Q2V Driving Quality. Technical Manual (Item code: Q2V-Axxxx-xxx, 2020)

7.5 Minor Faults/Alarms

7.5

Minor Faults/Alarms

This section gives information about the causes and possible solutions when a minor fault or alarm occurs. Use

the information in this table to remove the cause of the minor fault or alarm.

Code

Name

Causes

Possible Solutions

AEr

Station Address Setting Error

The node address for the communication option is

• For CC-Link communication, set F6-10 [CCLink Node

not in the permitted setting range.

Address] correctly.

• For MECHATROLINK communication, set F6-20 [MLII

Address] correctly.

• For CANopen communication, set F6-35 [CANopen Address]

correctly.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

bAT

Keypad Battery Low Voltage

The keypad battery voltage is low.

Replace the keypad battery.

Note:

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

• Parameter o4-24 [bAT Detection Selection] enables and disables bAT detection.

Code

Name

Causes

Possible Solutions

Baseblock

An external baseblock command was entered

Examine the external sequence and timing of the baseblock

through MFDI terminal DI1 to DI7, and the drive

command input.

output stopped as shown by an external baseblock

command.

Note:

The drive will not output a minor fault signal for this alarm.

Code

Name

Causes

Possible Solutions

bCE

Bluetooth Communication Error

The smartphone or tablet with Q2dev Mobile

Use the smartphone or tablet 10 m (32.8 ft) or nearer to the

installed is too far from the keypad.

keypad.

Note:

bCE can occur when the smartphone or tablet is 10 m or

nearer to the keypad depending on the specifications of the

smartphone or tablet.

Radio waves from a different device are causing

Make sure that no device around the keypad uses the same radio

interference with the communication between the

bandwidth (2400 MHz to 2480 MHz), and prevent radio

smartphone or tablet and keypad.

interference.

Note:

• The drive detects this error when you operate the drive with a smartphone or tablet with a Bluetooth LCD Keypad.

• If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Parameter o2-27 [BLE Disconn.Selection@BLE Ctrl] enables and disables bCE detection.

Code

Name

Causes

Possible Solutions

boL

Braking Transistor Overload

The duty cycle of the braking transistor is high (the

• Install a regenerative converter.

regeneration power or repetition frequency is high).

• Increase the deceleration time.

You enabled the protective function for the braking

Set L8-55 = 0 [DB IGBT Protection = Disable].

transistor when you have a regenerative converter.

The braking transistor in the drive is broken.

Replace the drive.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

bUS

Option Communication Error

The communications cable wiring is incorrect.

Correct wiring errors.

There is a short-circuit in the communications cable

• Repair short circuits and connect cables.

or the communications cable is not connected.

• Replace the defective communications cable.

Electrical interference caused a communication data

• Examine the control circuit lines, main circuit lines, and

error.

ground wiring, and decrease the effects of electrical

interference.

• Make sure that a magnetic contactor is not the source of the

electrical interference, then use a Surge Protective Device if

necessary.

• Use only the recommended cables or other shielded line.

Ground the shield on the controller side or the drive input

power side.

• Separate the communication wiring from drive power lines,

and install a noise filter to the input side of the power supply

for communication.

• Decrease the effects of electrical interference from the

controller.

The option card is incorrectly installed to the drive.

Correctly install the option card to the drive.

238

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

The option card is damaged.

If the alarm continues and the wiring is correct, replace the option

card.

Note:

• The drive detects this error if the Run command or frequency reference is assigned to the option card.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F6-01 [Comm.Error Selection].

Code

Name

Causes

Possible Solutions

CALL

Serial Comm Transmission Error

The communications cable wiring is incorrect.

Correct wiring errors.

There is a short-circuit in the communications cable

• Repair the short-circuited or disconnected portion of the cable.

or the communications cable is not connected.

• Replace the defective communications cable.

A programming error occurred on the controller

Examine communications at start-up and correct programming

side.

errors.

The communications circuitry is damaged.

• Do a self-diagnostics check.

• If the problem continues, replace the control board or the

drive. For information about replacing the control board,

contact the manufacturer or your nearest sales representative.

The termination resistor setting for Modbus

On the last drive in a Modbus network, set DIP switch S2 to the

communications is incorrect.

ON position to enable the termination resistor.

Note:

• The drive detects this error if it does not correctly receive control data from the controller when energizing the drive.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

Modbus Communication Error

The communications cable wiring is incorrect.

Correct wiring errors.

There is a short-circuit in the communications cable

• Repair short circuits and connect cables.

or the communications cable is not connected.

• Replace the defective communications cable.

Electrical interference caused a communication data

• Examine the control circuit lines, main circuit lines, and

error.

ground wiring, and decrease the effects of electrical

interference.

• Make sure that a magnetic contactor is not the source of the

electrical interference, then use a Surge Protective Device if

necessary.

• Use only the recommended cables or other shielded line.

Ground the shield on the controller side or the drive input

power side.

• Separate the communication wiring from drive power lines,

and install a noise filter to the input side of the power supply

for communication.

• Decrease the effects of electrical interference from the

controller.

The communication protocol is not compatible.

• Examine the values set in H5-xx.

• Examine the settings on the controller side and correct the

difference in communication conditions.

The value set in H5-09 [Mbus CE Detect Time] is

• Change the controller software settings.

too small for the communications cycle.

• Increase the value set in H5-09.

The controller software or hardware is causing a

Examine the controller and remove the cause of the problem.

communication problem.

Note:

• The drive detects this error if it does not correctly receive control data for the CE detection time set to H5-09.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in H5-04 [Mbus Error Stop].

Code

Name

Causes

Possible Solutions

CP1

Comparator 1 Limit Error

The monitor value set in H2-20 [Compare1 Mon.

Examine the monitor value and remove the cause of the fault.

Selection] was in the range of H2-21 [Compare1

Low Limit] and H2-22 [Compare1 Up Limit].

Note:

• The drive detects this error when the terminal is assigned to H2-01 to H2-03 = 3C [MFDO Function Select = Comparator 1].

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Parameter H2-33 [Compare1 Protection Selection] enables and disables CP1 detection.

Code

Name

Causes

Possible Solutions

CP2

Comparator 2 Limit Error

The monitor value set in H2-26 [Compare2 Mon.

Examine the monitor value and remove the cause of the fault.

Selection] was outside the range of H2-27

[Compare2 Low Limit] and H2-28 [Compare2 Up

Limit].

Note:

• The drive detects this error when the terminal is assigned to H2-01 to H2-03 = 3D [MFDO Function Select = Comparator 2].

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

• Parameter H2-35 [Compare2 Protection Selection] enables and disables CP2 detection.

Code

Name

Causes

Possible Solutions

CrST

Cannot Reset

The drive received a fault reset command when a

Turn off the Run command then de-energize and re-energize the

Run command was active.

drive.

239

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

CyC

MECHATROLINK

The communications cycle setting of the controller

Set the communications cycle of the controller in the permitted

CommCycleSettingErr

is not in the permitted range of the

range of the MECHATROLINK interface option.

MECHATROLINK interface option.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

CyPo

Cycle Power to Accept Changes

Although F6-15 = 1 [Comm. Option Parameters

Re-energize the drive to update the communication option

Reload = Reload Now], the drive does not update

parameters.

the communication option parameters.

Code

Name

Causes

Possible Solutions

dEv

Speed Deviation

The load is too large.

Decrease the load.

The acceleration/deceleration times are too short.

Increase the values set in C1-01 to C1-08 [Acceleration/

Deceleration Times].

The dEv detection level settings are incorrect.

Adjust F1-10 [Speed Dev Level] and F1-11 [Speed Dev Delay

Time].

The load is locked up.

Examine the machine.

The holding brake is stopping the motor.

Release the holding brake.

Note:

• The drive detects this error if the difference between the detected speed and the speed reference is more than the setting of F1-10 for longer than F1-11.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F1-04 [Speed Dev Detection Select].

Code

Name

Causes

Possible Solutions

dnE

Drive Disabled

A terminal set for H1-xx = 1A [Drive Enable]

Examine the operation sequence.

turned OFF.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

qAL2

Q2pack Alarm 2

There was an error in the Q2pack program.

Examine the Q2pack program and remove the cause of the fault.

This is not a drive fault.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

qAL3

Q2pack Alarm 3

There was an error in the Q2pack program.

Examine the Q2pack program and remove the cause of the fault.

This is not a drive fault.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

qAL1

Q2pack Alarm

There was an error in the Q2pack program.

Examine the Q2pack program and remove the cause of the fault.

This is not a drive fault.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

MECHATROLINK Watchdog

The drive detected a watchdog circuit exception

Examine the MECHATROLINK cable connection. If this error

Timer Err

while it received data from the controller.

occurs frequently, examine the wiring and decrease the effects of

electrical interference as specified by these manuals:

• MECHATROLINK-II Installation Guide (MECHATROLINK

Members Association, manual number MMATDEP011)

• MECHATROLINK-III Installation Manual

(MECHATROLINK Members Association, publication

number MMATDEP018)

Note:

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F6-25 [MLII Watchdog Error Sel].

Code

Name

Causes

Possible Solutions

FWD/REV Run Command Input

A forward command and a reverse command were

Examine the forward and reverse command sequence and correct

Error

input at the same time for longer than 0.5 s.

the problem.

Note:

• If the drive detects EF, the motor will ramp to stop.

• If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will be ON.

240

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

EF0

Option Card External Fault

The communication option card received an

Find the device that caused the external fault and remove the

external fault from the controller.

caus.

Clear the external fault input from the controller.

A programming error occurred on the controller

Examine the operation of the controller program.

side.

Note:

• The drive detects this error if the alarm function on the external device side is operating.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F6-03 [Comm Ext Flt Select (EF0)].

Code

Name

Causes

Possible Solutions

EF1

External Fault (Terminal DI1)

MFDI terminal DI1 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI1.

External Fault [H1-01 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI1, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EF2

External Fault (Terminal DI2)

MFDI terminal DI2 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI2.

External Fault [H1-02 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI2, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EF3

External Fault (Terminal DI3)

MFDI terminal DI3 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI3.

External Fault [H1-03 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI3, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EF4

External Fault (Terminal DI4)

MFDI terminal DI4 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI4.

External Fault [H1-04 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI4, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EF5

External Fault (Terminal DI5)

MFDI terminal DI5 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI5.

External Fault [H1-05 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI5, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EF6

External Fault (Terminal DI6)

MFDI terminal DI6 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI6.

External Fault [H1-06 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI6, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

241

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

EF7

External Fault (Terminal DI7)

MFDI terminal DI7 caused an external fault through

Find the device that caused the external fault and remove the

an external device.

caus.

Clear the external fault input in the MFDI.

The wiring is incorrect.

Correctly connect the signal line to MFDI terminal DI7.

External Fault [H1-07 = 2C to 2F] is set to MFDI

Correctly set the MFDI.

terminal DI7, but the terminal is not in use.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

EP24v

External Power 24V Supply

The voltage of the main circuit power supply

• Examine the main circuit power supply.

decreased, and the 24 V power supply is supplying

• Turn ON the main circuit power supply to run the drive.

power to the drive.

Note:

• Set o2-26 [Ext24V Mode Warning Display] to enable or disable EP24v detection.

• The drive will not output an alarm signal for this alarm.

Code

Name

Causes

Possible Solutions

FbH

Excessive PID Feedback

The FbH detection level is set incorrectly.

Adjust b5-36 [PID HiHi Limit Level] and b5-37 [PID HiHi

Time].

There is a problem with the PID feedback wiring.

Correct errors with the PID control wiring.

The feedback sensor is not operating correctly.

Examine the sensors on the control device side.

A fault occurred in the feedback input circuit of the

Replace the board or the drive. For information about replacing

drive.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

• The drive detects this error if the PID feedback input is more than the level set in b5-36 for longer than b5-37.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in b5-12 [Fdback Loss Select Mode].

Code

Name

Causes

Possible Solutions

FbL

PID Feedback Loss

The FbL detection level is set incorrectly.

Adjust b5-13 [Fdback Loss Lvl] and b5-14 [Fdback Loss Time].

There is a problem with the PID feedback wiring.

Correct errors with the PID control wiring.

The feedback sensor is not operating correctly.

Examine the sensors on the control device side.

A fault occurred in the feedback input circuit of the

Replace the board or the drive. For information about replacing

drive.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

• The drive detects this error if the PID feedback input is lower than the level set in b5-13 for longer than b5-14.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in b5-12 [Fdback Loss Select Mode].

Code

Name

Causes

Possible Solutions

HCA

High Current Alarm

The load is too heavy.

• Decrease the load for applications with repetitive starts and

stops.

• Replace the drive with a larger capacity model.

The acceleration time is too short.

• Calculate the torque necessary during acceleration related to

the load inertia and the specified acceleration time.

• Increase the values set in C1-01, C1-03, C1-05, or C1-07

[Acceleration Times] until you get the necessary torque.

• Increase the values set in C2-01 to C2-04 [S-Curve

Characteristics] until you get the necessary torque.

• Replace the drive with a larger capacity model.

