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
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REMOTE |
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SEQ |
REF |
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OC |
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FREF |
FOUT |
IOUT |
kWout |
F/R |
MONTR |
ACCEL |
DECEL |
VMTR |
V/F |
FGAIN |
FBIAS |
FLA |
PID |
kWsav |
PRGM |
DIGITAL OPERATOR JVOP-131U |
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DSPL |
ENTER |
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LOCAL |
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REMOTE |
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RUN |
STOP |
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RESET |
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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
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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 √ |
505 |
Undervoltage of the main circuit when running. |
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UV1 |
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230V Units - trip point 190V DC or less. |
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Uu1 |
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DC Bus Undervolt |
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460V Units - trip point 380V DC or less. |
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600V Units - trip point 546V DC or less.
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 |
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Undervoltage of the control circuit when running. |
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Uu2 |
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CTL PS Undervolt |
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230V Units - 30kW ~ 75kW, monitors the (-15V) |
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power supply. |
460V Units - 55kW ~ 160kW, monitors the (-15V) power supply.
Possible Cause(s): External load connected pulling down the inverter power supplies.
Corrective Action: Repair or replace the power/gate drive board.
PP.P5G5.03.Troubleshoot
Page 4
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 √ |
505 |
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UV3 |
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Uu3 |
The pre-charge contactor opened while the inverter is |
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MC Answerback |
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running. |
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This fault only applies to 230V units 18kW ~ 75kW , 460V units 22kW ~ 160kW and 600V units 30kW ~ 160kW .
Possible Cause(s): Contacts on contactor are dirty, contactor does not function mechanically.
Corrective Action: Check the contactor, check the ribbon cable from the control board to the gate drive board.
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Overvoltage of the main circuit when running. |
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OV |
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ou |
230V |
Units - trip point 400V DC or more. |
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DC Bus Overvolt |
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460V |
Units - trip point 800V DC or more. |
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600V |
Units - trip point 1050V DC or more. |
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.
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
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OC |
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oc |
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Over current |
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Designed to protect the inverter.
Output current has exceeded OC level of the inverter rated value instantaneously.
OC – 200% |
OC – 180% |
20P4 – 2015 |
2018 – 2075 |
40P4 – 4015 |
4018 – 4160 |
51P5 - 5160 |
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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.
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
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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 √ |
505 |
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SC |
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sc |
The inverter output is short-circuited. |
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Short Circuit |
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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
PUf |
Detects if the DC bus fuse has opened. |
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.
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
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Motor overload, designed to protect the motor. |
OL1 |
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ol1 |
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Fully adjustable from parameter setting (n033 and |
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Motor Overloaded |
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n034 for 506/P5 and E1-02 and E2-01 for 515/G5) |
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A pre-alarm can be selected as a minor fault by using
the multi-function outputs. Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
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Inverter overload, designed to protect the inverter. |
OL2 |
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ol2 |
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120 or150% of inverter rated current for 1 minute. |
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Inv Overloaded |
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515 - 150% for 1 minute |
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505 and 506 - 120% or 150% depending on drive |
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capacity and setting parameter n116 |
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
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OL3 |
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Over torque detection function. |
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ol3 |
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Overtorque Det 1 |
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A customer programmable current detection. Response |
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may be selected. A minor fault contact output can be |
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programmed by using the multi-function outputs. |
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Possible Cause(s): Motor is overloaded. |
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Corrective Action: Verify the program settings, reduce the load on the motor. |
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506 |
515 √ |
505 |
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OL4 |
N/A |
Over torque detection function (2). |
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Overtorque Det 2 |
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A customer programmable current detection. Response may be selected. A minor fault contact output can be programmed by using the multi-function outputs.
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
PP.P5G5.03.Troubleshoot
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Rev. 06/11/2003
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
506 √ |
515 √ |
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operator, and the fault relay is activated. |
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505 |
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PF |
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Inverter input power supply has an open phase. |
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sp1 |
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Input Pha Loss |
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Large imbalance of input voltage. |
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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 √ |
505 |
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LF |
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spo |
Inverter output has an open phase. |
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Output Pha Loss |
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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.
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
The motor speed has exceeded the overspeed level |
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OS |
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N/A |
when operating in the Closed Loop V/f or Closed |
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Overspeed Det |
Loop Flux Vector modes. |
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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 √ |
505 |
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PGO |
N/A |
Feedback pulses are not received by the PG option |
PG open |
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board. |
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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.
