Inovance IS300 Series Troubleshooting Instructions

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Page 2: Table Of Contents
Contents Contents Preface......................2 Chapter 1 Safety Precautions ...............3 Chapter 2 Technical Specifications and Electrical Installation....6 ..........6 2.1 IS300 Servo Drive Models and Specifications ..........8 2.2 Selection of Braking Unit and Braking Resistor ..................11 2.3 Electrical Wiring Chapter 3 Operation, Display and Trial Running ........13 ...
Page 3: Preface
Preface Preface Based on many applications of Inovance servo drive specialized for the hydraulic pump system and experts' experience in the industrial control technology, this manual is complied to help users quickly locate and solve problems. The manual collects onsite maintenance skills and experience of service personnel of Inovance and injection molding machine (IMM) manufacturers.
Page 4: Chapter 1 Safety Precautions
Chapter 1 Safety Precautions Chapter 1 Safety Precautions Servo motor insulation test Perform the insulation test when the servo motor is used for the first time, reused after being stored for a long time, or in a regular checkup, in order to prevent poor insulation of servo motor windings from damaging the servo drive.
Page 5 Do not connect the surge suppressor on the output side of the servo drive. Altitude and de-rating In places where the altitude is above 1000 m, the cooling effect reduces due to thin air, and it is necessary to de-rate the servo drive. Contact the agent or Inovance for technical support. Special usage If wiring that is not described in this manual such as common DC bus is applied, contact the agent or Inovance for technical support.
Page 6 Chapter 1 Safety Precautions 11. Adaptable motor The standard adaptable motor is permanent synchronous servo motor. The standard parameters of the adaptable motor have been configured inside the servo drive. It is still necessary to perform motor auto-tuning or modify the default values based on actual conditions.
Page 7: Chapter 2 Technical Specifications And Electrical Installation
Chapter 2 Technical Specifications and Electrical Installation Chapter 2 Technical Specifications and Electrical Installation 2.1 IS300 Servo Drive Models and Specifications Power Input Output Motor Power (S1) Servo Drive Model Capacity Current Current (kVA) Single-phase 220–230 V, 50/60 Hz IS300S002-C IS300S003-C 0.75 IS300S004-C...
Page 8 Chapter 2 Technical Specifications and Electrical Installation Power Input Output Motor Power (S1) Servo Drive Model Capacity Current Current (kVA) IS300T020-C IS300T030-C IS300T035-C 38.5 18.5 IS300T040-C 46.5 IS300T050-C IS300T070-C IS300T080-C IS300T100-C IS300T140-C IS300T170-C IS300T210-C IS300T250-C IS300T300-C IS300T370-C IS300T420-C IS300T460-C IS300T520-C IS300T580-C IS300T650-C IS300T720-C IS300T140-C-L...
Page 9: Selection Of Braking Unit And Braking Resistor
Chapter 2 Technical Specifications and Electrical Installation Power Input Output Motor Power (S1) Servo Drive Model Capacity Current Current (kVA) IS300-5T140-C IS300-5T170-C IS300-5T210-C IS300-5T250-C IS300-5T300-C IS300-5T370-C IS300-5T420-C IS300-5T460-C IS300-5T520-C IS300-5T580-C IS300-5T650-C IS300-5T720-C IS300-5T140-C-L IS300-5T170-C-L IS300-5T210-C-L IS300-5T250-C-L IS300-5T300-C-L 2.2 Selection of Braking Unit and Braking Resistor Recommended Power Recommended Braking...
Page 10 Chapter 2 Technical Specifications and Electrical Installation Recommended Power Recommended Braking IS300 Model Remarks of Braking Resistor Resistance Unit IS300-2T140-C 7.5 kW ≥ 6 Ω External MDBUN-60-S IS300-2T170-C 9 kW ≥ 4 Ω External MDBUN-90-S IS300-2T210-C 11 kW ≥ 4 Ω External MDBUN-90-S IS300-2T300-C 8 x 2 kW ≥...
Page 11 Chapter 2 Technical Specifications and Electrical Installation Recommended Power Recommended Braking IS300 Model Remarks of Braking Resistor Resistance Unit IS300T250-C-L 6.5 kW x 2 ≥ 8 Ω x 2 External MDBUN-90-T x 2 IS300T300-C-L 16 kW ≥ 2.5 Ω External MDBU-200-B Three-phase 480 V IS300-5T002-C 150 W ≥...
Page 12: Electrical Wiring
Chapter 2 Technical Specifications and Electrical Installation 2.3 Electrical Wiring The electrical wiring figures below are aiming at helping the users who initially use the servo drive to be able to perform the operations described in the troubleshooting process. 2.3.1 Wiring of the External Braking Unit Two wiring methods are provided, differing in the wiring of braking resistor overheat protection.
Page 13 Chapter 2 Technical Specifications and Electrical Installation Figure 3-19 Basic wiring method 2 2.3.2 Wiring Diagram of System Application Figure 2-3 Wiring of the IS300 system 37-55 kW Above 55 kW Braking resistor Braking resistor Below 30 kW Braking unit Braking unit MDBUN MDBUN Braking resistor P(+) P(+) External reactor...
