Year: 2025

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Analysis and Handling of Er050 Fault in Hilectro HI300 Series Servo System

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.

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.

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.”

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.

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.

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.

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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PROMPOWER Inverter PD310 Series User Manual Guide

The PROMPOWER Inverter PD310 Series is a powerful and versatile low-voltage inverter suitable for industrial automation scenarios that require high dynamic performance and a wide range of speed regulation. To help users better master its usage, this document provides a detailed English user guide based on the Russian user manual. The content covers the functions of the operation panel and related settings, external control implementation methods, and diagnostic and handling procedures for fault codes.

I. Introduction to Operation Panel Functions and Related Settings

The operation panel is the core tool for user interaction with the PD310 Series inverter. Through its keys and display, users can perform operations such as parameter viewing, modification, and device control. This section will introduce the functions of the operation panel in detail and explain how to restore factory settings for parameters, set and eliminate passwords, and set parameter access restrictions.

1.1 Introduction to Operation Panel Functions

The operation panel of the PD310 Series inverter includes a display and multiple function keys for displaying the running status and executing operations. According to Chapter 5 “Приступаем к работе” (Getting Started) of the manual, the main functions are as follows:

  • Display: Displays the current running status (such as frequency, voltage), parameter values, and fault codes.
  • Key Functions:
    • PRG (Programming Key): Enters or exits the programming mode to access the parameter setting menu.
    • ENTER (Confirm Key): Confirms parameter modifications or enters the next level of the menu.
    • UP (Up Key): Increases the parameter value or scrolls up the page.
    • DOWN (Down Key): Decreases the parameter value or scrolls down the page.
    • SHIFT (Shift Key): Switches between the parameter number and parameter value.
    • RUN (Run Key): Starts the inverter.
    • STOP/RESET (Stop/Reset Key): Stops the inverter operation or resets the fault status.

Operation Example: To modify a parameter, the user can press the PRG key to enter the programming mode, use the UP/DOWN keys to select the parameter number, press the ENTER key to enter the parameter value editing mode, use the UP/DOWN keys to adjust the value, and finally press the ENTER key to save.

1.2 Restoring Factory Settings for Parameters

To restore the inverter parameters to the factory default values, follow the steps in Section 5.3 “Сброс на заводские настройки” (Restoring Factory Settings) of the manual:

  1. Press the PRG key to enter the programming mode.
  2. Use the UP/DOWN keys to select the parameter group “F0”.
  3. Press the ENTER key to enter the “F0” group.
  4. Select the parameter “F0-00” (usually the factory reset parameter).
  5. Press the ENTER key to enter the editing mode and set the value to “1” (indicating factory reset).
  6. Press the ENTER key to confirm. The inverter will automatically restart, and the parameters will be restored to the factory values.

Note: This operation will clear all user settings. It is recommended to back up important parameters in advance.

1.3 Setting and Eliminating Passwords

The PD310 Series supports password protection to prevent unauthorized parameter modifications. The steps for setting and eliminating passwords are as follows:

  • Setting a Password:
    1. Press the PRG key to enter the programming mode.
    2. Select the parameter group “F0”.
    3. Enter the parameter “F0-01” (password setting parameter).
    4. Input a 4-digit password (e.g., 1234) and adjust the value using the UP/DOWN keys.
    5. Press the ENTER key to confirm. The password setting takes effect.
    6. The password must be entered the next time parameter access is required.
  • Eliminating a Password:
    1. Press the PRG key to enter the programming mode.
    2. Input the current password to unlock parameter access.
    3. Enter the parameter “F0-01”.
    4. Set the value to “0”.
    5. Press the ENTER key to confirm. The password is cleared.
1.4 Setting Parameter Access Restrictions

To prevent accidental operations, the PD310 allows restricting access permissions for certain parameters. The specific operations are as follows:

  • Setting Access Restrictions:
    1. Press the PRG key to enter the programming mode.
    2. Select the parameter group “F0”.
    3. Enter the parameter “F0-02” (access restriction setting).
    4. Set the parameter value to the number of the parameter group to be restricted (e.g., set to “1” to restrict the F1 group).
    5. Press the ENTER key to confirm. The restricted parameter group cannot be accessed or modified.
  • Lifting Access Restrictions:
    1. Press the PRG key to enter the programming mode.
    2. Input the password (if set) to unlock.
    3. Enter the parameter “F0-02”.
    4. Set the value to “0”.
    5. Press the ENTER key to confirm. All parameter groups resume accessible status.

Through the above settings, users can flexibly manage parameter permissions and ensure system security.

II. External Control Implementation

The PD310 Series inverter supports motor forward/reverse control and speed regulation through external terminals. This section will introduce how to achieve external terminal forward/reverse control and external potentiometer speed regulation through wiring and parameter settings.

2.1 External Terminal Forward/Reverse Control

External terminal forward/reverse control is achieved through digital input terminals (DI) and the common terminal (COM). According to Section 4.5 “Клеммы управления” (Control Terminals) of the manual:

  • Wiring:
    • Forward Switch: Connect DI1 and COM terminals.
    • Reverse Switch: Connect DI2 and COM terminals.
  • Parameter Settings:
    1. Press the PRG key to enter the programming mode.
    2. Select the parameter group “F1”.
    3. Set “F1-00” (control mode) to “1” (terminal control).
    4. Set “F1-01” (DI1 function) to “1” (forward command).
    5. Set “F1-02” (DI2 function) to “2” (reverse command).
    6. Press the PRG key to exit.
  • Operation Mode: When DI1 is closed, the motor runs forward; when DI2 is closed, the motor runs reverse. If both DI1 and DI2 are closed simultaneously, the motor may stop (depending on the parameter configuration).
2.2 External Potentiometer Speed Regulation

External potentiometer speed regulation achieves speed adjustment through analog input terminals (AI). According to Section 4.5 of the manual:

  • Wiring:
    • Potentiometer Middle Tap: Connect to the AI1 terminal.
    • Potentiometer One End: Connect to the +10V terminal.
    • Potentiometer Other End: Connect to the GND terminal.
  • Parameter Settings:
    1. Press the PRG key to enter the programming mode.
    2. Select the parameter group “F2”.
    3. Set “F2-00” (speed reference method) to “1” (AI1 analog input).
    4. Set “F2-01” (AI1 minimum input) to 0V (minimum potentiometer voltage).
    5. Set “F2-02” (AI1 maximum input) to 10V (maximum potentiometer voltage).
    6. Set “F2-03” (AI1 minimum frequency) to 0Hz.
    7. Set “F2-04” (AI1 maximum frequency) to 50Hz (or the maximum frequency required by the user).
    8. Press the PRG key to exit.
  • Operation Mode: Rotating the potentiometer linearly adjusts the motor speed from 0Hz to 50Hz.

III. Fault Codes and Handling

The PD310 Series inverter may encounter faults during operation and prompt the user with fault codes. This section lists common fault codes and their meanings based on Section 6.1 “Коды ошибок” (Fault Codes) of the manual and provides handling methods.

