Industrial control technology

Posted on 2025年4月3日2025年4月3日 by baiyuzhan — Leave a comment

Understanding and Resolving FAULT 3181 in ABB ACH580 Series Inverters

The ABB ACH580 series inverters are specifically designed for HVAC (Heating, Ventilation, and Air Conditioning) systems, renowned for their high efficiency, energy savings, and reliable operation. However, in practical applications, the FAULT 3181 error code may appear, affecting the normal operation of the system. This article will provide a detailed analysis of the nature of FAULT 3181, its generation mechanisms, on-site inspection steps, and specific repair strategies.

What is FAULT 3181?

In the ABB ACH580 series inverters, FAULT 3181 is typically associated with wiring or grounding faults in the main circuit. This fault code indicates that the inverter has detected electrical issues in the power input or motor output circuit, triggering its protection mechanism. According to the technical documentation, FAULT 3181 usually points to abnormal electrical connections in the main circuit, such as loose wiring, short circuits, or improper grounding. This fault is designed to prevent equipment damage or safety hazards and requires timely diagnosis and handling.

Generation Mechanisms of FAULT 3181

The occurrence of FAULT 3181 may involve the following mechanisms:

Loose or Poor Wiring Connections
If the power or control wires in the main circuit are not securely connected, it may lead to voltage fluctuations or signal interruptions. The inverter detects these anomalies and triggers fault protection.
Short Circuits
Short circuits in the main circuit, such as those caused by damaged cable insulation or incorrect wiring, may result in overcurrent. The ACH580 has built-in overcurrent protection, and it will immediately shut down and display FAULT 3181 when abnormal current is detected.
Grounding Issues
Grounding faults are a common cause of FAULT 3181. Poor grounding connections or the presence of grounding loops may lead to leakage currents or electrical noise, triggering the protection mechanism.
Cable Damage
Physical damage (such as cut or worn cables) may expose conductors, leading to short circuits or accidental grounding. This is particularly common in long-term operation or harsh environments.
Incorrect Parameter Configuration
Improper inverter parameter settings (such as mismatched motor ratings) may exacerbate electrical issues, ultimately manifesting as FAULT 3181.

On-Site Inspection Steps

To accurately diagnose FAULT 3181, it is recommended to follow these on-site inspection steps:

Safety Preparation
Disconnect the inverter power supply and implement the Lockout-Tagout (LOTO) procedure. Use a multimeter to confirm that the equipment is completely de-energized.
Visual Inspection
Inspect the power and control wires and grounding connections in the main circuit for signs of looseness, corrosion, or physical damage.
Check the inverter casing for dust, moisture, or other environmental factors that may affect electrical performance.
Electrical Testing
Use a multimeter to measure the voltage at the input terminals to ensure it falls within the rated range. Check for phase imbalance or phase loss.
Perform insulation resistance testing on the cables to detect short circuits or grounding faults.
Test the grounding resistance to ensure it meets electrical specifications.
Grounding Verification
Check that the grounding wires are securely connected without breaks or looseness. Use a grounding tester to confirm the integrity of the grounding path.
Parameter and Log Review
Access the inverter’s fault logs via the control panel or ABB Drive Composer tool to check for other related error codes.
Verify that key parameters match the actual application and ensure correct configuration.
Environmental Assessment
Check the environmental conditions at the installation location, such as temperature, humidity, and vibration levels, to ensure compliance with operational requirements.

Specific Repair Strategies

Based on the inspection results, the following repair measures can be taken:

Tighten Connections
If loose wiring is found, tighten the terminals according to the manufacturer’s recommended torque values to ensure good contact.
Replace Damaged Cables
If the cables have physical damage or insulation failure, replace them with new cables that meet the specifications.
Repair Grounding Issues
If grounding is poor, clean the grounding contact points and reconnect them to ensure the grounding resistance meets standards.
Address Short Circuits
If a short circuit is found, use a multimeter to trace the fault point and repair or replace the damaged components.
Adjust Parameters
If parameter configuration is incorrect, refer to the ACH580 manual to adjust the settings or restore factory defaults and reconfigure.
Reset and Test
After repairs, reset the inverter and conduct a trial run to observe whether the fault is cleared.
Preventive Measures
Develop a regular maintenance plan to check wiring and grounding conditions and clean dust inside the equipment.
Train operators to ensure proper installation and maintenance.

