Troubleshooting
Source: is580-troubleshooting.html (the “Fault Diagnosis and Remedies” chapter of the IS580-S 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. When the drive is installed in an enclosed cabinet or chassis, use a cooling fan or air conditioner to keep the intake temperature below 50℃.
Troubleshooting steps are for reference only. Do not attempt unauthorized repair or modification. If a fault cannot be cleared, consult a technician.
Troubleshooting flow
- Record the fault name, code, sub-code, action at the time of the fault, and the operating state shown on the operator panel.
- Determine whether the root cause is external, such as power supply, motor, encoder, braking resistor, contactor, fan, communication cable, or mechanical load.
- Before working on the main circuit or motor circuit with power off, 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 the fault history and contact a technician for diagnosis of internal parts such as the drive board, Hall sensor, control board, IGBTs, and terminal board.
Fault alarms and remedies
| Fault name | Main cause | Remedy |
|---|---|---|
| Detection-circuit fault | Current-detection circuit is damaged; current zero-drift is too large at standstill. | Check the current-detection circuit. |
| Overcurrent during acceleration | Output is shorted to ground or short-circuited; braking transistor is shorted; FVC/SVC control without parameter identification; acceleration time is too short; starting while the motor is rotating; external interference. | Clear external faults; disconnect braking resistor and repower to check the braking circuit; set motor parameters per nameplate and run identification; increase acceleration time; use flying-start or wait for motor to stop; review fault history and investigate interference. |
| Overcurrent during deceleration | Same as above plus deceleration time too short. | Same remedies plus check whether the motor is shorted or open, and increase deceleration time. |
| Overcurrent at constant speed | Output short-circuit or ground fault; braking-transistor short; FVC/SVC without parameter identification; steady-state current exceeds rated; external interference. | Same as above; if the running current exceeds motor or drive rated output, select a higher-power drive. |
| Overvoltage during acceleration | Input voltage too high; external force driving the motor during acceleration; no braking unit or resistor installed; acceleration time too short. | Bring voltage back to normal range; remove the external force or install a braking resistor; add braking unit and resistor; increase acceleration time. |
| Overvoltage during deceleration | Input voltage too high; external force during deceleration; deceleration time too short; no braking unit/resistor installed; motor shorted to ground. | Adjust voltage; remove external force or add braking resistor; increase deceleration time; add braking unit and resistor; clear output-cable or motor ground short. |
| Overvoltage at constant speed | Input voltage too high; external force drives the motor during operation. | Adjust voltage; remove external force or add braking resistor. |
| Buffer-resistor fault | Buffer resistor repeatedly disconnects and reconnects over a short period. | Power down and consult technical support. |
| Undervoltage | Input voltage out of range; bus voltage abnormal; rectifier, buffer resistor, drive board, or control board faulty; unable to enter the program for a long time after power-up. | Adjust voltage; check input voltage and bus voltage; consult a technician if necessary. |
| Drive overload | Load too heavy or motor stalled; drive oversized too small; motor encoder faulty. | Reduce load and check motor and mechanics; use a higher-rated drive; set A1-05 to a reasonable value (e.g. 2 s) to enable encoder checking. |
| Input phase loss | Three-phase input missing a phase; drive board, surge board, main-control board, or rectifier faulty. | Check and clear external wiring issues; consult a technician if needed. |
| Output phase loss | Motor fault; drive-to-motor cable abnormal; three-phase output unbalanced during operation; drive board or IGBT abnormal. | Check the motor for open circuit; clear external faults; inspect three-phase motor windings; consult a technician. |
| Module overheat | Ambient temperature too high; air duct blocked; fan damaged; module thermistor damaged; inverter module damaged. | Lower ambient temperature; clear duct; replace fan; replace thermistor or inverter module. |
| External fault | External fault signal on a multi-function DI input; pressing STOP under non-keypad mode or during a stall. | Clear external fault, confirm the mechanism can restart, then reset; check F8-18 if needed. |
| Communication fault | Host abnormal; communication cable abnormal; F0-28 communication-card setting wrong; FD-group communication parameters wrong. | Check host wiring; check cable; set card type correctly; set communication parameters; restore factory settings if needed and reconfigure. |
| Contactor fault | Drive board or power board abnormal; contactor abnormal; surge board abnormal; external interference. | Replace drive or power board; replace contactor; replace surge board; clear interference. |
| Current-detection fault | UVW current detection zero-drift or other abnormality. | Inspect the current-detection circuit; consult a technician if needed. |
Key diagnostic focus for overcurrent faults
Overcurrent faults are usually associated with output shorts, the braking circuit, motor parameters, sudden load changes, acceleration/deceleration times, and interference. Start by powering off and checking motor insulation, output cables, and wiring terminals, then check whether the braking resistor is shorted to the chassis. If the control mode is FVC or SVC without parameter identification, reset motor parameters from the nameplate and run identification. If the fault history shows the current was well below the overcurrent threshold, focus on interference sources, the drive board, Hall sensors, Hall cables, or the control board.
Key diagnostic focus for overvoltage and undervoltage faults
For overvoltage, first check whether the input voltage is high. Then check whether the motor is being driven by external force during deceleration or operation, whether a braking unit and resistor are installed, and whether acceleration/deceleration times are too short. For deceleration overvoltage, also consider whether a motor or output-cable ground short is forming a BOOST loop.
For undervoltage, check input voltage, bus voltage, rectifier, buffer resistor, drive board, and control board. If the drive cannot enter the program for a long time after power-up, check input and bus voltage and consult a technician if needed.
Key diagnostic focus for thermal protection
When the module overheats, first check ambient temperature, cabinet airflow, fan operation, heat-sink dust, and installation clearance. When installed in an enclosed cabinet, keep the intake temperature below 50℃. Blocked airflow, fan damage, and abnormal thermistors can all trigger thermal protection.
Key diagnostic focus for communication and external-signal faults
For communication faults, confirm the host, communication cable, communication-card type, and FD-group parameters. External faults are usually triggered by DI inputs: check the injection-machine controller, emergency-stop/safety loop, external protection contacts, and mechanical enabling conditions. After resolving the cause, confirm the mechanism can restart, then reset.
On-site record recommendation
For each fault, record the fault name, panel display, sub-code, action at occurrence, handling steps, whether it recurred, replaced parts, and modified parameters. For intermittent faults, keep the fault history and correlate with current, voltage, bus, DI/DO status, and environmental conditions.