The drive is trying to operate a specialized motor or

• Examine the motor nameplate, the motor, and the drive to

a motor that is larger than the maximum applicable

make sure that the drive rated current is larger than the motor

motor output of the drive.

rated current.

• Replace the drive with a larger capacity model.

The current level temporarily increased because of

If speed search or Auto Restart cause an increase in current, the

speed search after a momentary power loss or while

drive can temporarily show this alarm. The time that the drive

trying to Auto Restart.

shows the alarm is short. No more steps are necessary to clear the

alarm.

Note:

• The drive detects this error if the drive output current is more than the overcurrent alarm level (150% of the rated current).

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

L24v

Loss of External Power 24V Supply

The voltage of the backup 24 V power supply has

• Examine the external 24 V power supply for disconnected

decreased. The main circuit power supply is

wires and wiring errors and repair the problems.

operating correctly.

• Examine the external 24 V power supply for problems.

Note:

• Set o2-23 [Ext24V Off Warning Display] to enable or disable L24v detection.

• The drive will not output an alarm signal for this alarm.

242

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

LoG

Log Com Error

There is not a micro SD in the keypad.

Put a micro SD card in the keypad.

• The drive is connected to USB.

Set o5-01 = 0 [Log Start Selection = OFF].

• The number of log communication files is more

than 1000.

• The micro SD card does not have available

memory space.

• The line number data in a log communication

file was changed.

• A communication error between the keypad and

drive occurred during a log communication.

Note:

If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 6A [MFDO Function Select = DataLog Error] will be ON.

Code

Name

Causes

Possible Solutions

LT-1

Cooling Fan Maintenance Time

The cooling fan is at 90% of its expected

Use the procedures in this manual to replace the cooling fan.

performance life.

Set o4-03 = 0 [Fan.Oper Setting = 0 h] to reset the cooling

fan operation time.

Note:

When the estimated performance life is expired, the terminal assigned to H2-01 to H2-03 = 63 [MFDO Function Select = Maintenance] will be ON.

Code

Name

Causes

Possible Solutions

LT-2

Capacitor Maintenance Time

The capacitors for the main circuit and control

Replace the board or the drive. For information about replacing

circuit are at 90% of expected performance life.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

When the estimated performance life is expired, the terminal assigned to H2-01 to H2-03 = 63 [MFDO Function Select = Maintenance] will be ON.

Code

Name

Causes

Possible Solutions

LT-3

SoftChargeBypassRelay

The soft charge bypass relay is at 90% of its

Replace the board or the drive. For information about replacing

MainteTime

expected performance life.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

When the estimated performance life is expired, the terminal assigned to H2-01 to H2-03 = 63 [MFDO Function Select = Maintenance] will be ON.

Code

Name

Causes

Possible Solutions

LT-4

IGBT Maintenance Time (50%)

The IGBT is at 50% of its expected performance

Check the load, carrier frequency, and output frequency.

life.

Note:

When the estimated performance life is expired, the terminal assigned to H2-01 to H2-03 = 63 [MFDO Function Select = Maintenance] will be ON.

Code

Name

Causes

Possible Solutions

Heatsink Overheat

The ambient temperature is high and the heatsink

• Measure the ambient temperature.

temperature is more than the L8-02 [Overheat Alm

• Increase the airflow around the drive.

Level].

• Install a cooling device (cooling fan or air conditioner) to

lower the ambient temperature.

• Remove objects near the drive that are producing too much

heat.

There is not sufficient airflow around the drive.

• Give the drive the correct installation space as shown in the

manual.

• Make sure that there is sufficient circulation around the control

panel.

• Examine the drive for dust or other unwanted materials that

could clog the cooling fan.

• Remove unwanted materials that prevent air circulation.

The internal cooling fan or fans have stopped.

Use the procedures in this manual to replace the cooling fan.

Set o4-03 = 0 [Fan.Oper Setting = 0 h].

Note:

• The drive detects this error if the heatsink temperature of the drive is more than L8-02.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in L8-03 [Overheat Pre-Alarm Selection].

Code

Name

Causes

Possible Solutions

oH2

External Overheat (H1-XX=7D)

An external device sent an oH2.

Find the external device that output the overheat alarm.

Remove the cause of the problem.

Clear the Overheat Alarm (oH2) [H1-xx = 7D] set to MFDI

terminals DI1 to DI7.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

oH3

Motor Overheat (PTC Input)

The thermistor wiring that detects motor

Correct wiring errors.

temperature is defective.

A fault occurred on the machine.

Examine the machine and remove the cause of the fault

Example: The machine is locked.

243

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

The motor has overheated.

• Check the load level, acceleration/deceleration time, and motor

start/stop frequency (cycle time).

• Decrease the load.

• Increase the values set in C1-01 to C1-08 [Acceleration/

Deceleration Times].

• Set E2-01 [Mot Rated Current (FLA)] correctly to the value

specified by the motor nameplate.

• Make sure that the motor cooling system is operating correctly,

and repair or replace it if it is damaged.

• Adjust E1-04 to E1-10 [V/f Pattern Parameters]. For motor 2,

adjust E3-04 to E3-10. Decrease the values set in E1-08 [Mid

A Voltage] and E1-10 [Min Output Voltage].

Note:

If the values set in E1-08 and E1-10 are too low, the overload

tolerance will decrease at low speeds.

Note:

• The drive detects this fault if the motor overheat signal input from analog input terminal AI1 or AI2 is more than the fault detection level.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in L1-03 [Motor oH AL Reaction Select].

Code

Name

Causes

Possible Solutions

oL3

Overtorque 1

A fault occurred on the machine.

Examine the machine and remove the cause of the fault

Example: The machine is locked.

The parameters are incorrect for the load.

Adjust L6-02 [Trq Det1 Level] and L6-03 [Trq Det1 Time].

Note:

• The drive detects this fault if the drive output current is more than the level set in L6-02 for longer than L6-03.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Set the conditions that trigger the minor fault using L6-01 [Trq Det1 Select].

Code

Name

Causes

Possible Solutions

oL4

Overtorque 2

A fault occurred on the machine.

Examine the machine and remove the cause of the fault

Example: The machine is locked.

The parameters are incorrect for the load.

Adjust L6-05 [Trq Det2 Level] and L6-06 [Trq Det2 Time].

Note:

• The drive detects this error if the drive output current is more than the level set in L6-05 for longer than L6-06.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Set the conditions that trigger the minor fault using L6-04 [Trq Det2 Select].

Code

Name

Causes

Possible Solutions

oL5

Mechanical Weakening Detection 1

The drive detected overtorque as specified by the

Do a deterioration diagnostic test on the machine side.

conditions for mechanical weakening detection set

in L6-08 [MechF Enable].

Note:

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the Stopping Method set in L6-08.

Code

Name

Causes

Possible Solutions

Overspeed

There is overshoot.

• Decrease C5-01 [ASR PGain 1] and increase C5-02 [ASR

ITime 1].

• Adjust the pulse train gain with H6-02 to H6-05 [Pulse Train

Input Setting Parameters].

There is an incorrect number of PG pulses set in the

Set H6-02 [PI Frequency Scale] to the pulse train frequency

drive.

during 100% reference (maximum motor rotation speed).

The oS detection level is set incorrectly.

Adjust F1-08 [Overspeed Level] and F1-09 [Overspeed Delay

Time].

Note:

• The drive detects this error if the motor speed is more than the value set in F1-08 for longer than F1-09.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F1-03 [Overspeed Detection Selection].

Code

Name

Causes

Possible Solutions

Overvoltage

There are surge voltages in the input power supply.

Connect a DC reactor to the drive.

Note:

If you turn the phase advancing capacitors ON and OFF and

use thyristor converters in the same power supply system,

there can be surge voltages that irregularly increase the input

voltage.

The drive output cable or motor is shorted to ground

Examine the motor main circuit cable, terminals, and motor

(the current short to ground is charging the main

terminal box, and then remove ground faults.

circuit capacitor of the drive through the power

Re-energize the drive.

supply).

The power supply voltage is too high.

Decrease the power supply voltage to match the drive rated

voltage.

244

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

Electrical interference caused a drive malfunction.

• Examine the control circuit lines, main circuit lines, and

ground wiring, and decrease the effects of electrical

interference.

• Make sure that a magnetic contactor is not the source of the

electrical interference, then use a Surge Protective Device if

necessary.

• Set L5-01 ≠ 0 [Auto-Reset Attempts ≠ 0 times].

Note:

• The drive detects this error if the DC bus voltage is more than the ov detection level when the Run command has not been input (while the drive is stopped).

• The ov detection level is approximately 410 V with 200 V class drives. The detection level is approximately 820 V for 400 V class drives.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

PASS

Modbus Communication Test

The Modbus communications test is complete.

The PASS display will turn off after communications test mode is

cleared.

Code

Name

Causes

Possible Solutions

Input Phase Loss

There is a phase loss in the drive input power.

Correct all wiring errors with the main circuit power supply.

Loose wiring in the input power terminals.

Tighten the screws to the correct tightening torque.

The drive input power voltage is changing too

• Examine the supply voltage for problems.

much.

• Make the drive input power stable.

Unsatisfactory balance between voltage phases.

• Examine the supply voltage for problems.

• Make the drive input power stable.

• If the supply voltage is good, examine the magnetic contactor

on the main circuit side for problems.

The main circuit capacitors have become

• Examine the capacitor maintenance time in monitor U4-05

unserviceable.

[Capacitor Maintenance].

• If U4-05 is more than 90%, replace the capacitor. Contact the

manufacturer or your nearest sales representative for more

information.

• Examine the supply voltage for problems.

• Re-energize the drive.

• If the alarm stays, replace the circuit board or the drive. For

information about replacing the control board, contact the

manufacturer or your nearest sales representative.

Note:

• The drive detects this error if the DC bus voltage changes irregularly without regeneration.

• If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will be ON.

• Use L8-05 [In PhaseLoss Selection] to enable and disable PF detection.

Code

Name

Causes

Possible Solutions

PGo

Encoder (PG) Feedback Loss

The encoder cable is disconnected or wired

Examine for wiring errors or disconnected wires in the encoder

incorrectly.

cable, and repair problems.

The encoder is not receiving power.

Examine the encoder power supply.

The holding brake is stopping the motor.

Release the holding brake.

Note:

• The drive detects this error if it does not receive the speed detection pulse signal from the encoder in the detection time set in F1-14 [Encoder Open-Circuit Detect Time].

• If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the stopping method set in F1-02 [PGOpen Detection Select].

Code

Name

Causes

Possible Solutions

rUn

Motor Switch during Run

The drive received a Motor 2 Select [H1-xx = 61]

Make sure that the drive receives the Motor 2 Selection while the

during run.

drive is stopped.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

Modbus Test Mode Error

Modbus communications self-diagnostics [H1-xx =

Stop the drive and do Modbus communications self-diagnostics.

7F] was done while the drive was running.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

SToF

Safe Torque OFF Failure

One of the two terminals H1-HC and H2-HC

• Make sure that the Safe Disable signal is input from an

received the Safe Disable input signal.

external source to terminals H1-HC or H2-HC.

• When the Safe Disable function is not in use, connect

The Safe Disable input signal is wired incorrectly.

terminals H1-HC and H2-HC.

There is internal damage to one Safe Disable

Replace the board or the drive. For information about replacing

channel.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

If the drive detects this error, the terminal assigned to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will be ON.

245

7.5 Minor Faults/Alarms

Code

Name

Causes

Possible Solutions

TiM

Keypad Time Not Set

There is a battery in the keypad, but the date and

Set the date and time with the keypad.

time are not set.

Note:

• Parameter o4-24 [bAT Detection Selection] enables and disables TiM detection.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

Code

Name

Causes

Possible Solutions

TrPC

IGBT Maintenance Time (90%)

The IGBT is at 90% of its expected performance

Replace the IGBT or the drive. For information about replacing

life.

the control board, contact the manufacturer or your nearest sales

representative.

Note:

If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Selection = Alarm] will activate.

Code

Name

Causes

Possible Solutions

UL3

Undertorque Detection 1

A fault occurred on the machine.

Examine the machine and remove the cause of the fault

Example: There is a broken pulley belt.

The parameters are incorrect for the load.

Adjust L6-02 [Trq Det1 Level] and L6-03 [Trq Det1 Time].

Note:

• The drive detects this error if the drive output current is less than the level set in L6-02 for longer than L6-03.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Set the conditions that trigger the minor fault using L6-01 [Trq Det1 Select].

Code

Name

Causes

Possible Solutions

UL4

Undertorque Detection 2

A fault occurred on the machine.

Examine the machine and remove the cause of the fault

Example: There is a broken pulley belt.

The parameters are incorrect for the load.

Adjust L6-05 [Trq Det2 Level] and L6-06 [Trq Det2 Time].

Note:

• The drive detects this error if the drive output current is less than the level set in L6-05 for longer than L6-06.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• Set the conditions that trigger the minor fault using L6-04 [Trq Det2 Select].

Code

Name

Causes

Possible Solutions

UL5

Mechanical Weakening Detection 2

The drive detected undertorque as specified by the

Examine the machine for deterioration.

conditions for mechanical weakening detection set

in L6-08 [MechF Enable].

