Category: LS

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Table of Contents

1. Introduction
2. Basic Concept of AL-09 Overload Fault 2.1 What is AL-09 Overload Fault? 2.2 Common Manifestations of AL-09 Fault
3. Structure and Working Principle of LS Servo Drive APD-VP Series 3.1 Hardware Structure of APD-VP Series Servo Drive 3.2 Control Logic and Feedback Mechanism of Servo Drive 3.3 Working Principle of Overload Protection Mechanism
4. Causes of AL-09 Fault 4.1 Mechanical Load Abnormalities 4.2 Electrical Parameter Setting Errors 4.3 Motor or Encoder Failures 4.4 Power Supply Issues 4.5 Environmental Factors
5. Diagnostic Steps for AL-09 Fault 5.1 Preliminary Inspection 5.2 Mechanical System Inspection 5.3 Electrical Parameter Inspection 5.4 Motor and Encoder Inspection 5.5 Power Supply and Wiring Inspection
6. Solutions for AL-09 Fault 6.1 Optimization and Adjustment of Mechanical Load 6.2 Reconfiguration of Electrical Parameters 6.3 Maintenance and Replacement of Motor and Encoder 6.4 Improvement of Power Supply Stability 6.5 Control of Environmental Factors
7. Preventive Measures for AL-09 Fault 7.1 Regular Maintenance and Upkeep 7.2 Parameter Backup and Optimization 7.3 Runtime Monitoring and Alarm System
8. Case Studies 8.1 Case Study 1: AL-09 Fault Caused by Mechanical Jamming 8.2 Case Study 2: AL-09 Fault Caused by Parameter Setting Errors 8.3 Case Study 3: AL-09 Fault Caused by Unstable Power Supply
9. Conclusion and Recommendations
10. References

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1. Introduction

In the field of modern industrial automation, servo drives are core components for precise motion control, widely used in robotic arms, CNC machines, packaging machinery, and other equipment. The LS Electric APD-VP series servo drives are renowned for their high performance, reliability, and flexible control methods. However, in practical applications, servo drives may encounter various faults, with AL-09 overload faults being one of the most common issues. AL-09 faults not only cause equipment downtime but also severely impact the continuity and quality of production lines. Therefore, a deep understanding of the causes, diagnostic methods, and solutions for AL-09 faults is of significant practical importance for engineers and technicians.

This article comprehensively analyzes the causes, diagnostic steps, solutions, and preventive measures for AL-09 overload faults in the LS servo drive APD-VP series. It also validates these through practical case studies, aiming to provide a systematic and practical reference guide for relevant technical personnel.

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2. Basic Concept of AL-09 Overload Fault

2.1 What is AL-09 Overload Fault?

AL-09 is an alarm code for LS servo drives, indicating an overload fault (Over Load). When the load on the servo motor exceeds its rated capacity during operation, the drive triggers the overload protection mechanism and displays the AL-09 alarm. Overload faults can be caused by various factors, including mechanical load abnormalities, electrical parameter setting errors, motor or encoder failures, and power supply issues.

2.2 Common Manifestations of AL-09 Fault

When a servo drive encounters an AL-09 fault, the following phenomena typically occur:

1. The drive’s display shows the “AL-09” alarm code.
2. The servo motor stops operating and cannot continue executing motion commands.
3. The alarm indicator light turns on, usually red or yellow.
4. The system may be accompanied by abnormal noises, such as motor humming or mechanical friction sounds.
5. The upper-level machine or PLC may receive alarm signals, causing the entire control system to shut down.

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3. Structure and Working Principle of LS Servo Drive APD-VP Series

3.1 Hardware Structure of APD-VP Series Servo Drive

The LS servo drive APD-VP series adopts a modular design, primarily consisting of the following components:

1. Main Circuit Board: Includes IGBT inverters, PWM control circuits, current/voltage detection circuits, etc., responsible for converting input AC power into controllable three-phase AC power to drive the servo motor.
2. Control Circuit Board: Contains core control chips such as DSP (Digital Signal Processor) and FPGA (Field-Programmable Gate Array), responsible for motion control algorithms, parameter settings, communication interfaces, etc.
3. Interface Board: Provides various input/output interfaces, including analog input/output, pulse input, encoder feedback interfaces, etc., for communication with upper-level machines, PLCs, sensors, and other devices.
4. Power Supply Module: Supplies stable DC power to the internal circuits of the drive.
5. Cooling System: Includes heat sinks and fans to ensure stable operation of the drive under high loads.

