Category: Industrial control technology

I. Introduction

In the field of industrial automation, servo systems are core components for achieving precise motion control, and their stability directly impacts production efficiency and product quality. The Berger Lahr EXC-30 series servo drives are widely used in applications such as machine tools, packaging machinery, and robots due to their high precision and reliability. However, during long-term operation, the ER-13 overload fault is one of the most common alarms. If not addressed promptly, this fault can lead to motor burnout, drive damage, and even production shutdowns. Based on the hardware characteristics and control logic of the EXC-30 series, this article provides an in-depth analysis of the causes, troubleshooting procedures, and solutions for the ER-13 fault, offering practical guidance for engineering technicians.

II. Definition and Classification of the ER-13 Fault Code

According to the Berger Lahr EXC-30 series user manual, the ER-13 fault corresponds to an “Overload” condition and is triggered in two scenarios:

1. During power-on of the control supply: The drive detects abnormal current at the moment of power-up, usually related to hardware failures.
2. During motor operation: The actual torque of the motor exceeds its rated torque (or the torque limit set by the drive), or excessive torque fluctuations occur due to control abnormalities.

The core logic of this fault is as follows: The drive continuously monitors the motor winding current through current sensors. When the current exceeds 1.5 times the rated value (or the set overload threshold) and persists for a certain duration (typically 1-3 seconds), the ER-13 alarm is triggered, and the drive output is cut off to protect the motor and the drive itself.

III. In-depth Analysis of the Causes of the ER-13 Fault

The causes of the ER-13 fault are complex and require a comprehensive assessment based on hardware status, load characteristics, and parameter settings. The following is a detailed classification analysis:

(I) ER-13 Triggered at Power-on: Primarily Hardware Failures

1. Circuit Board Failures

• Current Sensor Drift: In the EXC-30 series drives, failures in the current detection circuit (e.g., Hall sensors), drive circuit (e.g., IGBT modules), or control board (e.g., CPU board) can lead to abnormal current detection at power-up. For example:
  • If the current sensor drifts, the detected current value may be significantly higher than the actual value, triggering overload protection.
  • If the IGBT module is short-circuited, a short circuit occurs at the power output terminal, causing a sudden increase in current at power-up.
  • If the control board program malfunctions, it may misinterpret current signals, resulting in false alarms.

2. Motor Winding Short Circuit

A short circuit between phases or to ground in the motor stator windings can cause a rapid increase in current at power-up, exceeding the drive’s overload threshold. This is often accompanied by motor overheating and a burning smell.

3. Brake Not Released (for motors with brakes)

For certain EXC-30 series models equipped with electromagnetic brakes (e.g., motors with brakes), if the brake coil is not energized or the brake is mechanically jammed, the motor is braked at power-up. The drive detects a “locked-rotor current” and triggers the ER-13 fault.

(II) ER-13 Triggered During Operation: Primarily Load and Control Issues

1. Operation Beyond Rated Torque

This is the most common cause and includes the following scenarios:

• Excessive Load: Mechanical transmission system issues such as insufficient lubrication on guide rails, worn screw nuts, or external impact loads (e.g., material jamming in packaging machinery) can increase the load beyond the motor’s rated capacity.
• Improper Parameter Settings: Incorrect settings for parameters such as the torque limit (e.g., P001 in EXC-30), start-stop frequency (P002), and acceleration/deceleration time (P004) can lead to operation beyond rated torque. For example:
  • Setting the torque limit (P001) too high (exceeding the motor’s rated torque).
  • Setting the start-stop frequency (P002) too fast, causing the starting impact torque to exceed the rated value.
  • Setting the acceleration/deceleration time (P004) too short, resulting in excessive acceleration and a surge in torque.

2. Brake Not Released During Operation

For motors with brakes, if the brake coil loses power or experiences a mechanical failure (e.g., worn brake pads, failed springs) during operation, the brake may not fully release. The motor then has to overcome the braking torque, causing the actual torque to exceed the rated value.

3. Motor Instability and Oscillation

Improper adjustment of servo system gains (e.g., excessively high position gain P003 or speed gain P005) can cause the motor to oscillate during operation, with torque fluctuating periodically. If the peak torque exceeds the rated value, the ER-13 fault is triggered. This is common in scenarios with a high load inertia ratio (load inertia/motor inertia), such as robot arms or large worktables.

4. Wiring Errors

• Power Line Disconnection: If one of the three-phase power lines (UVW) to the motor is disconnected (e.g., due to loose connectors or crushed wires), the motor operates in a phase-loss condition, reducing torque. To maintain speed, the current increases, eventually leading to overload.
• Incorrect Encoder Wiring: If the encoder feedback lines (e.g., A/B phase, Z phase) are reversed or loose, the drive cannot accurately detect the motor’s position or speed, causing control algorithm disruptions and abnormal torque output.

