We have listed the common faults and repair methods of Ultra3000 servo drives, if you need to replace the equipment, we provide Allen Bradley Rockwell Servo Drive.
Figure 1: Common Faults and Repair Methods of Allen Bradley Rockwell Servo Drive
Figure 2: Allen Bradley Rockwell Servo Drive failure, Rockwell Servo Drive Repair
Error Code |
Problem or Symptom |
Possible Cause |
Action/Solution |
E02 |
Velocity exceeds position rollover /2 |
The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled). |
Increase machine cycle size or reduce velocity profile. |
E03 |
Absolute feedback range exceeded |
The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback). |
· Decrease application range of motion. · Upgrade firmware. This error only applies to firmware revisions prior to 1.10. |
E44 |
Lost motion fault (only applies to applications with Stegmann feedback devices) |
Detection occurs during a fault reset. Absolute position in the drive is incorrect and the motion has been lost due to line loss condition. |
· Cycle power. · Cycle power and re-home drive if drive was homed in the same power cycle that the lost motion fault occurred. |
The following list of problematic symptoms (no error code shown) and problems with assigned error codes is designed to help you resolve problems.
When a fault is detected, the seven-segment LED will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the problem is cleared.
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
|
Power (PWR) indicator not ON |
No AC power or auxiliary logic power. |
Verify AC power or auxiliary +5V logic power is applied to the Ultra3000. |
Internal power supply malfunction. |
Call your Allen-Bradley representative. |
||
|
Power (PWR) indicator is ON, but seven segment Status LED display is OFF. Note: This applies to 2098-DSD-005, -010, and -020 Ultra3000 models only. |
Externally applied +5V auxiliary power supply voltage is too low. |
Verify that the external +5V auxiliary power supply (as measured at the drive terminals) reads between 5.10V and 5.25V. |
|
Motor jumps when first enabled |
Motor wiring error. |
Check motor wiring. |
Incorrect motor chosen. |
Verify the proper motor is selected. |
||
|
Digital I/O not working correctly |
I/O power supply disconnected. |
Verify connections and I/O power source. |
E01 |
Non-Volatile Memory Endurance Exceeded |
Range of motion and number of home position definitions during the product life exceeds the maximum allowed (applies only to systems with absolute feedback). |
This is an unrecoverable fault, the drive must be sent back to the factory. |
E02 |
Velocity Exceeds Position Rollover /2 |
The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled). |
Increase machine cycle size or reduce velocity profile. This error only applies to firmware versions prior to 1.10. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E03 |
Absolute Feedback Range Exceeded |
The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback). |
· Decrease application range of motion. · Upgrade firmware. |
E04 |
Motor Overtemperature |
Motor thermostat trips due to: · High motor ambient temperature and/or · Excessive current |
· Operate within (not above) the continuous torque rating for the ambient temperature (40°C maximum). · Lower ambient temperature, increase motor cooling. |
Motor wiring error. |
Check motor wiring. |
||
Incorrect motor selection. |
Verify the proper motor has been selected. |
||
E05 |
IPMFault |
Motor cables shorted. |
Verify continuity of motor power cable and connector. |
Motor winding shorted internally. |
Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced. |
||
Ultra3000 temperature too high. |
· Check for clogged vents or defective fan. · Ensure cooling is not restricted by insufficient space around the unit. |
||
Operation above continuous power rating. |
· Verify ambient temperature is not too high. · Operate within the continuous power rating. · Reduce acceleration rates. |
||
Ultra3000 has a bad IPM output, short circuit, or overcurrent. |
Remove all power and motor connections, and preform a continuity check from the DC bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair. |
||
An attempt was made to enable the drive without waiting at least 1.0 second after applying the main AC power. Note: This applies to 2098-DSD-005, -010, and -020 Ultra3000 models only (when using an external +5V auxiliary power supply). |
Wait at least 1.0 second after the main AC is applied before enabling the drive. |
||
E06 |
Hardware Overtravel (SERCOS only) |
Dedicated overtravel input is inactive. |
· Check wiring. · Verify motion profile. |
E07 |
RESERVED |
|
Call your local Allen-Bradley representative. |
E08 |
RESERVED |
|
|
E09 |
Bus Undervoltage |
Low AC line/AC power input. |
· 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. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E03 |
Absolute Feedback Range Exceeded |
The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback). |
· Decrease application range of motion. · Upgrade firmware. |
E04 |
Motor Overtemperature |
Motor thermostat trips due to: · High motor ambient temperature and/or · Excessive current |
· Operate within (not above) the continuous torque rating for the ambient temperature (40°C maximum). · Lower ambient temperature, increase motor cooling. |
Motor wiring error. |
Check motor wiring. |
||
Incorrect motor selection. |
Verify the proper motor has been selected. |
||
E05 |
IPMFault |
Motor cables shorted. |
Verify continuity of motor power cable and connector. |
Motor winding shorted internally. |
Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced. |
||
Ultra3000 temperature too high. |