3.2 Control Logic and Feedback Mechanism of Servo Drive

The APD-VP series servo drive employs a closed-loop control method, achieving precise motion control through the following steps:

1. Command Input: The upper-level machine (such as PLC or motion controller) sends motion commands (position, speed, or torque commands) to the drive.
2. Control Algorithm: The internal DSP of the drive calculates the control output based on the commands and feedback signals (such as encoder pulses and current sensor signals).
3. PWM Modulation: The control algorithm outputs PWM signals to drive the IGBT inverter, converting the DC bus voltage into variable frequency and amplitude three-phase AC power.
4. Motor Drive: The three-phase AC power drives the servo motor.
5. Feedback Detection: The encoder detects the motor’s position and speed in real-time, and the current sensor detects the actual current of the motor, sending feedback signals to the drive.
6. Closed-Loop Adjustment: The drive compares the commands and feedback signals and adjusts the output through the PID controller to achieve precise control.

3.3 Working Principle of Overload Protection Mechanism

The APD-VP series servo drive is equipped with an overload protection mechanism, which operates as follows:

1. Current Detection: The drive monitors the phase current of the motor in real-time. When the current exceeds the rated value, it triggers overload protection.
2. Torque Calculation: The drive calculates the actual output torque based on the current and motor parameters (such as torque constant). When the torque exceeds the set torque limit ([PE-205], [PE-206]), it triggers overload protection.
3. Load Monitoring: The drive calculates the actual load on the motor through encoder feedback and current detection. When the load exceeds the rated load (typically 300% of the rated torque), it triggers the AL-09 alarm.
4. Protection Action: Once overload protection is triggered, the drive immediately cuts off the PWM output, stopping the motor and displaying the AL-09 alarm code.

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4. Causes of AL-09 Fault

The causes of AL-09 overload faults are diverse and can be categorized as follows:

4.1 Mechanical Load Abnormalities

Mechanical load abnormalities are the most common cause of AL-09 faults, including:

1. Mechanical Jamming: Transmission mechanisms (such as gears, guides, and screws) may jam or experience excessive friction, preventing the motor from rotating normally.
2. Excessive Load: The actual load exceeds the motor’s rated load capacity, such as overweight workpieces or unreasonable mechanical design.
3. Coupling Misalignment: The motor shaft and load shaft are misaligned, resulting in additional radial or axial forces that increase the motor load.
4. Insufficient Lubrication: Transmission components lack lubrication, increasing friction and motor load.

4.2 Electrical Parameter Setting Errors

Incorrect parameter settings in the drive can directly affect the motor’s operating state. Common parameter setting errors include:

1. Torque Limit Set Too Low: [PE-205] (CCW Torque Limit) and [PE-206] (CW Torque Limit) are set too low, causing the motor to trigger overload protection under normal loads.
2. Incorrect Gain Parameter Settings: Speed proportional gain ([PE-307], [PE-308]) or position proportional gain ([PE-302], [PE-303]) are set too high, leading to system oscillation or overload.
3. Electronic Gear Ratio Error: [PE-701] (Electronic Gear Ratio) is set incorrectly, causing a mismatch between pulse commands and actual positions, resulting in overload.
4. Encoder Pulse Number Setting Error: [PE-204] (Encoder Pulse Number) does not match the actual encoder, leading to incorrect feedback signals and triggering overload protection.

4.3 Motor or Encoder Failures

Failures in the motor or encoder can also cause AL-09 alarms:

1. Motor Winding Short Circuit or Open Circuit: Internal winding damage in the motor causes abnormal current increases.
2. Encoder Signal Loss or Error: Encoder damage or loose wiring causes interruption or error in feedback signals.
3. Motor Bearing Damage: Worn or jammed bearings increase the motor’s rotational resistance.

4.4 Power Supply Issues

The stability of the power supply directly affects the operation of the drive and motor:

1. Voltage Fluctuations: Unstable input voltage, such as overvoltage or undervoltage, causes abnormal drive output.
2. Poor Power Line Contact: Loose or oxidized power lines cause excessive voltage drops.
3. Regenerative Resistor Failure: Damaged regenerative resistors or incorrect parameter settings prevent effective absorption of regenerative energy, leading to overvoltage or overload.

4.5 Environmental Factors

Environmental factors can indirectly cause AL-09 faults:

1. High Temperature: Operation of the drive or motor in high-temperature environments leads to poor heat dissipation and performance degradation.
2. Humidity or Corrosive Gases: Moisture or corrosive environments may cause short circuits or poor contact in the circuit board.
3. Vibration or Impact: Mechanical vibration or impact may loosen or damage internal components of the drive.

