The User Manual of 580 Series General Frequency Converter

9.1.4 Replacement of vulnerable parts for frequency converter

After the user purchased the frequency converter, the following points must be paid attention to concerning the temporary storage and long-term storage:

1) Upon storage try to put into the company’s packing box as per the original package

2) Storage for a long time can lead to the degradation of the electrolytic capacitor, so connecting to the power supply once within 2 years must be ensured, and the conduction time should be at least 5 hours, and also, the input voltage must be slowly raised to the rated value through the voltage regulator.

9.2 Maintenance instruction for frequency converter

1) Free maintenance refers to the frequency converter itself only.

2) Under normal uses, if failure or damage happens, our company is responsible for 18 months maintenance (starting from the date of in delivery, and subject to the body barcode, and also, implement according to the protocol if contractual protocol is available). If it is over 18 months, a reasonable maintenance costs shall be charged;

3) Within 18 months, if the following circumstances happen, a certain amount of maintenance costs shall be charged:

4) Machine damage brought by the user’s disobeying of the regulations stipulated in the operating manual;

5) Damage caused by the fire, flood, abnormal voltage, etc;

6) Damages caused since the frequency converter is used in improper functions;

7) Related service fees shall be calculated as per the factory unified standard, if any contract is available, handle it as the principle of contract first.

9.3 Failure alarm and measures

If failure for 580 series frequency converter occurs in running, the frequency converter will immediately protect the motor and stop outputting, meanwhile, there is the contact action for the frequency converter failure relay. The panel of the frequency converter will display the failure code. See the table below for the details concerning the failure type and the common solutions corresponded with the failure code. The examples listed in the table are just for references, please do not repair and modify without permission, if the failure cannot be removed, seek technical support from our company or the product agent.

