Allen Bradley Kinetix Ultra 3000 Servo Drive

Allen Bradley Kinetix Ultra 3000 Servo Drive Fault Codes:

Fault Code and Meaning	Cause and Remedy
(No Code) Power (PWR) indicator not ON	Cause: No AC power or auxiliary logic power. Internal power supply malfunction. Remedy: Verify AC power or auxiliary +5V logic power is applied to the Ultra3000. Call your Allen-Bradley representative.
(No Code) Power (PWR) indicator is ON, but seven segment Status LED display is OFF. (2098-DSD-005, -010, -020 models only)	Cause: Externally applied +5V auxiliary power supply voltage is too low. Remedy: Verify that the external +5V auxiliary power supply (as measured at the drive terminals) reads between 5.10V and 5.25V.
(No Code) Motor jumps when first enabled	Cause: Motor wiring error. Incorrect motor chosen. Remedy: Check motor wiring. Verify the proper motor is selected.
(No Code) Digital I/O not working correctly	Cause: I/O power supply disconnected. Remedy: Verify connections and I/O power source.
E01 Non-Volatile Memory Endurance Exceeded	Cause: Range of motion and number of home position definitions during the product life exceeds the maximum allowed (applies only to systems with absolute feedback). Remedy: This is an unrecoverable fault, the drive must be sent back to the factory.
E02 Velocity Exceeds Position Rollover /2	Cause: The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled). Remedy: Increase machine cycle size or reduce velocity profile. This error only applies to firmware versions prior to 1.10.
E03 Absolute Feedback Range Exceeded	Cause: The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback). Remedy: Decrease application range of motion. Upgrade firmware.
E04 Motor Overtemperature	Cause: Motor thermostat trips due to high ambient temperature, excessive current, or bad airflow. Motor wiring error. Incorrect motor selection. Remedy: Operate within (not above) the continuous torque rating for the ambient temperature (40°C maximum). Lower ambient temperature, increase motor cooling. Check motor wiring. Verify the proper motor has been selected.
E05 IPMFault	Cause: Motor cables shorted. Motor winding shorted internally. Ultra3000 temperature too high. Operation above continuous power rating. Ultra3000 has a bad IPM output, short circuit, or overcurrent. Enabling drive too quickly after main AC power application. Remedy: Verify continuity of motor power cable and connector. Disconnect motor power cables. If motor is difficult to turn by hand, it may need replacement. Check for clogged vents or defective fan. Ensure cooling is not restricted. Reduce acceleration rates. Remove all power/motor connections and perform continuity check from DC bus to U, V, W outputs. Wait at least 1.0 second after main AC is applied before enabling the drive.
E06 Hardware Overtravel (SERCOS only)	Cause: Dedicated overtravel input is inactive. Remedy: Check wiring. Verify motion profile.
E07 RESERVED	Cause: N/A Remedy: Call your local Allen-Bradley representative.
E08 RESERVED	Cause: N/A Remedy: Call your local Allen-Bradley representative.
E09 Bus Undervoltage	Cause: Low AC line/AC power input. Remedy: Verify voltage level of the incoming AC power. Check AC power source for glitches or line drop. Install an uninterruptible power supply (UPS) on your AC input.
E10 Bus Overvoltage	Cause: Excessive regeneration of power (motor acting as generator). Excessive AC input voltage. Remedy: Change the deceleration or motion profile. Use a larger system (motor and Ultra3000). Use a resistive shunt. If connected, verify wiring and fuse. Verify input is within specifications.
E11 IllegalHall State	Cause: Incorrect phasing. Bad connections. Remedy: Check the Hall phasing. Verify the Hall wiring. Verify 5V power supply to the encoder.
E12 Home Search Failed	Cause: Home sensor and/or marker is outside the overtravel limits. Remedy: Check wiring. Reposition the overtravel limits or sensor.
E13 Home Position In Limit	Cause: Home sensor, marker, or final home position exceeds a hardware overtravel limit. Remedy: Reposition the overtravel limits or home sensor. Adjust the final home position.
E14 SERCOS Hardware Fault OR DeviceNet Comms Problem	Cause: (SERCOS) Fault detected with internal SERCOS hardware. (DeviceNet) Communications network is broken. Remedy: (SERCOS) Contact your local Allen-Bradley representative. (DeviceNet) Troubleshoot DeviceNet communications.
E15 Excessive Electrical Cycle Length	Cause: Electrical cycle length exceeds maximum lines per electrical cycle. Remedy: Replace the linear motor/encoder.
E16 Software Overtravel (SERCOS only)	Cause: Programmed overtravel limit has been exceeded. Remedy: Verify motion profile. Verify overtravel settings are appropriate.
E17 User-Specified Current Fault	Cause: User-Specified average current level has been exceeded. Remedy: Increase to a less restrictive setting.
E18 Overspeed Fault	Cause: Motor speed has exceeded 125% of maximum rated speed. Remedy: Check cables for noise. Check tuning.
E19 Excess Position Error	Cause: Position error limit was exceeded. Remedy: Increase the feedforward gain. Increase following error limit or time. Check position loop tuning.
E20 Motor Encoder State Error	Cause: The motor encoder encountered an illegal transition or the encoder is bad. Remedy: Replace the motor/encoder. Use shielded cables with twisted pair wires. Route the feedback away from potential noise sources. Check the system grounds. Verify that the unbuffered encoder signals are not subjected to EMI in the CN1 cable. Remove these signals from the CN1 cable if they are not being used. Verify that the motor has a high-frequency bond to the drive’s enclosure panel. Verify that any stage connected to the motor shaft (for example using a ball screw) has a high-frequency bond to the machine frame and the drive’s enclosure panel.
