| Hardware Fault of Frequency inverter | In case of over-current or over-voltage existed in frequency inverter, it is judged as hardware fault |
|
ERR16 – Frequency Inverter Hardware Fault
What this means
ERR16 indicates that the VFD has detected an internal hardware protection fault.
This fault is triggered when the VFD experiences over-current or over-voltage conditions internally that exceed safe operating limits, and the drive determines the condition cannot be handled as a normal runtime fault.
At this point, the VFD is protecting itself from potential damage.
Why This Happens
ERR16 is not a “soft” or configuration-only error.
It occurs when the VFD detects conditions severe enough that it classifies the event as a hardware-level fault.
This may be caused by:
-
Extreme electrical events
-
Severe overloads
-
Internal component stress or failure
Most Common Causes We See
1. Severe over-current events
Examples:
-
Tool crash or sudden spindle stall
-
Hard mechanical binding
-
Large tool engagement beyond spindle capability
These can cause instantaneous current spikes that exceed internal limits.
2. Severe over-voltage events
Examples:
-
Power line spikes
-
Improper deceleration without braking capability
-
Regenerative voltage during rapid stops
This is more common when deceleration settings are too aggressive.
3. Repeated unresolved faults
If the VFD experiences repeated:
-
ERR01, ERR02, ERR03, ERR04, ERR05, or ERR06
Without correcting the root cause, the cumulative stress can eventually trigger ERR16.
4. Internal component damage (less common)
-
Output transistor damage
-
Power supply component failure
-
Internal protection circuitry failure
This is rare but possible, especially after severe electrical events.
What to Check First
Step 1: Treat as over-current or over-voltage
Because ERR16 is triggered by these conditions:
-
Review recent cutting conditions
-
Look for crashes, stalls, or aggressive toolpaths
-
Consider what was happening immediately before the fault
Step 2: Inspect wiring and connections
-
Power down and unplug the VFD
-
Inspect motor wiring for shorts or damage
-
Check terminals for looseness or overheating signs
Step 3: Review acceleration and deceleration settings
-
Ensure acceleration is not excessively aggressive
-
Increase deceleration time if necessary
-
Avoid abrupt stops under load
Improper ramp settings can contribute to internal stress.
Step 4: Verify input power quality
-
Confirm supply voltage is within specification
-
Check for unstable or noisy power
-
Avoid sharing circuits with high-current equipment
What ERR16 Is Not
-
Not a communication error
-
Not a simple configuration mismatch
-
Not a controller software issue
-
Not EMI related
ERR16 indicates a serious protection event, not a nuisance fault.
When Technical Support Is Required
If ERR16:
-
Occurs repeatedly
-
Appears immediately on power-up
-
Persists after correcting over-current or over-voltage causes
Then the VFD may require professional evaluation or replacement.
At that stage, technical support involvement is appropriate.
Summary
ERR16 means the VFD has detected an internal hardware protection fault, typically caused by severe over-current or over-voltage conditions.
Most common triggers:
-
Tool crashes or stalls
-
Aggressive ramp settings
-
Power quality issues
-
Repeated unresolved fault conditions
Start by addressing over-current and over-voltage causes.
If the fault persists, hardware service or replacement may be required.
