The upcoming fault message shows the following information:


Date/time (1)Time at the time the fault occurred
Alarm type (2)

S = System alarm (operation monitoring, function monitoring, component malfunction)

G = Limit value alarm (temperature monitoring, flow monitoring)

W = Maintenance alert (integrated maintenance request)

operating mode (3) Operating mode at the time the fault occurred

ID (4)

Fault ID
Assistance (5)Help text for the alarm with possible causes of malfunction

Disturbance overview


The last 100 fault messages that occurred can be displayed as follows:

  1. Select [Alarm Logbook].

  2. Select the desired fault message.

  3. Tap on the button () to open and display the fault message.

NOTE!

The fault messages are sorted according to the time the fault occurred (last fault at the top).

commissioning after the fault has been resolved

After the fault has been rectified, the following steps must be carried out to restart:

  1. Reset emergency stop devices.
  2. Acknowledge the fault by tapping the button () or by swiping to the left.
  3. Make sure there are no people in the hazardous area.
  4. Start up The unit in accordance with the instructions in the Quick operation Guide.

Disturbance table

ID

faultAlert levelPossible cause

E010

pump overcurrent

33
  • Mains voltage too high?
  • Nominal current correct?
  • Wiring/pump connection correct?
  • Smooth impeller and motor mount?
  • Short circuit in the motor winding?

E012

ZSM overcurrent heating

33
  • Heating defective (short circuit)?
  • Mains voltage too high?

E013

ZSM undercurrent heating

13
  • Mains voltage too low?
  • Unplugged cable or broken line?
  • Heating thermostat triggered?
  • Heating defective?

E014

phase missing frequency converter

33
  • fuse FU 1, FU 2 or FU 3 blown out?
  • Phase L1, L2, or L3 interrupted?
  • Cable X105 unplugged, broken cable, or poor contact between cable and frequency converter?
E014.1Phase missing L133
  • Phase L1 interrupted?
  • Is the ZSM-61 wiring correct?
  • ZSM-61 current measurement board defective?

E016

Frequency converter error

33
  • Write down the error code from the frequency converter and contact your HB-Therm country representative!

E017

ZSM solid-state relay fault

35
  • solid-state relay defective (contact does not close)?
  • ZSM-61 current measurement board defective?

E018

ZSM internal error

30
  • Replace ZSM-61 current measurement board

E020

Temperature limit

5
  • Controller on external sensor?
  • Inadequate cooling capacity?
  • Severe overswing (optimize control parameter)?
  • Set the limiting temperature too low?
  • unit disconnected directly from Mains voltage during heating (main switch OFF, power interruption)? → Background information
  • Cooler control defective?
  • Temperature sensor incorrectly calibrated?
  • Temperature sensor defective?

E021

Overtemperature circuit

33
  • Inadequate cooling capacity?
  • unit disconnected directly from Mains voltage during heating (main switch OFF, power interruption)? → Background information
  • Is the temperature limiter defective in the ST 1 Main line?
  • Temperature sensor incorrectly calibrated?
  • Temperature sensor defective?

E022

sensor failure main line

30
  • Cable X33.1 unplugged, cable break, or poor contact between cable and unit board GIF-61?
  • BT 1 temperature sensor defective?
  • GIF-61 unit board defective?

E023

sensor failure return line

30
  • Cable X33.2 unplugged, cable break, or poor contact between cable and unit board GIF-61?
  • BT 2 temperature sensor defective?
  • GIF-61 unit board defective?

E024

sensor failure external

10
  • Temperature sensor unplugged external or defective?
  • Cable X23 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • ZE-61 external sensor board defective?
  • GIF-61 unit board defective?

E025

External sensor failure comp.

10
  • ZE-61 external sensor board defective?
  • GIF-61 unit board defective?

E026

sensor failure cooler

10
  • Cable X36.1 unplugged, cable break, or poor contact between cable and unit board GIF-61?
  • BT 6 temperature sensor defective?
  • GIF-61 unit board defective?

E030

System pressure too high

20
  • Water drain blocked?
  • YV 1 air relief valve dirty or defective?
  • drain pressure too high?
  • BP 1 pressure sensor incorrectly calibrated?
  • BP 1 pressure sensor defective?

E031

System pressure too low

33
  • Water supply and minimum pressure available?
  • Filter screen (3) clogged in the cooling water inlet
  • Are the quick couplings used closed or clogged?
  • leakage or hose rupture?
  • YV 1 air relief valve leaking?
  • M 2 filling pump defective?
  • BP 1 pressure sensor incorrectly calibrated?
  • BP 1 pressure sensor defective?

