YASKAWA GA500 frequency converter troubleshooting

OC overcurrent: overload, short acceleration time, poor motor insulation, output short circuit, V/f or motor parameter error, contactor switching on the output side. First, disconnect the load and conduct a no-load test run, then check the U/V/W insulation and short circuit.

GF grounding fault: motor or cable short circuit to ground, insulation aging, large leakage current. Measure insulation resistance and inspect cables.

SC short circuit/IGBT fault: output side short circuit, IGBT damaged. Cut off the power and measure the short circuit between U/V/W and the casing. After confirmation, replace the driver.

OV overvoltage: Short deceleration time, excessive inertia, disconnected braking resistor or faulty braking transistor, input surge. Extend deceleration, add braking resistor/braking unit, check L3-04 and L3-11.

Uv1 undervoltage: Input phase loss, loose wiring, input voltage fluctuation, poor soft charging relay. Check the R/S/T voltage and terminals, and check the maintenance value of U4-06 pre charging relay.

Overload of oL1 motor: excessive load, poor heat dissipation during low-speed operation, incorrect setting of E2-01 rated current, mismatch of L1-01 protection curve. Check the oL1 level of U4-16 motor and calculate the low-speed torque.

Overload of oL2 frequency converter: heavy load, short acceleration time, low output frequency, high carrier frequency, and small driving capacity. Check the output current and C6-02.

Overheating of oH/oH1 heat sink: high ambient temperature, blocked air duct, fan stall, excessive load. Clean the dust, check the fan, reduce the carrier or amplify the capacity.

PF input phase loss, LF output phase loss: Input/output disconnection, loose terminals, motor winding disconnection. Check the settings and actual wiring of L8-05/L8-07.

CE/buS communication error: MEMOBU or option communication timeout, terminal resistance, shielding, address/baud rate mismatch. Check H5-01 to H5-09 or F6-01.

EF0-EF7 external faults: external device alarm, wiring error, H1 xx external fault setting does not match actual NO/NC.

CPF control circuit error: Hardware failure, power on again first, if it still persists, replace the control board or driver.

STPo/LSo motor out of step/low-speed out of step: PM motor parameter error, excessive load, initial magnetic pole detection failure, improper HFI gain. Check E5 parameters n8-55、n8-84、L8-93～L8-95。

RH/rr brake resistor overheating/brake transistor fault: high brake duty cycle, insufficient brake resistor capacity, damaged brake transistor.

DEv/os/PGo: speed deviation, overspeed, encoder disconnection. Check F1-02/F1-03/F1-04, encoder wiring, and F1-14.

Fbl/FbH: PID feedback is missing or too high. Check the settings of b5-13/B5-14, b5-36/B5-37, sensors, and H3-02/H3-10.

Attention during reset: If the Run command still exists, the fault reset will be rejected and the keyboard may display CrST; You should first revoke the Run command, then press RESET, S4 fault reset terminal, or power off to restart. For hardware failures such as CPF, do not repeatedly reset and forcefully run.

Troubleshooting when there is no fault display

The more common occurrence on site is' no fault code but equipment is not functioning properly '. If the parameters cannot be modified, first check if the A1-01 access level is Operation Only, if the H1 xx=1B programming lock is activated, if the A1-04 password is entered, and if it is in the Uv undervoltage state. If the motor does not rotate, check if it is running in Drive Mode, b1-02 command source, b1-01 frequency reference source, S1/S2 wiring, SC-SP/SC-SN jumper, LOCAL/REMOTE status, and if the frequency reference is lower than E1-09. If the motor reverses, check the U/V/W phase sequence and b1-14. If the motor overheats, check the load and low-speed operation E2-01、L1-01、 Carrier frequency and motor cooling. If there is stalling or excessive acceleration and deceleration time during startup, check L3-02/L3-06 for anti stall, L7 torque limit, C1 acceleration and deceleration time, and mechanical brake. If the PID output is abnormal, check if H3-02/H3-10 is set to B, if b5-01 is enabled, feedback signal, and PID gain.

Maintenance, spare parts and replacement

The maintenance monitoring of GA500 includes U4-03 cooling fan cumulative time, U4-04 fan maintenance percentage, U4-05 electrolytic capacitor, U4-06 soft charging relay U4-07 IGBT。 LT-1 is for fan maintenance, LT-2 capacitor, LT-3 soft charging relay LT-4 IGBT 50%、TrPC IGBT 90%。 The standard replacement cycle for fans and electrolytic capacitors is about 10 years, which is actually affected by environmental temperature, load rate, and operating rate. Reset o4-03=0 after replacing the fan; After replacing the driver or control board, set the o2-04 driver model and restore parameter backups.

When replacing spare parts, it is recommended to first use keyboard o3-01 to backup parameters, and o3-02 allows for backup; After the new machine is restored, check the parameters of A1-02, C6-01, E1/E2/E5, o2-04, and options. If using models with built-in EMC filters, it is necessary to confirm the position of the EMC filter switch: only symmetrical grounding networks can be set to ON, and asymmetrical grounding or high impedance grounding should be set to OFF, otherwise it may damage the drive. The drive of long-term inventory should be powered on for at least 30 minutes per year; If it has not been powered on for more than two years, it is recommended to slowly increase the rated voltage from 0 V using a voltage regulator and run the electrolytic capacitor without load for 1 hour to reform it. When replacing the safety function driver, pay attention to the replacement requirements for safety functions that have been in use for 10 years, and re verify H1/H2, EDM, and external safety circuits.