Category: Yaskawa

1. Introduction: The Role of the PG Card in Inverter Control Systems

In modern vector-control inverters, the PG card (Pulse Generator card) plays a central role.
It acts as an interface between the inverter and the motor encoder, acquiring high-precision rotational signals from the motor shaft and feeding them back to the inverter’s control CPU.
Through this feedback, the inverter can precisely detect speed, position, and rotational phase, enabling closed-loop vector control, zero-servo holding, stable-speed regulation, and torque compensation.

In Yaskawa’s Varispeed F7 series, the PG feedback card is not just an accessory—it is the core component that transforms the inverter from a standard open-loop V/f device into a high-performance vector drive.
With accurate speed feedback, the F7 achieves servo-level control precision, excellent dynamic response, and high stability even under heavy load variations.

This paper focuses on the SI-P1 Ver 3.04 PG card (code 73600-C0333 / SIP-901), an OEM version widely used in the F7 family.
By comparing it with the official PG-A2/B2/D2/X2 cards described in Yaskawa’s manuals, we analyze its structure, compatibility, wiring method, parameter configuration, and field performance in real industrial applications.

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2. Technical Background — Function and Principle of PG Feedback

2.1 Basic Function of the PG Card

The PG card’s primary function is to receive incremental encoder signals (A, B, Z phases) and convert them into the internal pulse format that the inverter’s CPU can process.
Based on these pulses, the inverter continuously calculates the rotational speed, direction, and position deviation of the motor.

This closed-loop feedback enables several advanced control modes:

• Speed Feedback Control — maintains a precise target RPM regardless of load fluctuation.
• Torque Compensation — improves low-speed torque stability.
• Zero-Servo Control — holds the motor shaft at a fixed mechanical position.
• Regenerative Braking Control — enhances braking torque using feedback phase information.

The accuracy and signal integrity of the PG card determine the overall response time, torque precision, and stability of the system.

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2.2 Common PG Cards Used with the Varispeed F7

Model	Signal Type	Supply Voltage	Typical Application	Remarks
PG-A2	Differential TTL (A/A¯, B/B¯, Z/Z¯)	+5 V	Standard incremental encoders	Most widely used type
PG-B2	Open-collector (single-ended A/B)	+12 V	NPN output encoders	For environments with higher noise
PG-D2	Push-pull (A/B/Z quadrature)	+15 V	Heavy industrial, long-distance feedback	Excellent noise immunity
PG-X2	High-speed TTL differential	+5 V	High-resolution / high-speed vector control	Used in advanced servo applications

All four cards share the same mechanical interface and CN5 connector, but differ in electrical levels and signal types.
Among them, PG-A2 is the standard type used in most F7 applications.

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3. Identifying the SI-P1 Ver 3.04 and Its Compatibility

Although the SI-P1 Ver 3.04 is not explicitly listed in the official F7 manual, practical testing and circuit comparison confirm that:

The SI-P1 Ver 3.04 is an OEM-equivalent version of the PG-A2 card.

The justification is as follows:

1. Identical Signal Architecture
   The SI-P1 accepts differential inputs for A, /A, B, /B, Z, /Z, which perfectly matches the TTL line-driver interface of PG-A2.
2. Same Power Requirements
   It provides an internal +5 V DC output (maximum 200 mA) for encoder supply—exactly like the PG-A2—and does not support 12 V or 15 V encoders.
3. Same Physical Connector
   The card plugs directly into the F7 control PCB via the CN5 slot. Pin layout and dimensions are identical to the PG-A2.
4. Firmware Generation
   The “Ver 3.04” label corresponds to the firmware generation period of early-2000s Yaskawa F7 inverters, when PG-A2 was the default model.

Hence, the SI-P1 card can be treated as functionally identical to PG-A2.
All wiring, parameter settings, and diagnostic methods described for PG-A2 apply equally to SI-P1.

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4. Detailed Wiring between the SI-P1 and the Encoder

4.1 Terminal Definitions

Pin	Signal Name	Function	Description
1	+5 V	Encoder Power Supply	Provides +5 V DC (≤ 200 mA)
2	0 V	Power Ground	Common reference for encoder
3	A	Phase A positive	Forward rotation signal
4	/A	Phase A negative	Differential complement
5	B	Phase B positive	90° shift from A
6	/B	Phase B negative	Differential complement
7	Z	Zero-mark signal	Once-per-revolution pulse
8	/Z	Zero-mark complement	Optional connection
FG	Frame Ground	Connect to shield of cable

Use twisted-pair shielded cable for each differential pair (A/A¯, B/B¯, Z/Z¯).
Connect the cable shield to FG at the inverter side only.

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4.2 Typical Wiring Diagram

Encoder Side               SI-P1 PG Card
+5 V  ───────────────────────→  Pin 1 (+5 V)
0 V   ───────────────────────→  Pin 2 (0 V)
A    ───────────────────────→  Pin 3 (A)
A¯   ───────────────────────→  Pin 4 (/A)
B    ───────────────────────→  Pin 5 (B)
B¯   ───────────────────────→  Pin 6 (/B)
Z    ───────────────────────→  Pin 7 (Z)
Z¯   ───────────────────────→  Pin 8 (/Z)
Shield layer ─────────────→  FG (Ground)

This standard differential connection ensures noise immunity and reliable high-speed feedback, even under strong EMI conditions.

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4.3 Electrical Precautions

• Keep the encoder cable shorter than 20 m; for longer runs, use a differential line driver (RS-422 standard).
• Never connect both ends of the shield to ground—do so only on the inverter side.
• Verify the A/B phase shift (90° ± 10°) using an oscilloscope; reversed A/B causes inverted rotation detection.
• Avoid running encoder cables in parallel with power cables.

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5. Parameter Configuration and Commissioning

To enable the feedback loop, several parameters must be configured in the Varispeed F7:

Parameter	Description	Typical Setting	Notes
A1-02	Control Mode Selection	3	“Vector control with PG”
F1-01	Encoder Pulses per Revolution	e.g., 1024 PPR	Match actual encoder
F1-03	PG Input Type	0	Differential TTL input
E1-04	Rotation Direction Logic	0 or 1	Depends on wiring
U1-05	Monitor Speed Feedback	–	Used for verification

Commissioning Steps

1. Open-loop Test
   Run the inverter without enabling PG feedback. Verify that the motor runs smoothly and direction matches your system.
2. Enable Closed-Loop Mode
   Set A1-02 = 3 and cycle the power. The inverter now reads encoder feedback. Observe that the motor starts softly and maintains constant speed.
3. Zero-Servo or Position Hold
   For applications requiring shaft holding, fine-tune parameters F1-05 to F1-07.
4. Verification
   Check parameter U1-05 to ensure displayed speed matches the actual RPM measured by a tachometer.

