Chapter 11 Troubleshooting

11.1 Safety Information

Safety Information

Do not disconnect the AC drive while power is on, and keep all breakers in OFF
state. Failure to comply may result in electric shock.

Make sure to ground the AC drive according to local laws and regulations. Failure
to comply may result in electric shock or a fire.
Do not remove the front cover or touch internal circuit while the power is on.
Failure to comply may result in electric shock.
Do not allow unqualified personnel to perform any maintenance, inspection or part
replacement work.
When installing the drive inside an enclosed cabinet, use cooling fan or air
conditioner to keep temperature below 50°C. Failure to comply may result in
overheating or even a fire.
Tighten all screws based on the specified tightening torque. Failure to comply may
result in electric shock or a fire.
Always confirm input voltage is within nameplate rating. Failure to comply may
result in electric shock or a fire.
Keep flammable and combustible materials away from the drive.
Cover the top of the drive with a temporary cloth or paper during installation so as
to prevent foreign matter such as metal shavings, oil and water from falling into
the drive. After the installation is completed, remove the temporary cloth or
paper.
Follow proper electrostatic discharge (ESD) procedures when operating the AC
drive. Failure to comply will damage internal circuit of the drive.
11.2 Troubleshooting During Trial Run

This section provides solutions to oscillation, poor torque or speed response, or other problems that
occur while performing a trial run.

Drive in Open-loop Vector Control (F0-01 = 0: Default value)

The AC drive implements control of the motor speed and torque without an encoder for speed feedback. In
this control mode, motor auto-tuning is required to obtain the motor related parameters.

Problem Solutions

Overload or 1. Set motor parameters F1-01 to F1-05 according to motor nameplate.

overcurrent detected
2. Select a proper motor auto-tuning mode by setting F1-37 and
during motor start
perform motor auto-tuning. If possible, select dynamic auto-tuning (F1-
37 = 2).

Poor torque or speed 1. If motor torque and speed response are too slow, increase the
response and motor setting of F2-00 (speed loop proportional gain 1) by 10 gradually or
oscillation at speeds decrease the setting of F2-01 (speed loop integral time 1) by 0.05
below 5 Hz gradually.
2. If motor oscillation occurs, decrease the setting of F2-00 and F2-01.

Poor torque or speed 1. If motor torque and speed response are too slow, increase the
response and motor setting of F2-03 (speed loop proportional gain 2) by 10 gradually or
oscillation at speeds decrease the setting of F2-04 (speed loop integral time 4) by 0.05
above 5 Hz gradually.
2. If motor oscillation occurs, decrease the setting of F2-03 and F2-04.

Low speed accuracy If speed error when motor runs with load is large, increase the setting
of F2-06 (vector control slip compensation gain) by 10% gradually.

Obvious speed If motor speed fluctuation is large, increase the setting of F2-07 (SVC
fluctuation torque filter time) by 0.001s gradually.

Too loud motor noise Increase the setting of F0-15 (carrier frequency) by 1.0 kHz gradually.
Note that increase in carrier frequency will result in an increase in the
leakage current of the motor.

Insufficient motor Check whether torque upper limit is small. If yes, please:
torque
Increase the setting of F2-10 (digital setting of torque upper limit in
speed control mode) in the speed control mode.
Increase the torque reference (A0-03) in the torque control mode.
 Drive in Feedback Vector Control (F0-01 = 1)

It is applicable to the application with an encoder for speed feedback. In this mode, you need
to set the encoder pulses per revolution (F1-27), the encoder type (F1-28) and the encoder
direction (F1-30) correctly.

Problem Solutions

Overload or Set F1-27, F1-28 and F1-30 correctly.

overcurrent fault
detected during motor
start

Overload or 1. Set motor parameters F1-01 to F1-05 according to the motor

overcurrent detected nameplate.
during motor running
2. Select a proper motor auto-tuning mode by setting F1-37 and perform
motor auto-tuning. If possible, select dynamic auto-tuning (F1-37 = 2).