3.1 Fault Code List

The following are common fault codes and their meanings (refer to page 201 of the manual):

  • Err01: Short-circuit protection (inverter output short-circuit).
  • Err08: Overvoltage during acceleration.
  • Err09: Overvoltage during deceleration.
  • Err10: Overvoltage at constant speed.
  • Err11: Undervoltage.
  • Err12: Input phase loss.
  • Err13: Output phase loss.
  • Err14: Inverter overload.
  • Err15: Motor overload.
  • Err17: Inverter overtemperature.
  • Err21: External fault.
  • Err23: Communication fault.
3.2 Fault Handling Methods

For the above faults, the following are the recommended handling methods:

  • Err01 Short-circuit Protection:
    • Check if the motor and output lines are short-circuited.
    • Ensure correct wiring and eliminate grounding faults.
  • Err08/Err09/Err10 Overvoltage Faults:
    • Check if the input voltage is too high.
    • Confirm if the braking resistor is correctly connected or damaged.
    • Extend the acceleration/deceleration time parameters (F0 group).
  • Err11 Undervoltage:
    • Check if the power supply voltage is below the requirement.
    • Check if the power supply line connections are good.
  • Err12 Input Phase Loss:
    • Check if the three phases of the input power are complete.
    • Ensure secure wiring.
  • Err13 Output Phase Loss:
    • Check if the motor wiring is loose or disconnected.
    • Verify if the motor is normal.
  • Err14 Inverter Overload:
    • Reduce the load or replace with a higher-power inverter.
    • Check if the parameter settings are reasonable.
  • Err15 Motor Overload:
    • Check if the load exceeds the motor capacity.
    • Adjust the motor protection parameters (F5 group).
  • Err17 Inverter Overtemperature:
    • Check if the cooling fan is operating normally.
    • Clean the heat sink to ensure good ventilation.
  • Err21 External Fault:
    • Check if the external fault input terminal (DI) is triggered.
    • Eliminate the external fault source.
  • Err23 Communication Fault:
    • Check if the communication line connections are correct.
    • Verify if the communication parameters (F11 group) match.

Handling Process: When a fault occurs, record the code and press the STOP/RESET key to reset. If the issue cannot be resolved, troubleshoot according to the above methods and contact PROMPOWER technical support if necessary.

Conclusion

Through this document, users can fully understand the operation and application of the PROMPOWER Inverter PD310 Series. The functions of the operation panel provide convenience for parameter management, and restoring factory settings, password protection, and access restrictions enhance system security. External terminal forward/reverse control and potentiometer speed regulation provide users with flexible control methods. The identification and handling methods for fault codes help quickly resolve issues and ensure stable equipment operation. This document aims to provide users with practical guidance and improve equipment usage efficiency.

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Application Scheme of Frequency Converters in Winding Machines and Traverse Devices

Below is the English translation of the provided article, with key sections highlighted in bold for emphasis.

Design and Application of the 900 Series Inverter in the Winding Machine Traverse System

The winding machine and its traverse system are primarily used to ensure that materials (such as paper, film, or wire) are neatly and evenly arranged on the reel during the winding process, preventing stacking or misalignment. The following sections detail the application of the inverter, including motor selection, wiring methods, parameter settings, control logic, and the integration of PLC, HMI, or industrial PC, based on the process equipment workflow.

1. Functional Analysis of the Winding Machine Traverse System

The traverse system of a winding machine typically requires the following functions:

  • Main Winding Motor: Drives the reel to rotate, completing the material winding process.
  • Traverse Motor: Drives the traverse device to move left and right, ensuring even material distribution on the reel.
  • Tension Control: Maintains constant material tension during winding to avoid stretching or slackening.
  • Speed Synchronization: The traverse motor’s movement speed must synchronize with the main winding motor’s speed to match the material winding speed.
  • Position Control: The traverse device must reciprocate based on the reel width, with left and right limit settings.
  • Start/Stop Control: Controls the start and stop of winding and traversing via external signals (e.g., buttons or PLC).
  • Fault Protection: Detects faults such as overload, phase loss, or overcurrent, stopping the system for protection.

A typical winding machine traverse device includes a main winding motor (driving the winding drum) and a traverse device (achieving left-right movement through a lead screw). We will use the 900 series frequency converters to control the main winding motor and the traverse motor.

2. Motor Selection and Function Assignment

2.1 Main Winding Motor

  • Function: Drives the reel to rotate, completing material winding.
  • Motor Selection: Based on the winding machine’s load and reel diameter, we assume a 4kW three-phase asynchronous motor (380V) is required. From the inverter model table on page 5 of the manual, we select the 900-0040G1 model (suitable for a 4kW motor, rated output current 18A).
  • Control Mode: Uses V/F control mode (ideal for scenarios with significant load variations like winding machines), adjusting speed via the inverter to control winding speed.

2.2 Traverse Motor

  • Function: Drives the traverse device to move left and right, achieving reciprocating motion via a lead screw mechanism.
  • Motor Selection: The traverse motor typically requires less power; we assume a 0.75kW three-phase asynchronous motor (380V) is needed. From the manual’s model table on page 5, we select the 900-0007M3 model (suitable for a 0.75kW motor, rated output current 2.5A).
  • Control Mode: Uses open-loop vector control mode (suitable for precise speed and direction control), managing the traverse motor’s forward/reverse rotation and speed via the inverter.

3. Inverter Wiring Design

3.1 Main Winding Motor Inverter (900-0040G1) Wiring

  • Power Input:
  • Inverter input terminals R, S, T connect to a three-phase 380V power supply.
  • Ground terminal PE connects to the ground wire for safety.
  • Motor Output:
  • Inverter output terminals U, V, W connect to the three-phase input of the main winding motor.
  • Control Terminal Wiring (refer to Chapter 3 of the manual, “Mechanical Installation and Electrical Connection”):
  • DI1 (Start/Stop Control): Connects to an external start button (normally open contact) to start/stop the main winding motor.
  • DI2 (Forward/Reverse): Connects to an external direction switch to control the main winding motor’s rotation direction (typically only forward rotation is needed for winding machines).
  • AI1 (Speed Reference): Connects to a potentiometer (0-10V) or PLC analog output to adjust the main winding motor’s speed.
  • DO1 (Operation Status Output): Connects to an indicator light or PLC input to output the inverter’s operating status.
  • +24V and COM: Used for the power supply and common terminal of the external control circuit.

3.2 Traverse Motor Inverter (900-0007M3) Wiring

  • Power Input:
  • Inverter input terminals R, S, T connect to a three-phase 380V power supply.
  • Ground terminal PE connects to the ground wire.
  • Motor Output:
  • Inverter output terminals U, V, W connect to the three-phase input of the traverse motor.
  • Control Terminal Wiring:
  • DI1 (Forward): Connects to the left limit switch (normally closed contact); when the traverse device reaches the left limit, it triggers to stop forward rotation.
  • DI2 (Reverse): Connects to the right limit switch (normally closed contact); when the traverse device reaches the right limit, it triggers to stop reverse rotation.
  • DI3 (Start/Stop Control): Linked to the main winding motor’s start/stop signal (via PLC or relay).
  • AI1 (Speed Reference): Receives a PLC analog output (0-10V) to set the speed, synchronized with the main winding motor.
  • DO1 (Operation Status Output): Connects to a PLC input to output the traverse motor’s operating status.