IV. Systematic Troubleshooting Procedure for the ER-13 Fault

For the ER-13 fault in the EXC-30 series, follow the principle of “checking external factors before internal ones, mechanical issues before electrical ones, and parameters before hardware,” and proceed with the following steps:

Step 1: Visual and Wiring Inspection (Quickly Eliminate Obvious Faults)

• Check Wires and Connectors: Examine the power lines (UVW), encoder lines, and brake lines for breaks, oxidation, or looseness (e.g., bent connector pins).
• Check Mechanical Status: Manually rotate the motor shaft (after disconnecting the load) to check for any binding (e.g., sticky guide rails, bent screw rods). Check the load for foreign objects (e.g., material rolls in packaging machinery, iron filings in machine tools).
• Check the Brake: For motors with brakes, listen for a “click” sound at power-up (indicating brake release). Use a multimeter to measure the brake coil voltage (usually DC24V). If the voltage is normal but there is no release action, the brake has a mechanical failure.

Step 2: Load and Parameter Verification (Core Troubleshooting Step)

• Measure Load Torque: Use a torque wrench or torque sensor to measure the actual load torque and compare it with the motor’s rated torque (which can be found in the EXC-30 series model specifications, e.g., the rated torque of the ECX-30PL30 is 10 N·m).
• Verify Parameter Settings: Enter the drive’s parameter mode (set via the operation panel or software in the EXC-30 series) and check the following key parameters:
  • Torque Limit (P001): Ensure it does not exceed the motor’s rated torque (recommended to be set at 1.2-1.5 times the rated value).
  • Start-Stop Frequency (P002): Check if it is too high (e.g., exceeding 50% of the motor’s rated frequency).
  • Acceleration/Deceleration Time (P004): Check if it is too short (e.g., start time < 0.1 seconds).
  • Gain Parameters (P003 position gain, P005 speed gain): Check if they are too high (gradually reduce them using the “gain adjustment” function and observe for motor oscillation).

Step 3: Electrical Testing (Locate Wiring and Hardware Faults)

• Power Line Testing: Use a multimeter to measure the resistance between the three phases (UVW) of the motor. The resistance should be balanced (e.g., 0.5 Ω ± 10%). If one phase shows infinite resistance, there is a break. Measure the resistance between the power lines and ground (should be > 10 MΩ). A lower value indicates insulation damage.
• Encoder Line Testing: Use an oscilloscope to measure the encoder’s A/B phase signals (normal signals are differential pulses with a frequency proportional to the motor speed). If the signals are missing or distorted, the encoder wiring is incorrect or the encoder is damaged.
• Current Testing: Use a clamp-on ammeter to measure the motor’s operating current (should be less than the rated current). If the current exceeds 1.5 times the rated value, the load is too heavy or the parameters are improperly set.
• Brake Testing: Measure the brake coil resistance (normal values range from tens to hundreds of ohms). If the resistance is infinite, the coil is burned out. Measure the brake release time (should be < 0.5 seconds). A longer time indicates mechanical jamming.

Step 4: In-depth Hardware Testing (Circuit Boards and Drive)

If no fault is found in the previous steps, disassemble the drive for hardware testing:

• Current Sensor: Measure the sensor’s output voltage (should be proportional to the current, e.g., 2.5V for 10A). If the output is abnormal, the sensor is damaged.
• IGBT Module: Use a multimeter to measure the resistance between the collector (C) and emitter (E) of the IGBT (should be infinite). If it conducts, the module is short-circuited.
• Control Board: Check for swollen electrolytic capacitors or burned resistors on the board. Use a programmer to read the control board program (if corrupted, reprogram it).

V. Solutions and Case Studies for the ER-13 Fault

(I) Common Fault Solutions

Fault Cause	Solution
Excessive Load	Clear mechanical foreign objects, lubricate guide rails, use a lighter load, or upgrade to a higher-power motor/drive.
Brake Not Released	Repair the brake coil (replace or rewind it), adjust the brake pad clearance, or check the brake power supply.
Improper Parameter Settings	Reduce the torque limit (P001), increase the acceleration/deceleration time (P004), or adjust the gains (P003/P005).
Power Line Disconnection	Reconnect the wires (crimp terminals) or replace damaged wires.
Incorrect Encoder Wiring	Verify the encoder pin definitions (usually a 25-pin D-type connector in EXC-30 series) and reconnect correctly.
Circuit Board Failure	Replace the current sensor, IGBT module, or control board (recommended to return to the manufacturer for repair).

(II) Typical Case Studies

Case 1: ER-13 Due to Material Jamming in Packaging Machinery

• Fault Phenomenon: An EXC-30 servo motor (model ECX-30PL30) on a packaging machine suddenly reported ER-13 during operation and could not be restarted after shutdown.
• Troubleshooting Process:
  • Manually rotating the motor shaft revealed that the load side (material roll) was jammed and could not rotate.
  • Disassembling the packaging machine revealed that a piece of packaging paper was stuck on the material roll support, causing a sudden increase in load torque.
  • After clearing the foreign object, the motor shaft rotated smoothly manually, and the drive restarted without fault.
• Solution: Add a protective cover to the material roll support and regularly clean foreign objects.