· Check for clogged vents or defective fan. · Ensure cooling is not restricted by insufficient space around the unit. |
||
Operation above continuous power rating. |
· Verify ambient temperature is not too high. · Operate within the continuous power rating. · Reduce acceleration rates. |
||
Ultra3000 has a bad IPM output, short circuit, or overcurrent. |
Remove all power and motor connections, and preform a continuity check from the DC bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair. |
||
An attempt was made to enable the drive without waiting at least 1.0 second after applying the main AC power. Note: This applies to 2098-DSD-005, -010, and -020 Ultra3000 models only (when using an external +5V auxiliary power supply). |
Wait at least 1.0 second after the main AC is applied before enabling the drive. |
||
E06 |
Hardware Overtravel (SERCOS only) |
Dedicated overtravel input is inactive. |
· Check wiring. · Verify motion profile. |
E07 |
RESERVED |
|
Call your local Allen-Bradley representative. |
E08 |
RESERVED |
|
|
E09 |
Bus Undervoltage |
Low AC line/AC power input. |
· 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. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E10 |
Bus Overvoltage |
Excessive regeneration of power. When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the Ultra3000’s power supply. The system faults to save itself from an overload. |
· Change the deceleration or motion profile. · Use a larger system (motor and Ultra3000). · Use a resistive shunt. · If a shunt is connected, verify the wiring is correct and shunt fuse is not blown. |
Excessive AC input voltage. |
Verify input is within specifications. |
||
E11 |
IllegalHall State |
Incorrect phasing. |
Check the Hall phasing. |
Bad connections. |
· Verify the Hall wiring. · Verify 5V power supply to the encoder. |
||
E12 |
Home Search Failed |
Home sensor and/or marker is outside the overtravel limits. |
· Check wiring. · Reposition the overtravel limits or sensor. |
E13 |
Home Position In Limit |
Home sensor, marker, or final home position exceeds a hardware overtravel limit. |
· Reposition the overtravel limits or home sensor. · Adjust the final home position. |
E14 |
SERCOS Hardware Fault (SERCOS drives only) |
A fault was detected with the operation of the drive’s internal SERCOS hardware. |
Contact your local Allen-Bradley representative. |
DeviceNet Communications Network problem (DeviceNet drives only) |
DeviceNet communications network is broken |
Troubleshoot DeviceNet communications. |
|
E15 |
Excessive Electrical Cycle Length |
Electrical cycle length exceeds maximum lines per electrical cycle |
Replace the linear motor/encoder. |
E16 |
Software Overtravel (SERCOS only) |
Programmed overtravel limit has been exceeded. |
· Verify motion profile. · Verify overtravel settings are appropriate. |
E17 |
User-Specified Current Fault |
User-Specified average current level has been exceeded. |
Increase to a less restrictive setting. |
E18 |
Overspeed Fault |
Motor speed has exceeded 125% of maximum rated speed. |
· Check cables for noise. · Check tuning. |
E19 |
Excess Position Error |
Position error limit was exceeded. |
· Increase the feedforward gain. · Increase following error limit or time. · Check position loop tuning. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E20 |
Motor Encoder State Error |
The motor encoder encountered an illegal transition. |
· 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. |
Bad encoder. |
Replace motor/encoder. |
||
E21 |
Auxiliary Encoder state error |
The auxiliary encoder encountered an illegal transition. |
· Use shielded cables with twisted pair wires. · Route the encoder cable away from potential noise sources. · Bad encoder - replace encoder. · Check the ground connections. |
Setup time violation for Step/Direction or CW/CCW input. |
Check timing of Step/Direction or CW/ CCW inputs to determine if setup time requirements are being met. |
||
E22 |
Motor Thermal Protection Fault |
The internal filter protecting the motor from overheating has tripped. |
· 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 |
The internal filter protecting the drive from over heating has tripped. |
· 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 |
Velocity error limit was exceeded. |
· Increase time or size of allowable error. · Reduce acceleration. · Check tuning. |
E25 |
Sensor Not Assigned |
Homing or registration motion was attempted without a sensor assigned. |
Assign a sensor to a digital input. |
E26 |
User-Specified Velocity Fault |
User specified velocity level was exceeded. |
Increase to a less restrictive setting. |
E27 |
Axis Not Homed |
Absolute positioning was attempted without homing. |
Verify homing sequence. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E28 |
Motor Parameter Error |
Parameter loaded from smart encoder or received from SERCOS controller is incompatible with the drive. |
· Select a different motor through the SERCOS controller. · Select a different motor. |
E29 |
Encoder Output Frequency Exceeded |
Encoder output frequency exceeds the maximum user specified value. This only applies when the encoder output is synthesized by the drive. |
· Increase the encoder output maximum frequency parameter. · Decrease the encoder interpolation parameter. · Increase the encoder output divider parameter. |
E30 |
Encoder Communication Fault |
Communication was not established with an intelligent encoder. |
· Verify motor selection. · Verify the motor supports automatic identification. · Verify motor encoder wiring. |
E31 |
Encoder Data |
Encoder data is corrupted. |
Replace the motor/encoder. |
E32 |
