ABB Application Error ABB Motion Drives Error trouble shoo

The drive displays a dash character ('-') or other single digit character ('0' to '9') permanently, indicating an initialization error. This signifies that the drive cannot get to the firmware loading stage, often due to an incorrectly fitted memory module, issues with firmware loading, or connected external hardware.

An over temperature condition has been detected for the motor. This can be triggered either by the hardwired X10 thermistor input or by a serial motor encoder (e.g., Hiperface DSP) providing thermistor resistance data. The drive trips if this value exceeds the MOTORTEMPERATURETRIP parameter.

The phase search procedure, required for controlling motors with an "encoder only" type feedback, failed to complete successfully. This indicates an issue with encoder settings or motor pole configuration preventing proper motor commutation.

This error occurs when the drive is configured for "Halls only" or "Encoder + Halls" feedback and detects an illegal Hall sensor state (0 or 7). This typically points to a faulty encoder (which often simulate Hall signals) or incorrect wiring.

The drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) is configured to use a Serial Encoder but is unable to provide position information. This error is generated if an attempt is made to enable the axis before the encoder is ready (which can take several seconds) or if the resolution configured on the drive is not compatible with the encoder. The axis will be crash stopped and disabled.

The three-phase drive (MotiFlex e100, MotiFlex e180) has detected the loss of one or more AC supply phases. MotiFlex e100 drives use dedicated phase monitoring hardware, while MotiFlex e180 drives monitor DC bus ripple; excessive ripple indicates an input phase loss. The drive can normally only operate with a three-phase supply.

Process Data Object (PDO) data from the remote axis (CN) to the manager (MN) has been lost. This error occurs if the manager detects that at least two consecutive PDO packets have not been received correctly. On a NextMove e100, this may happen if a drive disappears from the network.

The phase search operation has been prevented due to the drive's heatsink temperature exceeding its safe operating limits.

When controlling an axis using Real-Time Ethernet (RTE), one of the Process Data Objects (PDOs) sent to the drive was outside its permissible range. This is frequently observed with the velocity reference PDO, often when an axis is geared to a master axis/encoder and the master position/encoder value is programmatically changed to a new value, leading to an instantaneous and excessive velocity demand.

One or both of the Safe Torque Off (STO) inputs are not powered. This error can only occur when the drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) is enabled, indicating that the safety function has removed torque from the motor.

One or both of the internal fault circuit outputs within the drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) have been asserted, indicating an internal hardware fault in the Safe Torque Off (STO) circuits. This error can occur regardless of whether the drive is enabled or disabled.

The drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) has detected a mismatch in its internal Safe Torque Off (STO) registers, meaning the two redundant STO inputs are not in the same state. This error can occur when the drive is enabled or disabled.

The drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) has detected that the measured Hall transition angle differs from the electrical angle used in the control by at least 70 degrees, indicating a significant discrepancy in position feedback.

This is an informational message appearing in the error log to indicate that all axis-related errors have been successfully cleared from the drive's active error list.

This informational message can appear at startup or when the drive (MotiFlex e100, MotiFlex e180, MicroFlex e190) is enabled, indicating that the battery backup supply for a Smart Abs encoder has failed or is depleted.

An error has occurred when using the Resolver Adapter (OPT-MF-201 or FB-03). The error is caused by the loss of resolver signals, indicating issues with the wiring to the motor's feedback device, the motor connector, or connections inside to the adapter.

An error has occurred when the drive attempts to read position data over a Hiperface DSL encoder connection. This typically indicates issues with the wiring to the motor's feedback device, the motor connector, or connections inside the adapter, affecting the communication link.

The drive has detected that its output frequency exceeded 550 Hz. This restriction is implemented to comply with relevant European Export Control Regulations, indicating an attempt to operate beyond a regulatory limit.

The motor velocity has exceeded the value set in the DRIVESPEEDMAX(0) parameter. This indicates that the commanded drive speed is too high for the configured maximum limit or the DRIVESPEEDMAX parameter is set incorrectly.

