I. Product Overview

The DOVOL DV950E series permanent magnet synchronous frequency converter is a general-purpose, high-performance current vector frequency converter. It is mainly used to control and adjust the speed and torque of three-phase AC synchronous motors. This guide provides detailed information on the converter’s functional features, operation methods, parameter settings, and troubleshooting, helping users quickly master the skills of using the equipment.

II. Basic Functions and Wiring

Product Main Features

• Control Modes: Supports sensorless vector control (SVC), sensor-based vector control (FVC), and V/F control.
• Frequency Range: 0 – 500Hz.
• Overload Capacity: 150% of the rated current for 60 seconds, 180% of the rated current for 3 seconds.
• Speed Regulation Range: 1:50 in SVC mode, 1:1000 in FVC mode.
• Built-in PID Regulator: Supports process closed-loop control.
• Multiple Communication Protocols Supported: Modbus, ProfiBus-DP, CANlink, CANopen.

Electrical Installation Precautions

• Main Circuit Wiring: Correctly distinguish between input terminals (R, S, T) and output terminals (U, V, W).
• Braking Resistor: Do not connect the braking resistor directly between the DC bus (+) and (-) terminals.
• Motor Cable Length: When the motor cable length exceeds 100m, install an AC output reactor.
• Grounding: Ensure reliable grounding with a grounding wire resistance of less than 10Ω.
• Power Supply Voltage: Before powering on, ensure that the power supply voltage matches the rated voltage of the frequency converter.

III. Operation Panel Usage

Panel Layout and Indicators

• RUN: Running status indicator (lights up when in operation).
• LOCAL/REMOT: Control mode indicator (off – panel control; on – terminal control; flashing – communication control).
• FWD/REV: Forward/reverse rotation indicator (lights up for reverse rotation).
• TUNE/TC: Tuning/torque control/fault indicator.
• Five-digit LED Digital Display Area.
• Function Keys: PRG (programming), ENTER (confirmation), ▲▼ (increase/decrease), ◄ (shift), etc.

Basic Operation Process

1. Enter the parameter setting mode by pressing the PRG key.
2. Select the function group using the ▲▼ keys.
3. Press ENTER to enter the specific parameter setting.
4. After modifying the parameter value, press ENTER to save it.
5. Press the PRG key to return to the previous menu.

IV. Core Function Implementation Methods

Motor Forward/Reverse Rotation Control

Method 1: Panel Control

• Set P0-02 = 0 (panel command channel).
• Set the running direction via P0-09 (0 – same direction; 1 – opposite direction).
• Press the RUN key to start and the STOP key to stop.

Method 2: Terminal Control

• Set P0-02 = 1 (terminal command channel).
• Assign DI terminal functions: P4-00 = 1 (DI1 for forward rotation), P4-01 = 2 (DI2 for reverse rotation).
• Control the on/off state of the DI terminals through external switches to achieve forward/reverse rotation.

Method 3: Communication Control

• Set P0-02 = 2 (communication command channel).
• Send forward/reverse rotation commands through communication (requires a communication card).
• Note: To disable reverse rotation, set P8-13 = 1.

Frequency Regulation Methods

Digital Frequency Setting

• Set P0-03 = 0 or 1 (digital setting).
• Set the preset frequency via P0-08.
• During operation, fine-tune the frequency using the panel ▲▼ keys or UP/DOWN terminals.

Analog Frequency Setting

• Set P0-03 = 2 (AI1)/3 (AI2)/4 (AI3).
• Configure the curve characteristics of the corresponding AI input (P4-13 – P4-27).
• Adjust the frequency using an external potentiometer or PLC analog output.

Multi-speed Control

• Set P0-03 = 6 (multi-speed instruction).
• Assign DI terminals as multi-speed instructions (P4-00 – P4-09 = 12 – 15).
• Set the frequency values for each speed segment in the PC group (PC-00 – PC-15).

PID Frequency Regulation

• Set P0-03 = 8 (PID).
• Configure the PID parameters in the PA group.
• Automatically adjust the frequency based on the feedback signal.

Motor Parameter Tuning

No-load Tuning Steps

1. Ensure that the motor is mechanically decoupled from the load.
2. Correctly input the motor nameplate parameters (P1-01 – P1-05).
3. Set P1-37 = 12 (synchronous motor no-load tuning).
4. Press the RUN key to start tuning (approximately 2 minutes).
5. The parameters are automatically saved after tuning is completed.

Loaded Tuning Steps

1. Set P1-37 = 11 (synchronous motor loaded tuning).
2. Press the RUN key to start tuning.
3. The parameters are automatically saved after tuning is completed.

• Note: Loaded tuning cannot obtain the back electromotive force coefficient, and the control accuracy is slightly lower than that of no-load tuning.

V. Advanced Function Configuration

Frequency Sweeping Function (Textile Applications)

• Set PB-00 = 0 (relative to the center frequency) or 1 (relative to the maximum frequency).
• Set PB-01 (frequency sweeping amplitude), PB-02 (jump amplitude).
• Set PB-03 (frequency sweeping period), PB-04 (triangular wave rise time).
• Control the frequency sweeping pause through the DI terminal (P4-xx = 24).

Fixed-length Control

• Set DI5 function as length counting input (P4-04 = 27).
• Set PB-07 (pulses per meter).
• Set PB-05 (preset length).
• Assign DO terminals as length arrival signals (P5-xx = 10).

