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The following is a comprehensive list of fault codes associated with the Allen Bradley PowerFlex 527 drive system. These codes are crucial for diagnosing and troubleshooting various issues that may arise during the operation of the drive. Understanding these fault codes can help in maintaining optimal performance and ensuring the longevity of the equipment.
| Code | Description | Recommended Action |
|---|---|---|
| FLT M10 – CONTROL MODULE OVERTEMPERATURE FL | Control Module Overtemperature Fault |
PROBLEM: The temperature sensor on the Main Control Board detected excessive heat. |
| FLT M19 – DECEL OVERRIDE | Decel Override |
PROBLEM: The drive is not following a commanded deceleration because it is attempting to limit bus voltage. |
| FLT M21 – MOTOR TEST FAILURE | Motor Test Failure |
PROBLEM: The Motor Test procedure has failed. |
| FLT M26 – RUNTIME ERROR | Runtime Error |
PROBLEM: The drive firmware encountered an unrecoverable runtime error. |
| FLT M28 – SAFETY MODULE COM ERROR | Safety Module Communication Error | PROBLEM: Error in communicating to the Safety module. SOLUTION: • Cycle power. • Replace module. |
| FLT S03 – MTR OVERSPEED FL | Motor Overspeed Factory Limit Fault | PROBLEM: Motor speed has exceeded 590 Hz. SOLUTION: • Check control loop tuning. |
| FLT S04 – MTR OVERSPEED UL | Motor Overspeed User Limit Fault | PROBLEM: Motor speed has exceeded the user defined speed limit that is given by Motor Overspeed User Limit. SOLUTION: • Check control loop tuning. |
| FLT S07 – MTR OVERLOAD FL | Motor Thermal Overload Factory Limit Fault | PROBLEM: The motor thermal model has exceeded its factory set thermal capacity limit of 110%. SOLUTION: • Modify the command profile to reduce speed or increase time. |
| FLT S08 – MTR OVERLOAD UL | Motor Thermal Overload User Limit Fault | PROBLEM: The motor thermal model has exceeded the thermal capacity limit that is given by Motor Thermal Overload User Limit. SOLUTION: • Modify the command profile. • Increase the Motor Thermal Overload UL attribute value. |
| FLT S10 – INV OVERCURRENT | Inverter Overcurrent Fault | PROBLEM: Inverter current has exceeded the instantaneous current limit (determined by hardware). SOLUTION: • Check motor power cable for shorts. • Verify that motor windings are not shorted. • Verify motor power wire gauge. • Operate within the continuous power rating. • Reduce acceleration times. |
| FLT S11 – INV OVERTEMP FL | Inverter Overtemperature Factory Limit Fault | PROBLEM: The measured inverter temperature has exceeded the factory set temperature limit. SOLUTION: • Modify the command profile to reduce speed or increase time. • Reduce drive ambient temperature. • Verify that airflow through drive is not obstructed. |
| FLT S13 – INV OVERLOAD FL | Inverter Thermal Overload Factory Limit Fault | PROBLEM: The thermal model for the power transistors indicates that the temperature has exceeded the factory set thermal capacity rating of 110%. SOLUTION: • Modify the command profile to reduce speed or increase time. |
| FLT S16 – GROUND CURRENT | Ground Current Factory Limit Fault | PROBLEM: The sensing circuitry in the power stage has detected excessive ground current. SOLUTION: • Check motor power wiring; check power cable for shorts. • Replace motor if the fault persists. |
| FLT S23 – AC PHASE LOSS | AC Single Phase Loss Fault | PROBLEM: A single AC input phase was lost while the drive was enabled. SOLUTION: • Check AC input voltage on all phases. |
| FLT S25 – PRECHARGE FAILURE | Pre-charge Failure Fault | PROBLEM: The pre-charge circuit monitoring algorithm detected that the DC bus did not reach a factory set voltage level after charging for a period of time. SOLUTION: • Check AC input voltage on all phases. • Check input power wiring. • Replace drive if fault persists. |
| FLT S29 – BUS OVERLOAD FL | Bus Regulator Thermal Overload Factory Limit Fault | PROBLEM: The shunt thermal model has exceeded its factory set thermal capacity limit. SOLUTION: • Modify the duty cycle of the application. • Add external shunt for additional capacity. • Add capacitor module if needed. |
| FLT S34 – BUS UNDERVOLT UL | Bus Undervoltage User Limit Fault | PROBLEM: DC Bus voltage level is below the user set limit as given by Bus Undervoltage User Limit. SOLUTION: • Verify voltage level of the incoming AC. • Monitor AC power source for glitches or line droop. • Install UPS on AC input. • Decrease Bus Undervoltage UL attribute value. |
