Category: Other Drives

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Deep Analysis and Comprehensive Troubleshooting Guide for ALE08 Fault on DPSON DSL200P Servo Drives

Introduction

In the realm of industrial automation, servo drives serve as the critical “muscle” and “brain” of motion control systems, dictating the precision, speed, and stability of machinery. The DPSON DSL200P series, known for its cost-effectiveness and reliability, is widely deployed in packaging machinery, CNC lathes, conveyor systems, and printing equipment. However, like all sophisticated electronic devices, they are susceptible to specific operational faults.

One of the most frequent and disruptive alarms encountered by engineers is ALE08 (Position Deviation Counter Overflow). When this fault occurs, the drive halts the motor abruptly to prevent mechanical damage or motor burnout. If not diagnosed correctly, troubleshooting can be time-consuming, leading to significant production downtime.

ALE 8

This article provides an exhaustive technical analysis of the ALE08 fault. We will dissect the underlying control logic, categorize root causes into mechanical, electrical, and parametric domains, provide a step-by-step diagnostic workflow, analyze real-world case studies, and outline preventive maintenance strategies. This guide is designed for maintenance engineers, system integrators, and automation students seeking a deep understanding of servo dynamics.

I. The Principle of ALE08: Understanding Position Deviation

To effectively troubleshoot ALE08, one must first understand the Closed-Loop Position Control architecture inherent to servo systems.

1. The Control Loop Logic

A servo system operates on a feedback loop:

  1. Command Input: The host controller (PLC or Motion Card) sends a stream of Command Pulses (representing position or speed) to the drive.
  2. Feedback Input: The servo motor’s encoder sends Feedback Pulses back to the drive, reporting the actual rotor position.
  3. Deviation Calculation: The drive’s DSP (Digital Signal Processor) continuously subtracts the Feedback Pulse count from the Command Pulse count. The result is the Position Deviation (or Position Error).
  4. Correction: Using PID (Proportional-Integral-Derivative) algorithms, the drive adjusts the output voltage/current to the motor to minimize this deviation to zero.

2. The Position Deviation Counter

The Position Deviation Counter is a specific register within the drive’s memory (typically a 16-bit or 32-bit signed integer). It acts as a “bucket” that accumulates the difference between where the motor should be and where it is.

The Overflow Mechanism:
Every servo drive has a maximum limit for this counter (e.g., ±32,767 for a 16-bit system). If the motor fails to follow the command—due to being blocked, lack of torque, or signal loss—the deviation value accumulates rapidly. Once this value exceeds the register’s limit, an overflow occurs. The drive interprets this as a critical failure (the system has lost control of the axis) and triggers ALE08, cutting power to the motor (coast stop or decelerated stop) to protect the machinery.

II. Root Cause Analysis: The Three Domains of Failure

Based on field data and the DSL200P technical manual, the causes of ALE08 can be systematically categorized into three primary domains: Mechanical Load, Command Signal, and Motor/Drive System.

Domain A: Mechanical Load Anomalies (The Most Common Culprit)

This accounts for approximately 60% of ALE08 cases. The issue is not electronic; it is physical. The motor simply cannot generate enough torque to overcome the resistance.

  1. Excessive Load/Jamming:
    • Scenario: A conveyor belt gets stuck on a debris, or a packaging machine hopper gets clogged.
    • Physics: The load torque exceeds the motor’s peak torque (e.g., a 750W motor typically offers ~2.39 N·m rated torque, but the instantaneous load demands 5 N·m). The motor stalls, but the controller keeps sending pulses, causing the deviation counter to max out instantly.
  2. Transmission Component Failure:
    • Ball Screw/Lead Screw: Worn nuts, lack of lubrication, or bent shafts increase friction exponentially.
    • Belt Drive: Belt snapping, severe slippage, or incorrect tension.
    • Bearings: Seized bearings due to contamination or lack of grease.
    • Couplings: Failure of the flexible element (spider) in the coupling, disconnecting the motor from the load mechanically while the encoder still reports “zero movement.”
  3. Foreign Object Intrusion: Metal chips, plastic fragments, or dust entering the screw/nut interface creates a physical barrier.
  4. Misalignment: The motor axis and the load axis are not concentric, creating binding forces (radial load) that the motor bearings cannot handle.

Domain B: Command Pulse Anomalies (The “Confused” Drive)

If the drive receives incorrect instructions, it cannot calculate the deviation correctly, or the deviation accumulates erroneously.

  1. Controller/Source Issues:
    • Frequency Mismatch: The controller outputs pulses at 300kHz, but the DSL200P is rated for a maximum of 200kHz. The drive misses pulses, leading to calculation errors.
    • Electrical Interference (EMI): Noise from nearby VFDs or heavy machinery couples into the pulse line, creating “ghost pulses” or dropping real pulses.
    • Hardware Failure: A blown transistor in the controller’s output module.
  2. Wiring & Connection Faults:
    • Loose Terminals: Oxidation or vibration loosening screws on PUL+, PUL-, or SIGNAL GND.
    • Cable Damage: Broken shielding or shorted cores in the encoder/pulse cable.
    • Grounding Loops: Improper grounding causing reference voltage shifts.
  3. Parameter Mismatches:
    • Electronic Gear Ratio (EGR): If the mechanical reduction is 5:1 but the parameter is set to 1:1, the drive expects the motor to turn 5x faster than it physically can, causing immediate overflow.
    • Pulse Equivalent: Incorrect settings for “pulses per millimeter” lead to scaling errors in the deviation calculation.
    • Signal Type: Controller sends Differential Line Driver (RS422) signals, but the drive is set to NPN/Open Collector mode.

Domain C: Motor and Drive Output Failures (The “Weak” System)

Even with a perfect command and a free mechanical load, the system might fail to execute.

  1. Motor Faults:
    • Winding Short/Open: The motor generates zero torque.
    • Encoder Failure: A dirty code disk or broken cable causes the drive to lose position feedback. The drive thinks the motor isn’t moving (even if it is vibrating) and increases current, eventually triggering an error or overflow as it fights “phantom” resistance.
    • Brake Issues: If the motor has a holding brake that fails to release, the motor cannot turn.
  2. Drive Hardware Faults:
    • IGBT Module Damage: One phase of the inverter is dead, resulting in single-phasing. The motor hums but produces insufficient torque.
    • Output Line Break: The U/V/W power cable to the motor is severed.
    • Current Limit Settings: The “Torque Limit” parameter is set too low (e.g., 20% of rated current), physically preventing the motor from moving a heavy load.
  3. Incorrect Motor Parameters:
    • Auto-Tuning Failure: The drive has not been “tuned” to the specific motor inertia.
    • Mismatched Specs: The drive is configured for a 400W motor, but a 750W motor is attached (or vice versa), leading to current saturation.
DSL200-P5-0R7

III. Systematic Troubleshooting Workflow

Follow this “Outside-In” approach to isolate the fault efficiently. Safety First: Disconnect main power before physical inspection.

Step 1: Mechanical Isolation (The “Hand Test”)

Goal: Determine if the load is physically free.

  1. Power Down: Turn off the main breaker and wait for the drive LEDs to extinguish (capacitors discharge).
  2. Manual Rotation:
    • Direct Drive: Try to turn the motor shaft by hand. It should offer some resistance (magnetic detent) but turn smoothly. If it is locked solid, the motor bearings are seized, or the brake is engaged.
    • Belt/Screw Drive: Disconnect the coupling (if possible) and turn the motor side. Then turn the load side.
      • Motor turns, Load does not: The jam is in the transmission (screw, bearing, gearbox). Inspect for chips or lack of lube.
      • Neither turns: The jam is at the load end (conveyor, axis).
  3. Inspection: Visually check for broken belts, disconnected couplers, or obvious obstructions.

Step 2: Signal Verification (The “Oscilloscope Test”)

Goal: Verify the integrity of the Command Pulses.

  1. Reconnect Power: Keep the motor disconnected (or hold the brake) to prevent movement.
  2. Measure: Connect an oscilloscope to the drive’s PUL+ and PUL- terminals (referenced to SIGNAL GND).
  3. Analyze Waveform:
    • Shape: Look for clean square waves. “Rounded” edges or “stair-stepping” indicates weak drive circuitry or cable capacitance issues. “Spikes” indicate noise.
    • Amplitude:
      • Differential (RS422): Should be ~2V to 5V peak-to-peak.
      • Open Collector (NPN): Should swing from 0V to 24V (or 5V depending on the system).
    • Frequency: Command a move (e.g., 10kHz). Does the scope read 10kHz? If it reads 5kHz or 15kHz, the controller or cabling is faulty.
  4. Check Shielding: Ensure the cable shield is grounded at both ends (Controller and Drive) for high-frequency noise immunity.

Step 3: Parameter & Configuration Audit

Goal: Ensure the “Software” matches the “Hardware”.

Access the DSL200P parameter list (usually via keypad or software). Verify:

  • PA01 (Pulse Type): Matches wiring (Differential vs. Open Collector).
  • PA02 (Electronic Gear Ratio): Numerator/Denominator matches mechanical reduction (e.g., 1/5 for a 5:1 reducer).
  • PA03 (Pulse Equivalent): Correct value for the machine (e.g., 0.001mm/pulse).
  • PA05 (Motor Model): Matches the physical motor tag.
  • PA10 (Torque Limit): Is it set to 100% or higher? (Sometimes set low for safety testing).

Step 4: Electrical Component Testing

Goal: Test the Motor and Drive power stage.

  1. Motor Insulation & Resistance:
    • Use a Megger (insulation tester) to check U/V/W to Ground (should be >100MΩ).
    • Use a multimeter to measure U-V, V-W, W-U resistance. They should be balanced (e.g., all ~1.5Ω). An open circuit (OL) or short circuit (0Ω) indicates burnt windings.
  2. Encoder Check:
    • Rotate the motor shaft by hand slowly.
    • Monitor the diagnostic screen (or use a frequency counter) for A/B/Z phase pulses. They should increment/decrement smoothly without dropping counts.
  3. Drive Output (IGBT):
    • Warning: High Voltage. With power on (no run command), measure DC bus voltage (across P/+ and N/-). It should be ~1.41x the input AC voltage (e.g., 320VDC for 220VAC input).
    • If the DC bus is low or zero, the rectifier bridge is blown.

IV. Case Studies: Real-World Diagnostics

Case 1: The “Invisible” Jam in a Packaging Machine

  • Symptom: Intermittent ALE08 on a sealing bar axis. Manual rotation felt “heavy” but possible.
  • Investigation: Mechanical inspection revealed no broken parts. The ball screw was clean. However, the linear guide rails were covered in hardened glue residue from a previous product run.
  • Resolution: Cleaning the rails and re-greasing solved the issue. The friction coefficient had increased just enough to exceed the motor’s torque margin during high-speed moves.

Case 2: The Ground Loop Interference

  • Symptom: ALE08 occurred only when a large 5kW spindle motor started nearby.
  • Investigation: Oscilloscope revealed massive noise spikes on the pulse line coinciding with the spindle start-up. The pulse cable was routed in the same trunking as the 220V spindle power cable.
  • Resolution: Re-routing the pulse cable 30cm away from the power cable and installing a ferrite ring (magnetic bead) on the pulse line at the drive end eliminated the noise.

Case 3: Incorrect Electronic Gear Ratio

  • Symptom: ALE08 immediately upon starting a “Jog” command, even with the motor unloaded (coupling removed).
  • Investigation: The machine was a direct drive (1:1), but the parameter “Electronic Gear” was set to 2:1 from a previous machine setup. The drive was commanding the motor to move twice as fast as the encoder was reporting, causing instant overflow.
  • Resolution: Resetting the Electronic Gear Ratio to 1:1 cleared the fault.

