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Chapter

Troubleshooting

5.2 Troubleshooting of Common Faults without Alarm

replace the pressure sensor.

Hydraulic pump

damaged or stuck

Disconnect the hydraulic pump from the motor and try to rotate the motor or

hydraulic pump manually. Check whether there is resistance or noise during

rotation. If yes, it indicates that the motor or hydraulic pump is faulty and

needs to be repaired.

Fault Symptom

The motor does not rotate.

Fault Principle

External causes

Fault Cause

Solution

Improper servo drive

commissioning

Check whether the hydraulic control mode is set correctly, whether F0-02 is

set to 1 and whether A3-00 is set to 2. If not, correct the setting. Meanwhile,

check whether the RUN indicator on the operation panel is ON. If yes, it

indicates that the servo drive can receive signal and work. If not, go to the

next step.

No servo drive

enabled signal

In the state of hydraulic pump enabled, if the RUN indicator on the operation

panel is OFF, check whether the servo drive enabled signal DI1-COM is in

the normally closed (NC) state by using the diode function of the multimeter.

If not, find the cause in the circuits.

Servo drive not

receiving the flow and

pressure signals

View the value of U1-04 and U1-05 if there is signal input. If the displayed

values are both 0, it indicates that no signal is received by the servo drive

and you need to check the circuit.

Check the I/O board of the computer. Disconnect the cable and check

whether there is signal on the output side of the computer by using the

multimeter. If yes, re-connect the cable. If there is no display, it indicates that

the I/O board is abnormal. If the display is normal, it indicates that the

component of the servo drive may be damaged.

I/O board of servo

drive damaged

Measure the voltage of AI1-GND and AI2-GND by using the multimeter. If

there is reading but the displayed value of U1-04 and U1-05 are 0, it

indicates that the I/O board of the servo drive is damaged. In this case,

contact the IMM manufacture.

Fault Symptom

The pressure is instable and the overshoot is large.

Fault Principle

PID regulation problem

Fault Cause

Solution

PID regulation

problem

Solutions to instable pressure:

1. Increase the low-speed speed loop gain appropriately by increasing the

value of Kp (F2-00) and decreasing the value of Ki (F2-01)

2. View the value of U1-03 (Motor rotational speed) at maximum pressure

holding. If the motor rotational speed is low, open the overflow valve

approximately to increase the speed at maximum pressure holding. Then

perform commissioning on the motor.

3. Increase the pressure loop approximately by increasing the proportional

Содержание IS300 Series

Страница 2: ...2 3 Electrical Wiring 11 Chapter 3 Operation Display and Trial Running 13 3 1 Operation and Display 13 3 2 Viewing and Modifying Function Codes 15 3 3 Flowchart of Commissioning the Servo Hydraulic Pump 16 3 4 Motor Trial Running 16 3 5 Servo Pump Commissioning 19 Chapter 4 Function Code Table 20 Chapter 5 Troubleshooting 26 5 1 Troubleshooting of Common Faults with Alarm 26 5 2 Troubleshooting of...

Страница 3: ...nce skills and experience of service personnel of Inovance and injection molding machine IMM manufacturers It is aimed at helping users to perform routine maintenance and troubleshooting on Inovance IS300 servo drive and quickly locate and rectify basic faults to restore manufacturing This manual can also be used as the training material for the service personnel of IMM manufacturers and help them...

Страница 4: ...that of the servo drive especially when the rated power of the servo drive is greater than that of the motor adjust the motor protection parameters on the operation panel of the servo drive or install a thermal relay for the motor for protection 3 Motor heat and noise The output of the servo drive is pulse width modulation PWM wave with certain harmonics and therefore the temperature rise noise an...

Страница 5: ...ctromagnetic coil and electromagnetic brake around the servo drive are switched on or off If the inductive loads generate a very high surge voltage use a surge suppressor for the inductive load or use a surge suppressor together with a diode Do not connect the surge suppressor on the output side of the servo drive 8 Altitude and de rating In places where the altitude is above 1000 m the cooling ef...

