Category: Other Drives

Introduction

The Hilectro HI200 series servo drives are widely utilized in industrial automation for their high-performance capabilities, enabling precise control of servo motors to achieve efficient and accurate production processes. However, in practical applications, various faults may arise, with ER062 (phase current acquisition fault) being a common error code. This fault typically indicates an issue with the drive’s ability to acquire or measure phase current. If left unaddressed, it can lead to drive or motor damage and disrupt the stability of an entire production line.

This article leverages the user-provided screenshots and servo drive manual, combined with general servo drive troubleshooting expertise, to provide a detailed explanation of the potential causes, diagnostic steps, and solutions for the ER062 fault. The goal is to offer clear, logically sound, and practical guidance to help users resolve this issue effectively.

Section 1: Understanding the ER062 Fault (Phase Current Acquisition Fault)

1.1 What is Phase Current?

Phase current refers to the current flowing through each phase (A, B, C) in a three-phase AC system. In servo drives, measuring and controlling phase current is critical, as it directly impacts motor performance and protection mechanisms. Drives use current sensors (such as Hall effect sensors or shunt resistors) to acquire phase current, which is then processed by the control circuitry for vector control, overcurrent protection, and other functions.

1.2 Meaning of the ER062 Fault

The ER062 error code signifies a fault in the drive’s phase current acquisition process. Specifically, this could mean:

• The drive fails to accurately read or process phase current signals.
• There is an issue with the phase current acquisition circuit, such as a faulty sensor, broken wiring, or short circuit.
• An abnormality exists within the drive’s internal control circuitry.

As ER062 is specific to the Hilectro HI200 series, referencing the provided manual (Attachment ID: 2) or user screenshots (Attachment ID: 0) is essential for precise details. The flowchart (Attachment ID: 0) groups ER062 with ER057 and ER061 under phase current acquisition faults, suggesting a potential hardware or connection issue.

1.3 Why Phase Current Acquisition Faults Matter

Phase current acquisition is a core function of the drive. A fault in this area can result in:

• Inaccurate motor control, affecting position or speed precision.
• Disabled overcurrent protection, increasing the risk of motor or drive damage.
• Reduced overall system stability, impacting production efficiency.

Prompt diagnosis and resolution of the ER062 fault are therefore crucial.

Section 2: Common Causes of the ER062 Fault

Based on the characteristics of the Hilectro HI200 series and typical servo drive failure modes, the ER062 (phase current acquisition fault) may stem from the following causes:

2.1 Connection Issues

• Loose or Disconnected Cables: If the connection cables between the drive and motor (especially current acquisition lines) are loose or broken, the drive may fail to acquire phase current.
• Improperly Seated Plugs: The current acquisition module may rely on plugs, and poor contact due to incomplete insertion can trigger the fault.

2.2 Sensor Failures

• Damaged Current Sensors: Faulty sensors (e.g., Hall effect sensors or shunt resistors) due to aging or overloading can disrupt current acquisition.
• Calibration Issues: Uncalibrated sensors may prevent the drive from accurately reading phase current values.

2.3 Wiring Problems

• Short Circuits or Open Circuits: A short or open in the phase current acquisition wiring (from motor to drive) can compromise signal integrity.
• Interference or Noise: External electromagnetic interference or noise in the wiring may cause the drive to misinterpret current signals.

2.4 Internal Drive Issues

• Control Board Failure: The control board, responsible for processing current signals, may malfunction due to chip damage or poor soldering.
• Firmware or Software Bugs: Though rare, an outdated firmware version or software glitch could affect current acquisition functionality.

2.5 Motor Issues

• Short or Open Windings: Internal motor winding faults can disrupt normal phase current flow, leading to acquisition errors.
• Faulty Motor Cables: Damaged or poorly connected motor cables may also contribute to the problem.

2.6 Environmental Factors

• High Temperature or Dust: Excessive heat or dust accumulation can destabilize internal components like sensors or connectors.
• Vibration or Shock: Industrial vibrations or impacts may loosen connections or damage components.

The following table summarizes potential causes of the ER062 fault and their characteristics:

Cause Category	Specific Cause	Symptoms/Characteristics
Connection Issues	Loose or disconnected cables, unseated plugs	ER062 appears; may resolve temporarily after reseating
Sensor Failures	Damaged sensors, calibration errors	Abnormal or missing phase current signals
Wiring Problems	Short circuits, open circuits, electromagnetic interference	Unstable current signals, possible additional electrical faults
Internal Drive Issues	Control board failure, firmware bugs	Persistent fault despite normal connections
Motor Issues	Short or open windings, faulty cables	Motor runs abnormally, possibly with overheating
Environmental Factors	High temperature, dust, vibration	Intermittent faults linked to environmental changes

Section 3: Diagnostic and Resolution Steps for ER062 Fault

Below are detailed diagnostic and resolution steps for the ER062 fault in the Hilectro HI200 series, based on the user’s flowchart (Attachment ID: 0) and general servo drive troubleshooting practices.

3.1 Verify Phase Current Status

• Steps:
  • Use a multimeter or oscilloscope to check the phase current signals on the A, B, and C phases.
  • Ensure the current waveforms are sinusoidal and within expected values during normal operation.
• Judgment:
  • If phase current is abnormal (e.g., no signal or erratic readings), the issue may lie in connections or wiring.
  • If phase current is normal but ER062 persists, an internal drive problem is likely.
• Tools: Multimeter, oscilloscope.

3.2 Inspect Connections

• Steps:
  • Ensure the cables between the drive and motor (especially current acquisition lines) are secure.
  • Check that plugs are fully inserted and contacts are good.
  • Reseat cables if necessary.
• Precautions:
  • Disconnect power before inspecting to avoid electrical hazards or equipment damage.
  • This is the first step recommended by the flowchart (Attachment ID: 0).

3.3 Troubleshoot Wiring and Sensors

• Steps:
  • Use a multimeter to test the phase current acquisition wiring for short circuits or open circuits.
  • If accessible, verify the output of the current sensors.
• Precautions:
  • Replace damaged wiring if found.
  • Replace the sensor module if defective (refer to the manual, Attachment ID: 2).

3.4 Check Internal Drive Components

• Steps:
  • If prior steps fail, the issue may be an internal control board or firmware problem.
  • Per the flowchart (Attachment ID: 0), if phase current is normal but the fault persists, return the drive to the factory for professional inspection.
• Special Note:
  • For the Hi282 model, a boot alarm may require mainboard replacement.
• Reference: Hilectro HI200 Series Manual (Attachment ID: 2).

3.5 Inspect the Motor

• Steps:
  • Use a multimeter to check motor windings for shorts or opens.
  • Ensure motor cables are intact.
• Precautions:
  • Replace or repair the motor if issues are detected.

3.6 Environmental Assessment

• Steps:
  • Verify that the ambient temperature around the drive is below 40°C.
  • Remove dust from the drive’s surface and ventilation areas.
• Precautions:
  • Keep the drive away from strong electromagnetic interference sources.

3.7 Restart and Parameter Check

• Steps:
  • Restart the drive to see if the fault clears.
  • If possible, review drive parameter settings (e.g., current feedback gain) for accuracy.
• Precautions:
  • Refer to the manual (Attachment ID: 2) for parameter details, ensuring settings match the application.

3.8 Contact Technical Support

• Steps:
  • If all else fails, contact Hilectro technical support or arrange for factory service.
• Precautions:
  • Provide the error code, model number, and a detailed fault description when seeking support.

The following table outlines the diagnostic steps and their priority:

Step	Priority	Tools Required	Expected Outcome
Verify Phase Current Status	High	Multimeter, oscilloscope	Confirm normal current signals
Inspect Connections	High	None	Ensure secure connections
Troubleshoot Wiring/Sensors	Medium	Multimeter	Rule out shorts or opens
Check Internal Components	Medium	None (professional tools)	Determine need for factory service
Inspect Motor	Medium	Multimeter	Exclude motor winding/cable issues
Environmental Assessment	Low	None	Ensure suitable operating conditions
Restart and Parameter Check	Low	None	Resolve temporary faults
Contact Technical Support	Last Resort	None	Obtain professional assistance

Section 4: Preventive Measures

To prevent the recurrence of the ER062 (phase current acquisition fault), users can adopt the following preventive strategies:

4.1 Regular Maintenance

• Periodically inspect drive-to-motor cable connections for tightness and plug integrity.
• Clean the drive’s surface and vents to prevent dust buildup.

