Troubleshooting / Allen-Bradley Kinetix faults

Allen-Bradley Kinetix and Ultra3000 Fault Codes

The fault codes of Allen-Bradley servo drives: the E codes shared by Ultra3000, Kinetix 6000, 2000 and 300, and the most common FLT S codes of Kinetix 5500 and 5700. What each one means, which drives use it, the likely causes, the first checks in order, and how to log it so it stops coming back.

How faults show on the drive

Ultra3000, Kinetix 6000 and Kinetix 2000 flash an E on the seven-segment status display followed by the two-digit code, one digit at a time, repeating until the fault is cleared (a flashing L on Ultra3000 means an overtravel condition, and the Kinetix 6000/2000 drive status LED goes steady red).

The Kinetix 300 shows E plus the code without scrolling and after 30 seconds alternates it with its IP address, while the Kinetix 350 (F xx on a four-digit display), Kinetix 6200/6500 (FLT Sxx scrolling on a four-character display) and Kinetix 5500/5700 (FLT Sxx / FLT Mxx on the LCD, FAULT LOG menu) use the newer CIP fault codes instead of E codes.

In RSLogix 5000 / Studio 5000 Logix Designer the same fault appears as an axis fault such as MotFeedbackFault, DriveOvervoltageFault or PositionErrorFault, and a few faults (motor thermal, hard and soft overtravel, position error, drive enable input) have a programmable fault action on the Axis Properties Fault Actions tab.

Fix the cause first, then reset: an MAFR, MASR or MGSR instruction or the HIM on Kinetix 6000/2000, the Clear Faults command in Ultraware's Faults branch or a Fault Reset digital input on Ultra3000, a Fault Reset input, drive parameter 53 by explicit message or toggling drive enable on the Kinetix 300.

On Kinetix 5500/5700 the fault text leaves the display only after a Fault Reset service when the fault is no longer active, and the drive keeps a log of the last 128 faults.

Safety first.
The Ultra3000, Kinetix 6000 and Kinetix 350 troubleshooting chapters warn that DC bus capacitors can hold hazardous voltage after input power is removed, so measure the DC bus voltage to confirm it is at a safe level or wait the full time on the drive's warning label before working on the drive.

The Kinetix 300 manual says the capacitors hold charge for about 300 seconds and to wait at least 5 minutes, and the Kinetix 2000, 5500 and 5700 manuals say to wait 5 minutes for the DC bus to discharge. Rockwell also says never to defeat or override the drive fault circuits: find and correct the cause before running the machine again.

Follow lockout/tagout and your site's safe-work procedures, and check the manual for your exact model before you act.

Quick lookup

With the default fault action every code here stops the axis, so in OEE it is an availability loss; the few faults with a programmable action (overtravel, position error, motor thermal) count as warnings if you set them to report only.

Type a code or a word (feedback, overtravel, bus, overspeed) to filter the list. Some codes mean different things on different drives, so each meaning has its own row.

55 codes

CodeName
E00BusUndervoltage Fault (Blown fuse)
E04Motor Overtemperature (MotorOvertempFault)
E05IPM Fault (Ultra3000) / DriveOvercurrent Fault, Power Fault (Kinetix 6000, 2000)
E06Hardware Overtravel (HardOvertravelFault, +/- Hard Overtravel)
E07MotFeedbackFault (Motor Feedback Loss) / Feedback lost (Kinetix 300)
E09Bus Undervoltage (BusUndervoltageFault on Kinetix 6000/2000, DriveUndervoltageFault on Ultra3000)
E10Bus Overvoltage (DriveOvervoltageFault)
E11Illegal Hall State (CommutationFault on Ultra3000, MotFeedbackFault on Kinetix 6000/2000)
E12Home Search Failed
E14Ethernet I/O connection lost (Kinetix 300)
E16Software Overtravel (SoftOvertravelFault, +/- Software Overtravel)
E18Overspeed Fault (OverSpeedFault)
E19Excess Position Error (PositionErrorFault, HIM Follow Error)
E20Motor Encoder State Error (MotFeedbackFault, HIM Mtr Fdbk AQB)
E21AuxFeedbackFault (Aux Feedback Comm), Kinetix 6000 / 2000
E21Auxiliary Encoder State Error (AuxFeedbackNoiseFault), Ultra3000
E22Motor Thermal Protection Fault (OverloadFault in RSLogix 5000)
E23IPM Thermal Protection Fault (Ultra3000, DriveOvertempFault) / Drive Thermal Protection (Kinetix 300)
E27Axis Not Homed (Ultra3000) / Absolute move fault (Kinetix 300)
E30Encoder Communication Fault (Ultra3000, Kinetix 300) / MotFeedbackFault, Motor Feedback Comm (Kinetix 6000, 2000)
E31Encoder Data (Ultra3000, Kinetix 300)
E31DriveHardFault, excessive motor shaft movement (Kinetix 6000)
E34Ground Fault (GroundShortFault on Kinetix 6000/2000)
E35Precharge Fault (DriveUndervoltageFault on Kinetix 6000/2000)
E36Power Circuitry Overtemperature (Ultra3000) / DriveOvertemp Fault, System Overtemperature (Kinetix 6000, 2000)
E37AC Line Loss (Ultra3000) / PowerPhaseLoss Fault, Phase Loss Flt (Kinetix 6000, 2000)
E38SercosFault (Sercos Ring Flt)
E39Self-sensing Commutation Startup Error (DriveHardFault, HIM Self Sense Flt)
E39Safe Torque Off while enabled (Kinetix 300)
E40 / E41230V Shunt Protection Fault (E40) / 460V Shunt Protection Fault (E41)
E43Drive Enable Input (DriveEnableInputFault, HIM Drive Enable Flt)
E44Controller changed to PROG mode (Kinetix 300)
E49DriveHardFault (Safe-off HW Flt)
E50Duplicate Node Fault (Ultra3000) / SercosFault, Sercos Same ADDR (Kinetix 6000, 2000)
E64MotorFeedbackNoise (Mtr Fdbk Noise)
E67DriveHardFault (Task init) / Operating system failed
E72DriveOvertemp Fault (Drive Overtemp) / Drive temperature too high (Kinetix 300)
E73Communicate (Backplane Comm)
E74DriveOvercurrent Fault (Bus OverCurrent), Kinetix 6000 / 2000
E74Drive has exceeded peak current limit (Kinetix 300)
E75DriveOvervoltage Fault (Shunt Time Out)
E76Blank memory module (Kinetix 300, Kinetix 350)
E77DriveHardFault (Module Mismatch)
E79DriveOvervoltage Fault (Shunt Module Flt)
E90DriveHardFault (Precharge Timeout Flt)
FLT S03Motor Overspeed Factory Limit Fault (FLT S03 - MTR OVERSPEED FL)
FLT S05Motor Overtemperature Factory Limit Fault (FLT S05 - MTR OVERTEMP FL nn)
FLT S07Motor Thermal Overload Factory Limit Fault (FLT S07 - MTR OVERLOAD FL)
FLT S10Inverter Overcurrent Fault (FLT S10 - INV OVERCURRENT)
FLT S16Ground Current Factory Limit Fault (FLT S16 - GROUND CURRENT)
FLT S33Bus Undervoltage Factory Limit Fault (FLT S33 - BUS UNDERVOLT FL)
FLT S35Bus Overvoltage Factory Limit Fault (FLT S35 - BUS OVERVOLT FL)
FLT S43Feedback Signal Loss Factory Limit (FLT S43 - FDBK LOSS FL)
FLT S45Motor Feedback Data Loss Factory Limit Fault (FLT S45 - FDBK COMM FL)
FLT S54Excessive Position Error Fault (FLT S54 - POSN ERROR)

Each code: causes and first checks

E00: BusUndervoltage Fault (Blown fuse)

Hits OEE: Availability

What it means: The drive detected a blown fuse on the inverter circuit board; Logix reports it as BusUndervoltageFault with the HIM text Blown fuse.[3][4]

Also on: Kinetix 6000 and Kinetix 2000. Not listed for Ultra3000 or Kinetix 300.

