Heatsink Overtemperature

Possible causes

Investigation

Corrective actions

Wrong overtemperature limit. The controller temperature will vary on various factors, such as the current consumption, the environment temperature, and the cooling. 

Check if the correct overtemperature limit has been configured based on the operating conditions. 

Set the correct overtemperature limit

Insufficient cooling. The ratings of continuous and peak current in the controller datasheet require proper cooling

Measure the temperature of the controller's cooling plate to confirm that the reported correspond to the real value.

Keep in mind that the temperature sensors are placed in the heat sink near the Power Transistors
 and the actual temperature will rise and fall faster than the outside surface.

Improve the cooling of the controller by using air cooling or increasing the heatsink dimensions 

Underrated controller. If, despite proper cooling, the controller is still heating up, it may indicate that the nominal current required is higher than the rated value, or that the peak current is being provided for a longer duration than the allowed time.

Compare the motor and controller specs 

Use a higher-rated controller

 

Possible failure in the temperature measurement circuit. Although this is a rare fault, it could occur under certain conditions.

Power off the system for sufficient time to cool down and compare the reading with ambient temperature

This kind of failure is not repairable, so the damaged controller should be replaced

Damaged controller. An internal short can lead to increased temperature

If the controller temperature exceeds the ambient temperature by more than 10 degrees Celsius when the controller is idle, it may indicate possible damage

Replace the controller. 

A controller's input is supplied with more that 30 V. It has been observed that if more than 30 V are provided to any of the controller's inputs the analog input measurements of the other inputs can be affected.

Confirm that none of the controller inputs is supplied with more than 30 V. 

Do not use more than 24 V in the controller inputs

Miscalibrated Controller. If the controller is miscalibrated and the reported motor current is incorrect, the current limiting process will be affected. As a result, the temperature may increase without any apparent reason.

Measure the motor current by using a clamp meter and compate it with the reported current by the controller. 

If the reported current is wrong contact Roboteq's technical support

Motor overtemperature

Possible causes

Investigation

Corrective actions

Wrong overtemperature limit. The controller temperature will vary on various factors, such as the current consumption, the environment temperature and the cooling. 

Check if the correct overtemperature limit has been configured based on the operating conditions. 

Set the correct overtemperature limit

Misconfigured temperature sensor.

Ensure that the thermistor used is a NTC type

Confirm that b25 and R25 parameters are set correctly by referring to the Roboteq controllers user manual

 Power off the system for sufficient time to cool down and compare the readings with the ambient temperature values

Use the correct type of thermistor

 Set the correct b25 and R25 values

Insufficient cooling. 

Measure the temperature of the motor' chassis to confirm that the reported correspond to the real value.

Check the motor mounting plate dimensions and compare it with datasheet. Consider improving it if necessary

 Enable the motor overtemperature detection. Note that enabling this protection will impact the provided power if the motor temperature approaches the temperature limit.

Underrated motor. The motor power might exceed the nominal values.

Confirm that the motor operates within the allowed limits. Ensure that the continuous and peak current values are respected and that the current is supplied for the permitted time

Enable the motor overtemperature detection. Note that enabling this protection will impact the provided power if the motor temperature approaches the temperature limit.

 Get a higher rated motor.

Enable the I2T protection. I2T protection will start limiting the motor power if theenergy exceeds the configured limits.

Failed thermistor circuitry. The required circuitrly consists of a NTC thermistor and a 10 KOhm pullup resistor

Ensure the circuitry is functional by checking the connections, measuring the pullup resistor and measuring the thermistor resistance and comparing it with the ambient temperature value.

 If the values are out of the expected range, the circuit might be open or shorted

Fix the external circuitry

Failed controller input. If the external circuit is correct but the reported temperature is still wrong, then the controller might be damaged.

Power off the motor for sufficient time to cool down and compare the reading with ambient temperature

This kind of failure is not repairable, so the damaged controller should be replaced

A controller's input is supplied with more that 30 V. It has been observed that if more than 30 V are provided to any of the controller's inputs the analog input measurements of the other inputs can be affected.

Confirm that none of the controller inputs is supplied with more than 30 V. 

Do not use more than 24 V in the controller inputs

Miscalibrated Controller. If the controller is miscalibrated and the reported motor current is incorrect, the current limiting process will be affected. As a result, the temperature may increase without any apparent reason.

Measure the motor current by using a clamp meter and compare it with the reported current by the controller. 