Case 2: ER-13 Due to Brake Coil Burnout

• Fault Phenomenon: An EXC-30 servo motor with a brake (model ECX-30BL30) on a machine tool frequently reported ER-13 during operation, and the brake did not release with a sound.
• Troubleshooting Process:
  • Using a multimeter, the brake coil voltage was measured at DC24V (normal), but the coil resistance was infinite (normal value: 120 Ω).
  • Disassembling the brake revealed that the coil winding was burned black (due to long-term overload).
  • After replacing the brake coil, power-up testing showed normal brake release, and the motor operated without alarm.
• Solution: Check the brake load (ensure it does not exceed the rated braking torque) and avoid long-term overload.

Case 3: ER-13 Due to Improper Gain Adjustment

• Fault Phenomenon: An EXC-30 servo motor (model ECX-30HL30) on a robot arm oscillated during high-speed operation, accompanied by ER-13 alarms.
• Troubleshooting Process:
  • Using an oscilloscope to measure the motor current revealed periodic fluctuations in the current waveform, with peak values exceeding the rated value.
  • Checking the parameters revealed that the position gain (P003) was set to 1000 (rated value: 500), and the speed gain (P005) was set to 800 (rated value: 400).
  • Gradually reducing the gains (P003 to 600, P005 to 500) eliminated the oscillation and prevented further ER-13 alarms.
• Solution: Based on the load inertia ratio (8:1 in this case), recalculate the gain parameters (recommended to reduce gains by 20%-30% when the inertia ratio exceeds 5:1).

VI. Preventive Measures for the ER-13 Fault

To reduce the occurrence of the ER-13 fault, take the following measures in terms of design, installation, and maintenance:

• Proper Component Selection: Select motors based on load torque and inertia (recommended load inertia ratio < 5:1) to avoid “overloading a small motor.”
• Parameter Optimization: Verify parameters (torque limit, start-stop frequency, gains) before power-up and adjust them according to load characteristics (e.g., increase acceleration/deceleration time for heavy loads).
• Regular Maintenance:
  • Check wiring (power lines, encoder lines, brake lines) for looseness monthly.
  • Lubricate mechanical transmission parts (guide rails, screw rods) and clean dust (to prevent it from entering the drive) quarterly.
  • Test motor winding insulation annually (use a megohmmeter to measure ground resistance, which should be > 10 MΩ).
• Environmental Protection: Install the drive in a well-ventilated area (temperature < 40°C) and avoid humid or dusty environments (add protective covers if necessary for harsh environments).

VII. Conclusion

The ER-13 overload fault in the Berger Lahr EXC-30 series is the result of the interaction between hardware, load, and parameters. During troubleshooting, follow a logical approach from “external to internal” and “mechanical to electrical,” focusing on load status, parameter settings, and wiring integrity. Through the analysis and case studies in this article, engineering technicians can quickly locate the root cause of the fault and implement targeted solutions. Additionally, by selecting components properly, performing regular maintenance, and optimizing parameters, the occurrence of the ER-13 fault can be effectively prevented, ensuring the stable operation of the servo system.

In the field of industrial automation, the core of fault handling is “understanding system logic + mastering troubleshooting methods.” It is hoped that this article will provide practical technical references for Berger Lahr servo users and improve equipment maintenance efficiency.

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Table of Contents

1. Introduction
2. Basic Principles and Structure of Servo Drives
   • 2.1 Core Composition of Servo Systems
   • 2.2 Technical Features of the SD700 Series Servo Drive
   • 2.3 Operating Modes and Control Logic of Servo Drives
3. Common Fault Types and Cause Analysis of Servo Drives
   • 3.1 Fault Classification and Level Division
   • 3.2 Cause Analysis of Er.022 (System and Checksum Error)
   • 3.3 Comparison with Other Common Fault Codes (Er.001, Er.003, Er.016, etc.)
4. Diagnosis and Handling Process for Er.022 Fault
   • 4.1 Fault Phenomena and Preliminary Judgment
   • 4.2 Principle and Operation Steps of Soft Reset (FN002)
   • 4.3 Advanced Diagnosis: Parameter Verification and Hardware Inspection
   • 4.4 Case Study: Actual Handling Process of Er.022
5. Preventive Maintenance and Optimization of Servo Drives
   • 5.1 Key Points for Regular Inspection and Maintenance
   • 5.2 Parameter Backup and Recovery Strategies
   • 5.3 Environment and Wiring Optimization
   • 5.4 Firmware Upgrade and Compatibility Management
6. Fault Prediction and Intelligent Development Trends of Servo Systems
   • 6.1 Predictive Maintenance Based on Data Analysis
   • 6.2 Application of Artificial Intelligence in Servo Fault Diagnosis
   • 6.3 Intelligent Upgrade of Servo Systems in the Context of Industry 4.0
7. Conclusion and Recommendations

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1. Introduction

As the core execution unit of modern industrial automation systems, servo drives are widely used in CNC (Computer Numerical Control) machine tools, robots, packaging machinery, printing equipment, and other fields. Their high-precision and high-response control characteristics significantly improve production efficiency and product quality. However, due to complex working environments, electrical interference, and incorrect parameter settings, servo drive failures occur frequently. Among them, Er.022 (System and Checksum Error) is a relatively common fault in the SD700 series servo drives.

