YASKAWA GPD 505/P5 Troubleshooting Manual
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YASKAWA GPD 505/P5 Troubleshooting Manual

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Yaskawa Electric
America
Unit Troubleshooting Manual
Section Three:
Fault Codes & Appendix
GPD 506/P5 and GPD 515/G5
(0.4 ~ 160kW)
Page 1
Rev. 06/11/2003

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  • Page 1 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...
  • Page 2 Section Three: Fault Codes REMOTE FREF FOUT IOUT kWout ACCEL DECEL MONTR VMTR FGAIN FBIAS kWsav PRGM DIGITAL OPERATOR JVOP-131U DSPL ENTER LOCAL REMOTE STOP RESET GPD 515/G5 GPD 505/P5 GPD 506/P5 PP.P5G5.03.Troubleshoot Page 2 Rev. 06/11/2003...
  • Page 3 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.
  • Page 4 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ Undervoltage of the main circuit when running. 230V Units - trip point 190V DC or less. DC Bus Undervolt 460V Units - trip point 380V DC or less.
  • Page 5 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ The pre-charge contactor opened while the inverter is MC Answerback running. This fault only applies to 230V units 18kW ~ 75kW , 460V units 22kW ~ 160kW and 600V units 30kW ~ 160kW .
  • Page 6 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. Designed to protect the inverter. √ √ Output current has exceeded OC level of the inverter rated value instantaneously.
  • Page 7 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ The inverter output is short-circuited. Short Circuit 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.
  • Page 8 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ Motor overload, designed to protect the motor. Motor Overloaded Fully adjustable from parameter setting (n033 and n034 for 506/P5 and E1-02 and E2-01 for 515/G5) A pre-alarm can be selected as a minor fault by using the multi-function outputs.
  • Page 9 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ Over torque detection function. Overtorque Det 1 A customer programmable current detection. Response may be selected. A minor fault contact output can be programmed by using the multi-function outputs.
  • Page 10 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ Inverter input power supply has an open phase. Input Pha Loss Large imbalance of input voltage. Possible Cause(s): Open phase on the input of the inverter.
  • Page 11 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ The motor speed has exceeded the overspeed level when operating in the Closed Loop V/f or Closed Overspeed Det Loop Flux Vector modes.
  • Page 12 Replace defective transistor or resistor, monitor DC bus level. The braking resistor temperature has exceeded the allowable value. DynBrk Resistor (Protects Yaskawa 3% duty cycle resistors only) Can be selected as a minor fault by using the multi- function outputs. Possible Cause(s): Overhauling load, extended braking duty cycle, defective braking resistor.
  • Page 13 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ The actual torque during deceleration has reached Out of Control the regen torque limit for more than 3 seconds. (Open Loop Flux Vector mode only) Possible Cause(s): The regen torque limit value is set too low, load torque is excessively...
  • Page 14 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ The transistor cooling fin temperature exceeded the Heatsnk MAX Temp allowable value. 506/P5 (105 ° C), 515/G5 (105 ° C) Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.
  • Page 15 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ E-10 The CPU on the SI-F/G option board has stopped SI-F/G CPU down operating. ♣ Possible Cause(s): Defective option board, electrical noise effecting operation.
  • Page 16 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ After initial communication has been established, the SI-B Com Err connection was then lost. Response may be selected. Possible Cause(s): Connection is broken, master has stopped communicating.

  • Page 17: Table Of Contents

    Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ External fault at terminal number 3. External Fault3 Possible Cause(s): An external fault condition exists connected to terminal number 3. Corrective Action: Check for an external condition, verify the program parameters.
  • Page 18 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ External fault from serial communication. External Fault Possible Cause(s): An external fault condition exists. Corrective Action: Check for an external condition, verify the program parameters.
  • Page 19 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ The deviation of the speed reference and speed Speed Deviation feedback has exceeded the regulation level. A minor fault contact output can be programmed by using the multi-function outputs.
  • Page 20 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ CPF00 Transmission between the inverter and the operator cpf0 Com-Err(OP&INV) cannot be established 5 seconds after supplying power.
  • Page 21 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ CPF02 Baseblock circuit fault at power up. BB Circuit Err Possible Cause(s): Gate array hardware failure during power up. Corrective Action: Perform a factory initialization, cycle power, replace the control board.
  • Page 22 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ √ CPF04 cpf5 CPU internal A/D converter fault. 506 digital Internal A/D Err operator will display CPF05. Possible Cause(s): Noise or spike on the control board input terminals.
  • Page 23 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ CPF06 Option connection fault. Option Error Possible Cause(s): An option board is not correctly connected to the control board, an option board that is not made for the 515/G5 inverter is attached to the control board.
  • Page 24 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ CPF21 The CPU on the SI-B option board has locked up. Option CPU down Possible Cause(s): Noise or spike on the communication line, defective SI-B option board.
  • Page 25 Fault Codes Major Fault - Motor coasts to a stop, the fault is displayed on the digital operator, and the fault relay is activated. √ CPF23 DPRAM handshake timing between the 515/G5 and a Option DPRAM Err network or communication option card has timed out. Possible Cause(s): An option board is not correctly connected to the control board, an option board that is not made for the 515/G5 inverter is attached to the control board.
  • Page 26 Fault Codes Minor Fault - Operation continues and the digital operator indication blink The fault relay does not activate. √ √ The main circuit or control circuit voltage has fallen DC Bus Undervolt below the under voltage trip point momentarily. A minor fault contact output can be programmed by using the multi-function outputs.

