Troubleshooting
Source: 04.ES610_故障处理.html (the “Troubleshooting” chapter of the ES610 comprehensive manual)
Safety notes
🚫
Do not wire the drive while power is applied. Keep all breakers OFF; otherwise there is a risk of electric shock.
⚠️
Ground the drive per local regulations. Do not remove the housing or touch internal circuits while the drive is energized. Fault checks, maintenance, and repair must be carried out by qualified personnel.
Troubleshooting steps are for reference only. Do not attempt unauthorized repair or modification. If a fault cannot be cleared, consult a technician.
Common symptoms and remedies
| No. | Symptom | Possible cause | Remedy |
|---|---|---|---|
| 4 | Motor does not rotate after the drive runs | Motor wiring abnormal | Re-verify the drive-to-motor wiring |
| Drive parameter setting error (motor params) | Restore factory settings and reconfigure; check encoder and motor rated parameters (rated frequency, rated speed, etc.) | ||
Check F0-02 (run mode) is set correctly | |||
| Poor contact between drive board and control board | Unplug and reseat the connection, confirm it is firm | ||
| Drive-board fault | Consult a technician | ||
| 5 | DI terminal not effective | Parameter error | Recheck F4-group parameters |
| Wrong external signal | Rewire the external signal | ||
| Wrong J1 jumper | Confirm J1 jumper matches actual wiring | ||
| Control-board fault | Consult a technician | ||
| 6 | Drive frequently reports overcurrent and overvoltage | Motor parameters incorrect | Reconfigure motor parameters or run motor tuning |
| Acceleration/deceleration time inappropriate | Set appropriate acceleration/deceleration times | ||
| Load fluctuation | Consult a technician | ||
| 7 | Burnt buffer resistor | Braking-resistor lead shorted to chassis (PE) | Add insulation to the braking-resistor lead, e.g. wrap with electrical tape |
| Braking transistor blown | Replace braking transistor | ||
| DC-bus capacitor blown/shorted | Replace the bus capacitor | ||
| Negative bus shorted to ground | Clear the fault |
Fault-code summary
The following provides simple analysis for common fault types (sub-codes not listed mean the sub-code can be ignored).
Overcurrent faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E02.01 | W-phase overcurrent | Output ground or short circuit | Clear external fault |
| E02.02 | U-phase overcurrent | Output ground or short circuit | Clear external fault |
| E02.03 | V-phase overcurrent | Output ground or short circuit | Clear external fault |
| E02.04 | D/Q current overflow | Current-feedback abnormality causing register overflow | If persists after several power cycles, replace the drive |
| E02.05 | Braking overcurrent | Braking resistor undersized | Check braking-resistor sizing |
Overvoltage faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E05.00 | Bus overvoltage | Input voltage high | Adjust voltage to normal range |
| External force drives the motor while running | Remove the external force or add braking resistor | ||
| Acceleration or deceleration time too short | Increase F0-17 or F0-18 | ||
| No braking unit or resistor installed | Install braking unit and resistor | ||
| Motor grounded | Check output cable or motor for ground short |
Buffer and undervoltage faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E08.00 | Buffer-resistor fault | Buffer resistor repeatedly connects/disconnects in short time | Consult a technician |
| E09.00 | Undervoltage | Input voltage low | Check input and bus voltage; consult a technician |
| Rectifier, buffer resistor, drive board, or control board abnormal | Consult a technician |
Overload and phase-loss faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E10.00 | Drive overload | Load too large | Reduce load; check motor and mechanics |
| Drive undersized | Select a higher-power drive | ||
| E12.00 | Hardware input phase loss | Three-phase input missing a phase | Clear external wiring issues |
| E12.01 | Software input phase loss | Drive board, surge board, main-control board, or rectifier abnormal | Consult a technician |
| E13.00 | Output phase loss | Motor fault | Check motor for open circuit |
| Drive-to-motor wiring abnormal | Clear external fault | ||
| Three-phase output unbalanced | Check motor windings and clear fault | ||
| Drive board or IGBT abnormal | Consult a technician |
Overheat and external faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E14.00 | Drive overheat | Ambient temperature too high | Lower ambient temperature |
