Category: Inovance

In industrial automation, servo systems play a crucial role in precise control and efficient driving tasks. However, in practical applications, servo systems may encounter various faults that affect the stability and efficiency of production lines. One of the common error codes in the Inovance IS620P servo system is ER.258, which can disrupt the normal operation of the system. This article will provide an in-depth analysis of the ER.258 fault, explore its causes, and suggest reasonable handling methods.

1. Analysis of ER.258 Fault

1.1 Basic Meaning of ER.258 Fault

The ER.258 fault is typically associated with the speed, torque, and position control in the servo system during the return-to-zero process. According to the design of the Inovance IS620P servo, the return-to-zero process begins after the motor contacts the limit switch. When the motor hits the limit switch, if the motor’s speed and torque meet certain threshold values, the system considers that the motor has reached the limit position and triggers the return-to-zero operation. However, in some cases, if the motor’s speed and torque are out of the normal range, or the system fails to accurately determine if the motor has stopped, the ER.258 fault is triggered.

1.2 Conditions for the Fault to Occur

Specifically, the ER.258 fault is triggered in the following situations:

• Overcurrent or Overload: When the motor contacts the limit switch, if the current suddenly increases, or if the resistance at the limit position is too high, causing the motor’s torque to exceed the allowed range, an overcurrent or overload protection alarm will be triggered.
• Exceeding Position Limit: When the motor reaches the mechanical limit, if it continues to try to move or cannot stop properly, the system considers that the motor has exceeded the predefined position and triggers the alarm.
• Motor Has Not Fully Stopped: When the H05-56 parameter is set too sensitively (such as setting it to 0), the system might wrongly interpret that the motor has stopped while it has not completely stopped, leading to the ER.258 fault.

1.3 Influence of H05-56 Parameter on the Fault

The H05-56 parameter plays an important role during the return-to-zero process. It sets the minimum speed threshold, and when the motor’s speed falls below this value, the system assumes that the motor has stopped and initiates the return-to-zero process. If H05-56 is set to 0, the system becomes overly sensitive in determining if the motor has stopped, which might lead to the motor not fully stopping, but the system falsely interpreting it as a stop and triggering the ER.258 fault.

1.4 Impact of Parameter Setting on the Fault

When the H05-56 parameter is set to 1, the system requires the motor’s speed to drop below 1 rpm before it determines that the motor has stopped and initiates the return-to-zero process. This provides more time and space for the motor to decelerate and avoids triggering the fault caused by speed instability or excessive torque. According to data, changes in the H05-56 parameter directly affect the system’s tolerance, ensuring that the motor and drive system will not cause overcurrent or excessive torque after contacting the limit switch, thus preventing the ER.258 fault.

2. Causes of ER.258 Fault

2.1 Behavior of the Motor After Contacting the Limit Switch

During the return-to-zero process, the servo motor first contacts the mechanical limit switch. At this point, the motor’s torque and speed will be significantly affected. Once the motor contacts the limit switch, the system evaluates the motor’s speed and torque. If the torque exceeds a certain set value, the system assumes that the motor has reached the mechanical limit and stops further movement. If not, the motor may continue to attempt movement, leading to abnormal current or torque, triggering the ER.258 fault.

2.2 Incorrect Determination of Motor Stop Status

When the H05-56 parameter is set to 0, the system may mistakenly determine that the motor has stopped even if it has not completely stopped. This could happen because the motor might still have slight inertia or be moving slightly, causing the system to incorrectly interpret this as a stop condition and initiate the return-to-zero process prematurely, leading to the fault.

2.3 Excessive Current and Torque

After the motor contacts the limit switch, it may experience significant resistance or load, generating excessive torque. If the current exceeds the maximum allowable capacity of the drive, the system will trigger an overcurrent alarm, causing the ER.258 fault to occur.

2.4 Uneven Load or Slow Deceleration

If the motor’s load is uneven or the deceleration process is slow, the motor may continue to attempt movement after contacting the limit switch, generating excessive current or torque, triggering the ER.258 fault. Proper adjustment of the H05-56 parameter can help prevent this situation.

3. Handling Methods for ER.258 Fault

3.1 Adjusting the H05-56 Parameter

As mentioned earlier, the H05-56 parameter has a significant impact on the system during the return-to-zero process. Setting H05-56 to 1 can effectively prevent the ER.258 fault. This setting requires the motor’s speed to drop below 1 rpm before it is considered stopped, thus providing more time for the motor to decelerate and avoiding triggering the fault due to instability.

3.2 Checking Load and Torque

During the return-to-zero process, the motor’s load and torque can cause excessive current, triggering the ER.258 fault. Check whether the motor’s load and torque are too high and ensure that the motor can stop stably after contacting the limit switch. This will help avoid overcurrent or overload protection from being triggered.

3.3 Calibrating the Limit Switch

Check and calibrate the position of the mechanical limit switch to ensure that the motor stops at the correct position. Early or late contact with the limit switch could prevent the motor from stopping properly, leading to excessive torque and current, and triggering the ER.258 fault.

3.4 Adjusting the Motor’s Deceleration Settings

If the motor’s deceleration process is too slow, it may cause excessive torque or current, triggering the fault. Adjust the motor’s deceleration time and method to ensure that the motor decelerates smoothly after contacting the limit switch, avoiding excessive current and torque.

3.5 Regular Maintenance and Inspection

Regularly inspect the operation status of the servo system, including the motor, drive, limit switches, and other components. Clean the mechanical parts from dirt and check the motor’s operating condition to ensure that the system operates within normal ranges and prevent faults due to wear or malfunction.