V. Prevention and Maintenance Strategy

“An ounce of prevention is worth a pound of cure.” To minimize ALE08 occurrences:

  1. Mechanical PM Schedule:
    • Weekly: Lubricate screws and rails.
    • Monthly: Check belt tension and coupler set screws.
    • Quarterly: Clean debris from machine tracks.
  2. Electrical Best Practices:
    • Use shielded twisted-pair cables for encoders and pulses.
    • Ground the shield at both ends (for servo drives, this is usually preferred over single-point grounding to shunt high-frequency noise).
    • Separate power cables (220V/380V) from signal cables (24V/5V).
  3. Parameter Management:
    • Perform a “Backup” of parameters to a USB or PC after every commissioning.
    • Document the mechanical reduction ratios and pulse equivalents physically on the machine.
  4. Operator Training:
    • Train operators to recognize the sound of a “stalling” motor (a loud hum) and to hit the E-Stop immediately rather than resetting the drive repeatedly (which can burn the motor).

VI. Common Pitfalls and Safety Warnings

  1. The “Reset” Trap: Do not simply press “Reset” multiple times. If the mechanical load is jammed, resetting will cause the drive to try to push again, potentially overheating the motor windings or stripping gears. Find the root cause first.
  2. Ignoring the Encoder: A dirty encoder is a silent killer. If the feedback is lost, the drive assumes the motor is stationary and ramps up current to max, often tripping “Overcurrent” (ALE02) before “Overflow” (ALE08), but sometimes causing ALE08 if the error accumulates subtly.
  3. Safety: Always assume the motor can move. Secure the load with blocks or jacks before working under it, even if the drive is off (gravity can move vertical axes).

Conclusion

The ALE08 (Position Deviation Counter Overflow) fault on the DPSON DSL200P is a protective mechanism indicating a loss of synchronization between the commanded position and the actual position. While it signals a stop in production, it prevents catastrophic mechanical failure.

By understanding the closed-loop control logic, systematically isolating the problem into mechanical, signal, and parametric categories, and utilizing tools like oscilloscopes and multimeters, engineers can drastically reduce troubleshooting time. Remember that 70% of ALE08 faults are mechanical (friction/jamming), 20% are wiring/interference, and only 10% are drive/motor hardware failures.

Mastering the diagnosis of ALE08 is not just about fixing a single error code; it is about mastering the dynamics of motion control. With the guidelines provided in this article, maintenance personnel can transform from reactive “part changers” into proactive system diagnosticians, ensuring higher uptime and reliability for industrial automation systems.

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Analysis and Handling of E0020 Contactor Fault in WISCO South E-CONVERT 5 Series Inverter

Introduction

In the field of modern industrial automation, inverters, as the core equipment for motor control, play a crucial role in ensuring production safety and improving equipment utilization. The E-CONVERT 5 series inverter launched by WISCO South (Wuhan) Automation Co., Ltd. has gained widespread market recognition for its high performance, high reliability, and rich functionality. However, during actual operation, the E0020 contactor fault, as a relatively common type of fault, poses a threat to the normal operation of the equipment. This article will provide a detailed analysis of the meaning, causes, diagnostic methods, and handling measures of the E0020 fault, aiming to assist technicians in quickly locating problems and restoring normal equipment operation.

E0020 FAULT
filter: 0; fileterIntensity: 0.0; filterMask: 0; hdrForward: 0; highlight: true; brp_mask:0;
brp_del_th:null;
brp_del_sen:null;
delta:null;
module: photo;hw-remosaic: false;touch: (-1.0, -1.0);sceneMode: 8;cct_value: 0;AI_Scene: (-1, -1);aec_lux: 0.0;aec_lux_index: 0;HdrStatus: auto;albedo: ;confidence: ;motionLevel: -1;weatherinfo: null;temperature: 28;

I. Overview of E0020 Fault

1.1 Fault Definition

The E0020 fault code in the WISCO South E-CONVERT 5 series inverter represents a contactor fault. When the inverter detects that the contactor fails to engage normally or exhibits abnormalities during startup or operation, it triggers this fault code, causing the inverter to stop working and display corresponding fault information.

1.2 Fault Impact

As a key connecting component between the inverter and the motor, the contactor’s normal operation is vital for the motor’s startup, operation, and shutdown. Once a contactor fault occurs, it will directly affect motor control, potentially leading to production line shutdowns, equipment damage, or even safety accidents.

II. Causes of E0020 Fault

2.1 Contactor Faults

  • Contact Wear or Adhesion: After prolonged operation, the contacts of the contactor may become worn or adhered due to arc erosion, resulting in poor contact or an inability to disconnect.
  • Coil Faults: The contactor coil may be damaged due to voltage fluctuations, overheating, etc., leading to an inability to engage or maintain engagement.
  • Mechanical Faults: The internal mechanical structure of the contactor (such as springs, armatures, etc.) may experience wear, deformation, etc., causing sluggish action or seizure.

2.2 Control Circuit Issues

  • Abnormal Control Signals: The control signals output by the inverter may prevent the contactor from engaging normally due to line faults, interference, etc.
  • Incorrect Parameter Settings: Parameters within the inverter related to contactor control (such as engagement time, release time, etc.) may be set improperly, causing abnormal contactor action.
  • Program Errors: The inverter’s control program may contain logical errors or bugs, leading to incorrect or unsent contactor control commands.

2.3 Power Supply Problems

  • Unstable Power Supply Voltage: Excessive fluctuations in the power supply voltage may result in insufficient or excessive voltage at the contactor coil, affecting its normal operation.
  • Power Supply Phase Loss: The absence of any phase in a three-phase power supply will prevent the contactor from engaging or maintaining engagement.

2.4 Environmental Factors

  • High Temperature: Excessively high operating temperatures in the inverter’s environment may accelerate the aging of internal components in the contactor, degrading performance.
  • High Humidity: High humidity environments may cause condensation, short circuits, etc., inside the contactor.
  • Dust Pollution: Dust entering the contactor may affect the quality of contact between the contacts, leading to poor contact.

III. Diagnostic Methods for E0020 Fault

3.1 Visual Inspection

  • Observe the appearance of the contactor to check for damage, deformation, burning, etc.
  • Inspect the connecting wires to confirm they are not loose, detached, or damaged.

3.2 Electrical Measurement

  • Use a multimeter to measure the voltage across the contactor coil to confirm whether the voltage is normal and stable.
  • In a de-energized state, use a multimeter to measure the resistance value of the contactor contacts to confirm whether the contacts are in good contact.

3.3 Control Signal Inspection

  • Inspect the control signal lines to confirm they are intact and free from short circuits or open circuits.
  • Use an oscilloscope to observe the waveform of the control signal to confirm whether the signal is stable and meets the inverter’s requirements.

3.4 Parameter and Program Inspection

  • Verify the parameter settings within the inverter related to contactor control to confirm they are correct and error-free.
  • If possible, debug and inspect the inverter’s control program to confirm the correctness of the program logic.

3.5 Environmental Inspection

  • Confirm whether the inverter’s operating environment meets requirements, including temperature, humidity, dust, etc.
  • Clean the inverter and contactor to remove dust and dirt.
EC551-4AAX-075A

IV. Handling Measures for E0020 Fault

4.1 Replacing the Contactor

  • Confirming the Fault: After completing the above diagnostic steps, if it is confirmed that the contactor itself has a fault and cannot be repaired, promptly replace it with a contactor of the same model and specifications.
  • Replacement Steps:
    • Disconnect the power supply to the inverter and confirm there is no electricity.
    • Remove the faulty contactor and record its wiring method.
    • Install the new contactor and connect the wires according to the original wiring method.
    • Restore the power supply and test whether the contactor operates normally.

4.2 Repairing the Control Circuit

  • Repairing Line Faults: If short circuits or open circuits are found in the control signal lines, promptly repair or replace the lines.
  • Adjusting Parameter Settings: Adjust the parameter settings related to contactor control within the inverter according to the inverter’s manual to ensure the parameters are reasonable and meet actual needs.
  • Repairing Program Errors: If logical errors or bugs are found in the control program, promptly contact the manufacturer or professional personnel for repair.

4.3 Improving Power Supply Quality

  • Stabilizing Power Supply Voltage: Install voltage stabilizers, UPS devices, etc., to stabilize the power supply voltage and reduce the impact of voltage fluctuations on the contactor.
  • Checking for Power Supply Phase Loss: Use a phase sequence meter to check whether the three-phase power supply is missing any phase and promptly address the power supply phase loss issue.

4.4 Optimizing the Operating Environment

  • Controlling Temperature: Install air conditioners, ventilation equipment, etc., to control the operating temperature of the inverter’s environment within a reasonable range.
  • Reducing Humidity: Use dehumidifiers, desiccants, etc., to reduce the humidity of the operating environment and prevent condensation and short circuits.
  • Reducing Dust: Regularly clean the inverter and contactor to reduce the impact of dust pollution on the equipment.

V. Preventive Measures and Routine Maintenance

5.1 Regular Inspection and Maintenance

  • Developing a Maintenance Plan: Formulate a regular maintenance plan based on the equipment’s usage and the manufacturer’s recommendations, including contactor inspection, line tightening, parameter verification, etc.
  • Executing Maintenance Tasks: Regularly perform maintenance tasks according to the maintenance plan to ensure the equipment is in good condition.

5.2 Training and Operating Specifications

  • Training Technicians: Provide professional training to equipment operators to improve their understanding and handling ability of inverter and contactor faults.
  • Developing Operating Specifications: Formulate detailed equipment operating specifications and maintenance procedures to ensure operators follow the specifications for operation and maintenance.

5.3 Spare Parts Management

  • Stocking Spare Parts: Stock necessary spare parts (such as contactors, coils, etc.) based on the equipment’s usage and historical fault records to enable prompt replacement in case of faults.
  • Managing Spare Parts: Establish a spare parts management system to regularly inspect and update spare parts, ensuring they are of reliable quality and sufficient quantity.

VI. Conclusion

The E0020 contactor fault is a relatively common type of fault during the operation of the WISCO South E-CONVERT 5 series inverter. By thoroughly analyzing the fault causes, adopting scientific diagnostic methods, and implementing effective handling measures, normal equipment operation can be quickly restored, and the impact of faults on production can be reduced. Meanwhile, by formulating preventive measures and strengthening routine maintenance management, the reliability and stability of the equipment can be further improved, creating greater economic and social benefits for enterprises.

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In-Depth Analysis of E024 Fault in Sanjing DPG10 Inverter: A Full-Process Solution Guide from Theory to Practice

Introduction

In the field of industrial automation, inverters are core devices for achieving motor speed regulation, energy-saving control, and closed-loop adjustment. The Sanjing Electric DPG10 series inverter, with its high cost-performance ratio and stable closed-loop control performance, is widely used in constant pressure/constant current control systems for loads such as centrifugal pumps, fans, and compressors. However, during long-term operation, the E024 “Feedback Line Break Fault” is one of the most common faults in the DPG10 series—minor faults cause equipment downtime, while major ones disrupt production continuity. This article combines the technical characteristics of the DPG10 series with on-site practical experience to provide a actionable full-process solution guide covering fault principles, cause analysis, troubleshooting steps, and preventive measures, helping engineers and technicians quickly locate and resolve issues.