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5. Diagnostic Steps for AL-09 Fault

When the APD-VP series servo drive displays an AL-09 fault, follow these steps for diagnosis:

5.1 Preliminary Inspection

1. Confirm Alarm Code: Verify that the alarm code displayed on the drive is AL-09.
2. Check Mechanical Load: Manually rotate the motor shaft to confirm if there is jamming or abnormal resistance.
3. Check Power Supply: Ensure the input voltage is within the allowed range (AC200-230V) and the power line is normal.

5.2 Mechanical System Inspection

1. Inspect Transmission Mechanism:
   • Ensure gears, guides, screws, and other transmission components are well-lubricated and free from jamming.
   • Check if the coupling is aligned and free from offset or deformation.
2. Check Load:
   • Confirm that the load is within the motor’s rated range, such as workpiece weight and mechanical friction.
   • Reduce the load and observe if the fault disappears.

5.3 Electrical Parameter Inspection

1. Check Torque Limit:
   • Enter menus [PE-205] and [PE-206] to confirm if the torque limit is set too low.
   • If the torque limit is too low, increase the setting appropriately (usually not exceeding 300%).
2. Check Gain Parameters:
   • Check if the speed proportional gain ([PE-307], [PE-308]) and position proportional gain ([PE-302], [PE-303]) are too high.
   • If the gain is too high, gradually reduce the gain value and observe if the fault disappears.
3. Check Electronic Gear Ratio:
   • Ensure [PE-701] (Electronic Gear Ratio) matches the mechanical transmission ratio.
4. Check Encoder Settings:
   • Ensure [PE-204] (Encoder Pulse Number) matches the motor nameplate.

5.4 Motor and Encoder Inspection

1. Inspect Encoder:
   • Ensure encoder wiring is secure and free from breaks or short circuits.
   • Use an oscilloscope to check encoder signals (A, B, Z phases) for normality.
2. Inspect Motor:
   • Measure the insulation resistance of the motor windings to ensure no short circuits or open circuits.
   • Manually rotate the motor shaft to ensure bearings are free from abnormal noises or jamming.

5.5 Power Supply and Wiring Inspection

1. Check Power Supply:
   • Use a multimeter to measure the input voltage, ensuring it is within the AC200-230V range.
   • Check the power line for poor contact or oxidation.
2. Check Regenerative Resistor:
   • Ensure the regenerative resistor is connected correctly and parameters are set reasonably.
   • Check if the regenerative resistor is damaged and if the resistance value is normal.

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6. Solutions for AL-09 Fault

Based on the diagnostic results, the following solutions can be implemented:

6.1 Optimization and Adjustment of Mechanical Load

1. Reduce Load:
   • Lighten the workpiece weight or optimize the mechanical structure to reduce the motor load.
2. Lubricate Transmission Components:
   • Regularly add lubricating oil or grease to gears, guides, screws, and other transmission components.
3. Adjust Coupling:
   • Ensure the motor shaft and load shaft are aligned to avoid radial or axial forces.

6.2 Reconfiguration of Electrical Parameters

1. Adjust Torque Limit:
   • Based on the actual load, appropriately increase the torque limit values in [PE-205] and [PE-206].
2. Optimize Gain Parameters:
   • Gradually reduce the speed proportional gain ([PE-307], [PE-308]) and position proportional gain ([PE-302], [PE-303]) to avoid system oscillation.
3. Recalibrate Electronic Gear Ratio:
   • Reset [PE-701] (Electronic Gear Ratio) according to the mechanical transmission ratio.

6.3 Maintenance and Replacement of Motor and Encoder

1. Replace Damaged Encoder:
   • If the encoder signal is abnormal, replace it with a new one and ensure correct wiring.
2. Repair or Replace Motor:
   • If the motor windings or bearings are damaged, send them for repair or replace them with new ones.

6.4 Improvement of Power Supply Stability

1. Stabilize Power Voltage:
   • Use a voltage regulator or UPS (Uninterruptible Power Supply) to ensure stable input voltage.
2. Check Power Line:
   • Ensure the power line is in good contact and free from oxidation.

6.5 Control of Environmental Factors

1. Improve Cooling Conditions:
   • Ensure the cooling fans of the drive and motor operate normally to avoid high-temperature environments.
2. Prevent Moisture and Corrosion:
   • In humid or corrosive environments, take protective measures such as sealing the drive cabinet.