4.2 Environmental Control

• Maintain operating temperatures below 40°C and humidity below 90%.
• Avoid installing the drive in areas prone to vibration or impact.

4.3 Parameter Management

• Regularly back up drive parameter settings for easy recovery during restarts or replacements.
• Understand parameter meanings before adjustments, referencing the manual (Attachment ID: 2).

4.4 System Monitoring

• Use monitoring systems to track drive performance, particularly phase current values.
• Set alarm thresholds to detect anomalies early.

4.5 Firmware Updates

• Check for and apply the latest firmware updates to address known issues.

Conclusion

The ER062 (phase current acquisition fault) in Hilectro HI200 series servo drives, though common, can typically be resolved through systematic diagnosis and repair steps. This article, informed by user-provided screenshots and the manual, along with general servo drive troubleshooting knowledge, offers a comprehensive approach to addressing the issue.

It’s important to note that since ER062 is specific to the Hilectro HI200 series, users should prioritize consulting the official manual or contacting technical support for the most accurate guidance. If the problem cannot be resolved independently, returning the drive to the factory for professional servicing is recommended.

By implementing regular maintenance, environmental controls, and proper operating practices, users can significantly reduce the likelihood of ER062 faults, ensuring the stability and efficiency of their production systems.

Introduction

In the realm of industrial automation, servo systems are pivotal for achieving precise motion control, finding widespread use in CNC machines, robotics, packaging lines, and more. However, as complex electronic devices, servo systems can encounter faults that disrupt production. The ER055 hardware overvoltage fault (Hardware Overvoltage Fault) in the Hilectro HI282 series servo system is a common issue that can severely impact equipment operation. This article delves into the meaning of the ER055 fault, its potential causes, resolution methods, and preventive measures, empowering users to diagnose and address the problem efficiently while ensuring system stability.

Meaning of the ER055 Fault

The ER055 fault code in the Hilectro HI282 series servo system signifies a “hardware overvoltage” condition. This indicates that the internal voltage within the servo driver has exceeded its safe operating range, potentially triggering protective mechanisms that halt operation. According to the HI2xx series servo manual (Version 5.51), fault codes are typically displayed as “ErOSX,” where X denotes a specific fault number. For instance, “ErOS5” corresponds to fault number 53, indicating a system error. ER055 likely represents fault number 55, specifically a hardware overvoltage error, often linked to power supply, regenerative energy, or hardware issues requiring immediate attention.

Common Causes of ER055 Hardware Overvoltage Fault

Several factors may contribute to a hardware overvoltage fault, including:

1. Excessive Power Supply Voltage
   If the voltage supplied to the servo driver exceeds its rated value, it can trigger overvoltage protection. For example, the HI282 series driver typically operates within a specified voltage range (details in the manual), and exceeding this range can lead to an ER055 fault.
2. Excessive Regenerative Energy
   During rapid motor deceleration, the servo motor generates regenerative energy (converting kinetic energy into electrical energy fed back to the driver). If the driver’s regenerative resistor lacks sufficient capacity or is faulty, this energy can cause internal voltage spikes, triggering the fault.
3. Internal Component Failure
   Faulty voltage detection circuits, power modules, or capacitors within the driver can lead to inaccurate voltage monitoring or actual voltage anomalies. For instance, aged capacitors or damaged transistors might be culprits.
4. Wiring and Grounding Issues
   Improper wiring, loose connections, or inadequate grounding can result in voltage fluctuations or interference, activating overvoltage protection. Examples include loose power lines or improper grounding setups.

The following table summarizes potential causes and their characteristics:

Cause	Characteristics	Potential Impact
Excessive Power Voltage	Input voltage exceeds rated range	Driver halts, displays ER055
Excessive Regenerative Energy	Voltage rise during rapid deceleration	Overvoltage protection triggered
Internal Component Failure	Abnormal voltage detection or hardware damage	Frequent faults or unresolvable issues
Wiring/Grounding Issues	Voltage spikes or interference	Unstable operation, intermittent faults

Steps to Resolve ER055 Hardware Overvoltage Fault

Resolving an ER055 fault requires a systematic troubleshooting approach. The following steps are recommended:

1. Check Power Supply Voltage
   • Use a multimeter to measure the input voltage to the servo driver, ensuring it aligns with the rated range specified in the HI282 manual.
   • If the voltage is too high, inspect the power source (e.g., transformer or regulator) and adjust it accordingly.
   • Ensure power stability to avoid fluctuations or spikes.
2. Inspect Regenerative Resistor
   • Confirm the presence and functionality of the regenerative resistor.
   • Check for signs of burnout, open circuits, or shorts.
   • Replace with a resistor of adequate capacity if it’s insufficient (refer to manual recommendations).
3. Inspect Internal Components
   • Look for abnormal signs in the driver, such as overheating, unusual noises, or a burnt smell, which may indicate component failure.
   • Note: Non-professionals should not disassemble the driver; contact a Hilectro authorized service center for repairs.
4. Examine Wiring and Grounding
   • Ensure all power, signal, and ground connections are secure and correctly configured, with no loose or broken wires.
   • Verify grounding meets manufacturer standards, as proper grounding reduces interference and voltage spikes.
   • Use an oscilloscope to check for voltage surges or electromagnetic interference.
5. Reset the Driver
   • Attempt a power cycle by disconnecting the power, waiting a few minutes, then restarting to see if the fault clears.
   • If the driver has a “STOP” button, press it to attempt clearing the error state (ERR status), returning the driver to READY mode.
6. Review Parameter Settings
   • Access the driver’s parameter settings to check configurations related to voltage or regenerative control.
   • If misconfigured, restore factory settings or adjust parameters per the manual.
7. Consult the Manual or Contact Technical Support
   • Refer to the HI282 series user manual for the specific definition of ER055 and recommended troubleshooting steps.
   • If unavailable or unresolved, contact Hilectro technical support with details of the fault code and operating conditions.
8. Consider Driver Replacement
   • If the above steps fail and the driver is out of warranty or repair costs are high, consider replacing it.
   • Ensure the new driver’s model and specifications are compatible with the system.

The following table outlines the resolution steps and precautions:

Step	Action	Precautions
Check Power Voltage	Measure input voltage	Stay within rated range
Inspect Regenerative Resistor	Check status and capacity	Avoid using damaged or mismatched resistors
Inspect Internal Components	Observe for anomalies	Require professional handling
Check Wiring/Grounding	Ensure secure connections, proper grounding	Check for voltage spikes or interference
Reset Driver	Power cycle or press STOP button	Record fault status before/after
Review Parameters	Adjust or reset settings	Refer to manual to avoid errors
Contact Support	Provide fault details	Prepare model and logs
Replace Driver	Select compatible model	Ensure system compatibility

Preventive Measures for ER055 Faults

To prevent recurrence of ER055 faults, consider the following measures:

1. Regular Maintenance
   • Periodically inspect the driver’s operating condition, including temperature, noise, and vibration.
   • Clean cooling fans and heat sinks to ensure effective heat dissipation.
   • Check the aging of capacitors, resistors, and other wear-prone components, replacing them as needed.
2. Stable Power Supply
   • Use reliable power equipment to maintain input voltage within the driver’s rated range.
   • Install voltage regulators or UPS (uninterruptible power supply) to mitigate voltage fluctuations.
3. Proper Acceleration/Deceleration Control
   • Set reasonable acceleration and deceleration times in the servo system’s control parameters to minimize regenerative energy.
   • Ensure the regenerative resistor’s capacity is sufficient for rapid deceleration scenarios.
4. Correct Wiring and Grounding
   • Follow the manual’s guidelines for wiring and grounding to prevent faults caused by improper connections.
   • Use shielded cables to reduce electromagnetic interference.
5. Train Operators
   • Ensure operators are familiar with the servo system’s operation and maintenance, enabling them to identify and report issues promptly.
   • Provide training on fault troubleshooting and prevention to enhance team capability.

Conclusion

The ER055 hardware overvoltage fault is a common issue in the Hilectro HI282 series servo systems, typically caused by excessive power voltage, regenerative energy overload, internal component failure, or wiring problems. Through systematic troubleshooting—such as checking the power supply, regenerative resistor, wiring, and parameter settings—users can effectively resolve this fault. Additionally, adopting preventive measures like regular maintenance, stable power, and proper control settings can significantly reduce fault occurrences, ensuring long-term system reliability. If the problem persists, contacting Hilectro technical support or a professional repair service is advised for detailed guidance or repairs.