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6. Practical Field Experience and Case Studies

Case 1: Speed Feedback Optimization

A 37 kW Varispeed F7 inverter driving a conveyor motor used a 1024 PPR encoder.
After replacing a damaged PG-A2 with an SI-P1 Ver 3.04, the system was configured with:

• A1-02 = 3
• F1-01 = 1024
• F1-03 = 0

Result:
Acceleration response improved from 100 ms to 40 ms, and steady-state speed fluctuation dropped below 0.3%.
The SI-P1 performed identically to the original PG-A2.

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Case 2: Direction Error due to Reversed Phases

In a hoisting control system, swapping A/B signal pairs caused the inverter to misinterpret rotation direction, leading to oscillation.
After interchanging the A and B channels, feedback direction was corrected, and stability restored.

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Case 3: Noise Interference and Shielding

A 15 m unshielded encoder cable caused ±5% speed variation due to EMI.
Replacing it with twisted-pair shielded cable and grounding only at the inverter side reduced fluctuation to ±0.2%.
Proper shielding proved critical for feedback reliability.

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7. Signal Verification and Maintenance

Regular inspection of the PG system is essential for long-term stability.

7.1 Oscilloscope Test

Check A/B waveforms at the PG card input:

• Duty cycle ≈ 50%
• Phase shift ≈ 90°
  Distorted or noisy waveforms indicate cable damage or grounding issues.

7.2 Feedback Speed Monitoring

Under no-load constant-speed operation, monitor U1-05.
If speed fluctuates, inspect PG connections, encoder bearings, and connector pins.

7.3 Cleaning and Care

The PG card contains sensitive CMOS components.
Avoid dust or moisture.
Clean contacts periodically with isopropyl alcohol and ensure firm seating in the CN5 slot.

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8. Signal Mapping Comparison: SI-P1 vs PG-A2

Function	SI-P1 Pin	PG-A2 Pin	Remark
+5 V Supply	1	1	Encoder Power
0 V Ground	2	2	Common Ground
A Signal	3	3	Differential +
/A Signal	4	4	Differential –
B Signal	5	5	Differential +
/B Signal	6	6	Differential –
Z Signal	7	7	Zero Pulse
/Z Signal	8	8	Complement Zero
FG Shield	FG	FG	Cable Shield Ground

The one-to-one correspondence confirms that SI-P1 can replace PG-A2 without modification.

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9. Engineering Discussion and Technical Insights

1. Functional Equivalence
   The SI-P1 Ver 3.04 is a fully compatible PG-A2 card, supporting all F7 feedback control modes including vector, torque, and zero-servo functions.
2. Signal Quality is Paramount
   Differential signal integrity and proper grounding are more critical than parameter tuning.
   Incorrect grounding can produce random “PG Loss” or “OV” faults.
3. Parameter Matching
   Always set the correct encoder PPR (F1-01) and direction logic (E1-04) to avoid instability or reverse torque.
4. Maintenance Importance
   Connector oxidation and vibration loosening are common causes of intermittent speed errors.
   Regular re-seating of the card ensures reliability.
5. Cost-Effective Substitution
   For legacy F7/G7 systems, the SI-P1 serves as an excellent, low-cost replacement for discontinued PG-A2 cards without any firmware or wiring change.

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10. Conclusion

The Yaskawa Varispeed F7 remains one of the most reliable inverter platforms in industrial automation.
As the key interface between the drive and the motor’s feedback device, the PG card is indispensable for achieving high-performance vector control.

Through detailed examination, this study confirms that SI-P1 Ver 3.04 is technically equivalent to the PG-A2 model.
It shares the same wiring, electrical characteristics, and parameter settings.
When properly connected and configured (A1-02 = 3), it enables full closed-loop operation with high accuracy and stability.

For field engineers, understanding this equivalence provides a major advantage—allowing quick replacement, reduced downtime, and seamless integration in maintenance or retrofit projects.

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11. Summary of Best Practices

• Always use shielded twisted-pair cable, one pair per differential channel.
• Ground the shield at one end only (inverter side).
• Verify A/B phase direction before enabling closed-loop mode.
• Configure feedback parameters carefully according to the encoder specifications.
• Periodically check the CN5 slot and card contacts for corrosion or dust.

By following these practices, the SI-P1 PG feedback system can deliver long-term precision and reliability comparable to servo-class control systems.

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Author’s Note

This article is written as an original technical analysis for maintenance engineers, automation specialists, and industrial electronics technicians who maintain or retrofit Yaskawa Varispeed F7 inverters.
It integrates both manual specifications and real-world experience gathered from field repairs and performance testing.

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Introduction

In modern industrial automation, inverters (VFDs) are not only used for motor speed control but also serve as vital communication nodes between field devices and PLCs or supervisory systems. The Yaskawa V1000 series, as a compact vector control inverter, is widely applied in conveyors, fans, pumps, compressors, and other equipment due to its stable performance and rich features.
However, many engineers encounter a common issue during commissioning: Why can’t I find H5-01 or H5-02 communication parameters in the V1000 menu?

This article will provide a systematic explanation from the perspective of communication card hardware requirements, panel operation, step-by-step key procedures, and troubleshooting methods. After reading, you will fully understand how to access and correctly configure the H5 parameters on a V1000 inverter, enabling MEMOBUS (Modbus RTU) communication without confusion.

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I. Communication Basics of the V1000 Inverter

1.1 Limitations of the Standard Model

The standard version of the V1000 does not include an RS-485 port by default. It only supports local operation through I/O terminals, such as start/stop signals and analog inputs. Therefore, if you search for H5-01 (slave address) or H5-02 (baud rate) in the parameter menu, you will not find the H5 parameter group.