The amount of data intended for transmission cannot fit into a single ICM (Internal Communication Module) telegram. This typically occurs when a host application uses `doMultipleCommands` with too many encapsulated calls.

A warning occurred when downloading a parameter table to an e100 drive. This happens if a parameter in the table was not supported by the drive or that specific instance of the parameter did not exist. It can also be caused by an argument list having more than 2 parameters, a value list having more than 1 parameter, an incorrect value type, or downloading a parameter table generated for a different product configuration (e.g., MotiFlex e100 with resolver option vs. no option).

This error occurs when attempting to assign POWERREADYINPUT or POWERREADYOUTPUT to an input/output configured with incompatible settings (e.g., INPUTMODE, INPUTACTIVELEVEL, OUTPUTACTIVELEVEL). It also occurs if a subsequent attempt is made to alter the configuration of an input/output that has already been assigned as the POWERREADYINPUT or POWERREADYOUTPUT.

This error is returned if an attempt is made to issue (load) another move command while the axis is already in the process of stopping. This applies not only to move commands but also if a CANCEL or STOP command is issued while the axis is already stopping or processing another CANCEL.

The Mint program attempted to reference an event that is not present, has not been installed, or is undefined in the controller (MotiFlex e100, MotiFlex e180, MicroFlex e190).

The Mint program attempted to use an event that is not supported by the current controller hardware or firmware version (MotiFlex e100, MotiFlex e180, MicroFlex e190).

This synchronous programming error occurs when a specified data value, such as a parameter setting, falls outside its permissible operating range. An example is setting SCALEFACTOR(0) to a negative value when it must be positive. If no ONERROR event is defined, the program will terminate.

The drive (MotiFlex e180, MicroFlex e190) has detected that its internal temperature is dangerously hot. The internal temperature sensor reading (TEMPERATURE parameter) has exceeded the predefined TEMPERATURELIMITFATAL value (e.g., e190 3A is 80°C, e190 6A and 9A is 75°C, e180 is 80°C).

The controller's FPGA (Field-Programmable Gate Array) has failed to initialize properly during power-up or operation.

The drive's controller is unable to access its non-volatile memory, which stores configuration parameters and other critical data.

Errors have occurred during a parameter table download or during startup, preventing some parameters from being applied correctly. The controller's status display will flash 'E' only. This error is commonly associated with parameter file (.ptx) issues, particularly when generated from older firmware versions with different parameters or parameter limits. The Error Log provides specific details of the failures.

An unspecified internal error has occurred within the controller, specifically indicating a failed parameter read operation.

The drive (MotiFlex e180, MicroFlex e190) has detected that an internal cooling fan has failed or is not operating as expected.

A communication error has been detected by the drive (MotiFlex e180, MicroFlex e190) between itself and the Mint option card, specifically related to transmit (TX) operations.

The controller (MotiFlex e180, MicroFlex e190) has detected an ambient temperature lower than -5 °C. The drive cannot be enabled or operated under these conditions to prevent damage or unreliable performance.

This is an informational message appearing in the error log to indicate that all controller-related errors have been successfully cleared from the drive's active error list.

The controller hardware does not support Ethernet POWERLINK (EPL). This specifically applies to earlier hardware revisions of MotiFlex e180 drives (with GCU-01 control cards before Rev A). This error is generated on these older hardware revisions if the EPL address switches are not both set at '0'. These older drives will still function in other operating modes, but EPL functionality requires a hardware exchange.

This is a 'fatal' synchronous error indicating that the program's call stack has exceeded its allocated memory space. This typically occurs in complex or deeply nested Mint programs where too many function calls or recursive operations are active simultaneously. This error will terminate the Mint program immediately and will not call the ONERROR event.

This is a 'fatal' synchronous error indicating an attempt to access an array element or data structure using an index that is outside its defined bounds. For example, trying to access the 10th element of an array declared with only 5 elements. This error will terminate the Mint program immediately and will not call the ONERROR event.

