Category: Industrial control technology

Debugging, application, and maintenance techniques for industrial control products，Such as Variable speed driver(VSD),Variable frequency driver(VFD),Industrial touch screen,Programmable Logic Controller(PLC),Servo Driver,servo motor,servo amplifier,Servo Controller,etc.

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User Guide and E-04 Fault Meaning and Solution for NSA2000 Series Inverters from Nengshi

I. Introduction to the Operation Panel of the Nengshi NSA2000 Series Inverters

Basic wiring diagram of NS2000 frequency converter

The operation panel of the Nengshi NSA2000 series inverters features intuitive and powerful control functions, capable of meeting the demands of various industrial applications. The main function keys on the operation panel include:

  • RUN: The inverter run key, used to start the inverter.
  • REV/JOG: The reverse/jog key, which can be set to reverse or jog functions according to parameters.
  • STOP/RST: The stop/reset key, used to stop the inverter or reset it in case of a fault.
  • PRG: The mode switch key, used to switch the working mode of the operation panel.
  • ENTER: The confirmation key, used to confirm the current status or store parameters.
  • ▲/▼: The data modification keys, used to modify function codes or parameter values.
  • SHIFT: The data bit switch key, used to select the bit to be modified when modifying data.

How to Restore Factory Settings (Initialize Parameters)

  1. With the inverter in the stopped state, press the PRG key to enter the parameter query mode.
  2. Press the PRG key again to enter the parameter modification mode.
  3. Use the ▲/▼ keys to select the function parameter F3.01.
  4. Press the ENTER key to enter the parameter modification state.
  5. Set the parameter value to 1 and press the ENTER key to confirm, restoring the inverter to factory settings.

How to Set Passwords and Parameter Write Protection Functions, and How to Eliminate Passwords

  1. Setting a Password: Modify the function parameter F3.03 to set a 4-digit numeric password within the range of 0000-9999.
  2. Parameter Write Protection: Function parameter F3.02 is used to set parameter write protection, allowing choices between allowing modification of all parameters, only allowing modification of frequency settings, or prohibiting modification of all parameters.
  3. Eliminating a Password: Reset the value of function parameter F3.03 to 0 to eliminate password protection.

Function and Setting Method of Jump Frequencies

Jump frequencies are used to avoid the mechanical resonance points of load devices, preventing equipment damage or performance degradation due to resonance. The setting method is as follows:

  1. Use the ▲/▼ keys to select function parameters F2.36, F2.37, F2.38, F2.39, F2.40, and F2.41, which are used to set the three jump frequencies and their corresponding jump ranges.
  2. Press the ENTER key to enter the parameter modification state, use the ▲/▼ keys to set the desired jump frequencies and ranges.
  3. After setting, press the ENTER key to confirm.

II. Realization of Terminal Forward/Reverse Control and External Potentiometer Frequency Control Functions

Terminal Forward/Reverse Control

Terminal forward/reverse control is achieved by controlling the on/off states of the FWD and REV terminals. The parameters that need to be set include:

  • F0.04: Operation command channel selection, set to 1 to control via terminals.
  • F4.06: FWD/REV terminal control mode, select the appropriate control mode according to actual needs (such as two-wire or three-wire mode).

In terms of wiring, connect the external control switches to the FWD and REV terminals respectively, and ensure that the common terminal COM is correctly connected.

External Potentiometer Frequency Control

The external potentiometer frequency control function allows users to change the output frequency of the inverter by adjusting the resistance value of an external potentiometer. The parameters that need to be set include:

  • F0.01: Frequency setting channel selection, set to 0 to use the potentiometer on the operation panel.
  • If using an external potentiometer, set F0.01 to 4 (VCI analog setting) or 5 (CCI analog setting), and configure the input range of VCI or CCI (F5.00-F5.03) according to actual conditions.

In terms of wiring, connect the three terminals of the external potentiometer to the VCI (or CCI), GND, and +10V (or 0V) terminals of the inverter.

E-04 FAULT

III. Meaning and Handling of E-04 Fault

Meaning of E-04 Fault

The E-04 fault indicates overvoltage during the acceleration process of the inverter. This is usually caused by abnormal grid voltage, restarting a rotating motor, or excessively short deceleration time.

Handling Method

  1. Check the Input Power Supply: Ensure that the grid voltage is stable and meets the operating requirements of the inverter.
  2. Avoid Restarting a Rotating Motor: If it is necessary to start a rotating motor, set it to DC brake start.
  3. Extend the Deceleration Time: Appropriately extend the deceleration time of the inverter based on actual conditions to reduce overvoltage.

Fault Repair

If the above methods cannot resolve the E-04 fault, further inspection and repair of the inverter may be required. It is recommended to contact professional after-sales service personnel or a technical support team for troubleshooting and repairs. During the repair process, ensure that the power supply to the inverter is cut off and operate in accordance with relevant safety regulations.

Conclusion

The Nengshi NSA2000 series inverters feature a rich set of operation panel functions. Through reasonable parameter settings and wiring configurations, various control functions can be realized. When handling E-04 faults, first check the input power supply and the operating status of the inverter, and take corresponding measures based on actual conditions. If further repairs are needed, it is recommended to contact a professional technical support team. Through proper use and maintenance, the Nengshi NSA2000 series inverters will provide users with stable and reliable variable frequency speed regulation solutions.

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User Guide for GSK DAP03 Spindle Drive Unit and Troubleshooting for Err-11

I. Display Menu and Status Monitoring

1.1 Operation and Settings of the Display Menu

GSK DAP03 Spindle Drive Unit Standard Wiring Diagram

The GSK DAP03 spindle drive unit is equipped with a 6-digit LED digital tube for displaying various statuses and parameters. Users can operate the display menu and monitor statuses through the following steps:

Status Monitoring: Users can press corresponding buttons to select different monitoring statuses. For example, pressing the “+” or “-” button can flip through different monitoring contents such as motor speed, current position, input/output terminal status, etc. The specific monitoring content can be selected by setting parameter PA3, and the content displayed after power-on can also be set according to this parameter.

Parameter Setting: In parameter setting mode, users can adjust parameter values using the “+” and “-” buttons, and save the settings by pressing the “Confirm” button. Note that after modifying certain key parameters, a parameter write operation (EE-SEt) is required to ensure the changes take effect.