Counting Function

• Set DI terminals as counting input (P4-xx = 25) and reset (P4-xx = 26).
• Set PB-08 (preset count value), PB-09 (specified count value).
• Assign DO terminals as counting arrival signals (P5-xx = 8 or 9).

Timing Control

• Set P8-42 = 1 (timing function enabled).
• Set P8-44 (timing operation time) or select AI input via P8-43.
• The equipment automatically stops after reaching the preset time.

VI. Fault Diagnosis and Handling

Common Fault Codes and Handling

Fault Code	Fault Type	Possible Causes	Handling Methods
Err02	Acceleration Overcurrent	Short acceleration time/heavy load	Extend the acceleration time P0-17/check the mechanical load
Err03	Deceleration Overcurrent	Short deceleration time	Extend the deceleration time P0-18
Err04	Constant-speed Overcurrent	Load突变 (Load mutation)/motor short circuit	Check the motor insulation/adjust the torque limit P2-10
Err09	Undervoltage	Low input voltage/power outage	Check the power supply voltage/set P9-59 for instantaneous power failure without stop
Err11	Motor Overload	Heavy load/undersized motor	Reduce the load/check the rated current setting P1-03
Err14	Module Overheating	High ambient temperature/poor heat dissipation	Improve the heat dissipation conditions/reduce the carrier frequency P0-15
Err20	Encoder Fault	Signal interference/wiring error	Check the encoder wiring/set P2-32 = 0 to disable Z correction

Fault Reset Methods

• Panel Reset: Press the STOP/RES key in the fault state.
• Terminal Reset: Set the DI terminal function to 9 (fault reset).
• Communication Reset: Send a reset command through communication.

Fault Record Inquiry

• Recent Fault: Check P9-16 – P9-22.
• Second Fault: Check P9-27 – P9-34.
• First Fault: Check P9-37 – P9-44.

VII. Maintenance and Upkeep

Daily Inspection

• Check if the cooling fan is operating normally.
• Check for loose wiring terminals.
• Check if the enclosure temperature is abnormal.
• Regularly remove dust from the radiator.

Regular Maintenance

• Check the appearance of electrolytic capacitors every six months.
• Check the insulation resistance annually (measure after powering off).
• Replace the cooling fan every 2 years (depending on the operating environment).

Parameter Backup

• Set PP-01 = 4 (backup user parameters).
• To restore, set PP-01 = 501.
• Restore to factory settings: PP-01 = 1.

VIII. Safety Precautions

• Do not open the cover when powered on. After powering off, wait for 10 minutes before performing wiring operations.
• Do not connect the braking resistor directly to the DC bus.
• Perform an insulation check on the motor before the first use (≥5MΩ).
• Derate the equipment when the altitude exceeds 1000m (derate by 1% for every 100m).
• Derate the equipment when the ambient temperature exceeds 40℃ (derate by 1.5% for every 1℃).
• Do not install capacitors or surge suppressors on the output side of the frequency converter.

This guide provides a detailed introduction to the various function implementation methods of the DV950E frequency converter. When using it in practice, please select the appropriate configuration method according to the specific application scenario. For complex application scenarios, it is recommended to contact the manufacturer’s technical support for more professional guidance.

I. Operation Panel Functions and Basic Settings

1.1 Introduction to Operation Panel Functions

The operation panel of the XC-5000 series frequency converters adopts a three-level menu structure, with the main functional components including:

LED Display Area:

• 5-digit LED Digital Tube: Displays set frequency, output frequency, monitoring data, and alarm codes.

Function Indicator Lights:

• RUN: Indicates the running status.
• LOCAL/REMOT: Indicates the control mode (panel/terminal/communication).
• FWD/REV: Indicates forward/reverse rotation.
• TUNE/TC: Indicates tuning/torque control/fault status.

Key Functions:

• Programming Key (PRG): Enters/exits the first-level menu.
• Confirm Key (ENTER): Enters menus/confirms parameters.
• Increment/Decrement Keys (▲/▼): Increases/decreases data.
• Shift Key (◄): Selects display parameters/modification positions.
• Run Key (RUN): Controls keyboard operation.
• Stop/Reset Key (STOP/RES): Stops operation/resets faults.
• Multi-Function Selection Key (MF.K): Defines functions according to F7-01.

1.2 Parameter Initialization Settings

Restore Factory Parameters (excluding motor parameters):

• Set FP-01 = 1 and confirm.

Clear Operation Record Information:

• Set FP-01 = 2 and confirm.

Restore User Backup Parameters:

• Set FP-01 = 501 and confirm.

Notes:

• Initialization operations must be performed in the stop state.
• After initialization, running parameters need to be reset.
• In vector control mode, motor parameter identification needs to be redone.

1.3 Password Setting and Management

Setting a Password:

• Enter the function code FP-00 and set a 4-digit numerical password (1-65535), then confirm.

Password Protection Activation:

• Password protection takes effect after exiting the function code editing state.

Canceling Password Protection:

• Use the password to enter parameter settings and set FP-00 to 0, then confirm.

1.4 Parameter Access Restriction Settings

Function Group Display Control (FP-02):

• Units digit: U group display selection.
• Tens digit: A group display selection.

Personalized Parameter Group Display Control (FP-03):

• Units digit: User-defined parameter group display selection.
• Tens digit: User-modified parameter group display selection.

Function Code Modification Attribute (FP-04):

• Sets whether parameters can be modified (0 for modifiable/1 for non-modifiable).

Manufacturer Parameter Protection:

• Parameters marked with “*” are prohibited from being modified by users.