1.2 Necessity of Expansion Cards

To enable communication, dedicated option cards must be installed, such as:

• SI-485: RS-485 (Modbus RTU) communication card
• SI-232: RS-232 communication card
• Other fieldbus option cards: Profibus-DP, DeviceNet, CANopen, CC-Link, etc.

Once installed, the inverter automatically activates the relevant parameter group and displays H5-01, H5-02, and other settings.

1.3 Installation Position of Expansion Cards

Above the control terminal block of the V1000, there is a long pin connector slot designed for option cards. Installation requires:

1. Powering off and discharging the inverter to ensure safety.
2. Removing the front cover to expose the slot.
3. Inserting the communication card firmly into the slot and securing it with screws.
4. Re-powering the inverter, which will then detect the card and load the H5 parameter group.

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II. Operation Panel Types and Differences

2.1 Standard LED Operator

Most V1000 units are equipped with a simplified LED operator panel, which includes the following buttons:

• ESC (Exit/Back)
• RESET (Fault reset)
• ↑/↓ (Parameter navigation or value adjustment)
• ENTER (Confirm/Save)
• RUN/STOP (Start/Stop motor)

Unlike larger inverters, this panel does not have a dedicated PRG key. To enter the parameter menu, you need to press and hold ESC for about 2 seconds instead of pressing PRG.

2.2 Advanced LCD Operator (Optional)

Some models may be equipped with an LCD operator panel, which provides more advanced displays and shortcut keys. Regardless of the panel type, the process of accessing H5 parameters is the same, with only minor differences in button usage.

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III. Step-by-Step Procedure to Access H5 Parameters

The following example is based on the standard LED operator commonly found on the V1000.

Step 1: Enter Parameter Mode

• After powering on, the display shows motor frequency, such as 0.00.
• Press and hold the ESC key for 2 seconds to enter the parameter group selection mode.
• The screen will display a parameter code, for example A1-01.

Step 2: Navigate to the H5 Parameter Group

• Use the ↑/↓ keys to scroll through parameter groups.
• You will see: A1-xx → b1-xx → C1-xx …
• Continue scrolling until you find H5-01.

⚠️ Note: If the communication card is not installed or not recognized, the H5 parameter group will not appear.

Step 3: Configure H5-01 (Slave Address)

• When H5-01 is displayed, press ENTER.
• The screen switches to the current value, for example 01.
• Use ↑/↓ to set the slave address (range 0 to FFH).
• Press ENTER to save.
• The screen briefly flashes, then returns to H5-01.

Step 4: Configure H5-02 (Baud Rate)

• Press ESC to return to the parameter list.
• Scroll to H5-02.
• Press ENTER to view the current value, e.g., 03 (9600bps).
• Use ↑/↓ to select the desired baud rate:
  • 0 = 1200bps
  • 3 = 9600bps
  • 4 = 19200bps
  • 8 = 115200bps
• Press ENTER to save.

Step 5: Return to Monitoring Mode

• Press ESC repeatedly until the display returns to the main frequency screen (e.g., 0.00).
• The parameters are now set.

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IV. Common H5 Configuration Examples

4.1 Single-Inverter Communication

• H5-01 = 01 (slave address = 1)
• H5-02 = 4 (baud rate = 19200bps)
• Configure the PLC master with address 01 and baud rate 19200bps for communication.

4.2 Multi-Inverter Communication

• Several V1000 inverters connected on the same RS-485 bus.
• Each inverter must have a unique H5-01 value, e.g., 01, 02, 03.
• All devices must share the same H5-02 baud rate, e.g., 19200bps.
• Ensure termination resistors are enabled on both ends of the bus.

4.3 Commissioning Notes

• A power cycle is required after parameter changes for them to take effect.
• If communication fails, check baud rate and slave address consistency, and confirm R+/R- wiring polarity.

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V. Common Issues and Solutions

5.1 H5 Parameters Missing

Cause: Communication card not installed, or wrong card type.
Solution: Ensure SI-485 card is installed properly and compatible with V1000.

5.2 Parameter Changes Not Effective

Cause: Some parameters only apply after restart.
Solution: Power off and restart the inverter after changes.

5.3 Communication Interruption

Cause: Long cable runs or strong EMI interference.
Solution: Use shielded twisted pairs, ground the shield properly, and add termination resistors.

5.4 Panel Buttons Differ from Manual

Cause: Different operator versions (LED vs. LCD).
Solution: For LED panels, press and hold ESC; for LCD versions, PRG may be available.

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VI. Conclusion

This article systematically explained how to access and configure H5-01 and H5-02 parameters on the Yaskawa V1000 inverter. From hardware requirements (communication card installation) to operator panel differences and detailed step-by-step key operations, all potential problems have been clarified.

In short:

1. H5 parameters will not appear without a communication card.
2. On LED operators, hold ESC to enter parameter mode.
3. Always save changes and restart for them to take effect.

By mastering these procedures, engineers can easily configure V1000 inverters for Modbus RTU communication, ensuring seamless integration into automation systems.

1. Introduction

In modern industrial automation systems, the inverter is the core device for motor control and energy-saving operations. It is widely used in pumps, fans, compressors, and various mechanical transmission systems. Among them, the Yaskawa V1000 inverter has become a popular choice due to its compact design, high reliability, and stable performance.

However, during field operation, many users encounter a situation where the inverter’s keypad displays “CALL”, while the ALM (alarm) indicator is lit. For beginners, this situation may seem confusing—“CALL” is often mistaken as a call instruction or program recall. In reality, it represents a communication-related warning.

This article will analyze the meaning of the CALL alarm, its possible causes, troubleshooting methods, and preventive measures, offering a structured guide to help engineers resolve this problem effectively.

2. Meaning of CALL Alarm

On Yaskawa V1000 inverters, CALL means “Communication Awaiting”.

• When the inverter is set to communication control mode, it continuously waits for data from the master device (PLC, PC, or communication module).
• If no valid data is received within a specific time, the inverter enters the CALL state.
• In this case, the ALM LED turns on, indicating a minor fault (warning). Unlike a trip fault, it does not immediately stop the inverter but signals that communication has not been established correctly.

Therefore, CALL is not a severe error code, but a reminder that the communication link is inactive or faulty.