E032

sensor failure pressure BP 1

33
  • Cable X31.1 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • BP 1 pressure sensor defective?
  • GIF-61 unit board defective?

E033

sensor failure pressure BP 2

33
  • Cable X31.2 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • BP 2 pressure sensor defective?
  • GIF-61 unit board defective?
E035hose rupture33
  • leakage or hose rupture?

E036

sensor failure pressure BP 3

10
  • Cable X31.3 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • BP 3 pressure sensor defective?
  • GIF-61 unit board defective?

E041

initial fill period exceeded

33
  • Water supply available?
  • connections correctly attached?
  • Network water pressure too low?
  • Large external volume? (--> Acknowledge the fault and restart)
  • leakage or hose rupture?

E042

Refill volume exceeded

33
  • Is there a leakage?
  • YV 1 air relief valve leaking?
E045Leak stop interrupted33
  • Leakage too big?
  • Several leakage points?
  • Is the pressure drop in the system water circuit too great?

E050

Flow rate zero

33
  • External valve closed?
  • Integrated return line filter (3.1) or external filter clogged?
  • Does the M 1 pump deliver the heat transfer medium?

E051

invalid flow rate

33
  • Inadequate air relief?
  • Is the return line filter clogged? → Background information
  • Evaporation in the Return line due to a small cross section? → Background information
  • sonic transducer cable X53.1 and X53.2 unplugged or poor contact at the connectors?
  • sonic transducer defective?
  • GIF-61 unit board defective?
E052GIF-DMS communication error33
  • GIF-61 unit board defective?

E060

GIF-USR communication error

33
  • GIF-61 unit board defective?
  • Control board-USR-61 defective?
E061

Communication failure Flow

33
  • Control cable HB plugged in?
  • HB control cable defective?
  • USR-61 control board defective?
  • DFM-51/52 control board defective?
E062Remote cable unplugged13
  • Control cable connected?
  • Control cable defective?
  • Missing bridges in the control cable?

E065

communic. Disturbed FU

33
  • X100/X202 cable between the U 1 frequency converter and the PSU-61 power supply board unplugged, broken cable or poor contact at the connectors?
  • X216/X312 cable between the U 1 frequency converter and the ZSM-61 current measurement board unplugged, broken cable or poor contact at the plug connections?
  • U 1 frequency converter defective?
  • GIF-61 unit board defective?

E066.n

communication disturbed ZSM

30
  • Unplugged the X310/X41 cable between the ZSM-61 current measurement board board and the GIF-61 unit board, broken cable or poor contact at the connectors?
  • ZSM-61 current measurement board?
  • GIF-61 unit board?

E067

Pump speed is below

33
  • Check the type of unit in the information system with information on the nameplate
  • U 1 frequency converter defective?
  • M 1 pump motor defective?
E068no gate connection13
  • Network cable plugged in?
  • Network cable defective?
E069Multiple Gate-6 found13
  • There may only be one Gate-6 available on the same network.
E072remote address conflict11

Several Thermo-6 units with the same remote control address were found in the network.

  • Check the remote control addresses and resolve the address conflict.
E073address conflict Flow11

Several flow meter with the same identification and the same address range were found.

  • Check the ID and address range and resolve the address conflict.

E075

Overtemperature Gate-6

13
  • ambient temperature too high?
E079Database faulty03

The historical data database is faulty. The data can no longer be saved, displayed, or exported. The system must be rebooted to troubleshoot. The database is automatically deleted and re-created.

  • Restart the system to correct the error (turn the main switch off/on).
  • For error analysis, please export the analysis data after restarting the system and send it to your country representative.

E080

undercurrent step motor KV 1

10
  • Cable X32.1 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • M 3 step motor defective?
  • GIF-61 unit board defective?

E081

undercurrent step motor KV 2

10
  • Cable X32.2 unplugged, cable break or poor contact between cable and unit board GIF-61?
  • M 4 step motor defective?
  • GIF-61 unit board defective?

E082

Overcurrent step motor KV 1

30
  • M 3 step motor defective (short circuit)?
  • GIF-61 unit board defective?

E083

Overcurrent step motor KV 2

30
  • M 4 step motor defective (short circuit)?
  • GIF-61 unit board defective?

E087

Fan speed fell below

13
  • Cable X24 unplugged, broken cable or poor contact between cable and GIF-61 unit board?
  • EV 1 fan defective?
  • EV 1 fan blocked?
  • GIF-61 unit board defective?