E024 FAULT

I. Core Principles and Trigger Mechanism of E024 Fault

The E024 fault in the DPG10 series inverter is essentially a protection mechanism for feedback signal abnormalities in closed-loop control mode. Its trigger logic is as follows:
When the inverter operates in closed-loop mode (e.g., pressure closed-loop, flow closed-loop), it real-time monitors the feedback signal (analog: 4-20mA/0-10V; pulse: encoder signal). If any of the following conditions is detected and lasts longer than the line break detection time (default: 1 second), the E024 fault is triggered:

  1. Complete interruption of the feedback signal (e.g., line break);
  2. Feedback signal value exceeds the reasonable range (e.g., pressure sensor outputs 0mA or >20mA);
  3. Feedback signal fluctuation exceeds the threshold (e.g., intermittent poor contact).

Review of Closed-Loop Control Process:
Set target value (e.g., pipeline pressure 0.5MPa) → Sensor collects actual value (converted to electrical signal) → Inverter compares target value with actual value via PID algorithm → Adjusts output frequency → Maintains actual value stability. If the feedback signal is abnormal, the PID algorithm fails to work, and the inverter stops output and alarms to protect the equipment.

PDG10-4T0022B

II. Three Core Causes of E024 Fault

Based on statistics from over 100 on-site faults, the causes of E024 fault are distributed as: Line issues (60%) ＞ Sensor issues (30%) ＞ Parameter settings (10%). Detailed analysis is as follows:

(1) Line Issues: Break or Poor Contact (Most Common)

Lines are the “channel” for feedback signal transmission, and their faults mainly stem from physical damage or connection failure:

  • Line break: External force damage (rat bites, construction misoperation), line aging (insulation layer cracking causing core wire breakage), or loose terminal screws (core wire detachment);
  • Poor contact: Terminal oxidation (copper-aluminum connection produces oxide layer), loose plugs (aviation plugs not locked), or virtual connection of terminal blocks (screws not tightened).

Case: In a sewage treatment plant’s centrifugal pump system, moisture in the control cabinet caused oxidation of the pressure sensor terminals, resulting in intermittent feedback signals and frequent E024 faults in the inverter.

(2) Sensor Issues: Damage or No Output (Second Most Common)

Sensors are the “source” of feedback signals, and their faults directly lead to signal abnormalities:

  • Sensor damage: Overload (pressure exceeding the range causes deformation of elastic elements), overvoltage (power supply voltage exceeding the rated value burns the circuit), or environmental factors (moisture short circuit, high-temperature aging);
  • No feedback signal: Sensor not powered (power line break), range mismatch (e.g., sensor outputs 0-10V but the inverter is set to 4-20mA input), or installation error (pressure sensor not installed at the pressure tapping point).

Case: In a chemical plant’s fan system, the pressure sensor’s internal lead broke due to vibration, outputting 0V signal, and the inverter judged it as a line break.

(3) Parameter Settings: Too Short Detection Time or Incorrect Type (Rare)

  • Too short line break detection time: The default 1-second detection time cannot adapt to system fluctuations (e.g., pressure shock during pump startup), causing false alarms;
  • Incorrect feedback signal type: For example, if the sensor outputs 4-20mA but the inverter parameter is set to “pulse input”, the signal cannot be recognized.

Case: In a paper mill’s water pump system, the line break detection time was set to 1 second. During pump startup, pressure fluctuations lasted 1.5 seconds, and the inverter misjudged it as a line break. After adjusting the time to 3 seconds, the fault disappeared.

On-site control of water pump for constant pressure water supply by frequency converter

III. Full-Process Troubleshooting Steps for E024 Fault (Practical Guide)

Follow the principle of “hardware first, then software; simple first, then complex” and troubleshoot step by step:

Step 1: Check Feedback Lines (Priority, 60% of Causes)

Preparation: Disconnect the main power supply of the inverter (confirm power-off to avoid electric shock) and prepare a multimeter (continuity gear, voltage gear), screwdriver, and alcohol cotton.

  1. Check Terminal Connections:
    Open the control cabinet, find the signal line between the sensor and the inverter (usually a shielded wire with white/blue core wires), and check if the terminals at both ends (e.g., inverter AI1/AI2, sensor output end) are loose or oxidized. If loose, tighten with a screwdriver; if oxidized, clean with alcohol cotton and reconnect.
  2. Measure Line Continuity:
    Use the multimeter’s continuity gear to measure both ends of the signal line (e.g., sensor output end → inverter AI1 end). If the multimeter does not beep (discontinuous), the line is broken and needs to be replaced with a shielded wire of the same specification (recommended RVVP2×1.0mm², with the shield layer grounded at one end only).
  3. Check Shield Layer Grounding:
    Ensure the shield layer of the shielded wire is grounded only at the inverter end (to avoid ground loops caused by dual-end grounding), and the grounding resistance is ＜4Ω (measured with a grounding resistance tester).

Step 2: Verify Sensor Validity (30% of Causes)

  1. Power-On Check for Sensor:
    Use the multimeter’s voltage gear to measure the sensor’s power supply end (usually DC24V). If the voltage is 0V, check if the power line is broken or the power module is faulty.
  2. Detect Sensor Output Signal:
    • Analog Sensor (e.g., Pressure Sensor): Connect the multimeter in series (current gear) to measure the output current (4-20mA) or in parallel (voltage gear) to measure the output voltage (0-10V). If the output is 0mA/0V or exceeds the range, the sensor is damaged.
    • Pulse Sensor (e.g., Encoder): Use an oscilloscope to measure the output pulse signal (e.g., for a 1000P/R encoder, the frequency is 16.67kHz at 1000rpm). If there is no pulse or the frequency fluctuates greatly, the encoder is damaged.
  3. Replacement Verification:
    Replace with a spare sensor of the same model. If the fault disappears, the original sensor is damaged and needs to be replaced.

Step 3: Check Inverter Parameters (10% of Causes)

  1. Confirm Feedback Signal Type:
    Enter the parameter mode (press the “Menu” key and enter the password), find the “Feedback Signal Selection” parameter (e.g., F0-03), and ensure the setting matches the sensor (set to “0” for 4-20mA, “1” for pulse).
  2. Adjust Line Break Detection Time:
    Find the “Line Break Detection Time” parameter (e.g., F8-01), change the default 1 second to 3-5 seconds (adjusted according to system fluctuations; recommended not to exceed 10 seconds), save the parameter (press “Shift + Menu” keys), and restart the inverter.
  3. Verify Feedback Range:
    Confirm that the “Feedback Range Upper Limit” (F8-02) and “Feedback Range Lower Limit” (F8-03) match the sensor’s range (e.g., for a 0-1.0MPa pressure sensor, set F8-02 to 1.0 and F8-03 to 0).

Step 4: Eliminate System Interference and Logic Issues (5% of Causes)

  1. Check Communication Logic:
    If the inverter receives feedback signals via Modbus RTU, confirm that the register address, baud rate, and station number in the PLC program match the inverter (e.g., if the inverter’s station number is 1, the PLC must be set to 1).
  2. Electromagnetic Interference (EMI) Protection:
    • Route feedback lines separately in galvanized steel pipes and keep them away from power lines (≥30cm);
    • Connect a 0.1μF/250V ceramic capacitor in parallel at the inverter’s feedback terminal (for filtering);
    • Use a signal isolator (e.g., 4-20mA isolator) to cut off the interference path.

IV. Real Case Review: Practical Solutions for E024 Fault

Case 1: Centrifugal Pump E024 Fault in a Sewage Treatment Plant

Fault Phenomenon: A DPG10-4T022B inverter (22kW) controlling a centrifugal pump suddenly reported E024 during operation, and the pump stopped with the alarm light on.
Troubleshooting Process:

  1. Disconnect power, check the pressure sensor (CYB-20S, 4-20mA) terminals, and find that the screw of the inverter’s AI1 terminal was loose, causing the core wire to detach;
  2. Tighten the terminal, clean the oxide layer, and use a multimeter to confirm the line was conductive;
  3. Power on and start the pump—pressure feedback showed 0.3MPa (normal), and the fault disappeared.
    Cause: Loose terminal screws leading to poor contact.

Case 2: Fan E024 Fault in a Chemical Plant

Fault Phenomenon: A DPG10-4T030B inverter (30kW) controlling a fan reported E024 upon startup and could not enter closed-loop mode.
Troubleshooting Process:

  1. Check the line: The shielded wire was connected normally, and the continuity test passed;
  2. Detect the sensor: The pressure sensor (PT124B, 0-10V) had normal power supply but output 0V, indicating damage;
  3. Replace the sensor—feedback voltage was 5V (corresponding to 0.5MPa), and the fault disappeared.
    Cause: Internal circuit damage of the sensor (vibration caused lead breakage).

Case 3: Water Pump E024 Fault in a Paper Mill

Fault Phenomenon: A DPG10-4T015B inverter (15kW) controlling a water pump frequently reported E024 and could only run for a few minutes after restarting.
Troubleshooting Process:

  1. Lines and sensors were normal, and the sensor output was stable (4-20mA);
  2. Check parameters: The line break detection time (F8-01) was set to 1 second. During pump startup, pressure fluctuations lasted 1.5 seconds, causing false alarms;
  3. Adjust F8-01 to 3 seconds, save, and restart—fault disappeared.
    Cause: Too short line break detection time, unable to adapt to system fluctuations.

V. Preventive Measures for E024 Fault

  1. Regular Line Maintenance: Tighten terminal screws and clean oxide layers quarterly; replace aging shielded wires annually (recommended oil-resistant and corrosion-resistant types).
  2. Sensor Calibration and Replacement: Calibrate sensors with a standard signal source every six months; replace sensors after their service life (2-3 years).
  3. Rational Parameter Settings: Adjust the line break detection time (3-5 seconds) according to system fluctuations; ensure the feedback signal type and range match the sensor.
  4. EMI Protection: Route feedback lines in separate pipes and away from power lines; use shielded wires with one-end grounding; install signal filters.
  5. Fault Record and Analysis: Establish a fault log to record the time, phenomenon, and solution of each fault; analyze high-frequency causes (e.g., if line issues are common, strengthen line maintenance).

VI. Conclusion

The E024 fault in the Sanjing DPG10 series inverter is essentially a closed-loop control failure caused by feedback signal abnormalities. The key to solving it is accurately locating the fault point—troubleshoot step by step from lines (most common), sensors (second most common), to parameters (rare). On-site technicians need to be familiar with the inverter’s closed-loop principles, master methods for line inspection, sensor detection, and parameter adjustment, and accumulate experience through cases to quickly resolve issues.

Meanwhile, preventive measures such as regular maintenance, rational parameter settings, and EMI protection can effectively reduce the probability of E024 faults and ensure stable equipment operation. For unresolved faults, contact Sanjing Electric’s official after-sales service (provide inverter model, fault code, and working conditions) or use professional tools (oscilloscope, signal generator) for further diagnosis to avoid expanding losses due to misoperation.

Appendix: Reference Parameters for E024 Fault in DPG10 Series

Parameter CodeParameter NameDefault ValueAdjustment Suggestion
F0-03Feedback Signal Selection0Set to 0 for 4-20mA
F8-01Line Break Detection Time1 second3-5 seconds (adjusted by fluctuations)
F8-02Feedback Range Upper Limit100Match sensor range (e.g., 100 for 1.0MPa)
F8-03Feedback Range Lower Limit0Match sensor lower limit (e.g., 0 for 0MPa)

(Note: Parameter codes are subject to the DPG10 series manual; different models may vary slightly.)

With this guide, engineers and technicians can quickly resolve E024 faults in the DPG10 series and improve equipment operation reliability.

