Use the Faults window to:

 set fault limits,

 monitor fault statuses,

 execute the Clear Faults command,

 open a window where you can review the drive's fault history, and

 enable and Disable user faults.

The Faults window has the following parameters, statuses and commands:

Parameters: Description:

User Current The level, in amperes, that will generate a fault when exceeded by
Fault the average current level. The drive always protects itself and the
motor from average currents that exceed their ratings. This value is
only needed if a lower average current fault is desired (For
example, if another part of a machine would overheat). It has a
range of 0 to 256 Amps.

Note: Not available for SERCOS drive.

 
User Velocity The minimum velocity which causes the User Velocity fault. The
Fault drive always protects the motor from exceeding its ratings. This
value is only needed if a lower velocity fault is desired. (For
example, if another part of a machine could be damaged.)

Note: Not available for SERCOS drive.

 
User Velocity Select either:
Fault Enable
 Enabled: turns on User Velocity Fault detection by the
drive, or

 Disabled: turns off User Velocity Fault detection by the

drive.

Note: Not available for SERCOS drive.

 
Velocity Error The minimum velocity error that triggers the Velocity Error fault.
Fault Limit

Velocity Error The minimum time which the velocity error must be greater than
Fault Time the Velocity Error Fault Limit to cause a Velocity Error fault. It has
a range of 0 to 65535 milliseconds.
Following The minimum position error that triggers the Following Error fault.
Error Limit
Note: Not available for SERCOS drive.
 
Following The minimum time during which the position error must be greater
Error Time than the Following Error Fault Limit to cause a Following Error
fault. It has a range of 0 to 65535 milliseconds.

Note: Not available for SERCOS drive.

 
Status: Description: Possible Cause(s): Suggested Action:

Note: The value of statuses that are ON = 1. The value of statuses that are OFF = 0.
Error Codes are displayed on the drive's Status Indicator as a flashing E
followed by two numbers.
01: Non-Volatile A section of non- Range of motion and
Memory volatile memory is number of home This is an
Endurance used to assist in position definitions unrecoverable fault,
Exceeded tracking absolute during the product life the drive must be sent
position when the exceeds the maximum back to the factory.
drive is connected allowed.
to a motor with
absolute feedback.
This fault occurs
when the total
number of memory
writes to this area
exceeds the
maximum value
allowed.  

Note: This fault

can only be
generated for
systems with
absolute feedback.
02: Position This fault is The velocity command Increase machine cycle
Change Exceeds generated if the or feedback exceeds size or reduce velocity
Position Rollover / change in position half the machine cycle profile.
2 command or length per millisecond.
position feedback Note: This error only
exceeds half the applies to firmware
machine cycle size versions prior to 1.10.
during a position
loop update.  This
effectively limits
the velocity to half
the machine cycle
 size per
millisecond.

Note: This fault

can only be
generated when the
machine cycle
position rollover is
enabled
03: Absolute This fault is The motor position Decrease application
Feedback Range generated if the exceeds +/- 2047 range of motion.
Exceeded motor position revolutions from the
exceeds +/- 2047 home position. Upgrade firmware.
revolutions from
the home position,
but can only be
generated in
firmware versions
1.00 and 1.02.  

Note: This fault

can only be
generated when the
system includes
absolute feedback.
04: Motor ON indicates the Motor thermostat trips Operate within (not
Overtemp motor thermostat due to high motor above) the continuous
has tripped. ambient temperature torque rating for the
and/or excessive ambient temperature
current. (40ºC maximum).

Lower ambient
temperature, increase
motor cooling.
Motor wiring error Check motor wiring.

Incorrect motor
selection Verify the proper
motor has been
selected.
05: IPM Fault ON indicates that a Motor cables shorted Disconnect motor
fault was detected power cables from the
in the Integrated drive. If faults stop,
Power Module then either replace
which resides in cable or try to find the
the Ultra3000 short.
drive.
Motor winding Verify by
 shorted internally. disconnecting motor
from drive and then try
to turn by hand. If
difficult to turn by
hand, the motor needs
to be repaired or
replaced.

Ultra3000 temperature Check for clogged

too high. vents or defective fan.

Ensure cooling is not

restricted by
insufficient space
around the unit.
Operation above Verify ambient
continuous power temperature is not too
rating. high. Operate within
the continuous power
rating.