II. External Terminal Control and Speed Adjustment Settings

2.1 External Terminal Forward/Reverse Rotation Control

Hardware Wiring:

• Control power wiring: +24V-COM provides +24V power.
• Control signal wiring (two-wire control):
  • DI1-COM: Forward rotation signal input.
  • DI2-COM: Reverse rotation signal input.

Parameter Settings:

• Command source selection: F0-02 = 1.
• Terminal function definition: F4-00 = 1 (DI1 for forward rotation), F4-01 = 2 (DI2 for reverse rotation).
• Terminal command mode: F4-11 = 0.
• Reverse rotation control enable: F8-13 = 0.

2.2 External Potentiometer Speed Adjustment Settings

Hardware Wiring:

• Connect the two ends of the potentiometer to +10V and GND, and connect the sliding end to AI1-GND.
• Recommended potentiometer specifications: Resistance 1kΩ-5kΩ, power 0.5W or above.

Parameter Settings:

• Frequency source selection: F0-03 = 2.
• AI curve settings: F4-13 = 0.00V, F4-14 = 0.0%, F4-15 = 10.00V, F4-16 = 100.0%.
• Frequency range limitation: F0-10 = 50.00Hz, F0-12 = 50.00Hz, F0-14 = 0.00Hz.

III. Fault Diagnosis and Handling

3.1 Common Fault Codes and Solutions

Fault Code	Fault Type	Possible Causes	Solutions
ERR02	Acceleration Overcurrent	Load mutation, short acceleration time	Check the load, increase the acceleration time F0-17
ERR03	Deceleration Overcurrent	Short deceleration time, large load inertia	Increase the deceleration time F0-18, install a braking resistor
…	…	…	…
ERR20	Encoder Fault	PG card fault, wiring error	Check the encoder wiring, set the F1-36 detection time

3.2 Fault Information Query and Reset

Fault History Query:

• F9-14 to F9-16: Record the types of the last three faults.
• F9-17 to F9-46: Record the operating status parameters at the time of the fault.

Fault Reset Methods:

• Panel reset: Press the STOP/RES key.
• Terminal reset: Set the DI terminal to 9.
• Communication reset: Send a reset command through Modbus communication.

3.3 Fault Protection Action Settings

Fault Action Selection 1 (F9-47):

• Units digit: Motor overload action.
• Tens digit: Input phase loss action.

Fault Action Selection 2 (F9-48):

• Units digit: Encoder fault action.
• Tens digit: Parameter read/write abnormal action.

Fault Action Selection 3 (F9-49):

• Units digit: Custom fault 1 action.
• Tens digit: Custom fault 2 action.

IV. Advanced Functions and Application Examples

4.1 Multi-Motor Control Function

Motor Parameter Group Selection:

• Select the current motor parameter group using F0-24.

Motor Parameter Settings:

• First group: F1 group (motor parameters), F2 group (vector parameters).
• Second group: A2 group (motor parameters), A5 group (vector parameters).

Switching Notes:

• Switching must be performed in the stop state.
• After switching, check the motor rotation direction.

4.2 PID Control Function Application

Basic Parameter Settings:

• FA-00: PID setpoint source selection.
• FA-02: PID feedback source selection.

PID Parameter Settings:

• FA-05: Proportional gain Kp1.
• FA-06: Integral time Ti1.
• FA-07: Differential time Td1.

4.3 Communication Function Configuration

Basic Parameter Settings:

• Fd-00: Baud rate setting.
• Fd-01: Data format.
• Fd-02: Local address.

Communication Control:

• Run command: Communication address 0x1001.
• Frequency setpoint: Communication address 0x1000.

V. Maintenance and Upkeep

5.1 Daily Maintenance Points

Regular Inspection Items:

• Check the operation of the cooling fan.
• Remove dust from the radiator.
• Check the wiring terminals.
• Check the electrolytic capacitors.

Maintenance Cycle Recommendations:

• Daily: Check the operating status.
• Monthly: Clean the radiator.
• Annually: Conduct a comprehensive inspection.

5.2 Long-Term Storage Notes

Storage Environment Requirements:

• Temperature: -20°C to +60°C.
• Humidity: ≤95%RH (no condensation).

Inspection Before Reuse:

• Measure the insulation resistance of the main circuit.
• Check the control board.

5.3 Lifespan Prediction and Replacement

Lifespan Reference for Wear Parts:

• Electrolytic capacitors: Approximately 8-10 years.
• Cooling fans: Approximately 30,000-50,000 hours.

Replacement Notes:

• Cut off the power supply and wait for 10 minutes before operation.
• After replacement, check the parameter settings.

Conclusion

The XC-5000 series frequency converters are powerful and have superior performance. Through this guide, users can comprehensively master core skills such as operation panel usage, parameter settings, external control, and fault diagnosis. Correct installation, parameter settings, and maintenance are key to ensuring the long-term stable operation of the frequency converters. It is recommended that users refer to this guide and make appropriate adjustments according to specific working conditions to fully leverage the performance advantages of the XC-5000 frequency converters.

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I. Background and Problem Description

In CNC machining center maintenance and commissioning, the calibration of the Z-axis reference point and tool change point is critical for ensuring the machine’s precision and stability.
This article takes the XD-40A vertical machining center manufactured by Dalian Machine Tool Group as an example. The machine is equipped with a GSK983Ma-H CNC system, DA98D servo drive, and a Sanyo OIH 5000P/R incremental encoder.
The machine adopts an umbrella-type tool magazine, where the Z-axis must accurately position at the second reference point during tool change.