Poor torque or speed 1. If motor torque and speed response are too slow, increase the setting
response and motor of F2-00 (speed loop proportional gain 1) by 10 gradually or decrease
oscillation at speeds the setting of F2-01 (speed loop integral time 1) by 0.05 gradually
below 5 Hz
2. If motor oscillation occurs, decrease the setting of F2-00 and F2-01.

Poor torque or speed 1. If motor torque and speed response are too slow, increase the setting
response and motor of F2-03 (speed loop proportional gain 2) by 10 gradually or decrease
oscillation at speeds the setting of F2-04 (speed loop integral time 4) by 0.05 gradually.
above 5 Hz
2. If motor oscillation occurs, decrease the setting of F2-03 and F2-04.

Low speed accuracy If speed error when motor runs with load is large,, increase the setting of
F2-06 (vector control slip compensation gain).

Obvious speed If motor speed fluctuation is large, increase the setting of F2-07 (SVC
fluctuation torque filter time) by 0.001s gradually.

Too loud motor noise Increase the setting of F0-15 (carrier frequency) by1.0 kHz gradually.
Note that increase in carrier frequency will result in an increase in the
leakage current of the motor.

Insufficient motor Check whether torque upper limit is small. If yes, please:
torque
Increase the setting of F2-10 (digital setting of torque upper limit in
speed control mode) in the speed control mode.
Increase the torque reference (A0-03) in the torque control mode.
 Drive in V/F Control (F0-01 = 2)

It is applicable to application without an encoder for speed feedback. You need to set rated
motor voltage (F1-02) and rated motor frequency (F1-04) correctly.

Problem Solutions

Motor oscillation Increase the setting of F3-11 (V/F oscillation suppression gain) by 10
during running gradually. The permissible maximum setting here is 100.

Overcurrent during Decrease the setting of F3-01 (torque boost) by 0.5% gradually.
start

Very large current 1. Set rated motor voltage (F1-02) and rated motor frequency (F1-04)
during running correctly.
2. Decrease the setting of F3-01 (torque boost) by 0.5% gradually.

Too loud motor noise Increase the setting of F0-15 (carrier frequency) by 1.0 kHz gradually.
Note that increase in carrier frequency will result in an increase in the leakage
current of the motor.

Overvoltage detected 1. Ensure that F3-23 (voltage limit selection) is set to 1 (enabled). Increase
when heavy load is the setting of F3-24/F3-25 (frequency gain/voltage gain for voltage limit) by 10
suddenly removed or gradually. The permissible maximum setting here is 100. The default value of
during deceleration F3-22 is 30.
2. Decrease the setting of F3-22 (voltage limit) by 10 V gradually. The
permissible minimum setting here is 700 V. The default value of F3-20 is 770
V.

Overcurrent detected 1. Increase the setting of F3-20 (current limit gain) by 10 gradually. The
when heavy load is permissible maximum setting here is 100. The default value of F3-22 is 20.
suddenly added or
2. Decrease the setting of F3-18 (current limit level) by 10% gradually. The
during acceleration
permissible minimum setting here is 50%. The default value of F3-18 is
150%.

11.3 Fault Display

When a fault occurs during running, the AC drive stops output immediately, the fault indicator flashes,

and contact of the fault relay acts. The operation panel displays the fault code such as , as

shown in the following figure.

11.4 Resetting Fault

Stage Solution Remark

After the Check operating panel for detailed information of View these information via F9-14 to
fault occurs recent three faults, such as fault type and frequency, F9-44.
current, bus voltage, DI/DO state, accumulative
power-on time and accumulative running time at
occurrence of the faults.

Before the Find and remove cause of the fault. Then follow Troubleshoot the fault according to
fault is steps below to reset the fault. section 11.5 "Faults and
reset Diagnostics".

Fault Fault resetting through a DI terminal

resetting
Allocate a DI terminal with function 9 “Fault reset
method
(RESET)” by setting any of F4-00 to F4-09 to 9.

Fault resetting via operating panel

Confirm that F7-02 = 1 (default value). Then press

the key on operating panel.

Automatic resetting
Disconnect the power supply. Until the fault code
disappears, connect the power supply again.