If the reported current is wrong contact Roboteq's technical support

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?S_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?S 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?SS 1_?F 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?T 1_?T 2_?T 3_# 1000

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?TR 2_?BS 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?BS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

Encoder

# c_/?RMP 2_?S 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?P 2_?A 2_?T 2_?T 2_?T 3_# 1000

# c_/?TR 1_?S_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?S 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

SSI

# c_/?RMP 2_?SS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?SS 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 2_?F 2_?SS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?RMP 2_?BS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?RMP 1_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?TR 2_?BS 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?RMP 2_?F 2_?BS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?RMP 2_?S 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?S 1_?F 1_?P 1_?A 1_?TR 2_?S 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?S 1_?P 1_?A 1_?RMP 2_?F 2_?S 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?RMP 2_?SS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?TR 1_?SS 1_?F 1_?P 1_?A 1_?TR 2_?SS 2_?F 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?RMP 2_?F 2_?SS 2_?P 2_?A 2_?T 1_?T 2_?T 3_# 1000

Possible causes

Investigation

Corrective actions

Configured overvoltage limit is set too low. Notice that The battery voltage will exceed the nominal value when the battery is fully charged.  

Ensure that the configured voltage limit is higher than the maximum battery voltage.

 Perform a battery charge and note the maximum voltage. 

Confirm that the correct voltage limits are set through Roborun+ Utility,

Ensure that the maximum voltage of the battery is below the controller's maximum permitted voltage

 Avoid performing a full charge if necessary

Regeneration current has no path to return to the source. This can happen if a device connected between the battery and the controller prevents the curren flow

Ensure that the BMS used supports regeneration.

Ensure that the BMS is conifgured properly (overvoltage-overcurrent limits, max. reverse current etc.)

 If there is a switch between the battery and the controller, ensure that it remains closed while the motor rotates

Never allow an open circuit between the battery and the controller while the motor rotates

Use a BMS that enables regenerative energy to return to the source. Configure the BMS accordingly to support this operation

  

Battery cannot absorb the excessive regenerative energy. This can happen if the battery is fully charged, aged, or in poor health.

Check the battery's state of charge when the error occurs

Verify that the battery age is within the expected lifespan

 Assess the battery's health by obtaining BMS data  

Use a shunt regulator such as the Roboteq SR5K or
a breaking resistor. This will help disipating the exessive regerative energy when the motor decelerates.

The regenerative energy will be higher when the motor deceleration increases. To prevent the battery voltage from exceeding allowed limits, one workaround would be to decrease the deceleration rate.

 Replace the battery if needed.

 The power supply unit does not support regenarative energy. Typically, power supply units do not allow inverse current, resulting in an increase in the DC bus voltage.
 

Verify in the PSU datasheet whether regeneration is supported or not.

If the PSU does not support regenerative energy consider using a shunt regulator such as the Roboteq SR5K or a breaking resistor.

Damaged controller. A damaged controller can cause false positive overvoltage errors due to faults in the measuring circuit or MCU inputs.

 Measure the actual battery voltage and compare it with the reported value

Replace the controller. These kinds of failures are not repairable

Transients can induce voltage on the DC bus, triggering the overvoltage error.

Use an oscilloscope and monitor the DC bus voltage when the error occurs 

Ensure that induction loads (coils/solenoids) have flyback diodes

 If the amplitude of the spike is small, consider increasing the overvoltage threshold. Be aware that this level of noise may also exist in other parts of the system.

A controller's input is supplied with more that 30 V. It has been observed that if more than 30 V are provided to any of the controller's inputs the analog input measurements of the other inputs can be affected.

Confirm that none of the controller inputs is supplied with more than 30 V. 

Do not use more than 24 V in the controller inputs

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?V 2_# 10

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?TR 1_?S_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?S 1_?P 1_?A 1_?V 2_# 10

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?TR 1_?SS 1_?F 1_?P 1_?A 1_?V 2_# 10

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?V 2_# 10

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 2_?BS 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?BS 2_?P 2_?A 2_?V 2_# 10

Encoder

# c_/?RMP 2_?S 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 2_?S 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?S 2_?P 2_?A 2_?V 2_# 10

SSI

# c_/?RMP 2_?SS 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 2_?SS 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?SS 2_?P 2_?A 2_?V 2_# 10

Open Loop

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?RMP 2_?BS 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?TR 2_?BS 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?RMP 2_?F 2_?BS 2_?P 2_?A 2_?V 2_# 10

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?RMP 2_?S 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 1_?S_?F 1_?P 1_?A 1_?TR 2_?S 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 2_?F 2_?S 2_?P 2_?A 2_?RMP 1_?F 1_?S 1_?P 1_?A 1_?V 2_# 10

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?RMP 2_?SS 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?TR 1_?SS 1_?F 1_?P 1_?A 1_?TR 2_?SS 2_?F 2_?P 2_?A 2_?V 2_# 10

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?RMP 2_?F 2_?SS 2_?P 2_?A 2_?V 2_# 10

Undervoltage from Battery Volts

Possible causes

Investigation

Corrective actions

Configured undervoltage limit too high. 

