esense built-in systems
Troubleshoot steps
Icons used on this page:
Component failure suspected
Indication off
Indication blinking
Indication constantly lit
Component failure suspected
Indication off
Indication blinking
Indication constantly lit
System errors
File system read/write error.
Step 1
Check frequency of the fault in the Log file with PowerTalk.*
Step 2
If the fault is an isolated event (only logged a few times in the past months): no further action needed.
If the fault is not an isolated event:
Replace esense Controller Box.
* In most cases the error does not lead to the system switching to service mode. Therefore, the user may not notice anything. Incidental occurrence is no reason for replacement of the esense Controller Box.
System safe mode.
Step 1
Check frequency of the fault in the Log file with PowerTalk.*
Step 2
If the fault was an isolated event (only logged a few times in the past months): no further action needed.
If the fault was not an isolated event: use PowerTalk to set the right dipswitch for your system configuration.
Step 3
If the issue still exists:
Replace esense Controller Box.
* The esense Controller Box switches to system safe mode when an error occurs that is potentially harmful for the controller. Incidental occurrence is no reason for replacement of the esense Controller Box. The system switches also to safe mode when the system configuration does not match with the software version on the esense Controller Box. This can be corrected by stetting the correct system type with PowerTalk (User Level 3 only).
Pushbar errors
Pushbar out of range.
Step 1
Check sensor signals with PowerTalk.*
Step 2
Loosen and reassemble the failing sensor handle. **
Step 3
Use a plastic hammer to shift the sensor signal back in range. ***
Step 4
If the issue still exists:
Replace Sensor Handle.
Step 5
If the issue still exists:
Replace UI 2.
* Sensor signals can be checked on the “Overview” and “Values” tabs in PowerTalk (see for more info the PowerTalk use guide: PowerTalk screens). A sensor signal should be between 400 and 550 when in rest (not pushed). In case the sensor is outside of this range at start-up of the system, calibration will fail.
In case a sensor signal exceeds the range of 130-870, a cable break is detected. Check which sensor (S1 or S2) causes the failure and locate this sensor by following the cable leading from esense UI2.
NOTE: Sometimes the Log file shows a (couble) cable break directly after the system was stopped. This notification is caused by a timing issue; during switch off of the system the voltage of the sensors drops, causing extreme sensor values. In some cases the Main controller is still able to detect and log this. These notification after ‘system stopped’ can be ignored.
** Please refer to the Installation and maintenance manual for instructions on installation of Sensor and Sensor handles. To operate correctly the handle parts of Sensor Handles shall be mounted with a free space of 1 mm around the surface of the rube they are mounted on. The tube shall have a diameter of 25 mm +/- o.1
*** Hard shocks on a sensor handle may shift the sensor signal at rest. When a signal is not too far outsitde the 400-500 range (between 300-650), the sensor can often be repaired. Use a plastic hammer and hit the sensor handle in forwards or backwards drive direction. Hit the area where the handle is most wide, next tot the clamp part. Do not hit too hard, but shift the signal in a few repeated hits. Stop when the signal stabilizes between 450-500.
Pushbar cable break detected.
Step 1
Check sensor signals with PowerTalk.*
Step 2
If the issue still exists:
Replace Sensor Handle.
Step 3
If the issue still exists:
Replace UI 2.
* Sensor signals can be checked on the “Overview” and “Values” tabs in PowerTalk (see for more info the PowerTalk use guide: PowerTalk screens). A sensor signal should be between 400 and 550 when in rest (not pushed). In case the sensor is outside of this range at start-up of the system, calibration will fail.
In case a sensor signal exceeds the range of 130-870, a cable break is detected. Check which sensor (S1 or S2) causes the failure and locate this sensor by following the cable leading from esense UI2.
NOTE: Sometimes the Log file shows a (couble) cable break directly after the system was stopped. This notification is caused by a timing issue; during switch off of the system the voltage of the sensors drops, causing extreme sensor values. In some cases the Main controller is still able to detect and log this. These notification after ‘system stopped’ can be ignored.
Pushbar offset fault.
Step 1
Check if objects near the Sensor Handles risk to push or clamp on the sensor. *
Step 2
Check if Sensor Handles are used correctly: both hands must be fully placed on the handles.