Fault resetting via host computer

Confirm that F0-02 = 2 and write "7" (fault reset) to
communication address 2000H.
11.5 Faults and Diagnostics

Troubleshoot the fault according to the following table. If the fault cannot be eliminated, contact the
agent or Inovance

Operating Panel Display Fault Name

Overcurrent during acceleration

Cause Possible Solution

Ground fault or short circuit exists in Check whether short-circuit occurs on the motor, motor cable or
the output circuit. contactor.

Control mode is SVC or FVC but Set motor parameters according to motor nameplate and
motor auto-tuning is not performed. perform motor auto-tuning.

Acceleration time is too short. Increase acceleration time.

The overcurrent stall prevention Ensure that current limit is enabled (F3-19 = 1).
parameters are set improperly.
The setting of current limit level (F3-18) is too large. Adjust it
between 120% and 150%.
The setting of current limit gain (F3-20) is too small. Adjust it
between 20 and 40.

Customized torque boost or V/F Adjust the customized torque boost or V/F curve.
curve is not appropriate.

The spinning motor is started. Enable the catching a spinning motor function or start the motor
after it stops.

The AC drive suffers external View historical fault records. If the current value is far from the
interference. overcurrent level, find interference source. If external
interference does not exist, it is the drive board or hall device
problem.

Operating Panel Display Fault Name

Overcurrent during deceleration

Cause Possible Solution

Ground fault or short circuit exists in Check whether short-circuit occurs on the motor, motor cable or
the output circuit. contactor.

Control mode is SVC or FVC but Set the motor parameters according to the motor nameplate and
motor auto-tuning is not performed. perform motor auto-tuning.

Acceleration time is too short. Increase acceleration time.

The overcurrent stall prevention Ensure that current limit is enabled (F3-19 = 1).
parameters are set improperly.
The setting of current limit level (F3-18) is too large.
Adjust it between 120% and 150%.
The setting of the current limit gain (F3-20) is too small.
Adjust it between 20 and 40.

Braking unit and braking resistor are Install braking unit and braking resistor.
not installed.

The AC drive suffers external View historical fault records. If the current value is far from the
interference. overcurrent level, find interference source. If external
interference does not exist, it is the drive board or hall device
problem.

Operating Panel Display Fault Name

Overcurrent at constant speed

Cause Possible Solution

Ground fault or short circuit exists in Check whether short-circuit occurs on the motor, motor cable or
the output circuit. contactor.

Control mode is SVC or FVC but Set motor parameters according to motor nameplate and
motor auto-tuning is not performed. perform motor auto-tuning.

The overcurrent stall prevention Ensure that current limit is enabled (F3-19 = 1).
parameters are set improperly.
The setting of current limit level (F3-18) is too large. Adjust it
between 120% and 150%.
The setting of current limit gain (F3-20) is too small. Adjust it
between 20 and 40.

The AC drive power class is small. If output current exceeds rated motor current or rated output
current of the AC drive during stable running, replace a drive of
larger power class.

The AC drive suffers external View historical fault records. If the current value is far from the
interference. overcurrent level, find interference source. If external
interference does not exist, it is the drive board or hall device
problem.

Operating Panel Display Fault Name

Overvoltage during acceleration

Cause Possible Solution

Input voltage is too high. Adjust input voltage to normal range.

An external force drives motor during Cancel the external force or install a braking resistor.
acceleration.

The overvoltage stall prevention Ensure that the voltage limit function is enabled (F3-23 = 1).
parameters are set improperly.
The setting of voltage limit (F3-22) is too large. Adjust it between
700 V and 770 V.
The setting of frequency gain for voltage limit (F3-24) is too
small. Adjust it between 30 and 50.

Braking unit and braking resistor are Install braking unit and braking resistor.
not installed.

Acceleration time is too short. Increase acceleration time.

Operating Panel Display Fault Name

Overvoltage during deceleration

Cause Possible Solution

The overvoltage stall prevention Ensure that the voltage limit function is enabled (F3-23 = 1).
parameters are set improperly.
The setting of voltage limit (F3-22) is too large. Adjust it between
700 V and 770 V.
The setting of frequency gain for voltage limit (F3-24) is too
small. Adjust it between 30 and 50.