This article takes the SD700 Er.022 fault as the starting point to systematically analyze the causes, diagnostic methods, and handling processes of servo drive faults. It also discusses preventive maintenance and intelligent development trends, aiming to provide engineering and technical personnel with a scientific and efficient solution for fault handling and optimization.

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2. Basic Principles and Structure of Servo Drives

2.1 Core Composition of Servo Systems

A servo system typically consists of the following three parts:

1. Servo Drive: Receives control signals to drive the servo motor.
2. Servo Motor: The actuator that converts electrical energy into mechanical motion.
3. Feedback Device (Encoder): Detects the motor’s position and speed in real-time and feeds it back to the drive to form a closed-loop control.

Inside the servo drive, core components such as DSP (Digital Signal Processor), FPGA (Field-Programmable Gate Array), Power Module (IGBT), and Communication Interfaces are integrated to achieve precise control through high-speed computing.

2.2 Technical Features of the SD700 Series Servo Drive

The SD700 series is a high-performance servo drive with the following features:

• High-Speed Response: 3kHz speed loop response bandwidth, suitable for high-dynamic applications.
• Multiple Control Modes: Supports position control, speed control, torque control, and hybrid control.
• Rich Communication Interfaces: Supports industrial fieldbuses such as EtherCAT, Profinet, CANopen, and RS-485.
• Intelligent Adjustment Functions: Automatic inertia identification, robust control, bandwidth setting, etc.
• Fault Diagnosis and Protection: Built-in multiple fault codes and alarm mechanisms for quick problem localization.

2.3 Operating Modes and Control Logic of Servo Drives

The main operating modes of a servo drive include:

1. Position Control Mode: Precisely controls the motor position via pulse signals.
2. Speed Control Mode: Controls the motor speed via analog or digital signals.
3. Torque Control Mode: Directly controls the motor’s output torque, suitable for applications like tension control.

The control logic is based on the PID (Proportional-Integral-Derivative) algorithm, combined with feedforward compensation and filtering processing to achieve high-precision closed-loop control.

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3. Common Fault Types and Cause Analysis of Servo Drives

3.1 Fault Classification and Level Division

Servo drive faults can be divided into the following types:

1. Hardware Faults:
   • Power module damage (IGBT short circuit, open circuit).
   • Encoder wire break or signal abnormality.
   • Main circuit overvoltage/undervoltage.
2. Software/Parameter Faults:
   • Incorrect parameter settings (e.g., Pn000 control mode mismatch).
   • Firmware abnormality or checksum failure (e.g., Er.022).
3. Communication Faults:
   • Fieldbus communication interruption (EtherCAT, CANopen, etc.).
   • Command signal loss or interference.
4. Environment and Wiring Faults:
   • Electromagnetic Interference (EMI).
   • Poor grounding or power fluctuation.

According to severity, faults can be divided into:

• Category 1 (Severe): Requires immediate shutdown (e.g., overcurrent, overvoltage).
• Category 2 (Warning): Operation can continue but requires attention (e.g., overheating).
• Category 3 (Information): Recorded in logs, does not affect operation (e.g., parameter changes).

3.2 Cause Analysis of Er.022 (System and Checksum Error)

Er.022 is usually triggered by the following reasons:

1. Parameter Verification Failure:
   • Parameter groups (e.g., Pn000～Pn999) are set out of range or have logical conflicts.
   • Motor model parameters (e.g., Pn100, Pn101) do not match the actual hardware.
2. Firmware or EEPROM Abnormality:
   • Firmware upgrade interruption or data corruption.
   • Aging of EEPROM storage chip leading to data loss.
3. Encoder Initialization Failure:
   • Encoder communication interruption (SD+, SD- signal abnormality).
   • Insufficient battery voltage for absolute encoders (below 3.0V).
4. Power or Grounding Issues:
   • Control power supply (L1C, L2C) fluctuation.
   • Signal interference caused by poor grounding.

3.3 Comparison with Other Common Fault Codes

Fault Code	Description	Possible Causes
Er.001	Overcurrent	Excessive load, IGBT damage, motor stall
Er.003	Overvoltage	Excessive regenerative energy, braking resistor fault
Er.016	Encoder Disconnected	Encoder cable disconnected, poor contact
Er.020	Communication Timeout	Fieldbus communication interruption, address conflict
Er.022	System and Checksum Error	Parameter error, firmware abnormality, encoder initialization failure

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4. Diagnosis and Handling Process for Er.022 Fault

4.1 Fault Phenomena and Preliminary Judgment

Typical phenomena of Er.022:

• The drive panel displays “Er.022”, and the servo motor stops.
• Cannot start via the Servo ON (/S-ON) signal.
• The alarm light (ALM) is constantly on.