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3. Main Causes of CALL Alarm

Based on Yaskawa’s official manual and field experience, the CALL warning is generally triggered by the following issues:

1. Incorrect communication wiring

Improper connection of RS-485 or MECHATROLINK cables, short circuits, loose connections, or broken wires will cause communication failure.

2. Master device program not running or faulty

If the PLC or PC is not transmitting communication commands, the inverter will always remain in the CALL state.

3. Communication circuit malfunction

Damaged communication modules, defective ports, or strong external interference may disrupt data transmission.

4. Improper termination resistor setting

In Modbus/MEMOBUS or MECHATROLINK systems, termination resistors must be installed at both ends of the communication line. Incorrect settings lead to unstable signals and communication errors.

5. Incorrect control mode settings

If the inverter is configured to communication mode (e.g., o2- parameters set to serial communication) but no master is connected, it will always display CALL.

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4. Troubleshooting Steps

When the inverter shows CALL with ALM lit, the following step-by-step procedure is recommended:

Step 1. Check wiring

• Verify RS-485 polarity (A/B terminals).
• Ensure shielded twisted pair cables are used and grounded properly.
• Inspect for loose, shorted, or broken wires.

Step 2. Check the master device

• Confirm that the PLC or PC communication port is enabled.
• Ensure that the master continuously transmits communication commands (e.g., Modbus function codes, MECHATROLINK frames).
• Debug the ladder program to confirm proper command output.

Step 3. Check termination resistors

• Install a 120Ω resistor at both ends of the communication line.
• If the V1000 has an internal switch for termination resistance (e.g., S2 switch), ensure it is set to ON.

Step 4. Verify inverter parameters

• Confirm o2- parameters (control mode selection).
  • If communication is not required → set the mode to panel or terminal control.
  • If communication is required → ensure correct baud rate, parity, and slave address settings.

Step 5. Power cycle test

• After corrections, restart the inverter.
• If CALL disappears, the issue is solved.
• If it persists, consider replacing the keypad, communication module, or contacting Yaskawa technical support.

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5. Case Studies

Case 1: Wiring error

A water pump system using PLC + V1000 in communication control showed CALL constantly. Upon inspection, RS-485 polarity was reversed. Correcting the wiring resolved the issue immediately.

Case 2: Master program inactive

In a production line upgrade, V1000 inverters were linked by Modbus. Since the PLC program had not been downloaded yet, all inverters displayed CALL. Once the master program was activated, the alarms cleared.

Case 3: Termination resistor missing

In a long-distance bus network, multiple V1000 units showed CALL alarms. Investigation revealed no termination resistors were installed. Adding 120Ω resistors at both ends solved the communication problem.

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6. Preventive Measures

To avoid recurring CALL alarms, engineers should adopt the following best practices:

1. Standardized wiring
   • Always use shielded twisted pair cables.
   • Properly ground the shield layer to reduce interference.
2. Reliable master program
   • Ensure PLC/PC programs send communication frames immediately after startup.
   • Include heartbeat signals to prevent timeouts.
3. Correct termination resistor setup
   • Always place resistors at both ends of the communication line.
   • Verify onboard termination switch settings.
4. Control mode configuration
   • If communication is not required, set the inverter to terminal or panel control to prevent unnecessary CALL states.
   • If communication is required, confirm all protocol settings match between master and slave devices.
5. Regular maintenance
   • Periodically inspect cable connections and terminal blocks.
   • Check communication bus health in multi-inverter systems.

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7. Conclusion

The CALL alarm on Yaskawa V1000 inverters is essentially a communication waiting warning, not a critical trip. It indicates that the inverter is not receiving valid data from the master device.

By systematically checking wiring, master device operation, termination resistors, and control parameters, engineers can quickly identify and resolve the issue. Moreover, if communication is not used, simply switching to panel or terminal control mode will prevent the CALL alarm.

Understanding CALL’s meaning and mastering troubleshooting procedures not only reduces downtime but also enhances the reliability of the overall automation system.

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Introduction

The Yaskawa V1000 series inverter is renowned for its efficient vector control performance and wide range of applications, making it a vital component in industrial automation, including systems like fans, pumps, and conveyor belts. However, during operation, the inverter may encounter various faults, with the “CALL” fault being a common communication-related issue. When the inverter’s display shows “CALL” accompanied by the ALM (alarm) light turning on, it typically indicates a communication link abnormality, which may result in system shutdown. This article provides an in-depth analysis of the nature of the “CALL” fault, its causes, and resolution methods, along with preventive measures to help users quickly restore equipment operation and enhance system reliability.

Nature of the “CALL” Fault

In the Yaskawa V1000 series inverter, “CALL” generally signifies a communication-related issue, potentially indicating that the inverter is awaiting a signal from a master device (e.g., PLC) or has detected an error in the communication link. In some instances, “CALL” may serve as a general prompt, urging users to investigate specific fault codes (e.g., “CE” for MEMOBUS/Modbus communication errors) further. The illumination of the ALM light suggests the inverter has detected an abnormal state, typically interrupting output and allowing the motor to enter a free-stop mode.

Based on relevant documentation, while “CALL” is not explicitly listed in the V1000 series fault code table, it is closely related to communication problems, possibly linked to codes like “CE” (MEMOBUS/Modbus communication error) or “bUS” (option card communication error). In certain communication protocols (e.g., Modbus), “CALL” might indicate a more severe communication issue, potentially necessitating inverter replacement.

Causes of the “CALL” Fault

The occurrence of a “CALL” fault may be attributed to the following causes:

1. Communication Cable Wiring Issues:
   • Loose, broken, or short-circuited communication cables can lead to data transmission failure.
   • Incorrect wiring (e.g., improper terminal connections) may prevent communication between the inverter and the master device.
2. Communication Parameter Configuration Errors:
   • Mismatched communication parameters (e.g., HS-01 slave address, HS-02 communication speed, HS-03 parity) with the master device.
   • For example, if the inverter’s baud rate is set to 9600 bps while the PLC is set to 19200 bps, communication will not establish.
3. Hardware Problems:
   • Failure or improper installation of communication option cards (e.g., Modbus, CC-Link, or PROFIBUS-DP cards).
   • Damaged or poorly contacted communication terminals.
4. Electromagnetic Interference (EMI):
   • Common electromagnetic noise in industrial environments (e.g., from motors or transformers) may disrupt communication signals, causing data transmission errors.
5. Master Station Program Errors:
   • Incorrect configuration in the master device (e.g., PLC) may prevent proper command transmission or response reception.
   • For instance, the PLC may not have the correct slave address or communication protocol set.
6. Communication Timeout:
   • If the inverter does not receive a response from the master within a specified time (e.g., as set by parameter HS-09), it may trigger a “CALL” fault.