An external force drives motor during Cancel the external force or install braking resistor.
deceleration.

Deceleration time is too short. Increase deceleration time.

Braking unit and braking resistor are Install braking unit and braking resistor.
not installed.

Operating Panel Display Fault Name

 Overvoltage at constant speed

Cause Possible Solution

The overvoltage stall prevention Ensure that the voltage limit function is enabled (F3-23 = 1).
parameters are set improperly.
The setting of voltage limit (F3-22) is too large. Adjust it
between 700 V and 770 V.
The setting of frequency gain for voltage limit (F3-24) is too
small. Adjust it between 30 and 50.
The setting of frequency rise threshold during voltage limit (F3-
26) is too small. Adjust it between 5 Hz and 20 Hz.

An external force drives motor Cancel the external force or install a braking resistor
during running.

Operating Panel Display Fault Name

Pre-charge resistor fault

Cause Possible Solution

Bus voltage fluctuates around Contact the agent or Inovance.

undervoltage threshold continuously.

Operating Panel Display Fault Name

Undervoltage

Cause Possible Solution

Instantaneous power failure occurs Enable the power dip ride through function (F9-59 ≠ 0).

The AC drive's input voltage is not Adjust the voltage to normal range.
within the permissible range.

The bus voltage is abnormal. Contact the agent or Inovance.

The rectifier bridge, the buffer Contact the agent or Inovance.

resistor, the drive board or the
control board are abnormal.

Operating Panel Display Fault Name

AC drive overload

Cause Possible Solution

Load is too heavy or locked-rotor Reduce load or check motor and mechanical conditions.
occurs on motor.
The AC drive power class is small. Replace a drive of larger power class.

Operating Panel Display Fault Name

Motor overload

Cause Possible Solution

F9-01 (Motor overload protection Set F9-01 correctly.

gain) is set improperly.

Load is too heavy or locked-rotor Reduce load or check motor and mechanical conditions.
occurs on motor.

Operating Panel Display Fault Name

Input phase loss

Cause Possible Solution

Input phase loss occurs. Eliminate faults in external circuitry.

Drive board, lightning protection Contact the agent or Inovance.

board, control board, or rectifier
bridge is abnormal.

Operating Panel Display Fault Name

Output phase loss

Cause Possible Solution

Motor winding is damaged. Check resistance between motor wires.

Replace motor is winding is damaged.

The cable connecting the AC drive Check for wiring errors and ensure the output cable is
and the motor is abnormal. connected properly.
Correct wiring.

The AC drive's three-phase outputs Check whether the motor three-phase winding is normal.
are unbalanced when the motor is
running.

The drive board or the IGBT module Contact the agent or Inovance.
is abnormal.

Operating Panel Display Fault Name

 IGBT overheat

Cause Possible Solution

The ambient temperature is too Lower the ambient temperature.

high.

The ventilation is clogged. Clean the ventilation.

The fan is damaged. Replace the cooling fan.

Thermally sensitive resistor of IGBT Replace the damaged thermally sensitive resistor.
is damaged.

The inverter IGBT is damaged. Replace the inverter IGBT.

Operating Panel Display Fault Name

External fault

Cause Possible Solution

External fault signal is input via DI. Confirm that the mechanical condition allows restart (F8-18)
and reset the operation.

External fault signal is input via Confirm that the virtual I/O parameters in group A1 are set
virtual I/O. correctly and reset the operation.

Operating Panel Display Fault Name

Communication fault

Cause Possible Solution

Host computer is in abnormal state. Check the cable of host computer.

Communication cable is abnormal. Check the communication cables.

The serial port communication Set F0-28 of extension communication card correctly.
protocol (F0-28) of extension
communication card is set
improperly.

Communication parameters in group Set communication parameters in group Fd properly.

Fd are set improperly.
After all the preceding checkings are done but the fault still exists, restore the default settings.

Operating Panel Display Fault Name

Contactor fault

Cause Possible Solution

Drive board and power supply are Replace drive board or power supply board.
abnormal.

Contactor is abnormal. Replace contactor.

The lightning protection board is Replace the lightning protection board.

abnormal.

