E01 – Bus Overvoltage
Caused by rapid deceleration, incorrect braking resistor sizing, or excess regenerative energy.
✅ Flexa Systems checks the DC bus level, verifies the braking resistor circuit, and adjusts decel ramp settings to eliminate overvoltage tripping.

E02 – Velocity Exceeds Position Rollover
Occurs when commanded velocity or feedback is too high for the configured machine cycle.
✅ We assess your firmware version, adjust rollover distance, and reprogram your velocity profiles to stabilize motion behavior.

E05 – IPM Fault
Indicates a failure in the Intelligent Power Module (IPM), often due to shorted motor cables, internal heat, or hardware damage.
✅ We test the drive’s power stage, inspect motor insulation, and replace failed IPM components when necessary.

E10 – Bus Overvoltage
May occur during regeneration or AC input surges.
✅ Our technicians evaluate power input stability, braking resistor performance, and motion profile tuning.

E11 – Illegal Hall State
Caused by encoder/Hall sensor wiring mismatch or encoder failure.
✅ We verify encoder compatibility, wiring continuity, and stable voltage to encoder devices.

E12 – Home Search Failed
Occurs when the home sensor or marker pulse is not detected within expected bounds.
✅ We check sensor connections, reposition home markers, and reprogram the homing logic.

E18 – Overspeed Fault
Motor has exceeded safe operational speed, usually due to aggressive tuning or load surges.
✅ We perform dynamic testing, optimize PID tuning, and evaluate mechanical load behavior.

E21 – Feedback Loss
The encoder signal has been lost or disrupted.
✅ We test feedback cable integrity, reseat connectors, and confirm encoder signals in Ultraware.

E22 – Motor Thermal Protection Fault
Triggered when the internal motor temperature exceeds safe limits.
✅ We inspect thermal sensors, reduce motor duty cycle, and recommend cooling or insulation improvements.

E24 – Excess Velocity Error
Occurs when the actual motor velocity exceeds the commanded target, often due to poor tuning or mechanical issues.
✅ We analyze acceleration/deceleration profiles, inspect the mechanical system, and fine-tune motion parameters.

E27 – Axis Not Homed
Absolute moves attempted before homing.
✅ We assist with establishing proper homing routines and validate control system startup logic.

E28 – Motor Parameter Error
Incompatible or missing motor data detected.
✅ We confirm motor model compatibility, reconfigure the drive, and reset encoder recognition where needed.

E30 – Motor Encoder Communication Fault
Lost communication with the motor’s encoder, often due to cabling or mismatch.
✅ We test encoder wiring, verify correct motor part number, and restore encoder auto-recognition.

E34 – Ground Fault
Current leakage to ground detected, likely from damaged motor windings or insulation.
✅ Flexa Systems uses insulation resistance testing to identify faults and isolates/replaces defective components.

E35 / E36 – Indexing Errors
Happen when move distances or indexing parameters are misconfigured.
✅ We inspect motion index tables, homing parameters, and registration inputs to ensure accuracy.

E37 – AC Line Loss
One or more input power phases missing.
✅ We verify incoming power integrity and inspect line fuses, relays, and drive terminal connections.

E44 – Lost Motion Fault
Typically related to Stegmann encoder systems; triggered during line loss or fault resets.
✅ We perform full encoder calibration, cycle the drive through recovery mode, and validate encoder alignment.