Table 9-1 Failure List

Fault Name	Display	Failure causes analysis	Failure handling measures
Inverter unit protection	Err01	1. Short circuit for frequency converter output circuit 2. Too long wiring between motor and frequency converter 3. Too hot module 4. Loose internal wiring for frequency converter 5. Abnormal main control panel 6. Abnormal drive board 7. Abnormal inverse module	1. Troubleshoot the external failure 2. Install electric reactor or output filter 3. Inspect if the air channel is blocked, and if fan functions normally and then troubleshoot the existing problems 4. Properly plug in all the connecting lines; 5. Seek technical support; 6. Seek technical support; 7. Seek technical support;
Overcurrent during acceleration	Err02	1. Grounding or short circuit exist in the output circuit of frequency converter 2. The control mode is vector and parameter identification is not conducted 3. Too short acceleration time 4 Improper manual torque lifting or V/F curve 5 Relatively low voltage 6. Start the motor which are rotating 7. Sudden load in the acceleration process 8. Relatively small model selection for frequency converter	1. Troubleshoot the external failure 2. Conduct the motor parameter identification 3. Increase the acceleration time 4. Modify manual lifting torque or V/F curve 5. Adjust the voltage to the normal range 6. Select the rotating tracing start or restart after the motor stops 7. Cancel sudden load 8. Choose frequency converter with bigger power level
Overcurrent during deceleration	Err03	1 Grounding or short circuit exit in the output circuit of frequency converter 2. The control mode is vector and parameter identification is not conducted 3. Too short deceleration time 4. Relatively low voltage 5. Sudden load in the deceleration process 6. No installing of brake unit or brake resistance	1. Troubleshoot the external failure 2. Conduct the motor parameter identification 3. Increase deceleration time 4. Adjust the voltage to the normal range 5. Cancel sudden load 6. Install brake unit and resistance
Overcurrent at constant speed	Err04	1. Grounding or short circuit exit in the output circuit of frequency converter 2. The control mode is vector and parameter identification is not conducted 3. Relatively low voltage 4. Sudden load exist in the running 5. Relatively small model selection for	1. Troubleshoot external failure 2. Conduct the motor parameter identification 3. Adjust the voltage to the normal range 4. Cancel sudden load 5. Choose frequency converter with higher power level
Overvoltage during acceleration	Err05	1. Relatively high input voltage 2. External force dragging motor running exist in the acceleration process 3. Too short acceleration time 4. No installing of brake unit and brake resistance	1. Adjust the voltage to the normal range 2. Cancel the external force or install brake resistance 3. Increase acceleration time 4. Install brake unit and resistance
Overvoltage during deceleration	Err06	1. Relatively high input pressure 2. The external force dragging motor running exists in the deceleration process 3. Too short deceleration time 4. No installing brake unit and brake resistance	1. Adjust the voltage to the normal range 2. Cancel the external force or install brake resistance 3. Increase deceleration time 4. Install brake unit and resistance
Overvoltage at constant speed	Err07	1. Relatively high input pressure 2. The external force dragging motor running exists in running	1. Adjust the voltage to the normal range 2. Cancel the external force or install brake resistance
Control power supply fault	Err08	1. The input pressure is not within the range stipulated by standard	1. Adjust the voltage to the range required by standard
Undervoltage	Err09	1. Momentary power off 2. The terminal voltage of frequency converter is not within the range required by standard 3. Abnormal Bus voltage 4. Abnormal rectifier bridge and buffer resistance 5. Abnormal drive board 6. Abnormal control panel	1. Reset failure 2. Adjust the voltage to the normal range 3. Seek technical support 4. Seek technical support 5. Seek technical support 6. Seek technical support
AC drive overload	Err10	1. Whether the load is too heavy or the motor stalling happens 2. Relatively small model selection for frequency converter	1. Decrease the load and inspect the motor and machinery situations 2. Choose the frequency converter with higher power level
Motor overload	Err11	1. Whether the setting of motor protection parameter F9-01 is appropriate 2. Whether the load is too heavy or motor stalling happens 3. Relatively small model selection for frequency converter	1. Correctly set the parameter 2. Decrease the load and inspect the motor and machinery situation 3. Choose the frequency converter with higher power level
Power input phase loss	Err12	1. Abnormal three-phase input power 2. Abnormal drive board 3. Abnormal lightning protection plate 4. Abnormal main control panel	1. Inspect and troubleshoot the existing problems in the external lines 2. Seek technical support 3. Seek technical support 4. Seek technical support
Power output phase loss	Err13	1. Abnormal wiring from frequency converter to motor 2. Unbalanced frequency converter three-phase when the motor is running 3. Abnormal drive board 4. Abnormal module	1. Troubleshoot external failure 2. Inspect whether motor three-phase winding is normal and troubleshoot the failure 3. Seek technical support 4. Seek technical support
Module overheat	Err14	1. Too high environment temperature 2. Air channel blocks 3. Fan damages 4. Module thermistor damages 5. Inverse module damages	1. Reduce environment temperature 2. Clear air channel 3. Replace fan 4. Replace thermistor 5. Replace inverse module
External equipment fault	Err15	1. Input the signal of external failure through multifunctional terminal DI 2. Input the signal of external failure through virtual IO function	1. Reset running 2. Reset running
Communication fault	Err16	1. Upper computer functions abnormally 2. Abnormal communication line 3. Incorrect setting for communication expansion card F0-28 3. Incorrect setting for communication parameter Group FD	1. Inspect the upper computer wiring 2. Inspect communication connecting line 3. Correctly set the communication expansion card type 4. Correctly set the communication parameter
Contactor fault	Err17	1. The drive board and power source are abnormal 2. Abnormal contactor	1. Replace drive board or power panel 2. Replace the contactor
Current detection fault	Err18	1. Inspect Hall device is abnormal 2. Abnormal drive board	1. Replace Hall device 3. Replace drive board
Motor auto-tuning fault	Err19	1. The motor parameter is not set as per the name board 2. Time-out for parameter identification process	1. Correctly set the motor parameter as per the name board 2. Inspect the down-lead from frequency converter to motor
Encoder fault	Err20	1. Encoder model is not matching 2. Encoder wiring error 3. Encoder manages 4. Abnormal PG card	1. Correctly set the encoder type as per the actual situation 2. Troubleshoot line failure 3. Replace encoder 4. Replace PG card
EEPROM read- write fault	Err21	1. EEPROM chip damages	1. Replace main control panel
AC drive hardware fault	Err22	1. There is overpressure 2. There is overcurrent	1. Handling as per overpressure failure 2. Handling as per overcurrent failure
Short circuit to ground	Err23	1. Motor short circuit to earth	1. Replace cable or motor
Accumulative running ime reached	Err26	1. The accumulated running time reaches up to the set value	1. Use parameter initialization function to clear the record information
User-defined fault 1	Err27	1. Input the signal of user-defined Failure 1 through multifunctional terminal DI 2. Input the signal of user-defined Failure 1 through virtual IO function	1. Reset running 2. Reset running
User-defined fault 2	Err28	1. Input the signal of user-defined Failure 2 through multifunctional terminal DI 2. Input the signal of user-defined Failure 2 through virtual IO function	1. Reset operation 2. Reset running
Accumulative power-on time reached	Err29	1. The accumulated power-on time reaches to the set value	1. Use parameter initialization function to clear the record information
Load becoming 0	Err30	1. The running current for frequency converter is lower than F9-64	1. Confirm whether the load is disconnected or the parameter setting of F9-64 and F9-65 meets the real running conditions
PID feedback lost during running	Err31	1. The PID feedback is lower than the set value of FA-26	1. Inspect PID feedback signal or set FA-26 as an appropriate value
Waveband current limit failure	Err40	1. Whether the load is too heavy or motor stalling happens 2. Too small model selection for frequency converter	1. Reduce the load and inspect the motor and machinery conditions 2. Select the frequency converter with higher power level
Motor switchover fault during running	Err41	1. Change the current motor selection through terminal when the frequency converter is running	1. Conduct the operation of motor switching after the frequency converter stops
Too large speed deviation	Err42	1. Incorrect parameter setting for encoder 2. Parameter identification is not conducted 3. Too large speed deviation, and the detecting parameter F9-69 and F9-70 are not reasonably set	1. Correctly set the encoder parameter 2. Conduct the motor parameter identification 3. Reasonably set the detecting parameter based on the actual conditions
Motor over-speed	Err43	1. Incorrect parameter setting for encoder 2. Parameter identification is not conducted 3. The motor overspeed detecting parameter F9-67 and F9-68 are not unreasonably set	1. Correctly set the encoder parameter 2. Conduct motor parameter identification 3. Reasonably set the detecting parameter based on actual situation
Motor overheat	Err45	1. Loose temperature sensor wiring 2. Motor temperature is too high	1. Inspect temperature sensor wiring and troubleshoot the failure 2. Reduce carrier frequency or adopt other heat emission measures to make thermal management to the motor
Initial position fault	Err51	1. Too large deviation between the motor parameter and the reality	1. Reconfirm whether the motor parameter is correct, and focus on whether the rated current is set too small