4. Conclusion

The ER.258 fault is a common alarm in the Inovance IS620P servo system during the return-to-zero process. It is usually related to motor speed, torque, position control, and the functioning of the limit switch. By adjusting the H05-56 parameter, checking the load and torque, calibrating the limit switch, optimizing the motor deceleration settings, and performing regular maintenance, the occurrence of the ER.258 fault can be effectively prevented. Proper system settings and regular maintenance ensure the stable operation of the servo system, improving the reliability and efficiency of the equipment.

I. Introduction to the Operation Panel Functions and Parameter Settings

1.1 Operation Panel Functions

The operation panel of the Inovance MD380 series inverter is a crucial tool for users to set parameters, monitor status, and diagnose faults. The operation panel primarily consists of an LED display, function keys, and multiple input/output ports. The LED display shows current operating parameters such as frequency, voltage, and current. The function keys include PRG (Program), ENTER (Confirm), RUN (Run), STOP/RESET (Stop/Reset), and MF.K (Multi-Function Key), which users utilize for menu navigation and parameter modification.

1.2 Restoring Factory Defaults

Restoring factory defaults clears user-defined parameters, resetting the inverter to its default settings at the time of manufacture. The steps are as follows:

1. Enter the Function Parameter Mode: Press the PRG key to enter the function parameter mode.
2. Select the FP Group Function Code: Use the ▲ or ▼ keys to select the FP group function code (FP-01).
3. Set to Restore Factory Defaults: Press the ENTER key to enter the FP-01 parameter setting, set the value of FP-01 to 1, and then press ENTER to confirm. The inverter will then automatically restart and restore to its factory default settings.

1.3 Setting and Clearing Passwords

Password protection prevents unauthorized users from modifying inverter parameters. The steps to set and clear passwords are as follows:

1. Setting a Password: Set the value of the FP-00 function code to a non-zero number, such as 1234, and then press ENTER to confirm. Password protection is now enabled, and entering the function parameter mode will require a password.
2. Clearing the Password: Set the value of the FP-00 function code to 0 and then press ENTER to confirm. This disables password protection, and entering the function parameter mode will no longer require a password.

II. Terminal Start/Stop and External Potentiometer Speed Adjustment Settings

2.1 Wiring Instructions

To achieve terminal start/stop and external potentiometer speed adjustment, the control terminals of the inverter must be correctly connected. The specific wiring is as follows:

• Start Terminal (DI1): Connect one end of the external start button to DI1 and the other end to the common terminal (COM).
• Stop Terminal (DI2): Connect one end of the external stop button to DI2 and the other end to the common terminal (COM).
• Speed Adjustment Terminal (AI1): Connect the center tap of the external potentiometer to AI1, and the two ends of the potentiometer to +10V and GND, respectively.

2.2 Parameter Settings

After completing the wiring, the inverter must be configured with specific parameters to achieve the desired functionality. The settings are as follows:

1. Set the Command Source: Set the value of the F0-02 function code to 1 to select the terminal command channel.
2. Set DI1 and DI2 Functions: Set the value of the F4-00 function code to 1 (forward operation) and the value of the F4-01 function code to 4 (reverse operation) or as required.
3. Set AI1 Function: Configure the F4-13 to F4-16 function codes to set the input range and corresponding set values for AI1, ensuring that the output of the external potentiometer matches the frequency setting of the inverter.
4. Other Related Settings: Set parameters such as acceleration and deceleration times and frequency limits as needed.

III. Fault Codes and Troubleshooting

3.1 Fault Codes and Their Meanings

The Inovance MD380 series inverter features comprehensive fault self-diagnosis functionality. When a fault occurs, the inverter displays the corresponding fault code. Common fault codes and their meanings are as follows:

• Err01: Overcurrent fault, indicating that the inverter output current exceeds the set value.
• Err02: Overvoltage fault, indicating that the inverter input voltage is too high.
• Err03: Undervoltage fault, indicating that the inverter input voltage is too low.
• Err07: Overload fault, indicating that the inverter output torque exceeds the set value.
• Err11: Motor overload fault, indicating that the motor current is too high.
• Err12: Input phase loss fault, indicating that the inverter input power supply is missing a phase.
• Err15: External fault, indicating that the external fault input terminal is active.
• Err16: Communication abnormality fault, indicating that communication between the inverter and the host computer is abnormal.

3.2 Troubleshooting

Different fault codes require specific troubleshooting steps:

• Overcurrent Fault (Err01): Check if the motor and load are too large, and adjust the acceleration and deceleration times or reduce the output frequency.
• Overvoltage Fault (Err02): Check if the input power supply voltage is too high or install a braking resistor to dissipate excess energy.
• Undervoltage Fault (Err03): Check if the input power supply voltage is too low or if the power supply line connection is poor.
• Overload Fault (Err07): Check if the load is too large and adjust the overload protection parameters.
• Motor Overload Fault (Err11): Check if the motor is stalled or the load is too large, and adjust the motor overload protection parameters.
• Input Phase Loss Fault (Err12): Check if the input power supply is missing a phase or if the power supply line connection is good.
• External Fault (Err15): Check if the external fault input terminal is misconnected or damaged and eliminate the external fault source.
• Communication Abnormality Fault (Err16): Check if the communication line is connected correctly or replace the communication cable.

By following the steps outlined above, users can gain a comprehensive understanding of the operation panel functions, parameter setting methods, terminal start/stop and external potentiometer speed adjustment settings, as well as fault code troubleshooting for the Inovance MD380 series inverter, thereby enabling better use and maintenance of the inverter equipment.