1.2 Settings for Status Monitoring

Status monitoring allows users to view various statuses of the drive unit in real-time, such as motor speed, position, alarm codes, etc. Users can select the specific monitoring content by setting parameter PA3. For example, setting PA3 to “0” will display motor speed by default after power-on; setting it to “1” will monitor the low five-digit pulse count of the current motor position, and so on.

II. Manual and Inching Control

2.1 Manual Control

In manual control mode, users can directly control the motor’s forward and reverse rotation as well as acceleration and deceleration using the “+” and “-” buttons on the operation panel. The specific steps are as follows:

  • Set PA4=2 to select manual operation mode.
  • Set PA33=1 to enable forced enable (not dependent on external enable signals).
  • Enter the manual operation menu and control the motor using the “+” and “-” buttons. Pressing the “+” button accelerates the motor, pressing the “-” button decelerates it, and releasing the buttons allows the motor to maintain its current speed.

2.2 Inching Control

Inching control allows users to briefly run the motor at a preset speed. The specific steps are as follows:

  • Set PA4=3 to select inching operation mode.
  • Set PA21 to the desired inching speed (e.g., 300 represents 300 RPM).
  • Set PA33=1 to enable forced enable.
  • Enter the inching operation menu and press the “+” or “-” button to start the motor in forward or reverse rotation. The motor stops when the button is released.
DAP03 spindle drive unit and CN connection diagram

III. Position and Speed Control Modes

3.1 Position Control Mode

In position control mode, users control the motor’s precise position through pulse commands. The specific wiring and parameter settings are as follows:

Wiring: Connect the PULS+, PULS-, SIGN+, SIGN- terminals of the CN1 interface to receive position commands.

Parameter Settings:

  • Set PA4=0 to select position mode.
  • Set PA12 (position pulse command multiplication factor) and PA13 (position pulse command division factor) as needed to calculate the electronic gear ratio.
  • Set PA14 to select the pulse command mode (e.g., pulse + direction).

3.2 Speed Control Mode

In speed control mode, users can control the motor’s speed through analog voltage commands or internal digital commands. The specific wiring and parameter settings are as follows:

Analog Voltage Command Control:

  • Wiring: Connect the VCMD+, VCMD- terminals of the CN1 interface to receive analog voltage commands.
  • Parameter Settings: Set PA4=1 and PA22=1 to select analog command speed mode, and set PA42 to the motor speed corresponding to 10V analog input.

Internal Digital Command Control:

  • Wiring: Connect the SP0, SP1, SP2, etc., terminals of the CN1 interface to select preset speeds.
  • Parameter Settings: Set PA4=1 and PA22=0 to select internal command speed mode, and set the speeds for each segment through PA24 to PA30.

3.3 Electronic Gear Ratio Setting

The electronic gear ratio is used to convert input commands into the motor’s actual movement. The calculation formula is:

G = (ZM × CD × δ × CR × PA13) / (PA12 × ZM × L)

Where ZM and ZD are the gear ratios at the screw end and motor end (both are 1 when directly connected), L is the screw lead, C is the motor encoder’s number of lines, δ is the system’s minimum output command unit, and CR and CD are the multiplication and division factors for the upper machine’s commands. Users need to set PA12 and PA13 according to the actual mechanical structure to achieve the desired electronic gear ratio.

IV. Common Alarm Codes and Troubleshooting

The GSK DAP03 spindle drive unit displays corresponding alarm codes when abnormalities are detected. Below are some common alarm codes, their meanings, and troubleshooting methods:

  • Err-1: The spindle motor speed exceeds the set value. Possible causes include abnormal encoder feedback signals, improper acceleration/deceleration time settings, etc. Troubleshooting methods include checking encoder connections, adjusting acceleration/deceleration time parameters, etc.
  • Err-5: Motor overtemperature alarm. Possible causes include no temperature detection device inside the motor, overload, etc. Troubleshooting methods include setting PA73=1 to disable the alarm, reducing the load, etc.
  • Err-9: Abnormal motor encoder signal feedback. Possible causes include poor encoder signal wire connections, damaged encoders, etc. Troubleshooting methods include checking encoder connections, replacing encoders, etc.
GSK spindle servo DAP03 experiences ERR-11 fault

V. Err-11 Alarm Code Meaning and Troubleshooting

The Err-11 alarm code indicates a fault in the intelligent power module (IPM) inside the drive unit. The IPM is a core component of the drive unit, responsible for converting DC power into AC power to drive the motor. When the IPM detects abnormalities or damage, it triggers the Err-11 alarm.

Possible Causes:

  • IPM Overheating: Long-term high-load operation or poor heat dissipation may cause the IPM to overheat, leading to failure.
  • Short Circuit or Overload: Short circuits in the motor or power lines, as well as motor overload operation, can damage the IPM.
  • Power Voltage Fluctuations: Unstable power voltage may cause abnormal IPM operation or even damage.
  • IPM Quality Issues: In rare cases, the IPM may have manufacturing defects or early failure.

Troubleshooting Methods:

  • Check Power Voltage: Ensure stable input power voltage that meets the drive unit’s voltage requirements. If the power voltage fluctuates significantly, consider installing a voltage stabilizer.
  • Check Motor and Wiring: Disconnect the motor from the drive unit and check for short circuits or grounding faults in the motor and wiring. Use tools such as a multimeter to perform resistance and insulation tests to ensure the wiring is intact.
  • Improve Heat Dissipation: Ensure the drive unit’s cooling fan is working properly and the heatsink is clean of dust. In high-temperature or harsh environments, consider adding additional cooling measures, such as installing fans or lowering the ambient temperature.
  • Replace the IPM: If the above steps fail to solve the problem, it may be due to IPM failure. In this case, contact the supplier or manufacturer to purchase and replace the IPM. When replacing, ensure power is off, and the new module is compatible with the old one.
  • Contact Technical Support: If the problem persists, it is recommended to contact GSK’s technical support team for assistance. They can provide more professional fault diagnosis and repair advice.

Notes:

  • When dealing with any faults related to electrical equipment, always cut off the power first to ensure personal safety.
  • If you do not have relevant professional knowledge and skills, do not attempt to repair the drive unit or IPM yourself. Incorrect operations may lead to further equipment damage or safety hazards.