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7. Preventive Measures for AL-09 Fault

To prevent the occurrence of AL-09 faults, the following measures can be taken:

7.1 Regular Maintenance and Upkeep

1. Regularly Inspect Mechanical Transmission Components:
   • Check the wear and lubrication of gears, guides, screws, and other components.
2. Regularly Clean Drive and Motor:
   • Remove dust and debris to ensure good heat dissipation.
3. Regularly Check Electrical Connections:
   • Ensure all terminal connections are secure and free from oxidation or loosening.

7.2 Parameter Backup and Optimization

1. Backup Drive Parameters:
   • Regularly back up the drive’s parameter settings for quick recovery after faults.
2. Optimize Parameter Settings:
   • Optimize parameters such as gain and torque limit based on actual load and operating conditions.

7.3 Runtime Monitoring and Alarm System

1. Real-Time Monitoring of Operating Status:
   • Use upper-level machines or PLCs to monitor motor current, speed, position, and other parameters in real-time.
2. Set Alarm Thresholds:
   • Set reasonable alarm thresholds in the drive to detect and handle abnormalities promptly.

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8. Case Studies

8.1 Case Study 1: AL-09 Fault Caused by Mechanical Jamming

Fault Phenomenon: A CNC machine suddenly stopped during operation, and the drive displayed an AL-09 alarm. Manual rotation of the motor shaft revealed significant jamming in the screw transmission.

Diagnostic Process:

1. Inspected the mechanical transmission and found that the screw guide lacked lubrication, causing excessive friction.
2. Checked the drive parameters and found that the torque limit settings were normal.

Solution:

1. Added lubricating oil to the screw guide.
2. Adjusted the coupling alignment to reduce radial forces.
3. Reset the alarm, and the equipment resumed normal operation.

Experience Summary: Mechanical jamming is a common cause of AL-09 faults. Regular maintenance and lubrication of transmission components are crucial.

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8.2 Case Study 2: AL-09 Fault Caused by Parameter Setting Errors

Fault Phenomenon: An automated production line frequently displayed AL-09 alarms during debugging, and the motor failed to start normally.

Diagnostic Process:

1. Inspected the mechanical load and found no abnormalities.
2. Checked the drive parameters and found that the speed proportional gain ([PE-307]) was set too high, causing system oscillation.

Solution:

1. Gradually reduced the speed proportional gain until the system stabilized.
2. Optimized other control parameters, such as the integral time constant ([PE-309]).
3. Reset the alarm, and the equipment operated normally.

Experience Summary: Parameter setting errors are another significant cause of AL-09 faults. During debugging, parameters should be adjusted gradually to avoid excessive settings.

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8.3 Case Study 3: AL-09 Fault Caused by Unstable Power Supply

Fault Phenomenon: A packaging machine suddenly stopped during operation, and the drive displayed an AL-09 alarm. Inspection revealed significant voltage fluctuations in the input power.

Diagnostic Process:

1. Used a multimeter to measure the input voltage, which fluctuated between 180V and 250V.
2. Inspected the power line and found poor contact causing excessive voltage drops.

Solution:

1. Replaced the power line to ensure good contact.
2. Added a voltage regulator to stabilize the input voltage.
3. Reset the alarm, and the equipment resumed normal operation.

Experience Summary: Unstable power supply can cause abnormal drive output, triggering overload protection. Ensuring power stability is key to preventing AL-09 faults.

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9. Conclusion and Recommendations

AL-09 overload faults are common issues in the LS servo drive APD-VP series in practical applications. Through this analysis, we can draw the following conclusions:

1. AL-09 faults have diverse causes, including mechanical load abnormalities, electrical parameter setting errors, motor or encoder failures, power supply issues, and environmental factors.
2. Diagnosing AL-09 faults requires a systematic approach, involving inspections from mechanical, electrical, and environmental perspectives.
3. Solving AL-09 faults requires targeted measures, such as optimizing mechanical loads, adjusting electrical parameters, maintaining motors and encoders, and stabilizing power supplies.
4. Preventing AL-09 faults requires proactive measures, including regular maintenance, parameter optimization, and runtime monitoring.

Recommendations:

1. Establish Equipment Maintenance Records: Document the equipment’s operating status, fault history, and maintenance activities.
2. Regularly Train Operators: Enhance their ability to diagnose and handle servo drive faults.
3. Introduce Remote Monitoring Systems: Monitor equipment operating status in real-time to detect and address abnormalities promptly.

