Allen-Bradley Kinetix 5700 servo drive troubleshooting
The Kinetix 5700 is Rockwell Automation’s multi-axis servo drive system on EtherNet/IP, with DC-bus power supplies, regenerative bus supplies and single- and dual-axis inverters controlled from a Logix 5000 controller. Faults are shown on each module’s LCD as text such as “FLT S54 – POSN ERROR” and are also reported to the controller axis tags.
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How it reports faults
- Each module has an LCD. Under MAIN MENU select FAULT LOG to see active faults, the fault details and the fault help (possible solutions).
- Power supplies and inverters keep a persistent, time-stamped log of the last 128 faults. The log cannot be cleared on the module.
- Code types: FLT Sxx (standard runtime exceptions), FLT Mxx (manufacturer-specific), INIT FLT (initialization), NODE FLT (whole module), NODE ALARM and ALARM (report only), INHIBIT (drive prevented from enabling), SAFE FLT (safety function).
- FL at the end of the text means a factory-set limit was exceeded; UL means a user-set limit (for example FLT S07 – MTR OVERLOAD FL vs FLT S08 – MTR OVERLOAD UL).
- A Fault Reset from the controller clears the display only if the condition has gone. Use the AxisState tag, not AxisFault, to tell whether an axis is faulted.
Fault codes
| Code | Name |
|---|---|
| FLT S54 | POSN ERROR (Excessive Position Error Fault) |
| FLT S43 | FDBK LOSS FL (Feedback Signal Loss, factory limit) |
| FLT S07 | MTR OVERLOAD FL (Motor Thermal Overload, factory limit) |
| FLT S03 | MTR OVERSPEED FL – Motor overspeed, factory limit |
| FLT S05 | MTR OVERTEMP FL – Motor overtemperature, factory limit |
| FLT S08 | MTR OVERLOAD UL – Motor thermal overload, user limit |
| FLT S10 | INV OVERCURRENT – Inverter overcurrent |
| FLT S13 | INV OVERLOAD FL – Inverter thermal overload, factory limit |
| FLT S16 | GROUND CURRENT FL – Ground current, factory limit |
| FLT S22 | AC POWER LOSS |
| FLT S23 | AC PHASE LOSS |
| FLT S33 | BUS UNDERVOLT FL – DC-bus undervoltage, factory limit |
| FLT S35 | BUS OVERVOLT FL – DC-bus overvoltage, factory limit |
| FLT S37 | BUS POWER LOSS |
| FLT S45 | FDBK COMM FL – Motor feedback data loss, factory limit |
| FLT S47 | FDBK DEVICE FAILURE – Motor feedback device failure |
| FLT S50 | POS HW OTRAVEL – Positive hardware overtravel |
| FLT S51 | NEG HW OTRAVEL – Negative hardware overtravel |
| FLT S55 | VEL ERROR – Excessive velocity error |
| FLT S56 | OVERTORQUE LIMIT |
| FLT S61 | ENABLE INPUT |
| FLT M05 | FDBK BATTERY LOSS – Battery low, absolute position lost |
| FLT M06 | FDBK BATTERY LOW |
| INIT FLT M03 | MTR ENC STARTUP – Motor feedback communication startup |
| NODE FLT 01 | LATE CTRL UPDATE – Control connection update fault |
| INHIBIT M05 | SAFE TORQUE OFF – Start inhibit, safe torque off |
Evidence to collect
- Photo of the LCD with the full fault text and any sub-code
- Fault log entries with time stamps
- Studio 5000 axis properties: motor, feedback, Position Error Tolerance
- Drive and motor catalog numbers and firmware revision
- What the axis was doing at the fault
Work on fuel trains, burners, pressure vessels and electrical equipment must be done by qualified personnel following the manufacturer’s documentation and local codes. Never bypass a safety device or interlock.