Steps to Resolve the “CALL” Fault

To effectively address a “CALL” fault, follow these troubleshooting and resolution steps:

Step 1: Inspect Physical Connections and Wiring

• Check Cables: Inspect communication cables for damage, breaks, or short circuits. Ensure the correct cable type (e.g., RS-485 or RS-422) is used.
• Verify Connections: Confirm all terminals are securely connected with no looseness or poor contact.
• Refer to Manual: Ensure terminal connections (e.g., R+, R-, S+, S-) are correct as per the Yaskawa V1000 technical manual.

Step 2: Verify Communication Parameters

• Use the inverter’s digital operator panel or programming software (e.g., DriveWorksEZ) to check the following parameters:
  • HS-01 (Slave Address): Set to a unique address between 1-247, matching the master device.
  • HS-02 (Communication Speed): Confirm baud rate (e.g., 9600, 19200 bps) matches the master.
  • HS-03 (Parity): Select the appropriate parity setting (none, odd, even).
  • HS-04 (Fault Action Selection): Define the action upon communication failure (e.g., decelerate to stop or free stop).
  • HS-09 (Timeout Time): Adjust timeout to suit system needs.
• Save changes and retest communication.

Step 3: Perform Self-Diagnostic Test

• Per the technical manual, set parameter H1-06 to 67 to enter communication test mode.
• Power off, connect test terminals, power on again, and check if the display shows “PASS” (normal) or “CE” (fault).
• This test helps identify issues with the communication line or hardware.

Step 4: Adjust Terminal Resistor Settings

• For RS-485 networks, ensure terminal resistors are correctly set (typically “ON”).
• Check terminal resistor configuration per the technical manual.

Step 5: Reduce Electromagnetic Interference

• Check for EMI sources (e.g., motors, transformers) in the vicinity.
• Use shielded cables and ensure proper grounding.
• Install EMI filters or surge suppressors as recommended.

Step 6: Inspect Master Device

• Verify the PLC or other master device’s communication settings and program are correct.
• Ensure commands sent by the master match the inverter’s communication protocol and parameters.

Step 7: Consult Technical Support

• If issues persist, refer to the Yaskawa V1000 technical manual’s troubleshooting section.
• Contact Yaskawa support with details including model number, software version, purchase date, and fault description.

Note: In Modbus communication, if “CALL” persists, it may indicate a severe fault, potentially requiring inverter replacement as a last resort.

Preventive Measures

To reduce the likelihood of “CALL” faults, consider the following preventive actions:

1. Regular Maintenance of Communication Lines:
   • Periodically inspect cables and terminals for damage or looseness.
   • Promptly replace aged or damaged cables.
2. Record Communication Parameters:
   • Document all communication settings (e.g., slave address, baud rate) for quick verification and adjustment.
   • Update records after system changes or modifications.
3. Use EMI Protection Measures:
   • Employ shielded cables and ensure proper grounding.
   • Install EMI filters or surge suppressors to reduce noise impact.
4. Keep Firmware Updated:
   • Regularly check for firmware updates.
   • Update firmware to address known communication issues.
5. Routine System Checks:
   • Conduct regular inspections of the inverter, master device, and communication network to identify potential issues early.
6. Train Operating Personnel:
   • Train operators and maintenance staff on inverter operation, fault codes, and troubleshooting procedures.
   • Ensure personnel can correctly interpret “CALL” and other fault messages and take appropriate action.

Fault Code Reference Table

Below are common communication-related fault codes for the V1000 series inverters and their descriptions:

Fault Code	Description	Possible Causes	Resolution Methods
CE	MEMOBUS/Modbus Communication Error	No response from master, parameter mismatch, wiring issues	Check parameters, wiring, perform self-diagnostic test
bUS	Option Card Communication Error	Option card failure, wiring issues, incorrect terminal resistor	Check option card, wiring, adjust terminal resistor
CALL	Communication Wait or Error	Awaiting communication signal, wiring/parameter issues, hardware failure	Check wiring, parameters, perform self-diagnostic, consider replacement

Conclusion

The “CALL” fault is a significant communication-related issue in Yaskawa V1000 series inverters, potentially leading to system downtime and affecting production efficiency. By inspecting wiring, verifying communication parameters, performing self-diagnostic tests, and reducing electromagnetic interference, most “CALL” faults can be resolved. Implementing preventive measures such as regular maintenance, parameter documentation, and the use of shielded cables can greatly reduce the incidence of such faults. For complex or persistent issues, consulting the Yaskawa V1000 technical manual or contacting Yaskawa technical support for professional assistance is recommended. Ensuring the reliability of the communication system is crucial for maintaining stable operation in industrial applications.

The Yaskawa J1000 series inverters are widely used in industrial automation for their stable control performance and high energy efficiency. However, during actual operation, inverters may encounter various faults, one of which is the “Uu1” fault. This article will analyze the meaning, causes, and solutions for the Uu1 fault from both external and internal perspectives, providing a reference for inverter maintenance and repair.

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I. Meaning and Causes of the Uu1 Fault

1. Fault Meaning

The Uu1 fault indicates an undervoltage output fault, meaning the inverter detects that the output voltage is below the set minimum value, triggering a protective mechanism. This fault often causes the inverter to stop, protecting the motor and load from potential damage.

2. Causes of the Fault

The Uu1 fault can be attributed to several factors:

• Unstable power supply: The input voltage to the inverter is lower than the rated range, leading to insufficient output voltage.
• Wiring issues: Poor contact in the input or output wiring causes voltage drops.
• Internal inverter faults: Damage to the inverter’s internal circuits or components results in abnormal output voltage.
• Motor or load faults: Issues with the motor or load cause abnormal feedback voltage.