By following the above steps, you should be able to diagnose and solve the Err-11 alarm issue in the GSK DAP03 spindle drive unit. If the problem persists, seek help from professional technicians.

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User Manual Guide for Convo Inverter FSCG05 Series

I. Introduction to Operating Panel Functions and Initialization Settings

1. Operating Panel Function Introduction

The Convo FSCG05 series inverters come equipped with an intuitive operating panel that offers extensive functionalities for parameter setting, monitoring, and control.

2. Factory Default Initialization Settings
Function diagram of CONVO inverter CVF-G5 panel

To restore the inverter to its factory default settings, you need to modify specific parameters. The key parameter to be set is b-11 (Parameter Initialization). Here’s how to do it:

  • Parameter and Setting: b-11 = 1
  • Procedure:
    1. Access the advanced parameter mode by setting b-0 = 2.
    2. Navigate to b-11 and set its value to 1.
    3. Save the setting and restart the inverter to apply the factory defaults.
3. Copying and Downloading Parameters via Operating Panel

Copying Parameters:

  • Procedure for KP51B Keypad:
    1. Set the source inverter to parameter copy mode by pressing Enter, Stop, Down, Enter sequentially.
    2. Remove the keypad from the source inverter and insert it into the target inverter.
    3. Initiate the parameter download to the target inverter by pressing Enter, Stop, Down, Down sequentially.
  • Procedure for KP51S Keypad (due to limited memory, parameters need to be copied in two batches):
    • For copying B and L parameters: Press Enter, Stop, Down, Down, Enter.
    • For copying H and E parameters: Press Enter, Stop, Down, Stop, Down.
    • To copy all B, L, H, and E parameters, follow the above steps for each batch.

Downloading Parameters:

  • Simply reverse the above steps to download parameters from the keypad to an inverter.

II. Terminal Control for Forward/Reverse Rotation and Potentiometer Speed Regulation

CONVO frequency converter SCG05 multi machine RS485 communication synchronization function diagram
Setting Parameters for Terminal Control
  • Forward/Reverse Rotation Control:
    • Set b-3 to select the control mode (e.g., 1 for external terminal control with keyboard stop disabled).
    • Configure the function of terminals X1, X2, FWD, and REV via parameters like L-47 to L-53 based on your control requirements.
  • Potentiometer Speed Regulation:
    • Set b-1 to 0 to use the potentiometer on the operating panel for speed control.
    • No additional parameter settings are required if using the panel potentiometer exclusively.

CONVO is a brand under Bosch Rexroth,By following these steps and adjusting the specified parameters, you can effectively control the operation of your Convo FSCG05 series inverter, whether through the operating panel, external terminals, or by restoring factory settings. This user manual guide aims to provide a comprehensive reference for smooth and efficient inverter operation.

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Analysis and Solutions for Faults F30005 and F30025 in Siemens G130_G150 Series Frequency Converters

Introduction

Siemens G130 and G150 series frequency converters play a crucial role in industrial automation systems, and their stability and reliability are vital for the smooth operation of production processes. However, in practical applications, these converters may encounter various faults, with F30005 (overload) and F30025 (overheating) being two of the most common ones. This article aims to provide an in-depth analysis of the meanings and causes of these faults and offer corresponding solutions. Additionally, a practical maintenance case is presented to illustrate the complexity of fault handling and the strategies employed.

G130 physical picture

Fault Analysis

F30025 (Overheating)

The F30025 fault typically indicates that the power unit’s chip temperature is too high. This fault can be caused by various factors, including but not limited to:

  • Poor Heat Dissipation: Issues such as fan failure, obstructed ventilation, or excessively high ambient temperatures can prevent the power unit from effectively dissipating heat.
  • Overload Operation: Prolonged high-load operation generates significant heat within the power unit.
  • High Pulse Frequency: Operating at high frequencies increases the heat generation in the power unit.
fault F30025

F30005 (Overload)

The F30005 fault signifies an I2t overload in the power unit. Possible causes include:

  • Excessive Load: The motor or mechanical load exceeds the rated power of the frequency converter.
  • Unreasonable Operating Cycle: Continuous operation without sufficient cooling time for the frequency converter.
  • Improper Parameter Settings: Inappropriate settings for parameters such as acceleration and deceleration times, leading to excessive output current from the frequency converter.

Additionally, faults like overcurrent (F30001) and grounding (F30021) are also closely related to current detection and judgment, indicating output currents exceeding rated values and insulation damage to motors or cables, respectively.

FAULT F30005

Mechanisms of Fault Occurrence

Faults Occurring at Power-On

Faults that occur immediately upon power-on often point to hardware issues, such as damaged current sensors (transformers) or related detection circuit problems. These faults typically manifest as errors as soon as power is applied and are difficult to resolve through parameter adjustments.

Faults Occurring During Operation

Faults that arise during operation may be the result of a combination of factors, including load variations, ambient temperatures, and ventilation conditions. Such faults are usually addressed by optimizing parameters, reducing load rates, and improving ventilation conditions.

G130 internal physical image

Solutions

Optimizing Parameter Adjustments

  • Adjust Operating Cycles: Arrange the working and rest times of the frequency converter reasonably to avoid prolonged continuous operation.
  • Adjust Acceleration/Deceleration Times: Modify acceleration and deceleration times based on load characteristics to reduce the impact on the frequency converter.
  • Increase Preset Values for Electronic Thermal Protection: If the motor and frequency converter are not overloaded, the preset values for electronic thermal protection can be appropriately increased.

Reducing Load Rates

  • Check and Optimize Mechanical Loads: Ensure that mechanical loads operate within the rated power range of the frequency converter.
  • Adjust Gear Ratios: Where possible, adjust gear ratios to reduce the load on the motor axis.

Ensuring Adequate Ventilation

  • Regularly Clean Heat Sinks: Ensure that heat sink fins are free of dust and that fans are operating normally.
  • Improve Ventilation Conditions: Ensure that the frequency converter is installed in a well-ventilated location, away from direct sunlight and high-temperature environments.
ESM2000-9983

Fault Repair

Handling Faulty Current Sensors

  • Check Current Sensors: Use a multimeter to test the output of the current sensors for normality.
  • Replace Damaged Current Sensors: If a sensor is confirmed to be damaged, it should be promptly replaced with a compatible model.
  • Adopt Temporary Solutions: In emergencies, if only two current sensors are available, the frequency converter can be set to V/F control mode, but risks should be noted.

