Kollmorgen Repair Services – AKM Servo Motors, S700 & AKD Servo Drives
Wake Industrial specializes in Kollmorgen repair, replacement, and refurbishment services to get your production line back up and running. To receive an industry competitive, FAST quote on any Kollmorgen product, call 1-919-443-0207 or send an email to sales@wakeindustrial.com.
Kollmorgen is a leading manufacturer of motion control equipment, known for its AKM series synchronous servo motors and advanced S700 and AKD series servo drives. These high-performance motors and drives are the backbone of many industrial automation systems. However, even top-tier Kollmorgen products can experience faults or failures over time. In this guide, we provide an in-depth look at common fault codes and troubleshooting steps for AKM motors, S700 drives, and AKD drives – along with when to seek professional repair or replacement.
AKM Synchronous Servo Motors – Common Issues & Fixes
When to Call for Motor Repair: If you continue to experience motor-related faults after addressing wiring, cooling, and configuration issues, the AKM motor itself might be at fault. Symptoms like a persistent overtemperature trip or output stage fault often indicate internal problems (burnt windings, demagnetized rotor, sensor failures, etc.). In such cases, professional diagnosis is recommended. Wake Industrial offers expert servo motor repair and refurbishment. Rather than scrambling to find a brand-new motor (which can be costly or backordered), a refurbished Kollmorgen AKM motor from Wake Industrial can often solve the problem quickly and cost-effectively.
Kollmorgen’s AKM family of brushless synchronous servo motors are widely used for their reliability and high dynamic performance. The motors themselves don’t display error codes, but when an AKM motor has a problem, the connected servo drive will usually register a fault code indicating a motor-related issue. Here are some common AKM motor fault conditions and how to diagnose and fix them:
COMMON AKD FAULTS, CAUSES, AND FIXES
| Fault Code (Drive) | Description | Cause | Fix |
|---|---|---|---|
| S700 F06 / AKD F301 | Motor Overtemperature | Motor’s internal temperature sensor tripped (motor overheated due to overload or poor cooling). | Allow motor to cool; improve motor cooling/ventilation or reduce load. |
| S700 F15 / AKD F524 | Motor Overload (I²t) | Motor drew excessive current over time, causing drive thermal overload (often due to jammed or too heavy load). | Reduce mechanical load or duty cycle; use a larger drive/motor if needed. |
| S700 F04 / AKD F401 | Feedback/Encoder Fault | Feedback signal lost or invalid (encoder/resolver disconnected, miswired, or failed). | Check feedback device wiring and connections; ensure correct feedback type and replace device if faulty. |
| S700 F12 / AKD F525 | Motor Wiring/Phase Fault | A motor phase is not conducting or is shorted (cable break, loose connector, or short-circuit in motor wiring). | Inspect motor power cable and connectors; repair any wiring issues or replace damaged cables. |
| S700 F11 / AKD F305 | Motor Brake Fault | Motor brake coil fault (no current or abnormal current – brake coil open, shorted, or not releasing). |
Verify brake wiring and power supply; ensure brake control settings are correct and repair wiring or coil as needed. |
Kollmorgen S700 Servo Drives – Fault Codes & Troubleshooting
Professional S700 Drive Repair or Replacement: Many S700 faults can be resolved by the above adjustments or by replacing external issues (like cables or adding a braking resistor). But as noted, some faults (such as F07 or F14) indicate deeper hardware problems that simple troubleshooting cannot fix. If you’ve attempted the recommended fixes and the error still won’t clear, or if the same fault keeps returning frequently, it’s a clear sign the drive may need professional attention. In these cases, you should consider sending the drive for repair or getting a replacement unit to avoid prolonged downtime.