3.3 Wiring Diagram (Text Description)

Main Winding Motor Inverter Wiring Diagram:

Three-Phase Power 380V
  |  |  |
  R  S  T
  |  |  |-------> Inverter (900-0040G1) Input Terminals R, S, T
  PE-------------> Inverter PE Ground Terminal

Inverter Output U, V, W
  |  |  |
  U  V  W-------> Main Winding Motor (4kW)

Control Terminals:
External Start Button-------> DI1 - COM
Direction Switch-----------> DI2 - COM
Potentiometer (0-10V)------> AI1 - GND
Indicator Light------------> DO1 - COM

Traverse Motor Inverter Wiring Diagram:

Three-Phase Power 380V
  |  |  |
  R  S  T
  |  |  |-------> Inverter (900-0007M3) Input Terminals R, S, T
  PE-------------> Inverter PE Ground Terminal

Inverter Output U, V, W
  |  |  |
  U  V  W-------> Traverse Motor (0.75kW)

Control Terminals:
Left Limit Switch-----------> DI1 - COM
Right Limit Switch----------> DI2 - COM
Start/Stop Signal (PLC)-----> DI3 - COM
PLC Analog (0-10V)---------> AI1 - GND
PLC Input------------------> DO1 - COM

4. Parameter Settings

4.1 Main Winding Motor Inverter (900-0040G1) Parameter Settings

Referring to Chapter 5 of the manual, “Parameter Description,” set the following key parameters:

  • F0-00 (Command Source): Set to 1 (terminal control), using DI1 to control start/stop.
  • F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via the potentiometer.
  • F0-03 (Maximum Frequency): Set to 50Hz (adjust based on actual needs).
  • F0-09 (Motor Rated Frequency): Set to 50Hz.
  • F0-10 (Motor Rated Voltage): Set to 380V.
  • F1-00 (DI1 Function): Set to 1 (forward run).
  • F1-01 (DI2 Function): Set to 2 (reverse run).
  • F6-12 (Motor Overload Protection): Set to 150% (adjust based on motor rated current).
  • F7-00 (Communication Address): Set to 1 (if using PLC communication).

4.2 Traverse Motor Inverter (900-0007M3) Parameter Settings

  • F0-00 (Command Source): Set to 1 (terminal control), using DI1 and DI2 to control forward/reverse.
  • F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via PLC.
  • F0-03 (Maximum Frequency): Set to 30Hz (traverse motor speed is lower, adjust based on lead screw ratio).
  • F0-09 (Motor Rated Frequency): Set to 50Hz.
  • F0-10 (Motor Rated Voltage): Set to 380V.
  • F1-00 (DI1 Function): Set to 1 (forward run).
  • F1-01 (DI2 Function): Set to 2 (reverse run).
  • F1-02 (DI3 Function): Set to 5 (free stop), linked with the main winding motor.
  • F6-12 (Motor Overload Protection): Set to 150%.

5. Control Logic Design

5.1 Speed Synchronization Logic

  • The traverse motor’s speed must synchronize with the main winding motor’s speed. Assuming the reel diameter is (D), material thickness is (t), and reel speed is (n) (rpm), the material winding linear speed is:
    [
    v = \pi \cdot D \cdot n
    ]
  • The traverse device’s movement speed (v_{\text{traverse}}) must match (v). Assuming the lead screw pitch is (p) and the traverse motor speed is (n_{\text{traverse}}), then:
    [
    v_{\text{traverse}} = p \cdot n_{\text{traverse}}
    ]
  • Thus, the traverse motor speed should be:
    [
    n_{\text{traverse}} = \frac{\pi \cdot D \cdot n}{p}
    ]
  • The PLC calculates (n_{\text{traverse}}) and outputs the corresponding frequency signal (0-10V) to the traverse inverter’s AI1 terminal.

5.2 Reciprocating Motion Control

  • The traverse device uses left and right limit switches to control reciprocating motion:
  • When the traverse device reaches the left limit, the left limit switch opens, DI1 signal fails, the inverter stops forward rotation, and DI2 triggers reverse rotation.
  • When the traverse device reaches the right limit, the right limit switch opens, DI2 signal fails, the inverter stops reverse rotation, and DI1 triggers forward rotation.

5.3 Tension Control

  • Tension control can be achieved by fine-tuning the main winding motor’s speed. For more precise tension control, a tension sensor can be added, with the PLC collecting tension signals to dynamically adjust the main winding motor’s speed.

6. PLC and HMI Selection and Application

6.1 Necessity of PLC and HMI

  • PLC: Recommended to implement speed synchronization, reciprocating motion control, tension control logic, and communication with the inverter.
  • HMI: Used for parameter setting, monitoring operating status (e.g., speed, tension, fault information), and operational control (start/stop, speed adjustment).

6.2 Model Recommendations

  • PLC: Siemens S7-1200 series (e.g., CPU 1214C DC/DC/DC)
  • Reason: Supports Modbus-RTU communication (compatible with the inverter), has sufficient I/O points (digital and analog), and is cost-effective.
  • Configuration: Includes analog input/output modules (for collecting tension signals and outputting speed reference signals).
  • HMI: Siemens KTP700 Basic (7-inch)
  • Reason: Compatible with S7-1200, supports Modbus communication, user-friendly interface, suitable for industrial environments.

6.3 PLC and Inverter Communication

  • Communication Method: Uses Modbus-RTU protocol (refer to Chapter 6 of the manual).
  • Settings:
  • Main winding inverter communication address (F7-00) set to 1, baud rate (F7-01) set to 19200bps, data format (F7-02) set to 8-E-1.
  • Traverse inverter communication address (F7-00) set to 2, with the same baud rate and data format.
  • PLC Program:
  • Reads the main winding inverter’s speed (register U0-00).
  • Calculates the traverse inverter’s target frequency and writes to register 0x01.
  • Monitors fault status (registers U0-51 to U0-71); if a fault occurs, the system stops.

6.4 HMI Interface Design

  • Main Interface: Displays main winding motor speed, traverse motor speed, material tension, and operating status.
  • Parameter Settings: Sets reel diameter, material thickness, lead screw pitch, maximum speed, etc.
  • Control Buttons: Start, stop, emergency stop, and speed adjustment (via slider).

7. Control Schematic (Text Description)

PLC (S7-1200)
  |-------> RS485 Communication ------> Main Winding Inverter (Address 1)
  |-------> RS485 Communication ------> Traverse Inverter (Address 2)
  |
  |-------> Analog Output -----> Main Winding Inverter AI1 (Speed Reference)
  |-------> Analog Output -----> Traverse Inverter AI1 (Speed Reference)
  |
  |-------> Digital Input -----> Left Limit Switch
  |-------> Digital Input -----> Right Limit Switch
  |
  |-------> Analog Input -----> Tension Sensor

HMI (KTP700)
  |-------> Communicates with PLC for Display and Control

8. Implementation Steps

  1. Installation: Follow Chapter 3 of the manual to install the inverter and motors, ensuring proper ventilation and secure wiring.
  2. Wiring: Connect the power, motors, and control terminals as per the wiring diagrams above.
  3. Parameter Settings: Set the inverter parameters as described in Section 4, and test motor operation.
  4. PLC Programming: Write the speed synchronization and reciprocating motion control logic, and test communication functions.
  5. HMI Configuration: Design the interface and test operational functions.
  6. Commissioning: Start the winding machine, adjust speed and tension parameters, and ensure even traversing.

9. Precautions

  • Safety: Adhere to the safety precautions in Chapter 1 of the manual, ensuring reliable grounding and avoiding misoperation.
  • Motor Parameter Tuning: If using vector control, perform motor parameter auto-tuning (refer to Chapter 4 of the manual).
  • Fault Diagnosis: If overcurrent or overvoltage faults occur, refer to Chapter 7 of the manual for troubleshooting.

Through the above solution, the 900 Series Inverter can be effectively applied to the winding machine’s traverse system, achieving speed synchronization, reciprocating motion, and tension control. For more detailed PLC programming or HMI interface design, please feel free to contact us.