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The LG (now LS) iC5 series inverter is a versatile and reliable variable frequency drive designed for precise motor control in various industrial applications. This guide provides a comprehensive overview of using the iC5 series inverter, focusing on the operation panel functions, parameter initialization, parameter access restrictions, password management, external terminal control for forward/reverse operation, external potentiometer frequency control, and fault code troubleshooting. This article aims to help users effectively operate and maintain the iC5 inverter based on the provided manual.

1. Operation Panel Functions and Parameter Management

Operation Panel Overview

The operation panel of the LG iC5 series inverter is a critical interface for configuring and monitoring the device. It features a 7-segment LED display, status LEDs, and multiple keys for navigation and control:

• LED Display and Indicators:
  • FWD LED: Illuminates during forward operation and flashes when a fault occurs.
  • REV LED: Illuminates during reverse operation.
  • 7-Segment LED Display: Shows operational status, parameter codes, and values.
• Keys:
  • Run Key: Initiates inverter operation.
  • Stop/Reset Key: Stops the inverter or resets faults.
  • Four-Directional Keys (Up/Down/Left/Right): Used for navigating parameter groups, selecting codes, or adjusting values.
  • Prog/Ent Key: Confirms parameter settings or saves changes.
  • Potentiometer: Adjusts the running frequency manually.

The panel organizes parameters into four groups: Drive Group (basic parameters like target frequency and acceleration/deceleration times), Function Group 1 (basic frequency and voltage adjustments), Function Group 2 (advanced features like PID control), and I/O Group (input/output terminal settings).

Parameter Initialization

Parameter initialization resets all parameters to factory defaults, which is useful when troubleshooting or reconfiguring the inverter. To initialize parameters in the Function Group 2 at parameter H93:

1. Navigate to H0: Access Function Group 2 by pressing the Right key repeatedly until “H 0” is displayed.
2. Enter H93: Press the Prog/Ent key, then use the Up key to set the code to “93” (adjust digits with Left/Right keys as needed). Confirm with Prog/Ent.
3. Set Initialization: The default value is “0”. Use the Up key to change it to “1” to enable initialization, then press Prog/Ent. The display will flash, indicating completion.
4. Return to H0: Press Left or Right to return to the first code of Function Group 2.

Note: After initialization, all parameters revert to factory settings, requiring re-configuration for specific applications.

Parameter Access Restrictions and Password Management

To prevent unauthorized changes, the iC5 series allows setting parameter access restrictions and passwords:

• Setting Parameter Access Restrictions:
  • In Function Group 2, navigate to H94 (Parameter Lock).
  • Press Prog/Ent, set a value (e.g., “1” for lock), and confirm. This restricts access to parameter modifications until unlocked.
  • To unlock, return to H94, set the value to “0”, and confirm.
• Setting a Password:
  • Navigate to H95 in Function Group 2.
  • Press Prog/Ent, enter a desired password (e.g., a number between 0 and 9999) using Up/Down and Left/Right keys, then confirm with Prog/Ent.
  • The password will be required to access or modify parameters when H94 is locked.
• Removing a Password:
  • Access H95 and enter the current password.
  • Set the value to “0” and confirm with Prog/Ent to disable the password.
  • Ensure H94 is set to “0” to fully remove access restrictions.

Note: If the password is forgotten, contact LS technical support, as there is no user-accessible reset method.

2. External Terminal Control and Potentiometer Frequency Setting

Forward/Reverse Control via External Terminals

The iC5 series supports forward and reverse motor control using external terminals. The following steps outline the wiring and parameter settings:

• Wiring:
  • P1 (FX): Connect to a switch for forward run (I20 = 0, default setting for FX).
  • P2 (RX): Connect to a switch for reverse run (I21 = 1).
  • CM: Common terminal for P1 and P2.
  • Example: Wire a switch between P1 and CM for forward, and another between P2 and CM for reverse.
• Parameter Settings:
  • Drive Group, drv: Set to “1” (terminal control) to enable external terminal operation.
    • Navigate to “drv”, press Prog/Ent, set to “1”, and confirm.
  • I/O Group, I20: Ensure set to “0” (FX for forward run).
  • I/O Group, I21: Ensure set to “1” (RX for reverse run).
  • Function Group 1, F1: Set to “0” to enable both forward and reverse operations (if set to “1”, reverse is disabled).
• Operation:
  • Closing the P1-CM circuit initiates forward rotation.
  • Closing the P2-CM circuit initiates reverse rotation.
  • Ensure the frequency reference is set (e.g., via potentiometer or keypad).