The Kollmorgen S700 (Servostar 700 series) servo drives are advanced digital drives designed for complex industrial applications. They include built-in diagnostics and will display error codes prefixed with “F” (fault) or “n” (warning) on the front panel LED display when issues occur. Fault codes (F##) indicate critical errors that stop drive operation, whereas warning codes (n##) denote non-critical issues. Below we outline common S700 fault codes, their typical causes, and recommended fixes:
COMMON S700 FAULTS, CAUSES, AND FIXES
| Fault Code | Description | Cause | Fix |
|---|---|---|---|
| F01 | Heat Sink Overtemp | Drive’s heat sink temperature exceeded limit (≈80 °C), usually due to inadequate ventilation or high ambient temperature. | Improve drive cooling and ventilation; ensure ambient temperature is within specification. |
| F02 | DC Bus Overvoltage | DC bus voltage rose above safe limit (often caused by aggressive deceleration regenerating power or input voltage surges). | Add or verify a braking resistor; adjust deceleration ramps or reduce load inertia; check incoming supply voltage. |
| F03 | Following Error | Motor position error too large – the servo failed to follow commanded position (likely due to mechanical binding, overload, or poor tuning). | Check for mechanical jams or overloads; improve servo tuning or modify motion profile to avoid excessive error. |
| F04 | Feedback Fault | Feedback device signals are faulty or lost (encoder/resolver cable disconnected, shorted, or feedback device failure). | Inspect feedback wiring and connections; fix any cable issues or replace the feedback device; verify proper feedback configuration. |
| F05 | DC Bus Undervoltage | DC bus voltage fell below threshold (power supply dip, loss of phase, or insufficient supply voltage). | Check AC supply wiring and voltage; ensure no missing phase and that the power source remains within required voltage. |
| F06 | Motor Overtemp | Motor’s thermal sensor indicates the motor is too hot (overheating due to overloading or cooling issues). | Improve motor cooling (e.g. add fan or heatsink) or reduce the load; allow motor to cool down before reuse. |
| F07 | Internal Voltages Fault | One of the drive’s internal supply voltages is out of range (could be caused by an internal hardware fault or a short on an I/O supply). | Remove any external loads or shorts on the drive’s I/O; if fault persists, the drive may require repair/replacement. |
| F08 | Overspeed | Motor velocity exceeded the allowable limit (motor ran faster than commanded, possibly due to instability or runaway condition). | Verify motor control tuning and feedback integrity; ensure speed command limits are set correctly and not exceeded. |
| F09 | EEPROM Checksum Error | Corruption or error in the drive’s non-volatile memory (parameter storage error). | Reload or reset drive parameters from backup; if issue persists, update drive firmware or contact support for repair. |
| F11 | Brake Fault | Detected fault in motor brake circuit (brake coil not drawing current or shorted – wiring break or coil issue). | Inspect motor brake wiring and connections; repair any breaks or shorts in brake coil circuit and verify brake engagement. |
| F12 | Motor Phase Missing | One phase of the motor is not detected (open circuit in one motor power phase or disconnected motor lead). | Check motor power cable for loose or broken connections on all phases; repair wiring and ensure all phases are properly connected. |
| F13 | Ambient Overtemp | The ambient or cabinet temperature is too high for the drive (above specified operating range). | Improve enclosure cooling or ventilation; reduce ambient temperature around drive to within spec. |
| F14 | Output Stage Fault | Drive’s output power stage encountered a fault (often due to a shorted motor output or internal drive failure). | Examine motor power cables for shorts or insulation damage; fix wiring issues. If fault continues, the drive’s power stage may be damaged and need service. |