This translation maintains the technical accuracy and structure of the original article, with key points emphasized in bold as requested. Let me know if further adjustments are needed!

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ZTE ZXDU68 Series Integrated Power Supply User Manual Guide

I. Product Overview and System Configuration

1.1 Product Introduction

The ZTE ZXDU68 S601/T601 Series Integrated Power Supply is an intelligent unattended power system designed specifically for communication networks. It adopts a modular design, supports -48V DC output, and can be configured with up to 12 ZXD2400 (V4.0) 50A high-frequency switching rectifiers, achieving a total output current of 600A. The system features comprehensive monitoring capabilities and supports remote management, making it suitable for access networks, remote switching stations, mobile base stations, and other scenarios.

Key Features:

  • High Efficiency and Energy Saving: The rectifiers use active power factor correction (PFC) technology, with an input power factor >0.99 and efficiency >90%.
  • Intelligent Management: The centralized monitoring unit supports “Three Remotes” (remote measurement, remote signaling, remote control) functions, enabling real-time monitoring of voltage, current, temperature, and other parameters.
  • Flexible Expansion: Supports N+1 redundancy backup, and the rectifiers support hot-swappable, plug-and-play functionality.
  • Multiple Protections: Equipped with C-class, D-class, and DC lightning protection modules, and supports battery hierarchical load shedding protection.
ZXDU power panel image

1.2 Model and Configuration

  • Model Differences:
    • ZXDU68 S601: 2-meter-high cabinet, with space below for installing inverters or batteries.
    • ZXDU68 T601: 1.6-meter-high cabinet, with other functions identical to S601.
  • Standard Configuration:
    • AC Distribution: Single 100A input, 2 standby outputs.
    • DC Distribution: 4 primary load shedding circuits, 2 secondary load shedding circuits, 2 battery inputs.
    • Monitoring Unit: 1 set, supporting RS232/RS485 communication interfaces.
    • Rectifiers: 12 ZXD2400 (V4.0) rectifiers.

II. Safety Operation Guidelines

2.1 Safety Warnings

  • High Voltage Danger: Disconnect the power before operation and avoid working on live cables.
  • Anti-Static Measures: Wear an anti-static wrist strap and ground it before contacting circuit boards.
  • Tool Requirements: Use dedicated insulated tools and prohibit the use of non-standard tools.

2.2 Operation Precautions

  1. Installation Environment: The equipment should be placed in a dry, well-ventilated environment with a temperature range of -5℃~45℃.
  2. Wiring Specifications:
    • AC input must comply with three-phase five-wire or single-phase three-wire systems.
    • DC output must strictly distinguish polarity to avoid short circuits.
  3. Maintenance Requirements: Regularly check the status of lightning protectors (window color), the tightness of cable connections, and the cleanliness of the cooling air ducts.

III. System Structure and Working Principle

3.1 System Structure

The ZXDU68 system consists of four core units:

  1. AC Distribution Unit:
    • Function: Mains access, lightning protection, and standby output distribution.
    • Key Components: C-class lightning protector, D-class lightning protection box, AC input circuit breaker.
  2. Rectifier Group:
    • Function: Converts AC to -48V DC, supports hot-swappable.
    • Indicator Lights: Green “IN” indicates normal input, green “OUT” indicates normal output.
  3. DC Distribution Unit:
    • Function: Distributes DC power to loads and batteries, supports primary/secondary load shedding protection.
    • Key Components: Load fuses, battery fuses, DC lightning protection box.
  4. Monitoring Unit:
    • Function: Data acquisition, parameter setting, and alarm management.
    • Core Boards: PSU (Power Management), RSB (Rectifier Signal), SCB (Signal Conversion).

3.2 Working Principle

  • AC Input: Mains power is distributed to rectifiers and standby outputs after lightning protection.
  • Rectification Conversion: Rectifiers convert AC to DC and output it in parallel to the DC distribution.
  • Battery Management: The monitoring unit automatically switches between float and equalization charging modes based on battery status, supporting temperature compensation.
  • Load Protection: When the battery voltage falls below the set threshold, the system performs hierarchical load shedding (primary load shedding and secondary load shedding).
Picture inside ZXDU power cabinet

IV. Monitoring Unit Operation Guide

4.1 Interface and Button Functions

  • Operation Interface:
    • LCD Display: Real-time display of voltage, current, and alarm information.
    • Buttons: ▲/▼ keys to switch menus, Enter key to confirm, Esc key to return.
  • Indicator Lights:
    • PWR (Power), RUN (Running), ALM (Alarm) status lights.

4.2 Main Function Operations

  1. Information Query:
    • Path: Main Menu → 【Information】 → View DC output, battery status, AC input, etc.
    • Supports real-time data, historical alarm records, and discharge record queries.
  2. Parameter Setting:
    • Float Charging Voltage: 53.5V (default), range 42.0V~58.0V.
    • Equalization Charging Cycle: 180 days (default), range 15~365 days.
    • Path: Main Menu → 【Control】 → Enter password (default 0000) → Set float charging voltage, equalization charging cycle, etc.
    • Key Parameters:
  3. Alarm Handling:
    • Real-time alarms are displayed in the 【Alarm】 menu, with audio and visual alerts.
    • Historical alarms can be traced through the 【Records】 menu.

V. Routine Maintenance and Fault Handling

5.1 Routine Maintenance Process

  1. Startup Steps:
    • Disconnect load and battery fuses → Close AC input circuit breaker → Start rectifiers → Close standby output → Restore load.
  2. Shutdown Steps:
    • Disconnect load and battery fuses → Turn off rectifiers → Disconnect AC input.

5.2 Regular Inspection Items

  • Lightning Protectors: Check the window color of C-class lightning protectors (green is normal, red requires replacement).
  • Cooling System: Clean fan and air duct dust to ensure cooling efficiency.
  • Cable Connections: Check input/output terminals for looseness to avoid poor contact.

5.3 Common Fault Handling

Fault TypeHandling Method
AC Power FailureActivate backup oil machine power supply and check mains recovery.
Rectifier FaultReplace the faulty rectifier and ensure N+1 redundancy.
Low Battery VoltageCheck battery capacity settings and initiate equalization charging to repair.
DC Output OvervoltageCheck rectifier output voltage and replace abnormal modules.

VI. Appendix and Technical Support

6.1 Technical Specifications Quick Reference

  • Input Voltage: 80V~300V AC (phase voltage).
  • Output Voltage: -48V DC (range -42V~-58V).
  • Protection Rating: IP20, compliant with YD/T 1058-2000 standard.

Conclusion
The ZTE ZXDU68 Series Integrated Power Supply provides stable power protection for communication networks with its intelligent design and high reliability. Users can maximize equipment efficiency and reduce operational risks by mastering the operation and maintenance points in this guide. It is recommended to participate in regular ZTE official training to obtain deeper technical support.

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Application Scheme of OUke Inverter GD320 in Roller Shutter Equipment

I. Overview

This scheme aims to apply the Ouke inverter GD320 to roller shutter equipment to achieve precise control of the motor. Combining the technical data of the Lingshida inverter and the application requirements of the roller shutter equipment, this scheme details the motor application positions, wiring methods, parameter settings, and PLC control schemes.