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Deep Dive into EC.21 Fault in Shenzhen Kingda V600 Inverters: A Comprehensive Guide from Diagnosis to Resolution

Introduction

In the realm of industrial automation, the Variable Frequency Drive (VFD) stands as the heart of motor control systems, dictating the efficiency, precision, and reliability of production lines. Among the myriad of VFDs available in the market, the V600 Series manufactured by Shenzhen Kingda Electric Technology Co., Ltd. has carved a niche for itself due to its robust performance and cost-effectiveness. However, like all sophisticated power electronics, it is susceptible to specific failure modes. One of the most critical and frequently encountered alarms in this series is EC.21.

This alarm code signifies a Temperature Sensor Fault. While it may appear as a simple numeric code on the LED display, the implications are far-reaching. If misdiagnosed or ignored, an EC.21 fault can lead to catastrophic thermal runaway, IGBT module failure, and costly unplanned downtime. This article provides an exhaustive technical analysis of the EC.21 fault, dissecting its root causes, establishing a logical diagnostic workflow, and offering actionable solutions for engineers and maintenance personnel.

EC.21 FAULT

1. The Phenomenon: Understanding the Symptoms

When a V600 series inverter triggers an EC.21 alarm, the operation panel typically displays the red code “EC.21” (or similar alphanumeric variations depending on the specific firmware version). This visual indicator is accompanied by a sequence of operational changes:

  1. Immediate Trip/Stop: The inverter usually halts output to the motor immediately to prevent damage.
  2. Cooling Fan Anomaly: The control logic for the cooling fan may fail. You might observe the fan stopping completely, running at an erratic speed, or failing to ramp up during high-load operations.
  3. Thermal Accumulation: Without valid temperature data, the inverter cannot regulate its internal thermal environment. The heatsink temperature may rise rapidly, often triggering secondary protections like “Overheating” (if a backup thermal switch exists) or “Overcurrent” due to IGBT performance degradation at high temperatures.
  4. Performance Derating: Even if the drive attempts to run, it will likely limit the output frequency and current to a “safe” but inefficient level, causing the motor to stall or run unevenly.

The core issue is a loss of telemetry. The microcontroller unit (MCU) has lost the ability to “see” the temperature of the critical components (usually the IGBT module or the main heatsink), forcing it into a defensive “safe mode.”

2. The Mechanism: Why EC.21 Happens

To solve the problem, one must understand the physics and electronics behind it. The V600 series typically employs an NTC (Negative Temperature Coefficient) Thermistor as the primary temperature sensing element.

The Operational Principle:
An NTC thermistor is a resistor whose resistance decreases as temperature increases. The inverter’s mainboard supplies a small excitation voltage (often 5V or 3.3V) to the thermistor via a precision resistor, creating a voltage divider circuit. The resulting voltage is read by the MCU’s Analog-to-Digital Converter (ADC). The MCU then uses a lookup table or a mathematical formula (Steinhart-Hart equation) to convert this voltage into a temperature value (°C).

Failure Modes:
The EC.21 alarm is triggered when the measured voltage falls outside the expected operational window. This generally stems from two distinct categories:

Category A: Signal Chain Integrity Failure

  • Open Circuit: The wire is broken, or the connector is unplugged. The ADC reads maximum voltage (Vcc), interpreting it as an “infinite” resistance, which the logic interprets as a sensor failure or -273°C (absolute zero), both of which are invalid.
  • Short Circuit: The signal line is shorted to ground. The ADC reads 0V, interpreting it as 0 Ohms (infinite temperature), triggering an immediate fault.
  • Contact Resistance: Oxidation or loose pins create high resistance in the connector. This adds to the thermistor’s value, causing the MCU to read a temperature much higher than reality, potentially causing nuisance trips.
  • EMI/RFI Interference: In high-noise environments (near large contactors or welding machines), electromagnetic interference can induce noise spikes on the sensor line, corrupting the ADC reading.

Category B: Sensor Body Failure

  • Thermal Aging: Over years of operation, the chemical composition of the NTC bead degrades. Its resistance drifts out of specification (e.g., a 10kΩ sensor at 25°C might read 8kΩ or 15kΩ), causing calibration errors.
  • Physical Damage: The sensor is often embedded in the thermal paste between the IGBT and the heatsink. If the encapsulation cracks due to thermal cycling (expansion/contraction), moisture can enter, causing corrosion or a short circuit.
  • Incorrect Replacement: Using a non-OEM sensor with a different B-constant (sensitivity curve) will result in the MCU miscalculating the temperature, leading to persistent errors.
V600-4T550CM

3. The Diagnostic Workflow: A Step-by-Step Protocol

Troubleshooting EC.21 requires a “Systems Engineering” approach. Do not simply replace parts randomly. Follow this tiered diagnostic process:

Phase 1: Safety & Preliminary Inspection (The “Zero Cost” Checks)

  1. LOTO (Lockout/Tagout): Isolate the inverter from the mains power. Wait at least 5–10 minutes for the DC bus capacitors to discharge. Verify 0V at the input terminals using a multimeter.
  2. Visual Inspection: Open the inverter chassis. Locate the temperature sensor (usually a two-wire cable leading from the mainboard to the heatsink or IGBT module).
    • Check the Connector: Is it seated firmly? Look for black/green oxidation on the pins.
    • Check the Cable: Look for fraying, cuts, or “wire work hardening” (stiffness indicating internal copper breakage).
    • Check the Environment: Is the heatsink clogged with dust? Is there evidence of water ingress or oil contamination?

Phase 2: Signal Chain Verification (The “Electrical” Checks)
Tools: Multimeter, Megger (optional).

  1. Continuity Test: Disconnect the sensor plug. Measure resistance from the plug end to the mainboard header. It should be near 0Ω (<1Ω). If it is high or infinite, the wire or PCB trace is broken.
  2. Isolation Resistance (Megger Test): If moisture is suspected, use a 500V megger to test the insulation resistance between the sensor lines and the ground/heatsink. It should be >100MΩ.
  3. Voltage Injection Test (Simulation):
    • Reconnect power (carefully).
    • Disconnect the sensor.
    • Use a precision decade resistance box or a known-good resistor (e.g., 10kΩ for a standard sensor) to bridge the connector pins on the cable side.
    • If the EC.21 alarm clears and the drive runs, the Mainboard is functional, and the fault lies in the sensor or the cable on the heatsink side.

Phase 3: Sensor Performance Validation
Tools: Multimeter, Thermal Gun, Hair Dryer/Freezer Spray.

  1. Ambient Resistance Check: Measure the sensor’s resistance at room temperature. Compare it to the datasheet (e.g., 10kΩ ±1% at 25°C). If it reads 50kΩ or 0Ω, the sensor is dead.
  2. Thermal Response Test:
    • Heat the sensor gently with a hair dryer (do not exceed 100°C). The resistance should drop smoothly and continuously.
    • Cool it with freeze spray. The resistance should rise.
    • Failure Indicator: If the resistance jumps erratically, lags significantly, or stays flat, the NTC element is fractured.
  3. Oscilloscope Analysis (Advanced): Hook a probe to the signal line while the drive is running (if possible). Look for high-frequency noise riding on the DC level. If noise exceeds 100mV p-p, shielding is inadequate.

Phase 4: Mainboard Forensics
If the sensor and wiring are perfect, the fault is on the MCU board.

  1. ADC Reference Voltage: Check the 5V/3.3V rail supplying the sensor circuit. Is it stable?
  2. Filtering Capacitors: Check the small ceramic or electrolytic capacitors near the ADC input pin. If they are shorted or open, the signal will be corrupt.
  3. Firmware/EEPROM: In rare cases, the calibration data stored in the EEPROM might be corrupted. Try a factory reset (consult the manual for the specific key combination).

4. Solutions and Remediation Strategies

Once the root cause is identified, apply the appropriate fix.

Scenario A: Wiring/Connector Issues

  • Repair: Do not just twist wires. Solder the connection and use heat-shrink tubing with adhesive lining (marine grade) to prevent water ingress.
  • Contact Enhancement: Clean oxidized pins with DeoxIT or Isopropyl Alcohol (IPA). Apply a thin layer of dielectric grease before mating the connectors.
  • Shielding: If EMI is the culprit, wrap the signal pair in copper foil tape (grounded at one end only to avoid ground loops) or replace the cable with a shielded twisted pair (STP).

Scenario B: Sensor Replacement

  • OEM Sourcing: Critical. Do not use generic thermistors. Contact Kingda support with your Serial Number and Model (e.g., V600-4T0550CM) to get the exact part number.
  • Installation Best Practices:
    1. Clean the mounting surface (heatsink/IGBT) with IPA to remove old, hardened thermal paste.
    2. Apply a high-performance thermal compound (e.g., Arctic MX-4 or equivalent).
    3. Ensure the sensor is flush against the surface. Use thermal tape or a spring clip if not screw-mounted.
    4. Torque: If screw-mounted, use a torque screwdriver. Over-tightening can crack the sensor; under-tightening creates an air gap (thermal insulator).
  • Calibration: Some advanced V600 units allow “Sensor Offset” parameters. After replacement, you may need to run a self-tuning procedure or input a correction factor.

Scenario C: Environmental/Systemic Issues

  • Cooling Upgrade: If the ambient temperature inside the cabinet exceeds 40°C, the sensor isn’t “failed”—it’s doing its job by tripping! Install cabinet coolers, exhaust fans, or air filters.
  • Parameter Adjustment: Use with caution. You can slightly raise the “Temperature Warning Level” or “Temperature Trip Level” in the parameters (e.g., from 85°C to 90°C) to prevent nuisance trips, but never exceed the IGBT’s maximum junction temperature (usually 125°C-150°C).

5. Case Study: The “Ghost” Fault in a Humid Environment

Background: A textile factory reported intermittent EC.21 faults on three V600-4T0750CM drives. The maintenance team replaced the sensors twice, but the fault returned within two weeks.

Investigation:

  1. Visual: The factory floor had high humidity (>80%) and lint dust.
  2. Testing: The “old” sensors removed from the drive tested perfectly fine on a bench LCR meter. The wiring showed 5Ω resistance (high for a short run).
  3. Root Cause: Microscopic analysis revealed galvanic corrosion on the connector pins due to the humid, lint-filled environment. The lint absorbed moisture and acted as a wick, drawing humidity into the connector. The resistance increase mimicked a “high temperature” reading, triggering EC.21.

Resolution:

  1. Conformal Coating: The mainboard connector and sensor wires were sprayed with acrylic conformal coating (humidity protection).
  2. Sealed Connectors: Standard Molex connectors were replaced with IP67 rated circular connectors.
  3. Preventive Maintenance: The cabinet filters were upgraded to IP54, and a schedule for blowing out lint with compressed air was established.

Outcome: Zero EC.21 faults in the subsequent 12 months.

6. Preventive Maintenance & Lifecycle Management

Reactive repair is expensive. A proactive strategy is essential for the V600 series.

  1. Thermal Imaging: Use an infrared camera quarterly to scan the inverter heatsinks. Look for “hot spots” indicating poor contact between the IGBT and the heatsink (which the sensor might not detect if it’s mounted elsewhere).
  2. Vibration Analysis: If the inverter is on a vibrating machine, check connector tightness annually. Vibration loosens screws and fractures solder joints.
  3. Dust Management: Implement a “Clean Cabinet” policy. Dust is a thermal insulator. If the heatsink is coated in dust, the sensor will read high temps, and the components will age faster.
  4. Firmware Management: Check the Kingda website for firmware updates. Newer versions often include improved noise filtering algorithms for the ADC, which can eliminate false EC.21 triggers in electrically noisy environments.