Confirm that the undervoltage threshold is below the battery's nominal voltage. Be aware that the battery voltage may decrease when a high current is drawn.

In Roborun+ utility change the undervoltage levels.

Vmot supply is missing. The controller's logic can be powered either from pwr ctrl or Vmot, but the power stage is powered only from Vmot. The battery volts measurement takes place in the Vmot voltage

Confirm that the controller is properly powered through Vmot

Add the appropriate voltage in the Vmot connector.

Short in the harness. A short could occur on either the battery or the motor side. A short in the harness could result in a connection between the battery poles, causing a decrease in battery voltage and the development of excessive current.

Check the harness for any shorts by utilizing a continuity tester.

If a short exists on the battery side, the battery voltage will be permanently low. Remove the controller and measure the battery voltage to check if the voltage decrease is unrelated to the controller and the motor.

If a short exists on the motor side, the undervoltage might occur when a motor command is given. Most probably, the short error will be triggered as well. Remove the controller and measure the motor phase resistance using a specified tool. The short might exist either in the harness or in the motor itself.

 In both cases the excessive current should make the fuse or the BMS trip. 

If a short exists in the harness, the harness should be fixed.

 If a short exists in the motor, the motor should be replaced.

Shorted controller. A short in one or more of the controller's internal components could result in a connection between the battery poles, causing a decrease in battery voltage and the development of excessive current

Check the controller alone by using a power supply unit with current limitation, to see if it is shorted.

If there is a suspicion that the controller is shorted, verify the condition of its MOSFETs by following the method outlined in the appendix.

 If the MOSFETs are functioning properly but the voltage continues to drop when the controller is connected, it is possible that some other component of the controller is damaged

 If damage is found on the controller, replace it

Weak or discharged battery.

Investigate whether the undervoltage occurs when the motor draws high currents, typically during acceleration, deceleration, or when under a high load.

Confirm that the battery has the desired state of charge

Confirm that the battery is capable of providing the required current (by refering to its specs or testing it with special equipment)



 

Use a battery of higher capacity

Charge the battery

 Decrease the acceleration/deceleration ratio or decrease the amp limit value to limit the current

Damaged battery measurement circuit. A damage in the battery measurement circuit could create a false positive alarm

Check the battery harness

Test the controller separately. If the battery harness has no shorts and the battery voltage drops when the controller is connected, it indicates that the controller might be damaged and causing a short in the battery

 Utilize a multimeter to measure the battery voltage. If the measured voltage is inaccurate, it suggests that the battery measurement circuit could be damaged

Replace the controller. These kind of faults are not repairable.

Undervoltage from controller volts

Possible causes

Investigation

Corrective actions

STO jumper is removed and not both STO inputs are high. If the STO jumper is removed or not connected, both STO inputs should be high.  When STO functionality is not required, the STO jumper should be connected; otherwise, the MOSFET drivers will be deprived of voltage, triggering an undervoltage error. If you intend to use STO, both STO inputs must be high for the controller to function properly.

Check if the STO jumper is placed in the STO pins

If STO is used, confirm that both STO inputs are high and stable for proper operation. Use an oscilloscope to monitor the voltage of the STO inputs and confirm that the voltage does not have any temporary drops.

Confirm that the STO input voltages are within the supported range (>6 V and <= 30)

Confirm that the STO inputs are enabled, by checking at the Roborun+ input indicators

 Check if the undervoltage is triggered by a drop in the controller volts. In the Roborun+ utility monitor the "controller volts" parameter.

If STO is intended to be used, then both STO inputs should be high for normal operation. If there is no intention to use STO, then the STO jumper should be added. In controllers that do not have a jumper connection for the STO, having both STO inputs high is mandatory.

Hardware damage. A damage in the controller could affect the MOSFET drivers voltage (controller volts)

Ensure that the STO inputs are properly powered or that the jumper is connected.

Check the 'controller volts' voltage.

If the controller volts are below 10 and the STO is properly triggered, then hardware damage might be preventing the 12V from reaching the MOSFET drivers.

 If the STO circuitry is damaged, the controller will detect it during the STO self-test and trigger the STO fault alarm

If the controller is damaged then it should be replaced.

A controller's input is supplied with more that 30 V. It has been observed that if more than 30 V are provided to any of the controller's inputs the analog input measurements of the other inputs can be affected.

Confirm that none of the controller inputs is supplied with more than 30 V. 