External Potentiometer Frequency Control

To control the motor speed using an external potentiometer:

• Wiring:
  • VR: Provides 12V DC power for the potentiometer.
  • V1: 0-10V analog voltage input for frequency setting.
  • CM: Common terminal.
  • Connect a 1-5 kΩ potentiometer: one end to VR, the wiper to V1, and the other end to CM.
• Parameter Settings:
  • Drive Group, Frq: Set to “1” (V1: 0-10V input) for analog voltage frequency control.
    • Navigate to “Frq”, press Prog/Ent, set to “1”, and confirm.
  • I/O Group, I7-I10: Adjust analog input scaling if needed (e.g., I7 for minimum voltage, I8 for corresponding frequency).
    • Example: Set I7 = 0V, I8 = 0Hz; I9 = 10V, I10 = 60Hz for linear scaling.
  • Function Group 1, F21: Set the maximum frequency (e.g., 60Hz) to limit the frequency range.
• Operation:
  • Adjust the potentiometer to vary the voltage between 0-10V, which proportionally changes the output frequency from 0 to the maximum set frequency.

3. Fault Codes, Meanings, and Troubleshooting

The iC5 series inverter provides fault codes to diagnose issues, displayed on the operation panel. Below are common fault codes, their meanings, and troubleshooting steps:

• Over Current (OC):
  • Meaning: Output current exceeds 200% of rated current.
  • Causes: Short acceleration/deceleration times, excessive load, output short circuit, or mechanical brake issues.
  • Solution: Increase acceleration/deceleration times (Drive Group: ACC, dEC), upgrade inverter capacity, check output wiring, or adjust mechanical brakes.
• Ground Fault (GF):
  • Meaning: Ground fault current exceeds internal limits.
  • Causes: Faulty output wiring or motor insulation failure.
  • Solution: Inspect output wiring and replace the motor if insulation is damaged.
• Inverter Overload (IOL):
  • Meaning: Output current exceeds 150% for 1 minute.
  • Causes: Excessive load or incorrect inverter capacity.
  • Solution: Upgrade inverter/motor capacity or reduce load.
• Overload Protection (OL):
  • Meaning: Output current exceeds 150% for a set time.
  • Causes: Similar to inverter overload.
  • Solution: Adjust load, increase inverter capacity, or modify ETH settings (Function Group 1: F51, F52).
• Heat Sink Overheat (OH):
  • Meaning: Heat sink temperature is too high.
  • Causes: Cooling fan failure or high ambient temperature.
  • Solution: Clear heat sink obstructions, replace the fan, or maintain ambient temperature below 40°C.
• Output Phase Loss (OPL):
  • Meaning: One or more output phases (U, V, W) are open.
  • Causes: Faulty contactor or wiring issues.
  • Solution: Check output wiring and contactor functionality.
• Over Voltage (OV):
  • Meaning: DC bus voltage exceeds 400V during deceleration.
  • Causes: Short deceleration time or high line voltage.
  • Solution: Increase deceleration time (Drive Group: dEC) or use a dynamic braking unit.
• Low Voltage (LV):
  • Meaning: DC bus voltage drops below 200V.
  • Causes: Low input voltage or excessive load.
  • Solution: Verify input voltage and adjust bus capacity.
• Electronic Thermal Protection (ETH):
  • Meaning: Motor overheating detected.
  • Causes: Overloaded motor or low ETH settings.
  • Solution: Reduce load, adjust ETH settings (Function Group 1: F51, F52), or add external cooling.
• Parameter Save Error, Hardware Fault, Communication Error:
  • Meaning: Issues with parameter storage, control circuit, or panel communication.
  • Solution: Contact LS technical support for assistance.
• Cooling Fan Fault:
  • Meaning: Cooling fan malfunction.
  • Causes: Obstructions or fan wear.
  • Solution: Clear obstructions or replace the fan.
• External Fault A/B:
  • Meaning: Triggered by external signals (I20-I24 set to 18 or 19).
  • Solution: Remove external fault signal or correct wiring.
• Frequency Command Loss:
  • Meaning: Loss of analog or communication frequency reference.
  • Solution: Check V1/I wiring or communication settings (I/O Group: I62).

Conclusion

The LG iC5 series inverter is a robust solution for motor control, offering intuitive operation through its panel, flexible external control options, and comprehensive fault diagnostics. By understanding the operation panel functions, parameter management, external control setups, and fault troubleshooting, users can maximize the inverter’s performance and reliability. Regular maintenance, proper wiring, and adherence to the manual’s safety guidelines are essential for safe and efficient operation. For further details or support, refer to the official LS documentation or contact their technical support team.