During routine maintenance, the Z-axis servo motor was replaced. After replacement, the machine could start and home normally, but an abnormality appeared during tool change (M06):
The Z-axis stopped about 3 mm higher than before, causing the spindle taper to fail to engage the tool holder. The operator had to manually lower the Z-axis by 3 mm to complete the tool change.

Although this deviation did not trigger any alarms, it seriously affected the reliability of automatic tool change and could lead to tool gripper misalignment, incomplete release, or even tool crashes.

---

II. System Structure and Signal Relationship Analysis

To solve the issue, it is essential to understand how the GSK983Ma-H system defines the Z-axis “reference point (home position).”
The Z-axis homing position is determined by two signals:

1. Proximity switch signal (HOME/ORG) – used for coarse positioning;
2. Encoder Z-phase signal (Z-phase) – used for fine positioning.

When the machine executes the “Home” (G28 Z0) command after power-up, the sequence is as follows:

• The Z-axis moves in the specified direction until it detects the proximity switch signal.
• The system records the pulse position at this point.
• After the proximity signal is released, the axis continues moving.
• When the next Z-phase pulse is detected, the system defines that position as the machine reference point (zero point).
• Based on parameter 0161, the system then calculates the second reference point (e.g., tool change point).

Thus, the Z-axis zero position is not determined by the limit switch alone, but by the phase relationship between the proximity signal and the encoder Z-phase pulse.

---

III. Root Cause Analysis After Motor Replacement

In this case, the proximity switch, lead screw, and limit mechanism remained unchanged, yet a 3 mm tool change deviation occurred after replacing the motor.
The underlying causes are as follows:

1. Encoder Z-phase Signal Phase Difference

Even among identical motor models, the internal encoder Z-phase position relative to the rotor magnetic pole can vary slightly due to manufacturing tolerances.
When the system executes “find proximity then find Z-phase,” a phase delay or advance changes the zero-point position.

For a 5000-line encoder:
[
5\text{ mm / rev} \Rightarrow 1 \text{ Z pulse = 5 mm}
]
If the Z-phase triggers 0.6 turns later, the system’s reference point shifts upward by approximately 3 mm.

2. Coupling Installation Angle Deviation

If the motor–lead screw coupling is reassembled with a slight angular misalignment or reversed orientation, the timing between the proximity and Z-phase signals changes, causing a fixed offset.

3. Second Reference Point Parameter Not Recalibrated

Parameter 0161 in the GSK system defines the distance between the first and second reference points.
If the old value is retained after encoder replacement, the stored Z-phase relationship becomes invalid, resulting in a tool change height deviation.

4. Servo Phase Angle or Polarity Mismatch

If the servo drive’s electrical phase offset (in DA98D) is not re-calibrated, it can cause inconsistent homing. However, such errors typically lead to random deviations, not a consistent 3 mm offset.

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IV. Parameter Framework and Signal Interaction

The GSK983Ma-H system controls Z-axis referencing using several key parameters:

Parameter	Description	Function
0160	Home direction	Defines positive or negative direction of homing
0161	Distance from 1st to 2nd reference point	Defines tool change position
0162	Home offset	Compensates fine homing deviation (if available)
0163–0165	Homing speeds	Control homing speed at each stage
0171–0175	Home switch logic	Defines trigger mode and direction

Thus, the final tool change position can be expressed as:
[
Z_{tool} = Z_{prox} + ΔZ_{Z-phase} + P_{0161}
]
Any change in the above components—especially the Z-phase offset—will cause a physical shift in the tool change height.

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V. Comparative Analysis of Available Solutions

When parameter modification (0161) is restricted by password protection, alternative methods must be considered.
Below is a comparison of practical options used in the field.

Method	Principle	Application	Advantage	Risk
Modify 0161	Adjusts tool change offset	If password available	Accurate and safe	Requires password
Adjust proximity switch	Shifts home reference mechanically	No password	Simple and direct	Changes all Z references
Change servo electronic gear ratio	Alters pulses per unit	Mismatch in lead screw	Fixes scaling	Affects entire travel accuracy
Modify home offset (if available)	Software correction	Some versions only	No mechanical adjustment	Usually locked
Adjust motor phase	Alters encoder–rotor relationship	Encoder misalignment	Permanent correction	Complex, risky

Conclusion:

• If password access is available, adjusting 0161 is best.
• If not, physically adjusting the proximity switch by 3 mm is the most practical.
• Avoid changing gear ratios unless lead screw or encoder specifications differ.

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VI. Practical Solution Without Password Access

When the system password is unknown or locked, the following mechanical method effectively corrects the deviation.

1. Required Tools

Hex wrench, caliper or feeler gauge, insulation gloves, and a tool holder or alignment gauge.

2. Determine Adjustment Direction

• If Z-axis stops too high → move the proximity switch upward.
• If Z-axis stops too low → move the switch downward.

3. Adjustment Procedure

1. Power off the machine.
2. Loosen the Z-axis home switch screws.
3. Move the switch up by approximately 3 mm.
4. Tighten screws and power on.
5. Re-home the Z-axis and test tool change.

4. Verification

Execute:

G28 Z0
M06 T1

Check if the spindle taper aligns with the tool gripper. Fine-tune the switch by ±0.5 mm if needed.

5. Update Work Coordinate

Since the machine reference has shifted, redefine the Z=0 in G54 by touching off the workpiece again.

