Overload Max Alarm Trip

What does Max Alarm mean?

This fault indicates that the motor load has exceeded a predefined maximum threshold, typically signaling an overload condition. This can occur if a conveyor jams, a pump's discharge pressure is too high, or a process experiences excessive friction. It protects the driven equipment and motor from damage caused by excessive load. Continuous overload risks motor and VSD damage, leading to component failure and production downtime.

• Mechanical jamming or blockage of the driven equipment (e.g., conveyor jam, seized bearing, pump impeller obstruction).
• Excessive process load such as operating a pump against a closed or highly restricted discharge valve (e.g., 'Discharge pressure above 12 bar').
• Overly sensitive overload detection threshold (e.g., Parameter P1-32) configured too low relative to the motor's full load current.
• Degradation of motor or driven equipment components (e.g., worn motor bearings, failing gearbox, insufficient lubrication) causing increased friction.
• Sustained low input supply voltage (e.g., 'Line voltage below 380VAC phase-to-phase') causing the motor to draw higher current to maintain required torque.

Click steps to track your progress.

1. 1

   1. De-energize and mechanically inspect the driven equipment (e.g., conveyor, pump, mixer) for jams, blockages, or excessive mechanical resistance. Try to rotate the motor shaft by hand.

2. 2

   2. Verify process conditions. Check pump discharge pressure at port B2 and open or adjust any partially closed valves in the discharge line. Ensure material flow is unrestricted on conveyors.

3. 3

   3. Access the drive's programming and verify Parameter P1-32 (Overload Threshold) and P1-33 (Overload Delay Time) are correctly set for the motor's rated full load current.

4. 4

   4. Using a true-RMS clamp meter, measure the actual motor phase currents (L1, L2, L3) and input line voltages (R-S, S-T, T-R) during operation. Compare current to motor nameplate FLC.

5. 5

   5. Use an infrared thermometer to measure the surface temperature of the motor casing, gearbox, and bearings. Elevated temperatures indicate excessive friction or load.

6. 6

   6. De-energize and disconnect the motor from the drive. Perform an insulation resistance test (Megger) on the motor windings to ground and between phases to detect winding degradation.