Operating Panel Display Fault Name

Current detection fault

Cause Possible Solution

The hall is abnormal. Replace the hall .

The drive board is abnormal. Replace the drive board.

Operating Panel Display Fault Name

Motor auto-tuning fault

Cause Possible Solution

Motor parameters are not set Set motor parameters correctly according to nameplate.
according to nameplate.

Motor auto-tuning times out. Check the cable connecting AC drive and motor.

The encoder is abnormal. Check whether F1-27 (encoder pulses per revolution) is set
correctly.
Check whether signal lines of encoder are connected correctly
and securely.

Operating Panel Display Fault Name

 Encoder fault

Cause Possible Solution

Encoder is not matched. Set the type of encoder correctly.

Encoder wiring is incorrect. Check the PG card power supply and phase sequence.

Encoder is damaged. Replace encoder.

PG card is abnormal. Replace PG card.

Operating Panel Display Fault Name

EEPROM read-write fault

Cause Possible Solution

The EEPROM chip is damaged. Replace the main control board.

Operating Panel Display Fault Name

Short circuit to ground

Cause Possible Solution

Motor is short circuited to the ground. Replace cable or motor.

Operating Panel Display Fault Name

Accumulative running time reached

Cause Possible Solution

Accumulative running time reaches the Clear the record through parameter initialization.
setting value.

Operating Panel Display Fault Name

User-defined fault 1

Cause Possible Solution

User-defined fault 1 is input via DI. Reset the operation.

User-defined fault 1 is input via virtual I/O. Reset the operation.

Operating Panel Display Fault Name

User-defined fault 2

Cause Possible Solution

User-defined fault 2 is input via DI. Reset the operation.

User-defined fault 2 is input via virtual I/O. Reset the operation.

Operating Panel Display Fault Name

Accumulative power-on time reached

Cause Possible Solution

Accumulative power-on time reaches the Clear the record through parameter initialization.
setting value.

Operating Panel Display Fault Name

Load loss

Cause Possible Solution

The output current of AC drive is smaller Check whether load is disconnected or the setting of F9-64
than F9-64 (load loss detection level). and F9-65 (load lost detection time) satisfies actual
running condition.

Operating Panel Display Fault Name

PID feedback lost during running

Cause Possible Solution

PID feedback is smaller than the setting Check PID feedback or set FA-26 properly.
value of FA-26 (detection level of PID
feedback loss).
Operating Panel Display Operating Panel Display
 Pulse-by-pulse current limit fault

Cause Cause

Load is too heavy or locked-rotor occurs on motor. Reduce load or check motor and mechanical
conditions.

The AC drive power class is small. Replace a drive of larger power class.

Operating Panel Display Fault Name

Motor switchover fault during running

Cause Possible Solution

Motor switchover via terminal during drive running of Perform motor switchover after the AC drive stops.
the AC drive.

Operating Panel Display Fault Name

Speed error

Cause Possible Solution

Encoder parameters are set improperly. Set encoder parameters properly.

Motor auto-tuning is not performed. Perform motor auto-tuning.

F9-69 (detection level of speed error) and F9-70 Set F9-69 and F9-70 correctly based on actual
(detection time of speed error) are set incorrectly. condition.

Operating Panel Display Fault Name

Motor overspeed

Cause Possible Solution

Encoder parameters are set improperly. Set encoder parameters properly.

Motor auto-tuning is not performed. Perform motor auto-tuning.

F9-67 (Overspeed detection level) and F9-68 Set F9-67 and F9-68 correctly based on the actual
(Overspeed detection time) are set incorrectly. situation.

Operating Panel Display Fault Name

Motor overtemperature.

Cause Possible Solution

Cable connection of temperature sensor becomes Check cable connection of temperature sensor.
loose

The motor temperature is too high. Decrease carrier frequency or take other measures to
 cool the motor.

Operating Panel Display Fault Name

Braking unit overload

Cause Possible Solution

Resistance of braking resistor is too small. Replace a braking resistor of larger resistance.

Operating Panel Display Fault Name

Short-circuit of braking circuit

Cause Possible Solution

Braking module is abnormal. Contact the agent or Inovance.