If the above steps do not resolve the issue, it may indicate a more serious internal fault in the inverter. In such cases, it is recommended to contact ABB technical support for professional repair or component replacement.

Conclusion

FAULT 3181 is a common error in ABB ACH580 series inverters related to wiring or grounding faults in the main circuit. Through systematic on-site inspections, including visual observation, electrical testing, and parameter review, the root cause of the problem can be accurately identified. Repair strategies include tightening connections, replacing components, optimizing grounding, and adjusting parameters. Regular maintenance and correct installation are key to preventing such faults. If the issue is complex, ABB’s technical support will provide further assistance to ensure the normal operation of the ACH580, safeguarding the stability and efficiency of the HVAC system.

Posted on 2025年4月3日2025年4月3日 by baiyuzhan — Leave a comment

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:

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.
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.
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.
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.
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:

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.
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.
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.

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.
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:

Regular Inspections
Check motor, encoder, and power supply wiring quarterly to ensure there is no looseness or aging.
Parameter Management
Regularly back up parameter settings and monitor current waveforms during operation to ensure they are within normal ranges.
Environmental Optimization
Keep the control cabinet clean and dry, install ventilation or dehumidification equipment to prevent overheating and moisture accumulation.
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.

Posted on 2025年3月28日2025年3月28日 by baiyuzhan — Leave a comment

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:

Enter the HMI main menu and select “System Settings”.
Navigate to “Reset to Factory Defaults”.
Press the “Enter” key to confirm, and the screen will prompt “Confirm reset?”.
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.

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 Name	Function	Recommended Value
Start Time	Controls the motor’s acceleration time	2-20 seconds
Current Limit	Limits the start current multiple	2-4 times the rated current
Overload Protection	Sets the overload threshold	1.1-1.5 times the rated current
Stop Time	Controls the deceleration stop time	5-30 seconds
Bypass Delay	Time to switch to bypass after full speed	0.5-2 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 Code	Meaning	Solution
F001	Motor Overload	Check if the load exceeds the limit and adjust the overload protection parameters
F002	Soft Starter Overheating	Clean the fan and improve ventilation conditions
F003	Power Phase Sequence Error	Check the wiring order of L1, L2, L3
F004	Output Short Circuit	Check the motor and wiring to eliminate the short circuit point
F005	Communication Fault	Check the communication cable and settings

Troubleshooting Steps:

Record the fault code and refer to Chapter 11 of the manual.
Check the wiring, load, or cooling based on the prompt.
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.

Posted on 2025年3月26日2025年3月26日 by baiyuzhan — Leave a comment

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.

II. Hardware Selection

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.
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).
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:

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).
Control Terminal Wiring
Refer to the technical information of the standard I/O board in Section 7.2.1 of the installation manual:

Terminal	Function	Wiring Description
1	+10V Reference Voltage	Not used
2	AI1+ (Analog Input 1)	Connect to the flow sensor (positive pole of 4 – 20 mA output)
3	AI1- (Analog Input 1 Ground)	Connect to the flow sensor (negative pole of 4 – 20 mA output)
4	AI2+ (Analog Input 2)	Connect to the pressure sensor (positive pole of 4 – 20 mA output)
5	AI2- (Analog Input 2 Ground)	Connect to the pressure sensor (negative pole of 4 – 20 mA output)
6	24V Auxiliary Voltage	Supply power to relays or sensors (if needed)
7	GND	Control signal ground
8	DI1 (Digital Input 1)	Connect to the PLC output (start signal)
9	DI2 (Digital Input 2)	Connect to the PLC output (stop signal)
10	DI3 (Digital Input 3)	Connect to the external emergency stop button (normally closed contact)
11	CM (Common Terminal A)	Common ground for DI1 – DI3
12	24V Auxiliary Voltage	Not used
13	GND	Not used
18	AO1+ (Analog Output 1)	Connect to the PLC input (output frequency feedback, 0 – 10 V)
19	AO1- (Analog Output Ground)	Common ground for analog output
A	RS485 A	Connect to the RS485 A terminal of the PLC
B	RS485 B	Connect 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.