Preliminary Judgment Steps:

1. Check for recent parameter changes or firmware upgrades.
2. Confirm if the encoder cables are connected properly (SD+, SD-, BAT+, BAT-).
3. Check if the control power supply (L1C, L2C) is stable.

4.2 Principle and Operation Steps of Soft Reset (FN002)

Soft Reset is a standard operation to clear temporary fault states. It does not clear user parameters but reloads system defaults.

Operation Steps:

1. Enter Fn Mode: Press the MODE/SET key to switch to the auxiliary function (Fn) mode.
2. Select FN002: Use the ▲/▼ keys to select FN002 (Soft Reset).
3. Execute Reset: Press the MODE/SET key to confirm; the drive will re-initialize.
4. Observe Result:
   • If the fault clears, normal operation resumes.
   • If the fault persists, proceed to advanced diagnosis.

4.3 Advanced Diagnosis: Parameter Verification and Hardware Inspection

If the soft reset is ineffective, further diagnosis is required:

1. Parameter Verification:
   • Check if Pn000 (Control Mode) matches the actual application.
   • Confirm if Pn100 (Motor Model) and Pn101 (Encoder Type) are correct.
   • Use FN000 (Alarm Record) to view historical faults.
2. Encoder Inspection:
   • Measure if the encoder power supply (+5V, 0V) is normal.
   • Check the absolute encoder battery voltage (should be ≥3.0V).
   • Use an oscilloscope to detect if there is pulse output on SD+ and SD- signals.
3. Hardware Inspection:
   • Measure if the IGBT module is short-circuited (use a multimeter to measure resistance between U/V/W and ground).
   • Check if the main circuit capacitors are bulging or leaking.
   • Confirm if grounding is reliable (≤1Ω).

4.4 Case Study: Actual Handling Process of Er.022

Case Background:
A CNC machining center using an SD700-7R6A drive suddenly reported Er.022 and failed to start.

Troubleshooting Process:

1. Soft Reset: Executed FN002, but the fault remained.
2. Parameter Check: Found that Pn100 was mistakenly set to “0” (the default should be “7”).
3. Parameter Correction: After restoring Pn100 to “7”, the fault was cleared.
4. Root Cause Analysis: The parameter loss was caused by operator misoperation.

Conclusion:

• Er.022 is mostly caused by parameter errors or encoder abnormalities.
• Soft Reset is the first step; if ineffective, parameters and hardware need in-depth inspection.

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5. Preventive Maintenance and Optimization of Servo Drives

5.1 Key Points for Regular Inspection and Maintenance

1. Daily Inspection:
   • Confirm no alarms on the drive panel.
   • Check if the motor running sound is abnormal (e.g., noise, vibration).
2. Weekly Inspection:
   • Clean the drive cooling fan and filter.
   • Check if wiring terminals are loose.
3. Monthly Inspection:
   • Measure the absolute encoder battery voltage.
   • Check if the main circuit capacitors are bulging.
4. Yearly Inspection:
   • Use FN100 (Vibration Detection) to evaluate the mechanical state.
   • Back up all parameters (Pn group).

5.2 Parameter Backup and Recovery Strategies

• Use host computer software to back up parameters regularly (e.g., SD700 supporting debugging software).
• Backup files should include:
  • Pn parameters (control parameters).
  • Fn auxiliary function settings.
  • Internal position data (e.g., origin offset).
• When restoring, parameters should be loaded step-by-step to avoid conflicts caused by batch writing.

5.3 Environment and Wiring Optimization

1. Electromagnetic Compatibility (EMC):
   • Separate servo cables from signal cables by a distance of ≥30cm.
   • Use shielded cables and ensure the shield layer is grounded at a single point.
2. Power Quality:
   • Use a regulated power supply to avoid voltage fluctuations exceeding ±10%.
   • Install a noise filter at the main circuit input.
3. Grounding Standards:
   • Ensure common grounding for the drive, motor, and control cabinet, with grounding resistance ≤1Ω.
   • Avoid ground loops (e.g., interference caused by multi-point grounding).

5.4 Firmware Upgrade and Compatibility Management

• Check the manufacturer’s official website regularly for the latest firmware.
• Back up parameters before upgrading and confirm compatibility with the motor model.
• Do not power off during the upgrade process to prevent EEPROM damage.

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6. Fault Prediction and Intelligent Development Trends of Servo Systems

6.1 Predictive Maintenance Based on Data Analysis

Through IoT (Internet of Things) and big data analysis, real-time monitoring is performed on:

• Motor temperature, vibration, and current fluctuations.
• Drive alarm logs and parameter change trends.
• Using machine learning algorithms to predict faults (e.g., IGBT aging, encoder failure).

Case:
Brands like Siemens and Fanuc have launched cloud monitoring platforms that use AI to analyze historical data and warn of IGBT faults one month in advance.