Likely causes

  • Blown fuse on the inverter printed circuit board inside the IAM or AM module
  • The fuse is internal, so Rockwell treats it as a module repair, not a field fix

First checks, in this order

  1. Read the code on the module's seven-segment display to tell E00 apart from E09, because Logix shows both as BusUndervoltageFault
  2. Switch off and wait for the DC bus to discharge before touching the module
  3. Rockwell's action is to call your Rockwell Automation sales representative and return the module for repair

E04: Motor Overtemperature (MotorOvertempFault)

Hits OEE: Availability

What it means: The motor thermal switch (thermostat) tripped because the motor got too hot.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000 and Kinetix 300. On Kinetix 6000 the firmware I2t protection folds back current at 110% of motor rating instead of faulting, unless the Motor Thermal fault action is set to Status Only or Stop Motion. Same fault name on Kinetix 350/5500/5700: F 05 / FLT S05 Motor Overtemperature.

Likely causes

  • High motor ambient temperature, excessive current, or both
  • Running above the motor's continuous torque rating
  • Motor wiring error at the motor feedback (MF) connector, where the thermostat signal comes in
  • Wrong motor selected in the drive or axis configuration

First checks, in this order

  1. Check the motor temperature and the air around it; Rockwell rates continuous torque at 40 C (104 F) maximum ambient
  2. Compare the duty cycle with the motor's continuous torque rating, and lower the load or add motor cooling if it runs above it
  3. Check the motor wiring at the MF connector on the drive, including the thermostat leads
  4. Confirm the correct motor is selected in Ultraware, MotionView or Logix Designer

E05: IPM Fault (Ultra3000) / DriveOvercurrent Fault, Power Fault (Kinetix 6000, 2000)

Hits OEE: Availability

What it means: The intelligent power module (the output transistors) shut itself off because of a short, an overcurrent or overheating in the drive power stage.[1][2][3][4]

Also on: Ultra3000 (IPM Fault), Kinetix 6000 and Kinetix 2000 (Power Fault). On Ultra3000 2098-DSD-005, -010 and -020 drives with external +5V auxiliary power, enabling the drive less than 1.0 second after main AC is applied also causes E05. Kinetix 300 reports peak current problems as E74 instead. Same fault family on Kinetix 350/5500/5700: F 10 / FLT S10 Inverter Overcurrent.

Likely causes

  • Shorted motor power cable or connector
  • Motor winding shorted internally
  • Drive too hot (clogged vents, failed fan, too little space around it) or running above its continuous power rating
  • Short circuit, overcurrent or a failed component inside the drive

First checks, in this order

  1. With power off, check the motor power cable and connector for continuity and for shorts between phases
  2. Disconnect the motor power cable at the motor and turn the shaft by hand; if it is hard to turn, the motor may need replacing
  3. Check the vents, fan and clearance, and reduce acceleration and deceleration rates if the axis runs above its continuous rating
  4. With all power and motor wires removed, do a continuity check from the DC bus to U, V and W; any continuity means look for loose wire strands between terminals or send the drive for repair

E06: Hardware Overtravel (HardOvertravelFault, +/- Hard Overtravel)

Hits OEE: Availability

What it means: The axis moved past a physical travel limit and the dedicated overtravel input went inactive.[1][2][3][4][5]

Also on: Ultra3000 (SERCOS drives only), Kinetix 6000, Kinetix 2000, Kinetix 300. Ultra3000 shows a flashing L on the display while in an overtravel condition. Kinetix 350/5500/5700 use F 50 / F 51 and FLT S50 / FLT S51 Hardware Overtravel Positive / Negative.

Likely causes

  • The axis really ran onto the positive or negative limit switch
  • Overtravel input wiring broken or disconnected, so the input reads inactive
  • Motion profile or axis configuration sends the axis past its travel

First checks, in this order

  1. Look at where the axis is and whether a limit switch is actually made
  2. Check the overtravel input wiring and the switch
  3. Verify the motion profile and the axis configuration in software
  4. On Ultra3000 SERCOS and Kinetix 6000 the fault action is programmable (Hard Overtravel) and can be set to status only

E07: MotFeedbackFault (Motor Feedback Loss) / Feedback lost (Kinetix 300)

Hits OEE: Availability

What it means: The drive lost the motor encoder signals because the feedback wiring is open, shorted or missing.[2][3][4][5]

Also on: Kinetix 6000, Kinetix 2000 and Kinetix 300. On Ultra3000 the error code table lists E07 and E08 as RESERVED, while the Integration Manual's SERCOS fault behavior table maps E07 and E08 to MotFeedbackFault (Channel BM and Channel AM Line Loss). Same fault name on Kinetix 350/5700/6200: F 43 / FLT S43 Feedback Loss.

Likely causes

  • Feedback cable unplugged, damaged or with a broken conductor
  • Shorted feedback conductors or connector pins
  • Kinetix 300: the motor is not recognized on the drive's web-based motor configuration screen

First checks, in this order

  1. Check the motor feedback cable and both connectors (drive MF connector and motor end) for damage, bent pins and correct seating
  2. Check the encoder wiring against the wiring diagram
  3. Run the Hookup test in Logix Designer (Kinetix 6000 and 2000)
  4. On Kinetix 300, confirm the motor is recognized on the drive's web-based configuration motor screen

E09: Bus Undervoltage (BusUndervoltageFault on Kinetix 6000/2000, DriveUndervoltageFault on Ultra3000)

Hits OEE: Availability

What it means: With three-phase power present, the DC bus voltage fell below the trip point: 275V DC on 460V drives, 137V DC on 230V drives.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 350/5500/5700/6200 use F 33 / FLT S33 Bus Undervoltage.

Likely causes

  • Low incoming AC line voltage
  • Glitches or line drops on the AC supply
  • Kinetix 6000/2000: an axis on a common-bus follower rail was still enabled when power was removed

First checks, in this order

  1. Measure the incoming AC voltage on all phases at the drive
  2. Check the AC source for glitches or dips, for example when large loads start on the same supply
  3. On common-bus systems, make the program disable follower axes before power is removed
  4. Rockwell suggests a UPS on the AC input if the supply is unreliable

E10: Bus Overvoltage (DriveOvervoltageFault)

Hits OEE: Availability

What it means: The DC bus voltage went above the trip point (820V DC on 460V drives, 410V DC on 230V drives), usually from energy regenerated while braking.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 350/5500/5700/6200 use F 35 / FLT S35 Bus Overvoltage.

