**1. How to Distinguish Between Heavy Faults and Light Faults?**
In the case of a light fault, the system will trigger an alarm signal, and the corresponding indicator will flash. When a heavy fault occurs, the system will display a fault indication, and the indicator will remain lit. At the same time, the system will issue a command to disconnect the high voltage and close the switch, while storing the fault information and the high-voltage disconnection command. The fault status will not be cleared, and both the fault indication and the high-voltage disconnection command will remain active until resolved.
**2. What Are Light Faults?**
Light faults include transformer over-temperature alarms, cabinet temperature over-temperature alarms, cabinet door open, unit bypass, and similar conditions. These faults are not stored in the system, only indicated, and they automatically disappear once the fault is resolved. During inverter operation, a light fault does not stop the system from running. Even if a light fault occurs during shutdown, the inverter can still continue to operate.
**3. What Are Specific Faults?**
When certain critical faults occur, the system will display the fault type in the upper left corner of the monitor. Examples include external faults, transformer overheating, cabinet overheating, unit faults, inverter overcurrent, high-voltage loss, interface board faults, controller communication failure, motor overload, parameter errors, and main control board failures. Unit faults may involve fuse failure, unit overheating, drive failure, fiber failure, or unit overvoltage. External faults must be resolved (e.g., by opening the high-voltage disconnect) before the system can be reset. For other major faults, a direct system reset can restore normal operation, but it’s essential to identify and resolve the root cause before re-powering. After a unit fault, the unit status can only be checked by reapplying high voltage. If the fault is unclear, consult the manufacturer before attempting to power up again. **Never rush to restart without identifying the fault—this could damage the inverter.**
**4. Transformer Over-Temperature Alarm**
If the transformer temperature controller detects a temperature above its set alarm value (default 100°C), the over-temperature alarm contact will close. Check the fan at the top or bottom of the transformer cabinet for proper operation. Ensure the temperature sensor is functioning correctly, with no broken wires or poor connections. Inspect the filter for blockage—use an A4 sheet to check if it sticks. Also, verify that the inverter is not operating under long-term overload or in excessively hot environments (ambient temperature should be below 45°C). Ensure the fan control circuit is working properly.
**5. Cabinet Temperature Over-Temperature Alarm**
If the cabinet temperature at the measurement point exceeds 55°C, the system will trigger a light fault. Check the top fan of the unit cabinet, ensure the secondary room fan switch is not tripped, and inspect the filter for clogging. Make sure the inverter is not running under long-term overload, and check the ambient temperature. If necessary, install additional cooling solutions like wall-mounted fans or refrigeration equipment. Verify that the fan control circuit in the transformer cabinet is functioning correctly.
**6. Transformer Overheating**
If the transformer temperature exceeds its trip threshold (default 130°C), the system will report a heavy fault. Confirm the temperature reading on the controller. If it's below 130°C, check the alarm setting. Otherwise, refer to the transformer over-temperature alarm section for further troubleshooting.
**7. Cabinet Temperature Overheating**
If the cabinet temperature reaches 60°C, the system will report a heavy fault. Follow the same steps as for the temperature over-temperature alarm.
**8. Cabinet Door Interlocking Alarm**
Check whether the travel switch is properly aligned with the cabinet door. Ensure the pre-stroke and over-stroke settings are correct, and confirm the electrical function of the switch. If not, replace the interface board.
**9. Controller Does Not Communicate**
Verify that the communication cable between the monitor control board and the main control board is connected properly. Check the +15V and +5V voltages on the monitor control board. Replace the main control board or the monitor if needed.
**10. Main Control Board Fault**
If the monitor detects a faulty main control board, it will report the fault. Replace the monitor or the main control board accordingly.
**11. Interface Board Communication Failure**
The interface board will reset the monitor every 5 seconds. If communication isn’t established within 3 minutes and 30 seconds, it will be classified as a heavy fault. Check the communication cable, terminal connections, I/O board functionality, and chip installation.
**12. Parameter Error**
A parameter error occurs when incorrect values are set, especially during vector control. Reconfigure the parameters and press the reset button.
**13. External Fault**
An external fault is triggered when the high-voltage disconnect button is pressed or the high-voltage contact is closed. Check the high-voltage break button, short circuits, or interface board issues.
**14. High-Voltage Power Loss**
This usually happens during normal operations. If there’s an unexpected power loss without any fault record, check the upper switchgear circuit.
**15. Inverter Overcurrent**
If the inverter output current exceeds 1.5 times the rated current, it will trigger overcurrent protection. Check the output voltage detection board, optical fiber connections, main circuit screws, Hall element power supply, acceleration time, torque boost, motor condition, and unit performance. If all checks pass, consider replacing the controller or main control board.
**16. Motor Overcurrent**
If the motor current exceeds 1.2 times the rated current for more than 2 minutes, check the motor current setting and power supply voltage.
**17. Motor Not Turning After Inverter Run**
Check for contactors or switches in the inverter output. Ensure the primary cable is connected to the motor. If there’s voltage but no current, the main circuit is open. If there’s current, check for grounding or motor winding issues.
**18. Unit Heavy Faults**
Unit faults include fuse failure, drive failure, overheating, overvoltage, and fiber faults. Some can be bypassed if the unit has a bypass function.
**19. Fuse Failure**
If the unit detects a phase loss, the fuse may be faulty. Check the power supply, incoming lines, and replace the fuse if necessary.
**20. Drive Failure**
Check the voltage detection board for shorts. Ensure the power unit terminals are not shorted and the motor insulation is intact. Look for mechanical failures in the load.
**21. Unit Overheating**
If the unit temperature exceeds 85°C, the system will report an overheating fault. Check the fan, filter, and ambient temperature. Replace the temperature relay if needed.
**22. Unit Overvoltage**
If the DC bus voltage exceeds the protection limit, the inverter will report overvoltage. Adjust the input voltage or increase deceleration time if needed.
**23. Fiber Failure**
If the system cannot detect unit communication, the fiber may be faulty. Check the power unit power supply and fiber connections.
**24. Unit Bypass**
If the unit has three faults (drive, fuse, or overheating), it will bypass. Other units in the same position may also bypass. The inverter can still run, but output capacity will decrease. Clean the boards and address the fault promptly.
**25. Operating Frequency Mismatch**
This can happen due to acceleration limits, high voltage causing deceleration, or current limiting. Adjust settings or check sensors for faults.
**26. Monitor Black Screen**
Try resetting the system. If it doesn’t work, check the monitor power, cables, and internal circuitry. Replace the monitor if necessary.
**27. Cannot Modify Parameters**
Some parameters are locked during operation. Only certain parameters can be changed when the system is stopped.
**28. Automatic Restart After Stop**
In remote control mode, the inverter will restart automatically if the start signal remains active after stopping.
**29. Inverter Trips on Power-On**
The inverter may draw a high initial current (6–7 times rated) for a few milliseconds. Adjust the quick-break protection setting if needed.
**30. Output Frequency Fluctuation at Low Speed**
Cogging effects can cause large current fluctuations. Increase current limit, shorten startup time, or replace the unit if the output voltage is low.
**31. Automatic Bypass on Switch Trip**
Ensure the delay relay in the bypass cabinet is set correctly. Adjust the switch protection settings if necessary.
**32. Induced AC Voltage on External Terminals**
Use shielded cables and ground both ends to reduce induced voltage. Avoid mixing signal and power lines. For 4–20mA signals, use a 275V/0.33μF capacitor between the signal and ground.
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