11.6 Symptoms and Diagnostics

The following symptoms may occur during use of the AC drive. When these symptoms occur, perform
simple analysis based on the following table.

Operating Panel Display Fault Description

There is no display while power-on.

Cause Possible Solution

The mains voltage is not input or too low. Check the power supply.

The switching power supply on drive board of the AC Check bus voltage.
drive is faulty.
Check that the 24V output and +10V output on
the control board are normal.

Wires between control board and drive board and Re-connect the 8-pin wire and 40-pin wire.
between control board and operating panel break.

Pre-charge resistor of the AC drive is damaged. Contact the agent or Inovance.

Control board or operating panel is faulty.

Rectifier bridge is damaged.

Operating Panel Display Fault Description

"HC" is displayed while power-on.

Cause Possible Solution

Wire between drive board and control board is in Re-connect the 8-pin wire and 28-pin wire.
poor contact.

Related components on control board are damaged Contact the agent or Inovance.
The motor or motor cable is short circuited to ground.

The hall is damaged.

The mains voltage is too low.

Operating Panel Display Fault Description

"Err23" is displayed at power-on.

Cause Possible Solution

Motor or motor output cable is short circuited to Use a megger to measure insulation resistance
ground. of motor and motor cable.

The AC drive is damaged. Contact the agent or Inovance.

Operating Panel Display Fault Description

The display is normal while power-on. But after

running, “HC” is displayed and the drive stops
immediately.

Cause Possible Solution

The cooling fan is damaged or locked-rotor occurs. Replace the fan.

Short circuit exists in wiring of control terminals. Eliminate short circuit fault in control circuit
wiring.

Operating Panel Display Fault Description

Err14 (IGBT overheat) is detected frequently.

Cause Possible Solution

The setting of carrier frequency is too high. Reduce carrier frequency (F0-15).

The cooling fan is damaged, or ventilation is clogged. Replace the fan or clean the ventilation.

Components inside the AC drive are damaged Contact the agent or Inovance.
(thermistor or others).

Operating Panel Display Fault Description

- The motor does not rotate after the AC drive runs.

Cause Possible Solution

It is motor or motor cable problem. Check that wiring between AC drive and motor is normal.

Related AC drive and motor parameters Restore the factory parameters and re-set the following
are set improperly.
 parameters properly:
Encoder parameters
Motor ratings, such as rate motor frequency and rated
motor speed
Motor 1 control mode (F0-01) and command source
selection (F0-02)
F3-01 (torque boost) in V/F control under heavy-load start.

Cable connection between drive board Re-connect wirings and ensure secure connection.
and control board is in poor contact.

The drive board is faulty. Contact the agent or Inovance.

Operating Panel Display Fault Description

- DI terminals are disabled.

Cause Possible Solution

Related parameters are set incorrectly. Check and set parameters in group F4 again.

External signals are incorrect. Re-connect external signal cables.

Jumper across OP and +24 V becomes Re-confirm the jumper bar across OP and +24 V.
loose.

The control board is faulty. Contact the agent or Inovance.

Operating Panel Display Fault Description

- Motor speed does not rise in FVC control.

Cause Possible Solution

Encoder is faulty. Replace encoder and re-confirm cable connection.

Encoder connection is incorrect or in poor Reconnect the encoder to ensure in good contact.
contact.

PG card is faulty. Replace the PG card.

Drive board is faulty. Contact the agent or Inovance.

Operating Panel Display Fault Description

- The AC drive detects overcurrent and overvoltage

frequently.

Cause Possible Solution

Motor parameters are set improperly. Set motor parameters or perform motor auto-tuning again.

Acceleration/deceleration time is Set proper acceleration/deceleration time.

improper.

Load fluctuates. Contact the agent or Inovance.

Operating Panel Display Fault Description

Err17 is detected upon power-on or running.

Cause Possible Solution

The pre-charge relay or contactor is not Check whether the relay or contactor cable is loose.
closed.
Check whether the relay or contactor is faulty.

Check whether 24 V power supply of the contactor is faulty.

Contact the agent or Inovance.