Страница 6: ...ng or modify the default values based on actual conditions Otherwise the running effect and protection performance will be affected The servo drive may alarm or even be damaged when short circuit exists on cables or inside the motor Therefore perform the insulation short circuit test when the motor and cables are newly installed or during routine maintenance During the test make sure that the serv...

Страница 7: ...005 C 5 9 10 5 9 2 2 3 IS300 2T010 C 8 9 14 6 13 3 7 5 IS300 2T020 C 17 26 25 5 5 7 5 IS300 2T030 C 21 35 32 7 5 10 IS300 2T040 C 30 46 5 45 11 15 IS300 2T050 C 40 62 60 15 20 IS300 2T070 C 57 76 75 18 5 25 IS300 2T080 C 69 92 91 22 30 IS300 2T100 C 85 113 112 30 40 IS300 2T140 C 114 157 150 37 50 IS300 2T170 C 134 180 176 45 60 IS300 2T210 C 160 214 210 55 75 IS300 2T300 C 231 307 304 75 100 IS30...

Страница 8: ...26 220 300 IS300T460 C 355 468 465 250 400 IS300T520 C 396 525 520 280 370 IS300T580 C 445 590 585 315 500 IS300T650 C 500 665 650 355 420 IS300T720 C 565 785 725 400 530 IS300T140 C L 114 157 150 75 100 IS300T170 C L 134 180 176 90 125 IS300T210 C L 160 214 210 110 150 IS300T250 C L 192 256 253 132 200 IS300T300 C L 231 307 304 160 250 Three phase 480 V 50 60 Hz IS300 5T002 C 1 5 3 4 2 1 0 75 1 I...

Страница 9: ...00 5T170 C L 134 180 176 90 125 IS300 5T210 C L 160 214 210 110 150 IS300 5T250 C L 192 256 253 132 175 IS300 5T300 C L 231 307 304 160 210 2 2 Selection of Braking Unit and Braking Resistor IS300 Model Recommended Power of Braking Resistor Recommended Resistance Braking Unit Remarks Single phase 220 230 V IS300S002 C 80 W 200 Ω IS300S003 C 80 W 150 Ω IS300S004 C 100 W 100 Ω IS300S005 C 100 W 70 Ω...

Страница 10: ...040 C 1500 W 22 Ω IS300T050 C 2500 W 16 Ω IS300T070K C 3 7 kW 16 Ω Built in IS300T070 C 3 7 kW 16 Ω External MDBUN 45 T IS300T080 C 4 5 kW 16 Ω External MDBUN 45 T IS300T100 C 5 5 kW 16 Ω External MDBUN 45 T IS300T140K C 6 5 kW 12 Ω External MDBUN 60 T IS300T140 C 7 5 kW 12 Ω External MDBUN 60 T IS300T170 C 9 kW 8 Ω External MDBUN 90 T IS300T210 C 5 5 kW x 2 12 Ω x 2 External MDBUN 60 T x 2 IS300T...

Страница 11: ...rnal MDBUN 90 5T IS300 5T210 C 11 kW 8 Ω External MDBUN 90 5T IS300 5T250 C 6 5 kW x 2 12 Ω x 2 External MDBUN 60 5T x 2 IS300 5T300 C 16 kW 2 5 Ω External MDBU 200 D IS300 5T370 C 20 kW 2 5 Ω External MDBU 200 D IS300 5T420 C 22 kW 2 5 Ω External MDBU 200 D IS300 5T460 C 12 5 kW x 2 2 5 Ω x 2 External MDBU 200 D x 2 IS300 5T520 C 14 kW x 2 2 5 Ω x 2 External MDBU 200 D x 2 IS300 5T580 C 16 kW x 2...