9.4 Failure alarm and measures

The following failure conditions may be met when using the frequency converter. Please see the following methods for simple failure analysis:

Table 9-2 Common Failure and Handling Methods

No.	Failure phenomenon	Possible reasons	Solutions
1	No display when power on	No or too low network power; Switching power failure on the drive board of frequency converter; The rectifier bridge damages; The buffer resistance of frequency converter damages; Control panel and keyboard failure; Disconnection among control panel, drive board and keyboard;	Inspect input power; Inspect Bus voltage; Pull and plug 8-core and 28-core flat cable once again; Seek factory service;
2	Display “Err23” alarm when power on	Short circuit to earth for motor or output line; Frequency converter damages;	Use megger to measure the insulation of motor and output line; Seek factory service;
3	Frequently report Err14 (module overheating) failure	Too high setting for carrier frequency; Fan damages or air channel is blocked The internal components of frequency converter damage (thermocouple or others)	Reduce carrier frequency (F0-15); Replace fan and clean air channel; Seek factory service;
4	The motor doesn’t rotate after the frequency converter is running.	Motor and motor line; Frequency converter setting error (motor parameter); Poor contact wiring between drive board and control panel; Drive board failure ;	Reconfirm the wiring between frequency converter and motor; Replace motor or clear mechanical failure; Inspect and reset motor parameters;
5	Invalid DI terminal	Parameter setting error; External signal error; Loose OP and +24V jumper Control panel failure ;	Inspect and reset Group F4 related parameters; Reconnect the external signal line; Reconfirm OP and +24V jumper; Seek factory service;
6	When it is in closed-loop vector control, the motor speed cannot be raised	Encoder failure ; Encoder misconnection or poor contact; PG card failure ; Drive board failure ;	Replace the coded disk and reconfirm the wiring; Replace PG card; Seek service;
7	Frequency converter frequently reporting overcurrent and overpressure failure	Motor parameter setting error; Inappropriate acceleration/ deceleration time; Load vibration;	Reset the motor parameter or tune the motor; Set appropriate acceleration/ deceleration time; Seek factory service;
8	Err17 Err17 reporting when power on (or running)	Soft start contactor not-actuation	Inspect whether contactor cable is loose; Inspect whether contactor has any failure ; Inspect whether contactor 24V power supply has any failure ; Seek factory service;
9	Power-on display	Related components on the control panel damage;	Replace control panel;

Appendix A: Multifunctional IO Expansion Card 58IO

(Used for 3.7kW and the above machines)