Increase Motion Time

or allow dwell periods.

Reduce acceleration
rates.
Ultra3000 has a bad Remove all power and
IPM output, short motor connections, and
circuit, or overcurrent, then check continuity
from the DC bus to U,
V, and W outputs. If
continuity exists, check
for conductive
materials between
terminals.

Replace the Ultra3000

drive.
06: SERCOS ON indicates the Dedicated overtravel Troubleshoot SERCOS
overtravel SERCOS Limit input is inactive. by checking wiring and
indicator is lit. verifying motion
profile.

07: Encoder ON indicates a Motor wiring error.

channel line B wiring error with Check motor encoder
break channel line B. channel line B wiring.

Note: E07 is not

currently
supported by the
Ultra3000.
08: Encoder ON indicates a Motor wiring error.
channel line A wiring error with Check motor encoder
break channel line A. channel line A wiring.

Note: E08 is not

currently
supported by the
Ultra3000.
09: Bus ON indicates the Low AC line/AC Verify voltage level of
Undervoltage DC Bus is below power input. 100 VAC the DC Bus. The Bus
normal operating minimum for safe should be 1.414*VAC
voltage. Ultra3000 operation. level.

Check AC power
source for glitches or
line drop.

Install an
uninterruptible power
supply (UPS) on your
AC input.
10: Bus ON indicates the Excessive regeneration Change the
Overvoltage DC Bus is above of power. When the deceleration or motion
normal operating drive is driven by an profile.
voltage. external mechanical
power source, it may Use a larger system
regenerate too much (motor and Ultra3000).
peak energy through
the drive's power Use an Active Shunt.
supply. The system
faults to save itself
from an overload.

Excessive AC input Verify input is below

voltage. 264 VAC.

Output short circuit. Disconnect the power

line from the drive and
then do continuity
check from the positive
and negative poles of
the DC Bus to each of
the motor output
phases U,V, and W. If
a continuity exists,
check for wire fibers
 between terminals, or
send drive in for repair.

Motor cabling wires Disconnect motor

shorted together. power cables from the
drive. If faults stop,
then either replace
cable or try to find the
short.

Internal motor Verify by

winding short circuit. disconnecting motor
from drive and then try
to turn by hand. If
difficult to turn by
hand, the motor needs
to be repaired or
replaced.

11: Illegal Hall ON indicates there Incorrect phasing Check the Hall
State is a problem with phasing.
the motor's Hall
Effect sensors. Bad connections Verify the Hall wiring.

Verify power supply to

encoder.
12: Home Search ON indicates that Home sensor or Check wiring
Failed the home position marker is outside the
was not found. overtravel limit. Reposition the
overtravel limits or
home sensor.
13: Home Position ON indicates that Home sensor, marker Reposition the
Outside Limits the home position or final home position overtravel limits or
exceeds a hardware exceeds a hardware home sensor.
overtravel limit overtravel limit.
value. Adjust the final home
position.
14: Net ON indicates DeviceNet Master If the Idle Fault Action
Communication DeviceNet state change from is set to Fault/Zero
  (DeviceNet communications RUN to IDLE. Data, or Fault/Hold
drive) network problem. Last, the drive induces
  . an E14 fault to prevent
               or motion in the event
that a DeviceNet
   Drive’s internal Master is no longer
   SERCOS under active control of
Interface the drive.
   (SERCOS drive) After the DeviceNet
 Master is set to RUN
again, this fault may be
cleared with a Drive
Reset input.

Troubleshoot
DeviceNet DeviceNet
communications communications.
network is broken
ON indicates a Call your A-B
fault is detected   representative.
with the operation
of the drive's
internal SERCOS
hardware.

15: Electrical (For linear motors Replace the linear

Cycle only) ON indicates Electrical cycle length motor/encoder.
there is a problem exceeds maximum
with the motor's lines per electrical
maximum line cycle (256,000).
count.

16: SERCOS ON indicates Verify motion profile.

Overtravel SERCOS Programmed
overtravel limit overtravel limit has Verify overtravel
exceeded. been exceeded. settings are
appropriate.
17: User Current ON indicates the Increase User Current
User Current Fault User-specified average Level and Time to a
level, input above, current level exceeded. less restrictive setting.
has been exceeded.
Increase time allowed
for motion.
18: Overspeed ON indicates the Check cables for noise.
motor speed has Motor exceeded 125%
exceeded 125% of of the-specified Check Motor wiring.
maximum rated maximum rated speed.
speed. Retune drive & motor
combination.