Likely causes

  • Too much regenerated energy when decelerating a heavy or high-inertia load
  • The motor is driven by an external mechanical source and pushes energy back into the drive
  • No shunt, a wrongly wired shunt or (Ultra3000) a blown shunt fuse
  • AC input voltage above specification

First checks, in this order

  1. Note whether the fault happens during deceleration, and make the deceleration or motion profile gentler
  2. Check the shunt resistor or shunt module wiring, and on Ultra3000 the shunt fuse
  3. Measure the AC input voltage and confirm it is within the drive specification
  4. If it still trips, Rockwell's options are a shunt or a larger motor and drive

E11: Illegal Hall State (CommutationFault on Ultra3000, MotFeedbackFault on Kinetix 6000/2000)

Hits OEE: Availability

What it means: The Hall commutation signals from the motor are in a state that should never occur.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 350 uses F 02 Illegal Hall State; Kinetix 5500/5700 use FLT S02 Motor Commutation.

Likely causes

  • Incorrect Hall phasing
  • Bad or loose Hall connections
  • Missing or low 5V supply to the encoder

First checks, in this order

  1. Check the Hall wiring at the motor feedback (MF) connector
  2. Check the Hall phasing against the motor wiring diagram
  3. Measure the 5V supply to the encoder

E12: Home Search Failed

Hits OEE: Availability

What it means: The homing routine could not finish because the home sensor or encoder marker is outside the overtravel limits.[1][2][5]

Also on: Ultra3000 and Kinetix 300. Ultra3000 also has E13 Home Position In Limit, when the home sensor, marker or final home position is past a hardware overtravel limit.

Likely causes

  • Home sensor or marker sits outside the overtravel limits
  • Home sensor wiring fault

First checks, in this order

  1. Check the home sensor wiring and that the sensor switches
  2. Reposition the overtravel limits or the home sensor so home is inside the travel

E14: Ethernet I/O connection lost (Kinetix 300)

Hits OEE: Availability

What it means: The Kinetix 300 lost its EtherNet/IP I/O connection with the controller.[1][2][5]

Also on: Kinetix 300 with this meaning. On Ultra3000, E14 is SERCOS Hardware Fault on SERCOS drives or DeviceNet Communications Network problem on DeviceNet drives (SERCOSFault in RSLogix 5000).

Likely causes

  • Damaged Ethernet cable, connector or switch port
  • Ethernet cable routing problem
  • Controller program not scanning the drive I/O at the correct RPI

First checks, in this order

  1. Check the Ethernet cable, connectors and switch port
  2. Check the cable routing
  3. Check that the controller program scans the drive I/O at the correct RPI rate

E16: Software Overtravel (SoftOvertravelFault, +/- Software Overtravel)

Hits OEE: Availability

What it means: The axis position went past the programmed software travel limit.[1][2][3][4][5]

Also on: Ultra3000 (SERCOS only), Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 6200 uses FLT S52 / FLT S53 Software Overtravel.

Likely causes

  • Motion profile commands a position beyond the soft limit
  • Soft overtravel limits set wrong for the machine

First checks, in this order

  1. Compare the commanded move and the actual axis position with the soft limits
  2. Verify the soft overtravel settings are right for the machine
  3. On Ultra3000 SERCOS and Kinetix 6000 the fault action is programmable (Soft Overtravel) and can be set to status only

E18: Overspeed Fault (OverSpeedFault)

Hits OEE: Availability

What it means: Motor speed went over the overspeed trip point: 125% of maximum rated speed on Ultra3000 and Kinetix 300, 150% on Kinetix 6000 and 2000.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 350/5500/5700/6200 use F 03 / FLT S03 Motor Overspeed.

Likely causes

  • Noise on the feedback cables corrupting the speed reading
  • Poor tuning causing velocity overshoot
  • Kinetix 6000/2000: the 100% point is the lower of the user velocity limit and the motor rated base speed, so a low user limit trips earlier

First checks, in this order

  1. Check feedback and motor cables for noise, shield terminations and grounding
  2. Check the tuning for velocity overshoot
  3. On Kinetix 6000/2000 check the user velocity limits in the axis configuration

E19: Excess Position Error (PositionErrorFault, HIM Follow Error)

Hits OEE: Availability

What it means: The following error between commanded and actual position went over the position error limit.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. The fault action is programmable (Position Error) on Ultra3000 SERCOS and Kinetix 6000. Kinetix 350/5500/5700/6200 use F 54 / FLT S54 Excessive Position Error.

Likely causes

  • Position loop tuning too soft or feedforward gain too low
  • Following error limit or time set too tight
  • Drive or motor undersized, or the mechanics are binding or out of specification

First checks, in this order

  1. Check the mechanics for binding or damage (Rockwell: verify mechanical integrity is within specification)
  2. Check position loop tuning and increase the feedforward gain
  3. Review the following error limit and time
  4. Verify the drive and motor are sized for the load

E20: Motor Encoder State Error (MotFeedbackFault, HIM Mtr Fdbk AQB)

Hits OEE: Availability

What it means: The motor encoder A/B signals made an illegal state transition.[1][2][3][4][7]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. Kinetix 6200/6500 report the same kind of fault as FLT S41 MTR AQB STATE FL.

Likely causes

  • Electrical noise on the feedback cable
  • Poor grounding or no high-frequency bond between the motor and the drive panel
  • Failed encoder

First checks, in this order

  1. Use shielded twisted-pair feedback cable and route it away from noise sources such as motor power cables
  2. Check the system grounds and the bond from motor to drive enclosure panel
  3. On Ultra3000, take unused unbuffered encoder signals out of the CN1 cable
  4. If the fault stays, replace the motor/encoder

E21: AuxFeedbackFault (Aux Feedback Comm), Kinetix 6000 / 2000

Hits OEE: Availability

What it means: The drive could not establish communication with an intelligent (Stegmann) encoder on the auxiliary feedback port.[3][4]

Also on: Kinetix 6000 and Kinetix 2000. On Ultra3000, E21 means Auxiliary Encoder State Error instead (see the next row).

Likely causes

  • Auxiliary encoder cable or wiring fault
  • No communication from the intelligent encoder on the auxiliary port

First checks, in this order

  1. Check the auxiliary encoder cable and wiring at the auxiliary feedback connector
  2. Confirm the auxiliary feedback device set up in Logix Designer is the one actually connected

E21: Auxiliary Encoder State Error (AuxFeedbackNoiseFault), Ultra3000

Hits OEE: Availability

What it means: The auxiliary encoder signals made an illegal transition, or a Step/Direction or CW/CCW command input broke its setup time.[1][2][3]

Also on: Ultra3000 only with this meaning. Kinetix 6000/2000 use E61 (Aux Fdbk AQB) for an auxiliary encoder state error and E21 for Aux Feedback Comm.

Likely causes

  • Noise on the auxiliary encoder cable
  • Faulty auxiliary encoder or poor ground connections
  • Setup time violation on the Step/Direction or CW/CCW inputs

First checks, in this order

  1. Use shielded twisted-pair cable and route it away from noise sources
  2. Check the ground connections
  3. If Step/Direction or CW/CCW inputs are used, check their timing against the setup time requirement
  4. Replace the encoder if the fault continues

E22: Motor Thermal Protection Fault (OverloadFault in RSLogix 5000)

Hits OEE: Availability

What it means: The drive's internal motor thermal model estimated that the motor is overheating and tripped.[1][2]

Also on: Ultra3000. Same fault name on Kinetix 350/5500/5700/6200: F 07 / FLT S07 Motor Thermal Protection / Motor Thermal Overload.