Page 14: Chapter 3 Operation, Display And Trial Running
Chapter 3 Operation, Display and Trial Running Chapter 3 Operation, Display and Trial Running 3.1 Operation and Display You can modify the parameters, monitor the working status and start or stop the servo drive by operating the operation panel. The following figure shows the operation panel. Figure 3-1 Diagram of the operation panel 3.1.1 Description of Function Indicators ...
Page 15 Chapter 3 Operation, Display and Trial Running When the indicator is ON, it indicates torque control mode. When the indicator is blinking slowly, it indicates the auto-tuning state. When the indicator is blinking quickly, it indicates the fault state.  Unit Indicators means that the indicator is ON, and means that the indicator is OFF.
Page 16: Viewing And Modifying Function Codes
Chapter 3 Operation, Display and Trial Running Stop the servo drive when it is in the running state and Stop/Reset perform the reset operation when it is in the fault state. Quick Enter or exit Level I quick menu. Reserved Reserved 3.2 Viewing and Modifying Function Codes The operation panel of the IS300 adopts three-level menu.
Page 17: Flowchart Of Commissioning The Servo Hydraulic Pump
Chapter 3 Operation, Display and Trial Running cannot be modified. This may be because:  Such a function code is only readable, such as, servo drive model, actually detected parameter and running record parameter.  Such a function code cannot be modified in the running state and can only be changed at stop.
Page 18 Chapter 3 Operation, Display and Trial Running of A1-04 (Number of pole pairs of resolver). Then re-perform motor auto-tuning and perform motor trial running. If the motor oscillates or runs with low frequency noise, weaken the speed loop and the current loop appropriately. For example, decrease the values of F2-00, F2-03, F2-13, F2-14, F2-15 and F2-16, and increase the values of F2-01 and F2-04.
Page 19 Chapter 3 Operation, Display and Trial Running Auto-tuning Pr. Setting Application Mode After motor auto-tuning is completed, the value of F1-16 is No operation F1-16 = 0 restored to 0 automatically. This mode is used when the back EMF of the motor is known. Static F1-16 = 1 The motor runs at a low speed during auto-tuning, and auto-tuning 1 therefore, the overflow valve need not be opened.
Page 20: Servo Pump Commissioning
Chapter 3 Operation, Display and Trial Running 3.5 Servo Pump Commissioning 3.5.1 AI Zero Drift Auto Correction Function Parameter Step Remarks Code Setting Description 1. Set the The operation panel The LOCAL/REMOT indicator is F0-02 = 0 command source. control mode is used. OFF. After the operation panel displays The AI zero drift auto 2.
Page 21: Chapter 4 Function Code Table
Chapter 4 Function Code Table Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code Group U0: Servo Drive Viewing Parameters 0.00 Hz to maximum U0-00 Running frequency ● frequency (F0-10) Group U1: Servo Pump Viewing Parameters U1-00 Real-time angle 0.0°–359.9°...
Page 22 Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code control mode 1 (via CAN communication) 2: Servo drive hydraulic control mode 2 (via AI) 3:CAN hydraulic mode (reserved) 4: Reserved Rotational speed Maximum rotational corresponding to lower A3-01 1 RPM 2000 RPM ★...
Page 23 Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code Hydraulic pressure A3-18 0.001–10.000s 0.001s 0.100s ☆ control Ti4 Hydraulic pressure A3-19 0.000–1.000s 0.001s 0.000s ☆ control Td4 zero drift auto 0: Disabled A3-20 ☆ correction 1: Enabled Fault detection time of 0.000s: Detection invalid A3-21 hydraulic...
Page 24 Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code gain 2 Speed loop F2-04 0.01–10.00s 0.01s 0.30s ☆ integration time 2 F2-05 Switchover frequency 2 F2-02 to max. frequency 0.01 Hz 10.00 Hz ☆ Slip compensation F2-06 50%–200% 100% ☆...
Page 25 Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code protection 1: Enabled F9-17 Reserved ☆ F9-18 1st fault type 0: No fault ☆ 1: Reserved F9-19 2nd fault type ☆ 2: Overcurrent during acceleration (Err02) 3: Overcurrent during deceleration (Err03) 4: Overcurrent at constant speed (Err04)
Page 26 Chapter 4 Function Code Table Function Parameter Name Setting Range Min. Unit Default Property Code (Err23) 24-25: Reserved 26: Running time reached 27: Business running time reached 28-41: Reserved 42: CAN communication interrupted (Err42) 43: Encoder fault during motor auto-tuning (Err43) 44: Speed deviation too large (Err44) 45: Motor overheat (Err45)
Page 27: Chapter 5 Troubleshooting