7. Future Trends: The Evolution of Thermal Monitoring

As we move toward Industry 4.0, the way we handle EC.21 is evolving:

  • AI-Driven Predictive Maintenance: Modern IoT-enabled VFDs don’t just report “Fault.” They upload temperature trends to the cloud. AI algorithms analyze the rate of change of temperature. If the temperature rises 2°C faster than usual under the same load, the system predicts a fan failure or clogged filter before the EC.21 threshold is breached.
  • Wireless Sensor Networks: Instead of running analog wires (prone to noise), future retrofits may use Zigbee or LoRaWAN temperature nodes stuck directly onto the IGBTs, transmitting digital data wirelessly to the controller.
  • Redundancy: Critical applications are moving toward “Dual Sensor” logic. If Sensor A disagrees with Sensor B by more than 5°C, the system flags a “Sensor Discrepancy” warning (allowing continued operation) rather than a hard trip, giving operators time to schedule maintenance.

Conclusion

The EC.21 (Temperature Sensor Fault) on a Shenzhen Kingda V600 inverter is a solvable problem, but it demands a methodical approach. It is rarely just a “bad part” issue; it is often a symptom of environmental stress, poor installation practices, or signal integrity degradation.

By adhering to the diagnostic hierarchy—Visual -> Wiring -> Sensor -> Board—engineers can isolate the fault efficiently. Furthermore, by implementing robust preventive measures like conformal coating, proper torque application, and environmental control, the recurrence of this fault can be virtually eliminated.

Final Safety Warning: All procedures involving the opening of the inverter chassis must be performed by qualified electrical personnel adhering to NFPA 70E or local equivalent safety standards. The DC bus capacitors retain lethal voltages even after power disconnection. Always verify zero energy state before touching internal components.

Mastering the resolution of EC.21 is not just about fixing a single error code; it is about mastering the thermal management of the entire drive system, ensuring longevity and reliability in the harshest industrial environments.

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User Guide for Lingshida LSD-A1000 Series Inverter

Table of Contents

  1. Introduction to the Inverter Control Panel
    • 1.1 Control Panel Layout and Button Functions
    • 1.2 How to Restore Factory Default Settings
    • 1.3 How to Set and Remove Passwords
    • 1.4 How to Set Parameter Access Restrictions
  2. Terminal Forward/Reverse Control and External Potentiometer Frequency Adjustment
    • 2.1 Parameter Settings and Wiring for Terminal Forward/Reverse Control
    • 2.2 Parameter Settings and Wiring for External Potentiometer Frequency Adjustment
  3. Inverter Fault Codes and Solutions
    • 3.1 Common Fault Code List
    • 3.2 Fault Cause Analysis and Solutions
  4. Summary and Precautions
Lingshida LSD-A1000 Series Inverter

1. Introduction to the Inverter Control Panel

1.1 Control Panel Layout and Button Functions

The Lingshida LSD-A1000 series inverter control panel integrates a display screen and multiple functional buttons, facilitating parameter settings, status monitoring, and fault troubleshooting. The panel layout is as follows:

Button/IndicatorFunction Description
RUN (Run)Starts the inverter operation
STOP/RST (Stop/Reset)Stops operation or resets faults
PRG/ESC (Program/Exit)Enters or exits parameter setting mode
DATA/ENT (Data/Enter)Confirms parameter settings or enters the next menu level
△ (Increase)Increases parameter values or selects the previous item
▽ (Decrease)Decreases parameter values or selects the next item
→/SHIFT (Shift)Switches display parameters or selects the modification position
QUICK/JOG (Quick/Jog)Quick function switching or jog operation
Potentiometer KnobAdjusts output frequency or other analog parameters
LED IndicatorsDisplays operating status, fault status, frequency, current, voltage, etc.

LED Indicator Descriptions:

  • RUN (Red): Inverter is running.
  • FWD/REV (Red): Motor is in forward/reverse operation.
  • LOCAL/REMOT (Red): Local/remote control mode.
  • TC (Red): Torque control mode or fault status (flashing indicates a fault).

1.2 How to Restore Factory Default Settings

The Lingshida LSD-A1000 series inverter supports restoring all parameters to factory default values. Follow these steps:

  1. Enter Parameter Setting Mode:
    • Press the PRG/ESC key to enter the function code editing state.
    • Use the △/▽ keys to select FA-11 (Product Number) or FA-12 (Software Version Number) to confirm the current version.
  2. Restore Factory Settings:
    • In the stopped state, press and hold the PRG/ESC key for more than 5 seconds until the display shows the “rES” prompt.
    • Press the DATA/ENT key to confirm the restoration of factory settings.
    • The inverter will restart, and all parameters will be reset to default values.

Note:

  • Restoring factory settings will clear all user-defined parameters, including passwords and PID parameters.
  • After restoration, you need to reconfigure motor parameters (such as rated current and rated frequency).

1.3 How to Set and Remove Passwords

To prevent unauthorized parameter modifications, the Lingshida LSD-A1000 supports password protection.

Setting a Password:

  1. Enter FA-00 (User Password Setting):
    • Press PRG/ESC → Select the FA group → Select FA-00.
    • Enter a 5-digit password (default is 00000).
    • Press DATA/ENT to confirm.
  2. Enable Password Protection:
    • Enter FA-01 (Password Protection Enable):
      • 0: Disable password protection.
      • 1: Enable password protection.

Removing a Password:

  1. Enter the Correct Password:
    • When entering parameter settings, the system prompts for a password.
    • Enter the correct password and press DATA/ENT to confirm.
  2. Reset Password if Forgotten:
    • Press and hold the PRG/ESC key for 5 seconds to restore factory settings (password resets to 00000).

Note:

  • After setting a password, modifying critical parameters (such as F3 group motor parameters) requires entering the password.
  • The manufacturer’s password (for advanced parameters) cannot be cleared by restoring factory settings; contact the manufacturer.

1.4 How to Set Parameter Access Restrictions

To prevent accidental modifications, you can restrict access to certain parameters:

  1. Set Parameter Modification Permissions:
    • The “Change” column in the function code table indicates modification permissions:
      • ★: Can be modified during both operation and stop.
      • ☆: Can only be modified when stopped.
      • ●: Read-only, cannot be modified (such as fault records).
  2. Lock Critical Parameters:
    • After setting a password in FA-00 (User Password), parameters in F3 group (Motor Parameters) and FC group (PID Parameters) cannot be modified without the password.
  3. Lock Buttons:
    • Set via FA-00 (QUICK/JOG Key Function):
      • 0: QUICK/JOG key is disabled.
      • 1: Switch between local and remote control.
      • 2-4: Jog function (to prevent accidental operation).
Lingshida LSD-A1000 Series Inverter is used

2. Terminal Forward/Reverse Control and External Potentiometer Frequency Adjustment

2.1 Parameter Settings and Wiring for Terminal Forward/Reverse Control

The Lingshida LSD-A1000 supports forward/reverse control through DI (Digital Input) terminals.

Parameter Settings:

Function CodeSetting ValueDescription
F6-00 (DI1 Function Selection)1 (Forward Run)DI1 connected for forward operation
F6-01 (DI2 Function Selection)2 (Reverse Run)DI2 connected for reverse operation
F6-11 (Terminal Command Mode)0 (Two-Wire Mode 1)DI1/DI2 control forward/reverse separately

Wiring Steps:

  1. Connect DI1 (Forward) and DI2 (Reverse):
    • Connect DI1 to the forward button or PLC output.
    • Connect DI2 to the reverse button or PLC output.
    • Connect COM to 24V- (common ground).
  2. Set Command Source:
    • F0-21 (Command Source Selection) = 1 (Terminal Command Channel).
  3. Start Testing:
    • Connect DI1, and the motor runs forward.
    • Connect DI2, and the motor runs in reverse.

Note:

  • Ensure F1-06 (Stop Mode) = 0 (Deceleration Stop) to avoid sudden stops.
  • For three-wire control (forward/reverse/stop), set F6-11 = 2 (Three-Wire Mode 1).

2.2 Parameter Settings and Wiring for External Potentiometer Frequency Adjustment

Frequency adjustment can be achieved through AI1 (Analog Input) using an external potentiometer.

Parameter Settings:

Function CodeSetting ValueDescription
F0-02 (Main Frequency Source Selection)2 (AI1)Frequency given by AI1
F6-13 (AI Curve Minimum Input)0.00VPotentiometer minimum voltage corresponds to 0Hz
F6-16 (AI Curve Maximum Input)10.00VPotentiometer maximum voltage corresponds to 50Hz
J13 (AI1 Input Mode)1-2 (0-10V)Voltage input mode

Wiring Steps:

  1. Connect the Potentiometer:
    • Connect the middle pin of the potentiometer to AI1.
    • Connect one end of the potentiometer to +10V (provided by the inverter).
    • Connect the other end of the potentiometer to COM.
  2. Set Frequency Range:
    • F0-09 (Maximum Frequency) = 50.00Hz.
    • F0-12 (Minimum Frequency) = 0.00Hz.
  3. Start Testing:
    • Rotate the potentiometer, and the output frequency changes with the voltage.

Note:

  • The potentiometer resistance is recommended to be 5K-10KΩ.
  • For current input (4-20mA), short J13 to 2-3.

3. Inverter Fault Codes and Solutions

3.1 Common Fault Code List

Fault CodeFault DescriptionPossible Causes
E01Wave-by-Wave Current Limiting FaultHigh starting current, heavy load
E02Acceleration OvercurrentShort acceleration time, motor locked
E03Deceleration OvercurrentShort deceleration time, braking resistor failure
E04Constant Speed OvercurrentSudden load change, motor overload
E05Acceleration OvervoltageHigh input voltage, braking unit failure
E06Deceleration OvervoltageShort deceleration time, braking resistor damage
E11Motor OverloadMotor overheating, poor cooling
E12Input Phase LossLoose power line, blown fuse
E13Output Phase LossMotor line break, contactor failure
E15External FaultExternal emergency stop signal triggered
E16Communication FaultMODBUS communication interruption
E23Running Time ReachedTimer setting triggered stop
E24User-Defined Fault 1DI terminal triggered custom fault

3.2 Fault Cause Analysis and Solutions

E02 (Acceleration Overcurrent)

  • Cause: Acceleration time is too short, or the load inertia is too large.
  • Solution:
    • Increase F0-13 (Acceleration Time 1).
    • Check if the motor is locked.

E05 (Acceleration Overvoltage)

  • Cause: Input voltage is too high, or the braking unit is not enabled.
  • Solution:
    • Check if the input voltage is within 380V±10%.
    • Enable F1-14 (Energy Consumption Braking Point) and connect a braking resistor.

E11 (Motor Overload)

  • Cause: Motor overheating, cooling fan failure.
  • Solution:
    • Check if the motor cooling is normal.
    • Adjust F8-01 (Motor Overload Protection Gain).

E12 (Input Phase Loss)

  • Cause: Loose power line, blown fuse.
  • Solution:
    • Check if the R/S/T terminals are properly connected.
    • Replace the fuse.

E16 (Communication Fault)

  • Cause: MODBUS line disconnection, address conflict.
  • Solution:
    • Check the RS485 line connection.
    • Ensure P0-01 (Communication Address) is unique.