| Air duct blocked | Clear duct | ||
| Fan damaged | Replace fan | ||
| Module thermistor damaged | Replace thermistor | ||
| Inverter module damaged | Replace inverter module | ||
| E14.01 | NTC open | NTC broken | Consult a technician |
| E15.00 | External fault | External fault input via DI | Clear external fault and reset |
Communication faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E16.01 | Modbus timeout | Timeout too short or PLC send-cycle too long | Increase timeout or shorten PLC send cycle |
| Timeout configured but wrong baud/format | For 485, confirm match with host; for PN, confirm FD-00=9 baud and FD-01=3 format | ||
| E16.41 | Profinet disconnected | PN card disconnected | Check cabling |
| E16.46 | User-operation error | Incorrect master operation | Check the master’s PZD1 bit8–bit15; the high byte of PZD1 must be 0 |
Contactor and current-detection faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E17.00 | Contactor fault | Drive board or power board abnormal | Replace drive or power board |
| Contactor abnormal | Replace contactor | ||
| Surge board abnormal | Replace surge board | ||
| External interference | Clear interference |
Tuning-related faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E19.01 | Initial-angle identification error | Synchronous-motor pole-angle tuning fault | Check F1-group parameters; typically caused by large motor inductance or missing motor |
| E19.02 | Back-EMF identification error | Measured back-EMF too low | Check F1-group; replace with a known-good motor to test for demagnetization |
| E19.03 | Inductance identification error | Encoder wire broken | Check encoder |
| E19.04 | Resistance identification error | Encoder wire broken | Check encoder |
| E19.05 | Automatic phase-sequence identification error | Encoder wire broken | Check encoder |
EEPROM faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E21.01 | EEPROM write timeout | Function-code write error | Parameter writes in EEPROM are too frequent; if communication modifies parameters often, reduce write frequency |
| E21.02 | EEPROM read timeout | Function-code read error | Same as above |
| E21.04 | Too many function-code reads/writes | >1 s window exceeded | Reduce write frequency or the number of codes read/written |
| E21.05 | EEPROM write failure | EEPROM or board fault | Check EEPROM and board |
| E21.06 | Power-on function-code read error | EEPROM or board fault | Check EEPROM and board |
| E21.08 | Too many function-code reads/writes at power-on | EEPROM or board fault | Check EEPROM and board |
Output ground-short faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E23.01 | Output ground short (overcurrent) | Overcurrent during ground-short detection | Check motor for ground short; replace cable or motor; consult a technician if unresolved |
| E23.02 | Output ground short (overvoltage) | Overvoltage during ground-short detection | Same as above |
Running-time and commercial-time faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E26.00 | Running-time reached | Accumulated running time reached the setpoint | Check F8-17≠0; check whether F7-0 exceeds F8-17; F8-23=1 |
| E27.00 | Commercial-time reached | Commercial time reached | Check whether FA-08 (cumulative commercial running time) ≥ FA-01, FA-03, FA-05, or FA-07; ask the supplier for the running-time protection password if needed |
Internal faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E28.00 | Internal fault | Fault not enabled | Consult a technician |
| E28.01 | System-parameter abnormal | Momentary power loss during parameter save | Reapply power, reinitialize system parameters (FP-01=1); change parameter-writing method and re-save |
| Max parameter writes in a given period exceeded | Reduce writes or replace the drive | ||
| Software updated | Re-set drive model and reinitialize system parameters (FP-01=1) | ||
| Drive fault | Replace the drive | ||
| E28.02 | PLD config fault | FPGA and MCU software versions mismatch | Consult a technician for matching firmware |
| FPGA fault | Replace the drive | ||
| E28.03 | PLD interrupt fault | FPGA fault / FPGA–MCU handshake abnormal / internal computation timeout | Replace the drive |
| E28.04 | Internal program abnormal | EEPROM fault | Reinitialize (FP-01=1) and power-cycle |
| Drive fault | Replace the drive | ||