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.
Key Parameter Settings

Parameter Number	Parameter Name	Setting Value	Description
P1.1	Minimum Frequency	10 Hz	Ensure the minimum running speed of the pump
P1.2	Maximum Frequency	50 Hz	Match the rated frequency of the motor (typical value)
P3.1.1	Motor Rated Voltage	380 V	Set according to the motor nameplate
P3.1.2	Motor Rated Current	3.5 A	Set according to the motor nameplate
P3.3.1	Control Mode	1 (Frequency Control)	Use frequency control mode
P3.5.1.1	DI1 Function	1 (Start)	DI1 controls start
P3.5.1.2	DI2 Function	2 (Stop)	DI2 controls stop
P3.5.1.3	DI3 Function	6 (External Fault)	DI3 is used for emergency stop
P3.6.1	AI1 Signal Range	1 (4 – 20 mA)	Flow sensor input
P3.6.2	AI2 Signal Range	1 (4 – 20 mA)	Pressure sensor input
P3.7.1	AO1 Function	1 (Output Frequency)	Output frequency feedback to the PLC
P3.14.1	Overcurrent Protection	Enabled	Protect the motor and pump
P3.14.2	Overload Protection	Enabled	Prevent motor overload

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

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.
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]

VI. Implementation Steps

Installation and Wiring:
- Connect the power supply, motor, and control signals according to the wiring scheme.
- Ensure reliable grounding to avoid electromagnetic interference.
Parameter Configuration:
- Initialize using the start-up wizard on the inverter panel.
- Input the above parameters and save the settings.
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.
Debugging:
- Manually test the start/stop functions.
- Adjust the PID parameters to ensure stable flow rate.
- Simulate faults to verify the protection functions.
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.

Posted on 2025年3月24日2025年3月26日 by baiyuzhan — Leave a comment

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.

Fault Cause Analysis

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

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.
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#).
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.
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

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.”
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.
System Recovery
- Press the “start” button, and the inverter successfully restarts with operational parameters returning to normal (voltage, current, frequency, etc., no longer 0).

Summary of Solutions

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

Unexpected Findings

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

Table: Fault Causes and Solutions

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

Conclusion

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

Posted on 2025年3月24日2025年3月25日 by baiyuzhan — Leave a comment

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.

Possible Causes

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.
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.
Ventilation Blockage
- Dust, debris, or internal accumulations block ventilation ports, impeding airflow.
- Preventive Measure: Regularly clean the ventilation system.
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.
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

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).
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.
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.
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.
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.

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.

Posted on 2025年3月24日2025年3月24日 by baiyuzhan — Leave a comment

SHZHD.V680 Variable Frequency Drive E-06 Fault Analysis and Solutions

1. Fault Overview

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

2. Fault Cause Analysis

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

3. Solutions

3.1 Adjust Over-Excitation Gain

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

3.2 Optimize Deceleration Time Settings

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

3.3 Check Load Characteristics

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

3.4 Check Motor and Drive Compatibility

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

4. Precautions

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

5. Conclusion

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

Posted on 2025年3月24日2025年3月24日 by baiyuzhan — Leave a comment

In-Depth Analysis and Practical Guide to Horizontal Line Faults in Fuji Inverter G1S Series

As a key device in the field of industrial control, Fuji Inverter G1S series indicates fault states through different forms of horizontal lines on its operation panel. Based on extensive field cases and technical data, this article provides a comprehensive analysis of horizontal line faults (including the middle horizontal line “—-” and the upper and lower horizontal lines) and offers actionable diagnostic procedures and solutions.

I. Fault Patterns and Core Implications

1. Middle Horizontal Line “—-” Fault

Display Feature: The LED monitor displays four consecutive horizontal lines.
Core Implication:

PID Control Conflict: When J01=0 (PID control is not enabled), if the E43 parameter is forcibly set to display PID parameters, the system will return invalid data.
Communication Link Anomaly: Poor connection between the operation panel and the inverter body, such as damage to the shield layer of the extension cable or oxidation of the cable.

2. Lower Horizontal Line “_ _ _ _” Fault

Display Feature: The motor stops after the command is triggered, and the panel displays an underscore.
Core Implication:

Insufficient DC Bus Voltage: The measured voltage is below DC400V (for 400V models), often caused by non-compliant input power specifications or excessive line voltage drop.
Missing Main Power Supply: The control power is on, but the main power circuit breaker is not closed.
Power Configuration Conflict: When H72=1, an abnormal main power supply is detected, such as DC power supply incorrectly connected to the AC input terminal.

