Yaskawa GA500 Maintenance
60 fault codes documented
Keypad Battery Low Voltage
The internal battery providing backup power to the keypad has dropped to a low voltage level. This condition compromises the keypad's ability to retain parameter settings or maintain its display, potentially leading to loss of drive configuration or operational instability from the keypad if not addressed promptly.
Bluetooth Communication Fault
This fault indicates a failure in establishing or maintaining Bluetooth communication between the drive's keypad and a paired smartphone or tablet running DriveWizard Mobile. It commonly arises from the mobile device being too far from the keypad or from radio frequency interference from other 2.4 GHz devices. Unresolved, this prevents remote monitoring, parameter adjustments, and diagnostic functions, impacting operational efficiency.
Braking Transistor Overload Fault
The braking transistor, an internal component responsible for dissipating regenerative energy, is experiencing an overload condition. This occurs when the drive's deceleration duty cycle or regenerative power is too high, or if the transistor itself is faulty. Persistent overload can lead to overheating and irreversible damage to the transistor, impairing the drive's ability to manage braking energy safely and effectively.
Option Communication Error
This fault signals a critical communication failure involving an installed option card, indicating a disruption in data exchange with either the drive or an external controller. Causes range from incorrect or damaged wiring and short circuits to significant electrical interference or improper option card installation. Such a communication breakdown prevents the drive from receiving essential commands or feedback, potentially leading to unexpected stops or complete loss of control.
Communication Data Error
This fault indicates that the drive has experienced a communication data error, typically due to electrical interference on the control circuit lines. The drive detects this error if it fails to receive correct control data within the timeout period defined by parameter H5-09. If left unaddressed, this can lead to unreliable control of the motor, unexpected stops, or incorrect operation, potentially disrupting the process.
Control Fault
This fault can stem from various issues including incorrect motor parameter settings, an excessively low torque limit, or an over-sized load inertia relative to the drive's deceleration capability. It also occurs if wiring errors exist between the motor and drive, if Line-to-line Resistance Tuning has not been performed, or if a Run command is issued while the motor is still coasting. Unresolved control faults can lead to poor motor performance, unexpected stops, or damage to the motor/drive due to improper control.
Current Offset Fault
A Current Offset Fault occurs when the drive attempts to start operation while residual induced voltage is still present in the motor, such as after coasting to a stop or rapid deceleration. This indicates the current offset value has exceeded its permitted automatic adjustment range. In rare cases, this fault may also point to an internal hardware problem within the drive itself. Failure to resolve this can lead to incorrect motor control, erratic startup behavior, or potential damage if a hardware issue is present.
Comparator 1 Limit Error
This fault indicates that the value being monitored by Comparator 1 (as selected by H2-20) has fallen within the predefined limits set by H2-21 (Lower Limit) and H2-22 (Upper Limit). This typically signifies an unexpected condition within the monitored parameter that has triggered the comparator's protection function. Depending on the monitored parameter, this could indicate an underspeed, overcurrent, or other critical process deviation, requiring immediate attention to prevent system damage or operational failure.
Comparator 2 Limit Error
This fault signifies that the value monitored by Comparator 2 (selected by H2-26) has deviated *outside* the acceptable range defined by H2-27 (Lower Limit) and H2-28 (Upper Limit). This condition indicates that the monitored parameter has either gone too high or too low, triggering a protection response. Depending on the specific parameter being monitored, this could point to an over-temperature, under-pressure, or other critical process excursion that risks equipment damage or process instability if not resolved.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
EEPROM Memory Data Error
This fault indicates an error with the EEPROM memory data, possibly due to power loss during a parameter write operation from a communication option card or a fault in the EEPROM's peripheral circuit. This can lead to corrupted parameters and incorrect drive functionality.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Terminal Board not Connected
This fault indicates that the terminal board is not properly connected to the drive. A loose or disconnected terminal board will disrupt essential I/O functionality and communication, preventing normal drive operation.
Control Circuit Error
This code indicates a generic hardware problem within the drive's control circuit. This suggests an internal malfunction that could prevent safe and reliable operation and may require internal component inspection or replacement.
Communication Error1
This communication error indicates a temporary hardware problem in the drive, likely caused by electrical noise interference. This can disrupt internal drive communication and operation, leading to unexpected behavior or shutdowns.
Communication Error2
Similar to dCE1, this communication error points to a temporary drive hardware issue primarily caused by electrical noise. This can lead to unreliable drive performance, erratic operation, and potential system downtime.
Speed Deviation
The drive detected a significant deviation between the commanded speed reference and the actual detected speed, exceeding the set threshold (F1-10) for longer than the specified delay (F1-11). This indicates a problem with the motor's ability to follow the speed command, potentially leading to process disruption, mechanical stress, or loss of control.
Polarity Judge Timeout
The drive failed to detect motor polarity within the preset time, indicating an issue with the motor's electrical connection or winding integrity. This can prevent proper motor startup, accurate current control, and safe operation.
EEPROM Memory DWEZ Data Error
This fault indicates an issue with the EEPROM's peripheral circuit or corrupted DriveWorksEZ program data saved to the EEPROM. This can lead to incorrect drive operation or parameter settings and prevent the drive from functioning as intended.
DriveWorksEZ Fault 2
This fault indicates an issue originating from the DriveWorksEZ program itself, not a drive hardware fault. It signifies a problem with the user-defined logic or configuration which prevents proper program execution on the drive.
DriveWorksEZ Fault 3
Similar to dWF2, this fault signals a problem within the DriveWorksEZ program itself. It is not a hardware fault of the drive but rather an issue with the programmed logic that hinders correct operation.