Do not use more than 24 V in the controller inputs

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?V 1_?V 2_# 10

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?TR 1_?S 1_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?S 1_?P 1_?A 1_?V 1_?V 2_# 10

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?TR 1_?SS_?F 1_?P 1_?A 1_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?V 1_?V 2_# 10

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?TR 2_?BS 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?BS 2_?P 2_?A 2_?V1 _?V 2_# 10

Encoder

# c_/?RMP 2_?S 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?TR 2_?S 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?S 2_?P 2_?A 2_?V1 _?V 2_# 10

SSI

# c_/?RMP 2_?SS 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?TR 2_?SS 2_?F 2_?P 2_?A 2_?V1 _?V 2_# 10

# c_/?RMP 2_?F 2_?SS 2_?P 2_?A 2_?V1 _?V 2_# 10

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?RMP 2_?BS 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?TR 1_?BS 1_?F 1_?P 1_?A 1_?TR 2_?BS 2_?F 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?BS 1_?P 1_?A 1_?RMP 2_?F 2_?BS 2_?P 2_?A 2_?V 1_?V 2_# 10

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?RMP 2_?S 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_?RMP 2_?F 2_?P 2_?A 2_?V1 _?V 2 _# 10

# c_/?TR 1_?S 1_?F 1_?P 1_?A 1_?TR 2_?S 2_?F 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?S 1_?P 1_?A 1_?RMP 2_?F 2_?S 2_?P 2_?A 2_?V 1_?V 2_# 10

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?RMP 2_?SS 2_?P 2_?A 2_?V1 _?V 2__?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?P 1_?A 1_? RMP 2_?F 2_?P 2_?A 2_?V1 _?V 2 _# 10

# c_/?TR 1_?SS_?F 1_?P 1_?A 1_?TR 2_?SS 2_?F 2_?P 2_?A 2_?V 1_?V 2_# 10

# c_/?RMP 1_?F 1_?SS 1_?P 1_?A 1_?RMP 2_?F 2_?SS 2_?P 2_?A 2_?V 1_?V 2_# 10

Unsupported Specs

Possible causes

Investigation 

Corrective actions

Incompatible R-L values

Confirm that the resistance and inductance of the motor are within the supported range by referring to the controller's datasheet

If the motor's inductance is too low, you may need to add an external coil to the motor phases to match the supported values. Keep in mind that adding external inductance will decrease the performance of the motor.

 Consider using RoboG4 products that operate at a higher current control frequency, to help mitigate any current response issues related to low inductance

Unsupported sensor resolution or speed. The maximum sensor resolution that the controller can support depends on the maximum frequency of sensor input and the rotor's speed
 

Consult the controller's datasheet to determine the maximum supported frequency for the sensor input. If using quadrature encoders, you can calculate the maximum supported motor speed by considering the maximum frequency of the sensor input and the sensor's resolution as follows:

Max Resolution = 60 * Max Encoder frequency/ (Max Speed)

Example:

Consider an encoder with resolution of 2000 PPR and a FBLG2360T controller with a maximum Encoder frequency of 200 KHz. The maximum allowed speed in that case would be:

 Max Speed = (60*Max Encoder frequency)/(Max resolution) = 6000 RPM

If a sensor with unsupported resolution is already used, consider running the motor at lower speeds where the sensor resolution is supported.

Unsupported electrical frequency. The frequency of the electrical field required to drive a motor is proportional to the number of motor pole pairs and the rotor speed. For motors with a high number of pole pairs or those running at high speeds, the required electrical frequency may exceed the supported range of the controller

Consult the controller's datasheet to determine whether the maximum electrical frequency required to drive the motor is below the maximum electrical frequency supported by the controller. The maximum operating rotor speed can be calculated by dividing the maximum operating electrical speed of the controller by the number of motor pole pairs. The parameter values can be found in the controller's and motor's datasheets.

Example:

 In a motor with 4 pole pairs and a FBL2360T controller with maximum operating speed of 15000 RPM, the maximum operating rotor speed is 15000/4 = 3750 rpm

The maximum electrical speed will vary depending on the generation of the product. If the desired speed is not supported, consider switching to another product or do not exceeding the maximum supported speed.

Wrong controller rating. The peak current rating of the controller should be equal to or higher than the peak current specified by the application

Investigate if the current required to accelerate the motor at the desired rate is lower that the peak current of the controller. 

Use a higher rated controller

Decrease acceleration/deceleration values

 Use a milder PID or FOC tuning

Incompatible sensor. There are many parameters that can make a sensor incompatible, including insufficient signal amplitude, nonlinearity, sensor's time response and more. If the sensor signal is improper, it can affect the motor angle calculation and feedback, which can lead to an increase in motor current which eventually will trigger the Short Circuit error.

Check the sensor signals by using an oscilloscope. Examine them for deviations from the original values. Check the amplitude, frequency, response time and pattern.

Check the sensor signals in the diagnostics tab. Diagnostics tab offers the capability to plot sensor signals with an update rate up to 1 ms for debugging purposes.

 Some common scenarios involving unsupported sensors include Quadrature encoders with low signal amplitude (3.3 V is the minimum) and Sin/Cos sensors with outputs higher than 3.3 V, which are not supported on specific controller models.

