Kinetix 5500 Servo Drives Fault Codes Reference Data
Kinetix 5500 Servo Drives Fault Codes Reference Data
Kinetix 5500 Servo Drives Fault Codes Reference Data
This publication lists the fault codes for Kinetix ® 5500 Servo Drives
About This Publication For more information see: Kinetix 5500 Servo Drives User Manual
2198-UM001
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2198-RD005A-EN-P - February 2022 Copyright © 2022 Rockwell Automation Inc. All Rights Reserved. Printed in USA.
Summary of Changes
Date Changes
November 2019 First release as an Excel spreadsheet
April 2020 Updated format; no information changed
February 2022 This is the first revision as publication 2198-RD005A-EN-P.
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information see: 2198-UM001
3 3 FLT S03 – MTR OVERSPEED FL - 0 Motor Overspeed Factory Limit Fault Check control loop tuning.
Motor speed has exceeded 125% of its maximum speed.
3 3 FLT S03 – MTR OVERSPEED FL - 1 Motor Overspeed Factory Limit Fault • Check control loop tuning
The output frequency has exceeded 590 Hz. • Reduce the velocity command
3 4 FLT S04 – MTR OVERSPEED UL Motor Overspeed User Limit Fault • Check control loop tuning
Motor speed has exceeded motor overspeed user limit. • Increase the Motor Overspeed UL attribute value
3 5 FLT S05 – MTR OVERTEMP FL nn Motor Overtemperature Factory Limit Fault • Operate motor within continuous torque rating
Calculations based on the motor thermistor indicate that the motor factory • Reduce motor ambient temperature
temperature limit has been exceeded. • Add motor cooling
The nn sub-code is defined as follows: Available only on Kinetix VP and MP-Series™ motors. Not supported on induction motors.
01: Motor Thermostat or Thermistor
02: Encoder Temperature Sensor
3 7 FLT S07 – MTR OVERLOAD FL Motor Thermal Overload Factory Limit Fault Modify the command profile to reduce speed or increase time.
The motor thermal model has exceeded its factory set thermal capacity limit.
3 8 FLT S08 – MTR OVERLOAD UL Motor Thermal Overload User Limit Fault • Modify the command profile
The motor thermal model has exceeded the thermal capacity limit given by • Increase the Motor Thermal Overload UL attribute value
Motor Thermal Overload User Limit.
3 9 FLT S09 – MTR PHASE LOSS Motor Phase Loss Check motor connections.
Torque Prove function detected motor current below a limit set by Torque
Prove Current Limit.
3 10 FLT S10 – INV OVERCURRENT Inverter Overcurrent Fault • Check motor power cable for shorts
Inverter current has exceeded the instantaneous current limit (determined by • Verify motor windings are not shorted
hardware). • Verify motor power wire gauge
• Operate within the continuous power rating
• Reduce acceleration times. Modify the command profile to reduce
speed or increase time
3 11 FLT S11 – INV OVERTEMP FL Inverter Overtemperature Factory Limit Fault • Modify the command profile to reduce speed or increase time
The measured inverter temperature has exceeded the factory set • Reduce drive ambient temperature
temperature limit. • Verify airflow through drive is not obstructed
3 13 FLT S13 – INV OVERLOAD FL Inverter Thermal Overload Factory Limit Fault Modify the command profile to reduce speed or increase time.
The thermal capacity of the inverter has exceeded the factory set limit.
3 14 FLT S14 – INV OVERLOAD UL Inverter Thermal Overload User Limit Fault • Modify the command profile to reduce speed or increase time
The thermal capacity of the inverter has exceeded the user set limit given by • Increase the Inverter Thermal Overload UL attribute value
the inverter Thermal Overload User Limit.