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VII. DA98D Drive Parameter Verification

To ensure that the deviation is not caused by drive scaling, verify the following parameters in the DA98D servo drive:

Parameter	Function	Recommended	Description
P1.05	Electronic gear numerator	20000	Encoder output per rev
P1.06	Electronic gear denominator	1	1:1 transmission
P2.04	Home polarity	Depends on axis	Match direction
P4.01	Auto phase calibration	Execute after motor replacement	Syncs magnetic poles

Any incorrect electronic gear ratio can cause axis scaling errors and must be restored to 1:1.

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VIII. Pulse Calculation for 3 mm Offset

Given:

• Lead screw pitch = 5 mm
• Encoder = 5000 PPR
• Pulses per revolution = 5000 × 4 = 20000
• Pulses per mm = 20000 ÷ 5 = 4000

Then:
[
3 \text{ mm} × 4000 = 12000 \text{ pulses}
]
To compensate for a 3 mm height difference, parameter 0161 should change by ±12000 pulses.
For example:

0161: -133500 → -145500

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IX. Unlocking System Parameters

If full software correction is preferred, parameter protection can be disabled as follows:

1. Navigate to:
   SYSTEM → PARAM → NC PARAM
2. Press SET;
3. When prompted, enter one of the following passwords:

Password	Description
983	GSK default
889	Service engineer code
1111 / 0000	User level
1314 / 8888	OEM-defined

After successful entry, “Protection Released” appears at the bottom of the screen, allowing parameter editing.

If unavailable, restart and hold DELETE or ALT+M during boot to enter the maintenance menu and disable “Parameter Protection.”

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X. Understanding the Z-Axis Homing Logic

The following illustrates the Z-axis homing process:

 ↑ Z+
 │
 │       ┌────────────┐
 │       │ Proximity Switch │
 │       └────────────┘
 │                ↓ (continue)
 │               [Z-phase pulse]
 └──────────────────────────────→ Time

Explanation:

1. Axis moves until proximity signal triggers;
2. After signal release, continues to move;
3. When Z-phase is detected, zero point is set;
4. From that zero, parameter 0161 defines the tool change position.

If the Z-phase occurs later relative to the proximity switch, the zero point shifts upward, making the spindle stop higher during tool change.
By moving the proximity switch 3 mm upward, the zero point effectively moves downward by 3 mm, correcting the deviation.

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XI. Key Lessons and Maintenance Practices

1. Always re-calibrate reference points after replacing incremental encoders.
   Even a small Z-phase shift can cause millimeter-level errors.
2. Back up all NC parameters before maintenance.
   Parameter loss or mismatch is a frequent cause of deviation.
3. Prefer software compensation over mechanical adjustments.
   Mechanical adjustments are practical but less precise.
4. Do not change electronic gear ratios arbitrarily.
   They affect all axis scaling, not just tool change height.
5. Umbrella-type tool changers rely heavily on parameter 0161.
   Incorrect values lead to failed or dangerous tool changes.
6. After adjustment, verify through a full test:
   • Home the Z-axis;
   • Execute tool change;
   • Check gripper alignment;
   • Recalibrate work coordinate (G54).

---

XII. Conclusion

This study analyzed a real case of Z-axis tool change deviation on an XD-40A vertical machining center equipped with GSK983Ma-H control and DA98D servo drives.
Through a detailed investigation of encoder Z-phase behavior, servo drive settings, and CNC reference logic, it was concluded that the 3 mm deviation was caused by a Z-phase timing difference, not mechanical misalignment.

When parameter modification is possible, adjusting parameter 0161 is the optimal solution.
When access is restricted, mechanically adjusting the proximity switch by 3 mm effectively compensates for the offset.
If hardware specifications differ, recalibration of the electronic gear ratio is necessary.

This case highlights that CNC positioning precision depends not only on mechanical accuracy but also on the synchronization between hardware signals and software logic.
A deep understanding of the system’s internal mechanisms allows technicians to restore functionality efficiently, accurately, and safely.

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Preamble: Getting to Know the Weite TW-ZX Series Frequency Inverter

The Weite TW-ZX series frequency inverter is a high-performance drive control device specifically designed for lifting equipment. It is particularly suitable for precise control of heavy-duty machinery such as construction elevators and tower cranes. As a leading electrical transmission solution in the industry, this series of frequency inverters integrates advanced motor control algorithms and a rich set of functional configurations, enabling it to meet the stringent requirements of various lifting application scenarios.

This technical guide will comprehensively analyze the functional features, installation specifications, parameter settings, and maintenance essentials of the Weite TW-ZX frequency inverter, aiming to provide users with a systematic operational reference. By thoroughly understanding the content of this manual, users can fully leverage the performance advantages of the equipment, ensuring the safe, stable, and efficient operation of lifting equipment.

The TW-ZX series frequency inverter adopts optimized control algorithms specifically tailored for lifting applications, featuring core characteristics such as low-frequency high-torque output, intelligent braking control, and wide voltage adaptability. It is renowned in the industry for its high reliability and exceptional control precision. Below, we will commence with an overview of the product’s features and gradually unfold a complete application guide for this professional device.

I. Core Product Features and Technical Advantages

1.1 Professional Lifting Control Functions

The Weite TW-ZX frequency inverter is specifically designed for the lifting industry, incorporating a range of highly targeted professional functions:

Low-Frequency High-Torque Output: At 0.5Hz, it can provide 150% of the rated torque, ensuring stability during heavy-load startups and low-speed operations. This feature is particularly suitable for tower crane hoisting and elevator applications, addressing the industry challenge of insufficient torque in traditional frequency inverters at low frequencies.