Страница 12: ...t protection Wiring method 1 After the signal of the braking resistor overheat relay is sent the power supply of the IS300 is cut off Wiring method 2 The signal of the braking resistor overheat relay is used as input of the IS300 external fault Err15 Figure 3 18 Basic wiring method 1 In this wiring method the input voltage class of the contactor control coil is 220 VAC The NC contact of the therma...

Страница 13: ...eference 0 10 V Flow reference 0 10 V Current oil pressure detection 0 10 V 0 20 mA Current flow detection 0 10 V 0 20 mA COM DI1 DI2 COM DI3 COM DI4 Fault output NO NC Double discharge plunger pump sloping switchover NO Pressure control state output NC CN1 CN1 Three phase power supply L2 L3 L1 PE MCCB MC Contactor Magnetic core wind one coil L2 L3 L1 PE S T R Filter U U Z Z COS B COS B SIN B SIN ...

Страница 14: ...Diagram of the operation panel 3 1 1 Description of Function Indicators RUN ON indicates that the servo drive is in the running state and OFF indicates that the servo drive is in the stop state LOCAL REMOT It indicates whether the servo drive is operated by means of operation panel terminal or communication LOCAL REMOT OFF Operation panel control LOCAL REMOT ON Terminal control LOCAL REMOT blinkin...

Страница 15: ...splay The 5 digit LEDs are able to display the set frequency and output frequency all monitoring data and fault codes 3 1 2 Description of Keys on the Operation Panel Table 3 1 Description of keys on the operation panel Key Name Function Programming Enter or exit Level I menu Confirm Enter the menu interfaces level by level and confirm the parameter setting Increment Increase data or function code...

Страница 16: ...wn in the following figure Figure 3 2 Operation procedure on the operation panel You can return to Level II menu from Level III menu by pressing or The difference is as follows After you press the system saves the parameter setting first and then goes back to Level II menu and shifts to the next function code After you press the system does not save the parameter setting but directly returns to Le...

Страница 17: ...c control mode The servo drive is set to the non hydraulic control mode 2 Set the command source F0 02 0 Operation panel control The LOCAL REMOT indicator on the operation panel becomes OFF 3 Perform motor auto tuning For details see section 3 4 3 Setting and Auto tuning of Motor Parameters 4 Perform motor trial running F0 08 Trial running frequency Start trial running in operation panel control a...

Страница 18: ...onse if allowed 3 4 3 Setting and Auto tuning of Motor Parameters Parameter Setting The IS300 controls the servo pump in closed loop vector control CLVC mode This mode requires accurate motor parameters To guarantee good driving performance and running efficiency set the motor parameters strictly according to the nameplate of the standard adaptable motor The following table lists the parameters to...

Страница 19: ...otor runs at a high speed during auto tuning and therefore the overflow valve must be opened With load auto tuning reduces the accuracy of motor auto tuning affecting the system control performance Static auto tuning 2 F1 16 3 This mode is used when the back EMF of the motor is known and there is heavy load The motor runs at a low speed during auto tuning and therefore the overflow valve need not ...

Страница 20: ...After AI zero drift auto correction is completed the value of A3 20 is automatically restored to 0 3 5 2 Selection and Parameter Setting of Hydraulic Control Mode Hydraulic Mode Selection Function Code Setting Description Non hydraulic control mode A3 00 0 The speed mode is used Hydraulic control mode 1 A3 00 1 The host computer provides the hydraulic pressure reference and flow reference by using...

Страница 21: ...voltage 10 00 to 10 000 V U1 05 AI2 voltage 10 00 to 10 000 V U1 06 AI3 voltage 10 00 to 10 000 V U1 11 Resolver signal interference degree 0 1000 Group A1 PG Card Parameters A1 00 to A1 01 Reserved A1 02 Encoder installation angle 0 0 359 9 0 1 0 0 A1 03 Inversion of feedback speed 0 1 1 0 A1 04 Number of pole pairs of resolver 1 50 1 1 A1 05 Resolver signal fault detection time 0 000 Detection i...