  • Page 27: Corrective Action: Check For An External Condition, Verify The Program Parameters

    Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ √ The transistor cooling fin temperature exceeded the N/A ? Heatsnk Ovrtemp allowable value. GPD 506/P5 (95 ° C), GPD515/G5 (95 ° C) Response may be selected. Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.
  • Page 28 Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ √ Over torque detection function. A customer programmable current detection. Response Overtorque Det 1 may be selected. A minor fault contact output can be programmed by using the multi-function outputs.
  • Page 29 Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ √ External fault from serial communication. External Fault Possible Cause(s): An external fault condition exists. Corrective Action: Check for an external condition, verify the program parameters. Both the forward and the reverse run commands are External Fault input simultaneously for 500 ms or more.

  • Page 30: External Fault At Terminal Number

    Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ External fault at terminal number 3. External Fault3 Possible Cause(s): An external fault condition exists connected to terminal number 3. Corrective Action: Check for an external condition, verify the program parameters.
  • Page 31 Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ The motor speed has exceeded the overspeed level Overspeed Det when operating in the Closed Loop V/f or Closed Loop Flux Vector modes. Possible Cause(s): The load has changed considerably, the program settings are not set correctly.
  • Page 32 Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ The deviation of the speed reference and speed feedback has exceeded the regulation level. Speed Deviation A minor fault contact output can be programmed by using the multi-function outputs.
  • Page 33 Fault Codes Minor Fault - Operation continues and the digital operator indication blinks The fault relay does not activate. √ √ External baseblock command is input from the multi- Base Block function input terminals. A minor fault contact output can be programmed by using the multi-function outputs.
  • Page 34 Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ √ OPE01 ope 1 Inverter kVA setting error. kVA Selection Possible Cause(s): The control board was replaced and the kVA parameter is set incorrectly. Corrective Action: Enter the correct kVA setting (O2-4 for GPD515/G5) and (n115 for GPD506/P5) by referring to the inverter model number.
  • Page 35 Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ √ OPE03 ope 3 Multi-function input selection fault. Terminal Possible Cause(s): Duplicate functions are selected, up/down commands or trim control increase/decrease are not set simultaneously (GPD515/G5 only).
  • Page 36 Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ OPE06 Closed Loop Flux Vector mode has been selected PG Opt Missing without a PG board installed. Possible Cause(s): PG option board not correctly installed or missing.
  • Page 37 Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ OPE08 Multi-function input or multi-function output data Terminal setting error. Possible Cause(s): A multi-function selection has been chosen that is not offered in the present control mode.

  • Page 38: Pp.p5G5.03.Troubleshoot

    Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ OPE11 Carrier frequency data setting fault. FC/ On-Dly Upper limit (C6-01) >5KHz, and the lower limit (C6-02) <= 5KHz.
  • Page 39 Fault Codes Parameter Setting Error - Inverter can’t run. The fault is displayed on the digital operator, and the fault relay is not activated. √ CALL Serial communication transmission error. SI-F/G ComCall Communication has not yet been established. Possible Cause(s): Connection is broken, master has stopped communicating.
  • Page 40 Appendix In the appendix of this manual you will find the following information; Fault code list Terminal function diagram for the GPD 515/G5 Terminal function diagram for the GPD 506/P5 Procedure for power component replacement Thermal compound specifications Power module layout Parts lists not found in the technical manuals PP.P5G5.03.Troubleshoot Page 40...
  • Page 41 Appendix PP.P5G5.03.Troubleshoot Page 41 Rev. 06/11/2003...