Repairing Drive Boards

  • Check Optocouplers on Drive Boards: Optocouplers are key components for detecting the voltage drop across switching transistors and should be replaced if damaged.
  • Rewire or Replace Faulty Components: If other components (such as resistors, capacitors) on the drive board are damaged, they should be rewired or replaced.

Checking Current Detection Circuits

  • Trace Current Signal Paths: From the current sensors to the frequency converter’s control circuit, gradually check each component along the signal path.
  • Use Oscilloscopes to Detect Signal Waveforms: Observe the waveforms of current signals through an oscilloscope to identify any abnormalities.
  • Repair or Replace Faulty Components: Based on the detection results, repair or replace faulty components.
G130 CPU board

Practical Maintenance Case

In actual maintenance, we encountered a typical case that fully demonstrated the complexity of concurrent F30005 and F30025 faults and their solutions. The frequency converter immediately displayed an F30025 fault upon power-on, and further operation (such as pressing the ↓ key) revealed an F30005 fault, indicating simultaneous issues of overheating and overload.

Upon thorough inspection, it was found that the root cause was a damaged current sensor. This frequency converter utilized three ESM2000-9922 current sensors, each with a maximum secondary side output current of 400mA, collectively responsible for monitoring the three-phase current output of the converter. According to Kirchhoff’s Current Law, the sum of currents entering a node at any moment should equal the sum of currents exiting the node. In a three-phase system, this means that the algebraic sum of any two phase currents must equal the negative of the third phase current. Therefore, theoretically, as long as two current sensors are functioning normally, the reading of the third sensor can be inferred from their data.

However, this substitution scheme carries risks in practical operation, requiring that the three-phase currents and voltages output by the frequency converter remain relatively balanced and that the angle between the currents is close to the ideal 120°. Furthermore, since this frequency converter supports vector control, precise current measurement is crucial. Therefore, when adopting this temporary substitution scheme, we had to switch the converter’s operating mode from vector control to V/F control to avoid damaging the IGBT module due to inaccurate current calculations.

During the specific operation, we removed the damaged current sensor and reconnected the remaining two sensors. Then, through the frequency converter’s parameter setting interface, we changed its operating mode to V/F control. After these steps, although the frequency converter could be started and operated, the current values displayed on the screen were slightly lower than the actual values. In emergencies, this makeshift solution can temporarily restore the functionality of the frequency converter and ensure the continuity of the production process. However, in the long run, we still recommend replacing the damaged current sensor as soon as possible and restoring the frequency converter to its original vector control mode to ensure its performance and accuracy.

G130 power board

Conclusion

Although F30005 and F30025 faults are common in Siemens G130 and G150 series frequency converters, they can be effectively prevented and resolved through reasonable parameter adjustments, load reduction, improved ventilation conditions, and prompt fault repairs. In practical applications, targeted measures should be taken based on specific situations to ensure the stable operation of the frequency converters. Meanwhile, through meticulous inspections and flexible strategies, we can identify the key to solving problems and ensure the long-term reliable operation of the equipment.

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Schneider ATV303 Series Inverter User Guide and F014 Fault Resolution Method

I. Introduction to the ATV303 Series Inverter Operation Panel

The Schneider ATV303 series inverter’s operation panel (also known as the display terminal or HMI) features an intuitive interface, allowing users to easily set parameters, monitor operational status, and troubleshoot errors. The primary functions of the operation panel include:

  • Display Screen: Displays the current status, parameter values, error messages, etc., of the inverter.
  • Navigation Buttons: Used to navigate between menus and parameters, and to adjust parameter values.
  • Mode Button: Switches between “Given” (rEF), “Monitor” (MOn), and “Configuration” (ConF) modes.
  • Stop/Reset Button: Stops motor operation or resets faults under certain conditions.
  • Run Button: Starts motor operation.
ATV303 INVERTER F014 FAULT

Setting and Removing Passwords

To prevent unauthorized access, users can set a password for the inverter. Here’s how:

  1. Enter “Configuration” mode (ConF).
  2. Select the “Maintenance” menu (900-).
  3. Locate the “HMI Password” parameter (999).
  4. Enter the desired password value (range: 2-9999) and press the “Confirm” button to save.

To remove the password, simply set the “HMI Password” parameter (999) to “OFF”.

Restoring Factory Settings

To reset the inverter’s parameters to their factory defaults, follow these steps:

  1. Enter “Configuration” mode (ConF).
  2. Select the “Store/Restore Parameter Sets” menu.
  3. Set the “Factory/Restore Customer Parameter Settings” parameter (102) to “64”. The inverter will restart automatically and apply the factory settings.
Schneider inverter ATV303 control terminal wiring diagram

II. Terminal Forward/Reverse Control and External Potentiometer Speed Regulation

Terminal Forward/Reverse Control

To achieve motor forward/reverse control via the inverter’s control terminals, follow these setup and wiring steps:

  1. Parameter Settings:
    • Enter “Configuration” mode (ConF).
    • Select the “Input/Output” menu (200-).
    • Set the “Control Type” parameter (201) to “2-wire control” or “3-wire control”.
    • For “2-wire control”, configure the “2-wire Control” parameter (202), e.g., “Forward Priority”.
    • Set the “Reverse” parameter (503) to specify which logic input terminal controls reversal (e.g., LI2H for LI2 high level reversal).
  2. Wiring:
    • Connect the motor forward control terminal (e.g., LI1) to the forward control signal source.
    • Connect the motor reverse control terminal (e.g., LI2, based on parameter settings) to the reverse control signal source.
    • Ensure all control signal sources are passive dry contacts or provide appropriate level signals.

External Potentiometer Speed Regulation

To regulate inverter speed using an external potentiometer, configure the following parameters and connect the corresponding terminals:

  1. Parameter Settings:
    • Enter “Configuration” mode (ConF).
    • Select the “Control” menu (400-).
    • Set the “Given Channel 1” parameter (401) to “183” to receive speed input via analog input AI1.
    • Set the “AI1 Type” parameter (204.0) to “Voltage” or “Current” based on the external potentiometer’s output type.
    • For current output, also set the “0% AI1 Current Ratio Parameter” (204.1) and “AI1 Current Calibration Parameter 100%” (204.2).
  2. Wiring:
    • Connect the external potentiometer’s output terminal to the inverter’s analog input terminal AI1.
    • Connect the external potentiometer’s power terminals (if needed) to the inverter’s +5V and COM terminals, or provide an external power supply.

