group:
• MAC ID: Media Access Code Identifier, address range 0 to 63
• Baud rate: 125, 250, 500 kbit/s and auto detection
• Number of I points: Number of input control signals to be processed via the interface. Value range
16 to 64 input signals
• Number of O points: Number of output control signals to be processed via the interface. Value
• Receive data: Memory location for receiving the ID code, 0 to 64 bytes
• Send data Memory location for sending results, max. 254 bytes at 2 bytes for O points
After all the parameters have been set, create an ESD file with the button Create ESD file. Save the file
(*.eds) and import it into the DeviceNet configurator.
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IMpnio
Fig. 4–25: IMpnio parameter dialog (I/O and data, configuration, status information)
This parameter dialog contains three index cards that may be selected in the group Profinet IO Set up
interface:
• I/O and data
• Configuration
• Station information
I/O and data

The following settings can be made in this index card:
• Number of I points: Number of control signals to be processed via the PROFINET interface. Value
• Number of O points: Number of control signals to be processed via the PROFINET interface. Value
• Send data: Memory location for sending results, max. 254 bytes at 2 bytes for O points
These data are processed using the IL function block ControlFieldbus.
These data are processed using the IL function block ControlFieldbus.
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After all the parameters have been set, create a GSDML file with the button Create GSDML file. Save
the file (*.gsd) and import it into the PROFINET configurator.
 Click Accept to transfer the data to the configuration for the tightening channel in the BS350.
Configuration
• Get configuration via DHCP: If you select this item, the configuration is loaded in the BS350
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 config-
uration (address range)
– Gateway address: Establishes the external connection.
• Host name: Name by which the Ethernet participant (here the KE of the tightening system) can be
addressed.
Station information
The Station name field is grayed out and cannot be changed.
The Station name has to be set by the master PLC using the Naming function.
The following entries can be made in this index card:

• Station type
• Function
• Installation location
• Installation date
• Description
BS350 | V2.400 Release/2014-09

IMenip
Fig. 4–26: IMenip parameter dialog (I/O and data, configuration)
This parameters dialog consists of two index cards that can be selected in the EtherNet/IP Set up
interface group:
• I/O and data
• Configuration
I/O and data

• Number 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
(*.eds) and import it into the Ethernet configurator.
BS350 | V2.400 Release/2014-09

Configuration
or
addressed.
IMmtcp
Fig. 4–27: IMmtcp parameter dialog (I/O and data, configuration)
This parameters dialog consists of two index cards that can be selected in the ModbusTCP Set up in-
terface group:
• I/O and data
• Configuration
I/O and data

• Number 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
• Receive IL data: Option not available
• Send IL data: Option not available
BS350 | V2.400 Release/2014-09

Configuration
or
addressed.
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 4–15).
 In the Select interface module field (see Figure 4–28), select the desired module from the drop-
down list and set its parameters.
IM24V
Fig. 4–28: IM24V parameter dialog
BS350 | V2.400 Release/2014-09

4.5.2.6 Nutrunner docking configuration
Fig. 4–29: Parameters dialog for the nutrunner docking configuration
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 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 50)).
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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 4–30).
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 plau-
sible.
The global parameters are set in accordance with the online configuration (see Setting the global param-
eters (page 62)).
Permitted component Empty symbol field
Fig. 4–30: 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 50)). It must be sent to the tightening controller before commissioning the tightening channel.
BS350 | V2.400 Release/2014-09

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 108.
4.5.4 Defining a tightening program
Programs from the machine capability examination are already included on the device at the time of deliv-
ery. You can use these programs as the basis for your own tightening programs.
The tightening program coordinates the tightening process or sequence. It is divided into various tighten-
ing 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 Test tightening by overwriting the existing pro-
gram 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 4–31).
BS350 | V2.400 Release/2014-09

Fig. 4–31: Tightening program for the sequence test
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.
7. Double click the new tightening step symbol.

 The parameters dialog for the tightening step appears (see Figure 4–31).
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 start-
ed with PLC signal Ccw or if the Loosen button is clicked in the sequence test (see page 78).
BS350 | V2.400 Release/2014-09

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 4–32).
Fig. 4–32: Loosening program for the sequence test
7. Double click the new tightening step symbol.

 The parameters dialog for the tightening step appears (see Figure 4–32).
8. Enter the following data:
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 4–18), must not be exceeded.
Name, e.g. Loosen

Target function, e.g. Angle, value: 200 [ ˚]
Additional functions, e.g. Speed, value: -100 rpm.
BS350 | V2.400 Release/2014-09

Always enter a negative speed value for counterclockwise rotation.
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 50)).
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:
Table 4–15: Number of inputs and outputs

System component Number of inputs/outputs SE Number of inputs/outputs CS
ErgoSpin 4/0 4/0
IMpdp – 16 to 64/16 to 64
IMdev – 16 to 64/16 to 64
IMpnio – 0 to 64/0 to 64
IMenip – 16 to 64/16 to 64
IMmtcp – 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
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 pre-
settings when the compact system is commissioned with the ErgoSpin. It can be loaded from the com-
pact system by selecting System → SE/CS PLC assignment table.
Information on the configuration of the PLC assignment table is contained in the "Project planning" doc-
umentation of the Rexroth Tightening System 350.
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 50)).
The detailed description of the control signals is contained in the "Project planning" documentation of the
Rexroth Tightening System 350.
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 4–16 shows the possibilities for setting the time of the tightening con-
troller.
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Table 4–16: Setting the system time

Element Description
Date 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 cur-
rently 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.
The time is logged, e. g. in the course of the tightening results output, enabling times to be assigned to
the tightening results data.
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 ap-
plies to outputs in the BS350 like actual values or curves. The settings of the operating system are, how-
ever, not used! This is why there may be deviations between the PC time and the BS350 outputs.
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 sys-
tem 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 parameters dialog Rexroth BS350 - compact system appears.
Fig. 4–33: 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.
4.5.8 Sequence test
CAUTION
Incorrect fixing
Incorrect 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, 3 609 929 965!
BS350 | V2.400 Release/2014-09

4.5.8.1 Sequence test via the BS350

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 49).
2. Click System test → Sequence test or .
 The control panel shown in Figure 4–34 opens.

The sequence test is stopped by selecting this button again.
BTB OK/NOK
Channel selection Program selection System status displays Buttons
Fig. 4–34: Control panel in sequence test mode
To start the tightening program to tighten the bolt:

1. In the program selection, select the program number to be tested, e.g. 1: Test tightening.
2. Click Start.
3. Press the start button on the ErgoSpin within 15 s.
To start the loosening program:

 Click Loosen to start the loosening program (program 99, Ccw) independently of the program se-
lection.
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.
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.
For detailed information on LED displays for other (e.g. malfunctioning) operating states, see chapter
Troubleshooting from page 123.
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4.5.8.2 Sequence test via the TFT display of the CS351E-G or CS351S-G
For sequence tests using the TFT display of the CS351E-G, please observe the notes in the "ErgoSpin"
operating instructions, 3 609 929 965!
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 the BS350.
Fig. 4–35: Sequence test via the TFT display
BS350 | V2.400 Release/2014-09

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 4–36) opens when the following menu items have been selected:
• System → KE configuration in online mode (see page 82) and/or
• File → New → KE configuration in offline mode (see page 93).
Layout of the The configuration window in the BS350 displays the following (see Figure 4–36, from left to right):
configuration window • The front view of the KE
• The KE configuration with its available interfaces subdivided into 4 columns:
– Name
– Symbol
– Parameter
– Notes
Configuration fields
KE front view
Name Symbol Parameter Note
Fig. 4–36: 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.
BS350 | V2.400 Release/2014-09

For detailed information concerning troubleshooting, see chapter Troubleshooting from page 123.
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 46)).
Below is a description of the configuration and parameter assignment of the KE with the following com-
ponents:
• 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 4–36):
• 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
4.6.2.2 Setting up installed interfaces
Ethernet interface X7E1

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 4–36):
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" doc-
umentation of the Rexroth Tightening System 350.
BS350 | V2.400 Release/2014-09

Fig. 4–37: Parameter dialog X7E1
You can make the following settings in the Set up Ethernet interface 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 configu-
ration (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.
Detailed information on the data exchange via Ethernet is contained in the "Project planning" documen-
tation of the Rexroth Tightening System 350!
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 4–36):
Fig. 4–38: Parameter dialog X3C1
BS350 | V2.400 Release/2014-09

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 con-
trolled by this interface. It enables cyclical data exchange via the following interface modules:
• IMpdp
• IMdev
• IMpnio
• IMenip
• IMmtcp
Open the associated parameter dialog by double clicking the parameter field in line A (see Figure 4–36).
Fig. 4–39: Selection of A interface module in the KE
In the Code list (see Figure 4–39), select the desired module from the drop-down list and set its
parameters.
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IMpdp
Fig. 4–40: Parameter dialog IMpdp
You can make the following settings in the Set up Profibus DP interface group:
• Station address: Address of the IMpdp in the PROFIBUS network. Address range: 2 to 123.
• Number of I points: Number of control signals to be processed via the PROFIBUS interface: Value
• Number of O points: Number of control signals to be processed via the PROFIBUS interface: Value
• Send data: Memory location for sending results, max. 196 bytes
After all the parameters have been set, create a GSD file with the button Create GSD file. Save the file
(*.gsd) and import it into the PROFIBUS configurator.
BS350 | V2.400 Release/2014-09

IMdev
Fig. 4–41: Parameter dialog IMdev
You can make the following settings in the Set up DeviceNet interface group:
• MAC ID: Media Access Code Identifier, address range 0 to 63
• Baud rate: 125, 250, 500 kbit/s and auto detection
• Number of I points: Number of input control signals to be processed via the interface. Value range
16 to 2048 input signals
• Number of O points: Number of output control signals to be processed via the interface. Value
• Receive data: Memory location for receiving the ID code, max. 254 bytes at 2 bytes for O points.
(*.eds) and import it into the DeviceNet configurator.
BS350 | V2.400 Release/2014-09

IMpnio
Fig. 4–42: IMpnio parameter dialog (I/O and data, configuration, status information)
This parameter dialog contains three index cards that may be selected in the group Profinet IO Set up
interface:
• I/O and data
• Configuration
• Station information
I/O and data

• Number of I points: Number of control signals to be processed via the PROFINET interface: Value
• Number of O points: Number of control signals to be processed via the PROFINET interface: Value
• Receive data: Memory location for receiving the ID code, max. 254 bytes at 2 bytes for O points
After all the parameters have been set, create a GSDML file with the button Create GSDML file. Save
the file (*.gsd) and import it into the PROFINET configurator.
BS350 | V2.400 Release/2014-09

Configuration
or
addressed.
Station information
The Station name field is grayed out and cannot be changed.
In this window, you can enter the following data:
• Station type
• Function
• Installation location
• Installation date
• Description
IMenip
Fig. 4–43: IMenip parameter dialog (I/O and data, configuration)
This parameters dialog consists of two index cards that can be selected in the EtherNet/IP Set up
interface group:
• I/O and data
• Configuration
BS350 | V2.400 Release/2014-09

I/O and data

• Number 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
(*.eds) and import it into the Ethernet configurator.
Configuration
The following settings can be made in this window:
or
addressed.
BS350 | V2.400 Release/2014-09

IMmtcp
Fig. 4–44: IMmtcp parameter dialog (I/O and data, configuration)
This parameters dialog consists of two index cards that can be selected in the ModbusTCP Set up
interface group:
• I/O and data
• Configuration
I/O and data

• Number of I points: Number of control signals to be processed via the ModusTCP interface: Value
• Number of O points: Number of control signals to be processed via the ModusTCP interface: Value
• Receive IL data: Option not available
• Send IL data: Option not available
BS350 | V2.400 Release/2014-09

Configuration
or
addressed.
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 4–36).
In the Code list (see Figure 4–45), select the desired module from the drop-down list and set its
parameters.
Fig. 4–45: Selection of B interface module in the KE
BS350 | V2.400 Release/2014-09

IM24V
Fig. 4–46: IM24V parameter dialog
BS350 | V2.400 Release/2014-09


connected:

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 50)).
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. 4–48: 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 82).
The created KE configuration can be stored as a file on the PC (see Sending and saving (page 50)).
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 se-
lect a tightening channel.
If the tightening channels all have the same configuration, only one tightening channel has to be config-
ured. 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 50)).
Tightening channel configuration of the control unit in single-channel operation
If after its delivery, the control unit is operated directly next to a KE for the first time, the following sce-
nario 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.
The control unit controls and monitors the tightening process of up to two independent tightening chan-
nels 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.
Fig. 4–49: Motor current transducer function configuration for servo amplifiers
BS350 | V2.400 Release/2014-09

Fig. 4–50: LT: Setting the transducer function motor current
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.
BS350 | V2.400 Release/2014-09

4.6.4.2 Tightening channel configuration with BG5+
Offline tightening channel configuration with expanded limits is possible if an EC motor (EC305?) is
selected. Additionally, an adjusted system box SB355 with an increased intermediate circuit voltage is
required.
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:
Fig. 4–51: SE configuration according to example BG5+
nmax, motor = 12,500 rpm (previously 10,000 rpm)
Mmax, motor = 9.5 Nm (previously 8.5 Nm)
For an overview of the hardware requirements, see section BG5+ with increased performance (page 42)
in the "Project planning" documentation of the Rexroth Tightening System 350.
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4.6.5 Defining the tightening program
Proceed as listed in section Defining the tightening program (page 97) 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 50)).
Then test the function of the tightening program in each tightening channel with a sequence test (see
Sequence test (page 101)).
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.
Example 1. To generate a tightening application, select File → New → Tightening applications in the BS350
menu bar.
2. Select a program number, e.g. 1 and assign a name to the tightening application, e.g. Test appli-
cation, by overwriting the existing program name "n. a" (not available). (If program number 0 is se-
lected, "n.a." is not displayed) (see Figure 4–52).
3. Click Application info and enter a comment for the tightening program 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 tool tip.
BS350 | V2.400 Release/2014-09

