YASKAWA GPD 505/P5 Troubleshooting Manual Download Page 1

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PP.P5G5.03.Troubleshoot

Page 1

Rev. 06/11/2003

Yaskawa Electric

America

Unit Troubleshooting Manual

Section Three:

Fault Codes & Appendix

GPD 506/P5 and GPD 515/G5

(0.4 ~ 160kW)

Summary of Contents for GPD 505/P5

Page 1: ...PP P5G5 03 Troubleshoot Page 1 Rev 06 11 2003 Yaskawa Electric America Unit Troubleshooting Manual Section Three Fault Codes Appendix GPD 506 P5 and GPD 515 G5 0 4 160kW...

Page 2: ...6 11 2003 Section Three Fault Codes GPD 515 G5 DSPL ENTER DIGITAL OPERATOR JVOP 131U FREF FOUT IOUT ACCEL F R V F VMTR FLA PID DECEL FBIAS OC RUN STOP RESET LOCAL REMOTE REMOTE REF SEQ kWout MONTR FGA...

Page 3: ...ed faults The fault codes can be grouped into 3 categories Major Fault Motor coasts to a stop the fault is displayed on the digital operator and the fault relay is activated Minor Fault Operation cont...

Page 4: ...ower supply 460V Units 55kW 160kW monitors the 15V power supply UV2 CTL PS Undervolt Uu2 Possible Cause s Single phase condition on the input low input voltage at L1 L2 and L3 Corrective Action Check...

Page 5: ...tacts on contactor are dirty contactor does not function mechanically Corrective Action Check the contactor check the ribbon cable from the control board to the gate drive board Possible Cause s High...

Page 6: ...emove the motor and run the inverter without the motor Check the motor for a phase to phase short Check the inverter for a phase to phase short at the output Possible Cause s Motor lead shorted to gro...

Page 7: ...rform the checks without with power starting on page 10 Replace the shorted component s then replace the defective fuse 505 Possible Cause s Shorted inverter output phase to phase shorted motor locked...

Page 8: ...rter 120 or150 of inverter rated current for 1 minute 515 150 for 1 minute 505 and 506 120 or 150 depending on drive capacity and setting parameter n116 OL2 Inv Overloaded ol2 Possible Cause s Motor i...

Page 9: ...mer programmable current detection Response may be selected A minor fault contact output can be programmed by using the multi function outputs 505 Possible Cause s Motor is overloaded Corrective Actio...

Page 10: ...incorrectly n083 for 506 P5 L8 05 for 515 G5 Corrective Action Tighten the terminal screws check the input voltage verify the program settings Possible Cause s Open phase on the output of the inverter...

Page 11: ...t be set correctly Corrective Action Check the load on the motor verify the program settings F1 08 PG Overspeed Level and F1 09 PG Overspeed Time Possible Cause s The Pulse Generator feedback wires ma...

Page 12: ...outputs RH DynBrk Resistor Possible Cause s Shorted braking transistor high DC bus voltage defective braking resistor Corrective Action Replace defective transistor or resistor monitor DC bus level Po...

Page 13: ...set too low load torque is excessively large Corrective Action Verify the program setting L7 03 forward regen torque limit and L7 04 reverse regen torque limit extend the deceleration time Possible C...

Page 14: ...505 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 will stop if the digital operator is removed when the i...

Page 15: ...is broken master has stopped communicating Corrective Action Check all connections verify all user side software configurations E 15 SI F G Com Err After initial communication has been established th...

Page 16: ...l user side software configurations 505 N A Fault Codes Major Fault Motor coasts to a stop the fault is displayed on the digital operator and the fault relay is activated Possible Cause s Connection i...

Page 17: ...external fault condition exists connected to terminal number 3 Corrective Action Check for an external condition verify the program parameters Possible Cause s An external fault condition exists conne...

Page 18: ...condition at terminal S2 verify the program parameters ef0 External fault from serial communication Possible Cause s An external fault condition exists Corrective Action Check for an external conditio...