I. Introduction to Operation Panel Functions and Password Setting/Locking

Introduction to Operation Panel Functions

The operation panel of the LS Inverter LSLV-M100 series integrates display and operation functions, facilitating intuitive operation and monitoring for users. The panel primarily consists of a digital tube display, indicator lights, and buttons. The digital tube is used to display operating status and parameter information, while the indicator lights indicate the current working status, such as running, forward rotation, reverse rotation, etc. The button section includes commonly used function buttons such as run, stop, and fault reset, as well as direction buttons and a confirmation button for parameter setting.

Password Setting and Elimination

To prevent unauthorized parameter modifications, the LSLV-M100 series inverter provides a password protection function. The specific steps for setting a password are as follows:

• Enter the configuration function group: First, access the configuration function group (typically identified by P700 series codes) through the panel operations.
• Select the password registration parameter: Within the configuration function group, locate the password registration parameter (e.g., P701).
• Enter the password: Use the panel’s direction buttons and confirmation button to input the password, which must consist of 1 to 16 hexadecimal characters.
• Save the settings: After inputting, press the confirmation button to save the settings.

The method for eliminating the password is similar to setting it. Simply change the password in the password registration parameter to the initial password (usually 0000) or leave it blank.

Parameter Locking

In addition to password protection, the LSLV-M100 series inverter also offers a parameter locking function. By locking the parameters, unintentional changes can be prevented. The specific steps are as follows:

• Enter the configuration function group: Same as for setting the password, first access the configuration function group.
• Select the parameter locking parameter: Locate the parameter locking parameter (e.g., P702).
• Lock the parameters: Set the parameter locking parameter to 1 to lock all settable parameters.
• Unlock the parameters: When needing to modify parameters, set the parameter locking parameter to 0 and enter the password to unlock.

II. Forward/Reverse Control via Terminals and Speed Adjustment with External Potentiometer

Forward/Reverse Control via Terminals

The LSLV-M100 series inverter supports forward/reverse control through multifunction input terminals. The specific wiring and settings are as follows:

• Wiring: Connect the forward control signal to a multifunction input terminal (e.g., IN1) and the reverse control signal to another multifunction input terminal (e.g., IN2).
• Parameter settings:
  • Enter the input terminal function group (e.g., P300 series).
  • Set the forward control terminal function (e.g., P301) to 1 (forward rotation).
  • Set the reverse control terminal function (e.g., P302) to 2 (reverse rotation).
  • In the operation group (e.g., P000 series), set the run command source to external terminals.

Speed Adjustment with External Potentiometer

External potentiometer speed adjustment is a commonly used method, where the output frequency of the inverter is changed by adjusting the resistance of the external potentiometer. The specific wiring and settings are as follows:

• Wiring: Connect the two ends of the external potentiometer to the analog input terminals of the inverter (e.g., V1 and GND).
• Parameter settings:
  • Enter the input terminal function group.
  • Set the analog input terminal function to voltage input (e.g., set P310 to 1 for voltage input).
  • In the operation group, set the frequency setting method to analog input (e.g., set P003 to 2 for analog voltage input).

III. Fault Codes and Solutions

The LSLV-M100 series inverter features a comprehensive fault code display function, helping users quickly identify fault causes. Below are some common fault codes, their meanings, and solutions:

• OC (Overcurrent): Indicates that the inverter’s output current exceeds the rated value. Possible causes include excessive load, motor stall, etc. Solutions include checking the load condition and adjusting the acceleration/deceleration time.
• OV (Overvoltage): Indicates that the DC bus voltage of the inverter is too high. Possible causes include excessive input voltage and faulty braking resistor. Solutions include adjusting the input voltage and checking the braking resistor.
• UV (Undervoltage): Indicates that the input voltage of the inverter is too low. Possible causes include unstable power supply voltage and phase loss in the input power supply. Solutions include checking the power supply voltage and the input power lines.
• OH (Overheat): Indicates that the temperature of the inverter’s heatsink is too high. Possible causes include high ambient temperature and faulty cooling fan. Solutions include reducing the ambient temperature and replacing the cooling fan.

For the above faults, users can follow the fault troubleshooting process outlined in the manual to identify and resolve issues one by one based on the inverter’s fault code prompts.

IV. Conclusion

As a high-performance variable frequency speed control device, the LSLV-M100 series inverter provides a detailed operation guide and fault troubleshooting methods in its user manual. By familiarizing themselves with the functions of the operation panel, mastering password setting and locking, understanding the wiring and settings for forward/reverse control via terminals and speed adjustment with an external potentiometer, and grasping the solutions to common fault codes, users can operate and maintain the inverter more efficiently, ensuring its stable operation and optimal performance.