III. F014 Fault Resolution Method

F014 Fault Overview

The F014 fault indicates that one phase is missing from the inverter’s output to the motor. This fault can cause abnormal motor operation or even damage to the motor and inverter.

Mechanism of Occurrence

The primary mechanisms behind the output phase loss fault include:

  1. Loose or Poor Output Terminal Connections: Loose or poor contact between the inverter output terminals and motor connection terminals may prevent the transmission of electrical energy in one phase.
  2. Motor or Cable Faults: Internal motor winding damage or cable breaks can also lead to output phase loss.
  3. Inverter Internal Faults: Damage to power devices or control circuit faults within the inverter can cause output phase loss.

Repair Method

To resolve the F014 fault, follow these troubleshooting steps:

  1. Check Output Terminal Connections: Verify that the connections between the inverter output terminals and motor connection terminals are secure and free from loose or poor contacts.
  2. Inspect the Motor and Cable: Use a multimeter or other tool to check the continuity of the motor windings and cables, ensuring there are no breaks or shorts.
  3. Examine the Inverter Internals: If the above checks are clear, the fault may lie within the inverter. Disassemble and inspect the inverter for damaged power devices or control circuit faults, and perform necessary repairs or replacements.
  4. Re-execute Autotuning: After ruling out hardware faults, re-execute the inverter’s autotuning process to ensure correct parameter settings and normal motor operation.

By following these steps, users can effectively resolve the F014 fault on the ATV303 series inverter and restore normal device operation. Regular inspections and maintenance of the inverter are recommended to prevent similar faults from occurring.

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Huayuan Inverter User Manual Usage Guide and ERR02 Fault Solution

I. Introduction to the Function of Huayuan Inverter G1 Series Operating Panel (Keyboard)

Function diagram of Huayuan inverter keyboard

Operating Panel Functionality

The Huayuan Inverter G1 Series operating panel integrates multiple functions to facilitate parameter setting, status monitoring, and fault diagnosis. The panel primarily consists of a 5-digit 8-segment LED display, 4 indicator lights, 8 buttons, and a rotary potentiometer.

  • LED Display: Shows output frequency, current, various parameter settings, and abnormal statuses.
  • Indicator Lights: Indicate the current operating mode (e.g., Hz, A, V).
  • Button Functions:
    • Rotary Potentiometer: Used to adjust numerical settings; clockwise rotation increases the value, while counterclockwise rotation decreases it.
    • Multifunction Button: Can be set to invalid, jog, or forward/reverse functions.
    • Program Button: Enters or exits the parameter menu.
    • Confirm Button: Enters the parameter menu and confirms current modifications.
    • Shift Button: Switches between running status monitoring data and shifts parameters during modification.
    • Run Button: Controls the start and stop of the inverter.
    • Stop/Reset Button: Stops the inverter or resets faults.
    • Up/Down Buttons: Increases or decreases function codes or values.
Huayuan Inverter G1 Series Wiring Diagram

Parameter Upload and Download

  • Parameter Upload: Copies the internal parameters of the inverter to the keyboard memory. Set function parameter P07.02=H.#1, press the “‖” button to start the upload, and “CoPy” will be displayed upon completion.
  • Parameter Download: Writes the parameters stored in the keyboard to the inverter. Set function parameter P07.02 to H.12 or H.13, press the “‖” button to start the download, and “LoAd” will be displayed upon completion.

Setting Open-Loop Vector Control (SVC) and Closed-Loop Vector Control (FVC) Modes

  • Open-Loop Vector Control (SVC):
    1. Set P00.00=1.
    2. Set motor parameters (P02.01~P02.05) according to the motor nameplate.
    3. Perform motor parameter tuning (P00.25=1 for static tuning, P00.25=2 for dynamic tuning).
  • Closed-Loop Vector Control (FVC):
    1. Set P00.00=2.
    2. Set motor parameters (P02.01~P02.05) according to the motor nameplate.
    3. Set encoder-related parameters (e.g., P20.00 sets the encoder line count, P20.02 enables the PG card encoder function).
    4. Perform motor parameter tuning (P00.25=1 for static tuning, P00.25=2 for dynamic tuning).

Initializing Parameters

  • By setting function parameter P00.26, you can choose to restore factory default parameters (excluding or including motor parameters).

II. External Terminal Control

Achieving Forward/Reverse Rotation and Potentiometer Speed Adjustment

Terminal Connections

  • Forward/Reverse Control:
    • For forward rotation, connect the DI1 terminal to the common terminal (COM).
    • For reverse rotation, connect the DI2 terminal to the common terminal (COM).
  • Potentiometer Speed Adjustment:
    • Connect the output end of the external potentiometer to AI1 or AI2, and the other end to the common terminal (COM).

Parameter Settings

  • Forward/Reverse Parameters:
    • Set P05.00 (DI1 function) = 1 (forward rotation) or 2 (reverse rotation).
    • Ensure P00.01 (command source selection) = 0 (keyboard control) or change it to 1 (terminal control) as needed.
  • Potentiometer Speed Adjustment Parameters:
    • Set P00.02 (main frequency source X selection) = 1 (AI1) or select other analog inputs as needed.
    • Ensure P05.59 (AI voltage or current selection) is set correctly (e.g., 00 indicates AI1 is a voltage input).
err02 fault

III. ERR02 Fault Solution

Meaning of ERR02 Fault

ERR02 indicates an “acceleration overcurrent fault,” meaning an overcurrent is detected during inverter acceleration.

Fault Causes and Solutions

  1. Grounding or Short Circuit in Inverter Output Circuit:
    • Check and eliminate grounding or short circuits in peripheral wiring.
  2. Vector Control Mode Without Parameter Tuning:
    • Ensure motor parameter tuning has been correctly performed (SVC or FVC mode).
  3. Too Short Acceleration Time:
    • Increase the acceleration time (P00.17 or P00.18).
  4. Inappropriate Manual Torque Boost or V/F Curve:
    • Adjust the manual torque boost (P04.01) or select an appropriate V/F curve (P04.00).
  5. Low Voltage:
    • Adjust the voltage to the normal range.
  6. Starting a Rotating Motor:
    • Choose speed tracking start or wait for the motor to stop before starting.
  7. Sudden Load Increase During Acceleration:
    • Eliminate sudden load increases or reassess the load condition.
  8. Undersized Inverter Selection:
    • Select an inverter with a higher power rating.

