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Error with bit StatusWord.11 = Internal Limit Active. What happens? | 07 Sep 2022 | |

Error with bit StatusWord.11 = Internal Limit Active. What happens?

Dear community,

We are having a big problem with a drive which is having a random error which stops the movement of the axis. As said, it is random, meaning that it sometimes appears and other times, the position control motion can be finished without any problem, there is no pattern on it.

We are using a CanOpen communication in a drive S700-Scheneider PLC architecture. The only thing that we have seen that it is common every time the error appears is that the bit 11 of the StatusWord gets high, which means that the Internal Limit of the drive is activated. Besides, the driver it gives either the warning n03 (following error -which comes due to the stop of the motor-) or n04 (Fieldbus communication monitor has responded -which we disabled but still sometimes it continues giving the warning). In this last case, the drive also gives an internal error hex 8130 send to the controller which means lifeguard error or heartbeat error, for which we have modify the producer heartbeat time with no luck.

Therefore, we are thinking that it might be possible that it stops because any reason and then, due to that stop, it gives the warning, either n03 and n04. We are not sure that this happens with n04 but we are with n03, because having incremented the maximum following error allowed, we have seen that the motor stops, and it only takes more time until reaching that value. So first the error happens, and then n03 appears as a consequence.

So, the problem may come with the activation of that Internal Limit of the drive, but since it sometimes gives one and other times the other warning, it suggests that it may not be the cause of the problem but a consequence. Thus, we are lost with the error because we don't understand what might be happening internally in the drive so that it stops the motor (communication frames have been checked and the controller does not command the stop).

We have a resolver and an encoder and are using a PMCprotego S1-2 Safety Card.



Any ideas of what could be happening? 

Thanks for your time.



Comments & Answers

SergioIdom said ...

SergioIdom |

Hi I Gibb,

It has been some time already and we didn't receive any response.

Please, it is a little bit urgent.

Thanks in advance,


SergioIdom said ...

SergioIdom |

Hi I Gibb,

Besides we are suffering from another problem that it is being difficult to solve and have the machine inoperative.

We are using PMCprotego S1-2 cards (Order number: 680005 with Kollmorgen firmware) and the error appears in every movement. These is what it is shown:



It is not clear for us which is the first error that stops the machine since all of them show same timestamp. Just guessing, we thought that the first error is the lower one in yellow, related to the "power off test" of the digital outputs of the safety card.


So, with an oscilloscope the digital outputs from the safety card were checked. As the manual of the safety card says, a good behaviour of them was encountered before the error appeared: pulse of 200us.

STO Acknow. (green), Ready (red) and STO SIL3 (blue).



After the error, the following graph was depicted: STO Acknowledge and STO SIL 3 are active (the change was impossible to record).


So nothing strange was seen in the digital outputs.


Then, in order to find out if the problem was in the safety card or in the drive, several changes between safety cards of drives were made. As you can see in the image below we made 3 swaps:


Firstly, the problem appeared in just one safety card. (Safety Card 1)


Then, in step 2, safety cards between the 2 drives that moves the same axis were swapped. And again, the problem appeared with just that safety card (Safety Card 1). And since those 2 drives were needed for moving an axis, we decided to exchange again that faulty safety card with a new drive (not needed for moving this axis): step 3.

In this moment, we saw that in Safety Card 1 the error was still appearing in its new drive. But also it appeared the same errors in Safety Card 2, the one we exchanged last (the one which was originally located in the drive not needed for that axis). In conclusion, same behaviour with 2 of the safety cards was seen.


Every time we were changing the safety card from one driver to the other, we were manually changing the configuration parameters and uploading it.


Then, we went back again, and step 3 was undone. And it happened same thing that you can see in step 2. And again, we undid step 2, and same behaviour as step 1 was obtained.


Safety Card 1: Order number: 680005. Serial number: 100241.

Safety Card 2Order number: 680005. Serial number: 100237.


In conclusion, no identification of the source of the error has been made and it has been impossible to find a solution. Getting in contact with PILZ, this is what they told us:

As supposed 680005 is the Kollmorgen version of our safety card.

It seems to be that the cards have problems with tolerances of some electrical parts on it. If the cards are inserted in a certain drive, the bad tolerances can summarize and could cause to this problem.

Sorry as already said you must talk to Kollmorgen support for exchange of this cards. We are not allowed to accept the cards directly. 


So, hopefully you have seen this error before and you can tell us something.

Thanks in advance,


I Gibb | Thu, 09/08/2022 - 09:54

we have been sent this already from a local distributor also, and they will contact you with the response.

SergioIdom | Mon, 09/12/2022 - 07:33

Hi I Gibb,

Thanks for the reply. I am looking forward to hearing from them.

By the way, disabling the watchdog, which is something that the troubleshooting suggests for the warning n04 (EXTWD = 0) is not working. The warning is still appearing.

Any idea why this would be?

Thanks in advance.

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