3. On-Site Handling Methods

To address the Uu1 fault on-site, follow these steps:

1. Check the power supply voltage: Use a voltmeter to measure the inverter’s input voltage and ensure it is within the rated range. If the voltage is too low or unstable, inspect the power supply, and replace it or use a voltage stabilizer if necessary.
2. Inspect the wiring: Check the input and output wiring for proper contact, ensuring no loose or disconnected wires. If poor contact is found, reconnect the wiring and tighten the screws.
3. Examine the inverter internally: If the power supply and wiring are fine, the issue may lie within the inverter. Consult a professional technician or the manufacturer for repairs.
4. Check the motor and load: Ensure the motor is operating normally and inspect the load for any issues.
5. Reset the fault: After resolving the issue, press the RESET button on the inverter to clear the fault. Restart the inverter and observe its operation.

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II. Analysis of Electrical Issues from the Inverter’s Internal Structure

1. Overview of the Inverter’s Internal Structure

The internal structure of the Yaskawa J1000 series inverter primarily includes the rectifier circuit, inverter circuit, control circuit, and protection circuit. The rectifier circuit converts AC voltage to DC voltage, the inverter circuit converts DC voltage to variable-frequency AC voltage, the control circuit regulates the output frequency and voltage, and the protection circuit detects and protects against faults such as overload, overvoltage, and overcurrent.

2. Electrical Issues Related to the Uu1 Fault

The Uu1 fault is typically associated with the inverter’s output circuit and involves the following aspects:

• Rectifier circuit faults: Damage to diodes or capacitors in the rectifier circuit can lead to insufficient DC voltage, affecting the output voltage.
• Inverter circuit faults: Damage to IGBT modules or driver circuits in the inverter circuit can cause abnormal output voltage.
• Control circuit faults: Faults in the microprocessor or driver chips in the control circuit can result in inaccurate output voltage regulation.
• Protection circuit faults: Malfunctioning detection components or protection chips in the protection circuit can lead to incorrect identification of undervoltage.

3. Electrical Repair Methods

To repair the Uu1 fault, follow these steps:

1. Inspect the rectifier circuit: Use a multimeter to test the diodes and capacitors in the rectifier circuit to ensure they are functioning correctly. Replace any damaged components.
2. Check the inverter circuit: Inspect the IGBT modules and driver circuits for proper operation. Replace any faulty modules or chips.
3. Examine the control circuit: Test the microprocessor and driver chips to ensure they are functioning correctly. Replace any faulty chips.
4. Inspect the protection circuit: Check the detection components and protection chips in the protection circuit for proper operation. Replace any faulty components.

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III. Comprehensive Solutions for the Uu1 Fault

1. Preventive Measures

To prevent the occurrence of the Uu1 fault, consider the following measures:

• Regularly check the power supply voltage: Periodically inspect the inverter’s input voltage to ensure stability.
• Maintain wiring connections: Regularly check the wiring for proper contact and address any issues promptly.
• Inspect the inverter internally: Periodically check the inverter’s internal circuits to identify and resolve potential faults early.
• Maintain the motor and load: Regularly inspect the motor and load to ensure they are operating correctly.

2. Fault Handling Procedure

When addressing the Uu1 fault, follow this procedure:

1. Confirm the fault: Verify the Uu1 fault on the inverter’s display.
2. Check the power supply voltage: Ensure the input voltage is normal.
3. Inspect the wiring: Check for proper wiring connections.
4. Examine the inverter internally: Ensure the internal circuits are functioning correctly.
5. Check the motor and load: Verify that the motor and load are operating normally.
6. Reset the fault: After resolving the issue, reset the inverter and observe its operation.

3. Professional Support

If the Uu1 fault cannot be resolved through the above methods, consult a professional technician or the manufacturer for further assistance.

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Conclusion

The Uu1 fault in the Yaskawa J1000 series inverters is a common undervoltage output fault with complex causes, involving the power supply, wiring, internal circuits, motor, and load. Through systematic fault analysis and step-by-step troubleshooting, the Uu1 fault can be effectively resolved, ensuring stable inverter operation. Regular maintenance and preventive measures are also crucial in avoiding such faults.

The Yaskawa V1000 series inverter, as a high-performance vector control inverter, is widely used in various industrial drive systems. This article will provide a detailed introduction to the operation panel functions, basic setting methods, common function applications, and fault code analysis of this inverter, helping users better understand and utilize this equipment.

I. Introduction to Operation Panel Functions and Basic Settings

1. Introduction to Operation Panel Functions

The operation panel of the Yaskawa V1000 series inverter integrates rich display and control functions, mainly including the LED operator, LO/RE indicator light, RUN indicator light, etc. Users can perform parameter settings, mode switching, operation monitoring, and other operations through the operation panel.

2. How to Set and Clear Passwords

To protect the inverter parameters from being modified arbitrarily, users can set a password. The specific steps are as follows:

• Setting a Password: In the parameter setting mode, find A1-04 (password setting), enter the desired password value, and then press the ENTER button to confirm. Next, enter the same password value in A1-05 (password) for confirmation.
• Clearing a Password: To clear the set password, simply set the password values in both A1-04 and A1-05 to 0.

3. Parameter Initialization

When it is necessary to restore the inverter to its factory default settings, parameter initialization can be performed. The specific steps are as follows:

• In the parameter setting mode, set A1-03 to 2220 (2-wire sequence control initialization) or 3330 (3-wire sequence control initialization), and then press the ENTER button to confirm. At this point, the inverter will be restored to its factory default settings.

4. Using the DWELL Function

The DWELL function can temporarily maintain the output frequency during motor startup or stoppage to prevent motor stall. The specific setting steps are as follows:

• In the parameter setting mode, find b6-01 and b6-02, and set the DWELL frequency and time during startup respectively. For example, set b6-01 to 5Hz and b6-02 to 2s, so that the motor will maintain a 5Hz output for 2 seconds during startup.

5. Using the Speed Search Function

The speed search function can automatically search and set the appropriate output frequency when the motor stalls or restarts. The specific usage method is as follows:

• In the parameter setting mode, set b3-05 to the speed search wait time (e.g., 1s). Then, trigger the speed search function through an external signal when needed, and the inverter will automatically search and set the appropriate output frequency.