6.2 Application of Artificial Intelligence in Servo Fault Diagnosis

1. Automatic Fault Classification:
   • Use NLP (Natural Language Processing) to parse alarm descriptions and automatically match solutions.
2. Intelligent Parameter Optimization:
   • AI dynamically adjusts PID parameters and gain settings based on load changes.
3. Remote Expert Systems:
   • Combined with AR (Augmented Reality), technicians can receive real-time guidance via smart glasses.

6.3 Intelligent Upgrade of Servo Systems in the Context of Industry 4.0

• Digital Twin:
  • Build a virtual model of the servo system to simulate fault scenarios and optimize parameters.
• Edge Computing:
  • Embed edge AI chips in the drive to process data in real-time and reduce cloud latency.
• Adaptive Control:
  • The system automatically identifies load changes and switches control modes (e.g., from speed mode to torque mode).

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7. Conclusion and Recommendations

7.1 Summary

• Er.022 faults are mostly caused by parameter errors, encoder abnormalities, or firmware corruption, and can be quickly recovered via Soft Reset (FN002).
• Preventive maintenance is the key to reducing faults; regular parameter backup, wiring checks, and environment optimization are essential.
• Future servo systems will develop towards intelligence and predictive maintenance, combining AI, IoT, and Digital Twins to improve reliability.

7.2 Recommendations

1. For Engineers:
   • Familiarize yourself with the drive manual and master the use of Fn auxiliary functions.
   • Establish a parameter backup library to avoid data loss due to misoperation.
2. For Enterprises:
   • Invest in intelligent monitoring systems to implement predictive maintenance.
   • Train employees regularly to improve fault diagnosis capabilities.
3. For System Integrators:
   • Consider EMC protection and grounding standards during the system design phase.
   • Choose servo drive brands that support remote diagnosis.

The Zhensun Servo ZS100 series is a dedicated control system designed specifically for hydraulic servo oil pump systems. It consists of the ZS100 series servo drive, ZM permanent magnet synchronous servo motor, and ZB braking unit. Covering a power range from 7.5kW to 75kW, it adopts Closed-loop Vector Control (VCC) with a maximum frequency of 300Hz, starting torque of 180% at 0Hz, speed regulation range of 1:1000, stability accuracy of ±0.02%, and an overload capacity of 150% rated output current for 100s or 180% rated output current for 5s. The system is widely used in hydraulic equipment such as injection molding machines, die-casting machines, and spinning machines, emphasizing high reliability, high stability, and cost-effectiveness. In practical field applications, the ERR10 fault (displayed as “Err 10” on the panel) is one of the most frequent alarms, directly affecting equipment operational safety. Based on the complete structure of the ZS100 series manual, this article provides a comprehensive operational guide covering fault definition, internal coding mechanisms, in-depth analysis of four causes, step-by-step diagnosis procedures, targeted solutions, parameter optimization for prevention, and typical case reviews, helping engineers quickly locate and thoroughly resolve the issue.

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I. Nature of ERR10 Fault and Alarm Trigger Mechanism

The panel display for ERR10 corresponds to the fault name “Drive Overload”. In the drive’s internal fault address 8000H, its code is 000A, listed alongside ERR02~ERR07 (overcurrent/overvoltage series), ERR09 (undervoltage), and ERR11 (motor overload). The trigger conditions are strictly based on the drive’s hardware protection logic: when the output current continuously exceeds the rated value and surpasses the overload tolerance time, or when IGBT module temperature/bus voltage abnormalities cause a protection action, the system immediately locks the PWM output, the panel red light flashes, and “Err 10” is displayed. Unlike ERR11 (motor overload), ERR10 focuses on the drive unit’s own load-bearing capacity rather than the motor winding thermal protection.

1. Trigger Logic

Trigger conditions are strictly based on drive hardware protection logic:

• When output current continuously exceeds the rated value and exceeds overload tolerance time;
• Or when IGBT module temperature/bus voltage abnormalities cause protection actions;
• The system immediately locks PWM output, panel red light flashes, and displays “Err 10”.

Note: Unlike ERR11 (motor overload), ERR10 focuses on the drive unit’s load-bearing capacity, not motor winding thermal protection.

2. Trigger Paths

• Current Detection Circuit: Hall sensor or shunt resistor samples three-phase output current in real-time. Triggers after exceeding 150% rated value for 100s or 180% for 5s.
• Pressure Feedback Abnormality: Abnormal pressure sensor feedback (terminal A13) causes the control loop to output excessive setpoints, indirectly amplifying current.
• Hardware Abnormality: IGBT short-circuit leakage current directly increases bus current.

3. Reset Method

• Press the panel “Stop/Reset” button (red button);
• Or clear via DI digital input (D11~D15 programmed as reset signal).
• Warning: Root cause must be eliminated before reset, otherwise repeated triggering will cause permanent drive damage.

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II. In-depth Analysis of Four Major Causes

Section 4.1 of the manual clearly lists the troubleshooting checklist for ERR10, totaling four items, each corresponding to high-frequency field scenarios. The following analysis combines system specifications, wiring, parameters, and hydraulic application characteristics.