Note:

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

• If the drive detects this error, it will operate the motor as specified by the Stopping Method set in L6-08.

Code

Name

Causes

Possible Solutions

DC Bus Undervoltage

The drive input power voltage is changing too

• Use a better power supply voltage to align with the drive rated

much.

voltage.

• Make the drive input power stable.

• If there is not a fault with the input power supply, examine the

magnetic contactor on the main circuit side for faults.

A phase loss occurred in the drive input power.

Correct errors with the wiring for main circuit drive input power.

There is loose wiring in the drive input power

Examine for loose screws and tighten them as specified by the

terminals.

tightening torque values in the manual.

There was a loss of power.

Use a better power supply.

The main circuit capacitors have deteriorated.

Examine the capacitor maintenance time in monitor U4-05

[Capacitor Maintenance]. If U4-05 is more than 90%, replace the

control board or the drive. For information about replacing the

control board, contact the manufacturer or your nearest sales

representative.

The drive input power transformer is too small and

• Check for an alarm when a molded-case circuit breaker,

voltage drops when the power is switched on.

Leakage Breaker (ELCB, GFCI, or RCM/RCD) (with

overcurrent protective function), or magnetic contactor is ON.

• Check the capacity of the drive power supply transformer.

Air inside the drive is too hot.

Measure the ambient temperature of the drive.

The Charge LED is broken.

Replace the board or the drive. For information about replacing

the control board, contact the manufacturer or your nearest sales

representative.

Note:

• The drive detects this error if one of these conditions is correct when the Run command has not been input (while the drive is stopped).

-The DC bus voltage < L2-05 [UV Detection Lvl (Uv1)].

-The Contactor that prevents inrush current in the drive was opened.

-There is low voltage in the control drive input power.

• If the drive detects this error, the terminal set to H2-01 to H2-03 = 4 [MFDO Function Select = Alarm] will activate.

246

7.6 Parameter Setting Errors

7.6

Parameter Setting Errors

Parameter setting errors occur when multiple parameter settings do not agree, or when parameter setting values

are not correct.

Examine the parameter setting that caused the error, and remove the cause of the error. You must first correct the

parameter setting errors before you can operate the drive. The drive will not send notification signals for the faults

and alarms when these parameter setting errors occur.

Code

Name

Causes

Possible Solutions

oPE01

Drive Capacity Setting Error

The value set in o2-04 [Drive KVA Selection] does

Set o2-04 to the correct value.

not agree with the drive model.

Code

Name

Causes

Possible Solutions

oPE02

Parameter Range Setting Error

Parameters settings are not in the applicable setting

range.

Push

to show U1-18 [oPE Fault Parameter], and find

parameters that are not in the applicable setting range.

Correct the parameter settings.

Note:

If more than one error occurs at the same time, other oPExx

errors have priority over oPE02.

Set E2-01 ≤ E2-03 [Mot Rated Current (FLA) ≤

Make sure that E2-01 > E2-03.

Mot No-Load Current].

Note:

If it is necessary to set E2-01 < E2-03, first lower the value

set in E2-03, and then set E2-01.

Code

Name

Causes

Possible Solutions

oPE03

Multi-Function Input Setting Err

The settings for these parameters do not agree:

Correct the parameter settings.

• H1-01 to H1-07 [Terminals DI1 to DI7 Function

Selection]

• H7-01 to H7-04 [Virtual Multi-Function Inputs 1

to 4]

The settings for MFDIs overlap.

Set the parameters correctly to prevent MFDI function overlap.

Note:

This does not include H1-xx = 20 to 2F [MFDI

Function Select = External Fault] and

[Reserved].

These pairs of MFDI functions are not set to Digital

Set the MFDI pairs.

Inputs (H1-xx and H7-01 to H7-04) at the same

time:

• Setting values 62 [Up Command] and 63 [Down

Command]

• Setting values 65 [Up2 Command] and 66 [Dw2

Command]

• Setting values 3 [Run Command] and 4 [FWD/

REV Cmd]

A minimum of two of these MFDI combinations are

Remove the function settings that are not in use.

set to Digital Inputs (H1-xx and H7-01 to H7-04) at

the same time:

• Setting values 62 [Up Command] and 63 [Down

Command]

• Setting values 65 [Up2 Command] and 66 [Dw2

Command]

• Setting value 17 [Ac/Dec Hold]

• Setting value 16 [Ref Sample]

• Setting values E to 10 [Add Offset Frequency 1

to 3 (d7-01 to d7-03)]

These commands are set in Digital Inputs (H1-xx

Remove the function settings that are not in use.

and H7-01 to H7-04) at the same time:

• Setting values 67 [SpdSrch Fmax] and 68

[SpdSrch Fref]

• Setting values 40, 41, 42, 43 [KEB Thru1 NC,

KEB Thru1 NO, KEB Thru2 NC, KEB Thru2

NO] and 32 [HiSlipBraking]

• Setting values 61 [Motor 2 Select] and 19 [Ac/

Dec Time2]

• Setting values 40, 41 [KEB Thru1 NC, KEB

Thru1 NO] and 42, 43 [KEB Thru2 NC, KEB

Thru2 NO]

• Setting values 1, 2 [Forward Run, Reverse Run]

and 3, 4 [Run Command, FWD/REV Cmd]

• Setting values 30 [DCInj Cmd] and 1A [Drive

Enable]

• Setting values 61 [Motor 2 Select] and 65, 66

[Up2 Command, Dw2 Command]

247

7.6 Parameter Setting Errors

Code

Name

Causes

Possible Solutions

Settings for N.C. and N.O. input [H1-xx] for these

Remove one of the function settings.

functions were selected at the same time:

• Setting value 34 [Fast Stop NO]

• Setting value 35 [Fast Stop NC]

These settings were entered while H1-xx = 9 [Ext

Set H6-01 = 0.

Ref 1/2]:

• b1-15 = 4 [Freq. Ref. Sel. 2 = Pulse Train Input]

• H6-01 ≠ 0 [PI Pulse Train Function ≠ Freq Ref]

These settings were entered while H1-xx = 9 [Ext

Connect an input option to the drive.

Ref 1/2]:

• b1-15 = 3 [Option PCB] or b1-16 = 3 [Run

Comm. Sel 2 = Option PCB]

• No option is connected to the drive.

These settings were entered while H1-xx = 9 [Ext

Set H3-02 = 0 or H3-10 = 0.

Ref 1/2]:

• b1-15 = 1 [Analog Input]

• H3-02 ≠ 4 [AI1 Function Selection ≠ Freq Ref/

BIAS] or H3-10 ≠ 0 [AI2 Function Selection ≠

Freq Ref/BIAS]

These parameters are set at the same time:

Correct the parameter settings.

• H1-xx ≠ 1A [Drive Enable]

• H2-xx = 2 [Drive Enable]

These parameters are set at the same time:

Correct the parameter settings.

• H6-01 ≠ 3 [PG Feedback]

• H1-xx = 15 [FWD/REV Det]

These parameters are set at the same time:

Remove one of the function settings.

• H1-xx = 65/66 [Up2 Command / Dw2

Command]

• H3-01, H3-09 = 1 [AI1 Signal Level Select, AI2

Signal Level Select = 0 to +10 V (Without Lower

Limit)]

Code

Name

Causes

Possible Solutions

oPE05

Run Cmd/Freq Ref Source Sel Err

The setting to assign the Run command or

Correct the parameter settings.

frequency reference to an option card or the pulse

train input is incorrect.

b1-01 = 3 [Freq. Ref. Sel. 1 = Option PCB] is set,

Connect an option card to the drive.

but there is no option card connected to the drive.

b1-02 = 3 [Run Comm. Sel 1 = Option PCB] is set,

but there is no option card connected to the drive.

These parameters are set at the same time:

Set H6-01 = 0.

• b1-01 = 4 [Pulse Train Input]

• H6-01 ≠ 0 [PI Pulse Train Function ≠ Freq Ref]

Code

Name

Causes

Possible Solutions

oPE07

Analog Input Selection Error

The settings for H3-02 and H3-10 [MFAI Function

Set H3-02, H3-10, and H7-30 correctly to prevent overlap.

Select] and H7-30 [Virtual AIn Select Function]

Note:

overlap.

It is possible to set these functions to multiple analog input

terminals at the same time:

• Setting value 4 [Freq Ref/BIAS]

• Setting values 0 [Through Mode]

These parameters are set at the same time:

Remove the function settings that are not in use.

• H3-02, H3-10, H7-30 = F [PID Fbk]

• H6-01 = 1 [PI Pulse Train Function = PIDFbk

Value]

These parameters are set at the same time:

• H3-02, H3-10, H7-30 = 10 [PID SetPoint]

• H6-01 = 2 [PID SP Value]

These parameters are set at the same time:

• H3-02, H3-10, H7-30 = 10

• b5-18 = 1 [b5-19 PID SP Selection = Enabled]

These parameters are set at the same time:

• H6-01 = 2

• b5-18 = 1

248

7.6 Parameter Setting Errors

Code

Name

Causes

Possible Solutions

oPE08

Parameter Selection Error

A function was set that is not compatible with the

Push ENTER Key to show U1-18 [oPE Fault Parameter],

control method selected in A1-02 [Control Method].

and find parameters that are not in the applicable setting

range.

Correct the parameter settings.

Note:

If more than one error occurs at the same time, other oPExx

errors have priority over oPE02.

When A1-02 = 2 [OLVector], you used these

• Set n2-02 < n2-03.

parameter settings:

• Set C4-02 < C4-06.

• n2-02 > n2-03 [AFR Time 1 > AFR Time 2]

• C4-02 > C4-06 [Trq Comp Delay Time > M2

Trq Comp Delay Time]

When A1-02 = 0 [V/f Control], you used these

Correct the parameter settings.

parameter settings:

Note:

• H6-01 = 3 [PI Pulse Train Function = PG

You cannot use Speed Feedback (V/F Control) with the Motor

Feedback]

Switch function.

• H1-xx = 61 [MFDI Function Select = Motor 2

Select]

When A1-02 = 5 [PM OLVector], you set E5-02 to

• Set E5-01 [PM Mot Code Selection] correctly as specified by

E5-07 [PM q-Axis Inductance (mH/Phase)] = 0.

the motor.

• For specialized motors, refer to the motor test report and set

E5-xx correctly.

When A1-02 = 5, 6 [PM OLVector, PM

Set E5-09 or E5-24 to the correct value.

AOLVector], you used these parameter settings:

• E5-09 = 0.0 [PM BackEMF Vpeak (mV/(rad/ s))

= 0.0 mV/(rad/s)]

• E5-24 = 0.0 [PM BackEMF L-L Vrms (mV/rpm)

= 0.0 mV/min^-1]

When A1-02 = 5, 6, you set E5-09 ≠ 0 and E5-24 ≠

Set E5-09 = 0 or E5-24 = 0.

When A1-02 = 6, you set these parameters:

Correct the parameter settings.

• n8-57 = 0 [High-Freq Injection = Disabled]

• You set E1-09 [Min Output Frequency] < the

5% value of E1-06.

When A1-02 = 6, you set these parameters:

Correct the parameter settings.

• n8-35 = 1 [InitRotorPos Selection = Pull-In]

• n8-57 = 1 [Enabled]

When A1-02 = 8 [EZ Vector], you used these

When E9-01 = 1 or 2, set b3-24 = 1 [Speed Estimation].

parameter settings:

• E9-01 = 1, 2 [Motor Type Selection = PM,

SynRM]

• b3-24 = 2 [SpSrch Method Selection = Current

Det2]

Code

Name

Causes

Possible Solutions

oPE09

PID Control Selection Fault

These parameters are set at the same time:

• Set b5-15 ≠ 0.0.

• b5-15 ≠ 0.0 [Sleep Start Level ≠ 0.0 Hz]

• Set b1-03 = 0, 1 [Ramp->Stop, Coast->Stop].

• b1-03 = 2, 3 [Stopping Method Selection = DC

Inj->Stop, Timed Coast->Stop]

These parameters are set at the same time:

Correct the parameter settings.

• b5-01 = 1 [Enabled] and b5-72 = 0, 1 [PID D-

FF Mode = D=Fdback, D=FdFwd]

• d2-02 ≠ 0.0 [FRef Lower Limit ≠ 0.0%]

These parameters are set at the same time:

Correct the parameter settings.

• b5-01 = 1 and b5-72 = 0, 1 [D=Fdback, D=

FdFwd]

• b5-11 = 1 [PID Output Reverse Selection =

Negative lower limit]

These parameters are set at the same time:

Correct the parameter settings.

• b5-01 = 1 and b5-70 = 1 [PID MainRefMode =

Fref + PID] and B5-72 = 0, 1 [D=Fdback, D=

FdFwd]

• d2-02 ≠ 0.0 has been set.

Note:

The drive detects this error if the PID control function selection is incorrect.