II. Standardized Diagnostic Procedures

Step 1: Quick Status Confirmation

Power Supply Check:
- Main Power Supply: Measure the voltage between L1-L2-L3 to confirm compliance with the inverter specifications (e.g., 400V ±10%).
- Control Power Supply: Check the stability of the 24V auxiliary power supply to avoid OC3 alarms caused by fan shorts.
Panel Operation Verification:
- Perform a reset operation (long press the RST key) to observe if the fault can be cleared.
- Read the communication error counter through parameter viewing mode (e.g., d001-d005).

Step 2: Layered Fault Location

Fault Layer	Inspection Item	Technical Details
Communication Layer	Extension Cable	Use a megohmmeter to measure the cable insulation resistance >10MΩ and check the continuity of the shield layer.
Power Layer	DC Bus	Measure the P(+)-N(-) voltage during startup and compare it with the value displayed on the operation panel (error should be <5%).
Control Layer	Parameter Configuration	Focus on checking critical parameters such as J01 (PID control) and H72 (main power detection).

Step 3: In-Depth Hardware Inspection

Main Circuit Check:
- Disconnect the main power supply and measure the resistance of the rectifier bridge and IGBT module to check for short circuits.
- Check the connection status of the braking resistor to avoid OU1/OU2 overvoltage alarms.
Control Board Check:
- Use an oscilloscope to monitor the PWM output waveform of the mainboard to confirm the integrity of the drive signal.
- Perform a “hot swap” test on suspected faulty boards to locate the specific damaged component.

III. Practical Cases of Typical Faults

Case 1: Lower Horizontal Line Fault in a Plastic Extruder

Fault Phenomenon: The motor does not respond after the start command, and the panel displays a lower horizontal line.
Diagnostic Process:

Measure the main power supply voltage at 380V (standard 400V), confirming excessive voltage drop.
Check the DC bus voltage at 360V (standard ≥400V), locating insufficient voltage.
Find an incorrect transformer tap setting, resulting in low input voltage.
Solution:

Adjust the transformer tap setting to the 400V output position.
Install an APFC device to improve power quality.

Case 2: Middle Horizontal Line Fault in a CNC Machine

Fault Phenomenon: The panel displays “—-” after parameter modification.
Diagnostic Process:

Find that E43 is mistakenly set to PID feedback value, while J01=0.
Check the panel extension cable and find that the shield layer is worn at the cable tray.
Solution:

Change E43 to frequency display mode.
Replace the shield cable and optimize the cable routing path.

IV. Preventive Maintenance Strategies

Periodic Inspection Plan:
- Daily: Visually inspect the panel display status and record the operating environment temperature and humidity.
- Monthly: Measure the main power supply voltage, DC bus voltage, and calibrate PID control parameters.
- Quarterly: Perform a main power supply power-off restart test and check the contacto r suction status.
Spare Parts Management Optimization:
- Establish a lifespan model for critical spare parts (e.g., IGBT modules, DC capacitors).
- Sign an emergency supply agreement with suppliers to ensure a 48-hour response.
Technology Upgrade Path:
- Regularly upgrade firmware versions to utilize new algorithms for optimizing fault detection mechanisms.
- Consider an overall upgrade to the G1S-P series for aging equipment (>5 years).

V. Technical Development Trends

With the development of industrial IoT technology, Fuji Inverter G1S series now supports remote monitoring and predictive maintenance functions. By integrating edge computing nodes, the following can be achieved:

Real-time Fault Feature Extraction: Utilize AI algorithms to analyze waveform data and identify potential faults in advance.
Cloud Expert Diagnosis: Upload fault data to the cloud platform for expert system solutions.
Digital Twin Applications: Build a virtual model of the equipment to simulate fault scenarios and practice response drills.

Conclusion

Handling horizontal line faults in Fuji Inverter G1S series requires engineers to possess a solid knowledge of power electronics and a systematic diagnostic mindset. The standardized procedures and practical cases provided in this article enable users to quickly locate more than 80% of common faults. For complex issues, it is recommended to combine official technical documentation and dedicated diagnostic tools for in-depth analysis. Continuous technical training and knowledge updating are the keys to improving fault handling efficiency.