Introduction

In the field of industrial automation, Variable Frequency Drives (VFDs) are core devices for controlling the rotational speed of AC motors, widely used in scenarios such as water pumps, conveyor belts, elevators, and machine tools. The Sanken SAMCO-VM05 series inverter is renowned for its compact design, high performance, and low noise characteristics. However, during operation, inverters may encounter faults, with the OCN fault (overcurrent during constant speed) being one of the more common issues. This article will delve into the definition, possible causes, solutions, and preventive measures of the OCN fault, providing users with a clear and practical guide.

What is an Inverter?

An inverter is an electronic device that converts a fixed-frequency power supply into a variable-frequency power supply for precise control of the rotational speed of AC motors. By adjusting the output frequency, inverters enable smooth motor starting, energy-efficient operation, and process optimization. In industrial applications, inverters not only improve equipment efficiency but also extend motor life and reduce maintenance costs.

The Sanken SAMCO-VM05 series inverter is a compact vector control inverter suitable for various industrial scenarios. Its main features include high performance, low noise, and ease of operation, making it particularly suitable for applications such as water pump systems, elevators, and machine tools. However, even high-quality inverters may experience faults due to various reasons, such as the OCN fault.

Definition of the OCN Fault

The OCN fault indicates that the Sanken SAMCO-VM05 inverter detects that the motor current exceeds its rated value during constant speed operation. This fault is typically displayed on the inverter’s control panel as “OCN” or a similar code (e.g., “αCη ※ 3”), prompting operators to take immediate action. Overcurrent can lead to damage to the inverter or motor, making timely diagnosis and resolution crucial.

Based on manuals for similar models (e.g., SAMCO-NS series) and fault code information provided by users, the OCN fault is typically associated with the following issues:

• Output circuit short-circuit or ground fault.
• Abnormal internal switching elements (e.g., IGBTs).
• Excessive or sudden load changes.
• Improper parameter settings.
• Motor faults.

Possible Causes of the OCN Fault

To effectively resolve the OCN fault, it is essential to understand its potential causes. The following are common factors that may lead to overcurrent during constant speed:

1. Output Short-Circuit or Ground Fault

A short-circuit or ground fault in the output circuit can cause a sudden increase in current, triggering the OCN fault. This may be caused by:

• Cable damage, such as broken or exposed insulation.
• Loose or poor connections.
• Insulation failure due to moisture or contamination.

2. Abnormal Internal Switching Elements

Power semiconductor elements (e.g., IGBTs) inside the inverter may fail due to:

• Aging from long-term use.
• Element damage caused by overheating.
• Manufacturing defects.

3. Excessive or Fluctuating Load

If the motor load exceeds its rated capacity or experiences sudden changes, it may cause a current surge. For example:

• Load exceeding the design range of the motor and inverter.
• Mechanical system (e.g., conveyor belt) experiencing jamming or sudden increases in resistance.

4. Improper Parameter Settings

The parameter settings of the inverter directly affect its operational performance. The following setting errors may lead to overcurrent:

• Excessively short acceleration/deceleration times, resulting in high current demand.
• Excessively high current limit value (e.g., Cd043).
• Improper torque compensation settings.

5. Motor Faults

Faults in the motor itself may also trigger the OCN fault, such as:

• Winding damage or short-circuit.
• Increased mechanical resistance due to bearing wear.
• Ground fault caused by motor insulation aging.

Fault Code Table

The following table, compiled based on fault code information provided by users, lists codes related to the OCN fault and their descriptions:

Fault Code	Description	Check Points
αCη ※ 3	Overcurrent during constant speed	Is there an output short-circuit or ground fault?
αCη ※ 3	Overcurrent during acceleration	Is the operation involving abrupt acceleration/deceleration?
αCη ※ 3	Overcurrent during deceleration	Is there an abnormality in the main switching element itself?
αCPη	Short-term overload during constant speed	Is the current limit value Cd043 too high?

Note: The OCN fault corresponds to “overcurrent during constant speed.”

Steps to Resolve the OCN Fault

The following are systematic steps to resolve the OCN fault, aimed at helping users quickly locate and resolve the issue:

1. Check the Output Circuit

Steps:

• Inspect the cable from the inverter to the motor for signs of damage, burns, or exposure.
• Ensure all terminal connections are secure and free from looseness.
• Use a multimeter to check for short-circuits or ground faults in the circuit.

Note: Before inspection, be sure to disconnect the power supply to ensure safety.

2. Verify the Load

Steps:

• Confirm that the motor load is within the rated range.
• Check for sudden load changes, such as mechanical jamming.
• If the load is excessive, consider reducing the load or replacing the motor and inverter with higher-power units.

Note: Load fluctuations may require adjustments to the process flow or the addition of buffer devices.

3. Check the Motor

Steps:

• Visually inspect the motor for physical damage, such as a cracked casing or unusual noises.
• Use an insulation tester to check the motor’s insulation resistance to ensure no ground faults exist.
• If possible, test the motor with another inverter to confirm whether the fault is caused by the motor.

Note: Motor maintenance should be performed regularly to avoid potential issues.

4. Adjust Parameters

Steps:

• Enter the inverter’s parameter setting menu to check the current limit value (e.g., Cd043), acceleration/deceleration times, and torque compensation settings.
• Adjust the parameters according to the load characteristics to ensure they match the application requirements.
• Refer to the recommended settings in the Sanken SAMCO-VM05 manual.

Note: Parameter adjustments should be made cautiously, and it is advisable to record the original settings for restoration if necessary.

5. Check the Cooling System

Steps:

• Inspect the cooling systems of the inverter and motor to ensure that the fans and heat sinks are functioning properly.
• Measure the ambient temperature to ensure it does not exceed the inverter’s rated operating temperature.
• Clean dust and debris to improve ventilation.

Note: Overheating can cause element damage and requires special attention.

6. Reset the Inverter

Steps:

• Turn off the inverter’s power supply and wait a few minutes before restarting it.
• Observe whether the fault disappears. If it does, continue monitoring the system’s operation.

Note: If the fault recurs, further hardware inspection is required.

7. Contact Technical Support

Steps:

• If the above steps fail to resolve the issue, contact Sanken technical support or a professional technician.
• Provide the fault code, system configuration, and the steps you have already attempted to facilitate quick diagnosis.

Note: Internal element faults may require professional repair or replacement.

Preventive Measures

To reduce the occurrence of the OCN fault, the following preventive measures are recommended:

Regular Maintenance:

• Regularly inspect the inverter, motor, and circuit, clean dust, and ensure proper ventilation.
• Check for loose terminal connections and aging cables.

Proper Installation:

• Install the inverter in a dry, clean, and well-ventilated environment.
• Use cables that meet specifications and ensure secure connections.

Appropriate Selection:

• Ensure that the power of the inverter and motor matches the application requirements to avoid overloading.

Parameter Configuration:

• Correctly set parameters according to the Sanken manual and application requirements to avoid faults caused by incorrect settings.

Personnel Training:

• Train operators and maintenance personnel to ensure they are familiar with the operation and fault handling procedures of the inverter.

Conclusion

The OCN fault (overcurrent during constant speed) of the Sanken SAMCO-VM05 series inverter may be caused by various factors, including output short-circuits, load issues, improper parameter settings, or hardware faults. Through systematic inspection and adjustment, users can effectively resolve this issue. Regular maintenance, proper installation, and appropriate parameter configuration are key to preventing faults. If the problem persists, it is advisable to contact Sanken technical support or a professional technician for in-depth diagnosis.

By following the guidelines provided in this article, users can better understand and handle the OCN fault, ensuring the stable operation and long-term reliability of the inverter system.

References

• Sanken SAMCO-NS Series Manual (Reference for Similar Models)
• Fault Code List Provided by Users (Attachment ID: 2)

In the field of industrial automation, frequency inverters play a critical role in motor control. The stable operation of these devices is vital to maintaining production efficiency. The GTAKE GK820 series inverter, known for its performance and reliability, is widely used in various mechanical equipment. However, during operation, users may encounter OH-series fault codes (such as OH1, OH2, OH3), which indicate issues related to overheating protection. Understanding the causes and countermeasures for these faults is essential for maintenance and troubleshooting.

