Fault
Fault
Fault Codes
The fault code tables are designed to help you determine the source of the fault or
exception. When a fault condition is detected, the drive performs the appropriate
fault action, the fault is displayed, and the fault is added to a persistent fault log
(along with diagnostics data). The earlier faults have priority to be displayed.
The drive removes the fault text from the display when a Fault Reset service is
sent from the controller and the fault is no longer active. If a fault is still active
following a Fault Reset service, the fault is again posted to the display and written
to the fault log.
Fault Code Summary
Fault Code Type Description
FLT Sxx Standard runtime axis exceptions.
FLT Mxx
INIT FLT Sxx Exceptions that prevent normal operation and occur during the initialization process.
INIT FLT Mxx
INHIBIT Sxx Exceptions that prevent normal operation and indicate whenever the drive is active.
INHIBIT Mxx
NODE FLTxx Exceptions that prevent normal operation of the drive.
NODE ALARM xx Exceptions that prevent normal operation of the drive, but do not result in any action other
than reporting the alarm to the controller.
TIP Fault codes triggered by conditions that fall outside factory set limits are
identified by FL at the end of the display message. For example, FLT S07 – MTR
OVERLOAD FL.
Fault codes triggered by conditions that fall outside user set limits are
identified by UL at the end of the display message. For example, FLT S08 – MTR
OVERLOAD UL.
The fault status indicator is located between the LCD display and keypad. There
are also four status indicators located at the bottom right of the drive and can be
seen through the front cover of the control module.
Fault status
Module status
Network status
Link A status (Ethernet port 1)
Link B status (Ethernet port 2)
General Troubleshooting These conditions do not always result in a fault code, but can require
troubleshooting to improve performance.
General Troubleshooting
Condition Potential Cause Possible Resolution
Axis or system is unstable. The position feedback device is incorrect or open. Check wiring.
Motor tuning limits are set too high. Run Tune in the Logix Designer application.
Position loop gain or position controller accel/decel rate is improperly set. Run Tune in the Logix Designer application.
Improper grounding or shielding techniques are causing noise to be Check wiring and ground.
transmitted into the position feedback or velocity command lines, causing
erratic axis movement.
Motor Data is incorrectly set (induction motor is not matched to axis module). • Check setups.
• Run Motor Test in the Logix Designer application.
Mechanical resonance. Notch filter or output filter can be required (refer to Axis
Properties dialog box, Output tab in the Logix Designer
application).
You cannot obtain the motor Torque Limit limits are set too low. Verify that torque limits are set properly.
acceleration/deceleration that you Incorrect motor selected in configuration. Select the correct motor and run Tune in the Logix Designer
want.
application again.
The system inertia is excessive. • Check motor size versus application need.
• Review induction system sizing.
The system friction torque is excessive. Check motor size versus application need.
Available current is insufficient to supply the correct accel/decel rate. • Check motor size versus application need.
• Review induction system sizing.
Acceleration limit is incorrect. Verify limit settings and correct them, as necessary.
Velocity Limit limits are incorrect. Verify limit settings and correct them, as necessary.
Motor does not respond to a The motor wiring is open. Check the wiring.
command. The motor cable shield connection is improper. • Check feedback connections.
• Check cable shield connections.
The motor has malfunctioned. Repair or replace the motor.
The coupling between motor and machine has broken (for example, the Check and correct the mechanics.
motor moves, but the load/machine does not).
Primary operation mode is set incorrectly. Check and properly set the limit.
Velocity or torque limits are set incorrectly. Check and properly set the limits.
Brake connector not wired Check brake wiring
General Troubleshooting
Condition Potential Cause Possible Resolution
Presence of noise on command or Recommended grounding per installation instructions have not been • Verify grounding.
motor feedback signal wires. followed. • Route wire away from noise sources.
• See System Design for the Control of Electrical Noise,
publication GMC-RM001.
Line frequency can be present. • Verify grounding.
• Route wire away from noise sources.