| E28.05 | Product-match abnormal | Product number (motor or drive) not found / motor-drive power mismatch | Set correct motor and drive models per the servo system specs |
| E28.06 | Absolute-position-mode product-match fault | Motor mismatch or wrong motor number in absolute-position mode | Reset motor model F1-00 per nameplate or replace with a matching motor |
| E28.07 | FPGA sampling/compute timeout / current-sampling timeout | MCU communication timeout | Replace the drive; keep power and signal wiring separated on-site |
STO faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E29.00 | STO safe-state abnormal | STO safe-state abnormal | Check STO wiring; consult a technician |
| E29.01 | STO input error | STO safe-state abnormal | Check STO wiring; consult a technician |
| E29.02 | STO 5V supply abnormal | STO hardware abnormal | Check STO wiring; consult a technician |
| E29.03 | STO input circuit abnormal | STO hardware abnormal | Check STO wiring; consult a technician |
| E29.04 | STO buffer chip output abnormal | STO hardware abnormal | Check STO wiring; consult a technician |
Fan and terminal faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E30.00 | Motor-fan speed-control fault | Motor fan fault | Check motor fan |
| E30.01 | Drive-fan fault | Drive fan fault | Check drive fan |
| E31.00 | DI function-assignment fault | DI function conflict | Check DI assignments (F4-00–F4-15) |
| E32.00 | STO RAM check failed | Wrong program version | Check program version |
| E32.01 | STO Flash check failed | Wrong program version | Check program version |
Multi-pump and CAN faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E41.00 | Slave-pump stalled | Slave-pump fault | Check for slave-pump stall or damage |
| E42.01 | Disconnect after running for a while | Bus disconnected | Check cable contact |
| E42.02 | Severe interference | Severe interference (receive error) | Check shield, cable length; check CAN bus-load rate |
| E42.03 | No connection since power-up | Never received or sent successfully | Check CANH/CANL for swap; check A2-00, A2-01; check cables |
| E42.11 | CANopen timeout | CANopen communication timeout | Check heartbeat or node-guarding config; check for CAN interference; consult a technician |
| E42.12 | PDO length vs mapping mismatch | PDO length does not match mapping | Consult a technician |
| E42.15 | PDO mapping error | PDO mapping object wrong | Recheck PLC PDO mapping and reconfigure |
Speed and torque faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E44.00 | Speed deviation too large | Excessive speed deviation | Check encoder mounting and wiring; check motor power cable |
| E44.01 | Torque upper limit too small | Wrong parameter | Increase F2-10 torque upper limit |
| E44.02 | Speed exceeds maximum | Speed command beyond overspeed threshold / motor speed overshoot | Check the speed command; adjust speed-loop gain or mechanical conditions |
| E44.03 | Runaway | Motor runaway | Check drive phase sequence; if recurring after power-cycle, replace the drive |
Temperature and sensor faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E45.03 | Overtemperature | Motor over-temperature protection | Check motor temp sensor, fan, etc. |
| E45.04 | Short-circuit fault | PT1000 shorted or reversed | Check the motor temp sensor; check PTCP/PTCN wiring |
| E45.05 | Open-circuit fault | PT1000 open | Check the temp sensor |
| E46.00 | Pressure-sensor fault | Pressure-sensor fault | Check sensor wiring, supply, and output |
| E46.01 | Load too heavy | Load too heavy | Try to turn the motor by hand while stopped; check F2-10; check dynamic self-learning |
| E46.02 | Zero-drift learning fault | Pressure-sensor zero-drift learning fault | Confirm sensor is at zero pressure; confirm wiring (AI3 voltage matches U0-32); confirm F4-28 to F4-31 |
| E46.03 | Range out of limits | Pressure-sensor out of range | Sensor range is less than A3-55 or greater than A3-56; check sensor settings |
Multi-pump-mode faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E47.01 | Multi-pump merge slave fault | Slave-pump fault | See “Appendix C Injection-Machine Multi-Pump Mode” in the drive software manual |
| E48.00 | Station-number conflict | Duplicate station numbers | See “Appendix C” in the software manual |
| E52.00 | Multi-pump merge multi-master | Multiple masters under multi-pump mode | See “Appendix C” in the software manual |
Encoder faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E49.01 | Absolute encoder fault | Encoder wiring error | Rewire per the correct diagram |