Likely causes

  • Acceleration rates too high
  • On/off duty cycle of the commanded motion too heavy for the motor
  • Too little time allowed for each move, or poor tuning adding current
  • Motor and drive too small for the application

First checks, in this order

  1. Reduce acceleration rates
  2. Reduce the on/off duty cycle or allow more time for each move
  3. Check the tuning
  4. If nothing can change in the motion, Rockwell's answer is a larger Ultra3000 and motor

E23: IPM Thermal Protection Fault (Ultra3000, DriveOvertempFault) / Drive Thermal Protection (Kinetix 300)

Hits OEE: Availability

What it means: The drive's internal thermal model for its power stage tripped to stop the drive from overheating.[1][2][5]

Also on: Ultra3000 and Kinetix 300. On Ultra3000 SERCOS the fault action is programmable (Drive Thermal). Same fault family on Kinetix 350/5500/5700: F 13 / FLT S13 Inverter Thermal Protection / Inverter Thermal Overload.

Likely causes

  • Acceleration rates too high
  • Heavy on/off duty cycle or too little time for each move
  • Tuning problem adding current
  • Drive and motor too small for the duty

First checks, in this order

  1. Reduce acceleration rates
  2. Reduce the duty cycle or increase the time permitted for motion
  3. Check the tuning
  4. Move to a larger drive and motor if the duty cannot change

E27: Axis Not Homed (Ultra3000) / Absolute move fault (Kinetix 300)

Hits OEE: Availability

What it means: An absolute move was started before the axis was homed.[1][2][5]

Also on: Ultra3000 and Kinetix 300.

Likely causes

  • Absolute positioning commanded before the homing sequence has run
  • Homing sequence in the program or index table not set up or not completing

First checks, in this order

  1. Check that the homing sequence runs and finishes before any absolute move
  2. Home the axis, then retry the absolute move (Kinetix 300 says this also applies with an absolute encoder)

E30: Encoder Communication Fault (Ultra3000, Kinetix 300) / MotFeedbackFault, Motor Feedback Comm (Kinetix 6000, 2000)

Hits OEE: Availability

What it means: The drive could not establish communication with the intelligent (Stegmann) encoder on the motor feedback port.[1][2][3][4][5]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 350/5500/5700/6200 use F 45 / FLT S45 Feedback Comm (Feedback Data Loss).

Likely causes

  • Wrong motor selected, or a motor that does not support automatic identification
  • Motor encoder cable or wiring fault

First checks, in this order

  1. Verify the motor selection in the configuration
  2. Verify the motor supports automatic identification
  3. Check the motor encoder cable, connectors and wiring

E31: Encoder Data (Ultra3000, Kinetix 300)

Hits OEE: Availability

What it means: The data read from the motor encoder is corrupted.[1][2][5]

Also on: Ultra3000 and Kinetix 300 with this meaning. On Kinetix 6000, E31 is a DriveHardFault for shaft movement at power up (see the next row).

Likely causes

  • Corrupted encoder data
  • Faulty motor encoder (Rockwell's action is replacing the motor/encoder)

First checks, in this order

  1. Check the feedback cable and connectors for damage before condemning the motor
  2. Replace the motor/encoder if the fault returns

E31: DriveHardFault, excessive motor shaft movement (Kinetix 6000)

Hits OEE: Availability

What it means: The motor shaft moved too much during power up, during Sercos ring phase-up, or after a fault reset.[3]

Also on: Kinetix 6000 only with this meaning (fault behavior added in a later revision of 2094-UM001). On Ultra3000 and Kinetix 300, E31 is Encoder Data.

Likely causes

  • Shaft movement during power up
  • Shaft movement during Sercos ring phase-up
  • Shaft movement during or right after a fault reset

First checks, in this order

  1. Make sure nothing turns the motor shaft during power up, ring phase-up or a fault reset
  2. On loaded or vertical axes, check that the holding brake or the mechanics keep the axis still during those steps

E34: Ground Fault (GroundShortFault on Kinetix 6000/2000)

Hits OEE: Availability

What it means: Excessive ground current was detected in the converter, meaning current is leaking to earth.[1][2][3][4]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. Kinetix 5500/5700/6200 use FLT S16 Ground Current.

Likely causes

  • Motor power wiring or input power wiring error
  • Motor winding shorted to ground internally
  • Internal drive malfunction
  • Kinetix 6000/2000 230V systems: a grounded control power terminal

First checks, in this order

  1. With power off and the motor cable disconnected from the drive, check the cable and motor phases to ground
  2. Check the motor power wiring and the input power wiring
  3. Disconnect the motor power cable from the drive and enable with the current limit set to 0: if the fault clears, the problem is the wiring or the motor; if it stays, call Rockwell
  4. On 230V Kinetix 6000/2000, remove any ground from the control power input

E35: Precharge Fault (DriveUndervoltageFault on Kinetix 6000/2000)

Hits OEE: Availability

What it means: The converter precharge cycle failed, so the DC bus did not charge properly at power on.[1][2][3][4]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. Kinetix 5500/5700/6200 use FLT S25 Precharge Failure.

Likely causes

  • Low AC input voltage
  • Internal malfunction in the drive or converter

First checks, in this order

  1. Measure the AC input voltage on all phases
  2. If the input voltage is correct, call Rockwell, because the manual lists an internal malfunction as the other cause

E36: Power Circuitry Overtemperature (Ultra3000) / DriveOvertemp Fault, System Overtemperature (Kinetix 6000, 2000)

Hits OEE: Availability

What it means: There is too much heat in the power circuitry; on Kinetix 6000/2000 the converter thermal switch tripped.[1][2][3][4]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. Kinetix 5500/5700/6200 use FLT S18 Converter Overtemperature.

Likely causes

  • Acceleration and duty cycle too heavy for the converter
  • Clogged vents or a failed fan
  • Not enough space around the unit for cooling
  • Converter (IAM) too small for the system

First checks, in this order

  1. Check the vents, the fan and the clearance around the drive
  2. Reduce acceleration rates and the on/off duty cycle, or allow more time for moves
  3. Check the tuning
  4. Use a larger IAM converter module if the duty cannot change

E37: AC Line Loss (Ultra3000) / PowerPhaseLoss Fault, Phase Loss Flt (Kinetix 6000, 2000)

Hits OEE: Availability

What it means: One or more phases of the input AC power is missing.[1][2][3][4]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. Kinetix 5500/5700/6200 use FLT S23 AC Phase Loss.

Likely causes

  • A missing input AC phase
  • Kinetix 6000/2000: axis still enabled when main three-phase power was removed
  • Kinetix 6000/2000: common-bus follower axis enabled when DC bus power was removed

First checks, in this order

  1. Measure the input AC voltage on all three phases at the drive
  2. Check the upstream fuses, breaker and contactor on each phase
  3. Make the program disable the axes before main power is switched off

E38: SercosFault (Sercos Ring Flt)

Hits OEE: Availability

What it means: The SERCOS fiber-optic ring stopped being active after it had been active and running.[1][2][3][4][6]

Also on: Kinetix 6000, Kinetix 2000, and Ultra3000 SERCOS drives (in the Integration Manual fault behavior table; the Ultra3000 error code table shows E38 as RESERVED). On Kinetix 350, E38 means Memory module error: bad memory module, replace it.