Posted on 2025年3月21日2025年3月22日 by baiyuzhan — Leave a comment

In-Depth Analysis of Alarms 1080 (Trace Data Save) in Siemens SINAMICS S120 Drives

1. Introduction

In modern industrial automation, Siemens SINAMICS S120 drives are widely employed across various applications such as CNC machine tools, textile machinery, printing presses, papermaking equipment, robotics, and other sectors demanding high dynamic performance and precision. SINAMICS S120 offers a modular design, advanced control capabilities, and a robust diagnostic system. When an abnormal condition occurs or when the drive simply wishes to notify the user of a particular state, it displays corresponding alarm or fault codes on the Basic Operator Panel (BOP), in the STARTER/TIA Portal software, or on an external HMI (Human-Machine Interface).

Among the many potential fault and alarm messages, Alarms 1080—often accompanied by the text “comp trace data save”—commonly appears in actual usage. Some engineers or first-time users of S120 may misinterpret this alarm as a sign of major damage or serious malfunction. However, Alarms 1080 is typically an information-level or process-level alert, indicating that the drive is saving trace (data logging) information. It is neither a hardware breakdown nor a critical fault demanding immediate shutdown. Understanding and properly handling this alarm is important for maintaining the stability of the drive system and prolonging equipment life. This article will thoroughly explain Alarms 1080’s background, implications, and recommended actions.

2. Definition and Background of Alarms 1080

2.1 Overview of the Trace Function

Siemens SINAMICS S120 includes a built-in Trace (data logging or “oscilloscope”) feature. This function records specified operating parameters or signals (e.g., current, speed, position feedback, torque commands) within the drive’s memory. When the Trace function is enabled—either manually by the user in the engineering software (STARTER or TIA Portal) or triggered automatically by certain system conditions—these signals are sampled at set intervals or in response to defined triggers. The sampled data is then stored in the drive’s internal memory or on a connected storage card (such as a CF card).

Once the sampling cycle or trigger condition is completed, the drive writes or finalizes the captured data. During this process, the drive issues a notification to indicate that it is actively saving data. This valuable dataset can later be analyzed to optimize control parameters or diagnose intermittent or complex errors.

2.2 What Alarms 1080 Signifies

When you see Alarms 1080 with a description along the lines of “comp trace data save” or “Trace data is being saved,” it specifically indicates that the drive is performing the data save operation for an active Trace task.

This message does not imply hardware damage or a system crash.
It is typically a “system event” or “user-level” notification that does not disrupt the drive’s primary function.

2.3 How It Differs from Fault Codes

Unlike “Fault” codes (e.g., F07802, F30003) prefixed with “F,” which usually shut down or block the drive until reset, an alarm such as Alarms 1080 does not force the drive into a faulted or disabled state. Serious faults typically demand manual acknowledgment or system logic to reset them; meanwhile, Alarms 1080 is more akin to an informational prompt. Once data saving completes and no other higher-level issues exist, the system will clear or deactivate the alarm automatically.

3. Common Causes and Scenarios

In practice, Alarms 1080 (“comp trace data save”) most often arises from these scenarios:

Manually Enabled Trace During Commissioning
In many cases, an engineer sets up a Trace task in STARTER, TIA Portal, or directly on the panel to diagnose specific motor or drive behavior. For example, if you want to observe speed-loop responses or current-waveform patterns, you configure sampling frequency, trigger conditions, and the signals to track. As soon as the sampling finishes, the drive writes the data to storage, resulting in Alarms 1080.
Automatic Background Trace
Some drive configurations automatically initiate the Trace function for advanced monitoring or “fault logging.” When the system detects certain threshold conditions or a fault event, the drive begins collecting data. Once the event is captured, it proceeds to save it, displaying Alarms 1080 in the process.
Leftover Trace Settings
In some projects, the Trace function was used at one point but never deactivated. Even after the main commissioning is done, the drive may still be periodically recording data and subsequently saving it, inadvertently causing recurring Alarms 1080 messages. Though typically benign, these messages might raise questions among less-experienced personnel.

4. Impact on System Operation

Because Alarms 1080 is an informational or process-level alert, it does not necessarily prevent normal drive operation or motor control, as long as there are no simultaneous major fault codes. However, keep in mind the following:

Do Not Interrupt Power During Saving
If the drive is in the middle of saving Trace data and power is lost or intentionally shut off, it may lead to incomplete data or, in rare cases, corruption of the storage medium. In general, it is best to avoid powering down the drive while Alarms 1080 is active unless absolutely necessary.
Resource Consumption
The Trace function may consume a portion of the drive’s internal resources, including CPU and memory. Although typically minimal, high sampling rates combined with large data sets can create significant overhead. If the user no longer needs Trace data, disabling it can free up resources.
Parallel Occurrences with Faults
If a severe drive fault (e.g., F07802 “Infeed Not Ready”) appears alongside Alarms 1080, the fault should take priority for troubleshooting. Alarms 1080 in that case merely indicates that trace data related to the fault was captured or saved, but it is not the cause of the fault itself.