Chapter 5 Troubleshooting Chapter 5 Troubleshooting The mixture of the hydraulic circuit of the IMM and the electrical system is very complicated. Providing the only digital operation panel, the servo drive may reflect faults of all peripheral devices. These faults may seem to be caused by the servo drive, but may be actually caused by other reasons.
Page 28 Chapter 5 Troubleshooting ERR05, ERR06, ERR07 Fault Code Overvoltage during running Fault Principle After the fault occurs, view the value of F9-23. If the value exceeds the software overvoltage protection value, it indicates that overvoltage occurs on the servo drive. The software overvoltage protection value is 400 V for 2T, 790 V for T, and 890 V for 5T.
Page 29 Perform motor auto-tuning twice and check whether the value of A1-02 (encoder installation angle) changes. If the value changes a lot, contact Inovance. You can refer to section 3.4.3 “Setting and Auto-tuning of Motor Parameters” or the following procedure to perform the motor auto-tuning.
Page 30 Chapter 5 Troubleshooting large. In this case, to protect the IMM, you need to reduce the load and properly increase the cooling time. Perform any action on the IMM computer to check whether the motor and Motor hydraulic hydraulic pump rotate normally. If they do not rotate, it indicates that they get pump stuck stuck.
Page 31 Chapter 5 Troubleshooting ERR13 Fault Code Phase loss on the output side Fault Principle Fault Cause Solution Check whether the cables between the servo drive and the motor are short-circuited or in poor contact. Disconnect the servo drive from the motor, measure the inter-phase resistance of U, V, W phases of the motor by using the M mode in the ohm function of the motor, and check whether the resistance is the same and above 5 MΩ.
Page 32 Measure whether U, V, W cables of the servo drive are in contact with the Drive board earthing cable by using the diode function of the multimeter. On normal short-circuit to ground conditions, they are disconnected. If short-circuit occurs, contact Inovance ...
Page 33 Chapter 5 Troubleshooting for technical support. Check whether the cables between the servo drive and the motor are short-circuited or in poor contact. Disconnect the servo drive from the motor, measure the inter-phase resistance of U, V, W phases of the motor by using the M mode in the ohm function of the motor, and check whether the resistance is the same and above 5 MΩ.
Page 34 Chapter 5 Troubleshooting ERR43 Fault Code Encoder signal feedback abnormal or unavailable Fault Principle Fault Cause Solution If the fault occurs at the first-time auto-tuning, check whether the setting of F1-01 to F1-05 is correct. If not, correct the setting, and perform auto-tuning Auto-tuning fault again.
Page 35 Perform motor auto-tuning twice and check whether the value of A1-02 (encoder installation angle) changes. If the value changes a lot, contact Inovance. You can refer to section 3.4.3 “Setting and Auto-tuning of Motor Parameters” or the following procedure to perform the motor auto-tuning.
Page 36 Chapter 5 Troubleshooting ERR45 Fault Code Motor overheat protection enabled Fault Principle Fault Cause Solution Check whether the surface of the servo motor is hot. If yes, it indicates that the temperature is too high. In this case, check the following items: Whether the load is very heavy ...
Page 37: Troubleshooting Of Common Faults Without Alarm
Chapter 5 Troubleshooting replace the pressure sensor. Disconnect the hydraulic pump from the motor and try to rotate the motor or Hydraulic pump hydraulic pump manually. Check whether there is resistance or noise during damaged or stuck rotation. If yes, it indicates that the motor or hydraulic pump is faulty and needs to be repaired.
Page 38 Chapter 5 Troubleshooting gain (A3-05) and decreasing the integral time (A3-06) in the prerequisite of no motor oscillation. Solutions to large overshoot: 1. Decreasing the integral time of the hydraulic loop and increasing differential time of the hydraulic loop will restrain overshoot better. 2.
Page 39 Chapter 5 Troubleshooting board faulty servo drive, ensure there is no display, and then power on the servo drive again. If the display is normal, it indicates that the control board is faulty. In this case, contact the IMM manufacturer. The motor rotates inversely. Fault Symptom ...

This manual is also suitable for:

Is300s003-c Is300s002-c Is300-2t003-c Is300-2t002-c Is300-2t004-c Is300s004-c ... Show all

Inovance IS300 Series Troubleshooting Instructions

Chapter 1 Safety Precautions

Chapter 2 Technical Specifications and Electrical Installation

Chapter 3 Operation, Display and Trial Running

Chapter 4 Function Code Table

Chapter 5 Troubleshooting