Category: Other Drives

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In field maintenance work, we often encounter situations where equipment displays fault codes that are not documented in the user manual. This is especially common with domestic brands or cloned inverters. This article details the entire process of diagnosing and repairing a ZHZK ZK880-N series inverter that first displayed an ERR23 fault (ground short circuit), and after repairs, encountered an ERR42 fault (speed deviation too large). Through fault code analysis and comparative research, we uncover the significant similarities between this inverter and the Inovance MD380 series and explore the logic issues that arise.

1. Equipment Background

The inverter was applied in an industrial fan system at a factory, used for speed control and energy saving. After years of operation, the equipment suddenly failed and displayed ERR23. The user tried replacing the motor without success, and then entrusted our team with on-site diagnosis and repair.

2. First Fault: ERR23 — Ground Short Circuit

1. Fault Symptom

The inverter powered on and passed self-check, but tripped with an ERR23 alarm immediately upon startup. The motor did not rotate, and no output current was detected.

2. Fault Analysis

Based on experience, ERR23 typically indicates a ground short caused by:

• Motor winding insulation breakdown
• Damaged or damp output cables
• Internal failure of power components (IGBT)

3. Troubleshooting and Repair

1. Insulation Testing: Used a megohmmeter to check insulation between U/V/W and ground — >200MΩ, confirmed normal; cables also intact.
2. Output Voltage Check: Powered on without load and checked inverter output with an oscilloscope — no PWM waveform, indicating power circuit issues.
3. Drive Board Check: Found burn marks on the drive board; further inspection confirmed IGBT failure.
4. Component Replacement: Replaced IGBT module and repaired burned-out optocouplers and resistors in the drive circuit.
5. Testing: Simulated load in factory conditions — inverter output normal, PWM stable, fan rotates properly.

ERR23 fault was successfully resolved.

3. Post-Repair Fault: ERR42 — Speed Deviation Too Large

1. On-Site Issue

After reinstalling at the user site, the inverter powered on and passed self-check. Upon startup, it ran for about 1–2 seconds and then tripped with ERR42.

2. Confusion and Clue

The ZHZK manual did not mention ERR42, leaving no immediate path forward. We pursued two directions:

• First, determine if it was a false alarm — due to interference or wiring.
• Second, check for hidden parameters or compatibility issues — given the extremely brief manual.

3. Comparative Breakthrough — Inovance MD380

An engineer noticed that the ZHZK ZK880-N closely resembled the Inovance MD380 series in appearance, menus, and parameter structures. We referenced the MD380 manual and found:

ERR42: Speed deviation too large.
Applies when using encoder feedback in vector control (F0-01=1), and actual speed deviates significantly from target.

But the parameter F0-01 was set to 0, i.e., sensorless vector control (SVC), where no encoder feedback is involved. Logically, such an error shouldn’t occur in this mode.

4. Validation Through Trial and Error

We tested by changing F0-01 from 0 to 2 — i.e., switching to V/F control mode.

• Upon restart, the inverter operated normally.
• ERR42 no longer occurred.

This confirmed that:

• Although ERR42 should only trigger in closed-loop vector control, ZHZK’s firmware retained some residual logic from MD380, allowing the error even in SVC mode.

5. ZHZK ZK880-N vs. Inovance MD380 — An In-Depth Comparison

Several clues support that ZHZK is a cloned or customized variant of Inovance:

1. Parameter numbering identical: Including F0-01, F9 group, etc.
2. Fault codes mostly match: Even undocumented ZHZK codes behave like MD380 ones.
3. Hardware layout extremely similar: IGBT drive and control board layout nearly identical.
4. UI and navigation same: Menu structure, key functions, and parameter copy behavior identical.

Conclusion: ZHZK ZK880-N is highly likely based on early Inovance versions — a rebranded or cut-down variant, with leftover logic causing such confusion.

6. Key Repair Takeaways

1. Don’t rely solely on manuals when fault codes are missing: Look at similar products.
2. SVC mode in clone inverters is often unstable: Recommend V/F for reliability.
3. Always document parameters and take screenshots: Helps future diagnostics.
4. Validate by logic and testing: ERR42 was resolved by matching control logic with firmware behavior.

7. Conclusion

This case shows that engineers must go beyond the manual when diagnosing inverter faults — especially for custom or generic brands. The transition from ERR23 to ERR42 and its resolution illustrates the importance of comparative research, logical reasoning, and on-site validation.

For clone or OEM-modified inverters, avoid complex control modes like vector control unless absolutely necessary. Simplicity brings reliability in harsh field environments.

This process exemplifies how practical engineering insight bridges the gap between unknown errors and restored operation.

I. Phenomenon Review

After power-on, the panel alternately displays “‑L‑C‑” and the A29/Err29 code. According to the corresponding entry in the manual:

“Cumulative Power-On Time Reaches Fault Err29 — ① The cumulative power-on time has reached the preset value; ② Use the parameter initialization function to clear the recorded information” (see user screenshot).

This indicates that it is not a hardware failure but rather a software logic lock: when the internally recorded Power-On Time (cumulative power-on hours) exceeds the manufacturer’s preset threshold, the inverter actively enters a protection/shutdown state until the user performs a “parameter initialization” or other unlocking action.

II. Why the “Running Hours Lock” Exists

Driven by Business Models

Some low-cost domestic brands adopt a “runtime limit” strategy, treating inverters as “quasi-leased” equipment:

• The device is shipped with the main machine in the first year, and after 8,000 to 10,000 hours of operation, it locks, requiring the customer to pay the remaining balance or renew the subscription to obtain authorization for reset.

Post-Sales Risk Control

In the “semi-OEM” market, manufacturers find it difficult to control the final application environment. Binding the lifespan limit to the software layer can compress the warranty scope and reduce large claims due to the burnout of high-power components caused by overloading.

Spare Parts Sales and Brand Loyalty

Forces end-users to return to the original manufacturer or authorized repair points for “unlocking + maintenance,” driving sales of spare parts and upgrade packages.

