Common faults in AB servo drive maintenance include: no display, phase loss, overcurrent, overvoltage, undervoltage, overheating, overload, grounding, parameter errors, display but no output, module damage and other faults. When an AB servo drive fails, the fault or alarm code can provide some effective information to help repair the fault. The following introduces some common alarm codes of AB Kinetix 5500 servo drive.
1. Kinetix 5500 Servo Drive Fault Judgment regarding Indicator Light
(1) Module LED indicator light
Steady green light = Normal
Flashing green light = Standby
Steady red light = Fault
Flashing red light = Waiting for reset
Red and green lights flash alternately = Self-test status
(2) Network LED indicator light
All off = IP not matched or no power
Steady Green light= Normal
Flashing green light = IP has been captured and communication is being established
Steady red light = IP address conflict
Flashing red light = Connection timeout
Red and green lights flash alternately = Self-test status
Ethernet status LED indicator light
Off = No connection
On = Connection has been established
Flashing = Data transmission in progress
2. Kinetix 5500 Servo Failure Alarm Codes and Possible Causes
FLT Sxx/FLT Mxx = Failure alarm during standard operation
INIT FLT Sxx/INIT FLT Mxx = Fault alarm during initialization
NODE FLT xx = Alarm that will affect the normal operation of the drive
NODE ALARM xx = Alarm that affects the normal operation of the drive and alerts the controller
INHIBIT Mxx/INHIBIT Sxx = Alarm when the drive is activated
2.1 FLT Sxx Fault Codes
FLT S03 – MTR OVERSPEED FL = Motor overspeed: motor speed exceeds the set value
FLT S05 – MTR OVERTEMP FL = Motor over temperature or poor heat dissipation
FLT S07 – MTR OVERLOAD FL = Motor overload (factory limit fault)
FLT S08 – MTR OVERLOAD UL = Motor temperature exceeds servo setting parameters.
FLT S10 – INV OVERCURRENT = Inverter overcurrent
FLT S11 – INV OVERTEMP FL = Inverter overheated or poorly ventilated
FLT S13 – INV OVERLOAD FL = Inverter thermal overload (factory limit fault)
FLT S14 – INV OVERLOAD UL = Inverter thermal overload (user limit fault)
FLT S15 – CONV OVERCURRENT = Converter overcurrent fault
FLT S16 – GROUND CURRENT = The sensing circuitry in the power stage has detected excessive ground current.
FLT S18 – CONV OVERTEMP FL = Converter circuit over temperature
FLT S20 – CONV OVERLOAD FL = Converter thermal overload (factory limit fault)
FLT S21 – CONV OVERLOAD UL = Converter thermal overload (user limit fault)
FLT S23 – AC PHASE LOSS = A single AC input phase was lost while the drive was enabled.
FLT S25 – PRECHARGE FAILURE = Start charging failed
FLT S29 – BUS OVERLOAD FL = Bus thermal overload fault (factory limit fault)
FLT S30 – BUS OVERLOAD UL = Bus thermal overload fault (user limit fault)
FLT S31 – BUS REGULATOR = Broken bus detection circuit or bad bus bypass.
FLT S33 – BUS UNDERVOLT FL＝ Bus undervoltage (factory limit fault)
FLT S34 – BUS UNDERVOLT UL = Bus undervoltage (user limit fault)
FLT S35 – BUS OVERVOLT FL = Bus overvoltage
FLT S39 – BUS POWER LEAK = Bus power shortage fault
FLT S45 – FDBK COMM FL = Motor feedback circuit failure
FLT S47 – FDBK DEVICE FAILURE = Feedback device damage fault
FLT S54 – POSN ERROR = Excessive position error
FLT S55 – VEL ERROR = Excessive velocity error
FLT S56 – OVERTORQUE LIMIT = Servo output overtorque fault
FLT S57 – UNDERTORQUE LIMIT = Servo output undertorque fault
2.2 FLT Mxx Fault Codes
FLT M02 – MOTOR VOLTAGE = Motor voltage mismatch
FLT M14 – CURR FDBK OFFSET = Excessive current feedback deviation or unbalanced output
FLT M25 – COMMON BUS = Bus failure when using common DC bus
FLT M26 – RUNTIME ERROR = A runtime error occurred
2.3 INIT FLT Fault Codes
INIT FLT S03 – NVMEM CHKSUM = Memory check error
INIT FLT M01 – ENCODER DATA = Smart encoder data error
INIT FLT M02 – MTR DATA RANGE = Motor data error or mismatch
INIT FLT M03 – MTR ENC STARTUP = Communication with the encoder could not be established.