3 15 FLT S15 – CONV OVERCURRENT Converter Overcurrent Fault • Reduce acceleration times of all drives sharing the DC bus, reduce
The measured converter current has exceeded the factory set current limit. number of shared DC follower drives
• Reduce number of capacitor modules
3 16 FLT S16 – GROUND CURRENT Ground Current Factory Limit Fault • Check motor power wiring; check power cable for shorts
The sensing circuitry in the power stage has detected excessive ground • Replace motor if the fault persists
current. • Check DC-bus wiring if using a capacitor module
3 18 FLT S18 – CONV OVERTEMP FL Converter OverTemp Factory Limit Fault • Reduce number of shared DC follower drives
The measured converter temperature has exceeded the factory set • Modify the command profile to reduce speed or increase time
temperature limit. • Reduce drive ambient temperature
• Verify airflow through drive is not obstructed
3 20 FLT S20 – CONV OVERLOAD FL Converter Thermal Overload Factory Limit Fault • Reduce number of shared DC follower drives
The converter thermal model indicates that the temperature has exceeded • Reduce duty-cycle of commanded motion
the factory set capacity limit of 110%.
3 21 FLT S21 – CONV OVERLOAD UL Converter Thermal Overload User Limit Fault • Reduce number of shared DC follower drives
The converter thermal model indicates that the temperature has exceeded • Reduce duty-cycle of commanded motion
the limit given by Converter Thermal Overload User Limit. • Increase the Converter Thermal Overload UL attribute value
3 23 FLT S23 – AC PHASE LOSS AC Single Phase Loss Fault Check AC input voltage on all phases.
A single AC input phase was lost while the drive was enabled.
3 25 FLT S25 – CONV PRECHARGE Converter Pre-charge Failure Fault • Check AC input voltage on all phases
FAILURE The pre-charge circuit monitoring algorithm detected that the DC bus did not • Check input power wiring
reach a factory set voltage level after charging for a period of time or the DC- • Check if any inverter or motor is shorted to ground
bus voltage is too high. • Replace drive if fault persists
• Check multi-axis shared-bus configuration
3 29 FLT S29 – BUS REG OVERLOAD FL Bus Regulator Thermal Overload Factory Limit Fault • Modify the duty cycle of the application
The shunt thermal model has exceeded its factory set thermal capacity limit. • Add external shunt for additional capacity
• Add capacitor module
3 30 FLT S30 – BUS REG OVERLOAD UL Bus Regulator Thermal Overload User Limit Fault • Modify the duty cycle of the application
The shunt thermal model has exceeded the thermal capacity limit given by • Add external shunt for additional capacity
Bus Regulator Thermal Overload User Limit. • Increase the Bus Regulator Thermal Overload UL attribute value
• Add capacitor module
3 31 FLT S31 – BUS REG FAILURE Bus Regulator Failure • Check for shorts in the shunt connector
The shunt circuit has detected the shunt resistor is shorted. • Unplug the shunt connector and measure the resistance of the shunt
• Replace drive if shunt resistor is shorted
3 33 FLT S33 – BUS UNDERVOLT FL Bus Undervoltage Factory Limit Fault • Verify voltage level of the incoming AC
DC Bus voltage level is below the factory set limit as determined by the • Monitor AC power source for glitches or line droop
configured input voltage. • Install UPS on AC input
3 34 FLT S34 – BUS UNDERVOLT UL Bus Undervoltage User Limit Fault • Verify voltage level of the incoming AC
DC Bus voltage level is below the user set limit as given by Bus Undervoltage • Monitor AC power source for glitches or line droop
User Limit. • Install UPS on AC input
• Increase Bus Undervoltage UL attribute value
3 35 FLT S35 – BUS OVERVOLT FL Bus Overvoltage Factory Limit Fault • Change the deceleration or motion profile of all drives connected to
DC Bus voltage level is above the factory set limit as determined by the the DC bus
configured input voltage. • Unplug the shunt connector and measure the resistance of the shunt
• Replace drive if shunt resistor is open
3 39 FLT S39 – BUS POWER LEAKAGE Bus Power Leakage Fault • Check bus power sharing configuration attribute
Measured converter power exceeded estimated inverter output power by • Check AC input and DC bus-sharing connections
more than a factory limit.