5. Handling and Disabling Methods

When you see Alarms 1080 on the drive, and you confirm that a Trace save is in progress, you can use the following approaches to manage or eliminate it:

Wait for the Save to Complete
Typically, the drive only needs a short interval—ranging from a few seconds to maybe a minute—for large data sets—to store the captured Trace data. The alarm will then disappear on its own once the operation finishes.
Deactivate or Remove Trace Tasks
If data logging is no longer required, you can open the Trace or Recording screen in STARTER or TIA Portal, locate any active Trace configurations, and disable or delete them.
- Certain drive operator panels (like BOP20) may also allow you to view or halt ongoing Trace recordings if the firmware supports it.
Check Storage Space and Write Permissions
Occasionally, if the alarm persists, the storage medium (internal memory or CF card) might be full, write-protected, or otherwise inaccessible. Ensure you have enough free space or switch to a larger-capacity CF card if needed.
Reset Alarms If Needed
Usually, purely informational alarms clear automatically without requiring a reset. However, if Alarms 1080 coincides with an actual Fault, you may need to perform a fault reset (via the panel or a higher-level controller) after addressing the underlying issue.

6. Common Questions and Answers

Q1: “Does the presence of Alarms 1080 mean the drive is damaged?”
A1: Not at all. Alarms 1080 almost always indicates that the drive is recording or saving Trace data, not that any component has malfunctioned. If no additional serious alarms or faults are active, the system can continue operating normally.

Q2: “Will repeatedly seeing Alarms 1080 negatively affect the system?”
A2: In most cases, no. It simply appears whenever trace-saving occurs. Unless you are sampling enormous volumes of data at high frequencies, system performance typically remains unaffected. If you do not need the Trace feature, consider disabling it to keep messages streamlined.

Q3: “How do I check Trace configurations or the storage location?”
A3: Within STARTER or TIA Portal, navigate to the corresponding drive object, and look for “Trace” or “Recording” in the function tree. There, you can view and edit active tracing tasks. On certain operator panels, you might find a Diagnostics → Trace Logs menu that shows ongoing traces and storage status.

Q4: “What else can the Trace function be used for?”
A4: Beyond fault diagnosis, the Trace feature is invaluable for capturing transient oscillations, optimizing control loops (like speed-loop gains or filter time constants), and logging multiple signals simultaneously. It helps improve control accuracy and pinpoint root causes of sporadic or short-lived anomalies.

7. Case Study

Consider a textile production line where an engineer needs to diagnose oscillations in the S120 drive. By enabling two Trace channels (one for current loop, one for speed loop) at a high sampling rate, the system collected large volumes of data. While saving these data sets, “Alarms 1080: comp trace data save” appeared repeatedly on the drive’s screen. Initially, on-site maintenance personnel feared a serious error; however, it quickly became clear that the drive was simply finalizing the recording.

Once the trace was stored, Alarms 1080 cleared by itself. Analyzing the newly captured data, the engineer discovered a PID tuning issue. By fine-tuning the relevant parameters, they significantly reduced mechanical vibration. This real-world experience illustrates how Alarms 1080 is part of a normal diagnostic workflow and can be harnessed for performance improvements rather than being an indication of a critical failure.

8. Conclusion

In summary, Alarms 1080 (“comp trace data save”) in the Siemens SINAMICS S120 drive primarily indicates the system is saving Trace data—a process-level or informational message rather than a hardware or software malfunction. Proper use of the Trace function can substantially enhance commissioning and fault diagnosis, making it possible to observe internal drive states and parameter changes in great detail. If you do not need data logging, you can disable or remove the trace configuration to prevent recurrent alarms.

If a severe fault (e.g., an “Fxxxx” code) accompanies Alarms 1080, prioritize investigating the fault itself. Ensure power and wiring integrity, confirm that no IGBT or module fault exists, and only then determine whether to proceed with or discontinue trace logging. But in the absence of critical errors, Alarms 1080 simply signals that the drive is working as intended to capture and save valuable diagnostic data.