III. Triggering Mechanism Principle of A29/Err29

MCU-Integrated EEPROM/Flash Timer Writing to “Cumulative Power-On Counter”

• During power-on self-check, compare the Counter with the Limit.
• If ≥ Limit → Set Fault Flag → Output relay disconnects, and the panel reports Err29.
• Even after power-off and restart, the counter value remains saved in the EEPROM, so the fault “sticks” unless Parameter Initialize is executed or new firmware is flashed.

⚠️ Unlike ordinary faults (such as phase loss or overcurrent, which are instantaneous alarms), Err29 completely prohibits inverter output before reset, so the motor will not run, and the LED only cycles through error codes.

IV. Troubleshooting and Reset Steps from an Engineer’s Perspective

Step	Operation Points	Purpose
1. Confirm the model’s firmware version	Some versions hide the runtime limit menu; read the EEPROM to check; query the version number via the panel or serial command.	Determine if direct initialization is supported.
2. Back up all parameters	Use the keyboard to copy or serial software to export the parameter table.	Prevent the loss of process recipes after initialization.
3. Execute “Parameter Initialization”	Menu path: System Settings → Parameter Management → Initialize (refer to the manual for specific key sequences). After execution, the counter is automatically erased, and factory defaults are restored.	Clear the cumulative power-on time and resolve Err29.
4. Rewrite the backed-up parameters	Check item by item according to the backup table or use a PC debugging tool to write back in batches.	Restore the original logic and process limits.
5. Test run & observe the counter	Run for a short time to confirm no recurrence of A29; if the counter value still rises rapidly, check the motherboard’s RTC/timing interrupt for abnormalities.	Rule out hardware timing circuit faults.

V. Bypassing and Deep Modifications (Advanced Topics, for Reference Only)

Under legal and compliant premises, the following practices are common in authorized service centers or when users have terminated the after-sales agreement with the manufacturer:

Modify the Counter Threshold

• Directly increase the Limit in engineering mode (e.g., to 99,999 h).
• Drawback: In some older firmware versions, the threshold is hardcoded, and the menu is hidden.

Rewriting the EEPROM

• Use ISP or offline programmer to read the EEPROM image, manually modify the counter bytes, and then write back.
• Requires disassembly and possession of electronic soldering and programming tools.

Flashing Time-Unlimited Firmware

• Official “overseas” or “engineering test” firmware often removes the runtime limit; after replacing the entire MCU Flash, the limit is completely removed.
• Risk: Flashing failure may brick the device; may involve copyright issues.

VI. Impact on Enterprise Operations and Maintenance

Impact Point	Description	Coping Strategy
Production Downtime Loss	Accidental triggering of Err29 can lead to a complete line shutdown.	Include “running hours warning” monitoring in the PM plan to arrange maintenance windows in advance.
Maintenance Costs	If unauthorized, need to pay for unlocking or replace the entire unit.	Sign a long-term maintenance package with the manufacturer or train in-house technicians to master initialization skills.
Spare Parts Warehousing	Frequent lockouts increase the demand for backup units.	Equip key processes with hot backup drives to reduce the impact of lockouts on production capacity.

VII. Legal and Ethical Discussion

Software Lock vs. Contract Law: If the sales contract does not explicitly state the “runtime limit lock,” the manufacturer’s setting of software obstacles may violate the “right to know” clause of the Consumer Rights and Interests Protection Law.

Right-to-Repair: Internationally, more and more countries emphasize users’ right to repair their purchased equipment independently, opposing excessive software restrictions. Designs like “Err29” may face compliance reviews in European and American markets.

Balanced Viewpoint: Manufacturers use software locks to prevent equipment from continuing to operate in harsh environments beyond their designed lifespan, potentially causing safety accidents; however, they should disclose this protection logic transparently in advance and provide officially authorized ways to remove it.

VIII. Conclusion and Recommendations

A29/Err29 is not an electrical fault but a “running hours lock.” It can be cleared through “parameter initialization,” but attention must be paid to backing up/restoring process parameters.

It is recommended that enterprises establish a running time ledger and conduct planned maintenance or apply for an official extension of the service package when approaching the threshold to avoid line shutdowns.

For organizations with mature electronic technology teams, evaluating the flashing of time-unlimited firmware or replacing the brand may reduce long-term maintenance costs.

From an industry standard perspective, manufacturers should clearly state this protection logic in the sales contract and manual to maintain supply chain integrity.

I. Detailed Explanation of Operation Panel Functions

1. Overview of Operation Panel Functions
The operation panel of the Koreachuan KRC9 series inverter integrates functions such as parameter setting, status monitoring, and operation control. The core key functions are as follows:

• Programming Key: Enters or exits the menu.
• Enter Key (ENTER): Confirms parameters or navigates to the next menu level.
• Increment/Decrement Keys: Adjust parameter values.
• Shift Key: Switches display interfaces or parameter positions.
• Run/Stop/Reset Key: Controls start/stop or resets the inverter.
• Multi-function Selection Key (MP3): Switches between functional modes.

2. Password Management

• Set Password: Press the MP3 key to select password setting, enter the password, and confirm with ENTER.
• Clear Password: Enter the correct password and press MP3 to exit the password setting mode.

3. Parameter Access Permissions

• Set Restrictions: Enter the parameter setting interface, select parameters, and set permissions (e.g., read-only/write-only).
• Remove Restrictions: Restore permissions to default settings.

4. Factory Parameter Management

• Restore Factory Settings: Set PP-01 to 1 to reset parameters to factory defaults.
• Backup/Restore Parameters: Set PP-01 to 4 to backup parameters, or to 501 to restore from backup.

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II. External Control Setup Guide

1. External Terminal Forward/Reverse Control

• Wiring Instructions:
  • Forward Rotation: Connect to DI1 terminal.
  • Reverse Rotation: Connect to DI2 terminal.
• Parameter Configuration:
  • P0-02: Set to 1 (terminal control).
  • P4-00: Set to 1 (forward rotation).
  • P4-01: Set to 2 (reverse rotation).

2. External Potentiometer Speed Control

• Wiring Instructions: Connect the potentiometer output to AI1 or AI2 terminal.
• Parameter Configuration:
  • P0-03: Set to 2 (AI1 setting) or 3 (AI2 setting).
  • P4-13/P4-14: Set the potentiometer input range and corresponding frequency range.

