Motor Overload Fault

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This fault is triggered by the controller's internal electronic overload protection, signifying that the motor is drawing excessive current for an extended period. An excessive mechanical load is usually the cause. Sustained overload can lead to motor winding damage and premature controller failure.

• Sustained excessive mechanical load on the motor, causing it to draw continuous current above its rated FLA.
• Incorrectly set motor rated current (P1-08) or overload trip level (P1-10) in the controller parameters.
• High friction or resistance in the driven machinery (e.g., worn bearings, misaligned coupling) increasing motor current.
• Operating the motor at very low speeds without adequate forced ventilation (if not an inverter-duty motor), leading to overheating.
• Motor winding insulation degradation causing increased current draw for a given load or internal short.

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1. 1

   1. Measure the actual motor current (on phases U, V, W) with a clamp meter during normal operation and compare it to the motor's nameplate FLA.

2. 2

   2. Verify the motor nameplate data (rated current, voltage, RPM) is correctly entered into the controller parameters, specifically P1-08 (Motor Rated Current).

3. 3

   3. Inspect the mechanical system for high friction points, misalignments, or binding. Lubricate bearings or replace components as necessary.

4. 4

   4. Adjust the electronic thermal overload trip class (P1-10) if the motor is capable of handling higher overloads or if the application requires a different protection curve.

5. 5

   5. Monitor motor surface temperature with an infrared thermometer during operation and compare to the motor's maximum operating temperature (e.g., 80 degrees Celsius rise).