Working images of Ouke inverter GD320

II. Motor Application Positions and Functions

In roller shutter equipment, motors are mainly used in the following positions and functions:

  1. Opening/Closing Function:
    • The motor drives the lifting of the shutter to open and close it.
    • Position: The motor is usually installed at one end of the shutter shaft and drives the shaft to rotate through a transmission device.
  2. Limit Function:
    • The motor works with limit switches to ensure that the shutter stops accurately at predetermined positions when opening and closing.
    • Position: Limit switches are installed at the top and bottom of the shutter track.
  3. Safety Protection Function:
    • The motor cooperates with infrared protection devices. When an obstacle is detected, the motor stops or reverses to avoid crushing.
    • Position: Infrared protection devices are installed on both sides or the bottom of the shutter.
  4. Emergency Stop Function:
    • In an emergency, the motor power supply is cut off through an emergency stop button or password switch, causing the shutter to stop immediately.
    • Position: Emergency stop buttons or password switches are installed in easily accessible positions.

III. Wiring Methods

  1. Main Circuit Wiring
    • Power Wiring: Connect the three-phase power supply (L1, L2, L3) to the inverter’s RST terminals.
    • Motor Wiring: Connect the motor’s UVW terminals to the inverter’s UVW terminals.
    • Precautions:
      • Ensure that the power supply and motor phase sequences are consistent to avoid motor reversal.
      • Check if the wire ends are secure after wiring to avoid poor contact.
  2. Control Circuit Wiring
    • Control Signal Wiring:
      • Start/Stop Signal: Connect the start button and stop button to the inverter’s FWD and REV terminals, respectively.
      • Speed Signal: If external speed adjustment is needed, connect a potentiometer or analog signal output from the PLC to the inverter’s AI terminal.
      • Limit Switch Signal: Connect the upper and lower limit switches to the inverter’s LI1 and LI2 terminals, respectively.
    • Precautions:
      • The control circuit should use shielded wires to avoid electromagnetic interference.
      • The control circuit and main circuit should be wired separately to ensure safety.
  3. Grounding Wiring
    • Reliably ground the grounding terminals of the inverter and motor to ensure equipment safety.

IV. Parameter Settings

  1. Basic Parameter Settings
    • Pr000: Password
      • Set to 000 to unlock parameters.
    • Pr001: Operating Frequency Setting
      • Set to 50Hz (adjust according to the motor’s rated frequency).
    • Pr002: Operating Control Mode
      • Set to 1 (terminal command control).
  2. Motor Parameter Settings
    • Pr003: Main Frequency Setting Method
      • Set to 1 (analog input).
    • Pr004: Base Frequency
      • Set to 50Hz (consistent with the motor’s rated frequency).
    • Pr005: Maximum Output Voltage
      • Set to 380V (adjust according to the motor’s rated voltage).
  3. Acceleration/Deceleration Time Settings
    • Pr006: Acceleration Time 1
      • Set to 10s (adjust according to actual needs).
    • Pr007: Deceleration Time 1
      • Set to 10s (adjust according to actual needs).
  4. Limit Switch Settings
    • Pr008: Upper Limit Frequency
      • Set to 50Hz (consistent with the motor’s rated frequency).
    • Pr009: Lower Limit Frequency
      • Set to 0Hz.
    • Pr010: Electronic Thermal Relay Action Selection
      • Set to 1 (electronic thermal relay action).
  5. PID Control Settings (if needed)
    • Pr011: PID Setpoint
      • Set according to actual needs.
    • Pr012: PID Feedback Value
      • Set according to actual needs.
    • Pr013: PID Proportional Gain
      • Adjust according to actual needs.
    • Pr014: PID Integral Time
      • Adjust according to actual needs.
    • Pr015: PID Derivative Time
      • Adjust according to actual needs.

V. PLC Control Scheme

  1. PLC Selection
    • Choose a PLC with analog and digital outputs, such as Siemens S7-200 SMART.
  2. PLC and Inverter Wiring
    • Analog Output: Connect the PLC’s analog output module to the inverter’s AI terminal to adjust motor speed.
    • Digital Output: Connect the PLC’s digital output module to the inverter’s FWD, REV, LI1, LI2, and other terminals to control motor start, stop, and limits.
  3. PLC Programming
    • Manual Control Program:
      • Control motor start, stop, and forward/reverse rotation through buttons.
      • Program example (ladder diagram):复制代码| I0.0 (Start Button) |---|---|---| Q0.0 (Inverter FWD)| I0.1 (Stop Button) |---|---|---| Q0.1 (Inverter REV)
    • Automatic Control Program:
      • Detect obstacles through sensors or infrared protection devices and control motor stop or reverse.
      • Program example (ladder diagram):复制代码| I0.2 (Infrared Sensor) |---|---|---| Q0.2 (Inverter LI1)| I0.3 (Lower Limit Switch)|---|---|---| Q0.3 (Inverter LI2)
  4. Communication Settings (if needed)
    • If more complex control functions are required, communication between the PLC and inverter can be achieved through the RS-485 interface.
    • Set the inverter’s communication parameters, such as baud rate, data bits, stop bits, etc., to ensure consistency with the PLC.

VI. Conclusion

This scheme details the application of the Ouke inverter GD320 in roller shutter equipment, including motor application positions, wiring methods, parameter settings, and PLC control schemes. Through reasonable wiring and parameter settings, precise control of roller shutter equipment can be achieved, improving equipment stability and safety. If further customization or optimization of the scheme is needed, adjustments can be made based on actual equipment requirements.

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User Manual Guide for Lingshida Inverter LSD-C7000 Series

Introduction

As a high-performance vector inverter, the Lingshida LSD-C7000 series is widely used in industrial drive applications. This guide aims to provide users with an in-depth understanding of the inverter’s operation panel functions, parameter settings, external control, and troubleshooting, ensuring efficient and safe operation of the equipment.

I. Operation Panel Functions and Key Parameter Settings

1.1 Introduction to Operation Panel Functions

The LSD-C7000 series inverter’s operation panel integrates a variety of function keys and status indicators, including:

  • Function Keys: RUN (run), STOP (stop), JOG (jog), PU/EXT (operation mode switch), SET (confirm), MODE (mode selection), etc.
  • Status Indicators: RUN (green, running status), STOP (red, stop status), F/R (forward/reverse indication), ALARM (fault alarm), etc.
  • Display Screen: Real-time display of set frequency, output current, voltage, power, speed, and other key parameters.
LSD-C7200

1.2 Factory Reset of Parameters

When needing to reset the inverter parameters, follow these steps:

  1. Enter programming mode: Press the MODE key to select parameter setting mode (usually displayed as “Pr” or “P”).
  2. Set the reset parameter: Enter Pr001=11111 (specific reset code) via the numeric keys.
  3. Confirm execution: Press the SET key to confirm, and the inverter will automatically restart and restore all parameters to their factory defaults.

1.3 Password Setting and Access Restrictions

  • Password Setting:
    • Set a 4-digit password (range: 0-65535) via parameter Pr800.
    • After setting, accessing protected parameters (such as Pr001-Pr800) requires entering the password.
  • Password Elimination: Set Pr800 to 0 to remove password protection.
  • Access Restrictions: By setting Pr800 to an odd or even number, access permissions for different parameters can be controlled hierarchically.

II. External Terminal Control and Speed Regulation Configuration

2.1 Forward/Reverse Control Wiring and Parameter Settings

  • Wiring Method:
    • Connect external switch or relay contacts to the inverter control terminals S1 (forward) and S2 (reverse) respectively.
    • Ensure that the control circuit uses shielded wires to avoid electromagnetic interference.
  • Parameter Settings:
    • Pr006=1: Select terminal control mode.
    • Pr301=1 (forward function), Pr302=2 (reverse function): Assign terminal control logic.