Страница 22: ... ms 1 ms 20 ms A3 05 Hydraulic pressure control Kp1 0 0 800 0 0 1 210 0 A3 06 Hydraulic pressure control Ti1 0 001 10 000s 0 001s 0 100s A3 07 Hydraulic pressure control Td1 0 000 1 000s 0 001s 0 000s A3 08 Maximum reverse rotational speed 0 0 100 0 0 1 20 0 A3 09 Minimum flow 0 0 50 0 0 1 0 5 A3 10 Minimum pressure 0 0 50 0 kg cm 2 0 1 kg cm2 0 5 kg cm2 A3 11 Hydraulic pressure control Kp2 0 0 80...

Страница 23: ... motor 1 2 F1 01 Rated motor power 0 4 1000 0 kW 0 1 kW Model dependent F1 02 Rated motor voltage 0 440 V 1 V Model dependent F1 03 Rated motor current 0 01 655 35 A 0 01 A Model dependent F1 04 Rated motor frequency 0 00 to max frequency 0 01 Hz Model dependent F1 05 Rated motor rotational speed 0 30000 rpm 1 rpm Model dependent F1 15 Back EMF 0 65535 V 1 Model dependent F1 16 Auto tuning mode 0 ...

Страница 24: ... 1 200 0 F2 11 Encoder PPR 1 65535 1 1024 F2 12 Reserved F2 13 Shaft D current loop Kp 0 65535 1 50 F2 14 Shaft D current loop Ki 0 65535 1 50 F2 15 Shaft Q current loop Kp 0 65535 1 50 F2 16 Shaft Q current loop Ki 0 65535 1 50 Group F9 Fault and Protection Parameters F9 00 Motor overload protection selection 0 Disabled 1 Enabled 1 1 F9 01 Motor overload protection gain 0 20 10 00 0 01 1 00 F9 04...

Страница 25: ...nt speed Err04 5 Overvoltage during acceleration Err05 6 Overvoltage during deceleration Err06 7 Overvoltage at constant speed Err07 8 Reserved 9 Under voltage Err09 10 Servo drive overload Err10 11 Motor overload Err11 12 Phase loss on input side Err12 13 Phase loss on output side Err13 14 Module overheat Err14 15 External device fault Err15 16 Communication fault Err16 17 Contactor fault Err17 1...

Страница 26: ...lti pump parallel run fault Err47 Err48 49 Encoder signal fault Err49 52 Multi master fault in multi pump convergent flow Err52 58 Parameter restoration fault Err58 F9 21 Frequency upon fault 0 01 Hz F9 22 Current upon fault 0 1 A F9 23 Bus voltage upon fault 0 1 V F9 24 Input terminal state upon fault 1 F9 25 Output terminal state upon fault 1 Group FP User Password and Parameter Initialization F...

Страница 27: ...rrent it indicates that overcurrent occurs on the servo drive Fault Cause Solution Motor commissioning fault Refer to section 3 4 3 Setting and Auto tuning of Motor Parameters Motor short circuit to ground Disconnect the cables from the motor and measure the to ground housing of the motor resistance of U V W phases by using the M mode in the ohm function of the multimeter On normal conditions the ...

Страница 28: ... red probe connected to and black probe connected to If a voltage drop of about 0 3 V is displayed it indicates that the braking unit is normal otherwise the braking unit is damaged Note When you connect the terminals of the braking unit to the servo drive again ensure correct wiring if the wiring sequence is reversed the servo drive will be damaged Three phase AC power Safety contactor R S T U V ...

Страница 29: ... to section 3 4 3 Setting and Auto tuning of Motor Parameters or the following procedure to perform the motor auto tuning 1 Check that the setting of F1 00 to F1 05 is correct 2 Set A3 00 to 0 and F0 02 to 0 and then perform auto tuning 3 Set F1 16 to 1 and press to start auto tuning This moment TUNE is displayed on the operation panel After auto tuning is complete TUNE disappears 4 Restore the va...