1. Overview of OH Fault Codes

The OH-series fault codes on the GK820 inverter signify temperature-related issues that trigger automatic protection mechanisms. The main OH faults include:

• OH1: Heatsink Overtemperature
• OH2: External Thermal Protection Input
• OH3: Internal Module Overtemperature

When these faults occur, the inverter halts operation to prevent damage to internal components.

2. Root Causes of Each OH Fault

OH1: Heatsink Overtemperature

The heatsink is critical for dissipating the internal heat generated during inverter operation. When its temperature exceeds a safe threshold, the OH1 fault is triggered.

Possible Causes:

• High ambient temperature
• Dust accumulation or blocked airflow on the heatsink
• Fan failure or insufficient air volume
• Poor ventilation around the inverter

OH2: External Thermal Protection Input

OH2 faults are generally triggered by external thermal sensors (e.g., motor PTCs) connected to the inverter’s input terminal.

Possible Causes:

• High ambient temperature
• Incorrect thermal protection point setting
• Faulty or broken temperature detection circuit
• Poor contact or loose connection on the temperature sensor

OH3: Internal Module Overtemperature

OH3 indicates that the inverter’s internal components have exceeded their rated operating temperature.

Possible Causes:

• Internal fan malfunction
• Blocked internal air ducts
• Faulty internal circuit board
• Long-term overload operation without proper cooling
• Internal temperature detection circuit failure

3. Troubleshooting and Solutions

Resolving OH1 Fault:

• Check ambient temperature: Ensure the installation environment is below 40°C.
• Clean the heatsink: Remove dust and debris regularly to maintain airflow.
• Inspect the cooling fan: Verify that the fan is working properly; replace it if necessary.
• Improve ventilation: Leave enough space around the inverter for air circulation and avoid proximity to heat sources.

Resolving OH2 Fault:

• Check motor thermal sensor (PTC): Ensure correct type and proper installation.
• Verify parameter settings: Set the correct motor overheat protection threshold.
• Inspect signal wiring: Ensure the sensor wiring is securely connected and undamaged.
• Use shielded cable: Reduce electrical interference on sensor signals.

Resolving OH3 Fault:

• Inspect internal fans: Confirm proper operation and replace faulty fans.
• Clean internal components: Remove dust that may be affecting internal heat dissipation.
• Check module temperature detection circuit: Use a multimeter or diagnostic tool to verify if the circuit is working.
• Avoid overload operation: Reduce long-term full-load usage; apply load margins.
• Seek service: If the fault persists after inspection, contact GTAKE technical support.

4. Preventive Measures

• Routine cleaning: Clean air filters, fans, and heatsinks regularly to prevent dust accumulation.
• Ambient monitoring: Use sensors to monitor room temperature and humidity.
• Schedule maintenance: Periodically inspect terminal blocks, connectors, and sensors.
• Avoid overloading: Size the inverter and load correctly; prevent continuous operation at high torque.
• Install in suitable environments: Avoid corrosive gases, high humidity, or poor ventilation.

5. Summary

The OH fault codes in the GK820 series are designed to protect the inverter from damage caused by overheating. By identifying the specific fault (OH1, OH2, or OH3), users can systematically diagnose the root cause and take appropriate corrective actions. Preventive maintenance and environmental management are key to avoiding these issues.

Proper installation, regular inspection, and adherence to usage guidelines will significantly reduce the occurrence of thermal faults and extend the service life of the inverter. If problems cannot be resolved on-site, contacting professional technical support is recommended.

1. Background and Fault Phenomenon

At industrial sites, the Shihlin SF series inverters (e.g., SF‑040‑5.5K) display both “E1” and “BE” (or “bE”) codes simultaneously on the screen, as shown in the figure. This indicates that the inverter is currently in an “E1.BE” alarm state, typically accompanied by internal control shutdown, output disconnection, and other protective actions, causing the driven motor to stop running and affecting production continuity.

2. Alarm Code Interpretation

2.1 Definition of “E1” Abnormality

“E1” is the first-level alarm (Latest Alarm) of the inverter, used for general abnormality alarms. It is triggered immediately when an abnormality occurs in any aspect. However, this code does not directly define the cause of the fault but serves as a “trigger alarm” indicator, requiring subsequent additional information to determine the specific fault.

Through parameter group 06‑5606‑61 (e.g., P.752–P.757), the output frequency, current, voltage, temperature rise, PN voltage, and elapsed operating time at the time of the alarm can be read to assist in diagnosis.

2.2 Meaning of “BE” / “bE” Fault

“BE” refers to Brake‑relay abnormality, one of the hardware detection alarms, indicating an abnormality in the brake relay circuit or an out-of-range detection value.

The relevant code comparison also states: “brake resistor abnormal (Abnormal relay).”

Therefore, “E1.BE” indicates that the inverter has simultaneously triggered an E1 alarm and detected an abnormality in the brake unit.

3. Possible Causes of the Fault

Based on the hardware structure and on-site operating characteristics, the causes can be classified into the following categories:

3.1 Brake Relay Body Fault

The brake relay may have poor contact, damaged moving and stationary contacts, a short-circuited/open-circuited relay coil, etc., preventing it from switching states normally or causing abnormal sensing.

3.2 Brake Module and Resistor Abnormality

If the inverter integrates a braking unit (DBU) but the internal braking resistor is damaged, open-circuited, or loosely connected, it will also result in a failed detection of the brake circuit, triggering a BE alarm.

3.3 Loose Wiring or Interface

The brake unit is connected to the inverter mainboard via pins or terminals. If the connection is loose, oxidized, or dirty, it will also result in the inability to detect the expected state.

3.4 External Circuit Interference

Electromagnetic interference or high-voltage power supplies can cause malfunctions in the brake control circuit, including frequent operation of the brake relay or abnormal feedback. The manual recommends adding magnetic rings for filtering on sensitive lines.

4. Diagnostic Process and Response Strategies

4.1 Safety Isolation and On-Site Initial Inspection

• Power off and shut down the machine, turn off the main power supply, and wait for the DC circuit charge to dissipate (red light goes out).
• Ensure there is no voltage before opening the front door/removing the panel to avoid electric shock.

4.2 Inspection of Wiring, Plugs, and Interfaces

• Disassemble the brake module, clean the interface, and use 600# fine sandpaper or contact cleaner to treat the oxide layer.
• Ensure all connections are tight and reliable, with no increase in impedance.

4.3 Testing of Relay Coil and Moving Contacts

• Use a multimeter to measure the coil resistance to check for open/short circuits.
• Power on and test the coil drive to measure whether it engages. If it fails to engage or the contacts do not close, it is damaged.

4.4 Electromagnetic Interference Investigation

• Check if the brake lines are bundled with high-voltage main circuits or contactor output lines.
• Install magnetic rings or EMI filters and plan the wiring sequence to avoid mutual interference.

4.5 Replacement of Spare Relays or Components

• If a relay is suspected to be damaged, contact the manufacturer to purchase compatible replacement parts. If necessary, send the inverter along with the brake unit for repair.

5. On-Site Maintenance Recommendations

5.1 Regular Inspections

The brake relay should be maintained every 3–6 months, including cleaning the coil, contacts, and checking the wiring harness.

5.2 Environmental Considerations

• Avoid operating the inverter in humid, vibrating, or dusty environments; if necessary, equip the inverter with a protective enclosure and ensure good heat dissipation.

5.3 Parameter Monitoring and Alarm Logging

• Enable parameter groups P.290, P.291, etc., to collect brake action records through the PU panel or PC, enabling earlier detection of abnormal trends.

5.4 Comprehensive Analysis of E1 Abnormalities

“E1,” as a first-level alarm, can be paired with parameter groups P.752–P.758 to obtain on-site condition data. Combined with the alarm code BE, it generally indicates a hardware problem rather than operational parameter issues such as current overload.

6. Case Studies

Case 1: Brake Coil Open Circuit

An inverter on-site displayed an E1.BE alarm. Upon disassembly and inspection, it was found that the brake module had been used for an extended period in a hot environment, causing insulation aging and an open circuit in the internal coil. Replacing the relay module restored normal operation.

Case 2: Connector Oxidation

After multiple power-on cycles, the exposed positions of the relay interface oxidized, resulting in poor contact. Cleaning the contacts, applying anti-oxidation oil, and tightening the connections eliminated the fault.