2.2 Potentiometer Speed Regulation Wiring and Parameter Settings

  • Wiring Method:
    • Connect the potentiometer output terminal to the inverter’s analog input terminal FV, and connect it to GND.
    • It is recommended to use a 10kΩ linear potentiometer to obtain smooth speed regulation.
  • Parameter Settings:
    • Pr004=1: Select analog input as the frequency command source.
    • Pr203=100% (gain), Pr204=0% (offset): Calibrate the potentiometer output range.

III. Fault Code Analysis and Solutions

3.1 Common Fault Codes and Their Meanings

Fault CodeFault NamePossible Causes
Uv1UndervoltageInput voltage is below 70% of rated value
OCOvercurrentMotor overload, short circuit, or parameter setting error
OL1Motor OverloadProlonged overload operation
SPInput Phase LossPower supply phase loss or loose wiring
SPOOutput Phase LossMotor winding damage or poor contact

3.2 Fault Handling Procedures

  1. Uv1/SP Handling:
    • Check if the power supply voltage is within the rated range (e.g., 380V±15%).
    • Ensure that the terminal connections are secure to avoid poor contact.
  2. OC/OL1 Handling:
    • Reduce the load or adjust the acceleration time parameter (e.g., Pr005).
    • Check the motor insulation to rule out winding short circuits.
  3. SPO Handling:
    • Test the motor winding resistance and repair open or short circuits.
    • Check the inverter output contactor contacts to ensure reliable conduction.
LSD-C7000 standard wiring diagram

IV. Comprehensive Usage Suggestions

4.1 Regular Maintenance Items

  • Clean the Heat Sink: Clean the heat sink dust quarterly to prevent overheating.
  • Parameter Backup: Regularly back up parameter settings via the operation panel or dedicated software.
  • Capacitor Inspection: Test the DC bus capacitor capacity every two years, and replace it if it is below 80%.

4.2 Safe Operation Practices

  • Grounding Protection: Ensure reliable grounding of the inverter and motor, with a grounding resistance ≤4Ω.
  • Prohibited Operations: Do not disconnect the control cable during operation to avoid signal interference causing misoperation.
  • Environmental Adaptation: Avoid prolonged operation in environments with humidity >90% or temperature >45℃.

Through this guide, users can fully grasp the core operation and troubleshooting skills of the LSD-C7000 series inverter. It is recommended to combine the actual working conditions of the equipment and refer to the electrical schematic diagram in the manual for in-depth debugging to fully utilize the equipment’s performance. For complex faults, contact Lingshida’s technical support team promptly for professional guidance.

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ABB PSTX Series Soft Starter User Guide

The ABB PSTX series soft starter is an advanced device in the field of industrial motor control, integrating intelligent operation and multiple control functions. This guide will provide a detailed introduction to the functions of the operation panel (HMI), parameter initialization, parameter copying, password setting and removal, external terminal start mode, bypass control, wiring methods, key parameters, and the meanings and solutions of fault codes based on user needs, helping users fully master the usage skills of the PSTX.

I. Detailed Explanation of Operation Panel (HMI) Functions

The PSTX soft starter is equipped with an intuitive human-machine interface (HMI), which enables device status monitoring, parameter setting, and fault diagnosis through the display screen and buttons. Below are the specific functions of the operation panel:

1. Display Screen

  • Real-time Data Display: Displays the motor’s operating status, including parameters such as current, voltage, and power factor.
  • Fault Prompt: Displays fault codes and brief descriptions for quick diagnosis.
  • Menu Navigation: Displays multi-level menus, allowing users to browse setting options.

2. Button Functions

  • Navigation Keys (Up, Down, Left, Right): Used to move the cursor in the menu or adjust parameter values.
  • Confirm Key (Enter): Confirms selections or saves settings.
  • Return Key (Esc): Exits the current menu or cancels operations.
  • Reset Key (Reset): Clears fault status or restarts the device.
  • Start/Stop Key (some models): Directly controls the motor’s start and stop (in local mode).

3. Operation Methods

  • Enter the Main Menu: Press the “Menu” key (or long-press the navigation key, depending on the model).
  • Navigate to the Desired Function: Use the up and down keys to select modules such as “Basic Settings”, “Protection Settings”, or “Diagnostic Information”.
  • Modify Parameters: After selecting a parameter, press the “Enter” key to enter the editing mode. Use the navigation keys to adjust the value and press “Enter” again to save.
    For detailed operation instructions of the HMI, refer to Chapter 6 “Human-Machine Interface” in the manual. It is recommended that users familiarize themselves with the button layout to improve operation efficiency.

II. Parameter Initialization

Parameter initialization is used to restore the PSTX soft starter to its factory default settings, which is applicable for debugging or resetting after a fault. The operation steps are as follows:

  1. Enter the HMI main menu and select “System Settings”.
  2. Navigate to “Reset to Factory Defaults”.
  3. Press the “Enter” key to confirm, and the screen will prompt “Confirm reset?”.
  4. Press the “Enter” key again, and the device will reset all parameters and restart.
    Note: Initialization will clear all user settings. It is recommended to back up the parameters first (see “Parameter Copying” below).
PSTX Manual ABB Soft Starter Standard Wiring Diagram

III. Copying Parameters to Another Device

The PSTX supports copying parameters from one soft starter to another device, facilitating batch configuration. There are two methods:

1. Copying via HMI

  • Backup Parameters:
    • Enter the “System Settings” menu and select “Parameter Backup”.
    • Press the “Enter” key to save the current parameters to the internal memory.
  • Restore Parameters:
    • On the target device, enter the “System Settings” menu and select “Parameter Restore”.
    • Press the “Enter” key to load the backup parameters and restart the device after completion.

2. Copying via PSTX Configurator Software

  • Export Parameters:
    • Connect the soft starter to the computer using a USB or communication interface.
    • Open the PSTX Configurator software and read the device parameters.
    • Select “Export” and save as a parameter file (.prm format).
  • Import Parameters:
    • Connect the target device and open the software.
    • Select “Import”, load the parameter file, and write it to the device.

IV. Password Setting and Removal

The PSTX provides a password protection function to prevent unauthorized parameter modifications.

1. Set Password

  • Enter “System Settings” → “User Access”.
  • Select “Set Password”.
  • Enter a 4-digit password (e.g., “1234”) and press “Enter” to confirm.
  • Enter the same password again for verification. The password will take effect after successful saving.

2. Remove Password

  • Enter the “User Access” menu and select “Disable Password”.
  • Enter the current password and press “Enter” to confirm.
  • After the password is cleared, the device will return to an unprotected state.
    Tip: If the password is forgotten, contact ABB technical support to reset it using administrator privileges.
PSTX is working

V. External Terminal Start Mode

The PSTX supports controlling the motor’s start and stop through external terminals, which is suitable for PLC or manual switch control.

1. Wiring

  • Start Terminal (Start): Connect to the “Start” pin of the control terminal block (usually marked as “1”).
  • Stop Terminal (Stop): Connect to the “Stop” pin (usually marked as “2”).
  • Common Terminal (COM): Connect to the common terminal of the control power supply.

2. Configuration

  • Enter the “Control Settings” menu in the HMI.
  • Set the “Control Mode” to “External Terminal”.
  • Save the settings and exit.

3. Operation

  • Close the switch between the “Start” terminal and “COM”, and the motor will start.
  • Close the switch between the “Stop” terminal and “COM”, and the motor will stop.