Page 19: ...e s Control board hardware failure Corrective Action Cycle power replace the control board The deviation of the speed reference and speed feedback has exceeded the regulation level A minor fault conta...

Page 20: ...replace the digital operator replace the control board CPF01 Com Err OP INV Communication fault between the inverter and the operator has occurred for more than 2 seconds cpf1 Possible Cause s Digital...

Page 21: ...ardware failure during power up Corrective Action Perform a factory initialization cycle power replace the control board Possible Cause s Noise or spike on the control input terminals Corrective Actio...

Page 22: ...n the control board input terminals Corrective Action Perform a factory initialization cycle power replace the control board Possible Cause s Noise or spike on the control board input terminals Correc...

Page 23: ...ion Remove power to the inverter and connect the option board once more Perform a factory initialization cycle power replace the option board replace the control board Possible Cause s Defective AI 14...

Page 24: ...Perform a factory initialization cycle power replace the option board replace the control board Possible Cause s Unrecognizable communication or network option board is connected to the control board...

Page 25: ...to the control board an option board that is not made for the 515 G5 inverter is attached to the control board Corrective Action Remove power to the inverter and connect the option board once more Pe...

Page 26: ...rvolt Uu The DC bus voltage has exceeded the overvoltage trip point while the inverter output is off OV DC Bus Overvolt ou Possible Cause s Single phase condition on the input low input voltage at L1...

Page 27: ...le Cause s Cooling fan s are not working high ambient temperature Corrective Action Check for dirt build up on the fans reduce the ambient temperature around the inverter Possible Cause s An external...

Page 28: ...stomer programmable current detection Response may be selected A minor fault contact output can be programmed by using the multi function outputs Possible Cause s Motor is overloaded Corrective Action...

Page 29: ...ommand are input simultaneously Corrective Action Check external sequence logic ef0 External fault from serial communication Possible Cause s An external fault condition exists Corrective Action Check...

Page 30: ...ists connected to terminal number 3 Corrective Action Check for an external condition verify the program parameters Possible Cause s An external fault condition exists connected to one of the terminal...

Page 31: ...oad on the motor verify the program settings F1 08 PG Overspeed Level and F1 09 PG Overspeed Time Possible Cause s The Pulse Generator feedback wires may be broken or not properly connected to the PG...

Page 32: ...verify the program settings F1 10 PG Deviate Level F1 11 PG Deviate Time F1 04 PG Deviation Select Possible Cause s Connection is broken master has stopped communicating Corrective Action Check all c...

Page 33: ...by using the multi function outputs BB Base Block Possible Cause s A baseblock command was accepted at the multi function input terminals 3 4 5 6 7 or 8 Corrective Action Check for an external condit...

Page 34: ...n ope 1 OPE02 Limit Constant data is out of range 506 digital operator will display OPE06 ope 6 Possible Cause s The control board was replaced and the kVA parameter is set incorrectly Corrective Acti...

Page 35: ...option board is installed Remove power to the inverter and connect the option board once more OPE03 Terminal Multi function input selection fault ope 3 Possible Cause s Duplicate functions are select...

Page 36: ...ly installed or missing The control method selection parameter A1 02 is set to 1 or 3 without a feedback board installed Corrective Action Verify that an option board is installed Remove power to the...

Page 37: ...in the present control mode Corrective Action Check the modified constants area and verify the set values in parameters H1 01 H1 06 H2 01 H2 03 H3 05 H3 09 H4 01 and H4 04 V F data setting fault 506 d...

Page 38: ...requency proportional gain C6 03 6 and C6 01 C6 02 N A Possible Cause s Parameter setting incorrect Corrective Action Check the program settings and correct the errors Possible Cause s Connection not...

Page 39: ...e digital operator and the fault relay is not activated CALL SI F G ComCall Serial communication transmission error Communication has not yet been established N A Possible Cause s Connection is broken...

Page 40: ...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 comp...

Page 41: ...PP P5G5 03 Troubleshoot Page 41 Rev 06 11 2003 Appendix...