Intelligent Brake Control Logic: It incorporates optimized braking timing control to precisely coordinate the actions of mechanical brakes and motors. Parameters Fb-00 to Fb-11 allow for flexible adjustment of brake release/closure frequencies and delay times, effectively preventing hook slippage and significantly enhancing operational safety.

Dynamic Current Limiting Technology: Advanced current control algorithms automatically adjust output during severe load fluctuations, preventing frequent overcurrent trips. Users can configure current stall protection characteristics via parameter FC-07 to balance system response speed and stability.

Wide Voltage Adaptability: The input voltage range extends up to 380V±20%, with automatic voltage regulation (AVR) functionality. It maintains sufficient torque output even when grid voltage drops, making it particularly suitable for construction sites with unstable grid conditions.

1.2 Hardware Design Characteristics

The TW-ZX series reflects the unique needs of lifting equipment in its hardware architecture:

Enhanced Cooling Design: The entire series adopts a forced air cooling structure with real-time protection against overheating of the散热器 (radiator) (OH fault), ensuring reliable operation in high-temperature environments. Larger power models (above 90kW) utilize an up-draft and down-draft air duct design to optimize cooling efficiency.

Modular Power Units: The power modules employ industrial-grade IGBT devices with an overload capacity of 150% rated current for 1 minute and 180% rated current for 10 seconds, fully meeting the short-term overload requirements of lifting equipment.

Rich Interface Configuration: It provides 7 multifunctional digital input terminals (X1-X7), 2 analog inputs (VS/VF for voltage signals, IS/IF for current signals), 2 open-collector outputs (Y1/Y2), and 1 relay output (R1), catering to complex control needs.

Built-in Brake Units (Select Models): Models below 18.5kW come standard with built-in brake units, allowing direct connection to brake resistors. Larger power models require external dedicated brake units, with the BR100 series recommended as a complementary product.

1.3 Control Performance Advantages

Compared to general-purpose frequency inverters, the TW-ZX series has undergone in-depth optimization in its control algorithms:

Optimized S-Curve Acceleration/Deceleration: Parameter FC-00 enables the S-curve acceleration/deceleration mode, with FC-01/02 setting the S-curve proportions for the acceleration and deceleration phases, respectively, effectively reducing mechanical shock and enhancing operational smoothness.

Multi-Speed Precise Control: It supports up to 16 preset speed stages (F3-00 to F3-14), allowing rapid switching through terminal combinations to meet the speed requirements of lifting equipment under various operating conditions. Each speed stage can independently set acceleration and deceleration times (F3-15 to F3-20).

Motor Parameter Self-Learning: It offers both stationary and rotational self-identification modes (F1-15) to automatically measure motor electrical parameters, significantly improving vector control accuracy. For applications where the load cannot be decoupled, the stationary identification mode provides a safe and reliable option.

Table: Typical Models and Specifications of the TW-ZX Series Frequency Inverter

Model	Rated Power (kW)	Rated Current (A)	Brake Unit	Dimensions (mm)
TW-ZX-011-3	11	26	Built-in	270×200×470
TW-ZX-022-3	22	48	Built-in	386×300×753
TW-ZX-045-3	45	90	Built-in	497×397×1107
TW-ZX-110-3	110	220	External	855×825×793

II. Equipment Installation and Electrical Wiring Specifications

2.1 Mechanical Installation Requirements

Proper installation is fundamental to ensuring the long-term reliable operation of the frequency inverter. The TW-ZX series requires particular attention to the following points during installation:

Installation Orientation: It must be installed vertically to ensure unobstructed airflow through the cooling ducts. Sufficient space (recommended ≥100mm) should be left on all sides to prevent heat accumulation. When multiple frequency inverters are installed side by side in a control cabinet, the ambient temperature should not exceed 40℃.

Environmental Conditions: The operating environment should have a temperature range of -10℃ to +40℃ and a humidity range of 20% to 90%RH (non-condensing). It should be avoided in locations with conductive dust, corrosive gases, or oil mist, and kept away from vibration sources and electromagnetic interference sources.

Vibration Protection: The installation base should be sturdy and vibration-free, with a maximum allowable vibration of 0.5g. For vehicle-mounted or mobile equipment applications, shock absorbers are recommended to prevent internal components from loosening due to prolonged vibration.

Protection Level: Standard models have a protection level of IP20 and are not suitable for direct exposure to outdoor or humid environments. For special environments, customized protective enclosures or models with higher protection levels should be selected.

2.2 Main Circuit Wiring Specifications

The main circuit wiring directly affects system safety and EMC performance, and must strictly adhere to the following specifications:

Power Input Terminals (R/S/T):

• A suitable circuit breaker (MCCB) must be installed, with a rated current of 1.5 to 2 times the rated value of the frequency inverter.
• The power cable cross-sectional area should be selected according to Table 3-3, ensuring a voltage drop not exceeding 5V.
• An AC reactor (optional) can be installed on the input side to suppress grid surges and harmonics.

Motor Output Terminals (U/V/W):

• Motor cables should be shielded cables or laid through metal conduits to reduce electromagnetic radiation.
• It is absolutely prohibited to install power factor correction capacitors or LC/RC filters on the output side.
• When the motor wiring length exceeds 50 meters, the carrier frequency should be reduced or an output reactor should be installed.

