25200

Check Axis Movement

Navigate to Service → Axis → Manual Movement and test each axis individually at reduced feedrate (10% override) to identify binding.

Ensure machine is in safe position before manual movement

Inspect Mechanical Components

Check ballscrews, linear guides, and coupling for debris, damage, or inadequate lubrication. Verify proper backlash compensation in MD32450-MD32470.

Listen for unusual noise during movement - grinding indicates mechanical issues

Verify Load Conditions

Check if workpiece weight exceeds axis specifications. Review MD32000 (MOTOR_TORQUE) and ensure actual load is within 80% of rated capacity.

Use Diagnostics → Drive → Actual Values to monitor real-time current consumption

Verify Motor Data Parameters

Access Commissioning → Drive → Motor Data and compare MD32210 (RATED_CURRENT) with motor nameplate values. Ensure MD32200 (MAX_CURRENT) is set to 150-200% of rated current.

Always reference the exact motor model datasheet for precise current ratings

Check Current Controller Settings

Verify MD32300 (CURRENT_CTRL_P_GAIN) and MD32310 (CURRENT_CTRL_I_TIME) are optimized. Use automatic optimization via Commissioning → Drive → Current Controller.

Backup parameters before running automatic optimization

Validate Power Section Assignment

Confirm MD32020 (DRIVE_TYPE) matches the actual drive hardware and MD32030 (MOTOR_TYPE) corresponds to the connected motor type.

Mismatched drive types can cause current calculation errors leading to false alarms

Check Drive Status LEDs

Examine the SIMODRIVE status indicators. Red LED indicates hardware fault. Access Diagnostics → Drive → Hardware Status for detailed fault information.

Do not operate with hardware fault indications present

Monitor Drive Temperature

Check MD32800 (TEMP_MONITORING) status and verify drive cooling fans are operational. Excessive temperature can trigger protective current limiting.

Clean drive heat sinks and verify ambient temperature is within specifications

Perform Current Sensor Calibration

Execute current sensor offset calibration via Commissioning → Drive → Current Measurement → Offset Calibration with motor disconnected.

Motor must be electrically disconnected during current sensor calibration

Inspect Motor Cable Integrity

Check motor power cable for damage, proper shielding connection, and secure termination at both drive and motor ends. Verify cable length matches MD32040 (CABLE_LENGTH).

Use megohm meter to test insulation resistance between phases and to ground

Verify Connection Torque

Check all motor connection terminal torque specifications. Loose connections create resistance and heat, triggering overcurrent protection.

Power down drive completely before checking connections

Test Motor Winding Resistance

Measure motor phase-to-phase resistance and compare with motor specifications. Significant deviation indicates motor winding issues.

Resistance measurements should be within 5% between phases for balanced operation

Check Encoder Signal Quality

Access Diagnostics → Drive → Encoder and monitor signal amplitude and offset values. Verify encoder supply voltage is stable at 5V ±5%.

Encoder signals should show consistent amplitude without dropouts or noise spikes

Verify Encoder Cable Routing

Ensure encoder cables are properly separated from power cables and securely connected. Check MD31000 (ENC_TYPE) matches actual encoder specifications.

Never route encoder cables parallel to motor power cables

Perform Encoder Alignment

Execute encoder alignment procedure via Commissioning → Drive → Encoder → Alignment to ensure proper commutation timing.

Poor encoder alignment can cause 30-40% increase in current consumption