I. Introduction to the Operation Panel Functions and Parameter Settings

Operation Panel Functions

The LS Inverter SV-iGxA series features an intuitive operation panel that includes RUN, STOP/RESET, up and down arrow keys, as well as a confirmation key. The panel’s 7-segment LED display provides clear visual feedback on operational data and parameter settings. Here’s a detailed look at the functions of the operation panel:

• RUN Key: Starts the motor when pressed.
• STOP/RESET Key: Stops the motor during operation and resets fault conditions when pressed after a fault occurs.
• Arrow Keys: The up and down arrow keys are used to navigate through parameters and adjust their values.
• Confirmation Key: Confirms parameter settings and saves changes.
• 7-Segment LED Display: Shows operational data such as output frequency, output current, and fault codes.

Parameter Initialization

To initialize the parameters to their factory default settings, follow these steps:

1. Navigate to Parameter H93: Use the arrow keys to select parameter H93 (Parameter Initialization) in the function group 2.
2. Set Initialization Value: Press the confirmation key to enter the setting, then use the arrow keys to select the desired initialization level (e.g., 1 for initializing all parameter groups).
3. Confirm Initialization: Press the confirmation key again to save the setting and initialize the parameters.

Reading, Writing, and Copying Parameters

The SV-iGxA series supports reading and writing parameters using a remote panel or communication interface.

• Reading Parameters:
  1. Navigate to parameter H91 (Parameter Read) in the function group 2.
  2. Press the confirmation key to initiate the parameter read process.
  3. Follow the prompts on the remote panel or software interface to complete the read operation.
• Writing Parameters:
  1. Navigate to parameter H92 (Parameter Write) in the function group 2.
  2. Press the confirmation key to initiate the parameter write process.
  3. Follow the prompts on the remote panel or software interface to upload the new parameter settings to the inverter.

Setting a Password and Locking Parameters

To enhance security, the SV-iGxA series allows users to set a password and lock specific parameters.

• Registering a Password:
  1. Navigate to parameter H94 (Password Registration) in the function group 2.
  2. Press the confirmation key to enter the setting.
  3. Use the arrow keys to input the desired password (in hexadecimal format).
  4. Press the confirmation key to save the password.
• Locking Parameters:
  1. Navigate to parameter H95 (Parameter Lock) in the function group 2.
  2. Press the confirmation key to enter the setting.
  3. Use the arrow keys to select the desired lock level (e.g., locking all parameters by setting H95 to 0xFFFF).
  4. Press the confirmation key to save the setting and lock the parameters.

II. Terminal Control and Potentiometer Speed Regulation

Terminal Forward/Reverse Control

To achieve forward/reverse control via terminal inputs, the following parameters need to be configured:

• drv (Drive Mode): Set to 1 to enable terminal control.
• drC (Motor Rotation Direction Selection): Select the desired rotation direction (F for forward, r for reverse).
• I17-I18 (Multi-Function Input Terminal Definitions): Assign the FX (forward) and RX (reverse) commands to specific terminals (e.g., P1 for FX and P2 for RX).

Required Wiring:

• FX Terminal: Connect to a normally open (NO) contact to start the motor in the forward direction.
• RX Terminal: Connect to a normally open (NO) contact to start the motor in the reverse direction.
• CM (Common) Terminal: Provide a common ground connection for all input terminals.

Potentiometer Speed Regulation

For speed regulation using a potentiometer, the following parameters need to be configured:

• Frq (Frequency Mode): Set to 3 to enable potentiometer input for frequency control.
• I6-I10 (V1 Input Parameters): Configure the voltage range and corresponding frequency for the potentiometer input.
  • I7 (V1 Input Minimum Voltage): Set to the minimum voltage output by the potentiometer.
  • I8 (V1 Input Minimum Frequency): Set the frequency corresponding to the minimum voltage.
  • I9 (V1 Input Maximum Voltage): Set to the maximum voltage output by the potentiometer.
  • I10 (V1 Input Maximum Frequency): Set the frequency corresponding to the maximum voltage.

Required Wiring:

• V1 Terminal: Connect to the output of the potentiometer.
• CM Terminal: Provide a common ground connection for the V1 terminal.
• 10V Terminal (if applicable): Provide a 10V reference voltage for the potentiometer (not required for potentiometers with built-in reference voltage).

By configuring the above parameters and wiring the terminals correctly, the SV-iGxA series inverter can be easily controlled via external inputs for forward/reverse operation and speed regulation using a potentiometer.