By correctly recognizing Alarms 1080 and using it appropriately, maintenance and commissioning personnel can leverage the drive’s powerful built-in diagnostic capabilities without undue worry. This alarm can assist with targeted data capture, enabling users to optimize performance and quickly resolve intermittent failures. We hope this article clarifies the nature of Alarms 1080 in SINAMICS S120 and helps you confidently manage and benefit from its Trace functionality in real-world industrial scenarios.

Posted on 2025年3月20日2025年3月20日 by baiyuzhan — Leave a comment

Application Scheme of HLP-C100 Inverter for Desiccant Packaging Machine

I. Overall Concept

Application Points and Functions
In a desiccant packaging machine, there are often multiple drive motors, such as a feeding motor, a sealing motor, a blower/fan motor, a conveyor motor, and so on. If you are focusing on the “desiccant-blowing” or “air-blowing” process, you can apply the HLP-C100 inverter in the following situations:
- Blower/Fan Motor: By using the inverter to control air volume or blowing speed, you can flexibly adjust airflow according to packaging speed or desiccant characteristics.
- Conveying/Feeding Motor (if necessary): You can achieve more precise control of the speed at which desiccant moves, preventing blockage or spillage.
- Other Auxiliary Mechanisms (e.g., stirring, lifting, rotating, etc.): Based on your needs, you can also equip these with an inverter to implement multi-step speed or jog functionalities.
Control Method Selection
- To allow flexible speed adjustment, operators may directly set the speed on the inverter’s front panel using the built-in knob (local control mode), or use an external analog signal (0–10V/4–20mA from a PLC or industrial PC) as a remote speed reference.
- If the machine requires centralized automation control (e.g., unified operation from an HMI, production line linkage, recipe management), you can add a small PLC (e.g., Hailipu’s PLC, Mitsubishi FX series, Xinje, Delta, etc.) and an HMI (touch panel) to manage start/stop commands, frequency references, alarm display, and more.

Below, we address main circuit wiring, control circuit wiring, parameter settings, and how to select/connect a PLC/HMI.

II. Main Circuit Wiring

Motor-to-Inverter Connection
- Inverter Output Terminals: U, V, W → Connect to the three-phase terminals of the blower/fan motor (if you have a single-phase motor, this will not be suitable unless you use a model that supports single-phase output).
- Inverter Input Terminals: R, S, T → Connect to the three-phase AC supply (for single-phase 220 V models, connect to R and T).
- Ground Terminal PE: Must be reliably grounded to prevent leakage, interference, and induced voltages.
Refer to the “3.3 Main Circuit Wiring Diagram” in the manual.
For smaller motor power ratings (e.g., 0.75 kW to 1.5 kW), the HLP-C100 series is usually sufficient. Ensure that the motor’s rated power, voltage, and current match the inverter’s specifications, leaving some margin.
Peripheral Protection and Input-Side Components
- Circuit Breaker (Air Switch): Selected based on the inverter’s rated input current (see “3.2.1 Air Switch, Fuse, Contactor Selection” in the manual) to cut power promptly under overcurrent or other serious faults.
- AC Contactor (optional): Avoid using it too frequently for starting/stopping the inverter. Typically, it’s only used for maintenance or emergency power-off situations.
- Input Reactor/EMI Filter (optional): If the site has harmonic issues or other sensitive equipment, consider adding an input reactor or EMI filter on the supply side to reduce higher-order harmonics and electromagnetic interference.
Brake Unit and Brake Resistor (optional)
For a “blower” load, inertia is usually not large, and fast, frequent deceleration is rarely required, so you typically do not need an external brake unit/resistor. But if this inverter is used with higher-inertia loads or requires rapid stops (such as certain conveying or feeding mechanisms), you may consider using the built-in or external brake unit plus an appropriately sized brake resistor.
Main Circuit Diagram (Text Example) Power R ——┐ │ Power S ——┤—— [Circuit Breaker] —— [HLP-C100 Inverter] —— U —— Motor (UVW) │ V Power T ——┘ W Inverter PE ———— Ground (Earth) (The above example shows a three-phase 380 V connection; for single-phase, omit S and connect R/T to the live/neutral wires.)

III. Control Circuit Wiring

Control circuit wiring determines how the inverter receives start/stop, direction, and frequency commands, and how it outputs fault and run signals. If you need to use a PLC or external buttons for control, refer to the following.