Brake Resistor Connection:

• For models with built-in brake units, connect to the PB terminals. For models with external brake units, connect to the P/N terminals.
• The resistance value and power rating must be strictly selected according to Table 11-1 to prevent overload damage to the brake unit.
• Brake resistor wiring must use high-temperature-resistant cables and be kept away from flammable materials.

Grounding Requirements:

• The protective grounding terminal must be reliably grounded (Class III grounding, grounding resistance <10Ω).
• The grounding wire cross-sectional area should be no less than half of the power cable cross-sectional area, with a minimum of 16mm².
• When grounding multiple frequency inverters, avoid forming grounding loops and adopt a star grounding configuration.

2.3 Control Circuit Wiring Essentials

The control circuit serves as the bridge for interaction between the frequency inverter and external devices, and special attention should be paid to the following points during wiring:

Analog Signal Processing:

• Speed reference signals (VS/VF) should use twisted-pair shielded cables, with the shield grounded at one end.
• Signal lines should be separated from power lines by a distance of no less than 30cm and arranged perpendicularly when crossing.
• Jumpers JP1/JP2 can select the analog output M0/M1 to operate in voltage (0-10V) or current (0-20mA) mode.

Digital Terminal Configuration:

• By default, X1 is set for operation, X2 for forward/reverse rotation, and X3-X7 are programmable for functions such as multi-speed control (F2-00 to F2-06).
• The PLC common terminal can be connected to either 24V or COM, supporting both NPN and PNP wiring modes.
• The relay output R1 (EA-EB-EC) can directly drive contactor coils, with a contact rating of 250VAC/3A.

RS485 Communication:

• Use shielded twisted-pair cables to connect the A+/A- terminals, with proper termination resistor matching.
• Communication parameters are set via F1-16 to F1-19, supporting the Modbus RTU protocol.
• It is recommended to set the baud rate not exceeding 19200bps and reduce the rate for long-distance communication.

Figure: Standard Wiring Diagram for the TW-ZX Frequency Inverter
[Insert wiring diagrams similar to Figures 12-1 to 12-4 here, showcasing typical application wiring for elevators, tower crane hoisting, etc.]

III. Parameter Settings and Functional Configuration

3.1 Basic Parameter Setting Procedure

After powering on the TW-ZX frequency inverter, follow the procedure below for basic settings:

Restore Factory Settings:

• Set F0-28=1 to restore the factory settings corresponding to the application macro.
• Select F4-28=9 for elevator applications and F4-28=6 for tower crane hoisting applications.
• After resetting, check F0-27=1 to ensure all parameter groups are displayed.

Motor Parameter Input:

• Accurately input the motor nameplate data (F1-00 to F1-07).
• For elevators with dual motors in parallel, set the power and current to the sum of the two motors.
• The motor winding connection method (F1-06) must match the actual configuration (Y/△).

Motor Parameter Self-Learning:

• Perform rotational self-identification (F1-15=2) after decoupling the load.
• If the load cannot be decoupled, select stationary self-identification (F1-15=1).
• Do not operate the frequency inverter during the identification process. Parameters are automatically stored upon completion.

Speed Control Parameters:

• Set the maximum frequency F0-16 (usually 50Hz) and the upper limit frequency F0-17.
• Adjust the acceleration time F0-09 and deceleration time F0-10, extending them appropriately for heavy loads.
• The carrier frequency F0-14 is generally set to 1-4kHz, and can be increased if noise is significant.

Terminal Function Allocation:

• Configure X3-X7 according to application requirements for functions such as multi-speed control and fault reset.
• Set the output functions for Y1/Y2/R1, such as fault signals and brake control.

3.2 Configuration of Lifting-Specific Functions

The TW-ZX series requires special configuration for the unique functions tailored to lifting applications:

Brake Control Timing:

• Set the ascending brake release frequency Fb-00 (usually 3Hz) and the descending release frequency Fb-01.
• Configure the pre-release delay Fb-02 (approximately 0.3s) and the post-release delay Fb-03.
• Set the brake closure frequencies Fb-04/Fb-11 and the corresponding delays Fb-05/Fb-06.

Zero-Crossing Acceleration Function:

• Enable Fb-09 to set the zero-crossing acceleration/deceleration time (approximately 2s).
• Adjust Fb-10 to set the frequency point for acceleration/deceleration changes (usually 2.5Hz).
• Combine with S-curve parameters FC-01/02 to achieve smooth transitions.

Brake Inspection Function:

• Set the inspection torque Fd-09 (150% of rated) and time Fd-10 (4s).
• Define the inspection interval Fd-16 (e.g., 80 hours).
• Set the Y2 terminal to provide a brake inspection reminder (F2-13=27).

Industry-Specific Protections:

• Disable current limiting FC-07=0 and overvoltage stall FC-19=0010.
• Mask steady-state overvoltage protection FC-28=00010000.
• Set the number of fault retry attempts FC-24=01 (1 attempt).

3.3 Multi-Speed and PID Applications

The TW-ZX series supports flexible multi-speed and PID control schemes:

Multi-Speed Configuration:

• Preset 16 speed stages via F3-00 to F3-14.
• Define X3-X6 as multi-speed terminals using F2-02 to F2-05.
• Each speed stage can be associated with different acceleration and deceleration times (F3-15 to F3-20).

PID Control:

• Select the PID feedback source (F4-01) and reference source (F4-02).
• Set the proportional gain F4-03 and integral time F4-04.
• Define the PID output characteristics F4-05 and filtering time F4-06.