  • Page 42: External Fault Ef4

    Fault Codes Major Minor Parameter G5 MODBUS Code Text Code Fault Fault Setting Error Register Data Page # Base Block SI-B Com Err CALL Serial Com Call CALL CALL SI-F/G ComCall Memobus Com Err 74,90 Out of Control CPF00 Com-Err (OP&INV) CPF0 CPF01 Com-Err (OP&INV)
  • Page 43 Fault Codes Major Minor Parameter G5 MODBUS Code Text Code Fault Fault Setting Error Register Data Page # Over current Heatsnk Overtemp Heatsnk MAX Temp Over Heat 2 Motor Overloaded Inv Overloaded Overtorque Det 1 67,86 Overtorque Det 2 67,86 OPE01 KVA Selection OPE1...
  • Page 44 GPD 515G5 MODBUS Register Data The present fault may be obtained by accessing register 0090H. An example of an OL1 fault being read from a GPD515/G5 with the station address of 02 is shown below. TRANSMIT 0090 0001 Fault Length of Station Read Code...
  • Page 45 Terminal Functions of the GPD515/G5 Power 515/G5 Supply Multi-function Forward Run 0±10V 21 Analog Output Reverse Run Common 22 2mA maximum 0±10V 23 Multi-function Analog Output Multi-function Multi-function Contact Inputs Outputs 250Vac/30Vdc, 1A Fault Contact 250Vac/30Vdc, 1A Digital Common * The braking circuit is 15 (+15V, 20mA) factory installed in the Multi-function...
  • Page 46 Terminal functions of the GPD 506/P5 Braking resistor Power 506/P5 Supply 0-10V Forward Run Multi-function Output Common 2mA maximum Multi-function Multi-function output Inputs 250Vac/30Vdc 1A Digital Common Multi-function output Analog Supply (15v) 250Vac/30Vdc 1A Main Ref. (0-10V) Aux Ref. (4-20mA)* * Terminal FI is factory set as shown, but Analog Common can be changed to a voltage input, with a...
  • Page 47 Power Component Replacement Incorrect Method for Replacement of Circuit Board Mounted Components Large board-mounted components (input diodes, output IGBT’s, and power modules) are not being correctly installed into small size inverters during repair. The components are being soldered to the power board, before being mounted to the heat sink.
  • Page 48 Power Component Replacement Correct Method for Replacement of Circuit Board Mounted Components When mounted correctly, the power module with thermal compound applied, will be in contact with the heatsink. The specifications for the thermal compound can be found on the following page. POWER BOARD POWER MODULE THERMAL...
  • Page 49 Power Component Replacement Correct Method for Replacement of Circuit Board Mounted Components The component must first be mounted to the heat sink. The power board should then be installed into the inverter, over the top of the components. Then the components should be soldered to the power board.
  • Page 50 Thermal Compound In the chart below is a list of thermal compound specifications. The thermal compound used on all power components in Yaskawa inverters is highlighted. Vendor SHIN-ETSU SHIN-ETSU TOSHIBA CASTALL Thermal Compound Thermal Compound Thermal Compound Thermal Compound Description...
  • Page 51 Power Module Layout The power module layout for 230V models 0.4kW ~ 5.5kW and 460V models 0.4kW ~ 4.0kW is shown below. Pin # Description 7 8 9 10 11 PP.P5G5.03.Troubleshoot Page 51 Rev. 06/11/2003...
  • Page 52 Power Module Layout The power module layout for 230V model 7.5kW and 460V models 5.5kW and 7.5kW is shown below. Pin # Description Not Used 10 11 12 13 14 15 16 Not Used Not Used PP.P5G5.03.Troubleshoot Page 52 Rev. 06/11/2003...
  • Page 53 Power Module Layout The power module layout for 230V / 460V 11kW & 15kW models is shown below. C2E1 C2E1 PP.P5G5.03.Troubleshoot Page 53 Rev. 06/11/2003...
  • Page 54 Soft Charge Resistor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code Resistor Number Number Number Number Specifications Designation (G5) (PC5) 230V 230V CIMR- CIMR- G5U20P4 P5U20P4 KNYS7W400K R010064 7W 40 OHM +/- 10% G5U20P7 P5U20P7 G5U21P5 P5U21P5 KNYS7W220K R010072 7W 22 OHM +/- 10% G5U22P2...
  • Page 55 Soft Charge Resistor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code Resistor Number Number Number Number Specifications Designation 230V 230V CIMR- CIMR- G5U2018 P5U2018 RGHS60LS2R20HMJ R010062 60W 2.2 OHM +/- 5% G5U2022 P5U2022 G5U2030 P5U2030 G5U2037 P5U2037 SMR120W R007704 120W 1 OHM +/- 5% G5U2045...