Enable the sensor error detection. If it triggers, there is a problem with the sensors 

Damaged components

Possible causes

Investigation 

Corrective actions

One or more MOSFETs of the controller are shorted. 

Measure the MOSFETs body diode by using a multimeter in diode mode. More information about this test method can be found in the appendix.


If controller MOSFETs are damaged the short circuit error should trigger when supplying a small amount of voltage, even if the motor is not connected.

 At controllers featuring STO, Check the MOSFETs health by sending the !STT command. More information about the STT command can be found in the appendix and the Roboteq Controllers User Manual. A damaged MOSFET should also trigger the MOSfail error.

Controllers with damaged MOSFETs are not repairable, so the controller should be replaced.

The controller MOSFETs should not be damaged under normal conditions, so the root cause of the failure should be investigated to prevent future failures.

 If the cause cannot be found by referring to the troubleshooting table contact tech support.

Shorted motor phases. 

Check the motor harness for shorts

Disconnect the motor from the controller and use an insulation tester to measure the motor windings. If special equipment is not available, you can use a power supply unit with current control to measure the motor resistance. Check the appendix for more information on this method

If there is short on the motor side, the error will be triggered only when the motor is connected and even when a very small motor command is given

 At controller featuring STO, shorted motor phases may also trigger the MOSfail error, as the controller cannot determine whether the damage is located in the motor or its power stage

Replace the motor or fix the bad harness

 Ensure that both the nominal and peak currents of the application do not exceed the motor's rating, as this could eventually damage the motor. Be mindful of the duration for which these current values can be applied. 

Faulty sensor. A permanent or temporary sensor malfunction can affect the motor angle or motor feedback calculation and result in high motor current that can eventually trigger the Short Circuit error.   

Check the sensor signals by using an oscilloscope. Examine them for deviations from the original values. Check the amplitude, frequency response time and pattern.

 Check the sensor signals in the diagnostics tab. Diagnostics tab offers the capability to plot sensor signals with an update rate up to 1 ms for debugging purposes. 

Enable the sensor error detection. If it triggers, there is a problem with the sensors 

Misconfiguration

Possible causes

Investigation 

Corrective actions

High motor acceleration/deceleration values. High motor acceleration/deceleration values can result in a significant increase in the motor current, which may trigger the short error.




 

Log the motor phase amps (?PHA) and the motor amps (?A) until the error occurs. Because the phase amps are not RMS, they should be multiplied by 0.707 to compare them with the maximum current of the controller. If the calculated value exceeds the 120% of the controller's peak current the short error will trigger. Please note that sampling frequency of the controller is limited to 1KHz, so a current spike with less duration than that will not be noticable.

Decrease the motor acceleration/deceleration parameters

Use Sinusoidal mode with FOC gains enabled, where the motor current is being controlled in addition to the motor speed.

Use Closed Loop modes instead of Open Loop if they are not already being used

 If this acceleration profile is required and the controller cannot provide the necessary current, consider using a higher rated controller

Aggreessive PID values. A significant increase in the motor current caused by aggressive PID tuning can trigger the short error. 

Log the motor phase amps (_PHA) until the error occurs. Because the phase amps are not RMS, they should be multiplied by 0.707 to compare them with the maximum current of the controller. If the calculated value exceeds the 120% of the controller's peak current the short error will trigger. Please note that sampling frequency of the controller is limited to 1KHz, so a current spike with less duration than that will not be noticeable

Decrease the PID loop bandwidth (Both P and I). Lower speed or position PID gains will result in a smoother increase of the motor current

Decrease the proportional gain of the PID controller. A high proportional gain can cause the motor current and speed to be more sensitive to changes in the Loop Error parameter

Use FOC torque gains to enable current control. With current control enabled, the motor current will be adjusted in a controlled manner to drive the motor at the desired speed, instead of changing uncontrollably as is the case in the basic PWM drive without current control.

Decrease the FOC bandwidth to make the current loop less aggressive. The higher the FOC bandwidth, the faster the current will reach the setpoint. If the speed or position closed-loop system is unstable, a high FOC bandwidth can trigger the short error

 Decrease the speed filter cutoff frequency. The low-pass speed filter is set by default at 45 Hz. Lowering the cutoff frequency will attenuate the high-frequency components of the system's feedback that typically causes the short error. However, be aware that decreasing the cutoff frequency too much will introduce delay in the system's response

Wrong Encoder/SSI resolution configuration.  If the sensor resolution is set incorrectly, it can affect the calculation of the sensor angle and motor feedback. This can cause an increase in motor current that may eventually trigger a short error

Refer to the sensor datasheet to confirm the correct resolution.