Page 42: ...PF20 Option A D Error N A X 81 CPF21 Option CPU down N A X 82 CPF22 Option Type Err N A X 82 CPF23 Option DPRAM Err N A X 83 DEV Speed Deviation N A X X 19 77 90 E 10 SI F G CPU down N A X 24 73 E 15...

Page 43: ...93 OPE06 PG Opt Missing N A X 94 OPE07 Analog Selection N A X 94 OPE08 Terminal N A X 95 OPE10 V F Ptrn Setting OPE5 X 95 OPE11 FC On Dly N A X 96 OPR Oper Disconnect OPr X 1E 72 OS Overspeed Det N A...

Page 44: ...ple of an OL1 fault being read from a GPD515 G5 with the station address of 02 is shown below PLC GPD 515 G5 02 03 0090 0001 84 14 Station Address H5 01 Read Register Command Fault Code Register CRC H...

Page 45: ...Ref 0 10V 0 10V 23 0 10V 21 Common 22 Multi function Analog Output Multi function Analog Output 9 10 18 19 20 Multi function Contact Outputs 250Vac 30Vdc 1A 25 26 27 Multi function Open Collector Out...

Page 46: ...ng jumper J1 on the control board L1 L2 L3 T1 T2 T3 S1 S2 S3 S4 S5 S6 SC Forward Run Multi function Inputs Digital Common Power Supply IM MA MB MC Multi function output 250Vac 30Vdc 1A M1 M2 Multi fun...

Page 47: ...HEAT SINK 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...

Page 48: ...placement 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...

Page 49: ...nts 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 b...

Page 50: ...SHIN ETSU SHIN ETSU TOSHIBA CASTALL Description Thermal Compound Thermal Compound Thermal Compound Thermal Compound Material Silicon Grease Silicon Grease Silicon Grease Silicon Grease Appearance Whi...

Page 51: ...The power module layout for 230V models 0 4kW 5 5kW and 460V models 0 4kW 4 0kW is shown below W V U R S T N E GU GV GW EU EV EW GU GV GW P1 B GB P R S T B U V W P P1 N 1 2 3 4 5 6 7 8 9 10 11 Pin De...

Page 52: ...t for 230V model 7 5kW and 460V models 5 5kW and 7 5kW is shown below U V W N GW GV GU EW EV EU GZ GY GX P B GDB EX EY EZ W V U B P N 1 2 4 5 7 8 10 11 12 13 14 15 16 Pin Description 1 GW 2 EW 3 Not U...

Page 53: ...PP P5G5 03 Troubleshoot Page 53 Rev 06 11 2003 Power Module Layout The power module layout for 230V 460V 11kW 15kW models is shown below E2 C1 C2E1 G2 E2 E1 G1 C1 G1 E1 G2 E2 C2E1 E2...

Page 54: ...P2 KNYS7W4R5K R010065 7W 4 5 OHM 10 R14 R22 G5U23P7 P5U23P7 G5U25P5 P5U25P5 KNYS7W3R0K R010066 7W 3 OHM 10 R79 R80 G5U27P5 P5U27P5 R80 R83 G5U2011 P5U2011 RGHS60LS2R2OHMJ R010062 2 2 OHM 10 R1 G5U2015...

Page 55: ...60W 2 2 OHM 5 R1 G5U2022 P5U2022 G5U2030 P5U2030 G5U2037 P5U2037 SMR120W R007704 120W 1 OHM 5 R1 G5U2045 P5U2045 G5U2055 P5U2055 G5U2075 P5U2075 SMRW220W R007705 220W 1 OHM 5 R1 460V 460V G5U4018 P5U4...

Page 56: ...2 G5U53P7 P5U53P7 KNYS10W500K R010068 10W 500 OHM 5 R73 R74 G5U5P5 P5U5P5 KNYS10W4ROK RO10069 10W 40 OHM 10 R80 R85 G5U57P5 P5U57P5 G5U5011 P5U5011 RGHS80LS6R20HMJ R0100063 80W 6 2 OHM 5 G5U5015 P5U50...