Repairing the Inverter

If the above methods cannot resolve the ERR02 fault, further inspection and repair of the inverter may be necessary:

  1. Check the Drive Board and Main Control Board:
    • Confirm that the drive board and main control board are functioning normally, and replace faulty components if necessary.
  2. Check the Hall Sensor:
    • Confirm that the Hall sensor is operating correctly, and replace it if damaged.
  3. Contact the Manufacturer or Professional Repair Service:
    • If the problem persists, it is recommended to contact the inverter manufacturer or a professional repair service for further inspection and repair.

Conclusion

The Huayuan Inverter G1 Series user manual provides a detailed operation guide and fault solution. By correctly setting parameters and using external terminal control, various functions of the inverter can be realized. For the ERR02 fault, the inverter can be restored to normal operation by troubleshooting and solving the problem step by step. When necessary, contacting the manufacturer or a professional repair service is crucial to ensuring reliable operation of the equipment.

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Analysis and Solutions for the 3130 Fault in ABB Inverter ACH531

Introduction

The ABB inverter ACH531 is a high-performance drive equipment widely used in HVAC (Heating, Ventilation, and Air Conditioning) systems. However, during operation, various fault alerts may be encountered, with the 3130 fault being a relatively common one. This article will provide a detailed analysis of the meaning of the 3130 fault in the ABB inverter ACH531 and propose corresponding solutions to help technicians quickly locate and resolve the issue, ensuring stable operation of the equipment.

ACH531 Inverter

I. Meaning of the 3130 Fault

The 3130 fault in the ABB inverter ACH531 is defined as an input phase loss fault, also known as a DC voltage oscillation fault. The appearance of this fault code indicates that the inverter has detected an issue with the input power supply, resulting in fluctuations in the DC bus voltage exceeding the normal range (exceeding 13%). This fault typically causes the inverter to shut down to protect the motor and drive system from damage.

II. Cause Analysis of the 3130 Fault

  1. Power Phase Loss or Fuse Blowing:
    • When one phase of the input power supply to the inverter is missing or a fuse blows, it can lead to instability in the DC circuit voltage, triggering the 3130 fault.
  2. Excessive DC Filter Capacitor Discharge and Insufficient Power Supply:
    • The DC filter capacitors inside the inverter are used to smooth the DC bus voltage. If the capacitors discharge excessively and the power supply is insufficient, it can cause increased fluctuations in the DC bus voltage, leading to the 3130 fault.
  3. Power Grid Interference:
    • Interference factors such as imbalances, harmonics, or transient overvoltages in the power grid can affect the normal operation of the inverter and trigger the 3130 fault.
  4. Oscillation Issues Under Heavy Loads:
    • Under heavy load conditions, if the inverter’s parameter settings are unreasonable or the load fluctuates significantly, it may also cause DC bus voltage oscillation, leading to the 3130 fault.
  5. Hardware Failures:
    • Hardware failures such as the rectifier bridge, thyristors, and their trigger circuits inside the inverter may also cause the 3130 fault.
fault 3130

III. Solutions for the 3130 Fault

  1. Check Power Supply and Fuse:
    • First, check whether the input power supply to the inverter is stable and whether the three-phase voltage is balanced. Use a multimeter to measure the incoming voltage and ensure that the voltage of each phase is within the normal range.
    • Check whether the fuse has blown and, if so, replace it with a new one promptly.
  2. Check Rectifier Bridge and Thyristors:
    • Examine the thyristors and their trigger circuits inside the rectifier bridge for anomalies. An oscilloscope can be used to observe the trigger waveform of the thyristors to ensure their normal operation.
    • If a thyristor or trigger circuit fault is found, it should be replaced or repaired in a timely manner.
  3. Test DC Bus Voltage:
    • Test the actual value of the DC bus voltage under load to see if it fluctuates. If the actual value does not fluctuate while the detected value does, it may indicate a fault in the detection circuit.
    • In such cases, consider replacing the relevant detection components, such as sensors or circuit boards.
  4. Check Capacitor Capacity:
    • Check whether the capacity of the DC filter capacitors has decreased. If the capacitor capacity is insufficient, replace it with a new one to improve the stability of the DC bus voltage.
  5. Check Power Input Terminal:
    • Examine whether the wiring at the power input terminal is secure, with no loosening or poor contact.
    • Check whether the capacity of the power supply transformer meets the load requirements of the inverter system. If the transformer capacity is insufficient, replace it with a larger one.
    • Check whether the switches or circuit breakers are qualified, whether the fuse has blown, and whether the thermal relay has tripped.
  6. Adjust Parameter Settings:
    • Under heavy load conditions, try adjusting the inverter’s parameter settings, such as increasing acceleration and deceleration times or optimizing load balancing designs, to improve the stability of the DC bus voltage.
    • If needed, the 3130 fault can be masked by setting parameter 31.21 (input phase loss) to “0”, so that the inverter will not trip when it detects input phase loss. However, please note that this method is only a temporary measure, and the root problem still needs to be solved in the long run.
  7. Check Other Hardware Faults:
    • If the above methods fail to resolve the issue, further examine other hardware components inside the inverter, such as the RTAC (Real-Time Adaptive Control) module and the AIBP (Input Bridge Protection Board), for damage or poor insertion.
    • If hardware faults are found, replace or repair the corresponding components promptly.

IV. Conclusion

When the ABB inverter ACH531 encounters the 3130 fault, it should be troubleshooted and resolved from multiple aspects, including the power supply and fuse, rectifier bridge and thyristors, DC bus voltage testing, capacitor capacity, power input terminal, parameter settings, and other hardware faults. Through systematic inspection and adjustment, the 3130 fault can be effectively located and resolved, ensuring stable operation of the inverter. Meanwhile, it is also recommended to regularly maintain and service the inverter to prevent faults from occurring.