(When b5-01 = 1 [PID Enable = Enabled])

249

7.6 Parameter Setting Errors

Code

Name

Causes

Possible Solutions

oPE10

V/f Data Setting Error

The parameters that set the V/f pattern do not

Set the parameters correctly to satisfy the conditions.

satisfy these conditions:

• For motor 1: E1-09 ≤ E1-07 < E1-06 ≤ E1-11 ≤

E1-04 [Min Output Frequency ≤ Mid A

Frequency < Base Frequency ≤ Mid B

Frequency ≤ Max Output Frequency]

• For motor 2: E3-09 ≤ E3-07 < E3-06 ≤ E3-11 ≤

E3-04 [M2 Min Out Frequency ≤ M2 Mid A

Frequency < M2 Base Frequency ≤ M2 Mid B

Frequency ≤ M2 Max Out Frequency]

Code

Name

Causes

Possible Solutions

oPE11

Carrier Frequency Setting Error

These parameters are set at the same time:

Set C6-02 to C6-05 correctly.

• C6-05 > 6 [Carrier Freq Proportional Gain >

• C6-04 > C6-03 [Carrier Lower Frequency Limit

> Carrier Upper Frequency Limit]

Note:

When C6-05 < 7, C6-04 becomes disabled. The

drive sets the carrier frequency to the value set

to C6-03.

C6-02 to C6-05 settings are not in the applicable

setting range.

Code

Name

Causes

Possible Solutions

oPE13

Pulse Monitor Selection Error

H6-06 = 101, 102, 105, or 116 [PO Mon.Selection

Set H6-06 correctly.

= Frequency Reference, Output Frequency, Motor

Speed, Output Frequency after Soft Starter] has not

been set when H6-07 = 0 [PO Freq.Scaling = 0

Hz].

Code

Name

Causes

Possible Solutions

oPE16

Energy Saving Constants Error

The Energy Saving parameters are not set in the

Make sure that E5-xx is set correctly as specified by the motor

applicable setting range.

nameplate data.

Code

Name

Causes

Possible Solutions

oPE33

Digital Output Selection Error

These two parameters are set at the same time:

Clear the H2-01 to H2-03 = 1xx [Inverse output of xx] settings.

• H2-60 ≠ 0 [NO,NC,CM 2nd Function ≠ Through

Note:

Mode]

If you use the function to output logical calculation results

• H2-01 = 1xx [NO,NC,CM FuncSelection =

(H2-60, H2-63, H2-66 ≠ 0), you cannot set H2-01 to H2-03 =

Inverse output of xx]

1xx.

These two parameters are set at the same time:

• H2-63 ≠ 0 [DO1 2nd Function ≠ Through Mode]

• H2-02 = 1xx [DO1-O1C Func Selection =

Inverse output of xx]

These two parameters are set at the same time:

• H2-66 ≠ 0 [DO2 2nd Function ≠ Through Mode]

• H2-03 = 1xx [DO2-O2C Func Selection =

Inverse output of xx]

These parameter pairs are set incorrectly:

• Set parameters H2-21 ≤ H2-22.

• H2-21 [Compare1 Low Limit] > H2-22

• Set parameters H2-27 ≤ H2-28.

[Compare1 Up Limit]

• H2-27 [Compare2 Low Limit] > H2-28

[Compare2 Up Limit]

250

7.7 Auto-Tuning Errors

7.7

Auto-Tuning Errors

If the drive detects an Auto-Tuning error, the keypad will show the error and the motor will coast to stop.

The drive will not send notification signals for faults and alarms when Auto-Tuning errors occur.

Two types of Auto-Tuning errors are: Endx and Erx:

•

Endx identifies that Auto-Tuning has successfully completed with calculation errors. Find and repair the cause

of the error and do Auto-Tuning again, or set the motor parameters manually. You can use the drive in the

application if you cannot find the cause of the Endx error.

•

Erx identifies that Auto-Tuning was not successful. Find and repair the cause of the error and do Auto-Tuning

again.

Code

Name

Causes

Possible Solutions

End1

Excessive Rated Voltage Setting

The torque reference was more than 20% during

• Make sure that the input motor nameplate data is correct.

Auto-Tuning or the no-load current that was

• Do Auto-Tuning again and correctly set the motor nameplate

measured after Auto-Tuning is more than 80%.

data.

• If you can uncouple the motor and load, remove the motor

from the machine and do Rotational Auto-Tuning again.

• If you cannot uncouple the motor and load, use the results

from Auto-Tuning.

Code

Name

Causes

Possible Solutions

End2

Iron Core Saturation Coefficient

The motor nameplate data entered during Auto-

• Make sure that the input motor nameplate data is correct.

Tuning is incorrect.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

Auto-Tuning results were not in the applicable

• Examine and repair damaged motor wiring.

parameter setting range, and E2-07 or E2-08 [Mbus

• If you can uncouple the motor and load, remove the motor

Reg1 Bit Select] have temporary values.

from the machine and do Rotational Auto-Tuning again.

Code

Name

Causes

Possible Solutions

End3

Rated Current Setting Alarm

The rated current value is incorrect.

Do Auto-Tuning again and set the correct rated current shown on

the motor nameplate.

Code

Name

Causes

Possible Solutions

End4

Adjusted Slip Calculation Error

The Auto-Tuning results were not in the applicable

• Make sure the input motor nameplate data is correct.

parameter setting range.

• Do Rotational Auto-Tuning again and correctly set the motor

nameplate data.

The motor rated slip that was measured after

Stationary Auto-Tuning was 0.2 Hz or lower.

• If you cannot uncouple the motor and load, do Stationary

Auto-Tuning 2.

The motor rated slip that was measured after

compensation with E2-08 [Mbus Reg1 Bit Select] is

not in the applicable range.

The secondary resistor measurement results were

not in the applicable range.

Code

Name

Causes

Possible Solutions

End5

Resistance Tuning Error

The Auto-Tuning results of the Line-to-Line

• Make sure that the input motor nameplate data is correct.

Resistance were not in the applicable range.

• Examine and repair damaged motor wiring.

Code

Name

Causes

Possible Solutions

End6

Leakage Inductance Alarm

The Auto-Tuning results were not in the applicable

Make sure that the input motor nameplate data is correct, and do

parameter setting range.

Auto-Tuning again.

A1-02 [Control Method] setting is not applicable.

• Examine the value set in A1-02.

• Make sure that the input motor nameplate data is correct, and

do Auto-Tuning again.

Code

Name

Causes

Possible Solutions

End7

No-Load Current Alarm

The Auto-Tuning results of the motor no-load

Examine and repair damaged motor wiring.

current value were not in the applicable range.

Auto-Tuning results were less than 5% of the motor

Make sure that the input motor nameplate data is correct, and do

rated current.

Auto-Tuning again.

Code

Name

Causes

Possible Solutions

End8

HFI Alarm

• Inductance saliency ratio (E5-07/E5-06) is too

• Set the correct value on the motor nameplate to [E5: PM

small.

MOTOR SETTINGS] or do rotational/stationary Auto-Tuning.

• The drive cannot find the n8-36 [HFI Signal

• When it is necessary to set n8-35 = 2 [InitRotorPos Selection

Frequency] value.

= HiFreq Injection] or n8-57 = 1 [High-Freq Injection =

Enabled], make sure that there is no unusual noise in the low

speed range (10% or less) and that the motor does not rotate in

reverse at start.

Note:

If the drive detects End8, it will automatically set n8-35 =1

[Pull-In] and n8-57 = 0 [Disabled]. Do not change the

settings unless necessary.

251

7.7 Auto-Tuning Errors

Code

Name

Causes

Possible Solutions

End9

Initial Pole Detection Alarm

The drive cannot calculate the correct value for n8-

When n8-35 = 2 [InitRotorPos Selection = HiFreq Injection] or

84 [Polarity Det Current] during High Frequency

n8-57 = 1 [High-Freq Injection = Enabled], make sure that the

Injection Tuning.

motor does not rotate in reverse at start.

Note:

If the drive detects End9, it will automatically set n8-35 =1

[Pull-In] and n8-57 = 0 [Disabled]. Do not change the

settings unless necessary.

Code

Name

Causes

Possible Solutions

Er-01

Motor Data Error

The motor nameplate data entered during Auto-

• Make sure that the motor nameplate data is correct.

Tuning is incorrect.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

The combination of the motor rated power and

• Examine the combination of drive capacity and motor output.

motor rated current do not match.

• Do Auto-Tuning again, and correctly set the motor rated power

and motor rated current.

The combination of the motor rated current that was

• Examine the motor rated current and the no-load current.

entered during Auto-Tuning and E2-03 [Mot No-

• Set E2-03 correctly.

Load Current] do not match.

• Do Auto-Tuning again, and correctly set the motor rated

current.

The combination of the setting values of Motor

Do Auto-Tuning again, and correctly set the Motor Base

Base Frequency and Motor Base Speed do not

Frequency and Motor Base Speed.

match.

Code

Name

Causes

Possible Solutions

Er-02

Drive in an Alarm State

The motor nameplate data entered during Auto-

• Make sure that the motor nameplate data entered in Auto-

Tuning is incorrect.

Tuning is correct.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

You did Auto-Tuning while the drive had a minor

Clear the minor fault or alarm and do Auto-Tuning again.

fault or alarm.

There is a defective motor cable or cable

Examine and repair motor wiring.

connection.

The load is too large.

• Decrease the load.

• Examine the machine area to see if, for example, the motor

shaft is locked.

The drive detected a minor fault during Auto-

Stop Auto-Tuning.

Tuning.

Examine the minor fault code and remove the cause of the

prblem.

Do Auto-Tuning again.

Code

Name

Causes

Possible Solutions

Er-03

STOP Button was Pressed

Auto-Tuning did not complete correctly. Do Auto-Tuning again.

During Auto-Tuning,

was pushed.

Code

Name

Causes

Possible Solutions

Er-04

Line-to-Line Resistance Error

The Auto-Tuning results were not in the applicable

• Examine and repair motor wiring.

parameter setting range.

• Disconnect the machine from the motor and do Rotational

Auto-Tuning again.

Auto-Tuning did not complete in a pre-set length of

time.

There is a defective motor cable or cable

connection.

The motor nameplate data entered during Auto-

• Make sure that the input motor nameplate data is correct.

Tuning is incorrect.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

Code

Name

Causes

Possible Solutions

Er-05

No-Load Current Error

The Auto-Tuning results were not in the applicable

• Examine and repair motor wiring.

parameter setting range.

• Disconnect the machine from the motor and do Rotational

Auto-Tuning again.

Auto-Tuning did not complete in a pre-set length of

time.

The motor nameplate data entered during Auto-

• Make sure that the input motor nameplate data is correct.

Tuning is incorrect.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

Rotational Auto-Tuning was done with a load that

• Disconnect the machine from the motor and do Rotational

was more than 30% of the rating connected to the

Auto-Tuning again.

motor.

• If you cannot uncouple the motor and load, make sure that the

load is less than 30% of the motor rating. If a mechanical

brake is installed in the motor, release the brake during

Rotational Auto-Tuning.

252

7.7 Auto-Tuning Errors

Code

Name

Causes

Possible Solutions

Er-08

Rated Slip Error

The motor nameplate data entered during Auto-

• Make sure that the input motor nameplate data is correct.

Tuning is incorrect.

• Do Auto-Tuning again and correctly set the motor nameplate

data.

Auto-Tuning did not complete in a pre-set length of

• Examine and repair the motor wiring.

time.

• If the motor and machine are connected during Rotational

Auto-Tuning, decouple the motor from the machinery.

The Auto-Tuning results were not in the applicable

parameter setting range.

Rotational Auto-Tuning was done with a load that

• Disconnect the machine from the motor and do Rotational

was more than 30% of the rating connected to the

Auto-Tuning again.

motor.

• If you cannot uncouple the motor and load, make sure that the

load is less than 30% of the motor rating. If a mechanical

brake is installed in the motor, release the brake during

Rotational Auto-Tuning.

Code

Name

Causes

Possible Solutions

Er-09

Acceleration Error

The motor did not accelerate for the specified

Increase the value set in C1-01 [Accel Time 1].

acceleration time.

Disconnect the machine from the motor and do Rotational

Auto-Tuning again.

The value of L7-01 or L7-02 [FW Torque Limit or

Increase the value set in L7-01 or L7-02.

RV Torque Limit] is small.

Rotational Auto-Tuning was done with a load that

• Disconnect the machine from the motor and do Rotational

was more than 30% of the rating connected to the

Auto-Tuning again.

motor.

• If you cannot uncouple the motor and load, make sure that the

load is less than 30% of the motor rating. If a mechanical

brake is installed in the motor, release the brake during

Rotational Auto-Tuning.

Code

Name

Causes

Possible Solutions

Er-10

Motor Direction Error

There is defective drive and motor wiring.

Examine and repair motor wiring.

There is defective drive and encoder wiring.

Examine and repair the wiring to the encoder.

The machine pulled the motor to rotate in the

Disconnect the machine from the motor and do Rotational Auto-

opposite direction.

Tuning again.

When the torque reference is 100% or higher, the

sign of the speed reference was opposite of the

detected speed.