Case 3: Strong Electrical Interference Triggering False Alarms

The brake output lines were frequently routed in parallel with the main power supply, subject to electromagnetic interference. The factory installed magnetic rings for filtering on the brake lines and rerouted them, after which the BE alarm did not recur.

7. Summary and Recommendations

“E1.BE” represents a brake relay hardware abnormality, not an ordinary PID or current overload fault. Handling should focus on hardware, wiring, and electromagnetic environment investigations. Key points are as follows:

• Ensure safety by powering off before operations.
• Carefully inspect the relay body and coil.
• Clean and tighten all relevant wiring and connectors.
• Strengthen wiring and filtering to prevent EMI.
• Enable alarm logging and monitoring, and conduct regular inspections.
• Replace modules or report to the Shihlin manufacturer for repair if necessary.

By following these methods, on-site equipment can quickly resume stable operation, reducing the risk of mis-shutdowns and production interruptions.

8. Final Recommendations

• Incorporate brake relays and modules into routine maintenance projects.
• Conduct special inspections of on-site wiring specifications and EMI layout.
• Recommend configuring spare parts for commonly used modules at key nodes for quick replacement.
• If BE alarms occur frequently, suspect core hardware aging and directly contact the manufacturer for repair. Do not ignore hardware quality issues.

Introduction

The SQ1000 series inverter, manufactured by Suqu, is a robust and versatile piece of industrial equipment designed to deliver high torque, precision, and a wide range of speed adjustments for various mechanical applications. Its advanced control technology and adaptability to harsh environmental conditions—such as fluctuating power grids, extreme temperatures, humidity, and dust—make it a popular choice in industrial settings. However, like any sophisticated machinery, it can encounter operational issues, one of which is the E-15 fault code. According to the SQ1000 Series Inverter Detailed Manual, the E-15 code signifies “undervoltage during operation.” This article provides an in-depth exploration of what this fault code means, its potential causes, and a comprehensive guide to troubleshooting and preventing it, based on the user-provided image and manual references.

What is the E-15 Fault Code?

Definition and Significance

The E-15 fault code on the SQU1000 inverter indicates that the device has detected an input voltage below the acceptable threshold while it is actively running. This undervoltage condition triggers a protective mechanism to halt operation, preventing potential damage to the inverter or the connected motor. The manual (page 66) lists E-15 under the fault code table, explicitly associating it with “undervoltage during operation.” The undervoltage protection threshold is typically governed by parameter F8.02, which defines the voltage level below which the inverter will trip. For instance, if F8.02 is set to 160V, the inverter will display E-15 and stop if the input voltage drops below this value during operation.

This fault is significant because it not only interrupts the inverter’s functionality but also signals an underlying issue that could affect the entire system. Ignoring or repeatedly encountering this fault without resolution may lead to reduced equipment lifespan, motor instability, or production downtime.

Insights from the Image

Th image shows an SQ1000 inverter with a power rating of 0.75 kW, configured for single-phase 220V input and three-phase 220V output, with a rated current of 3.8A. The operation panel displays “E-15” on its five-digit LED screen, accompanied by a flashing red display, indicating an active fault state. The “V” indicator light is illuminated, suggesting that the fault pertains to voltage. The panel includes control buttons such as “Shift,” “Function/Program,” “Confirm,” “Up/Down,” and “Stop/Reset,” which are essential for troubleshooting and parameter adjustments. The inverter’s surface shows signs of dust and wear, hinting at operation in a challenging industrial environment, which may contribute to the fault’s occurrence.

Potential Causes of the E-15 Fault

The E-15 fault can stem from various sources, ranging from external power supply issues to internal inverter malfunctions. Based on the manual and practical considerations, the following are the primary causes:

1. Unstable Input Power Supply
   The manual (page 7) specifies that the SQ1000 inverter operates within an input voltage range of 220V ± 20% (176V–264V for single-phase models) or 380V ± 15% (323V–437V for three-phase models). Voltage fluctuations beyond these limits, common in industrial settings during peak load times, can trigger the E-15 fault.
2. Power Line Issues
   Excessive line length or undersized wire gauge can cause significant voltage drops. The manual (page 11, Chapter 3: Installation and Wiring) emphasizes the importance of reliable power connections to minimize such drops, recommending that voltage loss remain below 5%.
3. Insufficient Power Supply Capacity
   If the power transformer or supply source cannot handle the combined load of the inverter and other equipment, the voltage may sag, leading to undervoltage conditions.
4. Internal Inverter Faults
   A malfunction in the inverter’s power detection circuit or drive board could falsely detect low voltage. The manual (page 67) suggests that persistent fault displays despite normal voltage may indicate drive board or output module issues.
5. External Electromagnetic Interference
   While the SQU1000 boasts good electromagnetic compatibility (page 3), strong interference from nearby equipment, such as large motor startups, could disrupt voltage sensing, causing erroneous fault triggers.

Troubleshooting the E-15 Fault

Resolving the E-15 fault requires a systematic approach to identify and address the root cause. Below is a step-by-step guide:

Step 1: Verify Input Power Supply

• Action: Measure the voltage at the inverter’s input terminals (R, S, T) using a multimeter.
• Expected Range: For the 0.75 kW single-phase model shown in the image, the voltage should be between 176V and 264V.
• Solution: If the voltage is below 176V, consult the local power utility to address grid instability or install a voltage stabilizer (e.g., UPS) upstream of the inverter.

Step 2: Inspect Power Lines and Connections

• Action: Check the power cable length, wire gauge, and terminal connections for adequacy and security.
• Guideline: Ensure the voltage drop across the line is less than 5% of the supply voltage.
• Solution: Replace undersized or overly long cables with appropriately rated ones and tighten any loose connections at the input terminals.

Step 3: Assess Power Supply Capacity

• Action: Evaluate the transformer or power source capacity relative to the total load.
• Solution: If insufficient, upgrade the transformer or reduce concurrent loads on the same circuit.

Step 4: Review Parameter Settings

• Action: Access parameter F8.02 via the operation panel (page 62, manual):
  1. Press “Function” to enter the main menu.
  2. Use “Up/Down” keys to navigate to F8 group.
  3. Press “Confirm” to select F8.02 and check the undervoltage threshold (default may be 160V).
• Solution: If the threshold is set too high for the local grid (e.g., above typical voltage levels), lower it to a safe value like 150V, ensuring the inverter is stopped during adjustment.

Step 5: Check Inverter Hardware

• Action: If the power supply and parameters are normal, inspect internal components:
  • Open the inverter (after disconnecting power and waiting five minutes, per safety guidelines on page 5) and check input terminal connections.
  • Test the drive board and power detection circuit with professional tools (e.g., oscilloscope), as suggested on page 67.
• Solution: Tighten loose connections or replace faulty components (e.g., drive board) with assistance from the manufacturer.

Step 6: Mitigate External Interference

• Action: Assess the environment for electromagnetic interference sources (e.g., large motors).
• Solution: Install an EMI filter at the input or relocate the inverter away from interference sources. Ensure proper grounding (page 15, manual).

Step 7: Reset and Test

• Action: Press “Stop/Reset” on the panel (page 24) to clear the fault, then restart the inverter.
• Solution: If E-15 persists, repeat the steps or seek professional service, as persistent faults may indicate deeper hardware issues.

Preventive Measures

To minimize future E-15 faults, consider these proactive steps:

• Regular Voltage Monitoring: Use a voltmeter to check input voltage during peak operation periods, ensuring stability within the 176V–264V range.
• Optimized Wiring: Adhere to the manual’s wiring recommendations (Chapter 3), using adequately sized cables and minimizing line lengths.
• Protective Equipment: Install a voltage stabilizer or UPS to buffer grid fluctuations.
• Routine Maintenance: Clean the inverter periodically to remove dust (page 3) and inspect connections for wear, enhancing reliability.
• Parameter Tuning: Adjust F8.02 based on local grid conditions to avoid overly sensitive tripping, balancing safety and functionality.