Use an actual
oscilloscope to check
Encoder phasing.
19: Following ON indicates the Retune the drive, start
Error Following Error Position error limit by setting the
Limit, set above, exceeded. feedforward gain to
has been exceeded. 100%.
 Increase the Following
Error Limit and Time.

If in Follower Mode,
increase the Slew
Limit (in the Follower
window).

Check position loop

tuning.
20: Motor Encoder ON indicates the Replace the
State motor encoder Motor encoder motor/encoder.
encountered an encountered an illegal
illegal transition. transition Use shielded cables
with twisted pair wires.

Route the feedback

away from potential
noise sources.

Check the system

grounds.

Ensure digital filtering

of encoder signals is
enabled.

Bad encoder Replace

motor/encoder.
21: Auxiliary ON indicates the Use shielded cables
Encoder State auxiliary encoder Auxiliary encoder with twisted pair wires.
encountered an encountered an illegal
illegal transition. transition Route the encoder
cable away from
potential noise sources.

Bad encoder - replace

encoder.

Check the ground

connections.

Setup time violation Check timing of inputs

for Step/Direction or to determine if setup
CW/CCW input. time requirements are
met.
22: Motor Filter ON indicates the Reduce acceleration
internal filter Motor overheated
 protecting the rates.
motor from
overheating has Reduce duty cycle
tripped. (ON/OFF) of
commanded motion.

Increase time permitted

for motion.

Check system tuning.

Use larger Ultra3000

and motor.
23: Thermal ON indicates the Reduce acceleration
Protect Filter internal filter Drive overheated rates.
protecting the drive
from overheating Reduce duty cycle
has tripped. (ON/OFF) of
commanded motion.

Increase time permitted

for motion.

Check system tuning.

Use larger Ultra3000

and motor.
24: Velocity Error ON indicates that Increase Velocity Error
the velocity error Velocity error limit Fault Limit or Velocity
exceeds the exceeded. Error Fault Time value
Velocity Error or both.
Fault Limit for a
length of time Reduce Acceleration.
greater than the
Velocity Error Retune the drive.
Fault Time value.

25: Sensor not ON indicates that Assign a sensor to a

assigned homing or Homing or registration digital input.
registration motion motion attempted
was attempted without a sensor
without a sensor assigned.
assigned.

26: User Velocity ON indicates the Increase User Velocity

User Velocity Fault User-specified velocity Fault Level and Time
level, above, has level exceeded. to a less restrictive
been exceeded. setting.
27: Axis Not ON indicates that a Verify homing
Homed absolute move was Absolute positioning position.
tried, before Home attempted without
position was homing.
defined.

28: Motor ON indicates a Select a different

Parameter Error parameter loaded Connection to an SERCOS motor blob.
from a smart improperly
encoder or a programmed or Install a different
SERCOS blob is incompatible smart motor.
incompatible with encoder. An attempt to
the drive. load a SERCOS blob
for a motor that is not
supported by the drive.
29: Excessive ON indicates the Increase the encoder
Output Frequency motor encoder Encoder output output maximum
output frequency frequency exceeds the frequency parameter.
exceeds the maximum value.
maximum value. Decrease the encoder
interpolation
Note: This fault parameter.
can only be
generated when the Increase the encoder
encoder output is output divider
synthesized by the parameter.
Ultra3000.
Reduce motor speed.
30: Encoder ON indicates loss Verify motor selection.
Communication of communication Communication was
with an intelligent not established with an Verify the motor
encoder. intelligent encoder. supports automatic
identification.

Verify motor encoder

wiring.
31: Encoder Data ON indicates Replace the
encoder data is Encoder data is motor/encoder.
corrupted. corrupted.

32: Excessive ON indicates Reduce motor speed.

Interpolated Sine/Cosine Encoder output
Feedback frequency of frequency exceeds the Use encoder with
Frequency encoder exceeds maximum user lower resolution
specified value. specified value. (before interpolation).