Code

Name

Causes

Possible Solutions

Er-11

Motor Speed Error

The torque reference during acceleration is too high

• Increase the value set in C1-01 [Accel Time 1].

(100%).

• Disconnect the machine from the motor and do Rotational

Auto-Tuning again.

Code

Name

Causes

Possible Solutions

Er-12

Current Detection Error

There is a phase loss in the drive input power. (U/

Examine and repair motor wiring.

T1, V/T2, W/T3)

The current exceeded the current rating of the drive.

• Check the motor wiring for any short circuits between the

wires.

The output current is too low.

• Check and turn ON any magnetic contactors used between

motors.

• Replace the control board or the drive. For information about

replacing the control board, contact the manufacturer or your

nearest sales representative.

You tried Auto-Tuning without a motor connected

Connect the motor and do Auto-Tuning.

to the drive.

There was a current detection signal error.

Replace the control board or the drive. For information about

replacing the control board, contact the manufacturer or your

nearest sales representative.

Code

Name

Causes

Possible Solutions

Er-13

Leakage Inductance Alarm

The motor rated current value is incorrect.

Correctly set the rated current indicated on the motor nameplate

and perform Auto-Tuning again.

The drive could not complete tuning for leakage

Examine and repair motor wiring.

inductance in fewer than 300 seconds.

Code

Name

Causes

Possible Solutions

Er-14

Motor Speed Error 2

The motor speed was more than two times the

Decrease the value set in C5-01 [ASR PGain 1].

amplitude of speed reference during Inertia Tuning.

Code

Name

Causes

Possible Solutions

Er-15

Torque Saturation Error

During Inertia Tuning, the output torque was more

• Increase the value set in L7-01 to L7-04 [Torque Limit] as

than the value set in L7-01 to L7-04 [Torque Limit].

much as possible.

• Decrease the values set for the frequency and amplitude of the

test signals used when doing inertia tuning. First, decrease the

test signal amplitude, and then do Inertia Tuning. If the error

continues, decrease the test signal frequency and do Inertia

Tuning again.

253

7.7 Auto-Tuning Errors

Code

Name

Causes

Possible Solutions

Er-16

Inertia ID Error

The inertia found by the drive was too small or too

• Decrease the values set for the frequency and amplitude of the

large during Inertia Tuning (10% or less, or

test signals used when doing inertia tuning. First, decrease the

50000% or more).

test signal amplitude, and then do Inertia Tuning. If the error

continues, decrease the test signal frequency and do Inertia

Tuning again

• Correctly set the motor inertia as specified by the motor, and

do Inertia Tuning again.

Code

Name

Causes

Possible Solutions

Er-17

Reverse Prohibited Error

b1-04 = 1 [Reverse Operation Selection =

Enable reverse in the target machine.

Disabled]

Set b1-04 = 0 [Enabled].

Note:

Do Inertia Tuning again.

You cannot do Inertia Tuning if the drive cannot

rotate the motor in reverse.

Code

Name

Causes

Possible Solutions

Er-18

Back EMF Error

The result of the induced voltage tuning was not in

Make sure that the input motor nameplate data is correct.

the applicable range.

Do Auto-Tuning again and correctly set the motor nameplate

data.

Code

Name

Causes

Possible Solutions

Er-19

PM Inductance Error

The Auto-Tuning results of the PM motor

Make sure that the input motor nameplate data is correct.

inductance were not in the applicable range.

Do Auto-Tuning again and correctly set the motor nameplate

data.

Code

Name

Causes

Possible Solutions

Er-20

Stator Resistance Error

The Auto-Tuning results of the PM Motor Stator

Make sure that the input motor nameplate data is correct.

Resistance were not in the applicable range.

Do Auto-Tuning again and correctly set the motor nameplate

data.

Code

Name

Causes

Possible Solutions

Er-25

HighFreq Inject Param Tuning Err

The motor data is incorrect.

Do Stationary Auto-Tuning again.

Note:

If the drive detects Er-25 after doing Stationary Auto-Tuning,

the motor may not be able to use high frequency injection

control. Contact the manufacturer or your nearest sales

representative for more information.

254

7.8 Backup Function Operating Mode Display and Errors

7.8

Backup Function Operating Mode Display and Errors

◆ Operating Mode Display

When you use the LCD keypad to do the backup function, the keypad shows the running operation on the LC

display. These indicators do not show that an error has occurred.

Keypad Display

Name

Display

Status

Drive and Keypad mismatch.

Detection of inconsistency between the

Normally displayed

The drive detected the connection of a keypad from a different

drive and keypad

drive. Select [Yes] to copy parameters backed up in the keypad to

Should the parameters be

the connected drive.

restored?

Restore Restore from keypad

Restoring parameters

Flashing

The parameters stored in the keypad have been restored to the

drive.

End

Backup/restore/verify operation ended

Normally displayed

The parameter backup, restore, or verify operation ended

normally

normally.

Backup Backup from Drive

Backing up parameters

Flashing

The parameters stored in the drive are being backed up to the

keypad.

Verify Keypad & Drive

Verifying parameters

Flashing

The parameter settings stored in the keypad and the parameter

settings in the drive match or are being compared.

◆ Backup Function Error

When an error occurs, the keypad shows a code to identify the error.

Note:

Push any key on the keypad to clear an error.

Code

Name

Causes

Possible Solutions

CPEr

Control Mode Mismatch

The keypad setting and drive setting for A1-02

Set A1-02 on the drive to the same value that is on the

[Control Method] do not agree.

keypad.

Restore the parameters.

Code

Name

Causes

Possible Solutions

CPyE

Error Writing Data

Parameter restore did not end correctly.

Restore the parameters.

Code

Name

Causes

Possible Solutions

CSEr

Control Mode Mismatch

The keypad is broken.

Replace the keypad.

Code

Name

Causes

Possible Solutions

dFPS

Drive Model Mismatch

You tried to restore parameters to a different drive

Examine the drive model that you used to back up the

model than the one that you backed up.

parameters.

Restore the parameters.

Code

Name

Causes

Possible Solutions

iFEr

Keypad Communication Error

There was a communications error between the

Examine the connector or cable connection.

keypad and the drive.

Code

Name

Causes

Possible Solutions

ndAT

Error Received Data

The parameter settings for model and specifications

Make sure that drive model and the value set in o2-04 [Drive

(power supply voltage and capacity) are different

KVA Selection] agree.

between the keypad and the drive.

Restore the parameters.

The parameters are not stored in the keypad.

Connect a keypad that has the correct parameters.

Restore the parameters.

Code

Name

Causes

Possible Solutions

PWEr

Q2pack Password Mismatch

The password set in the backup operation with [q:

Set the Q2pack PC software password supplied for the Q2pack

Q2PACK PARAMETERS] and [r: Q2PACK

program user ID downloaded to the drive.

JOINTS] is incorrect.

Note:

U8-11 and U8-12 [Q2pack Ver 1 and Q2pack Ver 2] show the user ID of the Q2pack program.

Code

Name

Causes

Possible Solutions

rdEr

Error Reading Data

You tried to backup the data when o3-02 = 0

Set o3-02 = 1 [Enabled] and backup again.

[COPY Allow Selection = Disabled].

Code

Name

Causes

Possible Solutions

vAEr

Voltage Class, Capacity Mismatch

The power supply specifications or drive capacity

Make sure that drive model and the value set in o2-04 [Drive

parameter settings are different between the keypad

KVA Selection] agree.

and the drive.

Restore the parameters.

255

7.9 Diagnosing and Resetting Faults

7.9

Diagnosing and Resetting Faults

When a fault occurs and the drive stops, do the procedures in this section to remove the cause of the fault, then re-

energize the drive.

◆ Fault Occurs Without Power Loss

WARNING! Crush Hazard. Wear eye protection when you do work on the drive. If you do not use correct safety equipment, it

can cause serious injury or death.

WARNING! Electrical Shock Hazard. After the drive blows a fuse or trips an RCM/RCD, do not immediately energize the drive

or operate peripheral devices. Wait for the time specified on the warning label at a minimum and make sure that all indicators

are OFF. Then check the wiring and peripheral device ratings to find the cause of the problem. If you do not know the cause of

the problem, contact the manufacturer before you energize the drive or peripheral devices. If you do not fix the problem before

you operate the drive or peripheral devices, it can cause serious injury or death.

1. Supply power to the control circuit from the external 24 V input.

2. Examine the fault code shown on the keypad.

3. Use monitor parameters [U2: FAULT] to show the fault code and data about the operating status of the

drive immediately before the fault occurred.

4. Use the information in the Troubleshooting tables to remove the fault.

5. Do a fault reset.

Note:

1. To find the faults that were triggered, check the fault history in U2-02 [Previous Fault]. To find information about drive status (such

as frequency, current, and voltage) when the faults were triggered, check U2-03 to U2-20.

2. If the fault display stays after you re-energize the drive, remove the cause of the fault and reset.

◆ Fault Reset Procedure

If a fault occurs, you must remove the cause of the fault and re-energize the drive.

Table 7.3 Fault Reset Methods

Methods

Description

Method 1

While the keypad is showing the fault or alarm code, push

on the keypad.

Switch ON the MFDI terminal set to H1-xx = 7B [MFDI Function Select = Fault Reset].

Note:

The default setting for H1-04 [DI4 Function Selection] is 7B [Fault Reset].

Method 2

De-energize the drive main circuit power supply.

Energize the drive again after the keypad display goes out.

Method 3

Note:

If the drive receives a Run command from a communication option or control circuit terminal, the drive will not reset the fault. Turn the

Run command OFF to reset the fault. If you do a fault reset when the drive has a Run command, the keypad will show minor fault CrST

[Remove RUN Command to Reset].

257

7.10 Troubleshooting Without Fault Display

7.10

Troubleshooting Without Fault Display

If the drive or motor operate incorrectly, but the keypad does not show a fault or error code, refer to the items this

section.

• Motor hunting and oscillation

• Unsatisfactory motor torque

• Unsatisfactory speed precision

• Unsatisfactory motor torque and speed response

• Motor noise

◆ Typical Problems

Symptom

Reference

The Parameter Settings Will Not Change

258

The Motor Does Not Rotate After Entering Run Command

259

The Motor Rotates in the Opposite Direction from the Run Command

260

The Motor Rotates in Only One Direction

260

The Motor Is Too Hot

260

The Correct Auto-Tuning Mode Is Not Available

261

The Motor Stalls during Acceleration or Accel/Decel Time Is Too Long

261

The Drive Frequency Reference Is Different than the Controller Frequency Reference Command

262

The Motor Speed Is Not Stable When Using a PM Motor

262

There Is Too Much Motor Oscillation and the Rotation Is Irregular

262

Deceleration Takes Longer Than Expected When Dynamic Braking Is Enabled

262

The Load Falls When a Brake Is Applied

263

There Is Audible Noise from the Drive or Motor Cables When the Drive Is Energized

263

Residual Current Monitoring/Detection (RCM/RCD) Trips During Run

263

Motor Rotation Causes Unexpected Audible Noise from Connected Machinery

263

Motor Rotation Causes Oscillation or Hunting

263

PID Output Fault

264

The Starting Torque Is Not Sufficient

264

The Motor Rotates after the Drive Output Is Shut Off

264

The Output Frequency Is Lower Than the Frequency Reference

264

The Motor Is Making an Audible Noise

264

The Motor Will Not Restart after a Loss of Power

265

◆ The Parameter Settings Will Not Change

Causes

Possible Solutions

The drive is operating the motor (the drive is in Drive Mode).

Stop the drive and change to Programming Mode.

Parameter A1-01 = 0 [Access Level = Monitor only].

Set A1-01 = 2 [Access Level = Standard Parameters] or A1-01 = 3

[Expert Parameters].

Parameter H1-xx = 7C [MFDI Function Select = Prg Lock].

Turn ON the terminals to which H1-xx = 7C is set, and then change the parameters.

258

7.10 Troubleshooting Without Fault Display

Causes

Possible Solutions

An incorrect password was entered in A1-04 [Password Input].

• Enter the correct password to A1-04 again.

• If you forgot the password, set the password again with A1-04 and A1-05 [Password Setting].

Note:

If the password is set, it will not be possible to change these parameters until the password

matches:

• A1-01 [Access Level]

• A1-02 [Control Method]

• A1-03 [Init Parameters]

• A1-06 [Macro Preset]

• A1-07 [Q2pack Enable]

• A2-01 to A2-32 [MAN1 Param1 to MAN3 Param12]

The drive detected Uv [Undervoltage].

• View U1-07 [DC Bus Voltage] to see the power supply voltage.

• Examine the main circuit wiring.

◆ The Motor Does Not Rotate After Entering Run Command

Causes

Possible Solutions

The drive is not in Drive Mode.

Make sure that the READY LED on the keypad is on.

If the READY LED is off, push and hold the ESC Key to go back to the frequency reference

screen (the initial screen).

Do one of these two:

The drive stopped and you pushed

to transfer the Run command

source to the keypad.

• Push

• Re-energize the drive.

Note:

Set o2-01 = 0 [LO/RE Key Selection of Function = Disabled] to prevent changing the Run

command source with

Auto-Tuning completed.