Step 3
Try to reproduce the fault. Loosen and reassemble the failing Sensor Handle. **
Step 4
If the issue still exists: contact Indes to discuss options to modify Pushbar offset fault settings.
* Offset faults are generally caused by objects pushing or clamping on the sensor handles or by deviating (mis)use. Check with the end users if this is the case and make sure the Sensor Handles are pushed in the same way as described in the user manual. In case of frequent occurrence during normal use in some situations system settings may be changed to limit the chance on offset faults. Please contact Indes for this.
** Please refer to the Installation and maintenance manual for instructions on installation of Sensor and Sensor handles. To operate correctly the handle parts of Sensor Handles shall be mounted with a free space of 1 mm around the surface of the rube they are mounted on. The tube shall have a diameter of 25 mm +/- o.1
Pushbar calibration fault.
Step 1
Inform end user about calibration step.*
* During calibration at start-up of the system the Sensor Handles need not be touched. If a user starts pushing before calibration is complete, an alarm signal will sound. After 20 seconds the system switches to service mode and a Pushbar Calibration Fault is logged. This fault is not caused by component failure but by human error. Please notify the end user to be more patient during calibration. Please refer to the user manual for more information.
Interface errors
UI CAN offline.
Step 1
Reconnect CAB100 UI 2 – Box; specifically connector C3.
Step 2
If the issue still exists:
Replace CAB100 UI 2 – Box.
Step 3
If the issue still exists:
Replace esense UI 2.
Sticky button detected.
Step 1
Check frequency of the fault in the Log file with PowerTalk.*
Step 2
If the fault was an isolated event (only logged a few times in the past months): no further action needed.
If the fault was not an isolated event:
Replace esense Membrane Foil.
Step 3
If the issue still exists:
Replace esense UI 2.
* Sticky button detection checks if any switches on the esense Membrane Foil are continuously activated (pushed). If a button is pushed at start-up of the system, calibration is postponed. If the button remains activated for 20 seconds, the system switches to service mode and the error is logged. This may occasionally happen during normal use, but repeated occurrence indicates a system fault.
UI unexpectedly restarted.
Step 1
Check frequency of the fault in the Log file with PowerTalk.
Step 2
If the fault was an isolated event (only logged a few times in the past months): no further action needed.
If the fault was not an isolated event:
Replace esense UI 2.
Step 3
If the issue still exists:
Replace esense Membrane Foil.
Step 4
If the issue still exists:
Replace CAB100 UI 2 – Box.
Drive errors
Modbus offline.
Step 1
Reconnect the connectors in C7 and C12 of the esense Controller Box.
Step 2
If the issue still exists:
Replace Fuse 58V/20A on esense Controller Box.
Step 3
If the issue still exists:
Replace esense Controller Box.
BLDC undervoltage.
* BLDC undervoltage indicates that the voltage for the Drivewheel has been too low. This typically happens when the Drivewheel needs a sudden high current; for instance when passing thresholds or slopes or with sudden change in drive direction. During these peak currents the voltage of the Batterypack drops. Due to aging of the Batterypack, the voltage drop may get too high.
Step 1
Check frequency of the fault in the Log file with PowerTalk.
Step 2
If the fault was an isolated event (only logged a few times in the past months): no further action needed.
If the fault was not an isolated event:
Replace Batterypack.
Step 3
If the issue still exists:
Replace E1106-0666 Drivewheel.
BLDC controller fault.
Step 1
Reconnect CAB029 360 Wheel – Box or CAB040 Fixed Wheel – Box.
Step 2
If the issue still exists:
Replace CAB029 360 Wheel – Box or CAB040 Fixed Wheel – Box.
Step 3
If the issue still exists:
Replace E1106-0666 Drivewheel.
Step 4
If the issue still exists:
Replace E1106-1000 Driveunit 360.
Steer errors
Driveunit could not find center position.
Step 1
Reconnect CAB033 Position – Main IO.
Step 2
If the issue still exists:
Replace CAB033 Position – Main IO.
Step 3
If the issue still exists:
Replace CAB111 Main IO v3.
Step 4
If the issue still exists:
Replace E1106-1000 Driveunit 360.
Driveunit DC motor fault.
Step 1
Reconnect CAB032 Steering – Box.
Step 2
If the issue still exists:
Replace CAB032 Steering – Box.