Note: This fault

can only be
generated when the
 encoder output is
synthesized by the
Ultra3000.
33: Absolute ON indicates An absolute index is Set motion command
Position Exceeds motion is initiated that specifies to a position within the
Position Rollover commanded to a a position outside the position rollover range.
position outside the position rollover
position rollover range.
range.  The
position rollover A homing cycle is
range is [0 .. initiated with the home
machine cycle size position outside the
- 1].   position rollover
range.
Note: This fault
can only be A define home is
generated when the initiated with the home
machine cycle position outside the
position rollover is position rollover
enabled. range.

A preset position  is

initiated that specifies
a position outside the
position rollover
range.

The home position

parameter is changed
to a value outside the
position rollover
range, the system has
absolute feedback and
the drive is reset or
power cycled.
34: Ground Short Check motor power
Circuit ON indicates the Wiring error wiring.
motor ground is
shorted.
Motor internal ground
Replace motor.
short

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, a wiring
error or an error
internal to the motor
exists.
35: Soft-Starting
Fault ON indicates a soft Check AC input
Low AC input voltage
fault at startup. voltage on all phases.

Call your A-B

Internal malfunction
representative.
36: Power Module Reduce acceleration
Overtemperature ON indicates an Excessive heat in rates.
overtemperature power circuitry.
condition in the Reduce duty cycle
power module. (ON/OFF) of
commanded motion.

Increase time permitted

for motion.

Use large Ultra3000

and motor.

Check motor tuning.

37: AC Input ON indicates Check AC input

Loss of one or more
Phase Loss incorrect power voltage on all phases.
phases of power.
phasing.
Verify that there are no
39: Self-sensing ON indicates a Motion required for impediments to motion
Commutation self-sensing self-sensing startup at startup, such as hard
Startup Error commutation error commutation was limits.
was encountered obstructed.
during startup Increase self-sensing
current if high friction
or load conditions
exist.

Verify the line count,

pole count, or electrical
cycle length motor
parameters.

Swap any two motor

connections and verify
the motor feedback
counts in the correct
direction during
 positive motor
movement.
Ineffective shunt Verify that the shunt
40: 230V Shunt This fault indicates resistor resistor (internal or
Protection Fault the shunt transistor external) is connected.
has been ON for an Excessive regeneration
excessive period of If an external shunt
time. resistor is connected,
verify that the shunt
fuse is not blown.

If the external shunt

resistor is not an Allen-
Bradley shunt resistor,
verify that the resistive
value is within
specifications.

Verify that the motor is

not being driven
mechanically, causing
the motor to behave as
a generator.
Ineffective shunt Verify that the shunt
41: 460V Shunt This fault indicates resistor resistor (internal or
Protection Fault the shunt transistor external) is connected.
has been ON for an Excessive regeneration
excessive period of If an external shunt
time. resistor is connected,
verify that the shunt
fuse is not blown.

If the external shunt

resistor is not an Allen-
Bradley shunt resistor,
verify that the resistive
value is within
specifications.

Verify that the motor is

not being driven
mechanically, causing
the motor to behave as
a generator.

42: Motor Keying This fault indicates The motor physically Select the correct
Error the motor attached connected to the drive motor in the user
(SERCOS drives to the SERCOS differs from the motor program.
only) drive is different specified in the user
than that specified program.
in the user
program.
Disable the Drive
43: Drive Enable This fault indicatesAn attempt was made Enable Input fault.
Input the Drive Enable to enable the axis
(SERCOS drives signal or fault is through software while Verify that Drive
only) not properly set. the Drive Enable Enable hardware is
hardware input was active whenever the
inactive. drive is enabled
through software.
Duplicate node
50 Duplicate Node This fault indicates address detected on  Verify each SERCOS
Fault there are conflicts SERCOS ring. drive is assigned a
(SERCOS drives between assigned unique node address.
only) Node addresses in  
the SERCOS ring.
Commands: Description:

Fault Opens the Fault History window, where you can view a list of fault events that occurred si
History... drive was powered-up.

Clear Faults Clears all drive faults.

Toggle the Show Status selection to display or hide the Status pane. Toggle the Show
Commands selection to display or hide the Commands pane. Click on the Setup
button to open the Monitor Setup window, where you can customize the status display
for this window. Click on the Revert button to return parameter settings to the values
they held when you opened this window.