Yaskawa GPD 506-P5 User Manual

Yaskawa Electric

America

Unit Troubleshooting Manual

Section Three:

Fault Codes & Appendix

GPD 506/P5 and GPD 515/G5

(0.4 ~ 160kW)

PP.P5G5.03.Troubleshoot

Page 1

Rev. 06/11/2003

Section Three:

Fault Codes

REMOTE

SEQ

REF

OC

FOUT IOUT

FREF

MONTR

F/R

V/F

VMTR

FLA

PID

DIGITAL OPERATOR JVOP-131U

DSPL

LOCAL

REMOTE

RUN

kWout

ACCEL

DECEL

FGAIN

FBIAS

kWsav PRGM

ENTER

STOP

RESET

GPD 515/G5

GPD 505/P5 GPD 506/P5

PP.P5G5.03.Troubleshoot

Page 2

Rev. 06/11/2003

Fault Codes

The GPD 506/P5 and GPD 515/G5 inverters can store up to (4) faults.

The GPD 515/G5 inverter has a fault trace that saves the drive status
at the time of the fault, and a fault history indicating elapsed time of
the stored faults.

The fault codes can be grouped into (3) categories:



Major Fault - Motor coasts to a stop, the fault is displayed on the

digital operator, and the fault relay is activated.

 Minor Fault - Operation continues and the fault flashes on the

digital operator. The fault relay does not activate.

 Parameter Setting Error - Inverter can’t run. The fault is

displayed on the digital operator, and the fault relay is not activated.

A complete list of fault codes may be found in the appendix.

PP.P5G5.03.Troubleshoot

Page 3

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

UV1

DC Bus Undervolt

Possible Cause(s): Single phase condition on the input, low input voltage at L1, L2, and L3.

Corrective Action: Check the three phase input voltage, verify L2-05 for 515/G5 units.

UV2

CTL PS Undervolt

Possible Cause(s): External load connected pulling down the inverter power supplies.

Corrective Action: Repair or replace the power/gate drive board.

505

Uu1

Uu2

Undervoltage of the main circuit when running.

230V Units - trip point 190V DC or less.

460V Units - trip point 380V DC or less.

600V Units - trip point 546V DC or less.

Undervoltage of the control circuit when running.

230V Units - 30kW ~ 75kW, monitors the (-15V)
power supply.

460V Units - 55kW ~ 160kW, monitors the (-15V)
power supply.

PP.P5G5.03.Troubleshoot

Page 4

Rev. 06/11/2003

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

506 √ 515 √

Fault Codes

operator, and the fault relay is activated.

505

UV3

MC Answerback

 This fault only applies to 230V units 18kW ~ 75kW , 460V units 22kW ~ 160kW and

600V units 30kW ~ 160kW .

Possible Cause(s):

Corrective Action: Check the contactor, check the ribbon cable from the control board to the

gate drive board.

OV

DC Bus Overvolt

Possible Cause(s): High input voltage at L1, L2, and L3. The deceleration time is set too

short. Power factor correction capacitors are being used on the input to the inverter.

Corrective Action: Check the input circuit, verify the program parameters, add a braking

resistor, remove the power factor correction capacitors.

Uu3

Contacts on contactor are dirty, contactor does not function mechanically.

ou

The pre-charge contactor opened while the inverter is
running.

Overvoltage of the main circuit when running.

230V Units - trip point 400V DC or more.

460V Units - trip point 800V DC or more.

600V Units - trip point 1050V DC or more.

PP.P5G5.03.Troubleshoot

Page 5

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

OC

Over current

505

oc

Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.

Corrective Action: Remove the motor and run the inverter without the motor. Check the

motor for a phase to phase short. Check the inverter for a phase to phase short at the output.

Designed to protect the inverter.

Output current has exceeded OC level of the inverter
rated value instantaneously.

OC – 200%

20P4 – 2015

40P4 – 4015

51P5 - 5160

OC – 180%

2018 – 2075

4018 – 4160

GF

Ground Fault

gf

Designed to protect the inverter.

Inverter output grounding current has exceeded 50%
of the inverter rated current.

Possible Cause(s): Motor lead shorted to ground, DCCT defective.

Corrective Action: Remove the motor and run the inverter without the motor. Check the

motor for a phase to ground short. Check the output current with a clamp on meter to verify the
DCCT reading.

PP.P5G5.03.Troubleshoot

Page 6

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

SC

Short Circuit

Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.

Corrective Action: Remove the motor and run the inverter without the motor. Check the

motor for a phase to phase short. Check the inverter for a phase to phase short at the output.

PUF

DC Bus Fuse Open

Possible Cause(s): Shorted output transistor, shorted main circuit component.

Corrective Action: Remove power from the inverter and disconnect the motor. Perform the

checks without/with power starting on page 10. Replace the shorted component(s), then
replace the defective fuse.

505

sc

PUf

The inverter output is short-circuited.

Detects if the DC bus fuse has opened.

PP.P5G5.03.Troubleshoot

Page 7

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

OL1

Motor Overloaded

Possible Cause(s): Motor is overloaded.