Likely causes

  • Fiber-optic cable disconnected or loose
  • Broken or damaged fiber-optic cable
  • Receive and transmit fibers swapped at a drive

First checks, in this order

  1. Check that every fiber-optic cable in the ring is present and fully connected
  2. Use the Comm status indicator on each drive to find where the ring is broken (off means no communication)
  3. Inspect the fibers and replace any broken cable
  4. Check receive and transmit fibers are not swapped

E39: Self-sensing Commutation Startup Error (DriveHardFault, HIM Self Sense Flt)

Hits OEE: Availability

What it means: The small motion the drive needs at startup to find the motor commutation angle was blocked.[1][2][3][4][7]

Also on: Ultra3000, Kinetix 6000, Kinetix 2000. On Kinetix 300, E39 means Safe Torque Off while enabled (see the next row). Kinetix 6200 reports this as FLT M01 Self-sensing Startup Fault.

Likely causes

  • Something blocks motion at startup, such as a hard limit
  • High friction or a heavy load
  • Motor or encoder wiring error

First checks, in this order

  1. Make sure the axis is free to move a little at startup and is not sitting on a hard stop
  2. Increase the self-sensing current if friction or load is high
  3. Check the motor and encoder wiring using the wiring diagnostics

E39: Safe Torque Off while enabled (Kinetix 300)

Hits OEE: Availability

What it means: The safety circuit was opened while the drive was enabled or while it was trying to enable.[5]

Also on: Kinetix 300 only with this meaning. On Ultra3000, Kinetix 6000 and 2000, E39 is the self-sensing startup error; Kinetix 6000 reports a safe torque-off mismatch as E49.

Likely causes

  • Safety circuit opened while the drive was enabled
  • Safety circuit open at the moment the drive tried to enable

First checks, in this order

  1. Check the safety circuit that feeds the Safe Torque Off inputs: e-stops, guard switches and the safety relay
  2. Check the STO wiring and connector
  3. Close the safety circuit before enabling, then clear the fault

E40 / E41: 230V Shunt Protection Fault (E40) / 460V Shunt Protection Fault (E41)

Hits OEE: Availability

What it means: The shunt (braking resistor) circuit is not absorbing regenerated energy as it should.[1][2]

Also on: Ultra3000 (E40 on 230V models, E41 on 460V models).

Likely causes

  • Internal or external shunt resistor disconnected or ineffective
  • Blown fuse in an external shunt
  • Non Allen-Bradley external shunt resistor with a resistance outside specification
  • Too much regeneration, for example the load driving the motor like a generator

First checks, in this order

  1. Check that the internal or external shunt resistor is connected
  2. Check the external shunt fuse
  3. If a third-party resistor is fitted, measure its resistance against the specification
  4. Check whether the load drives the motor mechanically and reduce the regenerated energy

E43: Drive Enable Input (DriveEnableInputFault, HIM Drive Enable Flt)

Hits OEE: Availability

What it means: The hardware Drive Enable input was off when the axis was enabled through software, or it dropped out while the axis was enabled.[1][2][3][4][5]

Also on: Ultra3000 (SERCOS only), Kinetix 6000, Kinetix 2000, Kinetix 300. Kinetix 5500/5700/6200 use FLT S61 Enable Input.

Likely causes

  • Software enable sent while the hardware Drive Enable input was inactive
  • Drive Enable input went from active to inactive while the axis was enabled
  • Enable input wiring or its 24V supply interrupted

First checks, in this order

  1. Check the hardware enable input wiring and its 24V supply (IOD-2 on Kinetix 6000)
  2. Make sure the program only enables the axis while the hardware enable input is on
  3. If the application does not use the hardware input, Rockwell allows disabling the Drive Enable Input fault (programmable fault action)

E44: Controller changed to PROG mode (Kinetix 300)

Hits OEE: Availability

What it means: The Logix controller left Run mode because a program was downloaded or the key switch was turned to Program.[1][2][5]

Also on: Kinetix 300 only with this meaning. On Ultra3000, E44 is Lost motion fault (only applications with Stegmann feedback): cycle power, and re-home if the drive was homed in the same power cycle.

Likely causes

  • Program download to the controller
  • Controller key switch turned to the Program position

First checks, in this order

  1. Put the controller back in Run mode
  2. Clear the drive faults

E49: DriveHardFault (Safe-off HW Flt)

Hits OEE: Availability

What it means: The safe torque-off circuit reports a mismatch, so the drive does not allow motion.[3]

Also on: Kinetix 6000 IAM and AM modules with the safe torque-off feature (2094-xCxx-Mxx-S and 2094-xMxx-S).

Likely causes

  • Loose wiring at the STO connector
  • Cable or header not seated properly in the STO connector
  • Safe torque-off circuit missing its +24V DC

First checks, in this order

  1. Check the wire terminations at the STO connector and that the cable or header is fully seated
  2. Measure the +24V DC on the safe torque-off circuit
  3. Reset the error and run the proof test
  4. If it persists, return the drive to Rockwell Automation

E50: Duplicate Node Fault (Ultra3000) / SercosFault, Sercos Same ADDR (Kinetix 6000, 2000)

Hits OEE: Availability

What it means: Two drives on the same SERCOS ring have the same node address.[1][2][3][4]

Also on: Ultra3000 (SERCOS drives), Kinetix 6000, Kinetix 2000.

Likely causes

  • Node address switches set to the same value on two drives, for example after a drive swap
  • Node address on a drive does not match the SERCOS controller configuration

First checks, in this order

  1. Read the node address switch on every drive in the ring
  2. Give each SERCOS drive a unique node address that matches the controller configuration
  3. Check the Comm status indicator: flashing green that never goes steady can mean the address does not match the controller

E64: MotorFeedbackNoise (Mtr Fdbk Noise)

Hits OEE: Availability

What it means: Noise was detected on the motor feedback cable.[3][4][5]

Also on: Kinetix 6000 and Kinetix 2000. E63 (AuxFeedbackNoise, Aux Fdbk Noise) is the same fault on the auxiliary feedback cable. On Kinetix 300, E94 also points to motor feedback cable problems and grounding.

Likely causes

  • Grounding not done per the installation instructions
  • Feedback cable routed close to noise sources such as motor power cables

First checks, in this order

  1. Verify grounding and bonding against the installation instructions
  2. Route the feedback cable away from noise sources
  3. Follow Rockwell's System Design for Control of Electrical Noise reference manual (GMC-RM001)

E67: DriveHardFault (Task init) / Operating system failed

Hits OEE: Availability

What it means: The drive's operating system failed: a software initialization fault caused by hardware on Kinetix 6000/2000, a hardware or configuration failure on Kinetix 300.[3][4][5]

Also on: Kinetix 6000, Kinetix 2000, Kinetix 300.

Likely causes

  • Control hardware failure in the drive
  • Kinetix 300: invalid drive tag settings, or explicit messages writing to unpublished or reserved drive variables

First checks, in this order

  1. Cycle power
  2. On Kinetix 300, check the configuration settings and that no explicit messages write to reserved drive variables
  3. If the fault persists, replace the module

E72: DriveOvertemp Fault (Drive Overtemp) / Drive temperature too high (Kinetix 300)

Hits OEE: Availability

What it means: The inverter thermal switch or the heatsink temperature sensor detected that the drive is too hot.[3][4][5]

Also on: Kinetix 6000, Kinetix 2000, Kinetix 300. On Kinetix 6000 the I2t current foldback acts first unless the Drive Thermal fault action is changed. Same fault family on Kinetix 350/5500/5700: F 11 / FLT S11 Inverter Overtemperature.