 The resolution of a quadrature encoder can be estimated by using the Roboteq controller and sending the VPM command to rotate the rotor for a certain number of electrical degrees, without using the motor sensors. More information about this method can be found on the Appendix.

After setting the correct resolution of the encoder run again motor/sensor setup

Wrong pole pairs configuration. If the pole pairs parameter is configured incorrectly, the motor's commutation and feedback will be affected, and the motor current may increase, which could eventually trigger a short error.

Check the motor datasheet to confirm the correct pole pairs parameter. The pole pairs value is the number of motor pole pairs divided by 2.

 The number of a motor's pole pairs can be determined by using the Roboteq controller and sending the VPM command to rotate the shaft a certain number of electrical degrees. If the number of electrical degrees equals the number of pole pairs, the rotor will perform exactly one rotation (before the gearbox). For more information, please refer to the appendix.

After setting the correct pole pairs parameter run again motor/sensor setup

Electrical Noise 

Possible causes

Investigation 

Corrective actions

Noise in the motor sensors. Electrical noise in the sensors can lead to incorrect rotor angle and feedback calculation which in turn can create current spikes.

Use an oscilloscope to ckeck wether the sensor signals are clean of electrical noise. Voltage spikes that have an amplitude higher than 2.5 V can affect the readings
 

Enable the sensor error detection to check for any issues with the sensor signals

Use shielded sensor cables to reduce the EMI

Increase the distance between the power and signal cables, as electromagnetic interference (EMI) can be caused by the cables that switch the load.

Add a hardware low-pass filter. The values of the controller's internal components might be required for the filter's design.

 Check if the Y-cap is damaged. All controllers come with a Y-cap placed between the controller’s heatsink and the power ground. This capacitor helps in rejecting common-mode noise that can be induced through the motor chassis. The capacitor’s health can be verified using a capacitance meter. A value between 100 and 500 nF should be measured between the controller's chassis and the power ground connection, for proper operation. The exact value depends on the controller model.

Other reasons

Possible causes

Investigation 

Corrective actions

The controller operates at the voltage limit. If the voltage provided to the motor becomes saturated, the controller will not be able to adjust the PWM duty cycle sufficiently to control the motor and regulate its current. This situation can cause an increase in motor current.

Log the Motor Power parameter (P) of the controller which corresponds to the amount of PWM voltage supplied to the motor and the motor current (A). Check if the Motor Power is close to 1000 when the short error occurs.

Avoid running the motor at conditions were the motor power is saturated. Consult the motor's Speed - Torque curve to confirm that the motor runs under the operating limits

 Increase input DC voltage level (up to 60 V) to avoid voltage limit

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

Encoder

# c_/?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

SSI

# c_/?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?RMP 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CB 1_?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CB 2_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?FF 1_?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?PHA 1_?PHA 2_?PHA 3_?HS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

# c_/?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

Encoder

# c_/?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

SSI

# c_/?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?RMP 2_?BS 2_?P 2_?PHA 1_?PHA 2_?PHA 3_?HS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?HS 1_?ANG 1_?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?HS 2_?ANG 2_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?C 1_?ANG 1_?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?C 2_?ANG 2_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?CSS 1_?ANG 1_?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?CSS 2_?ANG 2_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

# c_/?RMP 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

Encoder

# c_/?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

SSI

# c_/?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?TR 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?BS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?F 2_?BS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

Encoder

# c_/?RMP 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?TR 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?S 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?F 2_?S 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

SSI

# c_/?RMP 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 1_?F 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?RMP 2_?F 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?TR 1_?F 1_?SS 1_?P 1_?PHA 1_?PHA 2_?PHA 3_?MA 1_?MA 2_?FC 1_?TR 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

# c_/?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?RMP 2_?F 2_?SS 2_?P 2_?PHA 4_?PHA 5_?PHA 6_?MA 3_?MA 4_?FC 2_?FF 1_# 2

Possible causes

Investigation

Corrective actions

Emergency stop is pressed in Roborun+. The Emergency Stop button in RoboRun+ sends an Emergency Stop command to the controller. The Emergency Stop can be released by clicking the Emergency Stop button again. The button can also be interacted with by using the 'Escape' key.

Check if the emergency stop is enabled in Roborun+ Utility

Release the emergency stop by clicking at it ,pressing the escape button or sending MG command.

Emergency stop is configured to be triggered on the controller. Roboteq controller's firmware allows to set the emergency stop as an action triggered by specific conditions such as inputs activation, firmware limits exceedance etc

Check if the emergency stop is configured to be triggered in the following cases:

- Consumer Heartbeat loss
- Encoder/SSI min/max
- Digital Input
- Analog/Pulse Input min/max
- Internal Sensor counter min/max
 - Amps Trigger 

Investigate why the limits are exceeded

 Modify the limits or adjust the configuration

An emergency stop command is sent through another device to the controller

Investigate if any of the connected devices sends an emergency stop command (!EX) to the controller. This command can be received through all supported communication modes, such as RS232, RS485, CANbus, Modbus etc.