Step 3
If the issue still exists:
Replace CAB111 Main IO v3.
Step 4
If the issue still exists:
Replace E1106-1000 Driveunit 360.
Primary indications overview
System does not start at all.
Step 1
Charge the battery pack and check voltage and capacity with PowerTalk.*
Step 2
If the issue still exists:
Replace Batterypack.
Replace Charger.
Step 3
If the issue still exists:
Replace esense Membrane Foil (on/off button).
Step 4
If the issue still exists:
Replace CAB100 UI 2 – Box.
Step 5
If the issue still exists:
Replace esense UI 2.
Replace esense Controller Box.
* The Voltage and Remaining Capacity of the esense battery pack can be checked in PowerTalk under the “Values” tab (see for more info the PowerTalk use guide: PowerTalk screens). For esense battery packs the Relative Remaining Capacity must always be above 10% in combination with a Voltage between roughly 24-27 V. If the Voltage is lower, the battery may not have been charged for a long time or the battery pack may be broken and is not able to hold capacity for a longer period anymore.
System does not start for some time (up to a few hours).
* If a system is not able to start up for some time this may be caused by a safety procedure in the esense battery pack. NOTE: Below instruction is applicable only for systems including the esense Batterypack. Esense Basic systems (E1409-9010/-9040) are powered by alternative power sources. Refer to the service instructions of these power sources for troubleshooting information.
Step 1
Try a restart after a few hours or (if that was not successful) after (dis)connecting the charger to the mains.
Step 2
If this does not solve the issue, check PowerTalk log file and the table below to find possible causes and advised actions. **
#1 = Battery voltage too low
The battery pack was not charged for a long period or the battery is broken.
> Check with the user if the product was not charged for a long time (months), e.g. due to storage.
> Check if charging is still working. Replace the battery pack or the charger if necessary.
#2 = Discharge current too high
The current required by the Drivewheel is higher than the battery pack is able to deliver. This fault should not occur in normal use scenarios. Please contact a product specialist at Indes in case this fault is logged frequently.
#3 = Battery temperature too high
The battery pack has been too warm. This may be caused by an external or internal heating of the cells during charging.
> Thoroughly check if the battery pack is used in warm environments (> 45 deg Celcius) or if the battery pack is installed close to any heatsources.
> Replace the battery pack if both external sources can be excluded and the issue is logged frequently.
#4 = Charge voltage too high
The supply voltage of the charger is incorrect. Make sure the original esense charger is used. Replace the charger in case the fault is logged frequently.
#5 = Charge current too high
The supply current of the charger is incorrect. Make sure the original esense charger is used. Replace the charger in case the fault is logged frequently.
** The displayed number is a log for cutoff of the battery; in these situations, power from the battery is temporarily switched off by the battery electronics caused by an unusual and potentially harmful event. The log fills from right to left, so the most right number is the last event.
System switches off after a few seconds or when first pushing the sensor handles.
Step 1
Charge the battery pack and check voltage and capacity with PowerTalk.*
Step 2
If the issue still exists:
Replace Batterypack.
Replace Charger.
* The Voltage and Remaining Capacity of the esense battery pack can be checked in PowerTalk under the “Values” tab (see for more info the PowerTalk use guide: PowerTalk screens). For esense battery packs the Relative Remaining Capacity must always be above 10% in combination with a Voltage between roughly 24-27 V. If the Voltage is lower, the battery may not have been charged for a long time or the battery pack may be broken and is not able to hold capacity for a longer period anymore.
Immobilizer LED is lit.
Step 1
Check cables and switches connected to input C4 on CAB111 Main IO v3.
Step 2
If the issue still exists:
Toggle the immobilizer polarity setting with PowerTalk.
Step 3
If the issue still exists:
Replace CAB111 Main IO v3.
Keylock LED is lit.
Step 1
Unlock the keylock (magnet or 4x hidden keylock switch).
Step 2
If the issue still exists:
Change the keylock activation setting with PowerTalk.
All LED's on the interface are blinking.
Step 1
Unlock the emergency switch and reactivate the system.
Step 2
If the issue still exists:
Replace EMO switch.
Step 3
If the issue still exists:
Replace CAB100 UI 2 – Box.
Battery level indications
First battery indication LED is blinking every 30 seconds.