4. Summary and Precautions

  • Control Panel: Familiarize yourself with button functions and set passwords and parameter restrictions reasonably.
  • Terminal Control: Correctly wire DI/AI terminals to avoid misoperation.
  • Fault Troubleshooting: Check power supply, load, and parameter settings one by one according to fault codes.
  • Safety Precautions:
    • Wait 10 minutes after power-off before maintenance.
    • Avoid using in high-temperature or humid environments.

Conclusion The Lingshida LSD-A1000 series inverter is powerful but requires strict operation according to the manual. This guide helps users quickly master basic operations, parameter settings, and fault troubleshooting methods to ensure stable equipment operation. For complex issues, contact the manufacturer’s technical support.

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In-depth Analysis of Fault 10.10 in SEW MOVIDRIVE® Generation C Drives and Research on Parameter Matching Issues Triggered by Encoder Replacement

Abstract

In industrial automation motion control systems, the meanings of servo drive fault codes are diverse. In a recent on-site case, the SEW MOVIDRIVE® Generation C series drive exhibited fault code 10.10 after replacing a SICK encoder. This fault is often misdiagnosed as an encoder not being zero-calibrated, but it is actually an “unsupported setpoint cycle time/data flex layer initialization error,” which falls under the category of parameter-level configuration conflicts. This paper discusses the issue from five dimensions, including drive platform structure and error triggering mechanisms.

CMP71-0 B637/BK/XAK0.00.17,SEW motor

I. Background Overview: Why Fault 10.10 is Prone to Misdiagnosis

After replacing an encoder in a servo system, it is necessary to re-establish the electrical angle reference, among other things. Most system errors are directly related to encoder hardware, such as 13.xx indicating encoder loss or feedback channel abnormalities. However, in this case, 10.10 (Setpoint Cycle Time unsupported / Data Flex Layer Init Error) is an alarm related to control cycle synchronization mechanism abnormalities. Due to the fact that encoder replacement is often accompanied by parameter reloading and drive initialization, on-site engineers tend to establish a connection between the encoder and the error, leading to misdiagnosis.

SKM36S-HFA0-K02

II. SEW MOVIDRIVE® Generation C System Architecture and DFL Explanation

The SEW MOVIDRIVE® adopts a multi-layer data processing system, where motion control and other parameters are distributed and synchronized through the DFL (Data Flex Layer). The DFL is responsible for managing the loading and switching of drive parameter sets, interfacing with bus cycles, validating motion setpoint cycles, and synchronizing feedback data with control loops. When the motion setpoint cycle exceeds limits or does not match the hardware, the drive will prohibit output and trigger Error 10.10 to protect the drive.

fault 10.10 ,sew servo

III. Why Encoder Replacement Can Indirectly Trigger 10.10

Although encoder replacement is not the direct cause of the 10.10 alarm, it can affect variables such as electrical angle, resolution, protocol, parameter rewriting, and cycle synchronization after engineering reset. This leads the drive to detect that the old operating cycle scheme cannot be adapted to the current hardware configuration, necessitating the resynchronization of system parameters and cycle settings, thereby triggering 10.10.

MDD90A-0080-503-X-S00

IV. Technical Troubleshooting Process

Step 1: Confirm Communication Cycle and Drive Support Range
Access the controller/software and check the Communication → Setpoint Cycle Time settings to ensure they are within the recommended range, such as 250us – 2ms for EtherCAT mode. If they exceed the limits, restore them to the supported range.

Step 2: Reinitialize the DFL and Refresh Configuration
Execute Parameter → Data Flex Layer → ReInit, then Save → Reboot Drive.

Step 3: Perform Motor and Feedback Re-matching
Conduct Motor Commission → Encoder Calibration and Rotor Alignment / Commutation Identification.

Step 4: Check for Contradictions in Key Control Parameters
Verify parameters such as Encoder Type, Feedback Resolution, Motor Pole Pairs, and Control Mode to ensure they match. After resetting parameters, execute Save + Reboot.

Step 5: Synchronize Cycles if Involving an Upper-level PLC
Especially in cases of EtherCAT/Profinet/Master Clock, ensure that PLC → Sync Cycle = Inverter Cycle and Clock Drift < 5%.

V. Quick-judgment Experience Rules for Fault 10.10

PhenomenonQuick Conclusion
Error reported immediately after encoder replacement → but encoder is readableHigh probability of cycle/parameter storage not being rebuilt
Brief operation after reset, then error recurs after a few secondsTypical manifestation of setpoint cycle mismatch
Returns to normal when original encoder is reinstatedParameter adaptation issue, not a hardware abnormality
Accompanied by output prohibitionOutput Stage Inhibit has been triggered
10.10 does not indicate a faulty encoder; it means the drive believes it cannot operate safely with the current cycle.

VI. Final Conclusions

The occurrence of 10.10 in SEW Generation C MOVIDRIVE drives is not due to encoder hardware failure but rather due to system setpoint cycle or DFL initialization failure.
Encoder replacement is one of the诱因 (contributing factors); the essence lies in parameter mismatch and sampling/cycle conflicts.
Most on-site cases can be resolved by reconfiguring the cycle → reinitializing the DFL → calibrating the encoder and electrical angle.
Class 10 alarms are of the application stop level, with the output stage locked, and must be addressed before continuing operation.

VII. Engineering Recommendations

  • When replacing an encoder, zero-point/pole-pair calibration must be performed. Do not misclassify 10.10 as an encoder fault.
  • Form a standard inspection unit for system debugging: correct feedback type, matched resolution, control cycle meeting drive hardware requirements, successful DFL initialization, and verification after saving and restarting.
  • For high-speed bus servo projects, it is recommended to lock the cycle within the 250 – 500us range.
  • It is advisable to back up parameters before release to avoid re-encountering issues during secondary maintenance.
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In-depth Analysis and Practical Guide: Handling the Err.23 Dynamic Ground Short Circuit Fault on KCLY KOC600 Inverters

Introduction: The “Safety Red Line” in Inverter Protection

In modern industrial automation, the inverter is the heart of the motor drive system, and its stability directly impacts production efficiency. The KOC600 Series High-Performance Vector Inverter by Shenzhen Kechuan Liyuan (KCLY) is widely recognized for its precision and robust protection features.

However, maintenance engineers occasionally encounter the Err.23 (Output to Ground Short Circuit) fault. A particularly puzzling scenario is when the inverter starts normally but suddenly trips with Err.23 after running for a period. This “dynamic fault” tests a technician’s diagnostic skills and threatens production continuity. This article provides a deep dive into the mechanisms, diagnostics, and solutions for Err.23 based on the KOC600 logic.

err.23

Chapter 1: Understanding Err.23 – The Technical Logic

1.1 What is an Output to Ground Short Circuit?

According to the KOC600 manual, Err.23 occurs when an unintended current path forms between the inverter’s output terminals (U, V, W) and the Ground (PE).

In a healthy state, the three-phase output currents are balanced; their vector sum should be near zero ($\vec{I_u} + \vec{I_v} + \vec{I_w} \approx 0$). If a phase leaks to the ground, this balance is broken. Internal Hall-effect current sensors detect this residual current. If it exceeds the safety threshold, the drive immediately blocks PWM output and triggers Err.23 to protect the internal IGBT power modules from destruction.

Chapter 2: Why Does it Fail After “Running for a While”?

When a fault occurs after minutes or hours of operation rather than at startup, it suggests a “dynamic” issue rather than a hard short circuit.

2.1 Heat-Induced Insulation Degradation

This is the most common cause. As the motor windings or cables heat up during operation:

  • Mechanism: Micro-cracks in insulation may hold under cold conditions. As temperatures rise, materials expand or moisture evaporates into high-pressure pockets, causing the insulation resistance to drop momentarily and creating a flashover to the ground.
  • Symptoms: The fault occurs once the motor reaches its rated load or thermal equilibrium.

2.2 Cumulative Leakage from Cable Capacitance

  • Mechanism: Inverters output high-frequency PWM waves. Long cables act as capacitors between the conductors and the earth.
  • Formula: $I = C \cdot \frac{dv}{dt}$.As operation continues, if humidity changes or the carrier frequency is set too high, high-frequency leakage current hits the protection circuit. At certain frequency points, resonance may cause the current peak to exceed the Err.23 threshold.

2.3 Environmental Factors: Condensation and Dust

In humid environments, temperature differences can cause condensation inside the motor terminal box. Initially, the system runs fine, but as moisture accumulates or mixes with conductive dust, it eventually creates a path to the chassis.

Chapter 3: The “Five-Step” Field Diagnostic Procedure

Step 1: Check Fault Scene Data (bC Parameter Group)

The KOC600 records vital data at the moment of failure. Before resetting, check the bC Group:

  1. bC-03: Output Frequency at fault.
  2. bC-04: Output Current at fault. Check if an overload accompanied the short.
  3. bC-05: Bus Voltage at fault. Fluctuations here can sometimes cause sensor errors.

Step 2: Decoupling Test (Disconnecting Motor Leads)

  • Action: Remove all wires from the U/V/W terminals of the inverter.
  • Conclusion:
    • Still Err.23: Internal hardware damage (IGBT failure or sensor drift).
    • No Error: The inverter is healthy; the fault lies in the cables or motor.

Step 3: Static Insulation Testing (Megger Test)

  • Action: Use a 500V Megohmmeter to measure motor windings to ground.
  • Standard: For a 380V motor, resistance should be > 5MΩ.
  • Warning: Always disconnect the cables from the inverter before using a Megger, or you will destroy the drive’s power modules.

Step 4: Inspect Terminal Box and Cables

Check the motor terminal box for signs of moisture, carbonization (black marks), or loose screws touching the casing. Inspect the cable run for jacket wear, especially in conduits that may hold water.

KOX600-022GT4

Chapter 4: Advanced Optimization for KOC600

If no hard short is found, parameter tuning can often resolve nuisance trips caused by leakage or interference.

4.1 Adjust Carrier Frequency (Parameter b0-11)

Higher carrier frequencies increase ground leakage current.

  • Optimization: Decrease the carrier frequency.
  • Effect: This reduces the charging/discharging current of the cable capacitance, often eliminating “ghost” Err.23 reports.

4.2 Installation of Hardware Suppressors

For cable runs exceeding 50 meters:

  1. Output Reactor: Installed between the drive and motor to smooth the $dv/dt$ and suppress leakage.
  2. Zero-sequence Reactor (Ferrite Core): Looping the three output phases through a ferrite core to suppress high-frequency common-mode current.

Conclusion

Err.23 is a vital protective feature of the KOC600. When facing a fault that only appears after running for some time, technicians should apply a logical loop of Data Analysis -> Decoupling -> Insulation Testing -> Parameter Tuning.

Always prioritize safety: ensure the CHARGE lamp is completely off before touching any terminals. Proper maintenance and environmental control are the best defenses against “running-time” faults.

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In-Depth Analysis and Solution Guide for ERCON Communication Fault in HiMEC HI2xx Series Servo Drives

Introduction

Servo drives, as the core control components of industrial automation equipment, directly determine the operational efficiency and production continuity of devices. The HiMEC HI2xx series servo drives, renowned for their high cost performance and user-friendliness, are widely applied in machine tools, robots, packaging machinery, and other fields. However, in practical use, the ERCON fault (flashing display) caused by communication interruption between the operator (e.g., drive panel) and the main board is one of the most common issues. If unresolved promptly, it can lead to equipment downtime and production stagnation. This article delves into the root causes of the ERCON fault in HI2xx series drives, provides a step-by-step solution guide, and proposes preventive measures to help technicians quickly locate and resolve the problem.

ercon fault

1. Overview of ERCON Fault

1.1 Fault Definition

ERCON (Error Communication) is a communication fault code specific to HiMEC HI2xx series drives, referring to the interruption of the communication link between the operator (e.g., drive panel, handheld programmer) and the main board. When the communication link is abnormal, the operator triggers a communication alarm and displays “ERCON” in a flashing manner, alerting users to check the communication system immediately.