This is a 'fatal' synchronous error indicating an attempt to pop data from an empty stack. This typically occurs in Mint programs when there are more stack pop operations (e.g., function returns without corresponding calls) than push operations. This error will terminate the Mint program immediately and will not call the ONERROR event.

This is a general encoder fault detected by the drive, indicating a potential issue with the encoder configuration, wiring, or the encoder's operational integrity. This can lead to inaccurate position or speed feedback.

A test move operation has been initiated which the drive determines will take an excessive amount of time to complete. This is often due to incorrect scaling parameters or an improperly configured test move velocity.

During velocity autotuning, the calculated velocity exceeded the configured DriveSpeedMax parameter. This indicates that the DriveSpeedMax parameter might be set too low or the autotuning process is attempting an excessively fast move.

The motor rated current parameter is set to a value less than 0.2A, which is too low for the drive to effectively control the motor. This typically indicates incorrect motor data entry or an attempt to use a motor too small for the drive.

The current control loop has not been properly tuned before attempting rotor parameters autotuning, specifically applicable to asynchronous motors. Proper current loop tuning is a prerequisite for accurate rotor parameter identification.

The desired autotuning procedure is not compatible with the currently configured motor type in the drive. This indicates that the motor data might be incorrect or an unsupported autotuning function was selected for the specific motor.

The drive is unable to set the proportional gain for the flux control loop. This typically points to incorrect motor data, which impacts the drive's ability to properly calculate and apply control parameters for flux regulation.

The drive is unable to set the integral gain for the flux control loop. This error typically indicates issues with motor data that prevent proper calculation and application of flux control parameters, although the manual states it may not appear as an API error.

The drive is unable to determine or set the motor's magnetizing inductance (Lm). This is typically caused by incorrect motor data entered into the drive, which is crucial for accurate motor modeling and control calculations.

This is a normal state during boot-up but should not persist permanently. If the drive remains in this state, it indicates an issue with the memory module, firmware, or connected external hardware, preventing it from transitioning to an operational state. Note: This state also indicates the drive is enabled, so distinguish from a normal enabled state.

This error is reported along with a Profile Code in the Mint WorkBench Error Log. The displayed profile code must be converted to hexadecimal to reveal the specific EtherCAT error code. This status indicates that the EtherCAT master has received an error code from the drive (e.g., MotiFlex e100, MotiFlex e180, MicroFlex e190).

This error is reported along with a Profile Code in the Mint WorkBench Error Log, which must be converted to hexadecimal to reveal the specific CIP (Common Industrial Protocol) general status code. This indicates that the EtherCAT master has received a CIP error code from the drive.

This error is reported along with a Profile Code in the Mint WorkBench Error Log, which must be converted to hexadecimal to reveal the specific POWERLINK error code. This indicates that the POWERLINK master has received an error code from the drive.

This error is reported when multicast MAC filter configuration fails. It indicates that the PROFInet master has attempted to configure the device ID but has failed on the drive (e.g., MotiFlex e100, MotiFlex e180, MicroFlex e190).

This is a normal state during boot-up but should not persist permanently. If the drive remains in this state, it indicates an issue with the encoder configuration or general drive parameter configuration preventing the system from loading its intended communication profile.

The drive is in a 'Suspend active' state, indicating that the Mint SUSPEND command is active. This is not an error but a commanded state that prevents the firmware from loading and the drive from transitioning to normal operation.

The drive displays a boot error code (starting with 'b' on the seven-segment display) indicating a fatal error during the boot-up process. This generally points to issues with the memory module, firmware, or connected external hardware.

This error occurs during or after a firmware upgrade when parameters are re-instated. It typically indicates that the new firmware version has introduced a new parameter that was not present in the old parameter file, preventing proper configuration.

The drive displays a boot error code (starting with 'b' on the seven-segment display) indicating a fatal error during the boot-up process. This generally points to issues with the memory module, firmware, or connected external hardware.