VI. Bypass Control Implementation

Bypass control connects the power supply directly through a bypass contactor after the motor reaches full speed, bypassing the soft starter to reduce energy consumption.

1. Wiring

  • Bypass Contactor: Connect to the bypass output terminals of the soft starter (marked as “Bypass” or “BP”).
  • Main Circuit: Connect the main contacts of the bypass contactor in parallel between the input (L1, L2, L3) and output (T1, T2, T3) of the soft starter.

2. Configuration

  • Enter the “Function Settings” menu in the HMI.
  • Enable “Bypass Mode”.
  • Set the “Bypass Delay”, usually 0.5-2 seconds, to ensure the motor is at full speed before switching.

3. Working Principle

  • When starting, the soft starter controls the motor’s acceleration.
  • After reaching full speed, the PSTX outputs a signal to close the bypass contactor, and the motor is directly powered by the power supply.

VII. Wiring Methods

1. Main Circuit Wiring

The main circuit connects the power supply and the motor. The schematic diagram is as follows (based on Chapter 4 of the manual):

复制代码Power Input       Soft Starter       MotorL1 ----+------[ L1  T1 ]------+---- M1L2 ----+------[ L2  T2 ]------+---- M2L3 ----+------[ L3  T3 ]------+---- M3       |                       |       +--------[ PE ]---------+---- GND
  • L1, L2, L3: Three-phase power input.
  • T1, T2, T3: Motor output.
  • PE: Grounding terminal.

2. Control Circuit Wiring

The control circuit is used for signal input and output. The schematic diagram is as follows:

复制代码Control Power       Soft Starter Control Terminals+24V ----+----[ COM ]           |----[ Start ]----[ Switch ]         |----[ Stop  ]----[ Switch ]         |----[ Fault ]----[ Alarm ]GND -----+----[ GND  ]
  • Start/Stop: Connect to external switches or PLCs.
  • Fault: Fault signal output, used for external indication.
    Note: Refer to Chapter 4 of the manual for wiring photos to ensure accuracy.

VIII. Important Parameter Settings

The following are the key parameters of the PSTX and their functions:

Parameter NameFunctionRecommended Value
Start TimeControls the motor’s acceleration time2-20 seconds
Current LimitLimits the start current multiple2-4 times the rated current
Overload ProtectionSets the overload threshold1.1-1.5 times the rated current
Stop TimeControls the deceleration stop time5-30 seconds
Bypass DelayTime to switch to bypass after full speed0.5-2 seconds

Setting Method: Enter the “Basic Settings” menu, adjust each parameter item by item, and save.

IX. Fault Codes and Solutions

The PSTX prompts problems through fault codes. The following are common codes and their solutions:

Fault CodeMeaningSolution
F001Motor OverloadCheck if the load exceeds the limit and adjust the overload protection parameters
F002Soft Starter OverheatingClean the fan and improve ventilation conditions
F003Power Phase Sequence ErrorCheck the wiring order of L1, L2, L3
F004Output Short CircuitCheck the motor and wiring to eliminate the short circuit point
F005Communication FaultCheck the communication cable and settings

Troubleshooting Steps:

  1. Record the fault code and refer to Chapter 11 of the manual.
  2. Check the wiring, load, or cooling based on the prompt.
  3. After repair, press the “Reset” key to clear the fault.

X. Summary

Through this guide, users can fully master the operation panel functions, parameter management, control mode settings, wiring methods, key parameter configuration, and fault handling techniques of the ABB PSTX series soft starter. It is recommended to use this guide in conjunction with the manual (document number: 1SFC132081M2001) to ensure the safe and efficient operation of the device.

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Application Solution of VACON 100 HVAC Inverter in Chemical Metering Pumps

I. Application Scenario and Function Analysis

The main functions of chemical metering pumps include:

  • Precise Flow Control: Achieve quantitative delivery of chemicals by adjusting the pump’s rotational speed.
  • Start/Stop Control: Ensure smooth start and stop of the pump to avoid pressure surges.
  • Pressure/Flow Feedback Regulation: Adjust the pump speed in real-time based on sensor feedback.
  • Fault Protection: Automatic shutdown in case of overload, over-temperature, under-load, etc.
  • Remote Monitoring and Operation: Realize automated operation through fieldbus or external controllers.

The VACON 100 HVAC inverter is suitable for these requirements. It supports multiple control methods (digital input, analog input, fieldbus), has built-in HVAC application macros, fault diagnosis functions, and rich parameter settings, which can well meet the control requirements of chemical metering pumps.

Specific Functional Positions in the Application

  • Main Drive Motor: Drives the metering pump and controls its rotational speed to regulate the flow rate.
  • Auxiliary Motor (if any): Used for the cooling system or stirring device (depending on the process requirements).
    The following design focuses on a single main drive motor. If an auxiliary motor is required, it can be expanded according to similar logic.
Working site of the metering pump

II. Hardware Selection

  1. Motor Selection
    • Type: Three-phase asynchronous motor (commonly used in metering pumps). The power is selected according to the pump’s load requirements, such as 0.75 kW or 1.5 kW.
    • Voltage: Match the inverter’s power supply voltage, such as 380 – 480 V (common industrial standard).
    • Protection Level: The chemical environment may be corrosive, so it is recommended to choose a motor with an IP55 or higher protection level.
  2. Inverter Selection
    • Model: VACON 100 HVAC. The rated current should be greater than the motor’s full-load current (e.g., for a 1.5 kW motor with a current of about 3.5 A, choose a model with a rated current ≥ 4 A).
    • Power Supply: 380 – 480 V three-phase AC (refer to Section 7.1.2 of the installation manual).
  3. External Devices
    • PLC: Select Siemens S7 – 1200 (such as 1214C) for logic control and data processing.
    • Touch Screen: Siemens HMI TP700 Comfort for parameter setting and running status display.
    • Sensors:
      • Flow Sensor: Outputs a 4 – 20 mA analog signal for flow feedback.
      • Pressure Sensor: Outputs a 4 – 20 mA analog signal for pressure monitoring.
    • Relay: 24 V DC for controlling the start/stop signals.

III. Wiring Scheme

Refer to Section 7.2.1 of the installation manual and relevant sections of the application manual for information on the control terminals of the VACON 100 HVAC inverter. The following is the wiring design for the chemical metering pump:

  1. Power and Motor Wiring
    • Power Input: Connect to the L1, L2, L3 terminals of the inverter (three-phase 380 V).
    • Motor Output: Connect to the U, V, W terminals of the inverter and then to the three-phase motor.
    • Grounding: Connect the PE terminal of the inverter to the grounding terminal of the motor to ensure grounding complies with the EN61800 – 5 – 1 standard (refer to Section 1.3 of the installation manual).
  2. Control Terminal Wiring
    Refer to the technical information of the standard I/O board in Section 7.2.1 of the installation manual:
TerminalFunctionWiring Description
1+10V Reference VoltageNot used
2AI1+ (Analog Input 1)Connect to the flow sensor (positive pole of 4 – 20 mA output)
3AI1- (Analog Input 1 Ground)Connect to the flow sensor (negative pole of 4 – 20 mA output)
4AI2+ (Analog Input 2)Connect to the pressure sensor (positive pole of 4 – 20 mA output)
5AI2- (Analog Input 2 Ground)Connect to the pressure sensor (negative pole of 4 – 20 mA output)
624V Auxiliary VoltageSupply power to relays or sensors (if needed)
7GNDControl signal ground
8DI1 (Digital Input 1)Connect to the PLC output (start signal)
9DI2 (Digital Input 2)Connect to the PLC output (stop signal)
10DI3 (Digital Input 3)Connect to the external emergency stop button (normally closed contact)
11CM (Common Terminal A)Common ground for DI1 – DI3
1224V Auxiliary VoltageNot used
13GNDNot used
18AO1+ (Analog Output 1)Connect to the PLC input (output frequency feedback, 0 – 10 V)
19AO1- (Analog Output Ground)Common ground for analog output
ARS485 AConnect to the RS485 A terminal of the PLC
BRS485 BConnect to the RS485 B terminal of the PLC