Fig. 4–52: Tightening application for the sequence test
5. Double click the start step symbol 1, A. The start step dialog (see Figure 4–52) 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 list Channel selection 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.
BS350 | V2.400 Release/2014-09

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.

connected:

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 on page 50).
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 the BS350 (page 79)) always simultane-
ously starts loosening program no. 99 in all the tightening channels. Proceed according to Defining a
tightening program (page 74) 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 77).
BS350 | V2.400 Release/2014-09

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.
Table 4–17: Number of inputs and outputs

System component Number of inputs/outputs KE
IMpdp 16 to 512/16 to 512
IMdev 16 to 512/16 to 512
IMpnio 16 to 512/16 to 512
IMenip 16 to 512/16 to 512
IMmtcp 16 to 512/16 to 512
IM24V 10/13
IL 256/256
XML 649/675
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 46)).
Use System → KE 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. 4–54: 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 50)).
Information on the configuration of the PLC assignment table is contained in the "Project planning" doc-
umentation of the Rexroth Tightening System 350. Related examples are contained as well as in the "Proj-
ect planning" documentation of the Rexroth Tightening System 350.
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.
BS350 | V2.400 Release/2014-09

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. 4–55: Setting the KE time
The time zone must be selected from the list (for Germany: time zone, see Figure 4–55). 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 78)) are described here.
To carry out the sequence test for a tightening application, proceed as described in Sequence test
(page 78).
Tightening spindles To start the tightening application to tighten the bolts, select:
clockwise • 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 When Loosen is selected, the loosening program (Ccw, no. 99) will be started simultaneously in all the
counterclockwise tightening channels in the selected tightening application.
4.7 Saved ("automatic") channel configuration
This function is supported from version V2.200 of the Rexroth Tightening System 350.
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.
BS350 | V2.400 Release/2014-09

The saved ("automatic") channel configuration eliminates the manual re-configuration step upon nutrun-
ner replacement. This function works as follows: Upon initial online- or offline configuration of the tighten-
ing 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. Pre-
viously saved configurations are overwritten.
When loading the saved configuration, the channel configuration is calculated automatically, e.g. maxi-
mum spindle torque or maximum speed.
Saved ("automatic") For tightening spindles, the following prerequisites have to be met to be able to save a created channel
channel configuration configuration:
 The measurement transducer 1 is of the DMC type.
If there are two measurement transducers, the configuration is saved to the transducer that is only con-
nected to one CAN line (MC1).
Other measurement transducers are not supported for this function. There will be no error messages
either.
 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 config-
uration will be overwritten.
Loading channel The following is required for reading in the saved configuration:
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.
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 compo-
nents detected (e.g. measurement transducer).
• If the saved spindle components and the spindle components detected are identical, the saved con-
figuration is accepted automatically. There is no more need to re-configure manually using the oper-
ating system BS350.
• If the saved tightening channel configuration and the spindle components detected automatically dif-
fer, 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 . After-
wards, the data have to be sent to the controller. Additionally, the error message1111 "Channel config-
uration missing" is issued. This procedure is identical to the behavior known from previous versions
when there was no configuration saved to the controller.
BS350 | V2.400 Release/2014-09

NOTE
Incorrect channel configuration
By replacing mechanical components or the measurement transducer (DMC), the saved channel con-
figuration may deviate from the actual configuration. Thus, erroneous tightenings may be the result.
 After having replaced mechanical components or the measurement transducer (DMC) always re-
configure the tightening channel. Use the operating program BS350. Finally, save this new con-
figuration to the hand-held nutrunner or tightening spindle, see Saved ("automatic") channel con-
figuration on page 102.
NOTE
Adaptes spindle component efficiency
The 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.
Deleting channel Use Data → Delete SE/CS → Configuration in the BS350, to delete the saved channel and spindle
configuration configuration data on the tightening controller. Furthermore, this function deletes the spindle configura-
tion 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, aBS350 operating system is required.
4.7.2 Modular system
The following describes the special features for commissioning a tightening channel that consists of in-
dividual 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:
BS350 | V2.400 Release/2014-09

LC display
LED displays
Reset button
ErgoSpin connection at the XDS1 interface
Fig. 4–56: 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 informa-
tion on the LC display, see section 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:
Table 4–18: LED display on the LTU350/1

LED display
BTB Green Ready for operation
Red System error
MS Green Ready for operation


Reset button Reset
Reset button Press this button to reset the servo amplifier.
XDS1 The ErgoSpin connection cable is connected to the XDS1 interface.
4.7.2.2 Interfaces and displays on the LTS350D/LTE350D servo amplifier

The following interfaces and displays are integrated in the LTS350D/LTE350D:
BS350 | V2.400 Release/2014-09

LC display
LED displays
Reset button
LTE350D: XDS1 interface for ErgoSpin

hand-held nutrunner
XDN3 interface for interrupting the
motor release
LTS350D: XDS2 interface for

tightening spindle
Fig. 4–57: 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. For more information on
the LC display, see section "LC display" on page 719 in the "Project planning" documentation of the
LED displays Three LEDs are located on the front plate of the servo amplifier and provide information on the following
operating states:
Table 4–19: LED display on the LTE350D

LED display
BTB Off No power supply or LTS/LTE is in download mode
Green, flash- Not ready for operation, but no system error; motor-breaker has been
ing triggered
Error LED Red System error
Reset button Reset
Reset button Press this button to reset the servo amplifier.
XDS1 The ErgoSpin connection cable is connected to the XDS1 interface.
4.7.2.3 Motor contactor control and fuses
Motor contactor Information on the position and locations of the PIN plug on the LTU350/1 can be found in Table 4–20
control and Figure 4–58.
Find information on the position and location of switch S2 at the LTS350D/LTE350D in Table 4–21 and
Figure 4–59.
BS350 | V2.400 Release/2014-09

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 motor-breaker 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 inde-
pendent of the position of the PIN plug. The motor-breaker 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 motor-breaker 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 4–20: Positions of the PIN plug in the LTU350/1

PIN plug in Explanation
position:
1 Operation of ErgoSpin as hand-held nutrunner without motor-breaker 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
Fig. 4–58: PIN plug
Table 4–21: Positions of switch S2 in the LTS350D/LTE350D

Position Explanation
1 Motor-breaker 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
BS350 | V2.400 Release/2014-09

Fig. 4–59: Switch S2
More detailed information on motor breaker circuits is contained in the "Project planning" documentation
of the Rexroth Tightening System 350.
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 de-
scribed above (for removal, see Figure 4–60).
Fig. 4–60: 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
4.7.2.4 Motor release interruption at the LTS350D/LTE350D

At the XDN3 interface, see figure 4–61, the motor release can be interrupted via a potential-free opening
contact.
BS350 | V2.400 Release/2014-09

Table 4–22: Positions of the PIN plug in the LTS350D/LTE350D

PIN plug in Explanation
position:
1 Motor-breaker Out
2 Motor-breaker In
PIN 1 and 2 are equipped with a jumper at the factory to ensure that the motor is ready for operation.
Fig. 4–61: 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 37)
• Insert the available interface modules in accordance with chapter Interface modules (IM) (page 37)
• 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 4–56) 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 39)
• 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 46) (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 com-
missioning. No configuration changes are required for basic commissioning. The configuration can also
be implemented manually at System → Tightening channel configuration (see Offline configuration:
(page 73)), if you are using deviating versions, additional components, or working in offline mode.
General information on sending files can be found at Sending and saving (page 50).
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 con-
figurations created offline which contain an ErgoSpin of type VarioLine (ESV) or of type pistol grip nut-
runner (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.
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.
BS350 | V2.400 Release/2014-09

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 55
– Modular system: see „Loading the KE configuration“ from page 82.
2. Adjust the tightening channel configuration.
– Compact system: see „Completing the tightening channel configuration“ from page 56
– Modular system: see „Configuring the tightening channels“ from page 94.
3. Send the changed tightening channel configuration to the tightening controller, see „Sending and
saving“ from page 50
 The tightening channel configuration on the tightening controller has been changed.
BS350 | V2.400 Release/2014-09

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 62)).
 In order to allow for tightenings, send the configuration to the control unit.
If deviating tightening programs (0 to 3, 99) are already on the tightening controller, they will be overwrit-
ten after acknowledgement of error message code 382, if the additional function Use tightening pro-
grams from hand-held nutrunner (program 99 and 0..3) (see Additional function (page 62)) is
activated.
The tightening programs on ErgoSpin hand-held nutrunners supplied from the factory can be deleted.
NOTE
Loss of data
Tightening programs can be deleted in the hand-held nutrunner, if the tightening programs in theSE
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.
4.7.3.2 Automatic configuration of the tightening channel
Automatic initial Automatic commissioning is active if there is no existing channel configuration. Here, the components rec-
commissioning ognized by the tightening controller are transferred to the channel configuration without querying the user
and configured with a default value (SE, IM, LTU).
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. To call up the configuration of the tightening chan-
nel, select System → Tightening channel configuration or the icon.
Automatic channel Automatic channel configuration is active if the Automatic option is selected under Channel in the global
configuration parameters (see Channel configuration (page 62)). 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.
BS350 | V2.400 Release/2014-09

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).
The PLC assignment table is generated automatically during automatic commissioning.
Programming the IM24V interface module in the type B1/B2 slot

 Click Edit in the open 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
 Click Edit to 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. Click Edit in the open 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 4–63)
For information on offline configuration, see chapter Configuration SE/CS PLC assignment table
(page 77)
4.7.3.4 Selecting tightening programs

As described in section Storing the tightening programs (page 110), up to five tightening programs (0 to
3, 99) can be stored in the ErgoSpin hand-held nutrunner ex factory (see Figure 4–62). 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: MCE (machine capability examination1)) 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
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 re-
sults 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.
BS350 | V2.400 Release/2014-09

Fig. 4–62: Selecting the tightening program in the BS350
Program selection can be implemented via 24 V signals (IM24V interface module), a field bus (IMpdp or
IMdev interface module) or, with the CS351E-G, directly via the TFT.
The PLC assignment table must be configured for this accordingly.
If no program is selected via one of these interfaces, program 0 is selected as standard. Loosening pro-
gram 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 control-
ler (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 Addi-
tional function (page 62) and Chapter Storing the tightening programs (page 110)).
If deviating tightening programs (0 to 3, 99) are already on the tightening controller, they will be overwrit-
ten after acknowledgement of error message code 382, if the additional function Use tightening pro-
grams from hand-held nutrunner (program 99 and 0..3) (see Additional function (page 62)) is
activated.
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 highlight-
ed in red (see Figure 4–63):
BS350 | V2.400 Release/2014-09

Fig. 4–63: 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.
BS350 | V2.400 Release/2014-09

4.7.4 Configuring the optional additional module barcode scanner
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.
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 nut-
runners 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 con-
figured 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 fix 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 4–23 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 follow-
ing options:
• Updating the configuration data
• Sending the configuration data to the hand-held nutrunner
BS350 | V2.400 Release/2014-09

Table 4–23: Barcode scanner within ErgoSpin: Timing parameter

Timing parame- Explanation Standard value Value range [s] Modification Special value [s]
ter [s] step [s]
Activation time Maximum – 0,5…25,5 0.1 0: Continuous
laser illumination time operation
until automatic de-
activation of the
laser
Release time The scanner can – 1…99 1 0: Scanner is re-
be released using leased as long is
the PLC signal the PLC signal is
EnScan. The du- present.
ration is set using 1…99 If the PLC
this parameter. signal is present,
the scanner is re-
leased from the
set time.
Time acoustic Duration of the – 0,1…9,9 0.1
signal decode acoustic signal
upon recognizing
a barcode
Delay during con- Only relevant if – 0,5…9,9 0.1
tinuous operation scanner in contin-
uous operation
(laser always
activated)
Waiting time upon
recognizing a bar-
code until the next
barcode is
recognized.
BS350 | V2.400 Release/2014-09

4.7.5 Nutrunner test
3
2
Fig. 4–64: ErgoSpin, SlimLine type
1 Start switch
2 CW/CCW reversal switch
3 Tool button
4 Socket for the ErgoSpin connection cable
4.7.5.1 Nutrunner start

The ErgoSpin is started by actuating the start switch (1) (see Figure 4–64).
Press the start switch (1) on the hand-held nutrunner and hold until the hand-held nutrunner automatically
switches off.
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 117)).
4.7.5.2 CW/CCW reversal switch
The direction of rotation for the nutrunner is determined by the algebraic sign for the speed in the tight-
ening program. The description in this section applies in case a positive speed is set in the tightening pro-
gram. With a negative speed, the description for clockwise/counterclockwise revolution has inverse
effects.
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 4–64).
BS350 | V2.400 Release/2014-09

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 pro-
gram (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 4–64), 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 (con-
trol signals), see SE/CS PLC assignment table (page 111).
4.8 Commissioning the CC-ErgoSpin hand-held nutrunner and its special

features
The CC-ErgoSpin can be connected as of version V2.300 SP1 of the BS350.
4.8.1 Commissioning the CC-ErgoSpin hand-held nutrunner
ATTENTION!
Incorrect motor alignment
When first starting the nutrunner after switching the tightening channel on, make sure that the output
drive can turn freely to allow for correct motor alignment.
Otherwise, the measurement accuracy may be impaired while the torque is registered!
 When the nutrunner turns for the first time after the device was switched on, it must not turn on
the bolt! The system always has to align the motor first. This is shown by a short vibration (1 s) of
the nutrunner. Thereafter, tightening can be started.
 The motor is re-aligned every time the device is switched on!
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.
BS350 | V2.400 Release/2014-09