Push and hold the ESC Key to go back to the frequency reference screen (the initial screen).

Note:

When Auto-Tuning completes, the drive changes to Programming Mode. The drive will not

accept a Run command unless the drive is in Drive Mode.

The drive received a Fast Stop command.

Turn off the fast stop input signal.

The settings for the source that supplies the Run command are incorrect.

Set b1-02 [Run Comm. Sel 1] correctly.

The frequency reference source is set incorrectly.

Set b1-01 [Freq. Ref. Sel. 1] correctly.

There is defective wiring in the control circuit terminals.

• Correctly wire the drive control circuit terminals.

• View U1-10 [In Terminal Status] for input terminal status.

The settings for voltage input and current input of the master frequency

Examine these analog input terminal signal level settings:

reference are incorrect.

• Terminal AI1: H3-01 [AI1 Signal Level Select]

• Terminal AI2: DIP switch S1 and H3-09 [AI2 Signal Level Select]

The selection for the sinking/sourcing mode and the internal/external power

• For sinking mode, close the circuit between terminals DIC-D24V with a wire jumper.

supply is incorrect.

• For sourcing mode, close the circuit between terminals DIC-D0V with a wire jumper.

• For external power supply, remove the wire jumper.

The frequency reference is too low.

• View U1-01 [Frequency Reference].

• Increase the frequency reference to a value higher than E1-09 [Min Output Frequency].

The MFAI setting is incorrect.

• Make sure that the functions set to the MFAI are correct. The frequency reference is 0 when

H3-02, H3-10 = 5 [MFAI Function Select = Freq Gain] and voltage (current) is not input.

• Use U1-13, U1-14 [Terminal AI1 InputLv, Terminal AI2 InputLv] to make sure that the analog

input values set to terminals AI1 and AI2 are applicable.

Turn the Run command OFF then ON from an external input.

You pushed

Note:

When you push

during operation, the drive will ramp to stop. Set o2-02 = 0 [STOP

Key Selection of Function = Disabled] to disable the

function.

The 2-wire sequence and 3-wire sequence are set incorrectly.

• Set one of the parameters H1-03 to H1-07 [DI3 Function Selection to DI7 Function Selection]

to 5 [3-Wire Seq.] to enable the 3-wire sequence.

• If a 2-wire sequence is necessary, make sure that H1-03 to H1-07 ≠ 5.

259

7.10 Troubleshooting Without Fault Display

◆ The Motor Rotates in the Opposite Direction from the Run Command

Causes

Possible Solutions

The phase wiring between the drive and motor is incorrect.

• Examine the wiring between the drive and motor.

• Connect drive output terminals U/T1, V/T2, and W/T3 in the correct sequence to agree with

motor terminals U, V, and W.

• Switch two motor cables U, V, and W to reverse motor direction.

The forward direction for the motor is set incorrectly.

• Connect drive output terminals U/T1, V/T2, and W/T3 in the correct sequence to agree with

motor terminals U, V, and W.

• Switch two motor cables U, V, and W to reverse motor direction.

A - Forward Rotation

B - Load Shaft

Direction

Figure 7.1 Forward Rotating Motor

Note:

• For Yaskawa motors, the forward direction is counterclockwise when looking from the

motor shaft side.

• Refer to the motor specifications, and make sure that the forward rotation direction is

correct for the application. The forward rotation direction of motors can be different for

different motor manufacturers and types.

The signal connections for forward run and reverse run on the drive control

Correctly wire the control circuit.

circuit terminals and control panel side are incorrect.

The motor is running at almost 0 Hz and the Speed Search estimated the

Set b3-14 = 0 [Speed Bi-Directional Search = Disabled], then the drive will only do speed search

speed to be in the opposite direction.

in the specified direction.

◆ The Motor Rotates in Only One Direction

Causes

Possible Solutions

The drive will not let the motor rotate in reverse.

Set b1-04 = 0 [Reverse Operation Selection = Enabled].

The drive did not receive a Reverse run signal and 3-Wire sequence is

Turn ON the terminals to which H1-xx = 5 [3-Wire Seq.] is set, and then enable reverse

selected.

operation.

◆ The Motor Is Too Hot

Causes

Possible Solutions

The load is too heavy.

• Decrease the load.

• Increase the acceleration and deceleration times.

• Examine the values set in L1-01 [Motor Cool Type for OL1 Calc], L1-02 [OL1 Protect Time],

and E2-01 [Mot Rated Current (FLA)].

• Use a larger motor.

Note:

The motor also has a short-term overload rating. Examine this rating carefully before setting

drive parameters.

The motor is running continuously at a very low speed.

• Change the run speed.

• Use a drive-dedicated motor.

The drive is operating in a vector control mode, but Auto-Tuning has not

• Do Auto-Tuning.

been done.

• Calculate motor parameter and set motor parameters.

• Set A1-02 = 0 [Control Method = V/f Control].

The voltage insulation between motor phases is not sufficient.

• Use a motor with a voltage tolerance that is higher than the maximum voltage surge.

• Use a drive-dedicated motor that is rated for use with AC drives for applications that use a

motor on drives rated higher than 400 V class.

• Install an AC reactor on the output side of the drive and set C6-02 = 1 [Carrier Frequency

Selection = 2.0 kHz].

Note:

When the motor is connected to the drive output terminals U/T1, V/T2, and W/T3, surges

occur between the drive switching and the motor coils. These surges can be three times the

drive input power supply voltage (600 V for a 200 V class drive, 1200 V for a 400 V class

drive).

The air around the motor is too hot.

• Measure the ambient temperature.

• Decrease the temperature in the area until it is in the specified temperature range.

The motor fan stopped or is clogged.

• Clean the motor fan.

• Make the drive environment better.

260

7.10 Troubleshooting Without Fault Display

◆ The Correct Auto-Tuning Mode Is Not Available

Causes

Possible Solutions

The desired Auto-Tuning mode is not available for the selected control

Change the motor control method with parameter A1-02 [Control Method].

mode.

◆ The Motor Stalls during Acceleration or Accel/Decel Time Is Too Long

Causes

Possible Solutions

The drive and motor system are at the torque limit or current suppression

• Decrease the load.

will not let the drive accelerate.

• Use a larger motor.

Note:

Although the drive has a Stall Prevention function and a Torque Compensation Limit

function, if you try to accelerate too fast or try to drive a load that is too large, it can be too

much for the limits of the motor.

Torque limit is set incorrectly.

Set the torque limit correctly.

The acceleration time setting is too short.

Examine the values set in C1-01, C1-03, C1-05, or C1-07 [Acceleration Time] and set them to

applicable values.

The load is too large.

• Increase the acceleration time.

• Examine the mechanical brake and make sure that it is fully releasing.

• Decrease the load to make sure that the output current stays less than the motor rated current.

• Use a larger motor.

Note:

• In extruder and mixer applications, the load can increase as the temperature decreases.

• Although the drive has a Stall Prevention function and a Torque Compensation Limit

function, if you try to accelerate too fast or try to drive a load that is too large, it can be too

much for the limits of the motor.

The frequency reference is low.

• Examine E1-04 [Max Output Frequency] and increase the setting if it is set too low.

• Examine U1-01 [Frequency Reference] for the correct frequency reference.

• Examine the multi-function input terminals to see if a frequency reference signal switch is set.

• When you use an MFAI, examine the low gain level set in H3-03, H3-11 [AI1 Gain Setting,

AI2 Gain Setting].

The frequency reference is set incorrectly.

When H3-10 = 5 [AI2 Function Selection = Freq Gain], see if the drive is set for voltage

(current).

• Examine the value set in H3-10.

• Use U1-14 [Terminal AI2 InputLv] to make sure that the analog input value set to terminal

AI2 is applicable.

The motor characteristics and drive parameter settings are not compatible.

• Set the correct V/f pattern to agree with the characteristics of the motor.

• Examine the V/f pattern set in E1-03 [V/f Pattern Selection].

• Do Rotational Auto-Tuning.

The drive is operating in vector control mode, but you did not complete

• Do Auto-Tuning.

Auto-Tuning.

• Calculate motor data and reset motor parameters.

• Set A1-02 = 0 [Control Method = V/f Control].

The Stall Prevention level during acceleration setting is too low.

Increase the value set in L3-02 [StallP Level@Accel].

Note:

If the L3-02 value is too low, the acceleration time can be unsatisfactorily long.

The Stall Prevention level during run setting is too low.

Increase the value set in L3-06 [StallP Level@Run].

Note:

If the L3-06 value is too low, speed will decrease before the drive outputs torque.

The drive is at the limit of the V/f motor control method.

• When the motor cable is longer than 50 m (164 ft), do Auto-Tuning for line-to-line resistance.

• Set the V/f pattern to “High Starting Torque”.

• Use a Vector Control method.

Note:

V/f control method does not supply high torque at low speeds.

261

7.10 Troubleshooting Without Fault Display

◆ The Drive Frequency Reference Is Different than the Controller Frequency

Reference Command

Causes

Possible Solutions

The analog input gain and bias for the frequency reference input are set

Examine the gain and bias settings for the analog inputs that set the frequency reference.

incorrectly.

• Terminal AI1: H3-03 [AI1 Gain Setting], H3-04 [AI1 Bias Setting]

• Terminal AI2: H3-11 [AI2 Gain Setting], H3-12 [AI2 Bias Setting]

The drive is receiving frequency bias signals from analog input terminals

• Examine parameters H3-02, H3-10 [MFAI Function Select]. If both of these parameters = 4

AI1 and AI2 and the sum of all signals makes the frequency reference.

[Freq Ref/BIAS], change the settings.

• Use U1-13, U1-14 [Terminal AI1 InputLv, Terminal AI2 InputLv] to make sure that the analog

input values set to terminals AI1 and AI2 are applicable.

PID control is enabled.

If PID control is not necessary, set b5-01 = 0 [PID Enable = Disabled].

Note:

When PID control is enabled, the drive adjusts the output frequency as specified by the target

value. The drive will only accelerate to the maximum output frequency set in E1-04 [Max

Output Frequency] while PID control is active.

◆ The Motor Speed Is Not Stable When Using a PM Motor

Causes

Possible Solutions

E5-01 [PM Mot Code Selection] is set incorrectly.

Refer to “Motor Performance Fine-Tuning” in the technical manual.

The drive is operating the motor at more than the specified speed control

Examine the speed control range and adjust the speed.

range.

The motor is hunting.

Adjust these parameters to have the largest effect:

• n8-55 [Load Inertia]

• n8-45 [SpdFbck Det.Gain]

• C4-02 [Trq Comp Delay Time]

Hunting occurs at start.

Increase the value set in C2-01 [Jerk@Start of Accel].

Too much current is flowing through the drive.

Set E5-01 [PM Mot Code Selection] correctly as specified by the motor. For special-purpose

motors, enter the correct value to E5-xx as specified by the motor test report.

Operation is not stable when n8-57 = 1 [High-Freq Injection = Enabled].

• Do High Frequency Injection Auto-Tuning.

• Decrease the value set in n8-41 [HFI PoleDet Pgain] in increments of 0.5.

Note:

Set n8-41 > 0.0 for IPM motors.

◆ There Is Too Much Motor Oscillation and the Rotation Is Irregular

Causes

Possible Solutions

Unsatisfactory balance of motor phases.

• Make sure that the drive input power voltage supplies stable power.

• Set L8-05 = 0 [In PhaseLoss Selection = Disabled].

The motor is hunting.

• Set n1-01 = 1 [HuntPrev Selection = Enabled].

• Increase the value of n2-01 [AFR Gain] or n2-02 [AFR Time 1].

◆ Deceleration Takes Longer Than Expected When Dynamic Braking Is Enabled

Causes

Possible Solutions

The stall prevention during deceleration setting is incorrect.

• Examine the setting for L3-04 [StallP@Decel Enable].

• When the drive has a dynamic braking option installed, set L3-04 = 0 [Disabled].

• If the drive detects ov [Overvoltage], set L3-04 = 1 [Enabled] and L3-50 = 2 [StallP@Decel

Mode = Gen Purpose w/ DB Resistor].

The deceleration time setting is too long.

Set C1-02, C1-04, C1-06, or C1-08 [Deceleration Times] to applicable values.

The motor torque is not sufficient.

Use a larger motor.

Note:

If these items are correct, the demand on the motor is more than the motor capacity:

• Parameter settings are correct.

• The drive does not detect ov [Overvoltage].

262

7.10 Troubleshooting Without Fault Display

Causes

Possible Solutions

The drive and motor system reached the torque limit.

• Examine the values set in L7-01 to L7-04 [Torque Limit] and increase them if necessary.

Note:

If the torque limit is enabled, deceleration time can increase because the drive cannot output

more torque than the limit.

• If H3-02, H3-10 = 9, B, C, D [MFAI Function Select = Torque Limit], examine the settings for

the MFAIs.

• Examine the values set in H3-02 and H3-10.

• Use U1-13, U1-14 [Terminal AI1 InputLv, Terminal AI2 InputLv] to make sure that the

analog input values set to terminals A1 and A2 are applicable.