3 45 FLT S45 – FDBK COMM FL Motor Feedback Data Loss Factory Limit Fault • Check motor feedback cable and connector
The number of consecutive missed or corrupted serial data packets, or invalid • Check motor power cable and feedback wire shields are secured
position feedback values from the intelligent feedback device has exceeded a correctly
factory set limit. • Check motor frame is grounded correctly
• Consult Possible Solutions for FLT S47
3 47 FLT S47 – FDBK DEVICE FAILURE Motor Feedback Device Failure Fault (DSL feedback) • Check motor feedback cable for proper connectivity and continuity
nn=01…37 The feedback device has detected an internal error. • Check motor phasing (U, V, W) and DSL feedback 2-pin wire
The nn sub-code is defined as follows: connections at the drive
01: ACCELERATION OVERFLOW • Review electrical noise reduction, bonding painted panels, and wire-
04: TRACKING FILTER ERROR braid bonding in the user manual
05: VECTOR LENGTH ERROR • Cycle control power
06: COUNTER ERROR • Check feedback shield connection
07: SYNCHRONIZATION ERROR • Reduce shock and vibration to motor
16: SINGLE TURN ERROR • Upgrade firmware, revision 2.008 or later
17: MULTI TURN AMPLITUDE ERROR • Replace motor if fault continues
18: MULTI TURN SYNC ERROR
19: MULTI TURN VECTOR LENGTH ERROR
35: STANDARD PARAMETER ERROR
36: INTERNAL COMMUNICATION ERROR1
37: INTERNAL COMMUNICATION ERROR2
3 47 FLT S47 – FDBK DEVICE FAILURE Motor Feedback Device Failure Fault (DSL feedback) • Check motor feedback cable for proper connectivity and continuity
nn=38…88 The feedback device has detected an internal error. • Check motor phasing (U, V, W) and DSL feedback 2-pin wire
The nn sub-code is defined as follows: connections at the drive
38: INTERNAL SYSTEM ERROR • Review electrical noise reduction, bonding painted panels, and wire-
48: CRITICAL TEMPERATURE braid bonding in the user manual
49: CRITICAL LED CURRENT • Cycle control power
50: CRITICAL SUPPLY VOLTAGE • Check feedback shield connection
51: CRITICAL SPEED • Reduce shock and vibration to motor
52: CRITICAL ACCELERATION • Upgrade firmware, revision 2.008 or later
53: COUNTER OVERFLOW • Replace motor if fault continues
54: INTERNAL MONITORING ERROR
66: INTERNAL RESOURCE ACCESS ERROR
For the 2198-H2DCK feedback converter kit, a Motion Axis Fault Reset is required and can take
up to 30 seconds to complete. Cycling control power does not always fix the error.
88: POSITION OUT OF RANGE
A control power cycle is required to reset the fault.
3 47 FLT S47 – FDBK DEVICE FAILURE Motor Feedback Device Failure Fault (Hiperface feedback) • Check motor feedback cable for proper connectivity and continuity
nn=01…12 The Hiperface feedback device has detected an internal error. • Check motor phasing (U, V, W) and Hiperface feedback 15-pin wire
The nn sub-code is defined as follows: connections at the drive
01: INCORRECT ALIGNMENT DATA • Review electrical noise reduction, bonding painted panels, and wire-
02: INCORRECT INTERNAL ANGULAR OFFSET braid bonding in the user manual
03: DATA FIELD PARTITIONING TABLE DESTROYED • Cycle control power
04: ANALOG LIMIT VALUES NOT AVAILABLE • Check feedback shield connection
05: INTERNAL I2C BUS INOPERATIVE • Reduce shock and vibration to motor
06: INTERNAL CHECKSUM ERROR • Upgrade firmware, revision 2.008 or later
07: ENCODER RESET OCCURRED AS A RESULT OF PROGRAM MONITORING • Replace motor if fault continues
08: COUNTER OVERFLOW
09: PARITY ERROR
10: CHECKSUM OF TRANSMITTED DATA IS INCORRECT
11: UNKNOWN COMMAND CODE
12: NUMBER OF TRANSMITTED DATA IS INCORRECT
3 47 FLT S47 – FDBK DEVICE FAILURE Motor Feedback Device Failure Fault (Hiperface feedback) • Check motor feedback cable for proper connectivity and continuity
nn=13…35 The Hiperface feedback device has detected an internal error. • Check motor phasing (U, V, W) and Hiperface feedback 15-pin wire
The nn sub-code is defined as follows: connections at the drive
13: TRANSMITTED COMMAND AGRUMENT IS NOT ALLOWED • Review electrical noise reduction, bonding painted panels, and wire-
14: THE SELECTED DATA FIELD MAY NOT BE WRITTEN TO braid bonding in the user manual
15: INCORRECT ACCESS CODE • Cycle control power
16: SIZE OF SPECIFIED DATA FIELD CANNOT BE CHANGED • Check feedback shield connection
17: SPECIFIED WORD ADDRESS LIES OUTSIDE THE DATA FIELD • Reduce shock and vibration to motor
18: ACCESS TO NON-EXISTENT DATA FIELD • Upgrade firmware, revision 2.008 or later
28: VALUE MONITORING OF THE ANALOG SIGNALS (process data) • Replace motor if fault continues
29: TRANSMITTER CURRENT CRITICAL
(contamination, transmitter breakage)
30: ENCODER TEMPERATURE CRITICAL
31: SPEED TOO HIGH, NO POSITION FORMATION POSSIBLE
32: SINGLETURN POSITION UNRELIABLE
33: MULTITURN POSITION ERROR
34: MULTITURN POSITION ERROR
35: MULTITURN POSITION ERROR
3 49 FLT S49 – BRAKE SLIP FLT Brake Slip Exception Check motor brake.