Corrective Action: Verify the program settings, reduce the load on the motor.

OL2

Inv Overloaded

Possible Cause(s): Motor is overloaded.

Corrective Action: Verify the program settings, reduce the load on the motor.

505

ol1

ol2

Motor overload, designed to protect the motor.

Fully adjustable from parameter setting (n033 and
n034 for 506/P5 and E1-02 and E2-01 for 515/G5)

A pre-alarm can be selected as a minor fault by using
the multi-function outputs.

Inverter overload, designed to protect the inverter.

120 or150% of inverter rated current for 1 minute.

515 - 150% for 1 minute

505 and 506 - 120% or 150% depending on drive

capacity and setting parameter n116

PP.P5G5.03.Troubleshoot

Page 8

Rev. 06/11/2003

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

506 √ 515 √

Fault Codes

operator, and the fault relay is activated.

505

OL3

Overtorque Det 1

Possible Cause(s): Motor is overloaded.

Corrective Action: Verify the program settings, reduce the load on the motor.

506 515 √

OL4

Overtorque Det 2

Possible Cause(s): Motor is overloaded.

Corrective Action: Verify the program settings, reduce the load on the motor.

ol3

505

N/A

Over torque detection function.

A customer programmable current detection. Response
may be selected. A minor fault contact output can be
programmed by using the multi-function outputs.

Over torque detection function (2).

A customer programmable current detection.
Response may be selected. A minor fault contact
output can be programmed by using the multi-function
outputs.

PP.P5G5.03.Troubleshoot

Page 9

Rev. 06/11/2003

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

506 √ 515 √

Fault Codes

operator, and the fault relay is activated.

505

PF

Input Pha Loss

Possible Cause(s): Open phase on the input of the inverter. Loose terminal screws at

terminals L1, L2, or L3. Program parameters set incorrectly (n083 for 506/P5, L8-05 for 515/G5)

Corrective Action: Tighten the terminal screws, check the input voltage, verify the program

settings.

506 515 √

LF

Output Pha Loss

Possible Cause(s): Open phase on the output of the inverter. Loose terminal screws at

terminals T1, T2, or T3. Program parameters set incorrectly.

Corrective Action: Tighten the terminal screws, check the output voltage, verify the

program settings.

sp1

505

spo

Inverter input power supply has an open phase.

Large imbalance of input voltage.

Inverter output has an open phase.

PP.P5G5.03.Troubleshoot

Page 10

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

OS

Overspeed Det

Possible Cause(s): The load has changed considerably, the program settings may not be

set correctly.

Corrective Action: Check the load on the motor, verify the program settings (F1-08 PG

Overspeed Level, and F1-09 PG Overspeed Time).

506 515 √

PGO

PG open

Possible Cause(s): The Pulse Generator feedback wires may be broken or not properly

connected to the PG feedback option board.

Corrective Action: Check for a broken wire or a loose connection from the Pulse

Generator, verify the program settings.

505

N/A

505

N/A

The motor speed has exceeded the overspeed level
when operating in the Closed Loop V/f or Closed
Loop Flux Vector modes.

Feedback pulses are not received by the PG option
board.

PP.P5G5.03.Troubleshoot

Page 11

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

RR

DynBrk Transistr

Possible Cause(s):

resistor.

Corrective Action: Replace defective transistor or resistor, monitor DC bus level.

RH

DynBrk Resistor

Possible Cause(s): Overhauling load, extended braking duty cycle, defective braking

resistor.

Corrective Action: Verify braking duty cycle, monitor DC bus voltage, replace resistor.

Shorted braking transistor, high DC bus voltage, defective braking

505

N/A

N/A

The braking transistor has failed.

230V Units - 0.4kW ~ 7.5kW

460V Units - 0.4kW ~ 15kW

The braking resistor temperature has exceeded the
allowable value.

(Protects Yaskawa 3% duty cycle resistors only)

Can be selected as a minor fault by using the multi­function outputs.

PP.P5G5.03.Troubleshoot

Page 12

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

CF

Out of Control

Possible Cause(s): The regen torque limit value is set too low, load torque is excessively

large.

Corrective Action: Verify the program setting, L7-03 forward regen torque limit and L7-04

reverse regen torque limit, extend the deceleration time.

SVE

Zero Servo Fault

Possible Cause(s): Torque limit or zero servo gain set too low, load torque excessively

large, PG signal noise.

Corrective Action: Verify the program parameters B9-01 zero servo gain and torque limit

settings L7-01 ~ L7-02, check for noise on the PG signals.

505

N/A

N/A

The actual torque during deceleration has reached
the regen torque limit for more than 3 seconds.
(Open Loop Flux Vector mode only)

In the zero servo mode, the motor shaft has
rotated 10,000 non-quadrature PG pulses from the
home position.

PP.P5G5.03.Troubleshoot

Page 13

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

OH1

Heatsnk MAX Temp

Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.

Corrective Action: Check for dirt build-up on the fans, reduce the ambient temperature

around the inverter.