The load is more than the internal torque limit as specified by the drive rated

Replace the drive with a larger capacity model.

current.

◆ The Load Falls When a Brake Is Applied

Causes

Possible Solutions

The open/close timing of the brake is incorrect.

Refer to “Notes on Controlling the Brake when Using the Hoist Application Preset” in the

technical manual and take appropriate measures.

The DC injection braking is not sufficient.

Increase the value set in b2-02 [DCI Braking Current].

◆ There Is Audible Noise from the Drive or Motor Cables When the Drive Is

Energized

Causes

Possible Solutions

The relay switching in the drive is making too much noise.

• Use C6-02 [Carrier Frequency Selection] to decrease the carrier frequency.

• Connect a noise filter to the input side of the drive power supply.

• Connect a noise filter to the output side of the drive.

• Isolate the control circuit wiring from the main circuit wiring.

• Use a metal cable gland to wire the drive.

• Shield the periphery of the drive with metal.

• Make sure that the drive and motor are grounded correctly.

• Make sure that ground faults have not occurred in the wiring or motor.

◆ Residual Current Monitoring/Detection (RCM/RCD) Trips During Run

Causes

Possible Solutions

There is too much leakage current from the drive.

• Increase the RCM/RCD sensitivity or use RCM/RCD with a higher threshold.

• Use C6-02 [Carrier Frequency Selection] to decrease the carrier frequency.

• Decrease the length of the cable used between the drive and the motor.

• Install a noise filter or AC reactor on the output side of the drive. Set C6-02 = 1 [2.0 kHz]

when connecting an AC reactor.

• Disable the internal EMC filter.

◆ Motor Rotation Causes Unexpected Audible Noise from Connected Machinery

Causes

Possible Solutions

The carrier frequency and the resonant frequency of the connected

• Adjust C6-02 to C6-05 [Carrier Frequency].

machinery are the same.

• Set C6-02 = 1 to 6 [Carrier Frequency Selection = Frequency other than Swing PWM].

Note:

If C6-02 = 7 to A [Carrier Frequency Selection = Swing PWM], the drive will not know if

the noise comes from the drive or the machine.

The drive output frequency and the resonant frequency of the connected

• Adjust d3-01 to d3-04 [Jump Frequency 1 to Jump Frequency Width].

machinery are the same.

• Put the motor on a rubber pad to decrease vibration.

◆ Motor Rotation Causes Oscillation or Hunting

Causes

Possible Solutions

The frequency reference is assigned to an external source, and there is

Make sure that electrical interference does not have an effect on the signal lines.

electrical interference in the signal.

• Isolate control circuit wiring from main circuit wiring.

• Use twisted-pair cables or shielded wiring for the control circuit.

• Increase the value of H3-13 [An.In FilterTime Constant].

The cable between the drive and motor is too long.

• Do Auto-Tuning.

• Make the wiring as short as possible.

The PID parameters are not sufficiently adjusted.

Adjust [b5: PID CONTROL].

263

7.10 Troubleshooting Without Fault Display

◆ PID Output Fault

Causes

Possible Solutions

There is no PID feedback input.

• Examine the MFAI terminal settings.

• Make sure that H3-02, H3-10 = F [MFAI Function Select = PID Fbk].

• Make sure that the MFAI terminal settings agree with the signal inputs.

• Examine the connection of the feedback signal.

• Make sure that [b5: PID CONTROL] is set correctly.

Note:

If there is no PID feedback input to the terminal, the detected value is 0, which causes a PID

fault and also causes the drive to operate at maximum frequency.

The detection level and the target value do not agree.

Use H3-03, H3-11 [AI1 Gain Setting, AI2 Gain Setting] to adjust PID target and feedback signal

scaling.

Note:

PID control keeps the difference between the target value and detection value at 0. Set the

input level for the values relative to each other.

Reverse drive output frequency and speed detection. When output frequency

Set b5-09 = 1 [PID Output Level Selection = Reverse output].

increases, the sensor detects a speed decrease.

◆ The Starting Torque Is Not Sufficient

Causes

Possible Solutions

Auto-Tuning has not been done in vector control method.

Do Auto-Tuning.

The control method was changed after doing Auto-Tuning.

Do Auto-Tuning again.

Stationary Auto-Tuning for Line-to-Line Resistance was done.

Do Rotational Auto-Tuning.

◆ The Motor Rotates after the Drive Output Is Shut Off

Causes

Possible Solutions

DC Injection Braking is too low and the drive cannot decelerate correctly.

• Increase the value set in b2-02 [DCI Braking Current].

• Increase the value set in b2-04 [DCInj Time@Stop].

The stopping method makes the drive coast to stop.

Set b1-03 = 0 or 2 [Stopping Method Selection = Ramp->Stop, DC Inj->Stop].

◆ The Output Frequency Is Lower Than the Frequency Reference

Causes

Possible Solutions

The frequency reference is in the Jump frequency range.

Adjust d3-01 to d3-03 [Jump Frequency 1 to Jump Frequency 3] and d3-04 [Jump Frequency

Width].

Note:

Enabling the Jump frequency prevents the drive from outputting the frequencies specified in

the Jump range.

The upper limit for the frequency reference has been exceeded.

Set E1-04 [Max Output Frequency] and d2-01 [FRef Upper Limit] to the best values for the

application.

Note:

This calculation supplies the upper value for the output frequency:

E1-04 × d2-01 / 100

A large load triggered Stall Prevention function during acceleration.

• Decrease the load.

• Adjust L3-02 [StallP Level@Accel].

L3-01 = 4 [StallP Mode@Accel = ILim Mode] has been set.

Check whether the V/f pattern and motor parameter settings are appropriate, and set them

correctly.

If this does not solve the problem, and it is not necessary to limit the current level of stall

during acceleration, adjust L3-02.

If this does not solve the problem, set L3-01 = 2 [General Purpose].

The motor is rotating at this speed:

Set E1-09 < b2-01.

b2-01 [ZSpd/DCI Threshold] ≤ Motor Speed < E1-09 [Min Output

Frequency]

◆ The Motor Is Making an Audible Noise

Causes

Possible Solutions

100% of the rated output current of the drive was exceeded while operating

If the sound is coming from the motor, set L8-38 = 0 [Carrier Reduction Mode = Disabled].

at low speeds.

264

8.1 Safety Precautions

8.1

Safety Precautions

DANGER

Electrical Shock Hazard

Do not examine, connect, or disconnect wiring on an energized drive. Before servicing,

disconnect all power to the equipment and wait for the time specified on the warning label at a

minimum. The internal capacitor stays charged after the drive is de-energized. The charge

indicator LED extinguishes when the DC bus voltage decreases below 50 Vdc. When all

indicators are OFF, measure for dangerous voltages to make sure that the drive is safe.

If you do work on the drive when it is energized, it will cause serious injury or death from electrical shock. The

drive has internal capacitors that stay charged after you de-energize the drive.

Disconnect all power to the drive and wait for the time specified on the warning label before you

remove covers. Check the drive for dangerous voltages before servicing or repair work.

If you do work on the drive when it is energized and there is no cover over the electronic circuits, it will cause

serious injury or death from electrical shock. The drive has internal capacitors that stay charged after you de-

energize the drive.

WARNING

Electrical Shock Hazard

The motor will run after you de-energize the drive. PM motors can generate induced voltage to

the terminal of the motor after you de-energize the drive.

If you touch a motor that is moving or energized, it can cause serious injury or death.

Do not operate the drive when covers are missing. Replace covers and shields before you

operate the drive. Use the drive only as specified by the instructions.

Some figures in this section include drives without covers or safety shields to more clearly show the inside of the

drive. If covers or safety shields are missing from the drive, it can cause serous injury or death.

Always ground the motor-side grounding terminal.

If you do not ground the equipment correctly, it can cause serious injury or death if you touch the motor case.

Only let approved personnel install, wire, maintain, examine, replace parts, and repair the drive.

If personnel are not approved, it can cause serious injury or death.

Do not wear loose clothing or jewelry when you do work on the drive. Tighten loose clothing

and remove all metal objects, for example watches or rings.

Loose clothing can catch on the drive and jewelry can conduct electricity and cause serious injury or death.

Fire Hazard

Tighten all terminal screws to the correct tightening torque.

Connections that are too loose or too tight can cause incorrect operation and damage to the drive. Incorrect

connections can also cause death or serious injury from fire.

Do not use the main circuit power supply (Overvoltage Category III) at incorrect voltages.

Operate the drive in the specification range of the input voltage on the drive nameplate.

Voltages that are higher than the permitted nameplate tolerance can cause damage to the drive.

Do not put flammable or combustible materials on top of the drive and do not install the drive

near flammable or combustible materials. Attach the drive to metal or other noncombustible

material.

Flammable and combustible materials can start a fire and cause serious injury or death.

268

8.1 Safety Precautions

WARNING

Electrical Shock Hazard

Do not modify the drive body or drive circuitry.

Modifications to drive body and circuitry can cause serious injury or death, will cause damage to the drive, and

will void the warranty. The manufacturer is not responsible for modifications of the product made by the user.

Sudden Movement Hazard

Make sure that you align the phase order for the drive and motor when you connect the motor to

drive output terminals U/T1, V/T2, and W/T3.

If the phase order is incorrect, it can cause the motor to run in reverse. If the motor accidentally runs in reverse, it

can cause serious injury or death.

CAUTION

Burn Hazard

Do not touch a hot drive heatsink. De-energize the drive, wait for a minimum of 15 minutes, then

make sure that the heatsink is cool before you replace the cooling fans.

If you touch a hot drive heatsink, it can burn you.

NOTICE

Obey correct electrostatic discharge (ESD) procedures when you touch the drive.

Incorrect ESD procedures can cause damage to the drive circuitry.

Use the instructions in this manual to replace the cooling fans. When you do maintenance on

the fans, replace all the fans to increase product life.

If you install the fans incorrectly, it can cause damage to the drive.

Make sure that all connections are correct after you install the drive and connect peripheral

devices.

Incorrect connections can cause damage to the drive.

The drive can fail if users frequently turn the drive ON and OFF with the MC on the power source

side to Run and Stop the drive. Incorrect operation can decrease the service life of the relay

contacts and electrolytic capacitors.

If you frequently use the magnetic contactor on the power source side to Run and Stop the drive, it can cause

drive failure.

Do not operate a drive or connected equipment that has damaged or missing parts.

You can cause damage to the drive and connected equipment.

Note:

Do not use unshielded cable for control wiring. Use shielded, twisted-pair wires and ground the shield to the ground terminal of the

drive. Unshielded wire can cause electrical interference and unsatisfactory system performance.

269

8.2 Inspection

8.2

Inspection

Power electronics have limited life and can show changes in performance and deterioration of performance after

years of use in usual conditions. To help prevent these problems, it is important to do preventive maintenance and

regular inspection, and replace parts on the drive.

Drives contain different types of power electronics, for example power transistors, semiconductors, capacitors,

resistors, fans, and relays. The electronics in the drive are necessary for correct motor control.

Follow the inspection lists in this chapter as a part of a regular maintenance program.

Note:

Examine the drive one time each year at a minimum.

The operating conditions, environmental conditions, and use conditions will have an effect on the examination frequency for connected

equipment.

Examine the drive more frequently if you use the drive in bad conditions or in these conditions:

• High ambient temperatures

• Frequent starting and stopping

• Changes in the AC power supply or load

• Too much vibration or shock loading

• Dust, metal dust, salt, sulfuric acid, or chlorine atmospheres

• Unsatisfactory storage conditions.

◆ Recommended Daily Inspection

Examine the following items each day to make sure that the components do not wear out or fail. Make a copy of

this checklist and put a check mark in the “Checked” column after each inspection.

Table 8.1 Daily Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

• Check the load coupling.

Examine for unusual oscillation or noise coming

Motor

• Measure motor vibration.

from the motor.

• Tighten all loose components.

• Check for a load that is too heavy.

Examine for unusual heat from the drive or motor

• Tighten loose screws.

and visible discoloration.

• Check for a dirty heatsink or motor.

Cooling System

• Measure the ambient temperature.

• Check for a clogged or dirty fan.

Examine the cooling fans.

• Use the performance life monitor to check for correct fan operation.

Surrounding

Make sure that the installation environment is

Remove the source of contamination or correct unsatisfactory environment.

Environment

applicable.

Make sure that the drive output current is not more

• Check for a load that is too heavy.

Load

than the motor or drive rating for an extended period

of time.

• Check the correct motor parameter settings.

Power Supply

• Correct the voltage or power supply to agree with nameplate specifications.

Examine main power supply and control voltages.

Voltage

• Verify all main circuit phases.

◆ Recommended Periodic Inspection

The following tables give information about the recommended periodic inspections for AC drives. Examine the

drive one time each year at a minimum. The operating conditions, environmental conditions, and use conditions

will have an effect on the examination frequency for connected equipment. You must use your experience with the

application to select the correct inspection frequency for each drive installation. Periodic inspections will help to

prevent performance deterioration and product failure. Make a copy of this checklist and put a check mark in the

“Checked” column after each inspection.

