Allen Bradley Kinetix 6500 Servo Drive Fault Codes:
| Fault Code and Meaning | Cause and Remedy |
|---|---|
| FLT S02…MTR COMMUTATION Illegal Hall State | Cause: State of Hall feedback inputs is incorrect due to improper connections. Remedy:
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| FLT S03…MTR OVERSPEED FL Motor Overspeed | Cause: Motor speed has exceeded 125% of maximum rated speed. Remedy:
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| FLT S04…MTR OVERSPEED UL (Kinetix 6500 only) Motor Overspeed | Cause: Motor speed has exceeded user velocity limits. Remedy:
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| FLT S05…MTR OVERTEMP FL nn Motor Overtemperature | Cause: High motor ambient temperature and/or Excessive Current. The nn sub-code is defined as follows: 01: Motor Thermostat or Thermistor (Motor wiring error). 02: Encoder Temperature Sensor (Incorrect motor selection). Remedy:
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| FLT S06…MTR OVERTEMP UL nn (Kinetix 6500 only) Motor Overtemperature | Cause: High motor ambient temperature and/or Excessive Current (User Limit). 01: Motor Thermostat or Thermistor. 02: Encoder Temperature Sensor. Remedy:
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| FLT S07…MTR OVERLOAD FL Motor Thermal Protection | Cause: The machine duty cycle requires an RMS current exceeding the continuous rating of the motor. (Exceeded 110% of rating). Remedy:
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| FLT S08…MTR OVERLOAD UL (Kinetix 6500 only) Motor Thermal Protection | Cause: The machine duty cycle requires an RMS current exceeding the continuous rating of the motor. (Exceeded user programmable limit). Remedy:
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| FLT S10…INV OVERCURRENT IPM Fault | Cause: The IPM fault output indicates that the power transistors were turned off. Potential causes: – Motor cables shorted. – Motor winding shorted internally. – The drive temperature is too high. – Operation above continuous power/environmental ratings. – The drive has a short circuit, overcurrent, or failed component. Remedy:
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| FLT S11…INV OVERTEMP FL Inverter Overtemperature | Cause: Inverter thermal switch tripped. – IAM or AM power module fan failed. – The cabinet ambient temperature is above rating. – The machine duty cycle requires an RMS current exceeding the continuous rating of the inverter. – The airflow access to the drive system is limited or blocked. Remedy:
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| FLT S13…INV OVERLOAD FL Inverter Thermal Protection | Cause: The machine duty cycle requires an RMS current exceeding the continuous rating of the inverter (Temperature exceeded 110% of rating). Remedy:
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| FLT S14…INV OVERLOAD UL (Kinetix 6500 only) Inverter Thermal Protection | Cause: The thermal model for the power transistors indicates that the temperature has exceeded the user-programmable limit. Remedy:
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| FLT S16…GROUND CURRENT Ground Fault | Cause: Excessive ground current was detected in the converter. – Wiring error. – Motor internal ground short. – Internal malfunction. Remedy:
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| FLT S18…CONV OVERTEMP FL Converter Overtemperature | Cause: Converter thermal switch tripped. Excessive heat exists in the power circuitry. Remedy:
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| FLT S20…CONV OVERLOAD FL Converter Thermal Protection | Cause: Excessive current is being drawn by the power circuitry (exceeded rating). Remedy:
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| FLT S21…CONV OVERLOAD UL (Kinetix 6500 only) Converter Thermal Protection | Cause: Excessive current is being drawn by the power circuitry (exceeded user-programmable limit). Remedy:
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| FLT S22…AC POWER LOSS AC Power Loss | Cause: Axis was enabled when main (three-phase) power was removed. Remedy:
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| FLT S23…AC PHASE LOSS nn AC Phase Loss | Cause: Faulty AC line control equipment. Some, but not all AC input phases are detected as absent. 01: L1 is missing. 02: L2 is missing. 03: L3 is missing. Remedy:
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| FLT S25…PRECHARGE FAILURE Pre-charge Failure | Cause: – Low AC input voltage. – Internal malfunction. Remedy:
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| FLT S29…SHUNT OVERLOAD FL Shunt Thermal Protection | Cause: The thermal model for the shunt circuitry indicates that the temperature has exceeded its rating. Remedy:
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| FLT S30…SHUNT OVERLOAD UL (Kinetix 6500 only) Shunt Thermal Protection | Cause: The thermal model for the shunt circuitry indicates that the temperature has exceeded a user-programmable limit. Remedy:
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| FLT S31…SHUNT MODULE Shunt Module Fault | Cause: – Over-temperature fault indicator on Bulletin 2094 shunt module is steady red. – Shunt-fault indicator on Bulletin 2094 shunt module is steady red. – Bulletin 2094 shunt module is missing from power rail. Remedy:
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| FLT S33…BUS UNDERVOLT FL Bus Undervoltage | Cause: DC bus voltage for 460V system is below 275V. Remedy:
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| FLT S34…BUS UNDERVOLT UL (Kinetix 6500 only) Bus Undervoltage | Cause: The DC bus voltage is measured below a user limit when the DC bus was expected to be charged. Remedy:
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| FLT S35…BUS OVERVOLT FL Bus Overvoltage | Cause: – Excessive regeneration of power. – DC bus voltage for 460V system is over 820V. Remedy:
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| FLT S38…FUSE BLOWN Blown Fuse (Bus Loss) | Cause: A blown fuse was detected in the power structure. Remedy:
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| FLT S41…MTR AQB STATE FL Motor Feedback State Error | Cause: The number of illegal state transitions of the AQB encoder signals has exceeded a factory limit. The motor feedback wiring is open, shorted, or missing. Remedy:
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| FLT S41…AUX AQB STATE FL Aux Feedback State Error | Cause: The auxiliary feedback wiring is open, shorted, or missing. Remedy:
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| FLT S43…MTR FDBK LOSS FL Feedback Loss | Cause: The motor feedback wiring is open, shorted, or missing. Remedy:
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| FLT S45…MTR FDBK COMM FL Feedback Serial Comms | Cause: Communication was not established with an intelligent encoder. Remedy:
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| FLT S47…MTR ENC SELF TEST nn Feedback Self Test | Cause: The Hiperface feedback device has detected an internal error. Sub-codes include: 01: Alignment Data, 02: Angular Offset, 06: Checksum Error, 29: Transmitter Current Critical, 30: Encoder Temperature Critical, etc. Remedy:
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| FLT S50…POS HW OTRAVEL Hardware Overtravel – Positive | Cause: Dedicated overtravel input is inactive. Axis moved beyond the physical travel limits in the positive direction. Remedy:
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| FLT S51…NEG HW OTRAVEL Hardware Overtravel – Negative | Cause: Dedicated overtravel input is inactive. Axis moved beyond the physical travel limits in the negative direction. Remedy:
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| FLT S52…POS SW OTRAVEL (Kinetix 6200 only) Software Overtravel – Positive | Cause: Axis position exceeded maximum software setting. Remedy:
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| FLT S54…POSN ERROR Excessive Position Error | Cause: Position error limit was exceeded due to: – Improperly sized drive or motor. – Mechanical system out of specifications. Remedy:
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| FLT S55…VEL ERROR nn Excessive Velocity Error | Cause: The velocity error has exceeded a limit for a period of time. – Improperly sized drive or motor. – Mechanical system out of specifications. Remedy:
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| FLT S56…OVERTORQUE (Kinetix 6500 only) Overtorque Limit | Cause: Motor torque has exceeded a user-programmable setting. – Overly aggressive motion profile. – Mechanical binding. – Mechanical system out of specifications. Remedy:
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| FLT S60…ILLEGAL MODE Illegal Control mode | Cause: Axis 1 was configured for dual feedback or load feedback with Axis 2 also configured for Feedback Only operation, but with different feedback attribute values. Remedy:
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| FLT S61…ENABLE INPUT Drive Enable Input | Cause: – An attempt was made to enable the axis through software while the Drive Enable hardware input was inactive. – The Drive Enable input transitioned from active to inactive while the axis was enabled. Remedy:
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| FLT S62…CONTROLLER (Kinetix 6500 only) Controller Initiated Exception | Cause: User configured software overtravel. The controller has requested the drive to generate an exception. Remedy:
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| FLT M01…SELF SENSING Self-sensing Startup Fault: The self-sensing commutation start-up algorithm failed. | Cause: Extremely light or heavy load on the motor. Mechanical obstruction. Remedy:
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| FLT M02…MOTOR VOLTAGE Motor Voltage Mismatch: Motor voltage incompatible with drive voltage. | Cause:
Remedy:
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| FLT M04…MTR FDBK FILTER nn Motor Feedback Filter: Excessive levels of noise have been detected by the digital feedback filter. 01: Sine or A channel 02: Cosine or B channel | Cause: The motor feedback wiring is open, shorted, or missing. Remedy:
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| FLT M04…AUX FDBK FILTER nn Aux Feedback Filter | Cause: The auxiliary feedback wiring is open, shorted, or missing. Remedy: See remedy for Motor Feedback Filter above. |
| FLT M05…MTR FDBK BATT LOSS Motor Encoder Battery Loss: Battery voltage low; absolute position lost. | Cause: Weak battery or poor battery connection. Remedy:
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| FLT M06…MTR FDBK BATT LOW Motor Encoder Battery Caution: Battery voltage below caution level. | Cause: Weak battery. Remedy: Replace battery. |
| FLT M07…MTR INCR LOSS Motor Incremental Position Loss: Incremental position vs absolute position out of tolerance. | Cause: The motor feedback wiring is open, shorted, or missing. Remedy:
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| FLT M07…AUX INCR LOSS Aux Incremental Position Loss | Cause: The auxiliary feedback wiring is open, shorted, or missing. Remedy: Check auxiliary encoder wiring. |
| FLT M10…CTRL OVERTEMP FL Control Module Overtemperature: Temperature exceeded limit. | Cause: Cabinet ambient temperature has exceeded 50 °C (122 °F). Remedy: Reduce cabinet ambient temperature. |
| FLT M11…CTRL OVERTEMP UL Control Module Overtemperature: Temperature exceeded user limit. | Cause: Cabinet ambient temperature has exceeded user limit. Remedy: Reduce cabinet ambient temperature. |
| FLT M12…POWER CYCLE FL Pre-charge Overload: Pre-charge circuit exceeded limit due to excessive power cycling. | Cause: The DC bus power has been cycled too frequently. Remedy: Limit power cycles to two per minute maximum. |
| FLT M13…POWER CYCLE UL Pre-charge Overload: Approaching user-defined limit due to excessive power cycling. | Cause: The DC bus power has been cycled too frequently. Remedy: Limit power cycles to two per minute maximum. |
| FLT M14…CURR FDBK OFFSET Excessive Current Feedback Offset. | Cause: Current feedback hardware fault detected. Remedy: Replace the power module. |
| FLT M15…REGEN PWR SUPPLY Regenerative Power Supply Fault. | Cause: Regen unit faulted. Hardware Regeneration OK input deactivated while drive enabled. Remedy: Reset faulted regen unit. |
| FLT M19…DC BUS LIMIT DC Bus Limited Position Error. | Cause: Excessive load drawn from DC bus by application. Remedy:
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| FLT M25…COMMON BUS DC Common Bus Fault. | Cause: Improper configuration or connection. AC Power detected while configured for Common Bus Follower. Remedy: Check IAM power configuration and wire accordingly. |
| FLT M26…RUNTIME ERROR Runtime Drive Error. | Cause: The drive firmware encountered an unrecoverable runtime error. Remedy:
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| FLT M27…BACKPLANE COMM Backplane COM: Communication problem detected. | Cause:
Remedy:
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| FLT M28…SAFETY COMM Internal Safety Communication. | Cause: Communication with the safety hardware within the drive malfunctioned. Remedy:
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| FLT M64…SENSOR ASSIGNMENT No Quick View message. | Cause:
Remedy: Assign proper function to the four available digital inputs. |
| FLT M68…IPIM IPIM Module Fault. | Cause: A fault has occurred in one or more IPIM modules on the power rail. Remedy: Refer to troubleshooting chapter in Kinetix 6000M User Manual (2094-UM003). |
| INIT FLT S03…NVMEM CHKSUM User Non-volatile Memory Checksum. | Cause: Non-volatile memory is corrupt due to control board software error. Remedy:
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| INIT FLT M01…ENCODER DATA Smart Encoder Data Corruption Fault. | Cause: Faulty intelligent encoder. Remedy:
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| INIT FLT M02…MTR DATA RANGE nn Motor Data Range Error. See manual for specific sub-code (nn) definitions (01-16). | Cause: Faulty intelligent encoder or incorrect motor file. Remedy:
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| INIT FLT M03…MTR ENC STARTUP Motor Feedback Communication Startup. | Cause:
Remedy:
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| INIT FLT M03…AUX ENC STARTUP Auxiliary Feedback Communication Startup. | Cause:
Remedy:
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| INIT FLT M04…MTR ABS SPEED Motor Absolute Encoder Overspeed Fault. | Cause: High motor speed while power was off. Remedy: Clear faults and re-home. |
| INIT FLT M05…MTR ABS TRAVEL Motor Absolute Encoder Power-off Travel. | Cause: Large travel distance while power was off. Remedy: Clear faults and re-home. |
| INIT FLT M06…MTR ABS STARTUP Motor Absolute Startup Speed. | Cause: Mechanical movement of machine causing excessive rotation of motor during powerup. Remedy: Allow machine motion to stop before powerup. |
| INIT FLT M07…COMMUTATION OFFSET Uninitialized Commutation Offset. | Cause: Third party motors do not contain Rockwell Automation motor data. Remedy: Run Commutation Test from the Logix Designer application. |
| INIT FLT M12…INVALID KCL REV Invalid KCL revision. | Cause: The FPGA image is incompatible with hardware operation. Remedy:
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| INIT FLT M13…INVALID BSP REV Invalid BSP revision. | Cause: The board support package is incompatible with hardware operation. Remedy:
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| INIT FLT M14…SAFETY FIRMWARE Invalid Safety Firmware. | Cause: Loaded Safety firmware is not a valid revision for the drive firmware. Remedy: Flash control module with correct revision of safety firmware. |
| INIT FLT M19…VOLTAGE MISMATCH Voltage Mismatch on Power Rail. | Cause: 230V and 460V modules have been installed on the same power rail. Remedy: Replace the mismatched AM module with one that matches the IAM module. |
| INIT FLT M20…UNKNOWN MODULE Unknown Axis on Backplane. | Cause: Faulty Module. Remedy:
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| INIT FLT M21…FACTORY CFG Factory Configuration Invalid. | Cause: Defective memory in module. Remedy: Replace defective module. |
| INIT FLT M22…ILLEGAL ADDRESS Illegal Node Switch Setting. | Cause: IAM node switch set such that an AM node address is greater than 254. Remedy: Select IAM node address that permits all AM node addresses to be less than 254. |
| INIT FLT M23…SERIES MISMATCH Series Mismatch on Power Rail. | Cause: Sercos and EtherNet/IP control modules exist on the same power rail. Remedy: Replace the mismatched control module. |
| INIT FLT M24…OPEN SLOT Open Power Rail Slot. | Cause: Missing module or bent pins on module. Remedy:
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| INIT FLT M32…MTR KEYING nn Motor Keying Fault. | Cause: Incorrect motor selected from motor database. Remedy: Verify motor selection in Axis Properties configuration. |