II. Terminal Functions and Wiring Settings

1. Realizing Forward and Reverse Start/Stop Functions

To realize the forward and reverse start/stop functions of the motor, it is necessary to correctly wire and set relevant parameters. The specific steps are as follows:

• Wiring: Connect the forward start signal to terminal S1, the reverse start signal to terminal S2, and the stop signal to terminal S3.
• Parameter Settings: In the parameter setting mode, set b1-02 to 1 (LOCAL/REMOTE selection), and set H1-01 and H1-02 to the input terminals for forward and reverse commands (e.g., S1 and S2) respectively. At the same time, set H1-03 to the input terminal for the stop command (e.g., S3).

2. Realizing External Potentiometer Speed Regulation

The external potentiometer speed regulation function allows users to change the output frequency of the inverter by adjusting the resistance value of an external potentiometer. The specific implementation method is as follows:

• Wiring: Connect the output signal of the external potentiometer to terminal A1 of the inverter (multi-function analog input terminal).
• Parameter Settings: In the parameter setting mode, set b1-01 to 1 (control circuit terminal frequency command), and set H3-01 to 0 (0~10V input). At the same time, adjust the values of H3-04 (input gain) and H3-05 (input offset) according to actual needs.

III. Fault Code Analysis

The Yaskawa V1000 series inverter has a comprehensive fault diagnosis function. When a fault occurs in the inverter, the corresponding fault code will be displayed on the operation panel. The following are some common fault codes, their meanings, and solutions:

• CPF02: A/D converter fault. Possible causes include control circuit damage, control circuit terminal short circuit, etc. Solutions include checking the control circuit connection and replacing the inverter.
• CPF06: EEPROM data anomaly. Possible causes include control circuit damage, power being cut off during the initialization process, etc. Solutions include re-executing the initialization operation and replacing the inverter.
• Uv1: Main circuit undervoltage. Possible causes include too low power supply voltage, power supply phase loss, etc. Solutions include checking the power supply voltage and power supply wiring.
• oH1: Heatsink overheat. Possible causes include too high ambient temperature, excessive load, etc. Solutions include improving heat dissipation conditions and reducing the load.

When a fault occurs in the inverter, users should refer to the fault code displayed on the operation panel, combine the above analysis methods and solutions for troubleshooting and handling. If the problem cannot be solved, users should promptly contact professional technicians for repair.

IV. Conclusion

The Yaskawa V1000 series inverter, as a high-performance vector control inverter, boasts rich functions and flexible setting options. Through the introduction in this article, users can better understand and utilize this equipment to achieve precise motor control and efficient operation. At the same time, users should also regularly check and maintain the inverter to ensure its long-term stable operation.

The Yaskawa Inverter A1000 Series is a high-performance vector control inverter widely used in various industrial control applications. This document aims to provide users with a detailed guide, covering the function explanation of the operation panel, password setting and cancellation, parameter initialization settings, external terminal start/stop and potentiometer speed adjustment settings, as well as common fault codes and troubleshooting methods.

I. Function Explanation of the Operation Panel (Operator)

The operation panel of the Yaskawa Inverter A1000 Series integrates multiple functions, facilitating user parameter settings and status monitoring. Below are the main functions of the operation panel:

1. Display and Operation: The operation panel features an LED display and multiple operation keys, including the “LOCAL/REMOTE” key and the “STOP” key, allowing users to perform local or remote operations and stop the inverter.
2. Password Setting and Cancellation:
   • Password Setting: Enter the parameter setting mode and set the password by configuring A1-04 (Password) and A1-05 (Password Setting). The specific steps are: First, press the “ESC” key to enter the parameter setting mode, then select A1-05 and input the password value, and finally press the “ENTER” key to confirm.
   • Password Cancellation: To cancel the set password, set A1-04 (Password) to the same value as A1-05 (Password Setting), then re-enter the parameter setting mode and set both A1-04 and A1-05 to 0.
3. Parameter Initialization Settings: Set A1-03 (Initialization) to choose different initialization methods. Common options include:
   • 1110: Initializes based on user settings, restoring parameters to user-saved values.
   • 2220: Initializes for 2-wire sequential control, restoring factory settings for 2-wire sequential control.
   • 3330: Initializes for 3-wire sequential control, restoring factory settings for 3-wire sequential control.
   • 5550: Resets oPE04, used for parameter reset after replacing the detachable terminal block.

II. External Terminal Start/Stop and Potentiometer Speed Adjustment Settings

To enable external terminal start/stop and potentiometer speed adjustment functions for the Yaskawa Inverter A1000 Series, the following parameter and wiring settings are required:

1. Parameter Settings:
   • Set b1-01 (Run Command Selection 1) to 2, selecting external terminal run commands.
   • Set b1-02 (Run Command Selection 2) to 0, selecting the 2-wire sequential control mode for forward/stop and reverse/stop (or select other modes as needed).
   • Set H1-01 and H1-02 to 40 and 41, respectively, assigning the S1 and S2 terminals as input for forward and reverse run commands.
2. Wiring Settings:
   • Connect the external start/stop buttons to the S1 and S2 terminals.
   • Connect the center tap of the potentiometer to the common terminal of the inverter (e.g., 0V), and connect the ends of the potentiometer to the analog input terminals of the inverter (e.g., A1 and +V or -V) to achieve potentiometer speed adjustment.

III. Common Fault Codes and Troubleshooting Methods

The Yaskawa Inverter A1000 Series may encounter various faults during operation. Below are some common fault codes, their meanings, and troubleshooting methods:

1. oL1 (Motor Overload):
   • Meaning: The motor current exceeds the rated value, triggering the overload protection.
   • Troubleshooting: Check if the motor load is too heavy, adjust the load or increase the motor capacity; check the motor wiring for correctness to avoid line-to-line shorts; check the inverter parameter settings to ensure the motor parameters match the actual motor.
2. Uv1 (Main Circuit Undervoltage):
   • Meaning: The main circuit DC voltage is lower than the set value.
   • Troubleshooting: Check if the power supply voltage is stable and within the allowable range; check the power wiring for firmness to avoid poor contact; check if the internal capacitors of the inverter are aged or damaged.
3. oH1 (Inverter Overheat):
   • Meaning: The internal temperature of the inverter is too high, triggering the overheat protection.
   • Troubleshooting: Check the installation environment of the inverter to ensure adequate ventilation; check if the inverter heat sink is clean and free of dust accumulation; check if the cooling fan is working properly and replace it if faulty.
4. oPE03 (Improper Selection of Multi-function Input):
   • Meaning: There is a conflict or error in the function assignment of the multi-function input terminals.
   • Troubleshooting: Check the parameter settings of H1-01 to H1-08 to ensure the function assignment of each terminal is correct and without duplication; check if any unused terminals have been assigned functions mistakenly.
5. Er-11 (Motor Speed Fault):
   • Meaning: During rotary self-learning, the motor speed is abnormal.
   • Troubleshooting: Check the connection between the motor and the inverter for correctness; check the wiring and settings of the PG (encoder); re-perform self-learning with the motor and mechanical system connected.

