Drive Overload

What does Drive Overload mean?

The load on the motor is too heavy for the drive's capacity, or the drive is being operated with too much torque at low speeds, causing its output current to exceed safe limits. Sustained overload can lead to the drive's thermal shutdown and potentially cause damage to its power semiconductor components.

• Motor operating continuously above its rated current due to excessive mechanical load on the driven equipment.
• Drive size (kW/HP rating) is insufficient for the motor or the application's continuous torque demand.
• Prolonged operation at very low speeds without adequate motor cooling or without reducing the motor's current limit.
• Drive parameter A1-03 ('Overload Protection') is set too low for the application, triggering prematurely.
• Mechanical issues in the driven system (e.g., seized bearings, clogged pump, binding conveyor) causing increased torque demand.

Click steps to track your progress.

1. 1

   1. Monitor the motor's output current (e.g., U1-02) during operation and compare it against the drive's rated current and motor nameplate full-load current (FLA).

2. 2

   2. Reduce the mechanical load on the motor if possible, or verify the drive and motor are correctly sized for the application's peak and continuous load requirements.

3. 3

   3. Increase the drive's overload protection trip time (e.g., parameter C1-04 'Motor Overload Relay Trip Time' or similar) if it is tripping too sensitively, but ensure adequate motor protection.

4. 4

   4. Verify that motor thermal protection parameters (e.g., C1-04, A1-03) are correctly configured for the motor's FLA.

5. 5

   5. Check for and correct any mechanical binding or excessive friction in the load (e.g., gearbox, pump, fan) that would abnormally increase motor torque.

6. 6

   6. If operating at low speeds, consider adding external cooling for the motor or reducing the output current limit (if permissible by application) to prevent overheating.