Fig. 4–65: Configuration of the MCE factor
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 exclu-
sively 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.
4.8.2 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". 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).
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 pro-
cesses" and "Working with the System" in 3 608 878 302 Rexroth System 350 project planning.
BS350 | V2.400 Release/2014-09

Other deviations of the CC version in the BS350 standard operating system
Fig. 4–66: CC-CS module configuration
• With the CC-CS351, module slot A is not displayed in the tightening channel configuration.
"HMS" firmware field bus 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 un-
configured 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.
BS350 | V2.400 Release/2014-09

4.9 Special characteristics of Nexo portable radio nutrunner operation

This section describes the characteristics of the operation of the Nexo portable radio nutrunner.
The portable Nexo radio nutrunner can be connected from V2.300 of the Rexroth Tightening System 350.
Please find information on the Rexroth Nexo portable radio nutrunner in the "Nexo" documentation.
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 con-
figured 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 ad-
dress 0.0.0.0 is displayed.
Fig. 4–67: Nexo configuration
BS350 | V2.400 Release/2014-09

Table 4–24: 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 ad-
dress 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 com-
ponent is available.
Click on the button to add new entries.
– Name
Default 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.
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.
BS350 | V2.400 Release/2014-09

BS350 | V2.400 Release/2014-09

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 124)

• Reset function (page 125)
• LED displays and operating elements (page 126)
• Error recognition on interface modules (page 132)
• Error recognition and acknowledgement on the TFT display (page 141)
• Error recognition and acknowledgement with the BS350 operating program
(page 142)
• Description of selected errors (page 156)
• Replacing defective components (page 159)
• Complete error list (page 161)
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 con-
trol unit, LT35x, LTU350/1 servo amplifier or LTS350D/LTE350D)
• The LEDs on the interface modules (IM24V, IMenip, IMmtcp, IMpnio, IMpdp, IMdev)
• 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 wait-
ing 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 161).
The error code assignment table is divided as follows:
Table 5–1: Description of the error code assignment table

Column heading Description
Error code Unique error number
English Error text, some entries with information on the affected components 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 125))
BS350 | V2.400 Release/2014-09

5.1.3 Error classes
Errors in the Tightening System 350 are divided into the following classes:
Table 5–2: Error classes

Error class Error type Remedy
1 This error class indicates the occurrence of a se- The tightening system can only be made ready for
rious error; the tightening system is no longer operation with the help of the user, e.g. by:
ready for operation, i.e. a tightening job is not – sending the correct configuration
possible. This error can be caused by e.g.: – power off/on
– missing configuration – reset
– failure of hardware components – replacement of hardware components
2 Currently not used -
3 This error class indicates a malfunction in the Acknowledgement of the error via the electronic
tightening system. Before the error is acknowl- interfaces:
edged, it is temporarily not ready for operation. – PLC signals
– BS350 error list
– TFT on the compact system
4 This error class indicates a malfunction in the Self-acknowledgement of the error by the tighten-
tightening system; however, the error is ac- ing system.
knowledged by the tightening system itself after
the remedy of the cause, e.g.:
– temperature error
– error motor-breaker circuit
5*?* System message (no error), e.g.: Remedy not required
– test interval ErgoSpin reached
* Errors of error class 5 are not displayed at the communication partner for the Open Protocol), the so-called "Open
Interface".
5.2 Reset function

Errors are signalized via the LED on the control and power electronics. In principle, the measures indicat-
ed in section Overview (page 124) 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.
BS350 | V2.400 Release/2014-09

NOTE
Damages caused by restarting the system too fast
Restarting 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.
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
IL RUN/STOP ERROR
CS351 without IL CS351 with IL
Fig. 5–1: LEDs at the front
Table 5–3: LED modes

LED Color Description
Off 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
Green Tightening case evaluation: OK
OK/NOK
Red, flashing Tightening case evaluation: NOK
Off Motor contactor not operated
Green Motor contactor operated
Red/green, flashing Servo amplifier initialization
Green Servo amplifier release
FG
RUN/ Green PLC program is running
STOP *?* Red PLC program is stopped
Off No PLC program is included in the tightening system
ERROR * Red, flashing Integrated logic error
* Only for CS351 with IL
BS350 | V2.400 Release/2014-09

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:
Table 5–4: Displays and operating elements on the LTU350/1

BTB-LED Off No power supply or LTU is in download mode
Green, flashing Not ready for operation, but no system error;
Motor-breaker 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
Button Reset
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; motor-breaker 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.
Table 5–5: Displays and operating elements on the LTS350D/LTE350D

BTB-LED Off No power supply or LTS/LTE is in download mode
Green, flashing Not ready for operation, but no system error;
Motor-breaker has been triggered
FG-LED Off No servo amplifier release
Error LED Red System error
Button Reset
BS350 | V2.400 Release/2014-09


• Constant green light: No error, LTS350D/LTE350D ready for operation
• Green flashing: LTS350D/LTE350D not ready for operation, but no system error; motor-breaker has
been triggered
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 (3 609 929 B32):
Table 5–6: Displays and operating elements on the VM

BTB-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
INT
LED Green External 24 V available
EXT
Button Reset
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.
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.
NOTE
Damages to components and parts
If 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!
BS350 | V2.400 Release/2014-09

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.
Table 5–7: LEDs and reset button on the SE

1 2 Color Description
LED Red, flashing System error
Green, flashing Not ready for operation1), but no system error;
LED Red, flashing Tightening result NOK
4
Green Tightening result OK
Button Reset
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:
Color Description
Green, flashing Not ready for operation
Red LT system error
LED Orange VM not ready for operation
Green Motor is triggered
Button Reset

• 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 (motor-breaker 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.
If the emergency OFF signal is interrupted during a tightening, e.g. by the motor-breaker, the tightening
spindle is decelerated actively and tightening is stopped and an error message is sent to the SE. Depend-
ing 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.
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:
BS350 | V2.400 Release/2014-09

Color Description
Green, flashing Not ready for operation
LED Orange Not ready for operation
Red/green, Data traffic active
flashing
Button Restart

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 144))
– 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/, LTS350D/LTE350D, VM, SE, LT, and KE when ready for
operation are listed in the following tables.
Table 5–8: LED displays in operating state

CS351 (when used with ErgoSpin)
On
Green (static)
– Green (static) during tightening (LTU350/1 or ErgoSpin active)

– Off in waiting mode (no tightening)
– Green (static) during tightening (LTU350/1 or ErgoSpin active), release servo
FG 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)

BS350 | V2.400 Release/2014-09

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, LT35x, and KE ready for operation

VM SE LT KE
Green (static) Green (static) Green (static) Green (static)
Off 4 Green (static) – Green (static) Off

depending on – Off, when the
the result of the motor is not
tightening triggered
Off
LED display – other operating states

Other operating states of the VM, SE, LT, and KE components are listed in the following tables.
Information about other CS351 and LTU350/1or LTS350D/LTE350D operating states can be found un-
der Compact system (page 126) and under LTU350 servo amplifier (page 127).
Table 5–12: Display of various operating states via LEDs

States Possible Error cause Measure
operating state
VM350
VM not ready for Undervoltage or Restore correct input voltage

operation overvoltage error
VM not ready for Temperature error establish permissible ambient
operation temperature
SE
4
Ready for operation NOK tightening check e.g. program parameters

and/or tightening case
Sequence test - -
* Deselection of tightening Spindle bypass Spindle selection and deselec-

spindles (bypass) tion possible under BS350
Configuration error, incorrect configuration Check and correct configura-

channel not ready for of the tightening channel tion under BS350
operation
Condition when switched Condition when switched on Wait until the tightening system
on or starting is ready
System error Pinpointing of errors Restart via KE
via BS350, SE error list
KE
BS350 | V2.400 Release/2014-09

Table 5–12: Display of various operating states via LEDs

States Possible Error cause Measure
operating state
Sequence test - -
Condition when switched Initialization not yet Wait until initialization is

on or starting completed 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 Activation 24V to X4
VM is missing on VM
System error Pinpointing of errors via Remedy error and reset on LT
BS350, SE/KE error list or acknowledge via BS350
Sleep mode VM not ready for operation Get VM ready for operation
* With NOK tightening

** Data transfer LED flashes during data transfer
Key:
: LED green
: LED red
: Static LED display or off
: LED flashes
5.4 Error recognition on interface modules

The LEDs on the IMenip, IMmtcp, IMpnio, IMpdp, and IMdev interface modules help recognize errors
during communication via these interfaces. The IM24V interface module does not have an LED.
Detailed information on the IM24V, IMenip, IMmtcp, IMpnio, IMpdp, and IMdev interface modules can be
found in the "Project planning" documentation of the Rexroth tightening system 350.
5.4.1 LEDs on the interface modules
The LEDs at the front of the interface modules display the respective network status.
BS350 | V2.400 Release/2014-09

IMenip
1 2 3 4
NS MS
LINK 5
Fig. 5–2: IMenip LED display
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 Meaning
Off 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 Meaning
Off No connection, no activity
Green Connection established, ready for operation
Flashing green Connection/activity
Table 5–15: MS
LED display Meaning
Off 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
Detailed information on the IMenip configuration is contained in the "Project planning" documentation of
BS350 | V2.400 Release/2014-09

IMmtcp
1 2 3 4
NS MS
LINK 5
Fig. 5–3: IMmtcp LED display

2 Modbus interface
5 Bolts
Table 5–16: NS
LED display Meaning
Off No voltage, not initialized or incorrect/missing IP address
Green Module is active or in idle mode
Flashing green Waiting for connection setup
Red Double IP address or blocking error
Flashing red Timeout reached for an active process
Table 5–17: LINK

LED display Meaning
Off No connection, no activity
Green Connection established
Flashing green Connection established, activity
Table 5–18: MS
LED display Meaning
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
Detailed information on the IMmtcp configuration is contained in the "Project planning" documentation of
BS350 | V2.400 Release/2014-09

IMpnio
1 2 3 4
NS MS
LINK 5
Fig. 5–4: IMpnio LED display

2 PROFINET interface
5 Bolts
Table 5–19: NS
LED display Meaning
Off 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 5–20: LINK

LED display Meaning
Off No connection, no communication
Green Connection established, no communication
Flashing green Connection established, communication running
Table 5–21: MS
LED display Meaning
Off 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 Diagnostic events available
once)
Flashing green (flashes Network configuration with module identification running
twice)
Red Exception error, module in "EXCEPTION" status
Red flashing (flashes Configuration error
once)
Red flashing (flashes Error in the IP address or IP address not assigned
twice)
Red flashing (flashes Error in station name or station name not assigned
three times)
Red flashing (flashes Severe internal error
four times)
Detailed information on the IMpnio configuration is contained in the "Project planning" documentation of
BS350 | V2.400 Release/2014-09

IMpdp
5 1
1 3
5
9 6
4
Fig. 5–5: IMpdp LED display
1 LED OP (operation mode)

2 Interface
3 LED ST (status)
4 Bolts
Table 5–22: OP
LED display Meaning
Off 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 5–23: ST
LED display Meaning
Flashing green Ready for operation, diagnoses available
Red Exception error
Detailed information on the IMpdp configuration is contained in the "Project planning" documentation of
IMdev
1 3
NS MS
4
1 2 3 4 5
Fig. 5–6: IMdev LED display

2 Interface
4 Bolts
BS350 | V2.400 Release/2014-09

Table 5–24: NS
LED display Meaning
Off After the device has been started and during the test for double MAC IDs; no power or con-
nection 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 5–25: MS
LED display Meaning
Off No voltage
Flashing green (1 Hz) Missing or incomplete configuration
Red The IMdev interface module can only be made ready for operation through measures per-
formed by the user.
Flashing red (1 Hz) Error has been self-acknowledged after the IMdev interface module has remedied the cause
of the same.
Detailed information on the IMdev configuration is contained in the "Project planning" documentation of
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. 5–7). A faulty slot is highlighted red in the KE configuration window.
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Fig. 5–7: 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. 5–8).
Fig. 5–8: KE error list ...
The configuration conflict is remedied by creating agreement between the programmed configuration and
the actual configuration of the KE.
The configuration conflicts listed in the following can occur in all interface modules and slots of the KE!
Example The IMpdp interface module configured and parameterized in the BS350 is not inserted into the KE on a
Error code 2208 type A slot. The KE configuration window shows the error message highlighted red Module IMpdp
removed! (Fig. 5–7, 5–9) and the error code 2208 in the error list:
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Table 5–26: Example error code 2208

Error code Error text Error class
2208 Module in <A> removed 1
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 (with-
out IMpdp). To do this, double-click line A in the configuration window and select none as interface mod-
ule (Fig. 5–9):
Fig. 5–9: KE configurations 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.
If already configured interface modules are missing on the type B1 and B2 slots, the following error codes
are displayed in the error list:

2208 Module in <A> removed 1
Example The IMpdp interface module not yet configured in the KE is inserted into the previously unoccupied type
Error code 2205 A slot of the KE. The Module in <A> new error message appears highlighted red in the KE configuration
window (Fig. 5–10) and the error code 2205 appears in the error list:

2205 Module in <A> new 1
Remedy:
Or the KE must be re-configured in the BS350 at System → KE configuration (Figure 5–10). For this,
double-click line A in the configuration window and parameterize the IMpdp interface module:
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Fig. 5–10: KE configurations 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.
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 5–29: Example error codes 2203 and 2205

2203 Module in <B1> new 1
2205 Module in <A> new 1
Example The IMpdp interface module is inserted into the KE into the type A slot, on which, however, the IMser in-
Error code 2211 terface 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:

2211 Module in <A> changed 1
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 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 5–31: Example error codes 2209 and 2211