1.2 Fault Impact

  • The operator cannot receive status information from the main board (e.g., motor speed, torque, alarm codes);
  • Control commands (e.g., start, stop, parameter modification) cannot be sent to the main board;
  • The drive enters protection mode, unable to drive the motor normally, and may cause equipment shutdown in severe cases.

2. In-Depth Analysis of Fault Causes

The communication link of HI2xx series drives consists of three parts: operator, communication cable, and main board interface (Figure 1). Any abnormality in these components can trigger the ERCON fault. Below is a detailed breakdown of the causes:

2.1 Communication Cable Fault (Most Common Cause)

The communication cable is the “signal bridge” connecting the operator and the main board, accounting for over 60% of ERCON faults. Specific causes include:

  • Physical damage: Internal conductors break due to long-term vibration or bending (e.g., copper foil fracture in a flat cable);
  • Loose connection: Poor contact between the plug and socket due to vibration or repeated插拔 (e.g., reduced clamping force between a pin header and socket);
  • Electromagnetic interference (EMI): The communication cable is not shielded or laid parallel to power cables (e.g., motor cables), causing EMI to disrupt communication (e.g., RS485 differential signals are submerged by noise);
  • Aging: The insulation layer of the communication cable ages due to high temperature or humidity, leading to short circuits or signal attenuation.

2.2 Interface Fault

The communication interfaces of the operator or main board are “nodes” in the link, accounting for about 30% of faults. Specific causes include:

  • Pin damage: Pins (e.g., pin header, DB9 interface pins) bend or break due to forced插拔 or vibration (e.g., a pin header pin is bent and cannot contact the socket);
  • Oxidation/contamination: Pins oxidize (e.g., copper pins turn black) or the interface is contaminated with dust/oil in humid/dusty environments, increasing contact resistance and blocking signal transmission;
  • Lock failure: The plug lock (e.g., flat cable clip) breaks due to aging, causing the plug to loosen and lose contact.

2.3 Equipment Itself Fault

Faults in the internal communication circuits of the operator or main board account for about 10% of cases. Specific causes include:

  • Operator fault: The operator’s communication chip (e.g., RS485 transceiver) is damaged, unable to send/receive signals;
  • Main board fault: The main board’s communication interface circuit (e.g., UART, RS485 circuit) fails (e.g., capacitor breakdown, resistor burnout), preventing signal processing;
  • Firmware incompatibility: Mismatched firmware versions between the operator and main board (e.g., the operator’s firmware is upgraded but incompatible with the old main board’s communication protocol) disrupt communication.

2.4 Environmental Factors

  • Excessive temperature: The operating environment exceeds the rated range (e.g., HI2xx series operates at 0–45°C), softening the communication cable’s insulation or loosening solder joints on interface pins;
  • High humidity: Ambient humidity exceeds 85%, accelerating pin oxidation or reducing the communication cable’s insulation resistance (e.g., insulation resistance drops from 10MΩ to <1MΩ, causing severe signal attenuation);
  • Vibration: Long-term operation in high-vibration environments (e.g., presses, vibration tables) loosens communication cable plugs or breaks internal conductors.
hilectro servo

3. Step-by-Step Solution Guide for ERCON Fault

The following steps follow the principle of “from simple to complex, from external to internal” to help technicians troubleshoot without盲目 disassembling the device.

3.1 Step 1: Power Off and Preliminary Inspection

Purpose: Ensure safety and avoid damaging the device during live operations;初步 locate the fault scope.
Details:

  1. Power off: Turn off the drive’s power switch (e.g., circuit breaker) and unplug the power cord. Wait 5 minutes to discharge the drive’s internal capacitors;
  2. Visual inspection:
    • Check the communication cable for obvious breaks, bends, or insulation damage (e.g., exposed copper foil in a flat cable);
    • Check the connection between the plug and socket for looseness (e.g., the flat cable plug is not fully inserted into the socket);
    • Check the operator and main board interfaces for dust or oil (e.g., black dust in the interface);
  3. Re-plug the communication cable:
    • Release the plug lock (e.g., flat cable clip) and slowly pull out the plug;
    • Check the plug pins for bending or breakage (e.g., a pin header pin is bent);
    • Brush dust from the plug and socket with a brush, then reinsert the plug and ensure the lock is fastened (e.g., the flat cable clip is fully locked).

Notes:

  • Align the pins when plugging/unplugging to avoid bending pins with force;
  • Replace the communication cable if the plug lock fails (avoid using tape, which can cause poor contact).

3.2 Step 2: Continuity Test of Communication Cable

Purpose: Verify if the communication cable has internal breaks and eliminate conductor faults.
Details:

  1. Prepare tools: Multimeter (set to “continuity mode” or “resistance mode”);
  2. Test method:
    • Connect both ends of the communication cable to the operator and main board interfaces (e.g., insert both ends of the flat cable into the operator and main board sockets);
    • Touch the corresponding pins of the communication cable with multimeter probes (e.g., pin 1 to pin 1, pin 2 to pin 2, etc.);
    • If the multimeter shows “continuity” (resistance <1Ω), the conductor is normal; if it shows “open circuit” (infinite resistance), the conductor is broken.

Example:

  • If pin 3 of the communication cable is not continuous to pin 3, the 3rd conductor is broken and the cable needs replacement.

Notes:

  • Ensure both ends of the communication cable are not connected to the operator or main board during testing (to avoid interference from the main board circuit);
  • If the communication cable is a shielded type, test the shield continuity (the shield must be grounded to avoid EMI).

3.3 Step 3: Interface Inspection and Cleaning

Purpose: Eliminate poor contact caused by pin damage, oxidation, or contamination.
Details:

  1. Inspect pins:
    • Use a magnifying glass to check interface pins (e.g., socket pins): look for bending or breakage (e.g., a socket pin is bent);
    • If a pin is bent, slowly adjust it to vertical with tweezers (avoid excessive force to prevent breakage);
    • If a pin is broken, replace the interface (e.g., socket) or main board (if the pin is soldered to the main board).
  2. Clean oxidation and dust:
    • Soak a cotton swab in anhydrous alcohol (≥99% concentration) and wipe the interface pins (e.g., socket pins, plug pins);
    • Brush dust from the interface with a brush;
    • Reinsert the communication cable after the alcohol evaporates.

Notes:

  • Do not grind pins with sandpaper (this damages the pin coating and accelerates oxidation);
  • Use anhydrous alcohol to clean oil stains (avoid corrosive solvents like gasoline or thinner).

3.4 Step 4: Replace the Communication Cable

Purpose: Eliminate faults caused by the communication cable itself (e.g., internal breaks, aging).
Details:

  1. Select the communication cable:
    • Use a HiMEC original communication cable (matching the HI2xx series drive model, e.g., HI2-CABLE-01);
    • If an original cable is unavailable, use a shielded communication cable of the same specification (e.g., RS485 communication cables must be twisted-pair with a shield, and the shield must be grounded).
  2. Replacement method:
    • Disconnect both ends of the old communication cable (operator and main board sides);
    • Insert both ends of the new communication cable into the operator and main board interfaces, ensuring the lock is fastened;
    • Power on the drive: if the ERCON fault disappears, the communication cable fault is resolved.

Notes:

  • Do not use non-original communication cables (incorrect pinout or impedance mismatch may cause communication faults);
  • If the ERCON fault persists after replacing the cable, check the operator and main board interfaces for damage (e.g., bent pins).

3.5 Step 5: Firmware Inspection for Operator and Main Board

Purpose: Eliminate communication faults caused by firmware incompatibility.
Details:

  1. Check firmware versions:
    • View the operator’s firmware version via the menu (e.g., “Parameter Settings” → “Version Information”);
    • View the main board’s firmware version via the drive’s upper computer software (e.g., HiMEC Servo Tool);
  2. Upgrade firmware:
    • If the operator and main board firmware versions are mismatched (e.g., operator firmware V1.2, main board firmware V1.0), upgrade to a compatible version (e.g., both to V1.3);
    • Follow HiMEC’s Firmware Upgrade Guide for firmware upgrades (e.g., via USB or SD card) to avoid device damage.

Notes:

  • Backup parameters before firmware upgrades (to avoid parameter loss after upgrading);
  • Do not upgrade to unvalidated firmware versions (may cause communication protocol incompatibility).

3.6 Step 6: Hardware Inspection of Main Board and Operator

Purpose: Eliminate hardware faults in the operator or main board (e.g., damaged communication circuits).
Details:

  1. Replacement test:
    • If a spare operator is available (e.g., the same model panel), replace the original operator. If the ERCON fault disappears, the original operator is faulty;
    • If a spare main board is available (e.g., the same model main board), replace the original main board. If the ERCON fault disappears, the original main board is faulty.
  2. Circuit testing:
    • Use a multimeter to test the voltage of the main board’s communication interface (e.g., RS485 interface voltage: normally 1–5V between A+ and B-);
    • Use an oscilloscope to test the communication signal (e.g., RS485 differential signal: normally clear waveform without noise);
    • If the voltage or signal is abnormal, repair or replace the main board (e.g., replace the communication circuit chip or resistor).

Notes:

  • Use the same model of device for replacement tests (to avoid compatibility issues);
  • Circuit testing must be performed by a professional technician (to avoid damaging other circuits).

4. Preventive Measures for ERCON Fault

4.1 Regularly Inspect the Communication Link

  • Weekly check: Visually inspect if the communication cable is loosely connected or damaged (e.g., flat cable copper foil breakage);
  • Monthly check: Test the communication cable’s continuity with a multimeter (to avoid internal conductor breaks);
  • Quarterly check: Clean dust and oxidation from the operator and main board interfaces (to avoid poor contact).

4.2 Environmental Maintenance

  • Temperature control: Keep the drive’s operating environment between 0–45°C (e.g., install cooling fans, avoid direct sunlight);
  • Humidity control: Maintain ambient humidity between 40%–85% (e.g., install dehumidifiers, avoid exposing the device to rain);
  • Vibration protection: Install the drive in a low-vibration area (e.g., fix the device with shock-absorbing pads) to prevent communication cable breaks due to vibration.

4.3 Standardize Operations

  • Plug/unplug communication cables: Align the pins and avoid forced insertion (e.g., use the lock to fix, avoid pulling out pins);
  • Firmware upgrades: Follow the manufacturer’s guide (e.g., backup parameters, use a stable power supply) to avoid upgrade failures;
  • Avoid EMI: Lay communication cables separately from power cables (e.g., spacing >30cm) or use shielded communication cables (the shield must be grounded).

4.4 Spare Parts Management

  • Stock original communication cables (e.g., HI2-CABLE-01), spare operators (e.g., same model panel), and spare main boards (e.g., same model main board) to enable quick replacement and reduce downtime.

5. Case Analysis

5.1 Fault Phenomenon

An HI200-01 drive in a packaging machinery factory (controlling a feeder motor for a packaging machine) displayed a flashing “ERCON” after power-on, and the motor could not start.

5.2 Troubleshooting Process

  1. Step 1: Re-plugging the communication cable after power-off did not resolve the fault;
  2. Step 2: A multimeter test showed an open circuit between pin 3 of the communication cable (internal conductor break);
  3. Step 3: Replacing the original communication cable (HI2-CABLE-01) eliminated the ERCON fault, and the operator displayed normally.