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III. Fault Codes and Troubleshooting Solutions

1. Common Fault Codes

Fault Code	Description	Possible Causes
Err02	Acceleration Overcurrent	Output circuit grounded/shorted
Err03	Deceleration Overcurrent	Output circuit grounded/shorted
Err04	Steady-state Overcurrent	Output circuit grounded/shorted
Err05	Acceleration Overvoltage	Input voltage too high
Err06	Deceleration Overvoltage	Overvoltage suppression settings improper

2. Troubleshooting Process

1. Identify the Fault: Locate the cause based on the fault code.
2. Check Peripheral Devices: Inspect motors, cables, contactors, etc.
3. Adjust Parameters: Optimize overcurrent/overvoltage suppression settings.
4. Restart the Device: After resolving the fault, restart to confirm normal operation.

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IV. Conclusion

The Koreachuan KRC9 series inverter is a high-performance and reliable device suitable for various industrial applications. By mastering the operation panel functions, parameter settings, external control, and fault handling, users can fully leverage its capabilities and enhance productivity. This guide aims to provide practical references for the use and maintenance of the device.

I. Introduction to the Operation Panel Functions and Basic Settings of the Inverter

The ADLEEPOWER AS series inverter is a high-performance, multifunctional inverter with an intuitive operation panel and rich features. The operation panel mainly includes the following function keys:

• FWD/RUN: Forward run key. Pressing this key will rotate the motor in the forward direction.
• REV/RUN: Reverse run key. Pressing this key will rotate the motor in the reverse direction.
• SHIFT: Shift key. Used to switch the position of digits during parameter setting.
• UP/DOWN: Up/down keys. Used to increase or decrease values during parameter setting.
• PROG: Memory key. Used to save the currently set parameters.
• FUNC: Function key. Used to select the function to be set.
• STOP: Stop key. Pressing this key will stop the motor and return it to standby mode.

Restoring Factory Default Parameters

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

1. Press the PROG key to enter parameter setting mode.
2. Use the UP/DOWN keys to find the CD52 parameter (regional version).
3. Press the FUNC key to enter parameter modification mode.
4. Use the UP/DOWN keys to set the CD52 parameter to USA (for the US version) or Eur (for the European version), then press the PROG key to save.
5. Power off and restart the inverter. The parameters will be restored to factory defaults.

Setting and Removing Passwords

The AS series inverter supports password protection to prevent unauthorized parameter modifications. To set a password, follow these steps:

(Note: The specific password setting method may vary depending on the model. The following are general steps.)

1. Enter parameter setting mode.
2. Find the parameter related to password setting (refer to the user manual of the specific model for the exact parameter number).
3. Use the UP/DOWN keys to set the password, then press the PROG key to save.

To remove the password, simply set the password parameter to the default value or leave it blank.

Setting Parameter Access Restrictions

The AS series inverter also supports parameter access restriction functions, which can limit users’ access and modification permissions for certain parameters. To set parameter access restrictions, follow these steps:

1. Enter parameter setting mode.
2. Find the parameter related to parameter access restrictions (refer to the user manual of the specific model for the exact parameter number).
3. Use the UP/DOWN keys to set the access level, then press the PROG key to save.

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

Terminal Forward/Reverse Control

The AS series inverter supports forward/reverse control of the motor through external terminals. The specific wiring and parameter settings are as follows:

• Wiring:
  • Connect the forward control signal terminal of the external control signal to the FWD terminal of the inverter.
  • Connect the reverse control signal terminal of the external control signal to the REV terminal of the inverter.
  • Ensure that the common terminal of the external control signal is connected to the COM terminal of the inverter.
• Parameter Settings:
  • Enter parameter setting mode.
  • Find the CD12 parameter (terminal or keyboard selection).
  • Set the CD12 parameter to 1, indicating that the forward/reverse control of the motor is through the terminals.

External Potentiometer Frequency Setting for Speed Regulation

The AS series inverter also supports speed regulation by setting the frequency through an external potentiometer. The specific wiring and parameter settings are as follows:

• Wiring:
  • Connect the signal output terminal of the external potentiometer to the FA1 or FA2 terminal of the inverter (the specific terminal to be used depends on the parameter setting).
  • Ensure that the common terminal of the external potentiometer is connected to the GND terminal of the inverter.
• Parameter Settings:
  • Enter parameter setting mode.
  • Find the CD10 parameter (analog or digital setting).
  • Set the CD10 parameter to 1, indicating that the frequency is set through an analog signal (i.e., an external potentiometer).
  • Set the CD44 or CD45 parameter (multi-function analog FA1 or FA2 setting) as needed to select the FA1 or FA2 terminal as the frequency setting input terminal.

III. DC BR Fault Analysis and Solution

Meaning of DC BR Fault

When the AS series inverter displays a “DC BR” fault, it usually indicates a DC braking fault. DC braking is a function of the inverter that injects DC current into the motor during shutdown to quickly decelerate or stop the motor. If there is a problem with the DC braking circuit, it may cause a “DC BR” fault.

Possible Causes of the Fault

1. Damage to the DC Braking Resistor: The DC braking resistor is an important component in the DC braking circuit. If the resistor is damaged or aged, it may cause abnormal braking current, triggering the fault.
2. Failure of the Braking Transistor: The braking transistor is responsible for controlling the on/off of the DC braking current. If the transistor is damaged or its performance degrades, it may also cause a braking fault.
3. Improper Parameter Settings: If the parameters related to DC braking (such as braking time, braking current, etc.) are set improperly, it may result in poor braking performance or trigger a fault.

Solutions

1. Check the DC Braking Resistor: Use a multimeter or other tools to check the resistance value of the DC braking resistor. If the resistor is damaged or aged, replace it with a new one.
2. Check the Braking Transistor: Use a multimeter or other tools to check the performance of the braking transistor. If the transistor is damaged or its performance degrades, replace it with a new one.
3. Check Parameter Settings: Recheck whether the parameters related to DC braking are set correctly. Adjust the parameter values according to the actual situation of the motor and braking requirements.
4. Contact Technical Support: If the above methods cannot solve the problem, it is recommended to contact the technical support team or professional maintenance personnel of ADLEEPOWER inverters for further inspection and repair.