2209 Module in <B1> changed 1
2211 Module in <A> changed 1
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5.5 Error recognition and acknowledgement on 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
In the Error list menu item you can select whether all or only the non-acknowledged errors of the KE
should be displayed.
The error list configuration is described using the following example:

1 2 3 4 5 6
Fig. 5–11: CS error list
1 Consecutive error number

2 Time
3 Date
4 Error message in clear text
5 Error code
6 Error class
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.
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5.6 Error recognition and acknowledgement with the BS350 operating

program
The System test menu (Fig. 5–12) 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 5–32.
.
Fig. 5–12: Diagnosis options in the BS350
Table 5–32: Brief description of the diagnosis options

Diagnosis option Brief description
Sequence test Functional test via BS350 (without PLC), see Sequence test (page 144)
Transducer test Diagnosis of the transducer signals, see Transducer test (page 145)
Tightening channel info General information on the tightening channel, see Tightening channel info (page 145)
KE info General information on the KE, see KE info (page 146)
Tightening cell info Information on the tightening cell (see Tightening cell info (page 146)) concerning:
– Firmware
– Cycle counter
– OK/NOK counter
– Temperature
– Language packs
– Units
Mass storage ... CF350 mass storage diagnosis, see KE mass storage (page 149)
SE/CS I/O interface … Monitoring of the SE and CS I/O signals, see SE, CS/KE I/O interface (page 151)
KE I/O interface ... Monitoring of the KE I/O signals, see SE, CS/KE I/O interface (page 151)
SE Arcnet bus ... Diagnosis data on the Arcnet SE status and participants, see SE/KE Arcnet bus (page 153)
KE Arcnet bus ... Diagnosis data on the Arcnet KE status and participants, see SE/KE Arcnet bus (page 153)
CAN bus ... Diagnosis data on the CAN bus status and participants, see CAN bus (page 154)
Ethernet ... Test functions for the Ethernet connection, see Ethernet (page 154)
CS field bus data ... Diagnosis data on the field bus in the SE, see Field bus data CS/KE (page 155)
KE field bus data … Diagnosis data on the field bus in the KE, see Field bus data CS/KE (page 155)
Field bus status ... Field bus diagnosis data, see Field bus status (page 155)
SE/CS error list … Documentation of errors that occurred in the SE/CS, see Error lists (page 143)
KE error list ... Documentation of errors that occurred in the KE, see Error lists (page 143)
Tightening cell error list ... Documentation of errors that occurred in the tightening cell, see Error lists (page 143)
... Description of the sequence trace, see ... FF3/FF4 (internal sequence trace) (page 156)
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5.6.1 Error lists
In order to quickly and simply pinpoint the cause of an error, the respective data from the tightening sys-
tem 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. 5–13)
• System test → Tightening cell error list ... (SE, KE, CS)
Figure 5–13 shows the contents and the configuration of the KE error list.
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. 5–13: 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).
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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In the Error frequency index card (Fig. 5–14), all errors from the respective error list are output sorted
according to their frequency.
Fig. 5–14: KE error frequency
Underneath the Error frequency list, the error time, number of errors, as well as the error frequency, ab-
solute 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 sort-
ing, increasing or decreasing.
Preset sorting: The
• Error list is sorted as increasing, according to the time (last error at the top) (Fig. 5–13)
• Error frequency is sorted as increasing, according to the number of errors (most frequent error at
the top) (Fig. 5–14).
5.6.2 Sequence test
Fig. 5–15: Control bar for the sequence test
Using the sequence test, individual programs or applications are started manually (without control e.g. via
a PLC).
As soon as the control bar (Fig. 5–15) is activated, the selected KE/SE switches to test mode. As an in-
dication 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. 5–16: 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, cali-
bration value, and actual values (torque, maximum torque value, angle)). Using Update, the actual values
are constantly updated.
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 trans-
ducer values are displayed.
Pressing the Update button puts the tightening channel in the operating state "not ready for operation"!
5.6.4 Tightening channel info
Fig. 5–17: Information on the tightening channel
Select one of the options (right in Fig. 5–17) 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.
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5.6.5 KE info
Fig. 5–18: 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. 5–19: 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 infor-
mation can be found at:
• www.boschrexroth.com/schraubtechnik
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. 5–20: 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. 5–21: OK/NOK counter within the tightening cell
The counter status of the OK/NOK counters can be viewed here. The affected tightening channel is dis-
played 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 count-
er. Sum NOK displays values, default values and counter directions according to the NOK values.
5.6.6.4 Temperature
Fig. 5–22: 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. 5–23: 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. 5–24: Units used within the tightening cell
The current settings for the torque measurement unit and the gradient calculated from the same are dis-
played 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.
BS350 | V2.400 Release/2014-09

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.
Detailed information on the installation of the CF350 mass storage is contained in the "Project planning"
documentation of the Rexroth Tightening System 350.
Fig. 5–25: Contents of the mass storage
The Contents index card illustrates the directory structure in the mass storage similarly to the Explorer in
Windows. The directory for the ID code files (IDCode), as well as the tightening results directories (FO
and CH_xx_x), can be read. Management data for transferring results to the FTP server can be found in
another directory system.
An overview of the mass storage assignment appears in the bottom right of the window.
Unused storage space in the mass storage on the communication unit is monitored, so that the danger
of overflow can be recognized in time. An acknowledgeable error message (error 2023, warning level
mass storage, error class 3) is generated to warn that mass storage is 80 % full. However, an non-ac-
knowledgeable error message (error 2024, mass storage is full, error class 1) is generated if mass stor-
age is 90 % full.
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Fig. 5–26: Prepared results files awaiting transfer via FTP
In the Statistics index card (Fig. 5–26), the not yet transferred results files are displayed.
The overview has the same structure as the directory in the mass storage:
• Column 1 shows whether the result is for a tightening application (FO) or an indicated tightening
channel (CH_xx_x).
• Column 2 shows with which application or with which tightening program the result was achieved.
• In column 3, the number of results files not yet transferred for the application/the tightening program
from column 1 and 2 is indicated.
Fig. 5–27: Maintenance index card
Various mass storage functions are available in the Maintenance index card (Fig. 5–27).
By clicking the Check button, you open a program checking the memory module and similar to the MS-
DOS Chkdsk program. The results are shown in the Status field.
Detailed information is contained in the "Project planning" documentation of the Rexroth Tightening Sys-
tem 350.
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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 inter-
face for SEs with the respective control signals.
Fig. 5–28: 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. 5–28). 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.
The detailed description of the control signals as well as sequence examples and timing diagrams are
contained in the "Project planning" documentation of the Rexroth Tightening System 350.
Check the Update checkbox to constantly receive current data.

Select Request to have the respective current data transferred once.
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 Update checkbox
shown in Fig. 5–28. 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.
1 For the sequence test, see Sequence test (page 144).
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5.6.8.1 Analysis of an operating state (during a tightening process) via KE I/O signals
Fig. 5–29: 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).
5.6.8.2 Analysis of an operating state (after the end of a tightening process) via KE I/O signals
Fig. 5–30: KE I/O signals after the end of a tightening process
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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).
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. 5–31: Arcnet bus (using SE as an example)
Diagnosis data on the status, participant, network coupler, and test function of the SE (or KE) control Arc-
net (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.
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5.6.10 CAN bus
The CAN bus is used for communication between control unit, servo amplifier, and measurement
transducer.
Fig. 5–32: 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.
5.6.11 Ethernet
Fig. 5–33: Ethernet test
To test the connection to the Ethernet, comprehensive functions are available.
Detailed related information is contained in the "Project planning" documentation of the Rexroth Tighten-
ing System 350.
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5.6.12 Field bus data CS/KE
Fig. 5–34: 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 hexa-
decimal.
5.6.13 Field bus status
Fig. 5–35: 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.
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5.6.14 ... FF3/FF4 (internal sequence trace)
Fig. 5–36: Sequence trace FF3
For internal purposes, the KE (FF3) Sequence trace window is called up, which supplies the trace code
and description.
5.7 Description of selected errors

Some error examples are described in more detail below.
5.7.1 Error code 100
Table 5–33: Error code 100

100 LT: Personnel safety missing 4
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 motor-breaker), the above error mes-
sage 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 inter-
rupted 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 129).
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 Com-
plete error list (page 161))
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5.7.2 Error code 102/206
Table 5–34: Error codes 102 and 206

102 Temperature error motor 4
206 MSEN 1: Supply error 1
These errors can have several causes, e.g.:

• Temperature error
• Power supply error
• Defective connection lines or components
The SE cannot recognize whether the connection line or the very component is defective (here: LT and
measurement transducer 1).
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 147))
• 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

204 MSEN 1: Overload (positive) 3
205 MSEN 1: Overload (negative) 3
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.
For an overload of a redundancy measurement transducer (MSEN 2), the error codes 224/225 are valid
respectively.
5.7.4 Error code 712/713

712 No KE found 4
713 No KE found 4
The KE no longer communicates with the Arcnet bus or the KE was restarted. After a restart, the KE re-
boots, 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.
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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 153)).

1111 Channel configuration missing 4
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.
5.7.6 Error code 1206/1209

1206 Torque plausibility error 3
1209 Speed plausibility error 3
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 product catalog.
Remedy: Do not exceed the maximum permissible torque/speed value when programming!

1221 Error while transferring result to KE 3
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
Table 5–40: Error codes 23xx and 24xx

23xx Control x.y has logged off from data Arcnet 1
24xx Control x.y has logged off from control Arcnet 1
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.
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5.8 Replacing defective components
WARNING
Improper execution of service work
In the event that service works are executed improperly, persons can be injured, components dam-
aged, 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.
Components and cables may only be replaced in de-energized condition.
For safety reasons, the LT35x/LTU350/1/LTS350D/LTE350D and VM must only be pulled out at the ear-
liest 3 minutes after the power supply voltage of the card rack field has been switched off.
3 Min
The following sections provide information on whether hardware and/or software settings must be per-
formed 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 (motor-breaker) or works setting
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.
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
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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 im-
plemented using the backup function). During "Restore", the system checks whether the same firm-
ware is available, after that, the tightening parameters are rewritten. Afterwards, the SE/CS is
functional again.
The detailed description of the data storage strategies is contained in the "Project planning" documenta-
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 im-
plemented using the backup function). During "Restore", the system checks whether the same firm-
ware is available, after that, the tightening parameters are rewritten. Then, the KE is functional again.
The detailed description of the data storage strategies is contained in the "Project planning" documenta-
5.8.7 Interface Modules
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 set-
ting is not necessary after a replacement.
5.8.7.1 IM24V
• Check jumper setting: setting of internal or external voltage supply for the outputs
5.8.7.2 IMenip, IMmtcp, IMpnio, IMpdp, IMser

Hardware setting: No
BS350 | V2.400 Release/2014-09

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 work
In the event that service works are executed improperly, persons can be injured, components dam-
aged, 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.
5.9.1 Servo amplifier (error code 100 - 199)
Table 5–41: Servo amplifier (error code 100 - 199)

Error Error Message Possible cause/consequence Suggested solution
code class
100 4 LT: motor-breaker has been triggered No motor release  Switch motor-breaker signal
– LTE350D signal not activated  Ensure that current firmware is used
– LTS350D signal not activated  Replace component
– 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
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
105 1 LT: Motor contactor will not open Servo amplifier or connection line for tight-  Exchange the servo amplifier
ening spindle defective
or
 Replace connection line for tightening
spindle
BS350 | V2.400 Release/2014-09


code class
106 1 LT: Overload Tightening spindle blocked or supply volt-  Check tightening spindle
age too high
 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 motor- Configuration "motor-breaker VM350 ac-  Correct motor and servo amplifier
breaker tive" and servo amplifier switch position combination or switch position.
do not correspond
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)  Exchange LTU350
or ErgoSpin LTU350 defective (batch  Replace spindle connecting line
883, 884)
 Replace ErgoSpin
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
118 4 LT: CAN bus monitoring error Keep-alive request by the control unit to  Reboot
the servo amplifier outside the admissible
If error reoccurs:
time window during the tightening.
 Find and replace faulty component (ca-
ble, 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  Check switch
Error with switch S2 setting (LTU350/1)  Check start switch position ErgoSpin
in case of use as spindle (must be
operated)
 Replace servo amplifier or have it
repaired
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 LT: Align motor Motor blocked or adjustment error  Check rotability of output drive
from  Perform a reset
V2.400  Find and replace possibly defective
4 component
124 4 LT: Plausibility error motor-breaker loop 2  Check motor-breaker loop (CS351)
 Replace component
BS350 | V2.400 Release/2014-09


code class
125 4 LT: Plausibility error motor-breaker loop 1  Check motor-breaker loop (CS351)
126 4 LT: Intermediate circuit under-voltage (FI  Check fuses and FI residual-current-
residual-current-operated protected de- operated protected device
vice, fuses)
 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,  Reboot device
driver)  Replace component
128 4 LT: Motor contactor will not close CS351, LTU350/1  Perform a reset
If error still occurs:
or
 Replace connection line for tightening
spindle
5.9.2 Measurement transducer (error codes 200 - 299)
Table 5–42: Measurement transducer (error codes 200 - 299)

code class
200 3 MSEN 1: Zero point error Measurement transducer defective  Replace defective component or have
Deformed tightening spindle the same repaired
 Check freedom of movement of the
tightening spindle
201 3 MSEN 1: Calibration error Measurement transducer defective  Replace defective component or have
tightening spindle
202 1 MSEN 1: Transducer system error VMC: Defective rotor electronics (occurs  Check measurement transducer cable
during tightening spindle start) and ErgoSpin
 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
spindle
206 1 MSEN 1: Supply error Measurement transducer or measurement  Replace defective component or have
transducer cable defective the same repaired
208 1 MSEN 1: CRC error Measurement transducer defective  Replace defective component or have
the same repaired
the same repaired
the same repaired
the same repaired
BS350 | V2.400 Release/2014-09

