Cause : Overcurrent at constant speed comes when the drive has detected an excessively high current while the motor is running at a steady speed.

"E04.04" fault in inovance MD800 drive indicate "Overcurrent at constant speed". This means there is a problem with the motor load, the drive’s settings, or potentially a hardware fault.

Possible Causes:

1. Mechanical Load Issues: There might be a sudden increase in the mechanical load on the motor, such as binding, jamming, or other obstructions.
2. Motor Misalignment: Misalignment between the motor and the load can cause additional strain, leading to an overcurrent condition.
3. Drive Settings Issues: Incorrect drive parameter settings, such as those related to motor control, could result in improper current regulation at constant speed.
4. Power Supply Problems: Instabilities or fluctuations in the power supply can lead to irregular current draw, even at constant speed.
5. Motor or Drive Fault: There could be an issue with the motor, such as winding damage, or a problem within the drive itself, such as a faulty IGBT module or current sensor.
6. Wiring Issues: Damaged or loose wiring between the motor and drive can cause intermittent overcurrent conditions.

Troubleshooting Steps:

1. Inspect Mechanical Load:

   • Check the connected mechanical system for any signs of jamming, binding, or other issues that might be causing a sudden increase in load.
   • Ensure that the load is appropriate for the motor and that no external factors are causing additional strain.

2. Check Motor Alignment:

   • Verify that the motor is properly aligned with the load. Misalignment can cause additional friction and lead to overcurrent faults.
   • Correct any misalignment to reduce unnecessary strain on the motor.

3. Review Drive Parameters:

   • Inspect the drive settings, particularly those related to motor control, such as current limits, torque limits, and speed regulation parameters.
   • Ensure that the drive’s parameters match the motor’s specifications and the application’s requirements.

4. Examine Power Supply:

   • Check for any fluctuations or instabilities in the power supply that could be causing irregular current draw.
   • Ensure that the power supply is stable and within the required voltage and current specifications for the drive.

5. Inspect Motor and Drive:

   • Test the motor for any signs of damage, such as insulation breakdown or winding issues. Use a megger to test motor insulation resistance if necessary.
   • Inspect the drive for any potential faults, such as overheating, IGBT failure, or a malfunctioning current sensor.
   • Consider testing the motor with another drive or the drive with another motor to isolate the issue.

6. Check Wiring:

   • Inspect all wiring between the drive and motor for damage, loose connections, or other issues that could cause intermittent overcurrent conditions.
   • Tighten any loose connections and replace damaged wires as needed.

7. Enable Current Monitoring and Protection:

   • If available, enable current monitoring and protection features in the drive to help detect and prevent overcurrent conditions more effectively.
   • Set appropriate current limits to avoid triggering the fault under normal operating conditions.