E088

Main contactor control KM 1

33
  • Cable X51.2 unplugged, broken cable or poor contact between main contactor and unit board GIF-61?
  • KM 1 main contactor defective?
  • GIF-61 unit board defective?
E089Overtemperature electrical part13
  • Is the filter mat (28) dirty on bottom of unit?
  • EV 1 fan defective?
  • ambient temperature too high?
  • GIF-61 unit board defective?
E095Update error GIF33
  • GIF-61 unit board defective?
E096.nZSM update error33
  • ZSM-61 current measurement board defective?
E097Soft-/hardware incompatible33

The software is not compatible with the hardware-version GIF-61.

  • Update the software to the latest version.

The latest software can be purchased via the e-cockpit mobile app or from the HB-Therm country representative.

E098Soft-/hardware incompatible33

The software is not compatible with the ZSM-61 hardware-version.

  • Update the software to the latest version.

The latest software can be purchased via the e-cockpit mobile app or from the HB-Therm country representative.

E099Invalid configuration31
  • Select [Service] > [Configuration]. The configuration must be carried out in accordance with the information on the unit's nameplate. Access is via the code “1.2.”.
E120upper temperature deviation10
  • Cooling capacity insufficient (cooling water supply)?
  • Parameter limit value (upper set/actual deviation) set too low?
  • control parameter (P, I, D) not set optimally?
  • Heating control defective?
E121lower temperature deviation10
  • Inadequate heating capacity?
  • Parameter limit value (lower set/actual deviation) set too high?
  • control parameter (P, I, D) not set optimally?
  • Is the cooling water valve leaking?
E122return/main difference10
  • flow rate too low?
  • Parameter limit value (return/main difference) set too low?
E124Temperature difference deviation13
  • Parameter limit value (set/actual difference deviation) set too low?
  • Is the return line filter clogged?
  • Quick couplings closed or clogged?
  • tool mould clogged?
  • Pump performance limit reached (increase the Set temperature difference)?
E150flow rate too big10
  • Limit value (maximum flow rate) set too low?
E151flow rate too low10
  • Main line (closed ball valve)?
  • Is the return line filter clogged?
  • Parameter limit (minimal flow rate) set too high?
E152flow rate deviation above10
  • Parameter limit value (upper set/actual deviation) set too low?
  • Has the pump's performance limit been reached (increase the Set flow rate)?
E153flow deviation below10
  • Limit value (lower set/actual deviation) set too low?
  • Is the return line filter clogged?
  • Quick couplings closed or clogged?
  • Has the pump's performance limit been reached (reduce the Set flow rate)?
E201maintenance pump13

The maintenance interval for the pump has been exceeded.

  • Check the pump and carry out maintenance if necessary
  • Reset the maintenance interval after maintenance has been performed.

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E203.1Heating maintenance13

The maintenance interval for the Heating has been exceeded.

  • Check the heating system and carry out maintenance if necessary
  • Reset the maintenance interval after maintenance has been performed.

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E204maintenance cooler13

cooler maintenance interval exceeded

  • Check the cooler and carry out maintenance if necessary
  • Reset the maintenance interval after maintenance has been performed.

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E206maintenance cooling water filter13

The maintenance interval for the cooling water filter has been exceeded.

  • Clean or replace the cooling water filter
  • Reset maintenance interval after maintenance has been performed

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E207maintenance return line filter13

The maintenance interval for the return line filter has been exceeded.

  • Clean or replace the return line filter
  • Reset maintenance interval after maintenance has been performed

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E208maintenance fan13

The fan maintenance interval has been exceeded.

  • Clean filter mat
  • Check and clean the fan
  • Reset maintenance interval after maintenance has been performed

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E210maintenance fill valve13The maintenance interval for the filling valve has been exceeded.
  • Check the valve and carry out maintenance if necessary
  • Reset maintenance interval after maintenance has been performed

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E211maintenance air relief valve13

The maintenance interval for the air relief valve has been exceeded.

  • Check the valve and carry out maintenance if necessary
  • Reset maintenance interval after maintenance has been performed

(Until then, the warning icon will be displayed in the tab bar of the standard display)

E301Filling valve not recognized33
  • YV 1 magnetic coil defective?
  • X51.4 cable defective?
  • GIF-61 unit board defective?
E302air relief valve not recognized33
  • YV 1 magnetic coil defective?
  • X51.3 cable defective?
  • GIF-61 unit board defective?
E310Voltage 15 VAC is missing33
  • Cable X16 from transformer TC1 to unit board GIF-61 unplugged, broken cable, or poor contact?
  • GIF-61 unit board defective?
  • TC 1 transformer defective?