Conclusion

The E-15 fault code on the SQ1000 inverter, indicating undervoltage during operation, is a critical alert that demands prompt attention to maintain operational efficiency and equipment longevity. By understanding its causes—ranging from power supply instability to internal faults—and following a structured troubleshooting process, users can effectively resolve the issue. The provided image and manual serve as valuable references, confirming the fault’s nature and guiding precise interventions. Implementing preventive measures further ensures the inverter’s robust performance, minimizing downtime and enhancing productivity in industrial applications. With this comprehensive approach, users can confidently manage and mitigate the E-15 fault, leveraging the SQ1000’s advanced capabilities to their fullest potential.

Introduction

Servo drives are the backbone of precision control in industrial automation, powering applications ranging from CNC machining to robotic assembly lines. The ZSMC K-Series servo drive, renowned for its reliability and efficiency, is no exception. However, even the most robust systems can encounter faults that disrupt operations. One such issue, the A.43 fault, has been reported by a user, with a screenshot showing the fault code displayed on the servo drive. This article delves into the A.43 fault—identified as a “Bus-type encoder cumulative count error”—to provide a comprehensive, step-by-step guide for troubleshooting and resolving it. Drawing from the official user manual (“ZSMC Servo K-Series User Manual Complete Version.pdf,” 2017 Engineering Version V3.0), this guide aims to equip technicians and engineers with the knowledge to address this fault effectively, minimizing downtime and ensuring system reliability.

Understanding the A.43 Fault

The A.43 fault is explicitly defined in the ZSMC K-Series servo drive manual under “Appendix C: Alarm Display List” (Page 191). It is described as “Bus-type encoder cumulative count error.” The accompanying note states, “Encoder cumulative count or encoder motor cumulative circuit connection is damaged.” This fault is classified as a high-priority (H-level) alarm, indicating its potential to significantly impact system performance, yet it is resettable, suggesting that it can often be cleared once the underlying issue is resolved.

At its core, the A.43 fault points to an issue with the bus-type encoder, a critical component that provides feedback on the motor’s position and speed. The “cumulative count” refers to the aggregated position data transmitted over a bus communication protocol (likely RS-485, as hinted in the manual’s communication sections). When this count becomes erroneous—due to hardware failure, wiring issues, or communication disruptions—the servo drive loses its ability to accurately track the motor’s position. This can result in erratic motor behavior, loss of precision, or complete system shutdown, making swift resolution essential.

Possible Causes of the A.43 Fault

To address the A.43 fault, we must first identify its root cause. The manual’s troubleshooting section (Chapter 7, “Fault Diagnosis and Troubleshooting,” Page 135) and practical engineering insights suggest several potential culprits:

1. Encoder Hardware Failure
   The encoder itself may be faulty due to physical damage, wear from prolonged use, or internal component failure. A damaged encoder can send incorrect or no data, leading to cumulative count errors.
2. Wiring Issues
   Faulty connections between the encoder and the servo drive—such as loose terminals, broken cables, or improper grounding—can interrupt signal transmission, triggering the A.43 fault.
3. Communication Interference
   Since the encoder operates over a bus system, electromagnetic interference (EMI) from nearby equipment (e.g., motors or inverters) or inadequate shielding can corrupt the data, causing count discrepancies.
4. Power Supply Instability
   An unstable or insufficient power supply to the encoder can impair its operation, resulting in erratic count data. The manual hints at power-related considerations in its wiring sections (Chapter 3, Page 17).
5. Configuration Errors
   Incorrect parameter settings in the servo drive, particularly those related to the encoder (e.g., resolution or communication protocol), may lead to misinterpretation of the encoder’s output, as noted in Chapter 5 (Page 54).

Each of these causes requires a distinct approach to diagnosis and resolution, which we will explore in the following sections.

Troubleshooting the A.43 Fault

A systematic troubleshooting process is key to isolating the cause of the A.43 fault. Below is a detailed, step-by-step guide based on the manual and standard servo system practices.

Step 1: Inspect Encoder Wiring

• Action: Refer to Section 3.4, “Encoder Operation Guide Wiring” (Page 27), to verify the encoder cable connections.
• Procedure:
  • Check that all connections to the encoder port (e.g., CN1 or CN2) are secure and free of corrosion or damage.
  • Ensure the cable shield is properly grounded, as recommended in Section 3.5 (Page 34), to minimize interference.
  • Use a multimeter to test the continuity of each wire in the encoder cable, identifying any breaks or shorts.
• Outcome: If wiring issues are found, they must be corrected before proceeding.

Step 2: Test the Encoder Hardware

• Action: Assess the encoder’s functionality, as suggested in Section 7.2, “Servo Drive Maintenance and Inspection” (Page 139).
• Procedure:
  • Visually inspect the encoder for physical damage (e.g., cracked housing or burnt components).
  • If possible, swap the suspect encoder with a known working unit of the same model to see if the fault persists.
  • For advanced diagnostics, use an oscilloscope to monitor the encoder’s output signals, checking for irregularities in the waveform.
• Outcome: A faulty encoder will require replacement.

Step 3: Evaluate Communication Environment

• Action: Investigate potential interference, referencing Section 6.3, “MODBUS Communication Protocol” (Page 107).
• Procedure:
  • Ensure the communication cable length complies with RS-485 standards (typically under 1200 meters).
  • Identify and mitigate EMI sources near the servo system, such as high-power machinery, by relocating them or adding shielding.
  • Verify that the cable routing avoids parallel runs with power lines, as advised in Section 3.8 (Page 36).
• Outcome: Improved shielding or rerouting may resolve communication-related errors.

Step 4: Verify Power Supply Stability

• Action: Check the power supply to the encoder and drive, per Section 3.2, “Typical Main Circuit Wiring Example” (Page 20).
• Procedure:
  • Measure the input voltage to the servo drive (typically 220V ±10%) using a multimeter to ensure it’s within spec.
  • Monitor the encoder’s power supply voltage (often 5V or 24V) for stability, using an oscilloscope if available to detect fluctuations.
• Outcome: Power instability may necessitate a regulated power source or additional filtering.

Step 5: Review Parameter Settings

• Action: Validate encoder-related parameters, as outlined in Section 5.4.5, “Absolute Encoder Settings” (Page 69).
• Procedure:
  • Access the servo drive’s parameter menu via the panel (Section 4.1, Page 38) and check settings like F[009] and F[010], which define encoder data formats.
  • Compare these settings against the encoder’s specifications and the manual’s recommendations.
  • If uncertain, reset to factory defaults (Section 4.2.6, Page 43) and reconfigure carefully.
• Outcome: Corrected settings should eliminate configuration-induced errors.

Resolving the A.43 Fault

Once the cause is pinpointed, apply the appropriate fix:

• Faulty Encoder: Replace it with a compatible unit, ensuring proper installation per Section 1.2, “Motor Model Naming” (Page 9).
• Wiring Issues: Repair or replace damaged cables, secure connections, and enhance grounding as needed.
• Communication Interference: Install noise filters (Section 4, Page 34), use ferrite cores, or adjust cable paths to reduce EMI.
• Power Supply Problems: Add a voltage stabilizer or filter to ensure consistent power delivery.
• Configuration Errors: Adjust parameters to match the encoder, save changes, and restart the drive.

After resolution, reset the fault via the panel (Section 4.1, Page 38) and test the system under normal operating conditions to confirm the fix.

Preventive Measures

Preventing future A.43 faults requires proactive maintenance and optimization:

• Routine Inspections: Regularly check the encoder, wiring, and connections for wear or damage (Section 7.2, Page 139).
• Environmental Optimization: Maintain an operating environment within 0–40°C and <90% humidity, avoiding EMI sources.
• Parameter Management: Document correct settings and verify them after any system changes.
• Staff Training: Educate operators on proper handling and maintenance to avoid accidental damage.

Conclusion

The A.43 fault in the ZSMC K-Series servo drive, while disruptive, is manageable with a structured approach. By understanding its meaning—a bus-type encoder cumulative count error—and systematically addressing potential causes like hardware failure, wiring issues, or interference, users can restore functionality efficiently. The detailed manual provides a solid foundation for this process, supplemented by practical troubleshooting steps and preventive strategies. With diligent maintenance and adherence to best practices, the reliability of the ZSMC K-Series servo system can be upheld, ensuring seamless performance in demanding industrial applications.

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Introduction

In modern industrial automation, variable frequency drives (VFDs) are pivotal for motor control, widely utilized across industries such as manufacturing, energy, and transportation. The INDVS Y300 series VFD stands out for its exceptional performance and reliability, making it a preferred choice for many businesses. However, users may occasionally encounter the ERR14 error, which indicates module overheating. This error can interrupt production and potentially damage equipment if not addressed promptly. This article offers an in-depth exploration of the ERR14 error, covering its technical basis, causes, solutions, and preventive strategies to help users maintain stable and efficient operations.