| F15 | Drive Overload (I²t) | Drive was delivering excessive current over time, exceeding its thermal (I²t) limit (indicates continuous overload condition). | Reduce the mechanical load or duty cycle; consider using a higher-capacity drive or motor to handle the required load. |
| F16 | Mains Phase Fault | Missing phase in the AC supply (one or more of the three input phases is lost or significantly undervoltage). | Inspect incoming power for a dropped phase; check input wiring, fuses, and contactors, and restore all phases of the AC supply. |
| F17 | A/D Converter Error | Error in the drive’s analog-digital conversion (could result from extreme electrical noise or internal ADC hardware fault). | Improve grounding and shielding of power and signal cables to reduce electrical noise; if error persists, the drive might need repair. |
| F18 | Regen Brake Circuit Fault | Fault in the braking resistor circuit (internal regen transistor or external regen resistor issue – e.g. improper resistor or wiring fault). | Verify that the regen resistor is correctly connected and sized; check brake resistor settings and wiring. If internal brake circuit failed, the drive may need service. |
| F19 | DC Bus Collapse | The DC bus voltage collapsed suddenly (indicative of a sudden power loss or a severe internal fault on the bus). | Check the AC power supply and DC bus connections for disruptions; ensure stable power. If internal, the drive might have an internal fault. |
| F23 | CAN-Bus Off | Critical CAN communication failure (the CAN bus went into “bus off” state due to communication errors or wiring issues). | Inspect CAN bus wiring and termination; ensure matching bit rates and no bus wiring faults; reset the fault and re-enable communication once resolved. |
| F25 | Commutation Error | The drive detected an error in motor commutation (feedback signals not aligned or missing – e.g. Hall sensor or encoder phase issue). | Verify motor phase wiring and feedback alignment; correct any wiring mix-ups and ensure the commutation settings match the motor’s feedback. |
| F27 | STO Input Error | Safe Torque Off error – the STO circuit detected an improper condition (for example, enable signal given while STO inputs are active). | Check the STO (safety) input wiring and sequence; ensure STO inputs are inactive (drive enabled only when STO circuit is closed correctly). |
| F30 | Emergency Stop Timeout | The motor did not decelerate to stop within the expected time after an E-stop command (could be due to high inertia or too short a stop ramp). | Increase the emergency stop deceleration time or ramp; check for excessive load inertia and adjust as needed so the drive can stop the axis safely. |
| F32 | Internal System Error | General internal drive error (unexpected firmware or hardware malfunction). | Power-cycle the drive to reset. If the fault recurs frequently, contact Kollmorgen support or consider drive repair/replacement. |
Kollmorgen AKD Servo Drives – Fault Codes & Solutions
Expert Help for AKD Drives: If an AKD drive is repeatedly tripping faults despite your troubleshooting, or if you encounter complex issues (like firmware errors or persistent hardware faults in the F2xx range), it may be time to seek professional repair. The AKD is a sophisticated drive, and some faults – especially those indicating internal failures – will require component-level repair or drive replacement. Wake Industrial has extensive experience with Kollmorgen AKD servo drive repair. They maintain stock of refurbished AKD units, so if you need a quick swap-out, they can often supply a replacement to get you up and running with minimal delay. Rather than scrapping a costly AKD drive at the first sign of trouble, consider using Wake Industrial’s repair services to extend the life of your equipment and save on costs. Use the quote form on this page to place a quote now, so you can receive a response in as fast as 15 minutes during business hours.