 Remove the communication bus to identify if the command is received externally

Investigate the reason why the external device sends the Emergency Stop command. Modify the program's logic accordingly

Emergency stop is triggered through script

If a script is used, check if there are any conditions that can trigger Emergency Stop

Investigate the reason why the emergency stop conditions are met. Focus on the primary conditions that trigger the error.

Emergency stop comes from DS402 implementation. When DS402 is used, some of the Finit State Automation functions are being implemented on the Roboteq Controller by applying Emergency Stop. These functions are the following:

Read the status word to get the FSA state

Use the appropriate FSA state

Possible causes

Investigation

Corrective actions

Electrical noise. The presence of electrical noise in the sensor signals can create a wrong rotor angle calculation that can trigger the Sensor Error.

Use an oscilloscope to check the amount of noise in the sensor signals

Check the Sensor Error Counter (SEC) for sensor errors (Hall sensors) or the determine the quality of the signals (sin/cos or resolver).

Check if a Y capacitor is installed in the controller. This can be done by following the instructions on the appendix. All new Roboteq controllers have this capacitor installed that helps in the reduction of the common mode noise.

If the error occurs during acceleration/deceleration where typically the motor current is higher, it is a sign that the erorr might be related to electrical noise.

Keep the maximum possible distance between power and control cables

Use the shortest possible cables for the motor and battery

Use shielded cables and ferite coils

 Add a snubber circuit to the motor phases 

Faulty or unsupported sensor. A faulty sensor that has distorted or missing signals will trigger the Sensor Error. Signals with unsupported voltage level will trigger the sensor error detection as well.

Check the signal pattern in diagnostics tab of Roboun.

Check the Sensor Error Counter (SEC).

Ensure that the sensor has the supported voltage levels by referring to the sensor and controller datasheet

Troubleshoot the sensors using the VPM command:

- In Hall sensor, all Hall transitions from 1 to 6 should be received and each transition should have the same duration.

- In Sin/Cos and resolver sensors the signals should have a sine and cosine waveform. The number of signal periods should correspond to the number of sensor poles, which for most sensors is one. The signals should perform one period for one full rotation of the motor's roter (prior to the gearbox).
 

More information about using the VPM comamnd and checking the sensor signals can be found on the  appendix

Replace the sensor if is found to be damaged or has unsupported specs.

Loose sensor connection. If the sesor error occurs radnomly it might be triggering by a loose sensor connection

Check the sensor connections

Take logs from the sensor readings (HS for Hall, C for encoder and ASI for Sin/Cos and Resolver). Check if the signal has the correct values during the motor operation. Refer to the appendix section for more information

Fix the connections

Sensor Error Detection is not disabled on unused channels. By default, Sensor Error Detection is enabled on both channels of the controller. If only one of the two channels is in use and there is no sensor present, an error will be triggered.

Check if the sensor error detection is enabled on the unued channels

Turn the Sensor error detection off if a channel is not used

Motor has high vibrations. If there are high vibrations in the motor, the sensor error might be triggered because it will detect an unexpected sensor pattern

Check the Sensor Error Counter (SEC) and the motor speed when the error occurs. 

If the error is related to motor vibrations, consider limiting these vibrations. To achieve that, the PID or FOC gains can be reduced. If the vibrations cannot be reduced, consider lowering the detection sensitivity

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_# 1

# c_/?VDV 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_# 1

# c_/?TR 1_?VDV 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_# 1

# c_/?RMP 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_# 1

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?C 1_# 1

# c_/?VDV 1_?S 1_?P 1_?A 1_?C 1_# 1

# c_/?TR 1_?VDV 1_?S 1_?P 1_?A 1_?C 1_# 1

# c_/?RMP 1_?S 1_?P 1_?A 1_?C 1_?SEC 1_# 1

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_# 1

# c_/?VDV 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_# 1

# c_/?TR 1_?VDV 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_# 1

# c_/?RMP 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_# 1

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?VDV 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?TR 2_?VDV 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?RMP 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

Encoder

# c_/?RMP 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?VDV 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?TR 2_?VDV 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?RMP 2_?S 2_?P 2_?A 2_?C 2_?SEC 2_# 1

SSI

# c_/?RMP 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?VDV 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?TR 2_?VDV 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?RMP 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

Open

Speed

Position

Torque

Hall-Sin/Cos or Resolver

# c_/?RMP 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_?RMP 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?VDV 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_?VDV 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?TR 1_?VDV 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_?TR 2_?VDV 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