Страница 30: ...ult Cause Solution Phase loss on the input side 1 Peripheral device problem Check whether the three phases of input voltage are balanced If not eliminate the problem Note When the mains capacity is small and the servo drive is powered on or off frequently mains fluctuation is large causing unbalance of the input three phases Rectifier bridge problem Power off the servo drive and measure the rectif...

Страница 31: ...he red probe to the terminal and measure R S T in turn by using the black probe Then connect the black probe to the terminal and measure R S T in turn by using the red probe If the six measurement values are all about 0 3 V it indicates that the IGBT is normal Internal component fault If the fault persists after you perform the preceding operations contact the IMM manufacturer Fault Code ERR14 Fau...

Страница 32: ...rd problem If the fault persists after you perform the preceding operations contact the IMM manufacturer Fault Code ERR18 Fault Principle Current detection fault Fault Cause Solution Hall problem Check whether hall wiring becomes loose If not replace the hall component Drive board problem If the fault persists after the hall problem is solved contact the IMM manufacturer Fault Code ERR23 Fault Pri...

Страница 33: ...ment Contact the IMM manufacturer Fault Code ERR42 ERR47 ERR48 Fault Principle Communication fault Fault Cause Solution ERR42 1 Check whether CAN bus cable breaks 2 Check whether the baud rate of the servo drive is set properly 3 Check whether all servo drives are in hydraulic control mode ERR47 This fault is reported by the master servo drive on normal conditions and is displayed as ERR47 in whic...

Страница 34: ...G card contact problem When the encoder is in good contact and powered on observe whether the red indicator on the PG card remains on If yes it indicates that the PG card is in poor contact or damaged After power off re connect the cable on the right side of the PG card to ensure good contact Perform auto tuning again If the fault persists go to the next step Peripheral interference View the value...

Страница 35: ...t the servo drive again and check whether the alarm persists If yes go to the next step Motor bearing damaged or stuck Hydraulic pump damaged or stuck Disconnect the hydraulic pump from the motor and try to rotate the motor or hydraulic pump manually Check whether there is resistance or noise during rotation If yes it indicates that the motor or hydraulic pump is faulty and needs to be repaired En...

Страница 36: ...ns short PTC P and PTC N and press to reset the servo drive Then if this fault still exists it indicates that the I O board is damaged In this case contact the IMM manufacturer Fault Code ERR46 except the servo drive used for hot melt adhesive Fault Principle Output current very large but feedback pressure very small during detection time Fault Cause Solution Encoder faulty Set F0 02 to 0 and A3 0...

Страница 37: ... and U1 05 if there is signal input If the displayed values are both 0 it indicates that no signal is received by the servo drive and you need to check the circuit Check the I O board of the computer Disconnect the cable and check whether there is signal on the output side of the computer by using the multimeter If yes re connect the cable If there is no display it indicates that the I O board is ...

Страница 38: ... Set the holding pressure to 175 kgf and observe the motor rotational speed If the rotational speed is over 200 RPM it indicates that the hydraulic pump may be faulty Then disconnect the hydraulic pump from the motor and check the motor first If the motor is not damaged you can judge that the hydraulic pump is faulty Fault Symptom HC is displayed upon power on Fault Principle Power supply fault Fa...

Страница 39: ...mal In the standby state view U1 02 The value of U1 02 is 0 on normal conditions If A3 10 Min pressure is set to the default value the value of U1 02 is below 0 5 and keeps changing If the viewed value of U1 02 is abnormal it indicates that the pressure feedback is abnormal Set F0 02 Command source selection to 2 Operation panel and press Set A3 00 to 0 and A3 20 to 1 Then press to perform AI zero...

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