Step 1
Batterypack communication is lost: check if loss of functionality is acceptable. *
Step 2
If loss of functionality is not acceptable (loss of essential features): reconnect the Batterypack connector in C2 of esense Controller Box.
Step 3
If the issue still exists:
Replace Batterypack.
* Communication between the Batterypack and esense Controller Box is used for various reasons:
1. Switch off of drive functionality during charging.
2. Precise display of battery charge level (when not available, a less precise display method is used).
3. Display of charge indication.
4. Display of battery values and settings in PowerTalk.
In case these features are not considered essential, the situation may be left as is. Lost Batterypack communication may be restored by the manufacturer: contact Indes for details.
Charge indication is not started at connection of charger or mains cable.
Step 1
Check if Batterypack communication is available. *
Step 2
Check the color of the indication LED on the charger. **
Step 3
If the issue still exists:
Replace Batterypack.
* Communication between the Batterypack and esense Controller Box is used for various reasons:
1. Switch off of drive functionality during charging.
2. Precise display of battery charge level (when not available, a less precise display method is used).
3. Display of charge indication.
4. Display of battery values and settings in PowerTalk.
In case these features are not considered essential, the situation may be left as is. Lost Batterypack communication may be restored by the manufacturer. Contact Indes for details.
** The LED on the charger communicates a number of states. Most colors indicate standard charge process states, but some may indicate faults. Check the meaning of the LED color in the table below:
OFF = Charger broken or connected to mains
Possible charger fault
YELLOW = No battery connected or shortly getting ready to start charging
No fault
ORANGE = Fast charge
No fault
GREEN = Trickle charge (battery full)
No fault
ORANGE/GREEN = Error
Charger fault
Charge indication remains active after disconnection of charger or mains cable.
Step 1
Make sure the charger is disconnected from the mains.
Step 2
If the issue still exists:
Replace Batterypack.
First battery LED is blinking and a beep signal sounds every 10 seconds.
Step 1
Recharge the Batterypack.
Unexpected performance
Drive functionality remains inactive.
Step 1
Reconnect CAB029 360 Wheel – Box or CAB040 Fixed Wheel – Box.
Step 2
If the issue still exists:
Replace CAB029 360 Wheel – Box or CAB040 Fixed Wheel – Box.
Step 3
If the issue still exists:
Replace E1106-0666 Drivewheel.
Step 4
If the issue still exists:
Replace E1106-1000 Driveunit 360.
The trolley does not brake automatically when the Sensor handles are released.
Step 1
Loosen and reassemble the Sensor handles. *
Step 2
If the issue still exists:
Replace E1106-1000 Driveunit 360.
* Please refer to the Installation and maintenance manual for instructions on installation of Sensors and Sensor handles. To operate correctly the handle parts of Sensor handles shall be mounted with a free space of 1 mm around the surface of the tue they are mounted on. The tube shall have a diameter of 25 mm +/- 0.1.
The trolley drives short distances by itself.
Step 1
Evaluate the facility floor on unevenness. *
Step 2
If the issue still exists:
Check if objects near the Sensor handles risk to push or clamp on the sensor.
Step 3
If the issue still exists:
Loosen and reassemble the Sensor handles. *
Step 4
If the issue still exists:
Replace Sensor handle.
* The electric brake of the esense system is switched off when the trolley is standing still. In case the trolley is standing on an uneven or slightly sloping floor, the trolley may start moving due to gravitational force. To secure a full standstill of the trolley, the parking brakes of the trolley shall be used.
** Please refer to the Installation and maintenance manual for instructions on installation of Sensors and Sensor handles. To operate correctly the handle parts of Sensor handles shall be mounted with a free space of 1 mm around the surface of the tube they are mounted on. The tube shall have a diameter of 25 mm +/- 0.1.
The trolley cannot be moved at all.
Step 1
Check if the Drivewheel is blocked from the outside: remove any obstacles.
Step 2
If this does not solve the issue:
Replace E1106-0666 Drivewheel.
The trolley cannot easily be moved in a straight line.
Step 1
Check if the Drivewheel is blocked from the outside: remove any obstacles from the wheels and make sure the wheels can spin freely.
The Driveunit 360 does not rotate sideways when a sideways switch is pushed.
Step 1
Replace esense Membrane Foil.