Definition and Impact of ERR14 Error

According to the INDVS Y300 series VFD user manual, the ERR14 error is a safety feature triggered when the power module’s temperature exceeds a predetermined safe limit. The power module, a vital component, converts input power into the specific frequency and voltage needed to drive the motor. Overheating prompts the VFD to shut down automatically, protecting the system from further harm. While this protective mechanism is effective, repeated incidents can lower production efficiency and, in extreme cases, destabilize entire production lines. Addressing the ERR14 error is thus critical for operational continuity.

The consequences of overheating are far-reaching. Sustained high temperatures can accelerate the degradation of the power module, reducing its lifespan. Moreover, the downtime caused by such errors can lead to significant economic losses, especially in continuous-operation settings. Identifying and resolving the underlying issues quickly is therefore a key priority for users.

Potential Causes of ERR14 Error

Understanding the root causes of the ERR14 error is the first step toward effective resolution. Based on the user manual and practical insights, the following factors are commonly responsible:

1. Excessive Ambient Temperature

The VFD operates optimally within a temperature range of -10°C to 40°C, as specified in the manual. When ambient temperatures exceed this limit—such as during hot seasons or in confined spaces—heat dissipation becomes less efficient, resulting in module overheating.

2. Poor Ventilation

The VFD depends on internal fans and heat sinks to manage heat. Dust and debris buildup can block airflow, impairing the cooling system’s performance. The manual emphasizes regular cleaning to ensure effective ventilation.

3. Overloading

Prolonged operation under heavy loads causes the power module to generate excessive heat. Incorrect parameter settings, such as insufficient current limits, can worsen this problem. The manual links load levels to heat output, urging users to configure settings carefully.

4. Improper Installation

The VFD’s installation site and surrounding space affect heat dissipation. The manual advises maintaining adequate clearance around the unit and avoiding proximity to heat sources or stacked equipment. Non-compliance with these guidelines can lead to heat buildup.

Diagnosis and Solutions for ERR14 Error

When the ERR14 error occurs, immediate action is necessary. Below is a step-by-step guide to diagnose and resolve the issue:

1. Safe Power-Down and Cooling

Upon receiving the overheating alert, disconnect the power supply and let the VFD cool down to a safe temperature. The manual suggests using a soft brush or compressed air to clean the cooling system, cautioning against liquids to avoid damaging components.

2. Inspect the Cooling System

Open the VFD casing to check the fans for proper operation and the heat sinks for dust accumulation. Replace faulty fans and ensure clear airflow paths.

3. Parameter Adjustment

Access the control panel to confirm that current limits and thermal protection settings are appropriate. The manual provides guidance on adjusting these parameters, recommending that users save the original settings beforehand.

4. Motor and Wiring Inspection

Use an insulation tester to detect short circuits or insulation issues in the motor and wiring. Such faults can cause abnormal currents, indirectly contributing to overheating.

Preventive Measures and Long-Term Solutions

Fixing the ERR14 error is only part of the solution; preventing its recurrence is equally vital. Here are some proactive steps:

1. Regular Maintenance

Set up a routine maintenance plan, including monthly cleaning of the cooling system and quarterly reviews of fans and settings. The manual’s suggested intervals can guide this schedule.

2. Environmental Optimization

Install the VFD in a well-ventilated, temperature-regulated area. In hot environments, consider adding external cooling solutions like fans or air conditioning.

3. Operator Training

Provide thorough training on the manual’s operational guidelines, ensuring staff can adjust parameters and perform inspections competently, thus improving equipment oversight.

4. Smart Monitoring

Utilize the Modbus communication protocol outlined in the manual to implement a temperature monitoring system. This allows real-time observation of module conditions and early warnings of potential issues.

Technical Principles and Application Scenario Analysis

To fully grasp the ERR14 error, it helps to examine its technical origins. The power modules in VFDs typically employ Insulated Gate Bipolar Transistors (IGBTs), which produce heat during operation. This heat is proportional to the square of the current and the switching frequency. High loads or overly permissive parameter settings increase heat buildup. If the cooling system cannot dissipate this heat effectively, the temperature exceeds the safety threshold, activating the ERR14 error.

In real-world scenarios—like pump control in petrochemical plants or spindle drives in textile production—VFDs often face sustained high loads. These applications demand robust cooling designs and precise parameter tuning. During selection and setup, users must evaluate operational needs carefully to prevent problems arising from poor planning.

Conclusion

The ERR14 error in the INDVS Y300 series VFD, though a frequent challenge, can be managed systematically. By understanding its causes, applying targeted fixes, and adopting preventive measures, users can minimize overheating risks, ensuring the equipment’s long-term reliability and performance. This article has offered a detailed roadmap—from technical details to actionable steps—to empower users in mastering industrial automation challenges with confidence.

Introduction

The CANWORLD CDE300 series inverter is a high-performance variable frequency drive (VFD) designed for three-phase motor control, widely used in industrial automation. Its primary functions include adjusting motor speed, improving energy efficiency, and ensuring smooth equipment operation. However, in practical applications, inverters may encounter faults due to various reasons. Among these, the ERR10 fault—indicating module overheating—is a common alarm that requires prompt attention to prevent equipment damage or downtime.

This article is based on the “CDE300 CANWORLD Three-Phase User Manual V1.10.pdf” and the provided fault screenshot. It provides an in-depth discussion of the ERR10 fault, including its meaning, potential causes, troubleshooting steps, and preventive measures. Through a clear structure and logical analysis, this article aims to offer practical guidance to help users quickly resolve module overheating issues and ensure long-term stable operation of the equipment.

Meaning of ERR10 Fault

The ERR10 fault in the CANWORLD CDE300 series inverter specifically indicates “module overheating.” The power module of the inverter, typically composed of core components such as Insulated Gate Bipolar Transistors (IGBTs), is responsible for converting the input power into the appropriate output voltage and frequency for motor operation. During operation, these components generate significant heat due to energy losses. To protect the equipment, the inverter is equipped with temperature sensors that monitor the power module’s temperature in real time. When the temperature exceeds a safe threshold, the system triggers the ERR10 fault alarm and may automatically shut down to prevent further thermal damage.

The consequences of module overheating should not be underestimated. Prolonged high temperatures can lead to IGBT aging, performance degradation, and even permanent damage to the power module. Therefore, accurately understanding the ERR10 fault and taking effective measures are crucial.

Possible Causes of ERR10 Fault

Module overheating is usually caused by a combination of factors. Based on the design features of the CDE300 series inverter, the user manual, and common issues in industrial applications, the following are the main potential causes of the ERR10 fault:

1. High Ambient Temperature
   According to the “Installation Site” section in Chapter 3 (PAGE22) of the user manual, the operating ambient temperature for the CDE300 series inverter should typically be between -10°C and 40°C. If the installation environment exceeds this range, the inverter’s cooling system may be unable to effectively reduce the module temperature, triggering the ERR10 fault.
2. Poor Ventilation
   The inverter requires adequate airflow for heat dissipation. The manual mentions the need for sufficient space around the inverter during installation (PAGE13, Section 2.5.1 “Product Installation Dimensions”). If the installation location is too confined or near other heat sources, heat accumulation may occur, affecting cooling efficiency.
3. Cooling System Failure or Blockage
   The CDE300 series inverter relies on built-in fans and heat sinks for thermal management. If the fan stops working, operates at reduced speed, or if the heat sink is clogged with dust or grease, cooling efficiency will significantly decrease. This is particularly common in industrial environments where the air may contain a high concentration of particulates.
4. Overloaded Condition
   When the load driven by the inverter exceeds its rated capacity, the power module will bear higher current and thermal stress. The manual’s Section 2.3 “CDE300 Series Inverter Models” (PAGE9) lists the rated power for each model, such as CDE300-4T7R5G/011P. If the actual load exceeds the specifications, it may lead to module overheating.
5. Wiring Issues
   Incorrect electrical installation (such as loose or poor connections) can increase resistance, generating additional heat. Section 3.2 “Electrical Installation” (PAGE25) and the “Main Contents of the Distribution Room” on PAGE30 emphasize the importance of proper wiring and grounding. Wiring errors may indirectly cause the ERR10 fault.
6. High Switching Frequency
   A higher switching frequency in IGBTs results in increased heat generation. If the switching frequency is set too high in the inverter’s parameters, it may exacerbate the thermal load on the module, leading to overheating.
7. Hardware Failure
   If all external factors are normal, the issue may lie with the power module or temperature sensor itself, such as a damaged IGBT or a malfunctioning sensor reporting false high temperatures.