| FLT S35 – BUS OVERVOLT FL | Bus Overvoltage Factory Limit Fault | PROBLEM: DC Bus voltage level is above the factory set limit as determined by the configured input voltage. SOLUTION: • Change the deceleration or motion profile of all drives that are connected to the DC bus. • Unplug the shunt connector and measure the resistance of the shunt. • Replace drive if shunt resistor is open. |
| FLT S37 – BUS POWER LOSS | Bus Power Loss | PROBLEM: DC Bus voltage level is below the Bus Power Loss Threshold for more than the timeout period specified Bus Power Loss Time value. SOLUTION: • Verify voltage level of the incoming AC. • Monitor AC power source for glitches or line droop. • Install UPS on AC input. |
| FLT S41 – FDBK SIGNAL NOISE FL | Feedback Signal Noise Fault | PROBLEM: Noise induced A/B channel state changes (illegal states) from a feedback device were detected by the drive. Specifically, the number of these noise events that have occurred on this channel has exceeded the Feedback Noise Factory Limit. The offending feedback channel number is encoded in the associated Fault/Alarm Sub Code. SOLUTION: • Check motor feedback cable and connector. • Cycle power. • Check feedback shield connection. • Reduce shock and vibration to motor. • Replace motor if fault continues. • Verify all HTL/TTL DIP switches on the 25-ENC-2/B encoder are set in the same position. |
| FLT S43 – FDBK SIG FL | Feedback Signal Loss Factory Limit Fault | PROBLEM: The absolute value of the differential A/B signals is below a factory limit. SOLUTION: • Check motor feedback cable and connector. • Check that motor power cable and feedback wire shields are secured correctly. • Check that motor frame is grounded correctly. |
| FLT S50 – HARDWARE OVERTRAVEL POSITIVE | Hardware Overtravel Positive | PROBLEM: Axis moved beyond the physical travel limits in the positive direction and activated the Positive Overtravel limit switch. SOLUTION: • Check wiring. • Verify motion profile. • Verify axis configuration in software. |
| FLT S51 – HARDWARE OVERTRAVEL NEGATIVE | Hardware Overtravel Negative | PROBLEM: Axis moved beyond the physical travel limits in the negative direction and activated the Negative Overtravel limit switch. SOLUTION: • Check wiring. • Verify motion profile. • Verify axis configuration in software. |
| FLT S54 – POSN ERROR | Excessive Position Error Fault | PROBLEM: The position error of the position control loop has exceeded the value that is given by Position Error Tolerance for a time period that is given by Position Error Tolerance Time. SOLUTION: • Check position loop tuning. • Increase the feedforward gain. • Verify sizing of the drive and motor. • Check motor power wiring. • Increase Position Error Tolerance and/or Position Error Tolerance Time attribute values. |
| FLT S55 – VEL ERROR | Excessive Velocity Error Fault | PROBLEM: The velocity error of the velocity control loop has exceeded the value that is given by Velocity Error Tolerance for a time period that is given by Velocity Error Tolerance Time. SOLUTION: • Check velocity loop tuning. • Reduce acceleration. • Verify sizing of the drive and motor. • Check motor power wiring. • Increase Velocity Error Tolerance and/or Velocity Error Tolerance Time attribute values |
| FLT S56 – OVERTORQUE LIMIT | Overtorque Limit Fault | PROBLEM: Motor torque has risen above user-defined maximum torque level that is given by Overtorque Limit for a time period that is given by Overtorque Limit Time. SOLUTION: • Verify Torque Trim value. • Verify motion profile • Verify sizing of the drive and motor. • Increase Overtorque Limit and/or Overtorque Limit Time attribute values. |
| FLT S57 – UNDERTORQUE LIMIT | Undertorque Limit Fault | PROBLEM: Motor torque has dropped below user defined minimum torque level that is given by Undertorque Limit for a time period that is given by Undertorque Limit Time. SOLUTION: • Verify motion profile. • Verify sizing of the drive and motor. • Decrease Undertorque Limit and/or Undertorque Limit Time attribute values |
| FLT S61 – ENABLE INPUT DEACTIVATED | Enable Input Deactivated | PROBLEM: Enable Input has been deactivated while the axis power structure is in Running state, enabled, and supplying current to the DC Bus or motor. SOLUTION: • Verify Enable Input level. • Check Enable Input wiring. |
| INHIBIT M05 – SAFE TORQUE OFF | Start Inhibit – Safe Torque Off | PROBLEM: The safety function has disabled the power structure. SOLUTION: • Check safety input wiring. • Check state of safety devices. |
| INHIBIT S01 – AXIS ENABLE INPUT | Axis Enable Input | PROBLEM: Axis Enable Input is not active. SOLUTION: • Verify Enable Input level. • Check Enable Input wiring |
| INHIBIT S02 – MOTOR NOT CONFIGURED | Motor Not Configured | PROBLEM: The motor has not been properly configured for use. SOLUTION: • Verify motor configuration in the Studio 5000 Logix Designer application. |