# c_/?RMP 1_?BS 1_?P 1_?A 1_?HS 1_?SEC 1_?RMP 2_?BS 2_?P 2_?A 2_?HS 2_?SEC 2_# 1

Encoder

# c_/?RMP 1_?S 1_?P 1_?A 1_?C 1_?RMP 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?VDV 1_?S 1_?P 1_?A 1_?C 1_?VDV 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?TR 1_?VDV 1_?S 1_?P 1_?A 1_?C 1_?TR 2_?VDV 2_?S 2_?P 2_?A 2_?C 2_# 1

# c_/?RMP 1_?S 1_?P 1_?A 1_?C 1_?SEC 1_?RMP 2_?S 2_?P 2_?A 2_?C 2_?SEC 2_# 1

SSI

# c_/?RMP 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_?RMP 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?VDV 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_?VDV 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?TR 1_?VDV 1_?SS 1_?P 1_?A 1_?CSS 1_?ASI 1_?ASI 2_?TR 2_?VDV 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

# c_/?RMP 2_?SS 2_?P 2_?A 2_?CSS 1_?ASI 3_?ASI 4_?RMP 2_?SS 2_?P 2_?A 2_?CSS 2_?ASI 3_?ASI 4_# 1

Possible causes

Investigation 

Corrective actions

A MOSFETS is damaged. The controller will check the MOSFETs health every time is powers on, when the STO is triggered, or every time !STT command is sent. If the alarm is triggered by a real MOSFET failure, the MOSfail alarm should not clear when the test runs again. 

Check if the controller MOSFETs are damaged by using a multimeter, following the method described on the appendix.

 Check if the controller MOSFETs are damaged by using the !STT command, following the information provided on the appendix. 

If the controller is damaged, replace it. The controller MOSFETs are not repairable

The controller is miscalibrated. If the voltage measurement gains are not set properly, then the controller might trigger a false positive MOSfail error.

Check if the occurrence of the error is consistent. If the error corresponds to a real MOSFET damage, it should not clear at all.

The controller cannot be calibrated by the user. Contact Roboteq technical support

Noise in phase readings. The controller uses the phase voltage readings to determine the MOSFETs health. If there is a high precence of electrical noise there, the controller might trigger a false positive MOSfail.

Check if the occurrence of the error is consistent. If the error corresponds to a real MOSFET damage, it should not clear at all.

Use the SNS parameter to log the motor phases voltage. Hit emergency stop and log the phase values at that time. Confirm if the voltage readings have a stable value.

Check the phase voltage by using an oscilloscope. Verify if the phase readings are clear from noise. The controller should be on Emergency stop when performing that test.

If the MOSFail it triggered because of EMI, try to eliminate the source of noise. The noise might be sourced from another switchning device that operates the time that the MOSfail test is being performed.

Possible causes

Investigation

Corrective actions

A firmware update has been peformed. After firmware update, the DefConfig error will appear until the controller is reset.

Reset the controller once. After resetting, the error should clear.

Reset the controller

Controller's flash memory is corrupted. This protection will detect that the default configuration is loaded on startup. If the error does not clear after reset, then the controller might be damaged.

Check if the error clears after resetting the controller

If the error does not clear contact Roboteq's technical support

Possible causes

Investigation

Corrective actions

The two STO inputs have different states. For regular operation of the STO, both inputs must be OFF or ON simultaneously.

Confirm that the signals do not have a delay. A delay of a few milliseconds is acceptable, but higher values (approximately more than 100 ms) will trigger a fault.

Monitor the STO inputs using an oscilloscope.

 Log the STO inputs in Roborun+. The STO inputs can be logged by reading their respective digital inputs.

If the signals are generated by a controller, ensure that both outputs are enabled simultaneously.

 If the signals are provided manually (e.g., through emergency stop buttons), make sure that pressing them cuts both STO inputs.

One or both STO inputs are damaged. The STO self test runs everytime the STO is triggered. If an input fails to change state, the STO fault will be triggered.

Check if the STO inputs state is changing using Roborun+ utility

If the input is actually damaged, the STO should be followed by Undervoltage error and possibly MOSfail

 If the STO fault is not followed by undervoltage, then the STO circuitry might be functional and the falure occurs in the MCU pins.

Replace the controller if found to be damaged.

 The STO voltage is not stable. If the STO voltage drops in one of the two inputs, then the STO fault will be triggered.

Check the STO signals by using an oscilloscope

 Confirm that the voltage is constant

Fix the voltage source

STO voltage is out of range. STO inputs work with voltage values between 6 to 30 V. Lower voltages may not enable the STO properly and higher voltages will damage the STO inputs

Check if the voltage is within the supported range

 Check if the problem is solved by applied the correct voltage

Apply the correct voltage

 Replace the controller if the STO inputs are damaged from high voltage