  • Page 56 Soft Charge Resistor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code Resistor Number Number Number Number Specifications Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 KNYS10W500K R010068 10W 500 OHM +/-5% G5U52P2 P5U52P2 G5U53P7 P5U53P7 KNYS10W500K R010068 10W 500 OHM +/-5% R73, R74 G5U5P5 P5U5P5...
  • Page 57 Soft Charge Contactor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code Contactor Number Number Number Number Specifications Designation (G5) (PC5) 230V 230V CIMR- CIMR- G5U20P4 P5U20P4 G5U20P7 P5U20P7 VSB-24MC POR003011 G5U21P5 P5U21P5 G5U22P2 P5U22P2 HE1AN-DC24V POR003013 G5U23P7 P5U23P7 DC 24V G5U25P5 P5U25P5...
  • Page 58 Soft Charge Contactor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code 24V & Number Number Number Number Specifications 24V Coil 230V Coil Designation 230V 230V CIMR- CIMR- G5U2018 P5U2018 HI-20ETCU-U MC003253 200V 35A G5U2022 P5U2022 HI-25ETCU-U MC003333 200V 58A G5U2030 P5U2030 HI-35E2T2CU-U MC003483...
  • Page 59 Soft Charge Contactor Part Numbers: Inverter Model Inverter Model Mfg. Part YEA Code 24V & Resistor Number Number Number Number Specifications 24V Coil 230V Coil Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 JC2AF-DC24V POR001074 DC24V AC250V 10A G5U52P2 P5U52P2 G5U53P7 P5U53P7 HE2AN-DC24V POR003014...
  • Page 60 Braking Transistor Part Numbers: Inverter Model Inverter Model Number Number IGBT (G5) (PC5) Mfg. Part Number YEA Code Specifications Designation 230V 230V CIMR- CIMR- G5U20P4 P5U20P4 G5U20P7 P5U20P7 G5U21P5 P5U21P5 INSIDE POWER MODULE G5U22P2 P5U22P2 (SEE OUTPUT TRANSISTOR PARTS LIST) G5U23P7 P5U23P7 G5U25P5...
  • Page 61 Braking Transistor Part Numbers: Inverter Model Inverter Model YEA Code IGBT Number Number Mfg. Part Number Number Specifications Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 INSIDE POWER MODULE G5U5P5 P5U5P5 (SEE OUTPUT TRANSISTOR PARTS LIST) G5U57P5 P5U57P5 G5U5011 P5U5011...
  • Page 62 Snubber Diodes Part Numbers: Inverter Model Inverter Model YEA Code Diode Number Number Mfg. Part Number Number Specifications Designation 230V 230V CIMR- CIMR- G5U2018 P5U2018 G5U2022 P5U2022 G5U2030 P5U2030 MS0650D225P-1 SID000583 50A 2.2MFD SM1,3,5 MS0650D225N-1 SID000582 50A 2.2MFD SM2,4,6 G5U2037 P5U2037 MS0650D225P-1 SID000583...
  • Page 63 Snubber Diodes Part Numbers: Inverter Model Inverter Model YEA Code Diode Number Number Mfg. Part Number Number Specifications Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 G5U5P5 P5U5P5 G5U57P5 P5U57P5 Not Required G5U5011 P5U5011 G5U5015 P5U5015 G5U5018 P5U5018 G5U5022 P5U5022...
  • Page 64 Snubber Resistors Part Numbers: Inverter Model Inverter Model YEA Code Resistor Number Number Mfg. Part Number Number Specifications Designation 230V 230V CIMR- CIMR- G5U2018 P5U2018 G5U2022 P5U2022 G5U2030 P5U2030 ERF-60WH100 R007497 60W 10 OHM +/- 5% R3~8 G5U2037 P5U2037 G5U2045 P5U2045 SMR90WA4748C R007157...
  • Page 65 Snubber Resistors Part Numbers: Inverter Model Inverter Model YEA Code Resistor Number Number Mfg. Part Number Number Specifications Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 G5U5P5 P5U5P5 G5U57P5 P5U57P5 G5U5011 P5U5011 G5U5015 P5U5015 Not Required G5U5018 P5U5018 G5U5022 P5U5022...
  • Page 66 Snubber Capacitors Part Numbers: Inverter Model Inverter Model YEA Code Capacitor Number Number Mfg. Part Number Number Specifications Designation 230V 230V CIMR- CIMR- G5U2018 P5U2018 MF-630MPD475K C006066 4.7 MFD +/- 10% C3~8 G5U2022 P5U2022 G5U2030 P5U2030 G5U2037 P5U2037 G5U2045 P5U2045 DE2110R472K2K C003017 2KV 4700PF...
  • Page 67 Snubber Capacitors Part Numbers: Inverter Model Inverter Model YEA Code Capacitor Number Number Mfg. Part Number Number Specifications Designation 600V 600V CIMR- CIMR- G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 Not Required G5U5P5 P5U5P5 G5U57P5 P5U57P5 G5U5011 P5U5011 C1NP3B335K-YA C006367 1250V 3.3UF +/-10% C3 - C5 G5U5015 P5U5015...

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