The Kollmorgen AKD series are advanced digital servo drives that offer Ethernet-based connectivity (such as EtherCAT) and high flexibility for modern automation systems. AKD drives continuously monitor their status and will flash fault codes on their display (an alphanumeric LED) to alert users to problems. An AKD fault code is shown as “F” followed by a three-digit number on the drive’s status display (warnings are shown with “n” for notice). Knowing what these codes mean and how to address them is key to maintaining AKD-driven systems. Below are some of the common AKD fault codes and steps to resolve each:
COMMON FAULT CODES AND ERRORS
| Fault Code | Description | Cause | Fix |
|---|---|---|---|
| F101 | Firmware Incompatible | The installed firmware is not compatible with the drive’s hardware model or version. | Install the correct firmware version that matches the drive hardware. |
| F301 | Motor Overtemperature | Motor’s temperature sensor indicates overheating (motor exceeded safe temperature due to load or insufficient cooling). | Allow motor to cool down; improve motor cooling (add fan or heatsink) or reduce the load on the motor. |
| F302 | Overspeed | Motor speed exceeded the configured threshold (velocity limit), suggesting the motor was driven too fast or experienced a runaway. | Check servo tuning and feedback integrity; lower commanded speed or increase the overspeed threshold if appropriate (within safe limits). |
| F305 | Brake Open Circuit | No current detected through the motor’s brake coil (brake coil not connected or coil has failed open). | Check the motor brake wiring and connections; repair any breaks and ensure the brake coil is within specifications and properly powered. |
| F401 | Feedback Config Fault | Feedback device not detected or mismatched (e.g. wrong feedback type selected or feedback cable unplugged). | Verify the primary feedback is correctly wired to X10 and the feedback type setting matches the device; reconnect or replace feedback device as needed. |
| F402 | Feedback Signal Fault | Feedback signal amplitude out of range (for resolver or sin/cos encoder, signals are too low or missing). | Inspect the feedback cabling for loose connections or shield issues; replace or repair the feedback device if signal levels are incorrect. |
| F501 | Bus Overvoltage | DC bus voltage too high (usually caused by excessive regenerative energy from deceleration or an AC input surge). | Install or increase a braking resistor to absorb regen energy; lengthen decel ramps or reduce load inertia; verify AC supply voltage is within spec. |
| F502 | Bus Undervoltage | DC bus voltage dropped below the minimum threshold (due to AC supply dip or power loss). | Check the AC input supply and wiring for issues; ensure the mains voltage remains stable and within the required range. |
| F503 | Bus Capacitor Overload | Excessive DC bus ripple or loading detected (often occurs if using single-phase input on a drive rated for three-phase, over-stressing the bus capacitors). | Use proper three-phase mains as required or reduce the load; ensure the drive is operated per its power specifications. |
| F521 | Regen Over-Power | Regeneration power exceeded the capacity of the braking resistor (too much energy being dissipated during braking). | Use a larger or additional braking resistor with higher power rating; consider sharing the DC bus with other drives or an active regen unit to absorb energy. |
| F524 | Drive Overload (Foldback) | Drive’s continuous output limit was exceeded – the drive reduced output (foldback) to protect itself (indicates too high continuous load). | Decrease the motion demand or duty cycle; if application requires, upgrade to a drive (and motor) with higher continuous power capability. |
| F525 | Output Overcurrent | The drive detected output current beyond its peak limit (possible short in motor leads or a sudden severe load spike). | Inspect motor power cables for short-circuits or insulation damage; address any mechanical conditions (jams or shocks) that could cause abrupt high current draw. |
| F535 | Drive Overtemperature | The drive’s internal temperature sensor tripped (power electronics beyond safe temperature, >85 °C) due to heavy use or poor cooling. | Improve drive cooling and airflow; ensure ambient temperature is within range and reduce continuous load if necessary to prevent overheating. |
| F541–F543 | AC Input Phase Missing | One or more phases of the three-phase AC supply are missing (loss of phase L1, L2, or L3 due to power issue or blown fuse). | Check the three-phase mains supply and wiring; replace any blown fuses and restore all missing phases before powering the drive. |
Minimizing Downtime with the Right Repairs
When problems persist or the fault points to a deeper issue, don’t hesitate to leverage professional repair services. Wake Industrial stands out as a leading source for Kollmorgen repair, replacement, and refurbishment. They can diagnose tricky faults, repair drives and motors to factory specs, or provide refurbished units when you’re in a pinch. With fast turnaround times and a deep inventory of Kollmorgen parts. Wake Industrial helps turn lengthy downtime into a quick, manageable maintenance event.
If you’re facing a Kollmorgen servo motor or drive issue that you’re not equipped to fix, contact Wake Industrial for a thorough repair solution. Call 1-919-443-0207 or send an email to sales@wakeindustrial.com. With the right expertise on your side, even the most stubborn fault codes can be cleared and your production kept on track. Don’t let an unexpected drive fault or motor failure halt your operations – a mix of proactive troubleshooting and reliable repair support will ensure your Kollmorgen systems continue to perform at their best.
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