Torque overload (stall)

What does 4636 mean?

A torque overload leading to a stall condition has been detected or reported in the drive or terminal. This means the motor is attempting to produce more torque than its capacity, typically due to excessive mechanical load, binding in the mechanical system, or incorrect drive tuning. A prolonged stall can lead to motor overheating and permanent damage.

• Mechanical jamming or obstruction in the driven machinery (e.g., conveyor belt jammed, valve stuck), preventing motor rotation.
• Incorrectly sized motor for the application, leading to continuous operation above its rated torque (Parameter P1-54, Motor rated torque, exceeded).
• Drive acceleration or deceleration times (e.g., P2-01, P2-02) set too short for the load inertia, requiring excessive torque.
• Insufficient motor brake release force or a dragging brake system preventing free rotation.
• Motor voltage (P1-02) or frequency (P1-04) parameters incorrectly configured, reducing available motor torque and leading to stall.
• Encoder feedback failure causing the drive to lose position reference and attempt to overcompensate with excessive current.

Click steps to track your progress.

1. 1

   Power down the system and manually inspect the mechanical load for any binding, obstructions, or damage that would impede free movement of the driven machine.

2. 2

   Review the drive's parameter settings for acceleration and deceleration times (e.g., P2-01, P2-02) and increase them if they are too aggressive for the load inertia.

3. 3

   Measure the actual current drawn by the motor (e.g., using a clamp meter on phases U, V, W) during operation and compare it to the motor's rated current (P1-03) and the drive's overload trip setting (P6-01).

4. 4

   Disengage the motor from the load (if possible) and test its free rotation by hand to check for stiff bearings or other internal motor issues.

5. 5

   Verify the motor's nameplate data (voltage, current, frequency) matches the configured motor parameters in the drive (e.g., P1-02, P1-03, P1-04).

6. 6

   Check the motor brake operation (if present) to ensure it fully releases when commanded; measure the voltage at the brake terminals (e.g., X1, X2) to confirm activation and proper coil voltage.