Variable frequency can be velocity feedback ripple or a disturbance caused by • Decouple the motor for verification.
gear teeth or ballscrew, and so forth. The frequency can be a multiple of the • Check and improve mechanical performance, for example,
motor power transmission components or ballscrew speeds resulting in the gearbox or ballscrew mechanism.
velocity disturbance.
No rotation The motor connections are loose or open. Check motor wiring and connections.
Foreign matter is lodged in the motor. Remove foreign matter.
The motor load is excessive. Verify the induction system sizing.
The bearings are worn. Return the motor for repair.
The motor brake is engaged (if supplied). • Check brake wiring and function.
• Return the motor for repair.
The motor is not connect to the load. Check coupling.
Motor overheating The duty cycle is excessive. Change the command profile to reduce accel/decel or increase
time.
The rotor is partially demagnetized causing excessive motor current. Return the motor for repair.
Abnormal noise Motor tuning limits are set too high. Run Tune in the Logix Designer application.
Loose parts are present in the motor. • Remove the loose parts.
• Return motor for repair.
• Replace motor.
Through bolts or coupling is loose. Tighten bolts.
The bearings are worn. Return motor for repair.
Mechanical resonance. Notch filter can be required (See Axis Properties dialog box,
Output tab in the Logix Designer application).
Erratic operation - Motor locks into Motor power phases U and V, U and W, or V and W reversed. Check and correct motor power wiring.
position, runs without control or with
reduced torque.
Logix5000 Controller and By using the Logix Designer application, you can configure how the
PowerFlex 527 drives respond when a drive fault/exception occurs.
Drive Behavior
TIP The INIT FLT xxx faults are always generated after powerup, but before the
drive is enabled, so the stopping behavior does not apply.
NODE ALARM xxx faults do not apply because they do not trigger stopping
behavior.
The drive supports fault action for Ignore, Alarm, Minor Fault, and Major Fault
as defined in PowerFlex 527 Drive Exception Action Definitions on page 128.
See the drive behavior tables beginning on page 129 for information on how the
fault and stopping actions apply to each of the exception fault codes.
For PowerFlex 527 drives, you can configure exception behavior in the
Logix Designer application from the Axis Properties dialog box, Actions
category.
PowerFlex 527 Drive Exception Action Definitions
Exception Action Definition
Ignore The controller completely ignores the exception condition. For some exceptions that are
fundamental to the operation of the planner, Ignore is not an available option.
Alarm The controller sets the associated bit in the Motion Alarm Status word, but does not
otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to the
drive, Alarm is not an available option. When an exception action is set to Alarm, the
Alarm goes away by itself when the exceptional condition has cleared.
Fault Status Only – Minor Fault Like Alarm, Fault Status Only instructs the controller to set the associated bit in the
Motion Fault Status word, but does not otherwise affect axis behavior. However, unlike
Alarm an explicit Fault Reset is required to clear the fault once the exceptional condition
has cleared.
Like Ignore and Alarm, if the exception is so fundamental to the drive, Fault Status Only
is not an available option.
Stop Planner – Minor Fault The controller sets the associated bit in the Motion Fault Status word and instructs the
Motion Planner to perform a controlled stop of all planned motion at the configured
maximum deceleration rate and holds at zero speed. An explicit Fault Reset is required
to clear the fault once the exceptional condition has cleared. If the exception is so
fundamental to the drive, Stop Planner is not an available option.
Stop Drive – Major Fault When the exception occurs, the associated bit in the Fault Status word is set and the
axis comes to a stop by using the stopping action defined by the drive for the particular
exception that occurred. There is no controller based configuration to specify what the
stopping action is, the stopping action is device dependent.
Shutdown – Major Fault When the exception occurs, the drive brings the motor to a stop by using the stopping
action defined by the drive (as in Stop Drive) and the power module is disabled. An
explicit Shutdown Reset is required to restore the drive to operation.
Only selected drive exceptions are configurable. In the fault behavior tables, the
controlling attribute is given for programmable fault actions.