5.3 Root Cause

The communication cable’s internal conductor broke due to long-term vibration from the packaging machine, interrupting the communication link.

5.4 Result

The device resumed normal operation after replacing the communication cable, and no further ERCON faults occurred.

6. Conclusion

The ERCON fault is a common communication fault in HiMEC HI2xx series drives, caused by communication link interruption. Technicians can quickly locate and resolve the problem by following the steps: power off and inspect → test communication cable → clean interfaces → replace communication cable → check firmware → inspect hardware. Additionally, preventive measures such as regular inspections, environmental maintenance, standardized operations, and spare parts management can effectively reduce the occurrence of ERCON faults and ensure stable device operation.

The solution guide and preventive measures in this article are not only applicable to HI2xx series drives but also provide a reference for troubleshooting communication faults in other servo drives. Technicians should adjust the troubleshooting steps flexibly based on specific device conditions (e.g., environment, frequency of use) to ensure rapid recovery of device operation.

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User Guide for Bohui E200 Series Variable Frequency Drive (VFD)

1. Introduction

The Bohui E200 series Variable Frequency Drive (VFD) is a high-performance, reliable vector control inverter widely used in industrial automation, including fans, pumps, textile machinery, machine tools, packaging, and food processing. It supports VF control, open-loop vector control, and closed-loop vector control, and features PLC functionality, PID control, multi-speed operation, and high-speed pulse input.

This guide provides a detailed explanation of the E200 series operation panel, parameter settings, external control wiring, and fault troubleshooting to help users efficiently operate and maintain the device.

2. Operation Panel Overview

Front panel of E200 VFD

2.1 Panel Buttons and Functions

The E200 series VFD operation panel includes the following buttons:

ButtonFunction
RUNStarts the VFD.
STOP/RESETStops the VFD or resets faults.
MODESwitches between parameter setting and monitoring modes.
UP/DOWNAdjusts parameter values or navigates menus.
ENTERConfirms parameter settings or enters submenus.
JOGUsed for jog operation or command source switching.

2.2 Display Screen Functions

The display screen shows real-time data, including:

  • Running frequency
  • Set frequency
  • Bus voltage
  • Output current
  • Fault codes

Users can customize the display content via F0-00 (Menu Mode Selection).

3. Parameter Settings and Management

3.1 Restoring Factory Default Settings

To reset all parameters to factory defaults:

  1. Press MODE to enter parameter setting mode.
  2. Navigate to F0-47 (Parameter Initialization).
  3. Set F0-47 = 1001 to restore factory settings (excluding motor parameters).
  4. Set F0-47 = 1002 to reset recorded information.
  5. Press ENTER to confirm. The VFD will restart automatically.

3.2 Setting and Removing Password Protection

To prevent unauthorized parameter changes, the E200 supports password protection:

Setting a Password

  1. Enter F0-46 (Password Setting).
  2. Set a non-zero value (e.g., 1234).
  3. Confirm with ENTER. The password will be required to access parameters.

Removing a Password

  1. Enter F0-46.
  2. Set the value to 0.
  3. Confirm with ENTER. Password protection will be disabled.

3.3 Parameter Access Restrictions

The E200 allows different access levels via F0-44 (Parameter Access Level):

LevelAccess Permission
0No restrictions.
1Basic parameter modifications only.
2Most parameter modifications allowed.
3Monitoring only (no modifications).
4Fully locked.

Steps to Set Access Level:

  1. Enter F0-44.
  2. Select the desired level (0~4).
  3. Confirm with ENTER.

4. External Terminal Control and Speed Adjustment

4.1 External Terminal Forward/Reverse Control

The E200 supports forward and reverse control via external terminals.

Wiring Terminals

  • X1: Forward run (default function).
  • X2: Reverse run (requires configuration).
  • COM: Common terminal.

Parameter Settings

  1. Enter F5-00 (X1 Input Function Selection) and set to 1 (Forward Run).
  2. Enter F5-01 (X2 Input Function Selection) and set to 2 (Reverse Run).
  3. Ensure F0-02 (Run Command Channel Selection) is set to 1 (Terminal Control).

Wiring Example:

  • Connect an external switch or PLC output to X1 and X2, with COM as the common terminal.

4.2 External Potentiometer Speed Control

The E200 supports speed adjustment via an external potentiometer (010V or 420mA).

Wiring Terminals

  • AI1: Analog input terminal (default 0~10V).
  • +10V: Reference voltage output.
  • ACM: Analog common terminal.

Parameter Settings

  1. Enter F0-03 (Main Frequency Source Selection) and set to 2 (AI1).
  2. Configure F5-24~F5-27 to set the AI1 input range (e.g., 010V corresponds to 050Hz).
  3. Ensure F0-02 (Run Command Channel Selection) is set to 1 (Terminal Control).

Wiring Example:

  • Connect the potentiometer to AI1 and ACM, and use +10V as the reference voltage.
Side (panel/view) of E200 VFD

5. Fault Codes and Troubleshooting

The E200 displays fault codes on the screen or via U0-62 (Current Fault Code). Below are common faults and solutions:

Fault CodeFault NamePossible CauseSolution
OC1Acceleration OvercurrentShort acceleration time, excessive loadIncrease acceleration time (F0-10), check load
OC2Deceleration OvercurrentShort deceleration time, high inertiaIncrease deceleration time (F0-11), add braking resistor
OU1Acceleration OvervoltageHigh supply voltage, insufficient brakingCheck power supply, add braking unit
LUUndervoltage FaultLow supply voltageCheck power supply stability
OL2Motor OverloadMotor overheating, excessive loadCheck motor cooling, reduce load
IPLInput Phase LossMissing input phaseCheck input power wiring
ETFExternal FaultExternal fault signalCheck external control wiring
CoFCommunication FaultCommunication line issueCheck communication interface and wiring

Troubleshooting Steps:

  1. Check U0-62 for the fault code.
  2. Refer to the table above to identify the cause.
  3. Take corrective action.
  4. Press STOP/RESET to clear the fault after resolution.

6. Conclusion

The Bohui E200 series VFD is a powerful and flexible device suitable for various industrial applications. This guide covers operation panel functions, parameter settings, external control wiring, and fault troubleshooting to help users operate the VFD efficiently.

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Analysis and Systematic Solutions for ER.022 Fault in Weichuang Servo SD700 Series

Introduction

In the field of modern industrial automation, servo systems are the core components for high-precision motion control, and their stability and reliability directly impact the efficiency and product quality of production lines. The SD700 series servo drives launched by Weichuang Electric have gained market recognition due to their excellent performance and wide applications. However, in actual operation, the ER.022 fault code, as a common system abnormality alert, poses a challenge to technicians. This article will provide a systematic technical guide for technicians from the aspects of definition, causes, diagnosis, solutions, and prevention.

ER.022 fualt

I. Overview of the ER.022 Fault Code

1.1 Definition of the Fault Code

The ER.022 fault code in the Weichuang Servo SD700 series represents a “system and checksum anomaly,” indicating that the servo drive has detected inconsistencies in system parameters, data, or checksums during self-check or operation, which may be caused by software errors, hardware failures, or external interference.

1.2 Fault Phenomena

When the SD700 series servo drive experiences an ER.022 fault, it is usually accompanied by the following phenomena:

  • The fault indicator light on the drive panel illuminates, displaying the ER.022 error code.
  • The servo motor stops running and fails to respond to control commands from the host computer.
  • The drive may automatically enter a protective state.

II. Analysis of the Causes of the ER.022 Fault

2.1 Software Errors

  • Loss or Damage of System Parameters: Parameters may be lost or damaged during storage or transmission due to sudden power outages or electromagnetic interference.
  • Incompatibility of Firmware Versions: The firmware may be incompatible with the host computer software or other devices.
  • Software Defects: The servo drive software may have undiscovered defects or vulnerabilities.

2.2 Hardware Failures

  • Memory Failures: Non-volatile memories such as EEPROMs and Flash memories may age, be damaged, or have write errors.
  • Processor Failures: The CPU or DSP may operate abnormally due to overheating, voltage instability, or manufacturing defects.
  • Communication Interface Failures: Data transmission errors may occur due to poor contact, damage, or protocol mismatches in communication lines.

2.3 External Interference

  • Electromagnetic Interference: Electromagnetic interference may be generated by frequency converters, high-voltage cables, etc., in the surrounding environment.
  • Power Supply Fluctuations: Unstable power supplies may cause abnormal operation of internal circuits in the drive, such as voltage dips or surges.
SD700 weichi drive

III. Diagnostic Process for the ER.022 Fault

3.1 Preliminary Checks

  • Confirm Fault Phenomena: Check the fault indicator light and error code on the drive panel.
  • Check Power Supply: Use a multimeter to measure the input power supply voltage to ensure it is stable without fluctuations.
  • Check Communication Lines: Check the connection status of communication lines to ensure there are no loose or damaged parts.

3.2 In-Depth Diagnosis

  • View Fault Logs: View fault logs through the host computer software or drive panel.
  • Parameter Backup and Restoration: Back up parameters and then perform initialization operations to restore factory settings. Reconfigure parameters and observe whether the fault disappears.
  • Firmware Upgrade: Check and upgrade the firmware version.
  • Hardware Detection: Use professional testing tools to detect key components such as memories, processors, and communication interfaces.

IV. Solutions for the ER.022 Fault

4.1 Software Solutions

  • Parameter Initialization and Reconfiguration:
    • Back up parameters to an external storage device.
    • Perform initialization operations to restore factory settings.
    • Reconfigure parameters according to requirements and observe whether the fault disappears.
  • Firmware Upgrade:
    • Download the latest firmware file from the official website.
    • Burn the firmware using the host computer software or a dedicated programmer.
    • Restart the drive and observe whether the fault disappears.

4.2 Hardware Solutions

  • Replace Memory: If memory failure is suspected, try replacing the EEPROM or Flash memory and reconfigure parameters.
  • Replace Processor: If processor failure is confirmed, replace the entire drive or processor module and reconfigure parameters and upgrade the firmware.
  • Repair Communication Interface: Check the connection status of communication lines and replace the communication interface module or the entire drive.

4.3 Solutions for External Interference

  • Electromagnetic Shielding: Perform electromagnetic shielding treatment on the drive and surrounding equipment and use shielded cables for connections.
  • Stable Power Supply: Provide a stable and reliable power supply and use a UPS or voltage regulator to ensure power quality.

V. Preventive Measures and Routine Maintenance

5.1 Preventive Measures

  • Regular Parameter Backup: Regularly back up parameters for quick restoration.
  • Avoid Sudden Power Outages: Avoid sudden power outages during operation as much as possible.
  • Use Genuine Software: Ensure that genuine software and firmware from the official source are used.

5.2 Routine Maintenance

  • Cleaning and Dust Prevention: Regularly clean the drive and surrounding equipment to keep them clean and well-ventilated.
  • Check Connection Lines: Regularly check whether connection lines are properly connected without looseness or damage.
  • Monitor Operating Status: Monitor the operating status and parameter changes of the drive through the host computer software or drive panel to promptly detect and handle potential problems.

VI. Conclusion

The ER.022 fault, as a common system abnormality alert in the Weichuang Servo SD700 series, has causes involving software errors, hardware failures, and external interference. Through a systematic diagnostic process and solutions, technicians can effectively locate and solve the problem to ensure the stable operation of the servo system. Meanwhile, taking preventive measures and strengthening routine maintenance can reduce the probability of fault occurrence and improve the efficiency and product quality of production lines.