Table 5–42: Measurement transducer (error codes 200 - 299)

code class
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
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  Replace defective component or have
tightening spindle
221 3 MSEN 2: Calibration error Measurement transducer defective  Replace defective component or have
tightening spindle
222 1 MSEN 2: Transducer system error VMC: Defective rotor electronics (occurs  Check measurement transducer cable
during tightening spindle start) and ErgoSpin
 Replace defective component or have
the same repaired
223 4 MSEN 2: Temperature error  Reduce cycle time
224 3 MSEN 2: Overload (positive)  Check tightening program and adjust
spindle
225 3 MSEN 2: Overload (negative)  Check tightening program and adjust
spindle
the same repaired
the same repaired
the same repaired
the same repaired
232 1 MSEN 2: SRAM error Measurement transducer defective  Replace defective component or have
the same repaired
the same repaired
the same repaired
BS350 | V2.400 Release/2014-09

5.9.3 ErgoSpin hand-held nutrunner (error codes 300 - 399)
Table 5–43: ErgoSpin hand-held nutrunner (error codes 300 - 399)

code class
301 3 Hand-held nutrunner does not support an-  Deselect angle redundancy in the op-
gle redundancy erating system
350 3 ErgoSpin: Zero point error ErgoSpin defective or deformed  Replace defective component or have
the same repaired
spindle
351 3 ErgoSpin: Calibration error ErgoSpin defective or deformed  Replace defective component or have
the same repaired
spindle
352 1 ErgoSpin: Transducer system error ErgoSpin or connection cable defective In connection with errors 1001, 355, 371:
 Replace connection cable
353 3 ErgoSpin: Temperature warning level Temperature warning level for handle, mo-  Adjust tightening and break time (cycle
tor, or torque converter time)
354 4 ErgoSpin: Temperature error Temperature of handle, motor, or torque  Adjust tightening and break time (cycle
converter time)
355 3 ErgoSpin: Overload Target angle possibly set without torque  Check tightening program and adjust,
monitoring if necessary
After tightening, do not use the tightening
tool as "spanner" for tightening The evalu-
ation defined after tightening is kept.
Depending on target and nutrunner size, a
bolt tightened and defined as OK can be
manipulated without affecting the tighten-
ing 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  Replace ErgoSpin or have it repaired
system boot, the red LED at the ErgoSpin
handle does not light up
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  Visually check the display elements
firmware not up to date
 Update firmware (install version
V0.97AO for ErgoSpin)
BS350 | V2.400 Release/2014-09

Table 5–43: ErgoSpin hand-held nutrunner (error codes 300 - 399)

code class
369 1 ErgoSpin: Operating element error Display elements/electronics defective or  Check the operating elements
firmware not up to date
 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  MtP repair plant
Transducer overload error
372 1 ErgoSpin: Invalid combination of modules  MtP repair plant
 Converter and standard machine are
not compatible
380 5*?* ErgoSpin: Monitoring limit reached Maintenance/test interval reached  Provide for ErgoSpin maintenance,
e.g. by Rexroth Service
381 3 ErgoSpin: Tightening program too large  Reduce the number of used tightening
for storing in hand-held nutrunner 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 tighten-
ing channel configuration
382 3 ErgoSpin: Hand-held nutrunner and SE Different tightening programs on the  Synchronize the control unit tightening
programs different ErgoSpin and the controller program with ErgoSpin or deactivate
using tightening programs from
ErgoSpin
* Errors of error class 5 are not displayed at the communication partner for the Open Protocol), the so-called "Open Interface".
5.9.4 CAN bus (error codes 500 - 699)
Table 5–44: CAN bus (error codes 500 -699)

code 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:  Find and replace faulty component
Control unit board defective
BS350 | V2.400 Release/2014-09


code class
505 4 CAN bus out of order LTU350 defective (batch 883, 884) or  Exchange LTU350
loose cable connection (plug-in contacts)
 Check cables that they are connected
or ErgoSpin defective correctly and securely
In connection with 504, 506:  Replace spindle connecting line
 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  Exchange LTU350
loose cable connection (plug-in contacts)  Check cables that they are connected
or ErgoSpin defective
correctly and securely
In connection with 504, 505:  Replace spindle connecting line
507 1 General error transducer 1  Replace primary measurement trans-
ducer
508 1 General error transducer 2  Replace redundancy measurement
transducer
510 3 CAN bus not ready CAN bus in "failure" condition  Reboot
If error reoccurs:
 Find and replace faulty component (ca-
ble, servo amplifier, ErgoSpin)
511 3 Primary/redundancy transducer  Adjust channel configuration
assignment error
 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.
514 3 LT tightening job error  Replace defective components, e.g.
515 3 Tran 1 tightening job error  Replace defective components, e.g.
516 3 Tran 2 tightening job error  Replace defective components, e.g.
517 3 Zero point error transducer 1 Tightening spindle deformed or compo-  Check the zero point using the "Trans-
nent outside the calibration ducer test" diagnosis
If OK:
 Adjust process for deformed tighten-
ing 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 compo-  Check the zero point using the "Trans-
nent outside the calibration ducer test" diagnosis
If OK:
 Adjust process for deformed tighten-
ing spindle.
If NOK:
 Recalibrate or replace component
520 3 Calibration error transducer 2 Component outside of the calibration  Recalibrate or replace component
BS350 | V2.400 Release/2014-09


code class
521 3 Tightening job log file error  Acknowledge in BS350
 Replace defective component
522 1 Start tightening error  Restart system
If error reoccurs:
 Find and replace faulty component
523 1 End tightening error  Restart system
If error reoccurs:
 Find and replace faulty component
524 3 Tightening job log file error  Acknowledge in BS350
 Replace defective component
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  Ensure compliant firmware versions
firmware versions
528 1 Unknown error CAN  Inform qualified personnel, e.g. the
Rexroth Service
530 3 No primary transducer data Measurement transducer very likely  Perform tightening channel reset and
defective then continue tightening
 Replace defective component, if nec-
essary, e.g. measurement transducer
531 3 No redundancy transducer data Measurement transducer very likely  Perform tightening channel reset and
defective then continue tightening
532 3 Job log file error primary transducer Too much data from primary measurement  Perform tightening channel reset and
transducer then continue tightening
533 3 Job log file error redundancy transducer Too much data from redundancy measure-  Perform tightening channel reset and
ment transducer then continue tightening
534 3 Job log file error primary transducer Too many timeouts from primary measure-  Perform tightening channel reset and
535 3 Job log file error redundancy transducer Too much data from redundancy measure-  Perform tightening channel reset and
536 3 Timeout tightening program System utilization  Acknowledge error
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
545 4 LT job log file error Service response during tightening  Inform qualified personnel, e.g. the
Rexroth Service
550 4 LT job log file error Service response without request Possible, in connection with FC109 after
error acknowledgement at the power sup-
ply 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
BS350 | V2.400 Release/2014-09


code class
560 4 LT job log file error No service mode response on request:  Check cable connections for correct
In connection with errors 560, 1123, positioning
1145, there is an error that is described in  Connection problem: Replace motor
the TIe151 (timing problem emergency- connection line or transducer line
off) - motor board failure
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
590 4 LT: Double login  Inform qualified personnel, e.g. the
Rexroth Service
595 4 LT: No login permission  Inform qualified personnel, e.g. the
Rexroth Service
Rexroth Service
Rexroth Service
Rexroth Service
Rexroth Service
Rexroth Service
Rexroth Service
Rexroth Service
635 4 LT: No measurement values in S mode  Inform qualified personnel, e.g. the
Rexroth Service
5.9.5 ARCNET (error codes 700 - 799)
Table 5–45: ARCNET (error codes 700 - 799)

code class
700 1 Initialization error Arcnet Arcnet data  Find and replace defective component,
e.g. network coupler
702 1 Error Arcnet SW driver Arcnet data  Find and replace defective component,
704 1 Error Arcnet controller Arcnet data  Find and replace defective component,
(Unused semaphore error) e.g. network coupler
(Semaphore error Int. RAM) e.g. network coupler
BS350 | V2.400 Release/2014-09


code class
710 1 Double assignment of Arcnet address Arcnet data  Find and replace defective component,
Double assignment of node ID e.g. control unit or communication unit
 Check address selection switches for
identical addresses
712 4 No KE found Arcnet data  Wait for communication unit to be
ready for operation after reset
In single-channel operation:
 Adjust configuration
714 1 Error Arcnet SW driver Arcnet data  Reboot communication unit
or
 Reduce communication unit load
716 4 Arcnet data failure Arcnet data  Check plug-in connection and line
routing
If a channel is marked with -1:
 Replace supply module
718 4 No Arcnet participant Arcnet data  Check connection to Arcnet partici-
In single-channel operation, the option pant
"single operation without KE" is not se- In single-channel operation:
lected in the configuration (no checkmark)
 Adjust configuration
720 3 Transmission error Arcnet data  Find and replace defective component,
 Check connection to the Arcnet partic-
ipant (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 1 Controller has logged off Arcnet data No action required
After controller restart / reset
724 1 Forbidden 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)
unit
If error occurs permanently after reboot:
 Exchange controller
(Unused error during verification) e.g. power supply module or control
unit
BS350 | V2.400 Release/2014-09


code class
(Unused error during RAM test) e.g. power supply module or control
unit
732 1 Double error while sending Arcnet data  Find and replace defective component,
Defective control unit e.g. power supply module or control
unit
of the Arcnet cable
734 3 Transmission aborted Arcnet data  Find and replace defective compo-
nent, e.g. power supply module or
control unit
of the Arcnet cable
736 3 Unknown message Arcnet data  Find and replace defective component,
unit
of the Arcnet cable
738 3 Arcnet not ready Arcnet data  Find and replace defective component,
unit
 Check connection to the Arcnet partic-
ipant (flat ribbon cable, connector)
of the Arcnet cable
If no hardware problem was identified, this
could be a software problem:
 Load current software patch
BS350 | V2.400 Release/2014-09


code class
740 3 Arcnet package too long Arcnet data  Check lines and network couplers
Data amount per data packet too large If a master/slave networking is concerned:
of the Arcnet cable
742 3 Transmission error (FBE) Arcnet data  Acknowledge in BS350
– No receipt buffer available (control unit  Troubleshoot any errors that follow
entry, if the communication unit has no
buffer and vise versa)
– System utilization
– Failures on Arcnet
744 3 Transmission (data bus/EXCNAK) Arcnet data  Check whether all control unit/ com-
aborted Transmission attempts on controller level munication units can be contacted
(hardware) exceeded  Reboot component, if necessary
750 3 Arcnet job log file error Arcnet data  Check lines and network couplers
Query of service messages between com-  Check driver component on controller
ponents defective or interrupted (service  Check flat ribbon cable and connector
job log file error) of the Arcnet cable
751 3 Arcnet job log file error Arcnet control  Check lines and network couplers
ponents defective or interrupted (timeout  Check flat ribbon cable and connector
during service query) of the Arcnet cable
ponents defective or interrupted (read pa-  Check flat ribbon cable and connector
rameter error) of the Arcnet cable
ponents defective or interrupted (write pa-  Check flat ribbon cable and connector
rameter error) of the Arcnet cable
ponents defective or interrupted (verifica-  Check flat ribbon cable and connector
tion error) of the Arcnet cable
ponents defective or interrupted (com-  Check flat ribbon cable and connector
mand execution error) of the Arcnet cable
757 3 Block transfer error Arcnet control  Find and replace defective component,
 Check lines and network couplers
of the Arcnet cable
BS350 | V2.400 Release/2014-09


code class
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 compo-
nent, e.g. network coupler
of the Arcnet cable
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 compo-
nent, e.g. network coupler
of the Arcnet cable
760 3 Block transfer error Arcnet data  Find and replace defective component,
of the Arcnet cable
761 4 NK350 supply voltage missing! Arcnet control  Check rack
– Rack with KE350 and NK350S not  Check network connections
switched on
 Check NK350S
– Bus cable interrupted
 check the voltage rate to the bus plug,
– NK350S defective if necessary
The pin assignment at the bus plug
(XDAcx) can be found in the NK350S
project planning manual
5.9.6 Interface module (error codes 800 - 899)
Table 5–46: Interface module (error codes 800 - 899)

code 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
BS350 | V2.400 Release/2014-09

Table 5–46: Interface module (error codes 800 - 899)

code class
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

820 3 IMpdp: Number of send/receive errors Not enough storage space reserved on  Check field bus configuration
module
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
5.9.7 Update CAN components (error codes 900 - 999)
Table 5–47: Update CAN components (error codes 900 - 999)

code class
900 1 FW download LT error Firmware files defective (buffer overflow)  Download suitable firmware files from
the internet
905 1 FW file LT error Firmware files defective (CRC error in hex  Download suitable firmware files from
file) 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  Download suitable firmware files from
error) the internet
920 1 FW file LT error Firmware files defective (no ASCII  Download suitable firmware files from
characters) the internet
925 1 FW download LT error Firmware files defective (wrong device  Download suitable firmware files from
firmware) the internet
930 1 FW download LT error Firmware files defective (wrong HW  Download suitable firmware files from
revision) the internet
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  Download suitable firmware files from
error) the internet
950 1 FW file LT error Firmware files defective (CRC entire file  Download suitable firmware files from
error). the internet
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  Update firmware version (or FPGA0
incompatible version)
BS350 | V2.400 Release/2014-09