IV. Conclusion

The ADLEEPOWER AS series inverter, as a high-performance, multifunctional inverter product, has been widely used in the field of industrial automation. Through the introduction in this guide, users can better understand the operation panel functions, basic setting methods, terminal control and external speed regulation functions, as well as fault solution methods of the inverter. It is hoped that this guide can provide help and guidance to users when using the AS series inverters.

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The Hilectro HI300 series servo system is a high-performance servo drive widely used in industrial automation, renowned for its high precision and reliability. However, in practical applications, the fault code “Er050” may occur. This article provides a detailed analysis of the meaning of the “Er050” fault, its causes, as well as on-site inspection, handling, and specific maintenance methods to help technicians quickly restore equipment operation and summarize preventive measures to reduce the occurrence of similar faults.

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1. Meaning of Er050 Fault

In the Hilectro HI300 series servo system, the “Er050” fault code indicates Software Overcurrent. This is a protective mechanism triggered when the servo drive’s software detects that the current value exceeds the preset safety threshold. Unlike hardware overcurrent (such as “Er056”), “Er050” is primarily detected and alarmed by software algorithms, usually related to control parameters, feedback signals, or external wiring issues. When this fault occurs, the system stops running and displays “Er050” on the digital display, accompanied by related indicator lights (such as “RDY” or “VCC”) lighting up, prompting the operator to take action.

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2. Causes of Er050 Fault

The occurrence of “Er050” is not due to a single reason but is the result of multiple potential issues. The common causes are as follows:

1. Excessive Current Loop PI Parameters
   The current control of the servo system relies on a Proportional-Integral (PI) controller, adjusted through parameters such as proportional gain (Kp, typically corresponding to CI.00) and integral gain (Ki, typically corresponding to CI.02). If these parameters are set too high, the controller may overreact to current changes, causing current fluctuations to exceed the normal range and trigger the software overcurrent protection.
2. Short Circuit or Grounding on the Motor Output Side
   A short circuit in the motor’s internal windings or a ground fault in the output cable can cause a sharp increase in current. The software detects this anomaly and immediately alarms to protect the drive and motor.
3. Encoder Wiring Issues
   The encoder provides feedback on the motor’s position and speed. If the encoder wiring is loose, disconnected, or short-circuited, the servo system cannot accurately obtain feedback data, leading to current control instability and eventually causing an overcurrent fault.
4. Incorrect Motor Parameter Settings
   The servo drive needs to be precisely controlled based on the motor’s electrical parameters (such as inductance Ls). If the parameter configuration does not match the actual motor, the drive may output incorrect current commands, resulting in overcurrent.
5. Environmental or Power Supply Interference
   Power supply voltage fluctuations or high ambient temperatures may affect current stability. Especially under long-term operation or harsh conditions, the software may misjudge it as overcurrent.

These causes may interact with each other. For example, an encoder fault may lead to current control errors, which in turn amplify the impact of PI parameters, ultimately triggering “Er050.”

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3. On-Site Inspection and Handling Methods

When the equipment displays “Er050,” technicians need to follow a systematic inspection process to quickly identify the problem and take preliminary measures. The specific steps are as follows:

1. Check Current Loop Parameters

• Operation Method: Use the servo drive’s control panel or host computer software to enter the parameter setting interface and check the values of current loop parameters (such as CI.00 and CI.02).
• Judgment Standard: If the parameter values are significantly higher than the recommended range (refer to the equipment manual), it may be the cause of the fault.
• Handling Measures: Gradually reduce the Kp and Ki values (recommended to adjust by 10%-20% each time), save the settings, restart the system, and observe if the fault is resolved.

2. Check Motor Insulation and Wiring

• Operation Method: Turn off the power and wait for the capacitor to discharge (about 5-10 minutes). Use a multimeter or insulation resistance tester to measure the insulation resistance between motor phases and to ground.
• Judgment Standard: The normal insulation resistance should be greater than 10MΩ. If it is lower, it indicates a short circuit or grounding.
• Handling Measures: Inspect the motor cables and terminals, repair or replace damaged parts.

3. Check Encoder Wiring

• Operation Method: Ensure the encoder cable connections are secure and the shielding is properly grounded. Use a multimeter to test the continuity of the lines or an oscilloscope to observe the feedback signal waveform.
• Judgment Standard: Signal interruption or abnormal waveform (such as excessive noise) indicates an encoder fault.
• Handling Measures: Tighten loose connectors or replace damaged cables.

4. Check Motor Parameters

• Operation Method: Verify the motor parameters set in the drive (such as inductance Ls) against the motor nameplate or manual data.
• Judgment Standard: Significant parameter deviations may be the cause of the fault.
• Handling Measures: Correct the parameters based on the actual motor data, save, and test.

5. Environmental and Power Supply Check

• Operation Method: Use a voltmeter to measure the stability of the input power supply (380V-480V) and check the temperature and ventilation inside the control cabinet.
• Judgment Standard: Voltage fluctuations exceeding the standard (±10%) or high temperatures (>40°C) may cause faults.
• Handling Measures: Install a voltage stabilizer or improve cooling conditions.

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4. Specific Maintenance Recommendations

Based on the on-site inspection results, take the following targeted maintenance measures:

1. Parameter Adjustment
   If the PI parameters are too large, gradually reduce the values of CI.00 and CI.02, testing after each adjustment to observe the system response. Avoid excessive reduction that may lead to control instability.
2. Wiring Repair
   For encoder or motor wiring issues, tighten loose connectors or replace damaged cables. Ensure the shielding is properly grounded to reduce electromagnetic interference.
3. Component Replacement

• Motor Fault: If insulation tests show a short circuit or grounding, replace the motor or repair the insulation.
• Encoder Damage: Replace with the same model encoder and recalibrate the system.

1. Hardware Maintenance
   If internal current sensors or power modules (such as IGBT) are suspected to be faulty, have a professional inspect and possibly replace the damaged components.
2. Safety Operations
   Ensure the power is off and capacitors are discharged before maintenance. Use insulated tools and protective equipment. If the issue is complex, contact Hilectro technical support with the serial number and fault details for guidance.