The brake proving function detected that motor displacement exceeded the
brake slip tolerance while the mechanical brake was engaged.
3 50 FLT S50 – POS HW OTRAVEL Hardware Overtravel - Positive Check digital input and axis position.
The axis has moved beyond the digital input travel limit in the positive
direction.
3 51 FLT S51 – NEG HW OTRAVEL Hardware Overtravel - Negative Check digital input and axis position.
The axis has moved beyond the digital input travel limit in the negative
direction.
3 54 FLT S54 – POSN ERROR Excessive Position Error Fault • Check position loop tuning
Does not apply to induction motors in The position error of the position control loop has exceeded the value given • Increase the feedforward gain
frequency control mode. by Position Error Tolerance for a time period given by Position Error Tolerance • Verify sizing of the drive and motor
Time. • Check motor power wiring
• Increase Position Error Tolerance and/or Position Error Tolerance
Time attribute values
3 55 FLT S55 – VEL ERROR Excessive Velocity Error Fault • Check velocity loop tuning
Does not apply to induction motors in The velocity error of the velocity control loop has exceeded the value given by • Reduce acceleration
frequency control mode. Velocity Error Tolerance for a time period given by Velocity Error Tolerance • Verify sizing of the drive and motor
Time. • Check motor power wiring
• Increase Velocity Error Tolerance and/or Velocity Error Tolerance
Time attribute values
3 56 FLT S56 – OVERTORQUE LIMIT Overtorque Limit Fault • Verify Torque Trim value
Does not apply to induction motors in Motor torque has risen above user defined maximum torque level given by • Verify motion profile
frequency control mode. Overtorque Limit for a time period given by Overtorque Limit Time. • Verify sizing of the drive and motor
• Increase Overtorque Limit and/or Overtorque Limit Time attribute
values
3 57 FLT S57 – UNDERTORQUE LIMIT Undertorque Limit Fault • Verify motion profile
Does not apply to induction motors in Motor torque has dropped below user defined minimum torque level given by • Verify sizing of the drive and motor
frequency control mode. Undertorque Limit for a time period given by Undertorque Limit Time. • Decrease Undertorque Limit and/or Undertorque Limit Time
attribute values
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information see: 2198-UM001
4 25 FLT M25 – DC COMMON BUS DC Common Bus Fault • Check the drive power configuration from
AC power was detected by the drive while controller
configured for shared DC operation. • Check wiring
4 26 FLT M26 – RUNTIME ERROR Runtime Error • Cycle control power
The drive firmware encountered an unrecoverable • Reset the drive
runtime error. • Return drive for repair if fault continues
4 28 FLT M28 – SAFETY COMM Safety Module Communication Error • Cycle control power
(2198-Hxxx-ERS2 drives only) Communication with the safety hardware within • Reset the drive
the drive has failed. • Return drive for repair if fault continues
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information see: 2198-UM001
2 3 INIT FLT M03 – MTR ENC STARTUP Motor Feedback Communication Startup Communication with the • Cycle control power
encoder could not be established. • Check motor feedback connector
• Check motor power and feedback shield terminations on the drive
• Return motor for repair if fault continues
2 14 INIT FLT M14 – SAFETY FIRMWARE Invalid Safety Firmware • Cycle control power
The loaded Safety firmware is not compatible with the drive • Update the drive firmware
firmware. • Return drive for repair if fault continues
2 20 INIT FLT M20 – UNKNOWN MODULE Unknown Module • Cycle control power
The product code of the power board is invalid. • Reset the drive
• Return drive for repair if fault continues