E311, E312, E313, E314

Voltage xx VDC outside Tolerance03
  • GIF-61 unit board defective?
E900.nnflow rate too low
(external flow meter)		10
  • circuit clogged?
  • Parameter limit (minimal flow rate) set too high?
  • Adjustment valve not opened enough?
E901.nnflow rate too big
(external flow meter)
10
  • Parameter limit (maximum flow rate) set too low?
E902.nnreturn/main difference
(external flow meter)
10
  • Heat transfer tool mould bad?
  • flow rate too low?
  • Parameter limit value (return/main difference) set too low?
  • Adjustment valve not opened enough?
E903.nnsensor failure return line (external flow meter)
10
  • Temperature sensor unplugged, cable break, or poor contact between cable and unit board DFM-51/52?
  • Temperature sensor defective?
  • DFM-51/52 unit board defective?
E904.nnsensor failure main line (external flow meter)
10
  • Temperature sensor unplugged, cable break, or poor contact between cable and unit board DFM-51/52?
  • Temperature sensor defective?
  • DFM-51/52 unit board defective?

Background information on possible causes of faults

The unit is directly disconnected from the Mains voltage during heating

Cause of the rise in temperature

The main line temperature rises sharply if the unit was heating at the time it was switched off (positive regulation ratio). Regardless of what caused the switch off (with/without pressure relief, mould evacuation, fault, main switch OFF or power failure). This rise in temperature is due to the stored energy in the heating system. Without circulation from the heat transfer medium (unit switched off), the water in the Heating absorbs the heat from the Heating. This behavior is physically determined and cannot be prevented, but only minimized.

The heating of the Thermo-6 units can store more energy than that of the Thermo-5 units, resulting in a higher temperature rise in the flow.

Depending on the main line temperature at which the unit is switched off and how high the Heating Capacity (positive regulation ratio was when switch off, the following error messages may occur:

  • edition error message E020 (temperature limit) main line
    temperature rises above the set limiting temperature +5 K. After the unit is switched on, it only starts heating when the temperatures (Main line, Return line and, if available, external) are lower than the set limiting temperature +5 K.
  • edition error message E021 (overtemperature circuit) main line
    temperature rises until the ST 1 temperature limiter triggers in the Main line. The unit can only be switch on again when the temperature in the Main line falls below the reset temperature of the ST 1 temperature limiter.

Possible measures

  • Avoiding uncontrolled shutdown due to abrupt interruption of the power supply (e.g. By main switch OFF)
  • Reducing the safety cooling temperature or mould evacuation temperature:
    → Select [Set values] > [Safety cooling temperature    ].
    → Select [Setting] > [Miscellaneous] > [Mould Evacuation Temperature].
    As a result, this first cools down to the set value before it switches off or starts emptying the mold. Active Cooling Before The Unit Is Switch Off Reduces The Stored Energy In The Heating And Thus Also Reduces The Temperature Rise In the flow.

Evaporation in the Return line with a small cross section

Cause of evaporation

If a component (nipple, coupling, etc.) whose inner diameter is small¹ is installed at the return connection, the water may evaporate due to a high flow rate. The resulting vapor bubbles interfere with the Flow rate measurement. As a result, individual incorrect measurements can occur up to a total failure of the Flow rate measurement.

With Thermo-6 units, this topic is the same as with Thermo-5 units. However, the Thermo-6 unit has a higher flow rate than the comparable Thermo-5 unit. For this reason, the majority of these problems are only found with the Thermo-6 unit.

¹ The diameter should be considered together with the flow rate. The flow rate can be calculated using the following formula:

→ flow rate [m/s] ≈ (flow [L/min] ÷ diameter [mm²]) × 21

If the flow rate is in the range of 10 m/s or higher, evaporation in water is possible.

In the case of couplings in particular, care should be taken that the term “DNx” does not necessarily correspond to the inner diameter of the flowing water (example: self-closing Hasco coupling DN9 has an inner diameter of 3-4 mm)! This is often significantly smaller. Especially with self-closing couplings, there are additional constrictions due to the built-in check valves.

Users who test the units in the service point using quick couplings (small cross section) and a direct connection between Main line and Return line could observe this behavior (many incorrect measurements or total failure of the Flow rate measurement).

Recognition

  • Constriction/small quick couplings at the return line
  • Many vents (created due to incorrect Flow rate measurement measurements)
  • invalid flow rate alarm (E051)

Possible measures

  • Remove constriction on Return line (recommended)
  • Reduce flow rate by reduction pump speed (if removal of constriction cannot be implemented)

Evaporation due to clogged filter screen

As with “evaporation in the Return line with small cross-sections,” a clogged filter screen can also lead to a very high flow rate. The scenario is the same.

Recognition

  • with additional ZF equipment: filter screen maintenance >100%

Possible measures

  • Clean the filter screen on the return line
  • Shorten the maintenance interval (without additional ZF equipment):
     → Select [Service] > [Parameter] > [Maintenance] > [Return Line Filter Limit factor]