Likely causes

  • Failed fan in the IAM or AM module
  • Cabinet ambient temperature above rating, or airflow limited or blocked
  • Duty cycle needs RMS current above the drive's continuous rating

First checks, in this order

  1. Check that the drive fan runs and the vents are not clogged
  2. Measure the cabinet temperature and check the airflow; re-route cables that block it
  3. Reduce speed or acceleration, or increase move time, to bring the RMS current down
  4. On Kinetix 6000/2000, replace the module if its fan has failed

E73: Communicate (Backplane Comm)

Hits OEE: Availability

What it means: CAN communication over the power rail backplane failed.[3][4]

Also on: Kinetix 6000 and Kinetix 2000.

Likely causes

  • Module not properly mounted on the power rail
  • Power rail connection shorted or open
  • Foreign objects in the power rail or module connector

First checks, in this order

  1. Check that each module is seated and mounted properly on the power rail
  2. With power off and the DC bus discharged, inspect the power rail and module connectors for foreign objects or damage

E74: DriveOvercurrent Fault (Bus OverCurrent), Kinetix 6000 / 2000

Hits OEE: Availability

What it means: DC link current exceeded the converter (IAM) rating.[3][4]

Also on: Kinetix 6000 and Kinetix 2000. On Kinetix 300, E74 means the drive exceeded its peak current limit (see the next row).

Likely causes

  • Motor or mechanical transmission malfunction
  • IAM module not sized for the total load on the rail

First checks, in this order

  1. Check the motor sizing and the transmission (gearbox, coupling, screw); replace a failed transmission device or motor
  2. Check the IAM sizing for all axes on the rail
  3. Install a larger kW rated IAM module if the system is undersized

E74: Drive has exceeded peak current limit (Kinetix 300)

Hits OEE: Availability

What it means: The Kinetix 300 went over its peak current limit and cannot regulate current properly.[5]

Also on: Kinetix 300.

Likely causes

  • Motor cables shorted or motor winding shorted internally
  • Duty cycle needs RMS current above the drive's continuous rating
  • Operation above the continuous power rating or the environmental rating
  • Short circuit, overcurrent or a failed component in the drive

First checks, in this order

  1. Check continuity of the motor power cables and connector
  2. Disconnect the motor and turn the shaft by hand; replace the motor if it is hard to turn
  3. Reduce speed and acceleration or increase move time
  4. With all power and motor wires off, check continuity from the DC bus to U, V and W

E75: DriveOvervoltage Fault (Shunt Time Out)

Hits OEE: Availability

What it means: The IAM, AM or shunt module ran past the continuous rating of its shunt resistor.[3][4]

Also on: Kinetix 6000 and Kinetix 2000.

Likely causes

  • Too much regenerated energy for the shunt over time
  • Shunt undersized for the duty cycle
  • System relies on the internal shunt but needs an external shunt for more capacity

First checks, in this order

  1. Check how often and how hard the axes decelerate, and change the duty cycle if possible
  2. Use a properly sized shunt
  3. Add an external shunt module if the internal shunt is not enough

E76: Blank memory module (Kinetix 300, Kinetix 350)

Hits OEE: Availability

What it means: A blank memory (MEM) module has been inserted into the drive.[3][4][5][6]

Also on: Kinetix 300 and Kinetix 350. On Kinetix 6000 and 2000, E76 is DriveHardFault (CAN Init), a DPI or backplane CAN initialization failure: reset the system and replace the module if it persists.

Likely causes

  • New or blank memory module fitted, for example when a drive is replaced
  • Memory module not yet formatted for this drive

First checks, in this order

  1. Press and hold the drive's enter key (the bottom red button) on the front display until it shows bUSY
  2. Let the drive format the memory module, then clear the fault

E77: DriveHardFault (Module Mismatch)

Hits OEE: Availability

What it means: An axis module of the wrong voltage class is on the power rail: a 230V AM with a 460V IAM, or a 460V AM with a 230V IAM.[3]

Also on: Kinetix 6000.

Likely causes

  • 230V axis module installed on a power rail with a 460V IAM module
  • 460V axis module installed on a power rail with a 230V IAM module

First checks, in this order

  1. Compare catalog numbers: 2094-ACxx and 2094-AMxx are the 230V (200V-class) modules, 2094-BCxx and 2094-BMxx are the 460V (400V-class) modules
  2. Replace the mismatched module with one that matches the IAM

E79: DriveOvervoltage Fault (Shunt Module Flt)

Hits OEE: Availability

What it means: The power rail mounted Bulletin 2094 shunt module has a fault, shown on the IAM module's seven-segment display.[3][4]

Also on: Kinetix 6000 and Kinetix 2000.

Likely causes

  • Over-temperature indicator on the shunt module is steady red
  • Shunt fault indicator on the shunt module is steady red
  • Shunt module missing from the power rail

First checks, in this order

  1. Look at the shunt module status indicators and follow the shunt module troubleshooting table
  2. If a slot is empty, install the missing module or a slot-filler module
  3. A latched shunt fault clears with MASR, MAFR, MGSR or the HIM only after the DC bus has discharged (bus status indicator flashing)

E90: DriveHardFault (Precharge Timeout Flt)

Hits OEE: Availability

What it means: Precharge resistor power went over the resistor rating, so the IAM stopped precharging the DC bus.[3][4]

Also on: Kinetix 6000 and Kinetix 2000.

Likely causes

  • Total bus capacitance on a common-bus system is more than the leader IAM can precharge
  • Precharge resistor overheated and needs time to cool

First checks, in this order

  1. Wait for the precharge resistor to cool before applying power again
  2. On common-bus systems, compare the total bus capacitance with the leader IAM precharge rating
  3. If the capacitance is too high, fit a larger leader IAM or remove IPIM or axis modules from the bus

FLT S03: Motor Overspeed Factory Limit Fault (FLT S03 - MTR OVERSPEED FL)

Hits OEE: Availability

What it means: Motor speed went above 125% of its maximum speed (sub-code 0), or the output frequency went above 590 Hz (sub-code 1).[6][7][8][9][11]

Also on: Kinetix 5500, Kinetix 5700, Kinetix 6200/6500 (FLT S03...MTR OVERSPEED FL), Kinetix 350 (F 03 Motor Overspeed). The user-limit version is FLT S04 MTR OVERSPEED UL. Older drives use E18 Overspeed Fault.

Likely causes

  • Control loop tuning causing speed overshoot
  • Velocity command too high
  • Noise on the cables (listed in the Kinetix 6200 and 350 tables)

First checks, in this order

  1. Check the control loop tuning
  2. Reduce the velocity command
  3. On Kinetix 350, also check motor wire phasing and the cables for noise

FLT S05: Motor Overtemperature Factory Limit Fault (FLT S05 - MTR OVERTEMP FL nn)

Hits OEE: Availability

What it means: The motor thermostat, thermistor or encoder temperature sensor shows the motor is over its factory temperature limit; sub-code 01 is the thermostat or thermistor, 02 the encoder temperature sensor.[6][7][8][9][11]

Also on: Kinetix 5500 and 5700 (Kinetix VP and MP motors only, not induction motors), Kinetix 6200/6500, Kinetix 350 (F 05). Older drives use E04 Motor Overtemperature.