DANGER! Electrical Shock Hazard. Do not examine, connect, or disconnect wiring on an energized drive. Before servicing,

disconnect all power to the equipment and wait for the time specified on the warning label at a minimum. The internal capacitor

stays charged after the drive is de-energized. The charge indicator LED extinguishes when the DC bus voltage decreases

below 50 Vdc. When all indicators are OFF, measure for dangerous voltages to make sure that the drive is safe. If you do work

on the drive when it is energized, it will cause serious injury or death from electrical shock. The drive has internal capacitors that

stay charged after you de-energize the drive.

270

8.2

Inspection

Table 8.2 Main Circuit Periodic Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

• Examine equipment for discoloration from too

• Replace damaged components as necessary.

much heat or deterioration.

• The drive does not have many serviceable parts and it could be necessary to

• Examine for damaged parts.

replace the drive.

General

• Examine enclosure door seal.

• Use a vacuum cleaner to remove unwanted particles and dust without

Examine for dirt, unwanted particles, or dust on

touching the components.

components.

• If you cannot remove unwanted particles and dust with a vacuum cleaner,

replace the components.

• Examine wiring and connections for discoloration

or damage. Examine wiring and connections for

Conductors and

discoloration from too much heat.

Repair or replace damaged wiring.

Wiring

• Examine wire insulation and shielding for

discoloration and wear.

Examine terminals for stripped, damaged, or loose

• Tighten loose screws.

Terminal Block

connections.

• Replace damaged screws.

• Examine contactors and relays for too much noise

Electromagnetic

during operation.

• Check coil voltage for overvoltage or undervoltage conditions.

Contactors and

Relays

• Examine coils for signs of too much heat, such as

• Replace broken relays, contactors, or circuit boards that you can remove.

melted or broken insulation.

Dynamic Braking

Examine the insulation for discoloration from too

If there is discoloration in the option, check to make sure that there is not damage

Option

much heat.

to the wiring. A small quantity of discoloration is not a problem.

• Examine for leaks, discoloration, or cracks.

Electrolytic

The drive does not have many serviceable parts and it could be necessary to

Capacitor

• Examine if the cap has come off, if there is

replace the drive.

swelling, or if there are leaks from broken sides.

Diodes, IGBT

Examine for dust or other unwanted material

Use a vacuum cleaner to remove unwanted particles and dust without touching

(Power Transistor)

collected on the surface.

the components.

Table 8.3 Motor Periodic Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

Operation Check

Check for increased vibration or unusual noise.

Stop the motor and contact approved maintenance personnel as necessary.

Table 8.4 Control Circuit Periodic Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

• Examine terminals for stripped, damaged, or

• Tighten loose screws.

loose connections.

• Replace damaged screws or terminals.

General

• Make sure that all terminals have been correctly

• If terminals are integral to a circuit board, it could be necessary to replace the

tightened.

control board or the drive.

• Tighten loose connections.

• Use a vacuum cleaner to remove unwanted particles and dust without

• Check for odor, discoloration, or rust.

touching the components.

• Make sure that all connections are correctly

• If you cannot remove unwanted particles and dust with a vacuum cleaner,

Circuit Boards

fastened.

replace the components.

• Make sure that the surface of the circuit board

• Do not use solvents to clean the board.

does not have dust or oil mist.

• The drive does not have many serviceable parts and it could be necessary to

replace the drive.

Table 8.5 Cooling System Periodic Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

• Check for unusual oscillation or unusual noise.

Cooling fan

Clean or replace the fans as necessary.

• Check for damaged or missing fan blades.

• Examine for dust or other unwanted material

Heatsink

collected on the surface.

Use a vacuum cleaner to remove unwanted particles and dust without touching

the components.

• Examine for dirt.

Examine air intake, exhaust openings and make sure

Air Duct

Clear blockages and clean air duct as necessary.

that there are no unwanted materials on the surface.

Table 8.6 Keypad Periodic Inspection Checklist

Inspection Area

Inspection Points

Corrective Action

Checked

• Make sure that the keypad shows the data

• Clean the keypad.

correctly.

General

• If you have problems with the display or the keys, contact the manufacturer or

• Examine for dust or other unwanted material that

your nearest sales representative.

collected on components in the area.

271

8.3 Maintenance

8.3

Maintenance

The drive Maintenance Monitors keep track of component wear and tell the user when the end of the estimated

performance life is approaching. The Maintenance Monitors prevent the need to shut down the full system for

unexpected problems. Users can set alarm notifications for the maintenance periods for these drive components:

• Cooling fan

• Electrolytic capacitor

• Soft charge bypass relay

• IGBT

Contact the manufacturer or your nearest sales representative for more information about part replacement.

◆ Replaceable Parts

You can replace these parts of the drive:

• Cooling fan

If there is a failure in the main circuit, replace the drive.

If the drive is in the warranty period, contact the manufacturer or your nearest sales representative before you

replace parts. The manufacturer reserves the right to replace or repair the drive as specified by the applicable

warranty policy.

DANGER! Electrical Shock Hazard. Do not examine, connect, or disconnect wiring on an energized drive. Before servicing,

disconnect all power to the equipment and wait for the time specified on the warning label at a minimum. The internal capacitor

stays charged after the drive is de-energized. The charge indicator LED extinguishes when the DC bus voltage decreases

below 50 Vdc. When all indicators are OFF, measure for dangerous voltages to make sure that the drive is safe. If you do work

on the drive when it is energized, it will cause serious injury or death from electrical shock. The drive has internal capacitors that

stay charged after you de-energize the drive.

◆ Part Replacement Guidelines

When you replace these parts, make sure that you use original replacement parts for the applicable model and

design revision number of your drive.

Table 8.7 Standard Replacement Period

Parts

Standard Replacement Period

Cooling fan

10 years

Electrolytic capacitor *1

10 years

If there is damage to parts that you cannot repair or replace, replace the drive.

Note:

Performance life estimate is based on these use conditions. These conditions are provided for the purpose of replacing parts to maintain

performance. Some parts may require more frequent replacement due to poor environments or rigorous use. Operating conditions for

performance life estimate: Ambient temperature: Yearly average of 40 °C (IP20/UL Open Type), Load factor: 80%, Operating rate: 24

hours a day

◆ Monitors that Display the Lifespan of Drive Components

The drive keypad shows percentage values for the replacement parts to help you know when you must replace

those components. Use the monitors in Table 8.8 to check replacement periods. When the monitor value is 100%,

the component is at the end of its useful life and there is an increased risk of drive malfunction. The manufacturer

recommends that you check the maintenance period regularly to make sure that you get the maximum

performance life.

Table 8.8 Performance Life Monitors

Monitor No.

Parts

Description

Shows the total operation time of fans as 0 to 99999 hours. After this value is 99999, the drive automatically

U4-03

resets it to 0.

Cooling fan

U4-04

Shows the total fan operation time as a percentage of the specified maintenance period.

U4-05

Electrolytic Capacitor

Shows the total capacitor usage time as a percentage of the specified maintenance period.

U4-06

Soft charge bypass relay

Shows the number of times the drive is energized as a percentage of the performance life of the inrush circuit.

U4-07

IGBT

Shows the percentage of the maintenance period for the IGBTs.

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8.3 Maintenance

◆ Alarm Outputs for Maintenance Monitors

You can use H2-xx [MFDO Function Select] to send a message that tells you when a specified component is near

the end of its performance life estimate. Set the applicable value to H2-xx as shown in Table 8.9 for your

component.

When the specified component is near the end of its performance life estimate, the MFDO terminals set for H2-xx

= 63 [Maintenance] will activate, and the keypad will show an alarm that identifies the component to replace.

Table 8.9 Maintenance Period Alarms

Digital Outputs

Display

Alarm Name

Cause

Possible Solutions

(Setting Value in

H2-xx)

Cooling Fan

The cooling fan is at 90% of its expected

Replace the cooling fan, then set o4-03 = 0 [Fan.Oper

LT-1

Maintenance Time

performance life.

Setting = 0 h] to reset the cooling fan operation time.

The capacitors for the main circuit and

Replace the board or the drive.

Capacitor

LT-2

control circuit are at 90% of expected

Contact the manufacturer or your nearest sales

Maintenance Time

performance life.

representative to replace the board.

Replace the board or the drive.

SoftChargeBypassRe

The soft charge bypass relay is at 90% of its

LT-3

Contact the manufacturer or your nearest sales

lay MainteTime

performance life estimate.

representative to replace the board.

IGBT Maintenance

The IGBT is at 50% of its expected

Check the load, carrier frequency, and output frequency.

LT-4

Time (50%)

performance life.

IGBT Maintenance

The IGBT is at 90% of its expected

Replace the IGBT or the drive.

TrPC

Time (90%)

performance life.

◆ Related Parameters

Replace the component, then set Maintenance Setting o4-03, o4-05, o4-07, and o4-09 = 0 to reset the

Maintenance Monitor. If these parameters are not reset after the corresponding parts have been replaced, the

Maintenance Monitor function will continue to count down the performance life from the value that was reached

with the old part. If the Maintenance Monitor is not reset, the drive will not have the correct value of the

performance life for the new component.

Note:

The maintenance period changes for different operating environments.

Table 8.10 Maintenance Setting Parameters

No.

Name

Function

o4-03

Fan.Oper Setting

Sets the value from which to start the cumulative drive cooling fan operation time in 10-hour units.

Note:

When o4-03 = 30 has been set, the drive will count the operation time for the cooling fan from 300 hours

and U4-03 [Fan Oper.Time] will show 300 h.

o4-05

Cap.Maint.Setting

Sets the value from which to start the count for the main circuit capacitor maintenance period as a percentage.

o4-07

PreChgRly Preset Maintenance Cnt

Sets as a percentage the value from which to start the count for the soft charge bypass relay maintenance

time.

o4-09

IGBT Preset Maintenance Cnt

Sets the value from which to start the count for the IGBT maintenance period as a percentage.

273

8.4 Replace Cooling Fans

8.4

Replace Cooling Fans

NOTICE: Use the instructions in this manual to replace the cooling fans. When you do maintenance on the fans, replace all the

fans to increase product life. If you install the fans incorrectly, it can cause damage to the drive.

To replace a cooling fan, contact the manufacturer or your nearest sales representative.

◆ Replace the Cooling Fan

Table 8.11 Applicable Models

Model

Cooling Fans

2006 - 2021

2042 - 2082

B010, B012

4005 - 4012

4031 - 4060

DANGER! Electrical Shock Hazard. Do not examine, connect, or disconnect wiring on an energized drive. Before servicing,

disconnect all power to the equipment and wait for the time specified on the warning label at a minimum. The internal capacitor

stays charged after the drive is de-energized. The charge indicator LED extinguishes when the DC bus voltage decreases

below 50 Vdc. When all indicators are OFF, measure for dangerous voltages to make sure that the drive is safe. If you do work

on the drive when it is energized, it will cause serious injury or death from electrical shock. The drive has internal capacitors that

stay charged after you de-energize the drive.

CAUTION! Burn Hazard. Do not touch a hot drive heatsink. De-energize the drive, wait for a minimum of 15 minutes, then make

sure that the heatsink is cool before you replace the cooling fans. If you touch a hot drive heatsink, it can burn you.

NOTICE: Use the instructions in this manual to replace the cooling fans. When you do maintenance on the fans, replace all the

fans to increase product life. If you install the fans incorrectly, it can cause damage to the drive.

■ Remove a Fan

1. To remove the fan finger guard from the drive, push the hooks on the left and right sides of it and pull up.

A - Fan finger guard

Figure 8.1 Remove the Fan Finger Guard

2. Pull the cooling fan straight up from the drive. Disconnect the power supply connector and remove the fan

from the drive.

A - Cooling fan

Figure 8.2 Remove the Cooling Fan

■ Install a Fan

Reverse the removal procedure to install a cooling fan.

274

8.4 Replace Cooling Fans

Note:

The connector installation position is different for different models.

Figure

8.6

Put

the

Connector

in the Recess

Figure 8.7

Put

the

Connector in Between the Fans

Figure 8.8 Put the Connector

Between the

Drive and Fan

4. Insert the fan cover straight until the

hook

clicks into

place.

Figure 8.9 Reattach the Fan Finger Guard

5. Energize the drive and set o4-03 = 0 [Fan.Oper Setting = 0 h] to reset the cooling fan operation time.

◆ Replace the Cooling Fan

Table 8.12 Applicabel Models

Model

Cooling Fans

2030

B018

4018, 4023

DANGER! Electrical Shock Hazard. Do not examine, connect, or disconnect wiring on an energized drive. Before servicing,

disconnect all power to the equipment and wait for the time specified on the warning label at a minimum. The internal capacitor

stays charged after the drive is de-energized. The charge indicator LED extinguishes when the DC bus voltage decreases

below 50 Vdc. When all indicators are OFF, measure for dangerous voltages to make sure that the drive is safe. If you do work

on the drive when it is energized, it will cause serious injury or death from electrical shock. The drive has internal capacitors that

stay charged after you de-energize the drive.

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Q2V Driving Quality. Technical Manual (Item code: Q2V-Axxxx-xxx, 2020) - page 7