| INHIBIT S05 – SAFE TORQUE OFF | Start Inhibit – Safe Torque Off | PROBLEM: The safety function has disabled the power structure. SOLUTION: • Check that Ethernet components such as cables are secured and switches are operational. • Check state of safety devices. |
| INIT FLT M14 – INVALID SAFETY FIRMWARE | Invalid Safety Firmware | PROBLEM: The safety firmware is not compatible with the drive firmware, or the main safety firmware is missing. SOLUTION: • Cycle power. • Upgrade drive firmware. • Return drive for repair if fault continues. |
| INIT FLT M15 – POWER BOARD | Power Board Checksum Error | PROBLEM: The power board has a checksum error. SOLUTION: • Cycle power. • Reset the drive. • Return drive for repair if fault continues. |
| INIT FLT M22 – ILLEGAL ADDRESS | Illegal IP Address Configuration | PROBLEM: Invalid Ethernet IP Address configuration or device Node Address is out of range (>254) For example, this fault will occur when the IP address and Gateway address are identical. When this fault occurs, IP address configuration will be changed to DHCP SOLUTION: • Change IP address, subnet mask, and gateway address to a legal configuration and cycle power. |
| INIT FLT S03 – NVMEM CHKSUM | Nonvolatile Memory Checksum Error | PROBLEM: Data in the nonvolatile memory has a checksum error. SOLUTION: • Cycle power. • Reset the drive. • Return drive for repair if fault continues. |
| NODE ALARM 01 – LATE CTRL UPDATE | Control Connection Update Alarm | PROBLEM: Updates from the controller have been late. SOLUTION: • Remove unnecessary network devices from the motion network. • Change network topology so that fewer devices share common paths. • Use high-performance network equipment. • Use shielded cables. • Separate signal wiring from power wiring. |
| NODE ALARM 03 – CLOCK JITTER | Clock Jitter Alarm | PROBLEM: The sync variance has exceeded the sync threshold while the device is running in sync mode. SOLUTION: • Check the Ethernet connection. • Check controller and Ethernet switch operation. |
| NODE ALARM 04 – CLOCK SKEW ALARM | Clock Skew Alarm | PROBLEM: The controller time and the drive system time are not the same. SOLUTION: • Check the Ethernet connection. • Check controller and Ethernet switch operation. |
| NODE ALARM 05 – CLOCK SYNC ALARM | Clock Sync Alarm | PROBLEM: Drive local clock has lost synchronization with controller's clock for a short time during synchronous operation. SOLUTION: • Check the Ethernet connection. • Check controller and Ethernet switch operation. |
| NODE FLT 01 – LATE CTRL UPDATE | Control Connection Update Fault | PROBLEM: Several consecutive updates from the controller have been lost. SOLUTION: • Remove unnecessary network devices from the motion network. • Change network topology so that fewer devices share common paths. • Use high-performance network equipment. • Use shielded cables. • Separate signal wiring from power wiring. |
| NODE FLT 02 – PROC WATCHDOG nn | Processor Watchdog Fault | PROBLEM: The processor on the power board or control board failed to update in a certain amount of time. The nn sub-codes 00…05 are internal and result in the same possible solution. SOLUTION: • Cycle power. • Update the drive firmware. • Return drive for repair if fault continues. |
| NODE FLT 03 – HARDWARE 00 | Hardware Fault - PwrIF | PROBLEM: Communication with the power board could not be established. SOLUTION: • Cycle power. • Update the drive firmware. • Return drive for repair if fault continues. |
| NODE FLT 03 – HARDWARE 01 | Hardware Fault - Piccolo HW | PROBLEM: DSP chip on the power board failure. SOLUTION: • Cycle power. • Return motor for repair if fault continues. |
| NODE FLT 05 – CLOCK SKEW FLT | Clock Skew Fault | PROBLEM: The controller time and the drive system time are not the same. SOLUTION: • Cycle power. • Check controller and Ethernet switch operation. |
| NODE FLT 06 – LOST CTRL CONN | Lost Controller Connection Fault | PROBLEM: Communication with the controller has been lost. SOLUTION: • Check Ethernet connection. • Check controller and Ethernet switch operation. |
| NODE FLT 07 – CLOCK SYNC | Clock Sync Fault | PROBLEM: Drive local clock has lost synchronization with controller's clock and was not able to resynchronize within allotted time. SOLUTION: • Check Ethernet connection. • Check controller and Ethernet switch operation. |
| NODE FLT 09 – DUPLICATE IP ADDRESS | Duplicate IP Address Fault | PROBLEM: Several consecutive updates from the controller have been lost. SOLUTION: • Select an IP address not already in use on the network. |