OPR

Oper Disconnect

Possible Cause(s):

Corrective Action: Attach the digital operator, check the cable connected to the digital operator,

verify the program setting of parameter O2-06 for 515/G5 models and n112 for 506/P5 models.

The operator is not attached, broken operator cable.

505

oh2

op

The transistor cooling fin temperature exceeded the
allowable value. 506/P5 (105 ° C), 515/G5 (105 ° C)

The inverter will stop if the digital operator is removed
when the inverter is commanded to run through the
digital operator.

PP.P5G5.03.Troubleshoot

Page 14

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

E-10

SI-F/G CPU down

Possible Cause(s): Defective option board, electrical noise effecting operation.

Corrective Action: Cycle power, replace the option board.

E-15

SI-F/G Com Err

Possible Cause(s): Connection is broken, master has stopped communicating.

Corrective Action: Check all connections, verify all user side software configurations.

♣ E-10 and E-15 fault codes may only appear when using the OMRON specification (O2-09=3).

505

N/A

N/A

The CPU on the SI-F/G option board has stopped
operating.

After initial communication has been established, the
connection was then lost.

Response may be selected.

♣

♣

PP.P5G5.03.Troubleshoot

Page 15

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

BUS

SI-B Com Err

Possible Cause(s): Connection is broken, master has stopped communicating.

Corrective Action: Check all connections, verify all user side software configurations.

506 √ 515 √

CE

Memobus Com Err

Possible Cause(s): Connection is broken, master has stopped communicating.

Corrective Action: Check all connections, verify all user side software configurations.

505

N/A

505

ce

After initial communication has been established, the
connection was then lost.

Response may be selected.

Transmission error. Control data was not received
normally when the power supply is turned on.

Response may be selected.

PP.P5G5.03.Troubleshoot

Page 16

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

EF3

External Fault3

Possible Cause(s): An external fault condition exists connected to terminal number 3.

Corrective Action: Check for an external condition, verify the program parameters.

EF4~8

External Fault

Possible Cause(s): An external fault condition exists connected to one of the terminals 4,

5, 6, 7, or 8.

Corrective Action: Check for an external condition, verify the program parameters.

505

ef3

ef4

~6

External fault at terminal number 3.

External fault at the multi-function inputs terminal
number 4 ~ 8. 506 is the same as 505 and only has
EF 4-6.

PP.P5G5.03.Troubleshoot

Page 17

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

EF0

External Fault

Possible Cause(s): An external fault condition exists.

Corrective Action: Check for an external condition, verify the program parameters.

506 √ 515

EF2

External Fault

Possible Cause(s): An external fault condition exists at terminal S2.

Corrective Action: Check for an external condition at terminal S2, verify the program

parameters.

505

ef0

505

ef2

External fault from serial communication.

External fault at the multi-function input terminal
number S2.

PP.P5G5.03.Troubleshoot

Page 18

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

DEV

Speed Deviation

Possible Cause(s): The load has changed considerably.

Corrective Action: Check the load on the motor, verify the program settings (F1-10 PG

Deviate Level, F1-11 PG Deviate Time. F1-04 PG Deviation Select.

ERR

EEPROM R/W Err

Possible Cause(s): Control board hardware failure.

Corrective Action: Cycle power, replace the control board.

505

N/A

N/A

The deviation of the speed reference and speed
feedback has exceeded the regulation level.

A minor fault contact output can be programmed by
using the multi-function outputs.

EEPROM internal data does not match the value in
RAM when setting a parameter.

PP.P5G5.03.Troubleshoot

Page 19

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 √ 515 √

CPF00

Com-Err(OP&INV)

Possible Cause(s): Digital operator cable not securely connected, digital operator

defective, control board defective.

Corrective Action: Check the operator cable, replace the digital operator, replace the

control board.

CPF01

Com-Err(OP&INV)

Possible Cause(s): Digital operator cable not securely connected, digital operator

defective, control board defective.

Corrective Action: Check the digital operator cable, replace the digital operator, replace

the control board.

505

cpf0

cpf1

Transmission between the inverter and the operator
cannot be established 5 seconds after supplying
power.

Communication fault between the inverter and the
operator has occurred for more than 2 seconds.

PP.P5G5.03.Troubleshoot

Page 20

Rev. 06/11/2003

Fault Codes

Major Fault - Motor coasts to a stop, the fault is displayed on the digital

operator, and the fault relay is activated.

506 515 √

CPF02

BB Circuit Err

Possible Cause(s):

Corrective Action: Perform a factory initialization, cycle power, replace the control board.

506 √ 515 √

CPF03

EEPROM Error

Possible Cause(s): Noise or spike on the control input terminals.

Corrective Action: Perform a factory initialization , cycle power, replace the control board.

Gate array hardware failure during power up.

505

N/A

505

cpf4

Baseblock circuit fault at power up.

EEPROM fault, check sum not valid. 506 digital
operator will display CPF04.

PP.P5G5.03.Troubleshoot

Page 21

Rev. 06/11/2003