Troubleshooting and Solutions for ERR10 Fault

To resolve the ERR10 fault and restore the inverter to normal operation, users can follow these step-by-step troubleshooting procedures:

1. Power Off and Cool Down the Equipment

Upon detecting the ERR10 fault, immediately turn off the inverter’s power and allow the equipment to cool naturally. The “Safety Markings” section in Chapter 1.1 (PAGE4) recommends waiting at least 10 minutes after powering off to ensure internal components have cooled and to avoid safety risks.

2. Check Ambient Temperature

Use a thermometer to measure the temperature around the inverter, ensuring it is within the -10°C to 40°C range. If the temperature is too high, improve environmental conditions by adding ventilation equipment (such as fans or air conditioning) or relocating the inverter.

3. Assess Ventilation and Installation

Refer to Section 2.5 “Product Type Diagram and Installation Hole Dimensions” (PAGE11-13) in the manual to check if there is sufficient space around the inverter (e.g., clearances in front, back, left, and right). Remove any objects that may obstruct airflow and ensure the inverter is not near other heat sources.

4. Clean the Cooling System

Inspect whether the fan is operating normally and clean any dust or debris from the fan blades and heat sink. Use compressed air or a soft brush for cleaning to ensure unobstructed airflow. If the fan is faulty, test its electrical connections and consider replacement.

5. Verify Load Matching

Check if the load parameters match the inverter’s rated capacity (see PAGE9). If the load is too high, reduce the operating load or upgrade to a higher power model. Additionally, inspect the motor for abnormalities (such as short circuits or mechanical jams) that could cause excessive current.

6. Inspect Electrical Connections

Follow the requirements in Section 3.2 “Electrical Installation” (PAGE25) to check the main circuit connections (R, S, T, U, V, W) and grounding (P, P+, P-) for secure and intact connections without looseness or aging. Ensure the input voltage is within the specified range to avoid overcurrent.

7. Adjust Switching Frequency

Using the keypad operation (Chapter 4, PAGE37), access the parameter settings interface to check and reduce the switching frequency (if the application allows). This can decrease the heat generated by the IGBTs, but be cautious not to affect motor performance.

8. Monitor Operation and Test

After completing the above adjustments, restart the inverter and observe its operating status. If the equipment provides temperature display functionality, monitor the module temperature in real time. If the ERR10 fault persists, it may indicate a hardware issue, and it is recommended to contact CANWORLD technical support for further inspection.

Preventive Measures for ERR10 Fault

To prevent the recurrence of the ERR10 fault, users can implement the following preventive measures:

1. Regular Maintenance
   Conduct a comprehensive inspection of the inverter every 3-6 months, cleaning the fan and heat sink to ensure the cooling system functions properly. In industrial environments, maintenance intervals may need to be shortened.
2. Optimize Installation Environment
   Choose a well-ventilated installation location away from heat sources, avoiding direct sunlight or high-temperature areas, in accordance with Section 3.1 of the manual.
3. Proper Load Management
   Monitor load conditions in real time to avoid prolonged overload operation. Utilize the inverter’s built-in diagnostic functions or external devices to track current and temperature.
4. Parameter Optimization
   Adjust operating parameters based on actual application needs, such as switching frequency and acceleration/deceleration times, to minimize unnecessary heat generation.
5. Personnel Training
   Train operators to familiarize them with the safety and installation guidelines in the manual and to equip them with basic troubleshooting skills.
6. Enhanced Cooling Measures
   In high-temperature environments, install additional external fans or air conditioning to further improve heat dissipation.

Conclusion

The ERR10 fault (module overheating) in the CANWORLD CDE300 series inverter is a critical protective alarm that may be triggered by high ambient temperatures, poor ventilation, cooling system failures, overloaded conditions, wiring issues, or hardware malfunctions. Through systematic troubleshooting—from checking the environment to adjusting parameters and performing maintenance—users can typically identify and resolve the issue quickly. Additionally, by implementing regular maintenance and optimizing the operating environment, the likelihood of ERR10 faults can be significantly reduced.

The CDE300 series inverter is renowned for its reliability, but its performance depends on proper installation and maintenance. By following the guidelines in the user manual and the solutions and preventive suggestions provided in this article, users can not only address current module overheating issues but also enhance the overall lifespan and efficiency of the equipment, ensuring stability and safety in industrial applications. For complex issues, it is advisable to contact CANWORLD’s official technical support for professional assistance.

1. Introduction

In industrial applications, inverters play a crucial role in motor speed control. Their performance directly affects system efficiency and reliability. The AnyHz (Anyi) FST-650 series inverter is widely used in fans, pumps, and compressors. Among its common faults, “Err13” is frequently encountered, indicating output phase loss. This article provides a comprehensive analysis of Err13, including its causes, diagnosis steps, parameter tuning, and long-term solutions.

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2. Meaning of Err13

According to the official user manual and display panel codes:

Fault Code: Err13
Fault Description: Power output phase loss

“Output phase loss” means that the inverter detects one of the output phases (U, V, or W) is missing or the current is significantly abnormal, triggering a protective shutdown.

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3. Common Causes of Err13

1. Loose or poor motor terminal connections

Caused by vibrations, poor tightening, corrosion, or wear, leading to poor contact on U/V/W terminals.

2. Damaged output cables

Aging insulation, rodents, mechanical stress, or improper bending could break one phase of the cable.

3. Motor winding failure

One phase of the stator coil is open due to burnout or manufacturing defects.

4. Inverter output module failure

The internal IGBT or current sensing circuit of the FST-650 is damaged, causing abnormal or missing output.

5. Output fuse blown (if used externally)

Some systems use fuses on each output phase. A blown fuse on one phase can cause Err13.

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4. On-Site Troubleshooting Steps

Step 1: Confirm if it’s a false alarm

• Use a clamp meter to measure U, V, W phase currents.
• Use a multimeter to check motor winding resistance symmetry.

Step 2: Inspect output cables

• Check all wiring terminals for secure connection and signs of overheating.
• Inspect cable routing for physical damage or moisture ingress.

Step 3: Test motor condition

• Use a megohmmeter to check insulation.
• If possible, replace with another working motor to isolate the issue.

Step 4: Inspect inverter internals

• Check IGBT module, driver board, and current sensors.
• Observe for damaged components or abnormal heating.

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5. Relevant Parameter Settings

The FST-650 inverter detects output phase loss via current monitoring and software logic. The following parameters affect phase loss detection:

Parameter No.	Name	Recommended Setting	Description
F9.10	Phase loss detection enable	1 (Enable)	Turns on the function
F9.11	Detection delay time	0.2–2.0s	Avoids false alarms
F2.10	Torque/current limit	≥110%	Avoids misjudgment as overcurrent
F0.17 / F0.18	Acceleration / deceleration time	10–30s	Prevents current overshoot

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6. Repair Actions

1. Re-tighten U/V/W terminal screws

Ensure all output terminals are properly secured.

2. Replace or test output cable

Swap suspected cables with known good ones to isolate faults.

3. Test or replace the motor

If the motor is suspected, test with a known good motor and observe for recurrence.

4. Repair or replace inverter output module

If all external components are normal, the inverter’s power module or current sensor may need replacement.

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7. Prevention and Maintenance Tips

1. Regular tightening of output terminals, especially in vibrating machinery.
2. Quarterly insulation testing of cables and motor windings.
3. Install output phase monitoring relay to detect early signs of failure.
4. Ensure proper cooling and dust protection for the inverter panel.
5. For critical systems, consider motor + encoder + phase monitor redundancy setup.

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8. Conclusion

The Err13 “Output Phase Loss” fault on AnyHz FST-650 inverters is a critical protection mechanism that prevents motor damage. While often caused by external wiring or motor faults, internal inverter failures can also trigger this alarm. Systematic diagnosis and parameter adjustments, along with preventive maintenance, will greatly improve system uptime. If issues persist, consult with qualified service professionals or the manufacturer.