Wiring Diagram (Text Description)

  • Power Input:
    • L1 —- [Inverter L1]
    • L2 —- [Inverter L2]
    • L3 —- [Inverter L3]
  • Motor Output:
    • [Inverter U] —- [Motor U]
    • [Inverter V] —- [Motor V]
    • [Inverter W] —- [Motor W]
  • Grounding:
    • [Inverter PE] —- [Motor PE] —- [Grounding Wire]
  • Control Signals:
    • [PLC DO1] —- [DI1] (Start)
    • [PLC DO2] —- [DI2] (Stop)
    • [Emergency Stop Button] —- [DI3]
    • [Flow Sensor +] —- [AI1+]
    • [Flow Sensor -] —- [AI1-]
    • [Pressure Sensor +] —- [AI2+]
    • [Pressure Sensor -] —- [AI2-]
    • [AO1+] —- [PLC AI1] (Frequency Feedback)
    • [AO1-] —- [GND]
    • [A] —- [PLC RS485 A]
    • [B] —- [PLC RS485 B]

IV. Parameter Setting

The following parameter settings are based on the application manual and the requirements of the chemical metering pump. Use the start-up wizard and HVAC application macro of the VACON 100 for configuration.

  1. Start-up Wizard Settings (Refer to Page 4 of the Application Manual)
    • Language: Select Chinese.
    • Time: Set the current time (e.g., 14:30:00).
    • Date: Set the current date (e.g., 15.10.2023).
    • Application Macro: Select the HVAC application macro.
  2. Key Parameter Settings
Parameter NumberParameter NameSetting ValueDescription
P1.1Minimum Frequency10 HzEnsure the minimum running speed of the pump
P1.2Maximum Frequency50 HzMatch the rated frequency of the motor (typical value)
P3.1.1Motor Rated Voltage380 VSet according to the motor nameplate
P3.1.2Motor Rated Current3.5 ASet according to the motor nameplate
P3.3.1Control Mode1 (Frequency Control)Use frequency control mode
P3.5.1.1DI1 Function1 (Start)DI1 controls start
P3.5.1.2DI2 Function2 (Stop)DI2 controls stop
P3.5.1.3DI3 Function6 (External Fault)DI3 is used for emergency stop
P3.6.1AI1 Signal Range1 (4 – 20 mA)Flow sensor input
P3.6.2AI2 Signal Range1 (4 – 20 mA)Pressure sensor input
P3.7.1AO1 Function1 (Output Frequency)Output frequency feedback to the PLC
P3.14.1Overcurrent ProtectionEnabledProtect the motor and pump
P3.14.2Overload ProtectionEnabledPrevent motor overload
  1. PID Control Settings (Flow Regulation)
    • P3.9.1: Enable PID Control = 1
    • P3.9.2: Setpoint Source = 0 (Fixed value, input from the touch screen)
    • P3.9.3: Feedback Value Source = AI1 (Flow Sensor)
    • P3.9.4: Proportional Gain = 2.0 (Adjust according to actual debugging)
    • P3.9.5: Integral Time = 1.0 s (Adjust according to actual debugging)

V. Control System Design

  1. System Architecture
    • PLC: Responsible for logic control, sensor signal processing, and communication with the inverter.
    • Touch Screen: Display running status (rotational speed, flow rate, pressure) and set the target flow rate.
    • Inverter: Execute motor rotational speed control, receive PLC instructions, and sensor feedback.
    • Sensors: Provide real-time flow rate and pressure data.
  2. Control Logic
    • Start/Stop:
      • The PLC controls the inverter’s start/stop through DI1/DI2.
      • The emergency stop button triggers DI3, and the inverter stops immediately.
    • Flow Regulation:
      • The touch screen inputs the target flow rate value, and the PLC transmits it to the inverter via RS485.
      • The inverter adjusts the motor rotational speed through PID regulation based on the feedback from AI1 (flow sensor).
    • Pressure Monitoring:
      • AI2 (pressure sensor) monitors the pipeline pressure. If it exceeds the set range (e.g., > 5 bar), the PLC issues a stop command.
    • Fault Handling:
      • When the inverter detects a fault (e.g., overcurrent, fault code 1), it notifies the PLC via RS485, and the touch screen displays the fault information.

Control Schematic Diagram (Text Description)

  • [Touch Screen] —- [RS485] —- [PLC]
    • | |
    • | |—- [DO1] —- [DI1] (Start)
    • | |—- [DO2] —- [DI2] (Stop)
    • | |—- [AI1] —- [AO1] (Frequency Feedback)
    • | |—- [RS485] —- [Inverter A/B]
  • [Flow Sensor] —- [AI1+/-]
  • [Pressure Sensor] —- [AI2+/-]
  • [Emergency Stop Button] —- [DI3]
  • [Inverter U/V/W] —- [Motor]
Vacon inverter in field use

VI. Implementation Steps

  1. Installation and Wiring:
    • Connect the power supply, motor, and control signals according to the wiring scheme.
    • Ensure reliable grounding to avoid electromagnetic interference.
  2. Parameter Configuration:
    • Initialize using the start-up wizard on the inverter panel.
    • Input the above parameters and save the settings.
  3. PLC and Touch Screen Programming:
    • Write the start/stop logic and PID control program for the PLC.
    • Design the touch screen interface, including flow rate setting, running status, and fault alarms.
  4. Debugging:
    • Manually test the start/stop functions.
    • Adjust the PID parameters to ensure stable flow rate.
    • Simulate faults to verify the protection functions.
  5. Operation and Optimization:
    • After long-term operation, fine-tune the parameters according to the actual working conditions.

VII. Precautions

  • Safety: Do not touch the internal circuits of the inverter after it is powered on (refer to Section 1.2 of the installation manual).
  • EMC: The chemical environment may have interference, so adjust the EMC jumpers (refer to Section 6.3 of the installation manual).
  • Support: If you encounter any problems, you can contact us.

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Diagnosis and Resolution of “Free Stop” Fault in ENC EDH2200 High-Voltage Inverter: Impact of S1# Function Configuration

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.

Emergency stop state

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.
Control circuit inside the high-voltage inverter cabinet

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.
EDH2200 terminal board

Table: Fault Causes and Solutions

Fault PhenomenonPossible CauseSolution
Free stop, unable to startS1# function (lift given) mis-triggerChange P05.00 to “0: No function”
S3# displays self-generated accidentChain reaction from S1# abnormal signalClear alarm after resolving S1# issue
System displays POFF stateProtection mechanism triggers power-offRestart system after clearing alarm
External device signal abnormalityLoose wiring or device faultCheck 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.

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Analysis and Solutions for Fan Overheating Fault in ENC EDH2200 High-Voltage Inverter

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.

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.

The alarm for fan overheating

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.

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.

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.
EDH2200

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.