Likely causes

  • Running above the motor's continuous torque rating
  • High motor ambient temperature
  • Motor wiring error at the feedback connector, or the wrong motor selected (Kinetix 6200 and 350 tables)

First checks, in this order

  1. Read the nn sub-code to see which sensor tripped
  2. Run the motor within its continuous torque rating, and lower the ambient or add motor cooling
  3. Check the thermostat wiring at the motor feedback (MF) connector (TS+ and COM on Kinetix 350)
  4. Confirm the right motor is selected in Logix Designer

FLT S07: Motor Thermal Overload Factory Limit Fault (FLT S07 - MTR OVERLOAD FL)

Hits OEE: Availability

What it means: The motor thermal model went over its factory thermal capacity limit (110% of rating per the Kinetix 6200 and 350 tables).[6][7][8][9][11]

Also on: Kinetix 5500, 5700, 6200/6500, Kinetix 350 (F 07 Motor Thermal Protection). The user-limit version is FLT S08 MTR OVERLOAD UL. Ultra3000 has the same fault name as E22 Motor Thermal Protection Fault.

Likely causes

  • Machine duty cycle needs more RMS current than the motor's continuous rating
  • Command profile too aggressive: too fast, too much acceleration, too little dwell time

First checks, in this order

  1. Change the command profile to reduce speed or increase move time
  2. Check the motor and drive sizing against the real duty cycle

FLT S10: Inverter Overcurrent Fault (FLT S10 - INV OVERCURRENT)

Hits OEE: Availability

What it means: Inverter current went above the instantaneous current limit set by the hardware.[6][7][8][9][11]

Also on: Kinetix 5500, 5700, 6200/6500, Kinetix 350 (F 10). Older drives use E05 IPM Fault / Power Fault.

Likely causes

  • Shorted motor power cable
  • Shorted motor windings
  • Wrong motor power wire gauge, or operation above the continuous power rating
  • Acceleration too aggressive for the drive

First checks, in this order

  1. Check the motor power cable for shorts
  2. Check the motor windings: phase to phase should not be open and phase to ground should be open (Kinetix 350 method)
  3. Verify the motor power wire gauge
  4. Reduce acceleration, or reduce speed and increase move time

FLT S16: Ground Current Factory Limit Fault (FLT S16 - GROUND CURRENT)

Hits OEE: Availability

What it means: The sensing circuit in the power stage detected excessive ground current.[7][8][9][11]

Also on: Kinetix 5500, Kinetix 5700 (shown as GROUND CURRENT FL; all modules in the same bus group then assert a Bus Power Sharing exception if enabled), Kinetix 6200/6500. Older drives use E34 Ground Fault.

Likely causes

  • Motor power wiring fault or a shorted power cable
  • Motor insulation failure to ground
  • DC-bus wiring fault when a capacitor module is used

First checks, in this order

  1. Check the motor power wiring and the power cable for shorts
  2. Replace the motor if the fault persists
  3. Check the DC-bus wiring if a capacitor module is fitted

FLT S33: Bus Undervoltage Factory Limit Fault (FLT S33 - BUS UNDERVOLT FL)

Hits OEE: Availability

What it means: The DC bus voltage fell below the factory limit for the configured input voltage.[6][7][8][9][11]

Also on: Kinetix 5500, 5700, 6200/6500, Kinetix 350 (F 33). The user-limit version is FLT S34 BUS UNDERVOLT UL. Older drives use E09 Bus Undervoltage.

Likely causes

  • Low incoming AC voltage
  • Glitches or line droop on the AC supply
  • Kinetix 6200: a follower axis still enabled while the DC bus fell

First checks, in this order

  1. Verify the incoming AC voltage
  2. Monitor the AC source for glitches or droop
  3. Install a UPS on the AC input if the supply is weak

FLT S35: Bus Overvoltage Factory Limit Fault (FLT S35 - BUS OVERVOLT FL)

Hits OEE: Availability

What it means: The DC bus voltage went above the factory limit for the configured input voltage, usually from regenerated energy.[6][7][8][9][11]

Also on: Kinetix 5500, 5700, 6200/6500, Kinetix 350 (F 35). Older drives use E10 Bus Overvoltage.

Likely causes

  • Too much regenerated energy from decelerating loads on the shared DC bus
  • Open shunt resistor
  • Long DC bus cables amplifying voltage overshoot (Kinetix 5700)

First checks, in this order

  1. Change the deceleration or motion profile of the drives on the DC bus
  2. Unplug the shunt connector and measure the shunt resistance; if it is open, replace the drive (Kinetix 5500) or the DC-bus power supply (Kinetix 5700)
  3. Add an external shunt resistor or an active brake module (Kinetix 5700)

FLT S43: Feedback Signal Loss Factory Limit (FLT S43 - FDBK LOSS FL)

Hits OEE: Availability

What it means: The A/B channel signal levels from the feedback device dropped below the factory limit, meaning the signal is lost.[6][7][10][11]

Also on: Kinetix 5700 (all compatible feedback except DSL), Kinetix 6200/6500 (FLT S43...MTR FDBK LOSS FL and AUX FDBK LOSS FL), Kinetix 350 (F 43 Feedback Loss). Not listed for Kinetix 5500. Older drives use E07 Motor Feedback Loss.

Likely causes

  • Motor feedback wiring open, shorted or missing
  • Noise on the feedback signals
  • Failed motor or encoder

First checks, in this order

  1. Check the motor feedback wiring and connectors
  2. Use shielded cables, route the feedback away from noise sources and check the system grounds
  3. Run the Hookup test in Logix Designer (Kinetix 350 and 6200)
  4. Replace the motor/encoder if the fault continues

FLT S45: Motor Feedback Data Loss Factory Limit Fault (FLT S45 - FDBK COMM FL)

Hits OEE: Availability

What it means: Too many consecutive missed or corrupted serial data packets, or invalid position values, came from the intelligent feedback device.[6][7][8][9][11]

Also on: Kinetix 5500, Kinetix 5700 (DSL and Hiperface feedback), Kinetix 6200/6500 (FLT S45...MTR FDBK COMM FL), Kinetix 350 (F 45, Kinetix TL motors and actuators only). Older drives use E30 Encoder Communication Fault.

Likely causes

  • Feedback cable or connector problem
  • Motor power cable and feedback shields not secured, or motor frame not grounded
  • Shock and vibration at the motor
  • Feedback device failure (see FLT S47)

First checks, in this order

  1. Check the motor feedback cable and connector
  2. Check that the motor power cable and feedback shields are clamped correctly and the motor frame is grounded
  3. Reduce shock and vibration at the motor
  4. If FLT S47 Feedback Device Failure also appears, follow its sub-code

FLT S54: Excessive Position Error Fault (FLT S54 - POSN ERROR)

Hits OEE: Availability

What it means: The position loop error stayed above the Position Error Tolerance for longer than the Position Error Tolerance Time.[6][7][8][9][11]

Also on: Kinetix 5500, 5700, 6200/6500, Kinetix 350 (F 54). Does not apply to induction motors in frequency control mode. Older drives use E19 Excess Position Error.

Likely causes

  • Position loop tuning or feedforward gain too low
  • Drive or motor undersized, or mechanics out of specification
  • Motor power wiring problem
  • Kinetix 350: partial loss of feedback signals

First checks, in this order

  1. Check the mechanics for binding
  2. Check position loop tuning and increase the feedforward gain
  3. Check the motor power wiring and the motor feedback (MF) connector
  4. Only then raise Position Error Tolerance or Tolerance Time, if the application allows it

Log it, or the same alarm comes back

A drive fault disables the axis, and on a machine that usually stops the cycle, so in OEE terms it is a breakdown. Log the fault code, the axis and the drive model with the minutes lost: the same number can mean different things on different drives.