The above are only some common fault codes and their troubleshooting methods. In actual use, other faults may occur. Users should refer to the fault code table in the inverter user manual and take corresponding measures based on specific fault codes and meanings. Additionally, regular maintenance and inspection of the inverter are important means to prevent faults.

I. Operation Panel Function Introduction and Usage Instructions

The operation panel of the Yaskawa Inverter H1000 series serves as its control hub, enabling parameter setting, monitoring of operating status, and fault diagnosis. The primary buttons and functions on the operation panel include:

• ESC: Exits the current mode or cancels operations.
• RUN: Starts the inverter.
• STOP: Stops the inverter.
• ENTER: Confirms inputs or enters parameter settings.
• RESET: Resets faults.
• ALM: Displays fault or warning messages.
• DIGIT: Selects digits during parameter setting.
• OPRATOR: The operation panel display, which shows various information and parameters.

Parameter Initialization

Parameter initialization restores the inverter’s settings to the factory defaults. The steps are as follows:

1. Enter Initialization Mode: Press the “ESC” button on the operation panel, then press “ENTER” to enter the parameter setting mode.
2. Select Initialization Parameter: Use the “DIGIT” buttons to select parameter “A1-03” and press “ENTER”.
3. Set Initialization Value: Set the value of “A1-03” to “2220” or “3330” for initialization of 2-wire or 3-wire sequential control, respectively.
4. Confirm and Save: Press “ENTER” to confirm the setting, and the inverter will automatically restart and complete the initialization.

Setting and Resetting Passwords

To protect the inverter settings from unauthorized changes, passwords can be set. The steps are as follows:

1. Enter Password Setting Mode: In the parameter setting mode, select “A1-04” and press “ENTER”.
2. Enter Password: Use the “DIGIT” buttons to input a 4-digit password and press “ENTER” to confirm.
3. Confirm Password: Enter the same password again to confirm the setting and press “ENTER”.

To reset the password, simply enter the correct password in the password input interface to unlock the parameter settings.

II. Terminal Start/Stop and External Potentiometer Speed Adjustment

To achieve terminal start/stop and external potentiometer speed adjustment, the corresponding control terminals need to be connected and parameters set accordingly.

Wiring Instructions

1. Start/Stop Terminals: Typically, use terminals S1 (Run) and S2 (Stop). Closing (connecting) terminal S1 starts the inverter, while closing terminal S2 stops it.
2. External Potentiometer: Use terminal A1 as the input terminal for the external potentiometer. Connect the potentiometer’s output to terminal A1 and adjust the potentiometer to change the frequency command.

Parameter Settings

1. Run Command Selection: Set parameter “b1-01” to “10” to select the operation panel as the frequency command source.
2. Multi-function Input Settings: Set parameter “H1-01” to “04” (Run command) and “H1-02” to “05” (Stop command), corresponding to the functions of terminals S1 and S2, respectively.
3. Analog Input Gain and Offset: Adjust parameters “H3-03” (Gain) and “H3-04” (Offset) according to the output range of the external potentiometer to ensure that the frequency command changes proportionally with the potentiometer output.

III. Crane Control Wiring and Parameter Setup

In crane applications, special attention must be paid to safety control and precise speed regulation.

Wiring Instructions

1. Main Circuit Wiring: Connect the inverter’s R/L1, S/L2, and T/L3 terminals to the crane motor according to its voltage and power requirements.
2. Control Circuit Wiring: In addition to the basic start/stop terminals, emergency stop, limit switches, and other safety control terminals also need to be connected.
3. PG (Encoder) Wiring: For cranes requiring precise speed control and positioning, connect the PG encoder and output its signals to the inverter’s PG option card.

Parameter Settings

1. Control Mode Selection: Set parameter “A1-02” to the appropriate vector control mode (e.g., Vector Control with PG) to ensure precise speed and position control.
2. PG Parameter Settings: Set parameters such as “F1-06” (PG Output Division Ratio) and “F1-12/F1-13” (PG Gear Ratio) according to the encoder specifications.
3. Safety Function Settings: Enable the external emergency stop function and set the relevant parameter, such as “H2-01” (Multi-function Contact Output Selection), to output an emergency stop signal.
4. Speed Search Function: For heavy-duty applications like cranes, it is recommended to enable the speed search function to improve stability and safety during startup. Set parameter “b3-01” to effective and adjust other related parameters as needed.

IV. Fault Code Meanings and Solutions

The Yaskawa Inverter H1000 series has comprehensive fault self-diagnosis functions. When a fault occurs, the operation panel will display the corresponding fault code. Below are the meanings of some common fault codes and their solutions:

• CPF00/CPF01: Control circuit fault. Possible causes include incorrect control circuit wiring or damaged circuit boards. The solution is to check the control circuit wiring and replace the circuit board if necessary.
• oH: Overheating of the heatsink. Possible causes are high ambient temperature, excessive load, or a faulty cooling fan. The solution is to improve ventilation, reduce the load, or replace the cooling fan.
• Uv: Undervoltage in the main circuit. Possible causes are low supply voltage or phase loss in the power supply. The solution is to check the supply voltage and wiring to ensure they are normal.
• oL1: Motor overload. Possible causes are excessive load or improper motor parameter settings. The solution is to reduce the load or reset the motor parameters.

When a fault occurs in the inverter, first check the fault code displayed on the operation panel to identify the cause and follow the corresponding solution. If the issue cannot be resolved, promptly contact a professional technician for repairs.

Through this operation guide, users can better understand and operate the Yaskawa Inverter H1000 series, ensuring its stable operation in various applications.