Cause 1: Drive Undersizing

Core Basis: ZS100 series sizing core basis is the table in Section 1.2.

• Example: Take ZS100T015-C (15kW, rated output current 32A). If actual hydraulic pump power demand reaches 18kW (considering 1.2~1.5x safety margin), the drive capacity is insufficient.
• Risk: Hydraulic pump starting torque peaks can reach over 200%. If sizing only matches rated power, long-term operation will inevitably overload.

Peripheral Component Matching Key Points (Section 1.5):

• MCCB needs ≥63A, contactor ≥40A, input wire ≥6mm². If wires are too thin or contactor capacity is insufficient, contact resistance heating further amplifies overload.
• Braking Unit: 15kW model built-in braking resistor recommended ≥32Ω/100W. Without external braking unit or if resistance value is too large, deceleration energy cannot be released, indirectly raising bus voltage and current.

Quantitative Judgment: Measured output current (A01/A02 analog output) long-term ≥110% rated value indicates undersizing.

Cause 2: Excessive Load or Motor Locked Rotor

High-load scenarios specific to hydraulic systems:

• Relief valve not fully open, pump blockage, injection/clamping pressure set too high;
• Oil temperature too low causing viscosity increase, pipeline leakage causing excessive compensation current.

Locked Rotor Characteristics:

• When motor locks, three-phase current instantly reaches over 300%, triggering ERR10 within 5s.
• Criteria: Speed feedback (PG card SIN/COS signal) is 0 while set frequency >0Hz, or A13 pressure feedback suddenly rises to upper limit.
• Commissioning Risk: Section 3.2 of commissioning flow clearly states that if load tuning (P1.16=2) fails during motor trial run, overload is easily caused by locked rotor. ZS100 overload protection time is strict: must act after 150% for 100s, otherwise IGBT burn risk is extremely high.

Cause 3: Drive Hardware Failure

Fault Scope: Includes IGBT module aging, current sensor drift, main control board/drive board abnormalities, lightning protection board breakdown.

• Accompanying Fault: ERR18 (current detection fault) often accompanies ERR10.
• Hardware Failure Features: ERR10 reported even without load, or three-phase current severely unbalanced (>20%).

Board-level Check Points:

• Bus capacitor capacity attenuation (measured voltage fluctuation >10%);
• Cooling fan speed <2000rpm;
• IGBT module Vce saturation voltage drop abnormality.
• Environmental Impact: 15kW model weighs 6.5kg. When installation environment temperature exceeds 40℃ or vibration >5.9m/s², hardware life significantly shortens.

Cause 4: Pressure Sensor Failure

ZS100 is optimized for hydraulic servo pumps. Terminal A13 (pressure sensor feedback) connects to ±10V or 0~20mA signal (selected by J5 jumper).

Fault Mechanism: Sensor output abnormality (open circuit, short circuit, zero drift >0.5%) causes closed-loop vector control to misjudge insufficient pressure, automatically increasing torque setpoint and causing current surge.

Typical Manifestations:

• Panel shows ERR10 while A13 input voltage remains constant at 0V or 10V limit values.
• If 13V sensor power supply (+13V~GND) output deviation >±10%, it will also indirectly trigger.
• Requirement: Hydraulic system pressure fluctuates greatly (0~250bar), requiring high sensor pressure resistance and linearity.

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III. Standardized Diagnostic Procedure (30-Minute Positioning Method)

Strictly follow the five-step method of “Power-off Inspection—Power-on Parameters—Load Isolation—Sensor Verification—Hardware Measurement” to avoid blind reset.

1. Safety Power-off Inspection (5 minutes)

Cut off main power R/S/T, wait for bus capacitor to discharge to <36V (confirm with multimeter DC range). Check:

• Main Circuit: Whether wires (U/V/W) are loose or insulation damaged;
• Grounding: Whether grounding terminal ⊕ is reliable (<0.1Ω);
• Braking Resistor: Whether (+、PB) connections are correct and resistance matches (15kW ≥32Ω);
• Sensor: Whether pressure sensor wires (A13-GND) have open or short circuits.
• Nameplate Check: ZS100T015-C-2 input 28A/output 30A, matches actual pump power?

2. Parameter Check and Self-Learning (10 minutes)

After power-on, enter P1 group (motor parameters):

• P1.01~P1.05: Confirm motor rated power, current, voltage, frequency, speed match ZM motor nameplate;
• P1.15: Motor overload coefficient default 1.0;
• P1.16: Execute static self-learning (=1) or dynamic self-learning (=2), must open relief valve before running. Learning failure directly correlates with ERR10.
• P0.02: =0 (panel control), confirm no external CAN setpoint interference.
• PD Communication: Check Appendix J (if using Modbus): baud rate consistent, address unique, timeout 0.0s (avoid ERR16 interference).