E21 Auxiliary Encoder state error	Cause: The auxiliary encoder encountered an illegal transition, or there is a setup time violation for Step/Direction or CW/CCW input. Remedy: Use shielded cables with twisted pair wires. Route the encoder cable away from potential noise sources. Bad encoder – replace encoder. Check the ground connections. Check timing of Step/Direction or CW/CCW inputs to determine if setup time requirements are being met.
E22 Motor Thermal Protection Fault	Cause: The internal filter protecting the motor from overheating has tripped. Remedy: Reduce acceleration rates. Reduce duty cycle (ON/OFF) of commanded motion. Increase time permitted for motion. Use larger Ultra3000 and motor. Check tuning.
E23 IPM Thermal Protection Fault	Cause: The internal filter protecting the drive from overheating has tripped. Remedy: Reduce acceleration rates. Reduce duty cycle (ON/OFF) of commanded motion. Increase time permitted for motion. Use larger Ultra3000 and motor. Check tuning.
E24 Excess Velocity Error	Cause: Velocity error limit was exceeded. Remedy: Increase time or size of allowable error. Reduce acceleration. Check tuning.
E25 Sensor Not Assigned	Cause: Homing or registration motion was attempted without a sensor assigned. Remedy: Assign a sensor to a digital input.
E26 User-Specified Velocity Fault	Cause: User specified velocity level was exceeded. Remedy: Increase to a less restrictive setting.
E27 Axis Not Homed	Cause: Absolute positioning was attempted without homing. Remedy: Verify homing sequence.
E28 Motor Parameter Error	Cause: Parameter loaded from smart encoder or received from SERCOS controller is incompatible with the drive. Remedy: Select a different motor through the SERCOS controller. Select a different motor.
E29 Encoder Output Frequency Exceeded	Cause: Encoder output frequency exceeds the maximum user specified value. This only applies when the encoder output is synthesized by the drive. Remedy: Increase the encoder output maximum frequency parameter. Decrease the encoder interpolation parameter. Increase the encoder output divider parameter.
E30 Encoder Communication Fault	Cause: Communication was not established with an intelligent encoder. Remedy: Verify motor selection. Verify the motor supports automatic identification. Verify motor encoder wiring.
E31 Encoder Data	Cause: Encoder data is corrupted. Remedy: Replace the motor/encoder.
E32 Sine/Cosine Encoder Frequency Limit Exceeded	Cause: Maximum frequency of the sine/cosine circuitry has been exceeded. Remedy: Decrease velocity. Use encoder with lower resolution (before interpolation).
E33 Absolute Position Exceeds Position Rollover	Cause: Motion is commanded to a position outside the position rollover range. An absolute index is initiated that specifies a position outside the position rollover range. A homing cycle is initiated with the home position outside the position rollover range. A define home is initiated with the home position outside the position rollover range. A preset position is initiated that specifies a position outside the position rollover range. Remedy: Set motion command to a position within the position rollover range.
E34 Ground Fault	Cause: Wiring error, Motor internal ground short, or Internal malfunction. Remedy: Check motor power wiring. Replace motor. Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault remains, call your A-B representative. If fault clears, then a wiring error or motor internal problem exists.
E35 Precharge Fault	Cause: Low AC input voltage or Internal malfunction. Remedy: Check input AC voltage on all phases. Call your A-B representative.
E36 Power Circuitry Overtemperature	Cause: Excessive heat exists in the power circuitry. Remedy: Reduce acceleration rates. Reduce duty cycle (ON/OFF) of commanded motion. Increase time permitted for motion. Use larger Ultra3000 and motor. Check tuning.
E37 AC Line Loss	Cause: One or more phases of the input AC power is missing. Remedy: Check input AC voltage on all phases.
E38 RESERVED	Cause: Reserved system error. Remedy: Call your local Allen-Bradley representative.
E39 Self-sensing Commutation Startup Error	Cause: Motion required for self-sensing startup commutation was obstructed. Remedy: Verify that there are no impediments to motion at startup, such as hard limits. Increase self-sensing current if high friction or load conditions exist. Check motor or encoder wiring using wiring diagnostics.
E40 230V Shunt Protection Fault	Cause: Ineffective shunt resistor or Excessive regeneration. Remedy: Verify that the shunt resistor (internal or external) is connected. If an external shunt resistor is connected, verify that the shunt fuse is not blown. If a non Allen-Bradley external shunt resistor is used, verify that the resistance value is within specifications. Verify that the motor is not being driven mechanically, causing the motor to behave as a generator.
E41 460V Shunt Protection Fault	Cause: Ineffective shunt resistor or Excessive regeneration. Remedy: Verify that the shunt resistor (internal or external) is connected. If an external shunt resistor is connected, verify that the shunt fuse is not blown. If a non Allen-Bradley external shunt resistor is used, verify that the resistance value is within specifications. Verify that the motor is not being driven mechanically, causing the motor to behave as a generator.
E42 Motor Keying Error (SERCOS drives only)	Cause: The motor physically connected to the drive differs from the motor specified in the user program. Remedy: Select the correct motor in the user program.
E43 Drive Enable Input (SERCOS drives only)	Cause: An attempt was made to enable the axis through software while the Drive Enable hardware input was inactive. The Drive Enable input transitioned from active to inactive while the axis was enabled. Remedy: Disable the Drive Enable Input fault. Verify that Drive Enable hardware input is active whenever the drive is enabled through software.
E50 Duplicate Node Fault (SERCOS drives only)	Cause: Duplicate node address detected on SERCOS ring. Remedy: Verify that each SERCOS drive is assigned a unique node address.
All others RESERVED	Cause: Unknown or reserved fault code. Remedy: Call your local Allen-Bradley representative.