| INIT FLT M33…ENABLE UNASSIGNED Enable Input Not Assigned. | Cause: Enable function requested but not assigned to a digital input. Remedy: Assign an available digital input as Enable. |
| INIT FLT M34…OTRAVEL UNASSIGNED Overtravel Input Not Assigned. | Cause: Overtravel function requested but not assigned to a digital input. Remedy: Assign an available digital input for the desired overtravel function. |
| INIT FLT M35…NAND FLASH nn Storage failure. | Cause: Faulty memory component. Remedy:
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| NODE FLT 01…LATE CTRL UPDATE Control Update Fault. | Cause:
Remedy:
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| NODE FLT 02…PROC WATCHDOG Processor Watchdog Fault. | Cause: The watchdog circuit monitoring processor operation detected a problem. Remedy:
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| NODE FLT 03…HARDWARE nn Hardware Fault. 01: Invalid slot ID 02: Cannot read slot ID 03/04: Memory failures | Cause:
Remedy:
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| NODE FLT 04…DATA FORMAT ERROR Data Format Error. | Cause: Faulty memory component. Remedy:
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| NODE FLT 06…LOST CTRL CONN Lost Controller Connection. | Cause:
Remedy:
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| NODE FLT 08…LOGIC WATCHDOG Custom Logic Update Timeout. | Cause: Faulty control module. Remedy:
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| NODE FLT 09…IP ADDRESS Duplicate IP Address. | Cause: Incorrect node switch setting (Identical IP on subnet). Remedy: Select a node address not already in use on the network. |
| NODE FLT 128…DRAM TEST DRAM Test Fault. | Cause: Faulty memory component. Remedy:
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| NODE FLT 129…FPGA CONFIG FPGA Configuration Fault. | Cause: Faulty component. Remedy: Replace module. |
| NODE FLT 133…SERCOS ADDRESS Duplicate Sercos Node Address. | Cause: This axis and one or more other axes have identical sercos addresses. Remedy: Check Node Switch configuration and adjust for no overlap. |
| NODE FLT 139…SERCOS RING Sercos Ring Fault. | Cause: Loose or damaged sercos cable. Remedy: Check that fiber-optic cable is present and connected properly. |
| NODE ALARM 01…CTRL UPDATE Control Connection Update Alarm. | Cause:
Remedy:
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| NODE ALARM 05…CLOCK SYNC Clock Jitter Alarm. | Cause:
Remedy:
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| NODE ALARM 128…NODE SWITCH No Quick View message. | Cause: Node Switches adjusted after powerup. Remedy: Return node switches to power-up setting. |
| INHIBIT S01…ENABLE INPUT Axis Enable Input Fault – Start Inhibit. | Cause: Enable input is inactive while axis is in Starting/Running/Testing/Hold state. Remedy:
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| INHIBIT S02…MOTOR NOT CONFIGURED Motor Not Configured. | Cause: The motor has not been properly configured for use. Remedy: Verify motor configuration in the Logix Designer application. |
| INHIBIT S03…FEEDBACK NOT CONFIGURED Feedback Not Configured. | Cause: The feedback has not been properly configured for use. Remedy: Verify feedback configuration in the Logix Designer application. |
| INHIBIT S04…COMMUTATION NOT CONFIGURED Commutation Not Configured – Standard Start Inhibit. | Cause:
Remedy:
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| INHIBIT M05…SAFE TORQUE OFF Start Inhibit – Safe Torque Off. | Cause: The safety function has disabled the power structure. Remedy:
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| INHIBIT M07…SAFETY NOT CONFIGURED Start Inhibit – Safety Not Configured Inhibit. | Cause: Drive firmware was uploaded. Remedy: Reapply safety configuration signature by using Apply File from the Safety Main web page. |
| ALARM S52…POS SW OTRAVEL Software Overtravel – Positive. | Cause: Axis position exceeded maximum software setting. Remedy:
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| ALARM S53…NEG SW OTRAVEL Software Overtravel – Negative. | Cause: Axis position exceeded maximum software setting. Remedy:
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| ALARM M13…POWER CYCLE UL Pre-charge Overload. | Cause: The DC bus power has been cycled too frequently. Remedy: Limit power cycles to two per minute maximum. |