3. Load Isolation Test (5 minutes)

Disconnect motor from pump coupling (or close all valves), execute no-load trial run:

• Press “Run” key, observe output current (A01 set as current monitoring, J4 jumper voltage output).
• If ERR10 still reported: Exclude excessive load, pointing to hardware or sizing issues.
• If current normal: Reconnect pump, gradually increase pressure (from 10bar), monitor corresponding relationship between A13 pressure feedback and current.

4. Pressure Sensor Special Verification (5 minutes)

• Measure +13V~GND output: should be 13V±1.3V;
• Measure A13-GND voltage: 0V at no pressure, 10V at full pressure (or 20mA range);
• Calibration: Calibrate sensor with standard pressure source. If output deviation >2%, replace immediately (recommend 0~350bar 4~20mA type).
• Hardware: Confirm J5 jumper correctly selects voltage/current input mode.

5. Hardware Deep Measurement (5 minutes)

• Current Balance: Three-phase output current balance <5%;
• Bus Voltage: (+、-) stable at 540V±10%;
• Temperature: IGBT module temperature sensor (if any) <80℃;
• Fault Troubleshooting: If current sensor failure suspected, refer to ERR18 troubleshooting: replace drive board or main control board.

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IV. Targeted Solutions and Field Operation Standards

1. For Undersizing

• Recalculation: Hydraulic pump theoretical power = pressure × flow × efficiency coefficient (usually 1.15~1.3).
• Hardware Upgrade: Upgrade to next level (e.g., ZS100T018-C 18kW). Simultaneously upgrade MCCB, wires, and filter per Section 1.5.
• Braking Unit: Install external braking unit ZB-70-B (mandatory for 37kW+).

2. For Excessive Load/Locked Rotor

• Mechanical Inspection: Open relief valve fully, clean pump filter; immediately stop if motor locks, check if pump shaft is stuck or oil solidified.
• Parameter Adjustment: Reduce pressure setpoint (AI1 terminal) or flow setpoint (AI2).
• PID Optimization: Optimize P3 group PID parameters (reduce proportional gain by 20%~30%, extend integral time).

3. For Hardware Failure

• Module Replacement: Replace corresponding module (IGBT module must match model);
• Maintenance: Clean heat sink, fan speed test >2800rpm;
• Return to Factory: Return entire unit or replace drive (free during warranty).

4. For Pressure Sensor Failure

• Replacement: Replace with same specification sensor, re-zero (pressure feedback zero calibration in P parameters);
• Anti-interference: Add shielded wire, keep away from strong current interference;
• Bus Check: For multi-unit systems, check CAN bus terminal resistance (J8 jumper).

Post-reset Monitoring: Must monitor for 30 minutes. Confirm current <105% rated value, pressure stable, no abnormal noise before putting into production.

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V. Parameter Optimization and Preventive Maintenance System

Preventing ERR10 core lies in parameter closed-loop and regular maintenance:

• Regular Self-learning: P1.16 execute dynamic self-learning monthly;
• Real-time Monitoring: A01/A02 output monitoring current/pressure, connect to PLC upper limit alarm;
• Environment Control: Ambient temperature -10~40℃, humidity <95%RH, altitude <1000m;
• Tightening Check: Every 3 months check wiring tightening torque (main circuit 4~6N·m), clean air duct;
• Braking Monitoring: Braking resistor temperature monitoring <120℃, upgrade power if necessary;
• Function Enable: Ver 2.0 parameters (ZS200 compatible) add jitter suppression and pressure overshoot functions, can reduce overload risk.

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VI. Typical Case Reviews (Injection Molding Machine Site)

Case 1: Undersizing

• Phenomenon: 15kW ZS100T015-C unit, frequent ERR10 during injection.
• Diagnosis: Actual pump power needed 17kW, undersizing.
• Solution: Upgraded to ZS100T018-C, current peak dropped to 85%, fault eliminated.

Case 2: Sensor Aging

• Phenomenon: Pressure sensor aged, A13 constantly 0V, causing torque setpoint to surge.
• Solution: Replaced sensor + zero calibration, system pressure fluctuation reduced from ±15bar to ±3bar.

Case 3: Mechanical Locked Rotor

• Phenomenon: Motor locked (filter clogged).
• Diagnosis: Normal operation after isolating pump.
• Solution: Cleaned filter, restored normal operation.

Case 4: Hardware Drift

• Phenomenon: Current sensor drift.
• Solution: Replaced drive board, ERR10 permanently disappeared.

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Conclusion: From Passive Alarm to Active Protection

ERR10 is not an isolated fault, but the result of four-dimensional coupling among drive, motor, hydraulic load, and sensor. Mastering the complete ZS100 series architecture (Chapters 1~10 + Appendices), combined with the five-step diagnosis and four targeted solutions above, can compress fault downtime by over 90%.

Recommendation: Establish equipment files, execute quarterly “parameter backup—self-learning—load test—sensor calibration” maintenance, combined with PLC upper monitoring to achieve zero-fault operation. The key to hydraulic servo system efficiency and stability lies in “proper sizing, precise parameters, timely maintenance”. Strictly following this process will transform ERR10 from a “common fault” into a controllable risk that is “predictable and avoidable”.