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5. Preventive Measures and Routine Maintenance

To prevent the recurrence of “Er050” faults, implement the following preventive measures:

1. Regular Inspections
   Check motor, encoder, and power supply wiring quarterly to ensure there is no looseness or aging.
2. Parameter Management
   Regularly back up parameter settings and monitor current waveforms during operation to ensure they are within normal ranges.
3. Environmental Optimization
   Keep the control cabinet clean and dry, install ventilation or dehumidification equipment to prevent overheating and moisture accumulation.
4. Personnel Training
   Train operators to recognize early anomalies (such as motor noise or overheating) and report them promptly for handling.

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6. Conclusion

The “Er050” fault in the Hilectro HI300 series servo system, indicating software overcurrent, is a common protective alarm typically caused by excessive current loop parameters, wiring faults, or incorrect motor parameters. Through systematic on-site inspections (such as parameter verification, insulation testing, and encoder checks) and targeted maintenance (such as adjusting parameters or replacing components), technicians can effectively resolve the issue. Preventive maintenance and a deep understanding of the fault mechanisms are key to ensuring long-term stable operation of the equipment. We hope this article provides practical guidance for on-site operations. For further assistance, refer to the equipment manual or contact professional technical support.

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Introduction

The ENC EDH2200 series high-voltage inverter is commonly used in industrial applications for motor control. However, during operation, it may enter a “free stop (emergency stop)” state due to faults, rendering it unable to restart. Based on an actual case, this article analyzes the causes of the inverter’s “free stop” fault, focusing on the impact of the input terminal S1# function configuration (P05.00), and summarizes solutions and preventive measures.

Fault Background

The inverter control panel (Attachment 5.jpg) displays an “actual alarm POFF state,” with operational parameters at 0 (input/output voltage 0V, current 0A, frequency 0Hz), indicating the system is in a non-operational state. The operation log (Attachment 1.jpg) shows S3# as “self-generated accident (total accident),” initially considered the root cause. However, after adjusting the S1# terminal function (P05.00) from “1: Lift given” to “0: No function,” the system returned to normal, and the inverter successfully restarted.

Fault Cause Analysis

Based on the operation log and the actual resolution process, the following is a detailed analysis of the fault causes:

1. Impact of S1# Function Configuration
   • P05.00 (S1# function selection) was originally set to “1: Lift given,” likely used to receive signals from external devices (e.g., pump lift control signals).
   • If the external device fails to provide a correct signal (e.g., signal loss, abnormality, or interference), the system may misjudge it as a fault and trigger a protection mechanism, leading to “free stop.”
   • Changing P05.00 to “0: No function” removes S1# from control, and the system exits the protection state, indicating that the S1# configuration is the core issue.
2. Correlation with S3# “Self-Generated Accident”
   • S3# (P05.02) displays “self-generated accident (total accident),” which may be a chain reaction triggered by S1# malfunction.
   • The inverter’s protection logic may be designed to trigger a total accident (S3#) and enter emergency stop mode when an abnormality is detected on a terminal (e.g., S1#).
3. Possible External Factors
   • S1# may be connected to external devices (e.g., pumps or sensors). If the device malfunctions or there are wiring issues (e.g., loose connections, short circuits), it may cause signal abnormalities.
   • Environmental interference (e.g., electromagnetic interference) may also affect S1# signal transmission.
4. Hardware and Parameter Configuration
   • Circuit board images (Attachments 3.jpg and 4.jpg) show relays K4/K5 and terminal connections. If S1#-related hardware is damaged, it may cause signal errors.
   • Improper configuration of P05 group parameters (input terminal function selection) may lead to system misjudgment.

Resolution Process

1. Problem Identification
   • The control panel displays “POFF state,” and the operation log shows S3# as “self-generated accident.” However, the “lift given” function of S1# raises concerns.
   • Referencing the P05 group parameter table (Attachment 6.jpg), it is confirmed that S1# (P05.00) is set to “1: Lift given.”
2. Parameter Adjustment
   • Change P05.00 from “1” to “0” (no function) to remove S1# from control.
   • After adjustment, use the control panel’s “reset” function to clear the alarm.
3. System Recovery
   • Press the “start” button, and the inverter successfully restarts with operational parameters returning to normal (voltage, current, frequency, etc., no longer 0).

Summary of Solutions

• Core Solution Steps: Change P05.00 (S1# function) from “1: Lift given” to “0: No function,” remove S1#’s control function, clear the alarm, and restart the system.
• Preventive Measures:
  • Check S1#’s wiring and external devices to ensure normal signal transmission.
  • Regularly maintain hardware to prevent loose connections or component damage.
  • Record parameter adjustments for future troubleshooting.

Unexpected Findings

• The S3# “self-generated accident” record may only be a result, not the cause. The actual issue stems from the S1# configuration. This highlights the need to consider all relevant terminals and parameters when troubleshooting inverter faults, rather than focusing solely on alarm records.
• The control panel brand is FLEXEM, while the inverter is ENC, which may involve terminological or logical differences. For example, the “POFF” state is defined in FLEXEM but not explicitly mentioned in the ENC manual.

Table: Fault Causes and Solutions

Fault Phenomenon	Possible Cause	Solution
Free stop, unable to start	S1# function (lift given) mis-trigger	Change P05.00 to “0: No function”
S3# displays self-generated accident	Chain reaction from S1# abnormal signal	Clear alarm after resolving S1# issue
System displays POFF state	Protection mechanism triggers power-off	Restart system after clearing alarm
External device signal abnormality	Loose wiring or device fault	Check S1# wiring and external devices

Conclusion

The “free stop (emergency stop)” issue in the ENC EDH2200 high-voltage inverter is caused by improper configuration of the S1# terminal function (P05.00), potentially triggered by abnormal external signals. By changing the S1# function to “no function,” the system returns to normal. Users are advised to regularly check terminal wiring and external devices, optimize parameter configurations, and take preventive measures to avoid recurrence of similar issues.

Introduction

Variable Frequency Drives (VFDs) are critical devices for controlling motor speed and torque in modern industrial applications. However, fan overheating alarms are a common fault during inverter operation. This document provides a comprehensive analysis of the fan overheating alarm issue in the ENC EDH2200 series high-voltage inverter, covering its meaning, possible causes, solutions, and operational log analysis to guide users in troubleshooting and resolving the problem.