Table 5–47: Update CAN components (error codes 900 - 999)

code class
961 1 Firmware and FPGA1 version incompati-  Update firmware version (or FPGA1
ble version)
962 1 Firmware and 1st MENMON version in- Update only possible with special soft-  Send in controller
compatible ware
963 1 Firmware and 2nd MENMON version in-  Update via operating system
compatible
964 1 Internal error: FPGA or MENMON string in  Inform qualified personnel, e.g. the
brcversion.c too long Rexroth Service
5.9.8 Control unit (error codes 1000 - 1051)
Table 5–48: Control unit (error codes 1000 - 1051)

code 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
Rexroth Service
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
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  Ensure that the ambient temperature
cabinet) exceeds the admissible maximum according to the specifications (techni-
value for the temperature cal data) is complied with, e.g. by
means of suitable cooling
1011 4 KE / SE / CS warning level temperature Ambient temperature (e.g. in the control  Ensure that the ambient temperature
error cabinet) exceeds the admissible maximum according to the specifications (techni-
value for the temperature cal data) is complied with, e.g. by
means of suitable cooling
1012 3 Battery empty / not inserted F376 separation paper  Remove separation paper
Battery empty  Insert new battery
 Switch off battery monitoring
1013 1 Printer initialization Initialization error on printer output  Check IMser and replace, if necessary
 Switch tightening system on/off.
1014 1 Serial server error  Switch tightening system on/off.
1017 4 Incompatible KE FW  Check firmware version, adjust, if
necessary
1018 3 BS350 program < V1.250 Operating system version not up to date,  Use firmware versions that are com-
firmware versions are not compatible patible 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
BS350 | V2.400 Release/2014-09


code class
1020 3 Number of graph points outside of the  Check tightening program
stipulated range
 Check configuration of graph memory
1021 3 Graph resolution outside of the stipulated  Check tightening program
range
 Check configuration of graph memory
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 →
Graph memory data
1025 3 Signature error in configuration saving to  Generate new configuration
SE  Inform qualified personnel, e.g. the
Rexroth Service
1026 3 CRC error in configuration of saving to SE Re-create graph memory configuration on After battery change:
the controller  Acknowledge error
 Re-create graph memory configuration
on the controller
1027 3 CRC error in graph memory administration After battery change:
 Data → Delete SE/CS →
Graph memory configuration
1028 3 Signature error in graph memory  Data → Delete SE/CS →
administration Graph memory configuration
1029 3 Data consistency error flash SRAM  Inform qualified personnel, e.g. the
(configuration/administration) Rexroth Service
 Check battery
1030 3 Results storage cannot be initialized in  Switch tightening system on/off.
SRAM
 Check battery
If the error reoccurs, the SRAM is proba-
bly defective:
Rexroth Service
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 prob-
ably defective:
Rexroth Service
1032 3 Graph memory problem on SE Graph memory test across allocated  Generate new graph memory
range configuration
If the error reoccurs.
Rexroth Service
1033 3 CRC error log book flash SE Exchanging the battery After battery change:
Flash defective  Acknowledge error
1034 3 Redundancy transducer for graph memory  Check configuration of graph
missing memory and compare with spindle
configuration
1035 3 Timeout during access to the results  Switch controller off/on
storage in SRAM
BS350 | V2.400 Release/2014-09


code class
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 Not all program selection bits assigned in  Correct PLC assignment table, i.e. as-
incompletely tightening controller (PLC) sign 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 Motor-breaker at start tightening!  Check motor-breaker loop
1042 4 Tightening aborted due to motor-breaker!  Check motor-breaker loop
1043 3 POST messages cannot be read POST test (hardware test) on the compo-  Replace defective component
nent 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
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
Rexroth Service
1050 3 Error FW version incompatible Incorrect firmware version  Use right compatible firmware version
No version string contained
1051 5 Error list has been re-created Error list has been deleted (time of dele-  No action required as system error; the
tion has been documented) entry is used for documentation
purposes.
5.9.9 Channel configuration (error codes 1100 - 1161)
Table 5–49: Channel configuration (error codes 1100 - 1161)

code 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  Install servo amplifier
– The servo amplifier is not recognized  Exchange the servo amplifier
 Exchange card rack field or system box
1102 1 Automatic restart due to change to single/  Function as note for the customer (an
2-channel operation control unit directly next to a communi-
cation unit is automatically brought into
single-channel operation)
generate new one
 Replace control unit, if necessary
BS350 | V2.400 Release/2014-09


code class
generate new one
 Replace control unit, if necessary
1105 1 Channel configuration data error The transmission values i with regard to  Check and correct the transmission
torque and/or angle are not plausible values i of the mechanical components
in the channel configuration
1106 1 Channel configuration data error The efficiency values eta are wrong or not  Check and correct the efficiency val-
plausible ues eta of the mechanical components
in the channel configuration
1109 3 Channel configuration reading error  Delete configuration and then gener-
ate new one
Rexroth Service
1110 1 Channel configuration error Incorrect control unit configuration  Delete configuration and then gener-
ate new one
Rexroth Service
1111 4 Channel configuration missing New ErgoSpin, channel configuration  Switch tightening system on/off.
missing or incorrect control unit
configuration
 Correct channel configuration
1112 1 BS350 channel configuration error The format code sent by the BS350 as  Ensure that the BS350 version is com-
part of the configuration files is not ac- patible with the firmware version
cepted by the firmware
1114 1 Electronic nameplate controller missing  Send in device
1115 1 Read signature error from channel  Generate a new configuration and de-
configuration lete the old one in advance, if applica-
ble
Rexroth Service
1116 1 CRC error while reading from channel  Generate a new configuration and de-
configuration lete the old one in advance, if applica-
ble
Rexroth Service
1118 1 Q Code CRC Flash error  Delete Q code table and then generate
new one
Rexroth Service
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 cor-
rect, if necessary
1121 1 New transducer 1 added Hardware configuration was changed  Check channel configuration and cor-
rect, if necessary
1122 1 New transducer 2 added Hardware configuration was changed  Check channel configuration and cor-
rect, if necessary
1123 4 LT missing – In connection with error codes 560:  Check transducer
Possible timing problem "emergency-  Check cables and connections and re-
off" (description see Technical Infor- place, if necessary
mation TIe_151)
– In connection with error codes 1124,
1125, 504, 560, 532:
Possible error at power supply module
VM310 (coupler relay PS damaged)
BS350 | V2.400 Release/2014-09


code class
1124 4 Transducer 1 missing – In connection with error codes 560,  Check transducer
1123:
 Check cables and connections and re-
Possible timing problem (description place, if necessary
see Technical Information TIe_151)  Replace supply module
504, 560, 532:
1125 4 Transducer 2 missing – In connection with error codes 560,  Check transducer
1123:  Check cables and connections and re-
Possible timing problem (description place, if necessary
see Technical Information TIe_151)
504, 560, 532:
1126 1 LT type has been changed New component does not correspond to  Correct configuration
the previous configuration
 Install suitable component
1127 1 Transducer 1 type has been changed New component does not correspond to  Correct configuration
the previous configuration  Install suitable component
1128 1 Transducer 2 type has been changed New component does not correspond to  Correct configuration
1129 1 LT serial no. has been changed In the configuration, the "Serial number  Update the serial number in the config-
monitoring" option is activated and a uration
component has been exchanged
1130 1 Serial no. transducer 1 has been changed In the configuration, the "Serial number  Update the serial number in the config-
1131 1 Serial no. transducer 2 has been changed In the configuration, the "Serial number  Update the serial number in the config-
1132 1 New hand-held nutrunner added New component does not correspond to  Correct 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  Correct 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
 Correct configuration
1153 4 Output drive removed  Check channel configuration and cor-
rect, if necessary
1154 4 Output drive has been modified  Check channel configuration and cor-
rect, if necessary
1155 1 Serial no. transmission has been changed  Check channel configuration and cor-
rect, if necessary
1156 1 Output drive transmission has been  Check channel configuration (output
changed drive transmission) and correct, if
necessary
BS350 | V2.400 Release/2014-09


code class
1157 1 Nutrunner serial number has changed An identical hand-held nutrunner with dif-  Check channel configuration and cor-
ferent serial number has been connected rect, if necessary
1158 5 Electronic nameplate display unit missing  Send in device
1159 1 Configuration error motor-breaker servo Configuration and position of jumper do  Check position of jumper in LTU350/1
amplifier not correspond
1160 1 LT: Emergency OFF jumper not inserted  Check position of jumper in LTU350/1
or defective
1161 1 Flat output drive function is not supported Incorrect combination of controller firm-  Inform qualified personnel, e.g. the
by the servo amplifier ware and servo amplifier firmware Rexroth Service
5.9.10 PLC assignment table (error codes 1180 - 1182)
Table 5–50: PLC assignment table (error codes 1180 - 1182)

code 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
5.9.11 Change engineering units (error codes 1190 - 1191)
Table 5–51: Change engineering units (error codes 1190 - 1191)

code class
1190 1 Conflict of units programs/configuration  Check units in the spindle configura-
tion and the tightening programs and
correct, if necessary
1191 3 Conflict of units tightening programs/  Check units in the spindle configura-
tightening programs tion and the tightening programs and
5.9.12 Sequence control (error codes 1200 - 1244)
Table 5–52: Sequence control (error codes 1200 - 1244)

code class
1200 1 Sequence control error Undefined status in sequence control  Inform qualified personnel, e.g. the
Rexroth Service
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
3 Tightening program BMW RPA mode not correct, if necessary
available or
 Generate tightening program
BS350 | V2.400 Release/2014-09


code class
1204 3 Unknown command The firmware version is not compatible  Generate a tightening program com-
with the available tightening programs patible with the firmware and BS
BS300 V1.500 Rel. access to SE with
V1.400:
– Programs can be converted without er-
ror message and returned to the con-
trol unit (without warning from BS)
– Error code 1204 appears with first
start
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  Connect measurement transducer as
primary transducer not possible 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
1213 1 Sequence control error Error in tightening program  Check tightening program
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 nec-
essary
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 nec-
essary
1217 3 Torque threshold redundancy error Torque thresholdRed > maximum permis-  In the tightening program, set the
sible spindle torque torque thresholdRed to a value smaller
than the admissible torque
1218 3 Redundancy suppression time error Redundancy suppression time Start-up  In the tightening program, set the re-
suppression time dundancy suppression time to a value
greater than the start-up suppression
time
BS350 | V2.400 Release/2014-09


code class
1219 3 Speed error – Wrong spindle configuration entry  Check spindle configuration on gear-
– Gear transmission box transmission
– Connection cable union nuts loose  Check union nuts
– Problem on one of the plug-in connec-  Check cables and contacts
tions e.g. contacts bent, cable pulled  Check connection cable for tightening
out spindle
– Connection cable for tightening spin-  Send hand-held nutrunner to Mur-
dle defective rhardt for inspection
– Motor defective  Check fuses in LTU350/1, replace
– Angle of turn transducer on rotor shaft LTU350/1, if necessary, and send to
damaged/defective Murrhardt for inspection
– in connection with LTU350/1 (channel  Reduce moment of inertia e.g. BG5
ready - speed error after start) VUK with ErgoStart
– Can occur in connection with motor
OFF
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 with-
out tightening, then one or more net-
work couplers could be defective
1222 3 Reference to preliminary step is missing  Adjust tightening program
(relative torque monitoring)
1223 3 Started program is 0>No>98  Check PLC program selection and
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 T graph threshold plausibility  Correct values in tightening program
1229 3 Gradient filtering error  Adjust filter interval in the start step
according to the table (see documen-
tation)
1230 3 Tightening program incomplete  Check tightening program and create
a new one, if necessary
1231 3 Spin direction change for relative torque  The step with the relative torque moni-
monitoring toring and its previous step must have
the same direction of rotation
1232 3 Selected OK/NOK counter is 0>No>47  Check PLC program/counter record
selection and correct, if necessary
1233 3 Error while initializing the docu buffers – Software error  Inform qualified personnel, e.g. the
– Possibly, there are further error entries Rexroth Service
– The tightening program is possibly not
compliant with the firmware version
1234 3 Angle overflow error (default values)  Check default value settings
1237 3 Sequence control: Coastdown monitoring Safety shutdown with redundancy evalua-  Inform qualified personnel, e.g. the
redundancy error tion in costdown Rexroth Service
1239 3 Sequence control: CAN access error – No measurement values  Acknowledge error
– Request of the CAN component failed
1240 3 Sequence control: Intit ZF input Error in tightening program  Generate new target function Input
plausibility error
BS350 | V2.400 Release/2014-09


code class
1241 3 Sequence control: ZF input plausibility Error in tightening program  Generate new target function Input
error
1242 3 Sequence control: Minimum plausibility Tightening program error:  Check tightening program
test error – Plausibility error for threshold value
lower torque
1243 3 Maximum permissible number of tighten-  Reduce number of tightening steps to
ing steps reached! max. number
1244 5 Sum counter blocks tightening Sum counter is not reset
5.9.13 Control unit (error codes 1301 - 1319)

code class
1301 1 No response  Switch system off/on
-
1319
5.9.14 Communication unit (error codes 2000 - 2099)
Table 5–54: Communication unit (error codes 2000 - 2099)

code class
2000 3 Faulty error list  Delete error list
2001 3 Error list overflow This error occurs if approx. 120 non-  Delete error list
acknowledged errors already exist and a
new error overwrites the existing non-
acknowledged errors
2002 1 Error flash administration Access to the internal flash is disturbed,  Inform qualified personnel, e.g. the
the flash module may be defective Rexroth Service
2003 1 File access error Internal file system inconsistent  Switch off/on. Replace if error reoc-
curs
Otherwise:
Rexroth Service
curs
Otherwise:
Rexroth Service
curs
Otherwise:
Rexroth Service
2006 1 Unknown HW identifier  Replace component or have it repaired
2007 1 SE initialization error  Switch controller off/on
Otherwise:
Rexroth Service
BS350 | V2.400 Release/2014-09