  • Reason code: the code plus the axis, for example Kinetix E07, cell 2 axis 3, so a feedback fault that returns every week on one cable run becomes visible.
  • Loss bucket: a stop that needs a reset, a part or a technician is an availability loss (breakdown). Stops shorter than your micro-stop threshold go to performance (minor stops). The six big losses page shows where each one belongs.
  • What to count: how often each code fires per week and the minutes it costs. Two numbers a week turn "that alarm comes up sometimes" into a ranked list. The MTBF and MTTR calculator and the downtime cost calculator do the math.

The free OEE tracker logs each stop with its reason and turns the week into a downtime Pareto, so the code that costs the most rises to the top.

For Allen-Bradley PLC faults, fabrico.io has the Allen-Bradley major fault codes guide. An alarm code tells you what the servo drive detected, not what happened at the machine in the seconds before. Fabrico's camera-based OEE software syncs camera video with machine data, so you can replay the moment the axis stopped next to the alarm.

Frequently asked questions

What does E07 mean on a Kinetix 6000?

E07 is MotFeedbackFault, shown as Motor Feedback Loss: the motor feedback wiring is open, shorted or missing. Check the feedback cable and connectors at the drive MF connector and at the motor, then run the Hookup test in Logix Designer. Kinetix 2000 uses E07 the same way and Kinetix 300 calls it Feedback lost, but the Ultra3000 error code table lists E07 as reserved.

How do I clear a fault on an Ultra3000 drive?

Fix the cause first, because the display keeps flashing E and the code until the problem is gone. Then use the Clear Faults command in Ultraware's Faults branch or a digital input configured as Fault Reset; SERCOS drives are reset from the Logix controller. On SERCOS Ultra3000 drives only the Shutdown and Disable Drive fault actions are active, and both let the motor coast to a stop.

Why does the same E code mean different things on different Allen-Bradley drives?

Each drive family has its own table. E39 is the self-sensing startup error on Ultra3000, Kinetix 6000 and 2000 but Safe Torque Off while enabled on Kinetix 300; E44 is lost motion on Ultra3000 but controller changed to PROG mode on Kinetix 300; E76 is CAN Init on Kinetix 6000/2000 but a blank memory module on Kinetix 300/350. Always look the code up for the exact drive catalog number.

Do Kinetix 5500, 5700, 6200 and 350 drives use E codes?

No. Kinetix 5500 and 5700 show FLT Sxx and FLT Mxx text on the LCD (the FAULT LOG menu lists active faults), Kinetix 6200/6500 scroll FLT Sxx on a four-character display, and Kinetix 350 shows F xx on a four-digit display using the same numbers, so F 43 Feedback Loss matches FLT S43. The Kinetix 350 still uses E38 and E76 for memory module problems.

Why do I get E37 or E09 when I switch off main power on a Kinetix 6000?

On Kinetix 6000 and 2000, E37 Phase Loss is also raised when an axis is still enabled as main three-phase power is removed, and E09 when an axis on a common-bus follower rail is enabled as the DC bus falls. Rockwell's fix is to disable the axes before removing power. If it happens with power on, measure all three input phases for a missing phase or dips.

Sources

Codes and meanings follow the manufacturer documentation below. Wording is ours, simplified for the shop floor; the manual for your exact model and software version wins if it differs.

  1. Ultra3000 Digital Servo Drives Installation Manual, publication 2098-IN003E-EN-P (April 2004), bundled with document update 2098-DU003B-EN-P (September 2006)
  2. Ultra3000 Digital Servo Drives Integration Manual, publication 2098-IN005C-EN-P (March 2008)
  3. Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001M-EN-P (December 2022)
  4. Kinetix 2000 Multi-axis Servo Drive User Manual, publication 2093-UM001A-EN-P (March 2007)
  5. Kinetix 300 EtherNet/IP Indexing Servo Drives User Manual, publication 2097-UM001F-EN-P (December 2022)
  6. Kinetix 350 Single-axis EtherNet/IP Servo Drives User Manual, publication 2097-UM002E-EN-P (December 2022)
  7. Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002I-EN-P (December 2022)
  8. Kinetix 5500 Servo Drives User Manual, publication 2198-UM001N-EN-P (September 2024)
  9. Kinetix 5500 Servo Drive Fault Codes Reference Data, publication 2198-RD005 (spreadsheet, last change September 2024)
  10. Kinetix 5700 Servo Drives User Manual, publication 2198-UM002Q-EN-P (June 2026)
  11. Kinetix 5700 Servo Drive Fault Codes, publication 2198-RD003 (spreadsheet, last change May 2024)

See the moment the axis stopped

Fabrico, a light MES with computer vision, syncs camera footage with machine and timeline data, so you can replay the exact moment the axis stopped and review the cause next to its alarm. Cameras also catch short stops and a line that is switched on but not producing, the losses nobody writes down. Machines connect through a PLC, a Fabrico IoT device or an AI camera.

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Related: servo drive troubleshooting · servo motor · FANUC servo amplifier alarm codes · pick and place

Other alarm code lookups: FANUC: servo amplifier · spindle amplifier · robot SRVO | Siemens: MICROMASTER 440 · MASTERDRIVES · SINAMICS G120 · SINAMICS V90 servo · SINAMICS V20 | ABB: ACS550 drive · ACS800 drive · robot IRC5 | Okuma: OSP alarms | Haas: alarm lookup | Mitsubishi: MELSERVO servo · FR-D700 and FR-E700 inverters · FX PLC | Allen-Bradley: MicroLogix · PowerFlex 753 and 755 · PowerFlex 70 and 700 · 1336 and 1305 | Yaskawa: V1000 drive · SERVOPACK servo · Motoman robot | Delta: VFD drives · ASDA servo | Eaton: DC1 and SVX9000 drives | Control Techniques: Commander SK and M200 | Kollmorgen: AKD servo | Lenze: SMVector, 8200, 8400, i500 | Magnetek: IMPULSE and DSD 412 | Omron: MX2 and RX inverters · G5 and 1S servo | WEG: CFW500, CFW300, CFW11, CFW08 | Hitachi: WJ200 inverter | Toshiba: E3, Q9, P9, S15, nC3, AS3 | AutomationDirect: GS10, GS20, GS4, GS1 to GS3 | SANYO DENKI: SANMOTION servo | Parker: SSD 590+, 690+, AC10 | KEB: COMBIVERT F5 | Epson: robot RC700, RC90 | B&R: ACOPOS servo | Schneider Electric: Lexium 32 servo | Bosch Rexroth: IndraDrive | Vacon: NX, VACON 100 and 20 | Fuji Electric: FRENIC-Mini, Multi, Ace, MEGA | LS Electric: S100, G100, iG5A | Panasonic: MINAS A6 and A5 servo | Invertek: Optidrive E3, P2, Eco | SEW-Eurodrive: MOVITRAC B and MOVIDRIVE B

Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary

OEE essentials: OEE calculator · What is OEE · How to improve OEE · Six big losses · Availability · TEEP · Cost of downtime · OEE benchmark · Free OEE tracker · Free OEE software · How to track downtime · How to implement OEE · Light MES vs full MES