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Fault Meaning

A fan overheating alarm indicates that the cooling fan of the inverter has exceeded its temperature threshold, potentially affecting normal device operation. As a key component for internal temperature control, the fan’s failure to cool the system effectively will lead to temperature rises, trigger protection mechanisms, and may even damage electronic components or cause system failures.
Key Detail: The operational log shows the alarm occurred at 13:34:02 on March 25, 2023, with a recovery time recorded as 14:31:58 on September 7, 2024. The abnormally long alarm duration requires urgent attention.

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Possible Causes

1. Excessive Ambient Temperature
   • The operating environment temperature exceeds the inverter’s default threshold of 75°C, causing the fan to run continuously for extended periods and overheat.
   • Manual Parameter: P08.27 sets the ambient temperature alarm threshold; verify if the actual temperature exceeds the limit.
2. Fan Malfunction
   • Damage to the fan motor or obstruction of blades leads to insufficient cooling.
   • Manual Parameter: P23 group parameters (e.g., P23.20 and P23.21) control fan start/stop temperatures; these may fail if the fan malfunctions.
3. Ventilation Blockage
   • Dust, debris, or internal accumulations block ventilation ports, impeding airflow.
   • Preventive Measure: Regularly clean the ventilation system.
4. Overload
   • The connected load exceeds the inverter’s rated capacity, increasing heat generation and burdening the fan.
   • Solution: Ensure the load is within the inverter’s specifications.
5. Improper Parameter Settings
   • Incorrect configuration of temperature control parameters results in inappropriate fan start/stop conditions.
   • Manual Parameter: Adjust P23.03 (overheat warning temperature 1, default 90°C) and P23.04 (default 110°C) based on actual conditions.

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Solutions

1. Check and Control Ambient Temperature
   • Measure the current ambient temperature and ensure it remains below the 75°C threshold.
   • If the temperature is too high, install air conditioning or improve ventilation (e.g., add exhaust fans).
2. Maintain and Inspect the Fan
   • Ensure the fan operates normally and check for damage or wear to the motor and blades.
   • If a fault is detected, replace damaged components by referring to Section 8.5 of the manual.
   • Regularly clean the fan to remove dust or blockages.
3. Optimize the Ventilation System
   • Ensure sufficient space around the inverter to meet ventilation requirements in the manual.
   • Clean ventilation ports and surrounding areas to prevent dust accumulation.
4. Verify Load and Inverter Capacity
   • Check if the current load exceeds the inverter’s rated capacity; if so, reduce the load or upgrade the inverter.
   • Ensure compatibility between the motor and the inverter.
5. Adjust Parameter Settings
   • Modify P23 group parameters based on actual needs (e.g., increase P23.03 to an appropriate value, but do not exceed 135°C).
   • Ensure P23.20–P23.23 settings align with actual operating conditions.

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Operational Log Analysis

• Key Log Entries:
  • March 25, 2023, 13:34:02: Fan overheating alarm triggered. Recovery time recorded as September 7, 2024, 14:31:58, indicating an abnormally long alarm duration that may not have been resolved promptly.
  • Multiple ambient temperature exceedance warnings (e.g., repeated records on February 7, 2024) support the hypothesis of excessive ambient temperature.
• Unexpected Detail: Inconsistent dates in the log (recovery time later than the alarm time) suggest a potential error in the system’s logging mechanism.
  • Recommendation: Check the system clock and logging function to ensure data accuracy.

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Conclusion

Resolving the fan overheating alarm in the ENC EDH2200 series high-voltage inverter requires a systematic investigation of potential causes and the implementation of the following measures to manage and prevent issues:

• Control ambient temperature, maintain the fan, optimize ventilation, verify load, and adjust parameters.
  Regular maintenance and monitoring are critical to ensuring the long-term reliability of the inverter.

Key Highlight: Prioritize addressing the inconsistent dates in the operational log to avoid misdiagnosis caused by logging errors.

1. Fault Overview

The E-06 fault indicates a deceleration overvoltage, a common issue that can occur during the deceleration process of the SHZHD.V680 variable frequency drive. When the output voltage exceeds the safe range during deceleration, the drive triggers a protection mechanism, leading to equipment shutdown or alarms. This fault is often related to motor load characteristics, parameter settings, and over-excitation control.

2. Fault Cause Analysis

• Improper Over-Excitation Settings: Low over-excitation gain settings can cause the voltage to rise too quickly during deceleration.
• Load Characteristics: Loads with high inertia can generate excessive reverse electromotive force during deceleration.
• Unreasonable Parameter Settings: Short deceleration times can cause the voltage to rise too quickly during deceleration.

3. Solutions

3.1 Adjust Over-Excitation Gain

• Parameter P3-10 (VF Over-Excitation Gain): Increase this value to better suppress voltage rise during deceleration. Recommended range: 0 ~ 200. Gradually increase based on actual conditions until the fault is resolved.

3.2 Optimize Deceleration Time Settings

• Parameter P0-18 (Deceleration Time 1): Extend the deceleration time to make the deceleration process smoother. Gradually increase based on actual load characteristics until the fault is resolved.

3.3 Check Load Characteristics

• If the load has high inertia, additional braking measures, such as adding a braking resistor or using a regenerative system, may be necessary during deceleration.

3.4 Check Motor and Drive Compatibility

• Ensure that the motor and drive parameters are matched to avoid overvoltage issues due to mismatched parameters.

4. Precautions

• Adjust parameters gradually to avoid introducing other issues.
• Conduct trial runs after adjustments to confirm that the fault has been resolved.
• If the problem persists, consult technical support or a professional repair technician for further diagnosis.

5. Conclusion

By appropriately adjusting the over-excitation gain, optimizing deceleration time settings, checking load characteristics, and ensuring motor and drive compatibility, the E-06 deceleration overvoltage fault in the SHZHD.V680 variable frequency drive can be effectively resolved. Proper parameter settings and regular maintenance are key to ensuring the efficient operation of the drive.