code class
2008 1 Internal error serial interface  Switch component on/off
Otherwise:
Rexroth Service
2009 1 Internal error serial interface  Switch component on/off
Otherwise:
Rexroth Service
2010 3 KE / SE / CS temperature warning level  Adjust tightening and break time (cycle
time)
Or:
 Check fan and replace, if necessary
2011 4 KE / SE / CS temperature error  Adjust tightening and break time (cycle
time)
Or:
 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 FTP results output: CF card warning level FTP data transmission is not working  Check FTP connection
properly
 Correctly set FTP data transmission
 Perform a reset
2024 4 FTP 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:
BS350 | V2.400 Release/2014-09


code class
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 FTP results output: CF card access error  Mass storage available?
 Check / format mass storage
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
Rexroth Service
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 ver-  Adjust firmware versions of
sions components
2035 3 Q code flash signature error  Delete table for Q code and then gen-
erate new one
2036 1 Q Code CRC - Flash error  Delete table for Q code and then gen-
erate new one
2037 4 FTP results output: Write transfer list  Delete transfer list and restart
error component
or
2038 3 FTP results output: Create transfer list  Delete transfer list and restart
error component
or
2039 4 FTP results output: Delete transfer list  Delete transfer list and restart
error component
or
2040 3 FTP results output: Error App. res. file  Check / format mass storage
creation
2041 3 FTP results output: SE res. file creation  Check / format mass storage
error
2042 3 FTP results output: Read results file error  Check / format mass storage
2043 4 FTP results output: ATA directory does  Install mass storage
not exist
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  Check FTP connection
access error
 Correct FTP server settings
2047 3 Error: Close FTP connection Communication problem with FTP server  Reset the controller
BS350 | V2.400 Release/2014-09


code class
2048 3 Error: Login FTP server  Correct FTP server settings
2049 3 Error: FTP directory access  Correct FTP server settings
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  Reduce number of channels
in to one KE
2053 1 DARC and SARC status different  Inform qualified personnel, e.g. the
Rexroth Service
2054 3 KE storage administration: SE has not yet  Restart KE
registered itself
2055 3 ID code file or directory wrong The set-up of the file name of the ID code  Inform qualified personnel, e.g. the
file received via FTP does not comply with Rexroth Service
the specification
2056 3 The SE could not be found in the channel  Restart KE
administration
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 conjunc-  Reduce number of channels
tion with KE312
2068 4 Insufficient storage for the channel results  Reboot controllers
2069 4 Check file system compact flash card Check disk was triggered automatically  Note for user
(chkdsk)
 Replace mass storage, if necessary
Rexroth Service
2070 3 KE must be plugged into slot 6 in rack 0 Incorrect KE slot or rack number 
2071 3 Rack coupler next to KE must be  Install NK350S next to KE in the rack
equipped with NK350S
2072 3 CRC results data record after transmis- Data transmission error  Check data-Arcnet cable and replace,
sion from SE → KE defective if necessary
2073 3 Data output error: Ethernet connection  Check Ethernet connection
interrupted/cable missing.
2074 3 Results data record not (completely)  Inform qualified personnel, e.g. the
received Rexroth Service
 If error reoccurs, reboot controller
2075 3 No storage space defined for channel re- Rack address changed during operation  Switch system off and on again.
sults data record
Rexroth Service
2076 3 Results were refused by KE due to incor- Incompatibility between KE and SE  Update firmware versions.
rect format identification firmware
Rexroth Service
2077 5 FTP process is requested and Task 
FtpcAsyn was restarted.
2090 3 Error on writing of the IPM data set into the During transmission of a IPM data set from  Insufficient resources (file handles).
FIFO file system the IPMConnectionmanager, the data set
 Check file system for errors.
could not be written into the FIFO file
system.  System off / on
2091 3 Result listing task has been closed Result listing task has crashed  Off / on.
(Watchdog) (Watchdog)
 Restart with BS350 IPM-RTP
BS350 | V2.400 Release/2014-09


code class
2092 3 IPM client task has been closed IPM client task has crashed (Watchdog)  Off / on.
(Watchdog)
2093 3 Logon to ResultServer failed Logon to ResultServer failed.  Off / on.
2094 3 Error reading message from the Result- Reading message from the ResultServer  Off / on.
Server message queue message queue failed.  Restart with BS350 IPM-RTP
2095 3 Error reading IPM configuration An error occurred during reading of the  Generate new configuration.
IPM configuration.
 Check file system.
2096 4 Error reading the CF card CF card not available / defective  Use new CF card.
5.9.15 Sequence control (error codes 2101 - 2199)

code class
2101 1 Application administration error Internal software error  Reboot tightening system.
2102 3 CRC error application  Delete application and then generate
new one.
2104 3 Unknown command A program version has been started which  Generate application compatible with
is not compatible with the firmware. the firmware version.
or
 Update KE firmware to the program
version.
2105 3 Timeout sequence end KE If Arcnet counters (RECON, NNID, and  Check application timeout time.
TXError) are high or also increase without
 Check Arcnet counters RECON,
active tightening:
NNID, and TX error.
– At least one network coupler is
 Replace network coupler, if necessary.
defective.
or
 Find and replace faulty component.
2106 3 CW & CCW simultaneously Too short period ( 200 ms) between the  Correct direction of rotation control.
Cw and Ccw signals for an application
 Increase period between signals.
block (FOx).
2107 3 Application already running  Adjust application number control.
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  Adjust PLC assignment table (ensure
channels simultaneously (on KE350G that no SE program bits are assigned
IL), interval time of the PLC task too to internal Arcnet).
short  Increase interval time of PLC task in
– Possible result: Download abort of a the IndraLogic task configuration win-
PLC program dow (e.g. 100 ms).
 In the case of download abort of a PLC
program: Check connection, delete
PLC project on target system, and inte-
grate new project with longer PLC task
interval.
While tightening the system: When there are no tightenings in the
– Activate/deactivate or reset system:
tightening channels not participating in  Activate, deactivate or reset non-
a tightening. participating tightening channels.
BS350 | V2.400 Release/2014-09


code class
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  Increase interval time of PLC task in
channels simultaneously (on the IndraLogic task configuration win-
KE350G IL), interval time of the PLC dow (e.g. 100 ms).
task too short  In the case of download abort of a PLC
– Possible result: Download abort of a program: Check connection, delete
PLC program PLC project on target system, and inte-
interval.
 Application was started and immedi-
ately closed before the channels were
initiated. Signal FOx Cw/Ccw must be
longer present.
2113 3 Application not defined Non-programmed application was select-  Adjust application number control.
ed 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  Check Ccw, Cw and En signals on in-
channels simultaneously (on ternal Arcnet and assign, if necessary.
KE350G IL), interval time of the PLC
 Increase interval time of PLC task in
task too short the IndraLogic task configuration win-
– Possible result: Download abort of a dow (e.g. 100 ms).
PLC program
 In the case of download abort of a PLC
program: Check connection, delete
PLC project on target system, and inte-
interval.
2116 3 Transmission error app.: Result through  Check communication partner, ensure
the RK512 connection.
2117 3 Sync. or rework point on KE known and  Program application on SE correctly.
SE is not defined
2118 3 Data element error while outputting results  Check configuration of the PLC data
using RK512 elements (PLC setting firmware).
 Check settings on the PLC side.
2119 3 Transmission error: Single channel result  Check communication partner
via RK512
Rexroth Service
2120 3 Send error: Application result through the  Check communication partner
FTP
2121 3 Send error: Single channel result through  Check communication partner
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 applica-
tion channels
BS350 | V2.400 Release/2014-09


code class
2127 3 Access error (timeout) while editing the Internal software error  Reboot system.
application results
2128 3 Access error while editing the application Internal software error  Reboot system.
results
2129 3 Initialization of Appl. information for results Internal software error  Reboot system.
data records not possible.
2130 3 Channel is already used (PLC driver 
monitoring)
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 ex-  Inform qualified personnel, e.g. the
ternal PFCS service (not firmware). Rexroth Service
Note: The error is no longer used in later
firmware versions.
2196 4 Reset RTS signal of PFCS interface With old firmware versions:  Update firmware.
– Entry with the information that the drive
has been re-initialized for the PFCS in-
terface.
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.
5.9.16 Configuration (error codes 2200 - 2700)
Table 5–56: Configuration (error codes 2200 - 2700)

code 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
BS350 | V2.400 Release/2014-09


code class
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 mod-  Check configuration in BS and con-
ule B1 firm, if necessary
2213 1 Serial no. in <B2> changed  Check configuration in BS and con-
firm, if necessary
2214 1 Serial no. in <A> changed  Check configuration in BS and con-
firm, 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 nec-
essary.
2220 1 Initialization error PLC card PLC card has not been recognized by the  Check / replace PLC card
system
Rexroth Service
2221 1 PLC assignment table error Active PLC assignment table does not System/PLC assignment table for SE or
correspond to the hardware configuration. KE:
 Update PLC assignment table
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  Adjust PLC assignment table for KE
I/O signals
2227 1 PLC assignment table: Modules equipped  Adjust PLC assignment table to actual
differently 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  Re-create PLC table
in. Reasons:
– Problem with flash access Rexroth Service
– Hardware defective
2231 1 PLC table: Save error  Re-create PLC table
Rexroth Service
2240 4 Cell configuration missing Signature for the cell configuration is miss-  Re-create the cell configuration and
ing. send it to the controller.
BS350 | V2.400 Release/2014-09


code class
2241 4 CRC error cell configuration CRC error while reading the cell  Re-create the cell configuration and
configuration 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 Connection to ResultServer no longer  Restart PLUS or controller
failed functions
2301 3 Logon to ResultServer failed Connection to result structure failed. The  Restart PLUS or controller
error can only occur after start or ??selec-
tion?? of PLUS.
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 generat-
ed offline or saved in backup) and save
afterwards.
2303 3 ResultServer task has been closed Permitted timeout time exceeded.  Restart defective controller
(Watchdog timeout)
2310 3 Error reading QDA configuration Error has to be acknowledged.  Check/correct the BS350
configuration
2311 3 QDA ResultServer task crashed. Watchdog timeout.  Restart system
2312 3 QDA file uploader task crashed. Watchdog timeout.  Restart system
2313 3 Logon to QDA ResultServer failed. Internal system error.  Restart system
2314 3 Receiving message from ResultServer Internal system error.  Restart system
failed
2315 3 Cannot generate the QDA results file in  Check/format the CF card.
the FIFO file system.  Restart the QDA service.
2316 3 QDA data error - Corrupt FIFO data  Check/format the CF card.
 Restart the QDA service.
2317 4 QDA error reading the CF card File system corrupted?  Check/format the CF card.
 Restart the QDA service.
2318 4 QDA error starting a kernel task Internal system error.  Restart system
2600 1 Controller x.x has logged off from data Note: Was replaced by 26xx, 27xx error If error occurs without external influence:
Arcnet codes in accordance with V1.250 SP1  Check component
This messages is a not for the user that
one controller has logged off (e.g. due to
reset).
2700 1 Controller x.x has logged off from control Note: Was replaced by 26xx, 27xx error If error occurs without external influence:
Arcnet codes after V1.250 SP1  Check component
This messages is a not for the user that
one controller has logged off (e.g. due to
reset).
BS350 | V2.400 Release/2014-09

5.9.17 Internal controller (error codes 2800 - 2843)
Table 5–57: Internal controller (error codes 2800 - 2843)

code 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  Switch system off/on, software error
great
2802 3 CRC checksum in SE results buffer  Switch system off/on, software error
incorrect
2810 3 Internal error, communication channel  Inform qualified personnel, e.g. the
cannot be opened (SALOpen) Rexroth Service
 Software error, switch system off/on.
2811 3 Internal error, timeout- no data exchange  Inform qualified personnel, e.g. the
possible (SALCall) Rexroth Service
2812 3 Internal error, timeout send process failed  Inform qualified personnel, e.g. the
(SALSend) Rexroth Service
2813 3 Message overflow on the data bus  Inform qualified personnel, e.g. the
(queue) Rexroth Service
2815 3 ResultServer SDR error  Inform qualified personnel, e.g. the
Rexroth Service
2816 1 ResultServer initializing Starting the ResultServer (results manag-  Inform qualified personnel, e.g. the
er) has failed. Rexroth Service
2830 3 Internal PFCS synchronization on  Inform qualified personnel, e.g. the
(re-)start failed Rexroth Service
2831 3 Cannot send the internal PFCS trigger  Inform qualified personnel, e.g. the
message Rexroth Service
2832 3 Cannot send the results in PFCS driver  Switch system off/on, software error
(internal)
2833 3 PFCS database cannot be created CF card missing/unformatted  Check CF card.
2834 3 Directory access to PFCS database not CF card missing/unformatted  Check CF card.
possible
2835 3 PFCS interface not ready for data output Output interface not ready/available, used  Inform qualified personnel, e.g. the
otherwise Rexroth Service
 Check output driver settings.
2836 3 Access to PFCS driver on mass storage CF card available?  Inform qualified personnel, e.g. the
not possible Rexroth Service
 Format or replace CF card, if
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.
BS350 | V2.400 Release/2014-09