Page 57: ...03011 G5U21P5 P5U21P5 G5U22P2 P5U22P2 HE1AN DC24V POR003013 G5U23P7 P5U23P7 DC 24V MC1 G5U25P5 P5U25P5 HE2AN DC24V POR003014 G5U27P5 P5U27P5 G5U2011 P5U2011 G7J 4A B DC24V POR003012 G5U2015 P5U2015 46...

Page 58: ...MC003483 200V 70A X MC1 G5U2037 P5U2037 G5U2045 P5U2045 HI 35E2TCU MC003259 250V 200A X MC1 G5U2055 P5U2055 G5U2075 P5U2075 HI 100E2TCU MC003257 200V 190A X MC1 460V 460V G5U4018 P5U4018 HP 20GU MC003...

Page 59: ...0V 10A X MC1 G5U52P2 P5U52P2 G5U53P7 P5U53P7 HE2AN DC24V POR003014 DC24V 20A 2 POLE X MC1 G5U5P5 P5U5P5 HP 20GU MC003260 DC24V 20A 3A X MC1 G5U57P5 P5U57P5 G5U5011 P5U5011 G5U5015 P5U5015 HP 20GU MC00...

Page 60: ...5 INSIDE POWER MODULE PM1 G5U22P2 P5U22P2 SEE OUTPUT TRANSISTOR PARTS LIST G5U23P7 P5U23P7 G5U25P5 P5U25P5 G5U27P5 P5U27P5 TM1 G5U2011 P5U2011 N A N A G5U2015 P5U2015 460V 460V G5U40P4 P5U40P4 G5U40P7...

Page 61: ...verter Model YEA Code IGBT Number Number Mfg Part Number Number Specifications Designation 600V 600V CIMR CIMR G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 PM1 G5U5P5 P5U5P5 G5U57P5 P5U57P5 G5U5011...

Page 62: ...61 MS0650D225N 2 SID000584 50A 2 2MFD SM22 42 62 G5U2055 P5U2055 MS0650D225P 1 SID000583 50A 2 2MFD SM11 31 51 MS0650D225P 2 SID000585 50A 2 2MFD SM12 32 52 MS0650D225N 1 SID000582 50A 2 2MFD SM21 41...

Page 63: ...Code Diode 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 P5U...

Page 64: ...R007497 60W 10 OHM 5 R3 8 G5U2037 P5U2037 G5U2045 P5U2045 SMR90WA4748C R007157 90W 10 OHM 5 X2 R3 5 G5U2055 P5U2055 G5U2075 P5U2075 SMR90WA4748M R007697 90W 5 OHM 5 X2 R3 8 460V 460V G5U4018 P5U4018 G...

Page 65: ...ion 600V 600V CIMR CIMR G5U51P5 P5U51P5 G5U52P2 P5U52P2 G5U53P7 P5U53P7 G5U5P5 P5U5P5 G5U57P5 P5U57P5 G5U5011 P5U5011 G5U5015 P5U5015 G5U5018 P5U5018 G5U5022 P5U5022 G5U5030 P5U5030 G5U5037 P5U5037 G5...

Page 66: ...10 C3 8 G5U2022 P5U2022 G5U2030 P5U2030 G5U2037 P5U2037 G5U2045 P5U2045 DE2110R472K2K C003017 2KV 4700PF C12 29 G5U2055 P5U2055 G5U2075 P5U2075 C17 52 460V 460V G5U4018 P5U4018 C3 8 G5U4022 P5U4022 G5...

Page 67: ...5U53P7 G5U5P5 P5U5P5 G5U57P5 P5U57P5 G5U5011 P5U5011 C1NP3B335K YA C006367 1250V 3 3UF 10 C3 C5 G5U5015 P5U5015 G5U5018 P5U5018 C1NP3B225K YA C006366 1250V 2 2UF 10 C7 C9 G5U5022 P5U5022 G5U5030 P5U50...

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