M900 Inverter err64 Fault: Meaning, Root Cause Analysis, and Solutions

(This article discusses the background of the “err64” fault in M900 series inverters, its potential causes, deeper hardware-level analyses, and practical troubleshooting steps. The goal is to help electrical maintenance personnel target the problem more effectively. This text, of over 1,000 words in its Chinese original, covers both theoretical and hands-on repair perspectives.)

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I. Background and Meaning of err64

In typical inverter applications, the most common faults involve overcurrent, overvoltage, undervoltage, overload, and cooling fan issues. However, in certain cases—especially after repairs or the replacement of internal components—M900 inverters may display a “err64” fault code. According to the manufacturer’s technical support, “err64” is not listed in the usual user manual but indicates a communication failure between the main control board and the driver board.

In other words, the inverter’s primary control circuitry (often referred to as the “master” or “main” board) and its power drive unit (“driver” board) cannot exchange data, causing the control system to fail to operate properly and thus triggering a fault protection.

To understand this issue, one must note that an M900 inverter typically consists of at least two major sections: a control board (hosting the microcontroller or DSP as the core of the logic) and a driver board (housing the power modules, IGBTs, or related gate driver circuitry). These boards communicate via a dedicated interface or set of pins. Sometimes, there may also be a small power supply board or other auxiliary boards, but the communication link between the main board and the driver board is central to the entire system. Once that link is broken or corrupted, the inverter will report a “board-to-board communication error” such as “err64” and shut down to protect itself.

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II. Common Causes of err64

1. Loose or Faulty Ribbon Cable/Connector
   During maintenance or reassembly, a ribbon cable or connector might not have been fully seated, or its metal pins could be bent, oxidized, or otherwise damaged. This often leads to poor signal transmission or no transmission at all, and is one of the most frequent root causes for communication errors.
2. Damaged Hardware Chips
   • Burned-out Transceiver/Bus Chip: The communication between the control and driver boards usually involves specialized transceiver components (e.g., RS485 driver chips, optical isolators, or TTL level transceivers). If subjected to excessive heat, current surge, or electrostatic discharge, these chips can fail and interrupt the data link.
   • Main CPU or Driver DSP Failure: Though less common, serious power surges, extended over-temperature conditions, or short-circuit mishandling can damage the main controller or DSP on either board. When that happens, the inverter can no longer exchange valid data, triggering the err64 alarm.
3. Auxiliary Power Supply Issues
   The main board and driver board typically rely on a regulated power supply—often +5V or +3.3V—to operate their digital circuits. If this low-voltage supply is weak or unstable, or if a regulator (LDO, DC-DC converter) on either board is failing, then even intact chips may produce garbled signals and fail to establish proper communication.
4. Secondary Damage During Fan or Relay Replacement
   Many reported err64 errors occur soon after a user replaces a fan or relay. This suggests that the process may introduce secondary problems:
   • An incompatible relay or altered circuit parameters causing abnormal power conditions;
   • Accidental short-circuits or soldering damage during the repair;
   • The inverter may already be partially degraded from prior overheating, so additional stress completes the failure pathway.

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III. Root Cause Analysis and Troubleshooting

At its core, “err64” represents an internal communication failure. This communication is usually a low-level or custom protocol rather than a typical external fieldbus (like Modbus). As a result, the inverter’s diagnostic does not offer many granular details. Because the issue can lie in various hardware points, it is best to follow a structured approach:

1. Physical Inspection and Connector Checks
   • First, turn off power and wait long enough for internal capacitors to discharge (generally at least 10 minutes).
   • Open the inverter casing to inspect all connectors, paying particular attention to the flat cables and sockets between the main board and driver board. Look for signs of looseness, oxidation, broken plastic housings, or bent pins.
   • Clean off any dust or grime with an appropriate solution such as isopropyl alcohol. Dry thoroughly, re-seat the connectors firmly, then restart and see if the error persists.
   • This preliminary step is simple but can resolve many “false” faults that arise after vibrations or reassembly.
2. Supply Rails and Signal Tests
   • Use a multimeter to check the low-voltage rails (+5V, +3.3V, etc.) on both the control and driver boards. Confirm stable, correct output levels.
   • If available, use an oscilloscope to observe the communication pins (TX, RX, or RS485 differential signals) for pulses or signals. If the line is held at a steady voltage with no pulses, it indicates that the transmitter is not functioning (which could mean the transceiver or even the CPU is compromised).
   • If the signal is noisy or the amplitude is too low, consider the possibility of defective coupling resistors, capacitors, or the transceiver chip itself.
3. Suspecting Transceiver or MCU Failure: The Swap/Replacement Method
   • After verifying connectors, supply rails, and passive components, you may try replacing the communication transceiver chip with one of the same model if you suspect it is burned out.
   • If replacing the transceiver chip does not help, the fault may lie in the main CPU, driver DSP, or other major components on the board. Diagnosing or replacing these can require specialized tools and is best handled by trained professionals.
4. Reset to Factory Defaults or Firmware Update
   • Occasionally, firmware or software anomalies can also trigger internal communication timeouts.
   • Attempt a factory reset (restoring default parameters) and then power up again to see if the fault clears. If the manufacturer provides a firmware update procedure, you can try upgrading the system firmware. However, if the hardware is physically damaged, these software-level attempts typically will not resolve an err64 alarm.

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IV. Precautions and Preventive Measures

1. Prompt Cooling System Maintenance
   If the M900 inverter’s cooling fan stops working or its venting is blocked, the internal boards can operate at high temperatures, accelerating aging. Quick repair or replacement of fans can prevent serious damage that leads to communication issues.
2. Standardized Repair Operations
   • Always allow adequate discharge time after powering off the inverter to avoid electric shock or component damage.
   • When replacing a relay or other parts, match the specifications (coil voltage, contact ratings, etc.) exactly.
   • Proper soldering tools and techniques are crucial—poorly done solder joints or bridging can damage sensitive PCB traces and components.
3. Cleanliness and Protective Practices
   • In dusty or humid environments, regularly open the inverter casing for an internal check and cleaning.
   • If connectors or components show corrosion or rust, replace or clean them promptly.
   • Perform these repairs or inspections in as clean an environment as possible, avoiding metal particles, oil, or fine dust contamination on open circuit boards.
4. Fault Log and Data Recording
   • If the inverter can store internal logs or provide real-time data, document those details as soon as a fault appears.
   • Observing the inverter’s normal operating waveforms versus the state just before a failure can guide you to the precise area of malfunction.