DriveWorksEZ Fault
This generic DriveWorksEZ fault indicates an issue within the user-programmed logic or configuration. It is not a drive hardware malfunction but a problem in the custom program that prevents normal drive functionality.
MECHATROLINK Watchdog Timer Err
The drive detected a communication watchdog error on the MECHATROLINK network, indicating a problem with data reception from the controller. This can lead to loss of control, unexpected motor stops, and disrupted automation sequences.
FWD/REV Run Command Input Error
This minor fault occurs when both a forward and a reverse run command are simultaneously active for more than 0.5 seconds, indicating a conflict in control signals. The motor will ramp to stop, preventing potential mechanical damage from conflicting commands.
Option Card External Fault
This fault indicates that the communication option card has received an external fault signal from the connected controller or that there is a programming error on the controller side. It can cause the motor to stop according to the drive's stop method settings.
External Fault (Terminal S1)
An external fault signal was received via MFDI terminal S1, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-01 is set for an external fault (range 20 to 2F) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S2)
An external fault signal was received via MFDI terminal S2, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-02 is set for an external fault (range 20 to 2F) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S3)
An external fault signal was received via MFDI terminal S3, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-03 is set for an external fault (range 20 to 2F) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S4)
An external fault signal was received via MFDI terminal S4, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-04 is set for an external fault (range 20 to 2F) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S5)
An external fault signal was received via MFDI terminal S5, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-05 is set for an external fault (range 20 to 2F) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S6)
An external fault signal was received via MFDI terminal S6, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-06 is set for an external fault (range 20 to 2B) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
External Fault (Terminal S7)
An external fault signal was received via MFDI terminal S7, possibly due to a problem with the connected external device, faulty wiring, or a misconfiguration where parameter H1-07 is set for an external fault (range 20 to 2B) but the terminal is not actively utilized. This will cause the drive to trip and stop the motor, potentially disrupting the process.
EEPROM Write Error
This error indicates a problem with the EEPROM hardware or data corruption during a write operation, likely due to electrical interference. This can lead to incorrect parameter storage, unpredictable drive operation, and loss of configuration.
Overtorque Detection 1
This fault indicates that the machine has encountered a mechanical lock or the drive parameters are incorrectly configured for the load. The drive triggers this fault when its output current exceeds the level set in L6-02 for a duration longer than L6-03. Prompt resolution is crucial to prevent mechanical damage to the machine or motor.
Overtorque Detection 2
This fault signifies a mechanical issue with the machine, such as a lock, or improperly set load parameters. The drive detects this fault if the output current surpasses the threshold defined by L6-05 for a period longer than L6-06. Ignoring this fault can lead to significant mechanical stress and potential equipment failure.
Mechanical Weakening Detection 1
This fault occurs when the drive detects an overtorque condition that meets the criteria for mechanical weakening, as defined by the L6-08 [Mechanical Fatigue Detect Select] parameter. This suggests a potential deterioration or fatigue in the mechanical components of the system. Failure to address this can result in unexpected mechanical breakdown.
High Slip Braking Overload
This fault is triggered when the load inertia is excessively large, an external force rotates the motor, or deceleration is impeded. It can also occur if the n3-04 [HSB Overload Time] parameter is set too low. The drive detects this when the output frequency remains constant beyond the duration specified by n3-04. Ignoring this can lead to excessive heat and damage to the drive or motor.
Keypad Connection Fault
This fault indicates that the keypad is either not securely connected to the drive or its connection cable is damaged or disconnected. It specifically triggers if keypad disconnect detection is enabled (o2-06=1) and the run command is from the keypad or the drive is operating in LOCAL mode with the keypad. An insecure connection prevents proper control and monitoring of the drive.
Overspeed
This fault occurs due to speed overshoot, incorrect PG pulse settings in the drive, or an improperly configured overspeed detection level. An overspeed condition can lead to mechanical failure, instability, and safety hazards if not promptly addressed.
Keypad Time Not Set
This fault indicates that the keypad contains a battery, but the date and time have not been configured. This prevents proper logging and timestamping of events, potentially hindering accurate troubleshooting later. This detection can be enabled/disabled via parameter o4-24.
Undertorque Detection 1
This error suggests a machine fault, such as a broken pulley belt, or incorrect load parameters causing the motor to operate with insufficient torque. The drive triggers this error if the output current falls below the level set in L6-02 for a duration exceeding L6-03. This can lead to process disruptions or damage if the motor is allowed to run under these conditions.
Undertorque Detection 2
This error indicates a mechanical problem, like a broken drive belt, or that the load parameters are incorrectly configured, resulting in the motor drawing less current than expected. The drive detects this when the output current drops below the threshold set in L6-05 for longer than L6-06. Persistent undertorque can signal a serious mechanical malfunction or inefficient operation.
Mechanical Weakening Detection 2
This error is generated when the drive detects an undertorque condition that satisfies the criteria for mechanical weakening, as configured by the L6-08 [Mechanical Fatigue Detect Select] parameter. This suggests potential wear, damage, or loosening of mechanical components within the system. Unresolved mechanical weakening can lead to catastrophic equipment failure.
DC Bus Undervoltage
This fault occurs due to a phase loss in the drive's input power, loose input wiring, excessive fluctuations or loss of input power, or degraded main circuit capacitors or soft-charge bypass relays. The drive detects this when the DC bus voltage falls below a critical level (e.g., 190V for 200V class, 380V for 400V class) while running. Sustained undervoltage can cause erratic drive behavior or complete shutdown.