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 √ |
505 |
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The braking transistor has failed. |
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RR |
N/A |
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DynBrk Transistr |
230V |
Units - 0.4kW ~ 7.5kW |
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460V |
Units - 0.4kW ~ 15kW |
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Possible Cause(s): Shorted braking transistor, high DC bus voltage, defective braking resistor.
Corrective Action: Replace defective transistor or resistor, monitor DC bus level.
RH |
N/A |
The braking resistor temperature has exceeded the |
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DynBrk Resistor |
allowable value. |
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(Protects Yaskawa 3% duty cycle resistors only)
Can be selected as a minor fault by using the multifunction outputs.
Possible Cause(s): Overhauling load, extended braking duty cycle, defective braking resistor.
Corrective Action: Verify braking duty cycle, monitor DC bus voltage, replace resistor.
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
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CF |
N/A |
The actual torque during deceleration has reached |
Out of Control |
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the regen torque limit for more than 3 seconds. |
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(Open Loop Flux Vector mode only)
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 |
N/A |
In the zero servo mode, the motor shaft has |
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Zero Servo Fault |
rotated 10,000 non-quadrature PG pulses from the |
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home position. |
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.
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 √ |
505 |
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The transistor cooling fin temperature exceeded the |
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OH1 |
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oh2 |
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Heatsnk MAX Temp |
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allowable value. 506/P5 (105 ° C), 515/G5 (105 ° C) |
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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 |
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Oper Disconnect |
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op |
The inverter will stop if the digital operator is removed |
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when the inverter is commanded to run through the |
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digital operator. |
Possible Cause(s): The operator is not attached, broken operator cable.
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.
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 √ |
505 |
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E-10 |
N/A |
The CPU on the SI-F/G option board has stopped |
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SI-F/G CPU down |
operating. ♣ |
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Defective option board, electrical noise effecting operation.
Cycle power, replace the option board.
E-15 |
N/A |
After initial communication has been established, the |
SI-F/G Com Err |
connection was then lost. ♣ |
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Response may be selected. |
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).
PP.P5G5.03.Troubleshoot
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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 √ |
505 |
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BUS |
N/A |
After initial communication has been established, the |
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SI-B Com Err |
connection was then lost. |
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Response may be selected.
Possible Cause(s): Connection is broken, master has stopped communicating.
Corrective Action: Check all connections, verify all user side software configurations.
506 √ 515 √ |
505 |
Transmission error. Control data was not received |
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CE |
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ce |
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Memobus Com Err |
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normally when the power supply is turned on. |
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Response may be selected. |
Possible Cause(s): Connection is broken, master has stopped communicating.
Corrective Action: Check all connections, verify all user side software configurations.
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 √ |
505 |
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EF3 |
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ef3 |
External fault at terminal number 3. |
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External Fault3 |
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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
ef4
~6
External fault at the multi-function inputs terminal number 4 ~ 8. 506 is the same as 505 and only has EF 4-6.
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.
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 √ |
505 |
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EF0 |
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External fault from serial communication. |
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ef0 |
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External Fault |
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Possible Cause(s): An external fault condition exists.
Corrective Action: Check for an external condition, verify the program parameters.
506 √ 515 |
505 |
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EF2 |
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External fault at the multi-function input terminal |
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ef2 |
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number S2. |
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External Fault |
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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.
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 √ 505
DEV |
N/A |
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Speed Deviation |
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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.
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 |
N/A |
EEPROM internal data does not match the value in |
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EEPROM R/W Err |
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RAM when setting a parameter. |
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Possible Cause(s): Control board hardware failure.
Corrective Action: Cycle power, replace the control board.
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 √ |
505 |
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CPF00 |
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Transmission between the inverter and the operator |
Com-Err(OP&INV) |
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cpf0 |
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cannot be established 5 seconds after supplying |
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power. |
Possible Cause(s): Digital operator cable not securely connected, digital operator defective, control board defective.
Corrective Action: control board.
CPF01
Com-Err(OP&INV)
Check the operator cable, replace the digital operator, replace the
cpf1 |
Communication fault between the inverter and the |
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operator has occurred for more than 2 seconds. |
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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.
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 √ |
505 |
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CPF02 |
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N/A |
Baseblock circuit fault at power up. |
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BB Circuit Err |
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Gate array hardware failure during power up.
Perform a factory initialization, cycle power, replace the control board.
506 √ 515 √ |
505 |
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CPF03 |
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cpf4 |
EEPROM fault, check sum not valid. 506 digital |
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EEPROM Error |
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operator will display CPF04. |
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Noise or spike on the control input terminals.
Perform a factory initialization , cycle power, replace the control board.
PP.P5G5.03.Troubleshoot
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Rev. 06/11/2003
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