INIT FLT M20 – UNKNOWN MODULE = Unrecognized module
INIT FLT M21 – FACTORY CONFIG =Factory data is lost or cannot be reset
2.4 INHIBIT Fault Codes
INHIBIT S02 – MOTOR NOT CONFIGURED = The motor has not been properly configured for use.
INHIBIT S03 – FEEDBACK NOT CONFIGURED =The encoder is not configured.
INHIBIT M05 – SAFE TORQUE OFF = Start inhibit – safe torque off
2.5 NODE FLT Fault Codes
NODE FLT 01 – LATE CTRL UPDATE = The controller has been updated too many times and the data has been lost.
NODE FLT 02 – PROC WATCHDOG = Processor watchdog fault
NODE FLT 03 – HARDWARE 00 = Hardware fault: the drive cannot establish communication with the power board
NODE FLT 03 – HARDWARE 01 = Hardware fault: DSP chip on the power board failure
NODE FLT 05 – CLOCK SKEW FLT = The clock is not synchronized, and the controller and drive time are inconsistent.
NODE FLT 06 – LOST CTRL CONN = Controller communication failure, such as Ethernet...
NODE FLT 07 – CLOCK SYNC = System failure: control and drive time settings are inconsistent
NODE FLT 09 – DUPLICATE IP ADDRESS = IP address conflict
2.5 NODE ALARM Fault Codes
NODE ALARM 01 – LATE CTRL UPDATE = Controller update alarm
NODE ALARM 03 – CLOCK JITTER = Clock jitter occurs, which caused by network or setting failure
NODE ALARM 05 – CLOCK SYNC ALARM = Clock synchronization alarm: check the network or switch
3. Kinetix 5500 Servo Common Fault Codes and Solutions
3.1 Kinetix 5500 Servo Drive Alarm Code FLT M02
Fault content: Motor voltage mismatch fault.
The configured drive voltage is greater than the rated voltage of the motor, for example, a 400V-level drive and a 200V-level motor.
Solution: Set the drive voltage to a lower value or replace the motor with one whose rated voltage matches the drive’s.
3.2 Kinetix 5500 Servo Drive Alarm Code FLT M26
Fault content: Runtime error
An unrecoverable runtime error occurred in the drive firmware.
Solution: Reconnect the control power supply and reset the drive. If the fault persists, return the drive to the factory for repair.
3.3 Kinetix 5500 Servo Drive Alarm Code FLT S57
Fault content: Under torque limit. Motor torque is below the user-programmed setting.
Solution:
• Verify motion profile.
• Verify sizing of the drive and motor.
• Decrease undertorque limit and/or undertorque limit time attribute values.
4. Conclusion
During the maintenance process of AB servo drives, maintenance personnel need to have rich professional knowledge and experience. They need to understand the circuit diagram and working principle of the drive so that they can accurately find the fault point. In this process, they also need to use a variety of different tools and equipment, including programmers, test software, etc.
Once the cause of the malfunction is found, maintenance personnel need to take appropriate measures to repair it. This may involve replacing circuit boards or chips, adjusting parameters, etc. They need to be very careful and attentive during this process to ensure that the repair does not cause any additional damage or impact to the drive.