2 21 INIT FLT M21 – FACTORY CONFIG Factory Configuration Error • Cycle control power
Factory configuration data is missing or invalid • Reset the drive
• Return drive for repair if fault continues
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information, see: 2198-UM001
2 5 INHIBIT M05 – SAFE TORQUE OFF Start Inhibit – Safe Torque Off • Check safety input wiring
The safety function has disabled the power structure. • Check state of safety devices
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information, see: 2198-UM001
Fault Code
(Motion Device Axis
Fault Type Object Attribute 16) Display Text Fault Action
1 NODE FLT 01 – LATE CTRL UPDATE Control Connection Update Fault • Remove unnecessary network devices from the motion network
Several consecutive updates from the controller have been lost. • Change network topology so that fewer devices share common paths
• Use high performance network equipment
NODE FLT • Use shielded cables
• Separate signal wiring from power wiring
2 NODE FLT 02 – PROC WATCHDOG nn Processor Watchdog Fault • Cycle control power
The processor on the power board or control board failed to update • Return drive for repair if fault continues
NODE FLT in a certain amount of time.
The Possible Solutions are the same for all nn sub-codes.
3 NODE FLT 03 – HARDWARE 03 DSL Internal Hardware Fault • Check DSL feedback device, wiring, and cable
NODE FLT A DSL hardware error internal to the drive was detected. • Cycle power
• Return drive for repair if fault continues
3 NODE FLT 03 – HARDWARE 04 Hardware Fault - Board Compatibility Return drive for repair if fault continues
NODE FLT The control and power boards are incompatible.
5 NODE FLT 05 – CLOCK SKEW FLT Clock Skew Fault • Cycle control power
NODE FLT The controller time and the drive's system time are not the same. • Check controller and Ethernet switch operation
6 NODE FLT 06 – LOST CTRL CONN Lost Controller Connection Fault • Check Ethernet connection
NODE FLT Communication with the controller has been lost. • Check controller and Ethernet switch operation
7 NODE FLT 07 – CLOCK SYNC Clock Sync Fault • Check Ethernet connection
NODE FLT Drive's local clock has lost synchronization with controller's clock • Check controller and Ethernet switch operation
and was not able to resynchronize within allotted time.
9 NODE FLT 09 – DUPLICATE IP ADDRESS Duplicate IP Address Fault Select an IP address not already in use on the network
NODE FLT Several consecutive updates from the controller have been lost.
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information, see: 2198-UM001
Fault Code
(Motion Device Axis
Fault Type Object Attribute 17) Display Text Fault Action
NODE ALARM 1 NODE ALARM 01 – LATE CTRL UPDATE Control Connection Update Alarm • Remove unnecessary network devices from the motion network
Updates from the controller have been late. • Change network topology so that fewer devices share common paths
• Use high performance network equipment
• Use shielded cables
• Separate signal wiring from power wiring
NODE ALARM 3 NODE ALARM 03 – CLOCK JITTER Clock Jitter Alarm • Check the Ethernet connection
The sync variance has exceeded the sync threshold while the device • Check controller and Ethernet switch operation
is running in sync mode.
NODE ALARM 4 NODE ALARM 04 – CLOCK SKEW ALARM Clock Skew Alarm • Check the Ethernet connection
The controller time and the drive’s time are not the same. • Check controller and Ethernet switch operation
NODE ALARM 5 NODE ALARM 05 – CLOCK SYNC ALARM Clock Sync Alarm • Check the Ethernet connection
Drive's local clock has lost synchronization with controller's clock for • Check controller and Ethernet switch operation
a short time during synchronous operation.
Kinetix® 5500 Servo Drive Fault Codes
Content from Chapter 7 - Troubleshoot the Kinetix 5500 Drive System
For more information, see: 2198-UM001