| E49.02 | Single-turn calculation error | Encoder cable loose | Check on-site vibration and reconnect; use standard cable |
| E49.03 | Absolute encoder count abnormal | Interference on encoder signal | Keep strong/weak currents separated; avoid bundling motor and encoder cables; ensure good motor and drive grounds; check encoder connectors |
| E49.04 | Encoder EEPROM read delay too long | Encoder fault | Replace servo motor |
| E49.05 | Encoder parameter abnormal | Serial-encoder cable open or loose | Check wiring; separate motor and encoder cables |
| E49.06 | Encoder algorithm warning | Serial-encoder read/write abnormal | If persists after power cycles, replace the servo motor |
| E49.07 | Encoder multi-turn counter overflow | Encoder algorithm error | If persists after power cycles, replace the servo motor |
| E50.01 | Encoder battery invalid | Battery fault | Check battery |
| E50.02 | Encoder multi-turn count error | Interference | Add a ferrite core before the encoder |
| E50.03 | Encoder battery alarm | Battery fault | Check battery |
| E50.04 | Encoder overheat | Encoder overheat | Lower ambient temperature, clear air duct; if motor fan or encoder damaged, consult a technician |
User parameters and other faults
| Code | Name | Cause | Remedy |
|---|---|---|---|
| E58.00 | User-parameter restore fault | User parameters were not saved before restoring | After setting parameters correctly, save them (FP-04 enter password, FP-05=1 to save) |
| E61.00 | Braking transistor long-time protection | Braking transistor protected too long | Check whether bus voltage is high for extended time; check the braking-protection time |
| E63.00 | Reverse-running time reached | In pressure mode, reverse cumulative time exceeds A4-09 | Check whether the flow-decrease time and oil-cooler decrease time are too short |
| E64.00 | Drive-board EEPROM fault | Drive-board EEPROM fault | Power off and contact technical support |
| E67.00 | Initialization abnormal | Initialization parameter abnormal at power-up | Consult a technician |
| E69.00 | Motor stall | Motor stalled | Power off and check motor cables; confirm drive-motor UVW match; check load; if stall is reported when enabling from stop, check for output phase loss |
| E70.01 | Motor ROM data checksum error | Drive and motor type mismatch | Replace with matching drive/motor and reapply power |
| E70.02 | Motor ROM data checksum error | Serial-encoder ROM parameter error or not stored | Use standard encoder cable and tighten screws at both ends; replace cable if needed; avoid bundling with power cable |
| E70.03 | Motor ROM torque-ripple compensation read error | Drive fault | Replace the drive |
| E72.01 | CANopen disconnected | Communication disconnected | Check the electronic-scale wiring |
| E72.02 | CANopen timeout | Communication timeout | Interference causes disconnect; check position-scale grounding |
| E72.03 | CANopen position-sensor invalid | No position sensor | Position-scale magnet failed; replace the scale |
| E73.00 | Output wiring abnormal | Wrong phase sequence or output phase loss | Check motor UVW phase sequence; check for output phase loss; consult a technician |
| E95.00 | Over-pressure during mold opening | Feedback pressure during mold-open exceeds system max | Contact technical support |
| E97.00 | Motor-parameter modification fault | F1-group motor params were modified | Confirm F1-group changes are correct; contact technical support |
| E98.00 | Parameter change needs power-cycle | Change needs power-cycle or software reset to take effect | Power-cycle |
| E99.00 | Software-defined function-code count abnormal | Software-defined function-code count abnormal | Redefine the software function-code count |
Troubleshooting flow
- Record the fault name, code, sub-code, action at the time of the fault, and the operating state shown on the panel.
- Determine whether the cause is external: power, motor, encoder, braking resistor, contactor, fan, communication cable, or mechanical load.
- Before powering off to work on the main circuit or motor circuit, confirm the CHARGE lamp is off and wait for the specified time.
- After clearing the fault, run at low speed and low pressure first to confirm no alarms, then return to normal duty.
- If the same fault recurs, review fault history and consult a technician for diagnosis of internal components (drive board, Hall sensor, control board, IGBTs, terminal board).