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Conclusion

In summary, an M900 inverter reporting “err64” indicates a lost or compromised communication link between its main control board and driver board. This can stem from something as simple as a partially inserted ribbon cable or can be as severe as a failed bus transceiver chip or main CPU.

The recommended troubleshooting approach is systematic:

1. Inspect and re-seat cables and connectors;
2. Verify supply voltages and signals;
3. Replace suspect transceiver and check associated passive parts;
4. Finally, if those attempts fail, look toward the main CPU, DSP, or more advanced board-level repairs.

Meanwhile, ensuring proper cooling, following proper service procedures, and regularly cleaning the inverter’s internals will significantly lower the likelihood of such communication failures. If all methods are exhausted, contacting a professional repair center or the manufacturer is advisable for advanced diagnostics. By fully understanding the root cause and progression of “err64” faults, you can remedy them swiftly and maintain the M900 inverter’s reliability for critical industrial processes.

The JTE Inverter JT26N series is a high-performance general-purpose inverter widely used in various industrial control scenarios. This article provides a detailed introduction to the usage of this inverter, including panel startup and speed adjustment settings, external terminal forward/reverse and external potentiometer speed adjustment settings, parameter copying and initialization methods, as well as the meaning and resolution of the ERR10 fault.

I. Basic Settings for the JTE Inverter JT26N

1. Panel Startup and Speed Adjustment Settings

The panel startup and speed adjustment settings for the JTE Inverter JT26N are relatively straightforward. Users can complete basic startup and speed adjustment operations through the buttons and display on the control panel. Here are the specific steps:

1. Startup Settings:

• Press the “PRGM” key to enter programming mode.
• Use the “Δ” and “∇” keys to select the function code F0-02, and confirm that the command source is set to the control panel command channel (value 0).
• Press the “ENTER” key to confirm the setting.

1. Speed Adjustment Settings:

• In programming mode, select the function code F0-03 and set the main frequency source X to panel potentiometer speed adjustment (value 1).
• Adjust the frequency by rotating the potentiometer on the panel to achieve speed control.

2. External Terminal Forward/Reverse and External Potentiometer Speed Adjustment Settings

The JTE Inverter JT26N supports forward/reverse control and external potentiometer speed adjustment functions through external terminals. Here are the specific wiring and setup methods:

1. Forward/Reverse Control:

• Wiring: Connect the external control signal to the digital input terminals of the inverter (such as MI1, MI2, etc.).
• Settings: In programming mode, select the function code F0-09 and set the running direction to forward (value 0) or reverse (value 1).

1. External Potentiometer Speed Adjustment:

• Wiring: Connect the signal line of the external potentiometer to the analog input terminals of the inverter (such as AI1, AI2, etc.).
• Settings: In programming mode, select the function code F0-03 and set the main frequency source X to external potentiometer speed adjustment (value 2, 3, or 4, depending on the specific terminal).

II. Parameter Copying and Initialization

1. Parameter Copying

The JTE Inverter JT26N supports parameter copying, allowing users to copy parameters from one inverter to another. Here are the specific steps:

1. Prepare a blank storage card or USB drive and insert it into the parameter copying interface of the inverter.
2. Press the “PRGM” key to enter programming mode and select the parameter copying function.
3. Follow the prompts to copy the parameters to the storage card or USB drive.
4. Insert the storage card or USB drive into another inverter and follow the prompts to copy the parameters to the new inverter.

2. Parameter Initialization

In some cases, users may need to initialize the inverter parameters. Here are the specific steps:

1. Press the “PRGM” key to enter programming mode.
2. Select the function code F0-27 and set the parameter initialization option to fully initialize parameters (value 03).
3. Press the “ENTER” key to confirm, and the inverter will reset to factory settings.

III. Meaning and Resolution of the ERR10 Fault

1. Meaning of the ERR10 Fault

The ERR10 fault is a common fault code for the JTE Inverter JT26N, indicating an overload condition. An overload occurs when the output current of the inverter exceeds its rated current, which may be caused by the following reasons:

1. The load is too large, exceeding the rated capacity of the inverter.
2. There is a mechanical fault in the motor or other load equipment, causing abnormal current increases.
3. The parameter settings of the inverter are incorrect, leading to overload protection activation.

2. Handling the ERR10 Fault

When the ERR10 fault occurs on-site, users should follow these steps to address it:

1. Check the Load: Ensure that the load is within the rated capacity range of the inverter, reducing the load if necessary.
2. Inspect the Motor and Equipment: Check the motor and other load equipment for mechanical faults, such as jamming or excessive resistance.
3. Verify Parameter Settings: Ensure that the inverter’s parameter settings are correct, especially those related to the load.
4. Restart the Inverter: After confirming that the load and equipment are normal, restart the inverter and observe if the ERR10 fault still occurs.

3. Repair Methods for the ERR10 Fault

When repairing the internal circuit board of the inverter after an ERR10 fault, users should follow these steps:

1. Inspect Under Power-Off Conditions: Open the inverter’s casing in a power-off state and inspect the internal circuit board for any visible damage or burnout.
2. Clean the Circuit Board: Use a clean cloth or cotton swab dipped in isopropyl alcohol to gently wipe the surface of the circuit board, removing dust and dirt.
3. Replace Damaged Components: If any damaged or burned components are found on the circuit board, replace them with new components of the same model.
4. Reassemble: After ensuring that the circuit board has no visible faults, reassemble the inverter and perform a functional test.

IV. Conclusion

The JTE Inverter JT26N is a powerful and easy-to-operate inverter suitable for various industrial control scenarios. By correctly setting up panel startup and speed adjustment, external terminal forward/reverse, and external potentiometer speed adjustment, users can easily achieve basic control functions of the inverter. Additionally, the inverter supports parameter copying and initialization functions, making it convenient for users to manage parameters. In the event of an ERR10 fault, users should promptly check the load and equipment and follow the correct procedures for handling and repair to ensure the normal operation of the inverter.