Sine/Cosine Encoder Frequency Limit Exceeded |
Maximum frequency of the sine/cosine circuitry has been exceeded. |
· Decrease velocity. · Use encoder with lower resolution (before interpolation). |
E33 |
Absolute Position Exceeds Position Rollover |
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. |
Set motion command to a position within the position rollover range. |
E34 |
Ground Fault |
Wiring error. |
Check motor power wiring. |
Motor internal ground short. |
Replace motor. |
||
Internal malfunction. |
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 |
Low AC input voltage. |
Check input AC voltage on all phases. |
Internal malfunction. |
Call your A-B representative. |
||
E36 |
Power Circuitry Overtemperature |
Excessive heat exists in the power circuitry. |
· 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 |
One or more phases of the input AC power is missing. |
Check input AC voltage on all phases. |
E38 |
RESERVED |
|
Call your local Allen-Bradley representative. |
Error Code |
Problem or Symptom |
Possible Cause(s) |
Action/Solution |
E28 |
Motor Parameter Error |
Parameter loaded from smart encoder or received from SERCOS controller is incompatible with the drive. |
· Select a different motor through the SERCOS controller. · Select a different motor. |
E29 |
Encoder Output Frequency Exceeded |
Encoder output frequency exceeds the maximum user specified value. This only applies when the encoder output is synthesized by the drive. |
· Increase the encoder output maximum frequency parameter. · Decrease the encoder interpolation parameter. · Increase the encoder output divider parameter. |
E30 |
Encoder Communication Fault |
Communication was not established with an intelligent encoder. |
· Verify motor selection. · Verify the motor supports automatic identification. · Verify motor encoder wiring. |
E31 |
Encoder Data |
Encoder data is corrupted. |
Replace the motor/encoder. |
E32 |
Sine/Cosine Encoder Frequency Limit Exceeded |
Maximum frequency of the sine/cosine circuitry has been exceeded. |
· Decrease velocity. · Use encoder with lower resolution (before interpolation). |
E33 |
Absolute Position Exceeds Position Rollover |
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. |
Set motion command to a position within the position rollover range. |
E34 |
Ground Fault |
Wiring error. |
Check motor power wiring. |
Motor internal ground short. |
Replace motor. |
||
Internal malfunction. |
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 |
Low AC input voltage. |
Check input AC voltage on all phases. |
Internal malfunction. |
Call your A-B representative. |
||
E36 |
Power Circuitry Overtemperature |
Excessive heat exists in the power circuitry. |
· 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 |
One or more phases of the input AC power is missing. |
Check input AC voltage on all phases. |
E38 |
RESERVED |
|
Call your local Allen-Bradley representative. |
05/12/2022
We have listed the common faults and repair methods of Ultra3000 servo drives, if you need to replace the equipment, we provide <a href="https://okmarts.com/servo-product/allen-bradley-serve-product.html" alt="Allen Bradley Rockwell Servo Drive, Ultra3000 Servo Drive Repair">Allen Bradley Rockwell Servo Drive</a>
03/16/2021
FANUC spindle drive maintenance problems mainly appear as stalls, abnormal speeds, motor oscillations, jitter during processing, and main circuit overcurrent alarms. Compared with AC FANUC spindle drive maintenance problems, the primary manifestations are motor overvoltage, fuse blown, etc.
03/15/2021
The motor does not rotate or the speed is abnormal After starting the spindle drive system, if the main motor does not rotate or the speed is abnormal, the possible causes are as follows
03/15/2021
What are the characteristics of CDHD2 high-performance servo drive? What are the advantages of CDHD2 high-performance servo drive?
03/15/2021
Common faults of Alpha servo drives include: power-on without display, with display without output, overcurrent, overvoltage, undervoltage, overheating, overload, overspeed, phase loss, jitter, encoder abnormality, module damage, ground fault, parameters Errors etc.
03/14/2021
1.Maintenance of operating environment of servo driver In order to prolong the service life of the servo driver, the following problems should be paid attention to in the process of use. Temperature, humidity, dust, vibration, input voltage and other factors should be considered for the system environment.
03/14/2021
Regeneration and dynamic braking function; Instant power down protection function for quick shutdown;
03/13/2021
At present, most servo drivers use digital signal processor (DSP) as the control core, which can achieve more complex control algorithm, digitalization, networking and intellectualization. The drive circuit based on intelligent power module (IPM) is widely used in power devices.
03/13/2021
The working modes of servo driver are: open loop mode, voltage mode, current mode (torque mode), IR compensation mode, Hall speed mode, encoder speed mode, tachometer mode, and analog position loop mode (ANP mode). (not all of the above modes exist in all models of drives)
03/12/2021
The controller is usually a computer or PID control circuit, and its main task is to transform and process the deviation signal output by the comparison element, so as to control the executive element to act as required.
IWAYA DENKI Water Pump 25CJT0752
Panasonic Servo Motor MHMF022L1V2M
Honeywell Solenoid Valve VE4025B1045
ROTEN Mechanical Seal 8E5K-22-X
AirTAC Air Cylinder TACQ63X60
YASKAWA CPU Module JANCD-NCP01-1
BANDO Belt T5-165-17
NORGREN Air Cylinder CA/8050/M/200