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VACON NX Inverter Series User Manual Guide

I. How to Achieve Forward/Reverse Rotation and Speed Control via External Terminals

The VACON NX series of frequency converters allows for straightforward forward/reverse rotation and speed control via external terminals. Here’s how to achieve this:

Application diagram of VACON inverter NX series control IO
  1. Terminal Connections:
    • Forward/Reverse Control:
      • Forward rotation is typically connected to the DI1 (forward start) terminal of the frequency converter.
      • Reverse rotation is typically connected to the DI2 (reverse start) terminal.
      • Note that different NX series models may have different terminal numbers; refer to the specific model’s user manual for confirmation.
    • Potentiometer Speed Control:
      • Connect the three terminals of the potentiometer to the AI1 (analog input 1), GND (ground), and +10V (analog input positive power) terminals of the frequency converter, respectively.
  2. Parameter Settings:
    • Forward/Reverse Parameters:
      • Set the control source to external terminal control and ensure that the DI1 and DI2 functions are correctly configured for forward and reverse rotation.
    • Potentiometer Speed Control Parameters:
      • Set AI1 as the frequency reference source.
      • Adjust the input range of AI1 as needed to ensure that the potentiometer’s output range matches the frequency converter’s frequency range.
VACON inverter NX series PID control IO wiring diagram

II. Characteristics of PID Function and Its Application in Constant Pressure Control of Water Pumps

The PID function of the VACON NX series frequency converter is highly capable and suitable for various automatic control applications. Here are its key features and how to apply it to constant pressure control of water pumps:

  1. PID Function Characteristics:
    • Supports multiple PID control modes, including standard PID and sleep/wake-up functions.
    • Flexible PID parameter configuration via external terminals or fieldbus.
    • Provides comprehensive monitoring and alarm functions to ensure stable system operation.
  2. Application in Water Pump Constant Pressure Control:
    • Terminal Connections:
      • Connect the output signal of the pressure sensor to the AI1 (analog input 1) terminal of the frequency converter.
      • Connect other control terminals as needed, such as start and stop.
    • Parameter Settings:
      • Set AI1 as the actual value input for PID control.
      • Configure the reference value for the PID controller (target pressure value).
      • Adjust the PID parameters (proportional, integral, derivative) to achieve optimal control performance.
      • Set the sleep/wake-up function as needed to save energy.

III. Fieldbus Protocol and Communication with Siemens PLC

The VACON NX series supports multiple fieldbus protocols, including Profibus, Modbus, etc., facilitating communication with various PLCs. Here’s how to set up communication with a Siemens PLC:

  1. Fieldbus Protocol:
    • The NX series supports multiple fieldbus protocols; users can select the appropriate protocol based on actual needs.
  2. Communication with Siemens PLC:
    • Wiring:
      • Connect the frequency converter’s fieldbus interface to the corresponding interface of the Siemens PLC using a dedicated fieldbus communication cable.
    • Parameter Settings:
      • Configure fieldbus parameters in the frequency converter, including station address, baud rate, etc.
      • Configure corresponding communication parameters in the Siemens PLC to ensure compatibility with the frequency converter.
      • Program the PLC to send start, stop, and speed adjustment commands to the frequency converter via the fieldbus.

IV. Fault Code Meaning Analysis and Troubleshooting

The VACON NX series provides comprehensive fault codes to help users quickly locate and resolve issues. Here are some common fault codes, their meanings, and troubleshooting methods:

  1. F1: Overcurrent Fault
    • Meaning: The output current of the frequency converter exceeds the set value.
    • Troubleshooting: Check for motor overload, cable short circuits, and correct frequency converter parameter settings.
  2. F2: Overvoltage Fault
    • Meaning: The DC bus voltage of the frequency converter is too high.
    • Troubleshooting: Check for stable input voltage and proper operation of the braking resistor.
  3. F5: Charging Switch Fault
    • Meaning: The internal charging switch of the frequency converter is abnormal.
    • Troubleshooting: Check the charging switch and related circuits for proper functioning.

V. Conclusion

The VACON NX series user manual provides detailed usage guides and parameter setting instructions, helping users quickly get started and implement various complex control functions. Through this guide, users should now have a comprehensive understanding of how to achieve forward/reverse rotation and speed control via external terminals, the characteristics and application of the PID function, fieldbus protocol and communication with Siemens PLC, as well as the meanings and troubleshooting methods of fault codes. In practical applications, users should flexibly configure parameters and wiring based on specific needs and site conditions to achieve optimal control performance.

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Delta VFD-E Series Inverter User Manual Operation Guide

I. Introduction to the Panel Functions and Operations of the Delta VFD-E Series Inverter

VFD-E inverter

Panel Function Introduction

The panel of the Delta VFD-E series inverter primarily consists of the following function keys and display areas:

  • Power Indicator: Indicates whether the inverter is powered on.
  • RUN Indicator: Indicates the running status of the inverter.
  • FREQ Display: Displays the current operating frequency of the inverter.
  • MODE Key: Switches between different modes for parameter setting and monitoring.
  • ▲/▼ Keys: Used for increasing or decreasing parameter values or frequency settings.
  • STOP Key: Stops the operation of the inverter.
  • RESET Key: Resets the inverter to its initial state or clears fault alarms.
  • ENTER Key: Confirms the setting of parameters.
  • JOG Key: Enables jogging (inching) operation of the motor.
  • FWD/REV Keys: Controls the forward and reverse rotation of the motor.

Panel Operations

Copying Parameters to Another Inverter

  1. Connect to the Inverter: Use a suitable communication cable to connect the source inverter (containing the desired parameters) to the target inverter.
  2. Enter Copy Mode: On the source inverter, press the MODE key until the “Copy” mode is displayed.
  3. Initiate Copy: Press the ENTER key to initiate the parameter copy process.
  4. Complete Copy: Follow the prompts on the display to complete the parameter copy. Disconnect the communication cable after copying is finished.

Setting and Removing Passwords

Setting a Password:

  1. Navigate to the parameter group 00 User Parameters.
  2. Select parameter 00-08 Parameter Protection Password.
  3. Enter the desired password value (00-65535).
  4. Press ENTER to confirm.

Removing a Password:

  1. Navigate to the parameter group 00 User Parameters.
  2. Select parameter 00-08 Parameter Protection Password.
  3. Enter the password value you want to remove (set it to 00).
  4. Press ENTER to confirm.