Table 5–57: Internal controller (error codes 2800 - 2843)

code class
2840 3 BS350 error display driver(0) Error in firmware responsible for communi-  Inform qualified personnel, e.g. the
cation with display in BS350 (channel 1). Rexroth Service
No update in BS 350 (instance 0), driver  Switch system off/on.
not running correctly
2841 3 BS350 error display driver(1) Error in firmware responsible for communi-  Inform qualified personnel, e.g. the
cation with display in BS350 (channel 2). Rexroth Service
No update in BS 350 (instance 1), driver  Switch system off/on.
not running correctly
2842 3 Timeout message processing BS350 dis- Error in firmware responsible for communi-  Inform qualified personnel, e.g. the
play(0) cation with display in BS350 (channel 1). Rexroth Service
Data could not be sent.  Check BS350 condition.
 Switch system off/on.
2843 3 Timeout message processing BS350 Error in firmware responsible for communi-  Inform qualified personnel, e.g. the
display(1) cation with display in BS350 (channel 2). Rexroth Service
Data could not be sent.  Check BS350 condition.
 Switch system off/on.
5.9.18 Data output (error codes 2899 - 2907)
Table 5–58: Data output (error codes 2899 - 2907)

code class
2899 3 Timeout of field bus MultiTelegramm Request of MultiTelegramm data or Ac-  Communication partner not connect-
output knowledge not within the defined TimeOut ed.
time
 Incorrect TimeOut time --> increase
timeout time in field bus configuration
view. Handshake procedure of com-
munication partner too slow
2900 3 HMI error texts for field bus output not  Send HMI configuration to compo-
available nent.
2901 1 Field bus data configuration error Incorrect configuration of data  Correct field bus data configuration.
PROFIBUS
2902 3 Field bus data configuration error (number Incorrect configuration of data  Correct field bus data configuration.
of tightening positions) PROFIBUS
2903 3 Cannot save field bus configuration in  Inform qualified personnel, e.g. the
flash Rexroth Service
2904 3 IDS_SYSERR_2904  Inform qualified personnel, e.g. the
Rexroth Service
2905 3 No field bus module available for field bus  Equip field bus module.
configuration
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  Check PLC, check field bus cable.
"RUN”.
2908 3 Wrong command sequence on field bus Incorrect command sequence in  MultiTelegramm - Check sequence for
MultiTelegramm data output. MultiTelegramm mode. PLC
BS350 | V2.400 Release/2014-09

5.9.19 Time zone (error codes 2910 - 2913)
Table 5–59: Time zone (error codes 2910 - 2913)

code class
2910 3 Access error on time zone The software reports an error as it has not  Switch tightening system on/off.
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 The error can be generated in the tighten-  Switch tightening system on/off.
set ing 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.
5.9.20 Firmware download (error code 2915 - 2916)
Table 5–60: Firmware download (error code 2915 - 2916)

code class
2915 3 FW download: Firmware does not corre- Firmware does not correspond to ad-  Select suitable firmware files.
spond to the system hardware dressed hardware component
 Update firmware.
2916 1 FPGA missing! Perform update!  Update firmware version.
2917 3 Restore could not be completed. The restore process did not complete  Check controller status for available
properly. data. If incorrect, restart controller and
repeat Restore.
2918 1 Background process Backup/Restore Performing Backup/Restore is not  Restart controller.
start failed. possible
5.9.21 Hardware error (error code 3000 - 3002)
Table 5–61: Hardware error (error code 3000 - 3002)

code 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  Equip battery.
equipped.
 Replace battery.
Before you switch the controller off, we
recommend the following:
 Backup necessary documentation files
using the operating system like e.g.:
– Results storage
– Tightening and result graphs
3003 5 PLC table save error 
BS350 | V2.400 Release/2014-09

5.9.22 Open protocol error (error codes 3050 - 3053)
Table 5–62: Open protocol error (error codes 3050 - 3053)

code class
3050 1 Selection of programs via OpenProtocol  Check configuration.
is not fully configured
3051 1 Selection of the application via Open Pro-  Check configuration.
tocol is not fully configured
3052 3 OpenProtocol: CF card for saving results  Insert CF card.
not available
3053 3 Faulty Open Protocol configuration file  Generate new configuration.
3054 5 OP slave connection problems 
3055 5 OP disable not successful 
3060 1 HVO BMS Config Error Data transmission not possible  Check system settings and communi-
cation partner settings. Check
network connection independent
from protocol.
5.9.23 CAQTNG errors (error codes 3070 - 3074)
Table 5–63: CAQTNG errors (error codes 3070 - 3074)

code class
3070 3 No connection to the CAQTNG communi- The CAQTNG server is not available in or-  Check configuration.
cation partner der to output the tightening result data af-
ter a tightening has been completed.
3071 No connection to the CAQTNG communi- The CAQTNG server is not available in or-  Check configuration.
cation partner der to output the tightening result data af-
ter a tightening has been completed.
3073 3 Error: CAQTNG message buffer full The tightening result data cannot be trans-  Check network connection and/or
mitted to the CAQTNG server fast CAQTNG server.
enough.
3074 5 CAQTNG acknowledge not OK No or incomplete communication partner  Compare settings of both communica-
acknowledgement tion partners.
5.9.24 PLC error (error codes 3100 - 3148)
Table 5–64: PLC error (error codes 3100 - 3148)

code class
3100 3 PLC error: Task monitoring failed, PLC in Software watchdog of IEC task has  Acknowledge error in BS error list. In-
mode expired crease task cycle time or shorten
program.
Note: Synchronous file access func-
tions can be time consuming.
3101 5*?* PLC error: Hardware monitoring failed Hardware watchdog expired. Global soft-  Increase watchdog time.
ware error
 Deactivate watchdog.
3102 5* PLC error: bus error Field bus error  Acknowledge error in BS error list. In-
valid address was accessed in IEC
program. More information in stack
trace.
3103 3 PLC error: Check sum error. PLC in stop Check sum error after program download  Acknowledge error in BS error list. Try
mode! download again. Could have been
caused by defective data transfer or
corrupt file system.
BS350 | V2.400 Release/2014-09


code class
3104 5* PLC error: Field bus error Field bus error: at least one configured IO  Acknowledge error in BS error list.
driver could not be loaded Check the runtime system configura-
tion (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  Acknowledge error in BS error list.
– pfStartReadInputs, CalllOltfFunction- Check used IO drivers.
ReadInput, pfDoneReadInputs or  Check whether configured and non-
– Output of a field bus driver failed 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 ver-
sions.
3107 3 PLC error: Retain variables could not be Boot project was not loaded as retain vari-  Cold reset. Reduce number of retain
floated. PLC stopped! ables could not be reset variables. Reload boot project.
3108 3 PLC error: Boot project was not loaded. Boot project was not loaded. File system  Regenerate and load boot project.
PLC in stop mode! could be defective
3109 5* PLC error: Task could not be completed  Acknowledge error in BS error list. Re-
set or reset (origin), reload boot proj-
ect.
3110 3 PLC error: Maximum charge volume ex- Charge volume exceeded  Acknowledge error in BS error list. Re-
ceeded. PLC in stop mode! duce size of PLC program, adjust vari-
able list.
3111 1 PLC error: SRAM battery empty. Reset re- SRAM battery empty  Replace battery.
manent variables. PLC stopped!
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.
Bosch Rexroth.
3124 5* PLC error: Page error Page error  Acknowledge error in BS error list.
Bosch Rexroth.
3125 5* PLC error: Stack overflow Stack overflow  Acknowledge error in BS error list.
Bosch Rexroth.
3126 5* PLC error: Invalid disposition Invalid disposition  Acknowledge error in BS error list.
Bosch Rexroth.
3127 5* PLC error: Invalid access identification Invalid handle  Acknowledge error in BS error list.
Bosch Rexroth.
3128 5* PLC error: Access to protected page Protected page  Acknowledge error in BS error list.
Bosch Rexroth.
3129 5* PLC error: Double error Double error  Acknowledge error in BS error list.
Bosch Rexroth.
3130 5* PLC error: Invalid instructions Transmission error in IndraLogic  Check instructions.
BS350 | V2.400 Release/2014-09


code class
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.
Bosch Rexroth.
3135 5* PLC error: Unavoidable exception Unavoidable exception  Acknowledge error in BS error list.
Bosch Rexroth.
3136 5* PLC error: Floating decimal point: General Floating decimal point: General error  Acknowledge error in BS error list.
error
Bosch Rexroth.
3137 5* PLC error: Floating decimal point: Non- Floating decimal point: Non-normalized  Acknowledge error in BS error list.
normalized operand operand
Bosch Rexroth.
3138 5* PLC error: Floating decimal point: Division Floating decimal point: Division by zero  Acknowledge error in BS error list.
by zero
Bosch Rexroth.
3139 5* PLC error: Floating decimal point: Inaccu- Floating decimal point: Inaccurate result  Acknowledge error in BS error list.
rate result
Bosch Rexroth.
3140 5* PLC error: Floating decimal point: Invalid Floating decimal point: Invalid instructions  Acknowledge error in BS error list.
instructions
Bosch Rexroth.
3141 5* PLC error: Floating decimal point: Over- Floating decimal point: Overflow  Acknowledge error in BS error list.
flow
Bosch Rexroth.
3142 5* PLC error: Floating decimal point: Stack Floating decimal point: Stack check failed  Acknowledge error in BS error list.
check failed
Bosch Rexroth.
3143 5* PLC error: Floating decimal point: Under- Floating decimal point: Underflow  Acknowledge error in BS error list.
flow
Bosch Rexroth.
3145 3 PLC error: Initialization data output IL Internal error of FW; access to the results  Restart controller,
data from the PLC program not possible
3146 3 PLC error: Initialization IL device Error during controller boot process; ID  Restart controller,
transfer and data access from the PLC
program impossible
3147 3 PLC error: Data access Internal error FW; access to the results  Restart controller,
data from the PLC program not possible
3148 3 Field bus data configuration error, send/ You have set more than 256 bytes.  Reduce the set width to maximally 256
transmit IL data too large bytes.
* Errors of error class 5 are not displayed at the communication partner for the Open Protocol), the so-called "Open Interface".
BS350 | V2.400 Release/2014-09

5.9.25 Errors Rexroth XML (error code 3204 - 3211)
Table 5–65: Errors Rexroth XML (error code 3204 - 3211)

code class
3204 1 Error PLC assignment table XML The PLC signals have been incorrectly as-  Check and correct configuration
signed to the "XML" PLC module.
3206 5 Connection to XML communication part- Either the network or the master controller  Check network and master PC
ner port B cannot be established (master PC) is not available.
3207 3 XML archiving: CF card not found Files for local buffering cannot be saved  Equip memory module CF350 (com-
pact flash card; CF card)
3208 3 XML archiving: Error access directory Files for local buffering cannot be saved  Check memory module CF350 (com-
3210 3 XML archiving: No storage space –  Check archive server
3211 3 XML archiving: Faulty file Faulty archive file  Check memory module CF350 (com-
3212 1 XML: Initialization error XML driver failed.  Restart system.
5.9.26 Job functionality (error code 3250 - 3252)
Table 5–66: Job functionality (error code 3250 - 3252)

code class
3250 3 Job number not available Job with this number does not exist.  Generate job or use different job.
3251 1 Error performing Job init Script Software error or transfer error.  Generate job or use different job.
3252 3 Error performing Job Script Software error or transfer error.  Generate job or use different job.
5.9.27 System error (error codes 3700 - 3800)
Table 5–67: System error (error codes 3700 - 3800)

code 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 | V2.400 Release/2014-09

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:
service.svc@boschrexroth.de
Worldwide service
Our global service network can be reached at any time in over 40 countries. You can find detailed infor-
mation on our service locations in Germany and worldwide on the Internet at:
www.boschrexroth.com/service-405060
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.
6.2 Sales
Bosch Rexroth AG
Post box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
You can contact us
• By telephone
+49 9352 18 0
• By fax
+49 9352 18 8400
• By email
6.3 Internet
Information on Rexroth's tightening technology can be found on the Internet at
www.boschrexroth.com/electrics
Additional information on service, repairs, and training, as well as the current addresses of our sales
offices can be found at
www.boschrexroth.com
If you are located outside of Germany, please contact your nearest Rexroth partner.
BS350 | V2.400 Release/2014-09

Bosch Rexroth AG
Postfach 1161
71534 Murrhardt, Germany
Fornsbacher Str. 92
71540 Murrhardt, Germany
Phone +49 71 92 22 208
Fax +49 71 92 22 181
www.boschrexroth.com/schraubtechnik
FÜR BALKENCODE
06113609929910
Contact:
Your concessionary
BS350
EN | 2014-09-AG
© Bosch Rexroth AG, 2014
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BS350

350 Operating System V2.400 Release | 2014-09

Title 350 Operating System

Type of Documentation Online help

Record of Revision Version Status Comments

Copyright © Bosch Rexroth AG, 2014

Published by Bosch Rexroth AG

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

BS350 | V2.400 Release/2014-09

BS350 | V2.200 Release/2010-04

BS350 | V2.200 Release/2010-04

This chapter contains general information on the present documentation.

• Overview of this documentation (page 6)

1.1 Overview of this documentation

Chapter Title Contents

BS350 | V2.400 Release/2014-09

1.2 Validity of the documentation

1.3 Additional documentation

1.4 Representation of information

1.4.1 Safety instructions

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

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Table 1–1: Warning symbols used

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

1.4.2 Symbols and identifications

Table 1–2: Identifications used in the documentation

BS350 | V2.400 Release/2014-09

Table 1–2: Identifications used in the documentation

Torque filter factor Additional parameter for determining the gradient.

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

Controller Controllers are

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BS350 | V2.400 Release/2014-09

The following abbreviations are used in this documentation:

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

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• About this chapter (page 14)

2.1 About this chapter

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2.1.2 Instructions for use

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Country-specific regulations that the user must observe

2.1.3 Operating instructions

2.1.4 Cleaning instructions

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2.1.5 Maintenance and repair instructions

2.1.6 Disposal instructions

2.2 Intended use

2.2.2 Application areas

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2.3 Improper use

2.4 Personnel qualifications

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2.5 General safety instructions

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2.6 Product- and technology-dependent safety instructions for

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For electrical drive and filter components:

Safety warning sticker

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

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2.6.2 Protective extra-low voltage for protection against electric shock