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| Fault Code | Description | Probable Cause | Corrective Action | | :--- | :--- | :--- | :--- | | | Following Error Exceeded | Motor cannot keep up with commanded position. Load jammed or tuning too aggressive. | 1. Check mechanical drive train for jams. 2. Reduce acceleration/speed. 3. Retune servo loop gains (Kv, Tn). | | F4100 | Position Limit Switch Tripped | Axis moved beyond soft or hard limits. | 1. Manually jog axis back into range. 2. Check limit switch wiring (if hard switch). | | F4200 | Drive Enable Missing | Hardware enable signal removed unexpectedly. | 1. Check safety circuit (E-Stop, Light curtains). 2. Check 24VDC supply to enable inputs. | | F5001 | PLC Program Error | Runtime error in the user logic (e.g., division by zero). | 1. Check PLC logs for specific line number. 2. Debug logic code. |
For parameter-related errors (F15-F18), a firmware or parameter restore is often the fastest fix.
The controller categorizes faults by system architecture layers:
Common Rexroth PPC Fault Codes and Their Solutions * 1. Power On State Errors (Codes -01 to -2X) Upon powering the PPC controller, Wake Industrial Main Failure Codes of PPC Controller and Removal Method 14 Oct 2019 —
Critical fatal errors that often indicate hardware failure in the controller itself. rexroth ppcr221 fault codes full
The fiber optic ring must be intact. If one driver loses power, the whole ring may break. Common Troubleshooting Actions
Occurs if an automated application script attempts to access a protected parameter block without clearing safety privileges.
Solution: Flash the correct firmware build variant specified by the OEM or the Bosch Rexroth Product Portal. Commissioning and Component Integrity Faults (F21 to F23)
Internal RAM or memory addressing failure. Attempt a reset via power cycle. F31 to F40 Bus Communication Errors | Fault Code | Description | Probable Cause
: Status steps indicating the CPU initialization progress. A hang here means the control card cannot boot up properly.
These errors are related to the logical configuration of devices on the fiber optic ring.
Elias checked the fiber optic ring. A single kink in the cable was disrupting the "Link Ring" signal that synchronized the machine axes. Wake Industrial 3. The Danger Zones (F2000 series)
Ready for Operation. Control voltage is present, and no errors exist. Check mechanical drive train for jams
You have the full list of Rexroth PPCR221 fault codes. But some codes indicate terminal failure:
: Normal operational states indicating ready-for-power or drive enabled statuses. 2. Full Categorization of Rexroth PPCR221 Fault Codes Parameter and CF Card Faults (Codes F01 to F10)
Faults on the PPC-R22.1 often involve communication, memory, or drive synchronization issues. 2.1 Configuration and Memory Errors