Resetting to Factory Defaults

  1. Navigate to the parameter group 00 User Parameters.
  2. Select parameter 00-02 Parameter Reset Setting.
  3. Set the value to 09 for resetting to factory defaults at 50Hz, or 10 for resetting to factory defaults at 60Hz.
  4. Press ENTER to confirm and restart the inverter to apply the reset.
Delta VFD-E inverter standard wiring diagram

II. Terminal Control for Forward/Reverse Start and Stop

Terminal Control Configuration

  1. External Terminal Connection: Connect the external control terminals (FWD, REV, STOP) to the corresponding terminals on the inverter.
  2. Parameter Configuration:
    • Navigate to the parameter group 02 Operation Mode Parameters.
    • Set parameter 02-01 First Operation Command Source to 01 (External Terminal).
    • Set parameter 02-05 Two-Wire/Three-Wire Control to the desired control mode (e.g., 00 for two-wire control).
  3. Control Logic:
    • Forward Rotation: Close the FWD terminal and open the REV terminal.
    • Reverse Rotation: Close the REV terminal and open the FWD terminal.
    • Stop: Open both the FWD and REV terminals.

Monitoring and Troubleshooting

  • Monitoring: Use the inverter panel or an external monitoring device to check the operating status and parameters.
  • Troubleshooting: Refer to the inverter’s fault codes and troubleshooting guide in the user manual to diagnose and resolve issues.

By following the above steps, users can effectively operate and configure the Delta VFD-E series inverter for various applications, including terminal control for forward/reverse start and stop, parameter copying, password setting/removal, and resetting to factory defaults.

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BEST Inverter FC300 User Manual Usage Guide and Distinction between HOC and OC Faults

I. Introduction to BEST Inverter FC300 Panel Functions and Parameter Settings

1.1 Introduction to Panel Functions

The BEST Inverter FC300’s operation panel is equipped with multiple function keys, including ESC, ENT, MF, >>, ↑, ↓, STOP/RESET, each with specific functions:

  • ESC: Exits the current setting or cancels the current operation.
  • ENT: Confirms the current setting or proceeds to the next operation.
  • MF: Multifunction key with different functions depending on the context.
  • >>: Switches between menus or parameters.
  • ↑ and ↓: Adjust parameter values or scroll through menus.
  • STOP/RESET: Stops the inverter operation or resets the fault status.
OC FAULT

1.2 Parameter Initialization and Upload/Download

The BEST Inverter FC300 supports parameter initialization, upload, and download, primarily through parameter P087.

  • Parameter Initialization: Set P087 to 1 and press ENT to confirm, restoring the inverter to factory settings.
  • Parameter Upload: Set P087 to 4, ensure correct connection between the inverter and computer, and upload current parameter settings via dedicated software.
  • Parameter Download: Set P087 to 5, ensure correct connection, and download parameters to the inverter via software.

1.3 Setting and Removing Passwords

To protect the inverter settings from unauthorized changes, the BAST FC300 supports password protection.

  • Setting a Password: Set a new password in P086 and choose 2 in P087 to memorize the password.
  • Removing a Password: Enter the current password in P086 and choose 3 in P087 to clear the password.

II. Terminal Start/Stop, Potentiometer Speed Adjustment, and Forward/Reverse Control

2.1 Terminal Start/Stop and Potentiometer Speed Adjustment

To achieve terminal-based start/stop of the inverter and potentiometer-based speed adjustment, correct wiring and parameter settings are required.

  • Wiring: Connect the start and stop signals to the X1 and X3 terminals of the inverter, respectively (or other designated terminals, as per the manual). Connect the potentiometer to the AVI or ACI terminals for analog speed adjustment.
  • Parameter Settings:
    • Set P064 to 1 to select external terminal control.
    • Configure the function of the AVI or ACI terminals, e.g., set P091’s X1 function to “Forward Start” and X3 to “Stop”.
    • Adjust parameters like P053 as needed to set the range and mode of analog speed adjustment.
HOC FAULT

2.2 Terminal-Based Forward/Reverse Control

To achieve terminal-based forward/reverse control of the inverter, correct wiring and parameter settings are also necessary.

  • Wiring: Connect the forward and reverse signals to the X1 and X2 terminals of the inverter, respectively (or other designated terminals).
  • Parameter Settings:
    • Ensure P064 is set to support external terminal control.
    • Configure the functions of the X1 and X2 terminals, e.g., set P091’s X1 function to “Forward” and X2 to “Reverse”.
    • Adjust parameters like P066 as needed to ensure motor reversal is allowed.

III. Distinction between HOC and OC Faults and Solutions

3.1 Distinction between HOC and OC Faults

  • HOC Fault: Typically refers to an overcurrent fault caused by damage to the inverter’s inverter module. This fault is severe and may be accompanied by damage to internal components of the inverter.
  • OC Fault: Generally refers to an overcurrent fault on the output side, which may be caused by motor stalls, excessive loads, short acceleration times, etc.

3.2 Fault Solutions

  • HOC Fault Solution:
    1. Check the Inverter Module: Confirm if the inverter module is damaged and replace it if necessary.
    2. Check the Drive Circuit: Inspect the drive circuit for normal function and troubleshoot drive faults.
    3. Contact the Manufacturer: If the issue is complex or unresolved, contact BAST for repair or replacement.
  • OC Fault Solution:
    1. Check the Motor and Load: Confirm if the motor is stalled or if the load is excessive, and adjust the load or motor parameters as necessary.
    2. Adjust Acceleration Time: Increase the acceleration time to avoid instantaneous overcurrent during motor startup.
    3. Check Wiring: Verify the wiring between the motor and the inverter for correctness and eliminate any wiring errors that may cause faults.
    4. Reset the Inverter: Press the STOP/RESET button to reset the inverter and attempt to restart it.

IV. Conclusion

The BEST Inverter FC300, as a high-performance inverter, boasts a rich set of panel functions and flexible parameter settings, capable of meeting control demands in various complex operating conditions. Through correct wiring and parameter settings, functions such as terminal-based start/stop, potentiometer speed adjustment, and forward/reverse control can be achieved. Meanwhile, for common HOC and OC faults, users should be able to quickly identify the fault phenomenon and take corresponding measures for resolution to ensure the normal operation of the inverter. During use, users must strictly adhere to the safety precautions and operating procedures outlined in the manual to ensure the safety of personnel and equipment.