Analog Signal Processing:

• Configure VS/VF as speed references (F2-08/F2-10=0).
• Adjust the analog input filtering F8-04/F8-06.
• Calibrate the range of the analog outputs M0/M1 (F2-22 to F2-27).

IV. Operation and Fault Handling

4.1 Operation Modes and Monitoring

The TW-ZX frequency inverter offers multiple operation and monitoring modes:

Operation Mode Selection:

• Keyboard control (F0-04=0): Operate using the panel RUN/STOP keys.
• Terminal control (F0-04=1): Supports two-wire/three-wire modes (F0-05).
• Communication control (F0-04=2): Remote start/stop via RS485.

Operational Status Monitoring:

• View real-time output frequency C0-00, current C0-13, and other parameters.
• Monitor terminal statuses C0-26 (inputs) and C0-27 (outputs).
• Output key parameters to meters via M0/M1 analog outputs.

Inching and Micro-Movement Operations:

• Set the inching frequency F0-11 (usually 5Hz).
• Adjust the inching acceleration and deceleration times F0-12/F0-13.
• Operate using the JOG key or defined inching terminals.

4.2 Commissioning Steps

New equipment or equipment after major repairs should undergo commissioning according to the following specifications:

No-Load Testing:

• Decouple the load and operate at low speed to check the rotation direction and vibration.
• Gradually increase the frequency and observe whether the current and speed are normal.
• Test the switching between speed stages and the timing of brake actions.

Light-Load Testing:

• Apply 10-30% of the rated load to verify torque output.
• Check whether all protection functions are operating normally.
• Measure the temperature rise at key points (brake resistor, radiator, etc.).

Full-Load Testing:

• Gradually load to the rated load and operate continuously for 1 hour.
• Record operational parameters and confirm the absence of abnormal vibration and noise.
• Test the emergency stop function and fault self-reset capability.

4.3 Common Fault Analysis and Handling

Diagnosis and handling methods for common faults in the TW-ZX series frequency inverter:

Overcurrent Fault (HOC/SOC):

• Check motor insulation and cable connections.
• Extend acceleration and deceleration times and adjust torque boost.
• Verify whether the load exceeds the capacity of the frequency inverter.

Overvoltage Fault (HOU/SOU):

• Increase the deceleration time or install a brake unit.
• Check whether the grid voltage is too high.
• Enable the overvoltage stall function FC-19=2.

Brake-Related Faults:

• Check the mechanical condition and power supply of the brake.
• Readjust the brake timing parameters Fb-xx.
• Confirm that the brake inspection current Fb-28 is set reasonably.

Cooling Fault (OH):

• Clean the air ducts of dust and check the fan operation.
• Reduce the carrier frequency to decrease heat generation.
• Improve the ventilation conditions of the installation environment.

Table: Quick Reference Table for Fault Codes of the TW-ZX Series Frequency Inverter

Fault Code	Type	Possible Causes	Recommended Actions
SC/EMC	Short Circuit	Output short circuit or module damage	Check motor cables and insulation
HOC	Instantaneous Overcurrent	Acceleration too fast or load突变 (sudden change)	Extend acceleration time F0-09
Ol	Overload	Continuous overload operation	Check load or replace with a larger frequency inverter
StP	Brake Inspection Failure	Insufficient braking torque	Adjust brake or increase Fd-09

V. Maintenance, Upkeep, and Advanced Techniques

5.1 Regular Maintenance Plan

To ensure the long-term reliable operation of the TW-ZX frequency inverter, the following maintenance plan is recommended:

Daily Inspection:

• Listen for abnormal noise and check the cooling fan status.
• Record the DC bus voltage (C0-16) and radiator temperature.
• Check for loose or overheated connections at various terminals.

Quarterly Maintenance:

• Clean internal dust (after powering off).
• Tighten the screws of the main circuit terminals to the specified torque.
• Check electrolytic capacitors for bulging or leakage.

Annual Overhaul:

• Test the insulation resistance (between terminals and to ground).
• Calibrate the accuracy of analog signal detection.
• Replace aging components (fans, capacitors, etc.).

5.2 Parameter Backup and Restoration

The TW-ZX frequency inverter supports advanced functions for parameter management:

Parameter Copying:

• Use F3-31=1 to upload parameters to the operation panel.
• Use F3-31=2 to download parameters to other frequency inverters.
• It is recommended to save multiple versions of parameter backups.

Password Protection:

• Set a user password F0-31 to prevent unauthorized operations.
• Parameter locking is available in two levels (F0-29=1/2).
• If the password is forgotten, contact the manufacturer’s technical support.

Fault Record Query:

• View current and historical faults via the E0 group.
• Record operational status parameters at the time of the fault.
• Analyze fault frequency and occurrence conditions.

5.3 Performance Optimization Techniques

Advanced adjustment methods for specific applications:

Dynamic Response Optimization:

• Adjust slip compensation F3-30 (usually 100%).
• Optimize stator voltage drop compensation F7-25.
• Fine-tune dead-time compensation F7-26.

Energy-Saving Operation Settings:

• Enable energy-saving mode FC-10=1.
• Set the energy-saving starting frequency FC-11 (e.g., 20Hz).
• Adjust the energy-saving delay time FC-13.

Communication Network Configuration:

• Set the station address F1-16 and baud rate F1-17.
• Select the parity check method F1-18 (none/even/odd).
• Define the communication timeout F1-30 (0 for disabled).