Digital Inputs (DI)
- The HLP-C100 provides five digital input terminals (FOR, REV, DI1, DI2, DI3) configured as NPN by default (see “3.4 Control Circuit Wiring” in the manual).
- Typically, FOR is set as the “forward run” command, REV as “reverse run” (if necessary), and the remaining DI1, DI2, DI3 can be set up for multi-step speed selection, emergency stop, reset, jog, etc.
- For a blower needing only forward run and stop, you can place an external “START” button (normally open) and a “STOP” button (normally closed) to the respective terminals. For example:
  - FOR = Start (via a normally open button + 24 V power; pressing it gives a high-level signal to the inverter)
  - DI1 = Stop (via a normally closed button + 24 V; pressing it breaks the circuit, giving a low-level signal to stop)
  - Or you can assign “start-stop in one” to FOR (reverse logic).
Analog Input (VI)
- If you want to adjust blower speed remotely using an external analog signal (0–10 V / 4–20 mA from a PLC or sensor), wire the signal to VI and GND on the inverter.
- In the parameters (e.g., C03.15, etc.), select “Reference Source 1 = VI,” and calibrate the range in C06.10~C06.19 to match your actual voltage or current signal.
Relay Output (FA-FB-FC)
- If you want a dry contact output from the inverter to indicate a fault or run status, set parameter C05.40 (Relay Output Function) to 9 (Fault), 5 (Running), etc. Then a PLC or external indicator can monitor the inverter state.
Control Circuit Diagram (Text Example) [+24V] —— Start Button (NO) ——> FOR terminal on inverter —— Stop Button (NC) ——> DI1 terminal on inverter GND ---------------------------------> Inverter GND Analog: PLC AO(0-10V) ——> VI PLC AGND ——> GND Relay Output: FA-FB-FC (FB is common, FA is NC, FC is NO) (If you are only using the inverter’s keypad for start/stop and knob for speed, you can omit the digital inputs or just keep a dedicated emergency stop.)

IV. Key Parameter Settings (Example)

Suppose the motor is 0.75 kW, rated voltage 380 V, rated frequency 50 Hz, rated current 1.8 A (example). You want to control start/stop with external FOR and DI1, and 0–10 V analog for speed. Below are key configuration points (see the manual’s “Chapter 5–7: Function Parameter Table” and “Quick Application Guide” for details):

Motor Parameters (Group 01)
- C01.20 = Motor Power = 0.75 (kW)
- C01.22 = Motor Rated Voltage = 380 (V)
- C01.23 = Motor Rated Frequency = 50.0 (Hz)
- C01.24 = Motor Rated Current = 1.80 (A)
- C01.25 = Motor Rated Speed = 1440 (rpm) (example)
Operating Mode
- C01.00 = 0 (Open-loop speed)
Reference Frequency and Acc/Dec (Group 03)
- C03.03 = 50.00 (Max Reference; set to 50 if you want up to 50 Hz, or higher if you want 60 Hz, etc.)
- C03.15 = 1 (Reference Source 1 = “Terminal VI”)
- C03.41 / C03.42 = 5.0 s / 5.0 s (Acceleration/Deceleration time; adjust as needed for the blower’s inertia)
Start/Stop & Direction Control (Group 05)
- C05.10 (FOR Input Function) = 8 (“Start”)
- C05.12 (DI1 Input Function) = 6 (“Stop, inverse logic”) or 46 (“Stop, normal logic”)
- If reverse is not required, set C04.10 (Motor Run Direction) to 0 to allow only forward operation, preventing accidental reverse.
Analog Input (Group 06)
- C06.19 = 0 (Indicates VI is a voltage input)
- C06.10 = 0.00, C06.11 = 10.00 (0–10 V corresponds to 0–50 Hz)
- If you need a zero deadband, set C06.18 accordingly; if the input fluctuates too much, increase C06.16 (filter time), etc.
Protections and Warnings
- C04.58 = 0 (Motor phase-loss detection; set to 1 if you need it)
- C14.01 = 5 (Carrier frequency, typically 4–6 kHz is fine; lower it if there’s high EMI)
- Other defaults (overcurrent, overvoltage, overheat, external faults, etc.) already provide complete protection but can be tuned further if required.
Other Common Functions
- Multi-step Speed: Use DI1, DI2, DI3 in combination to set up multi-speed operation (e.g., fast, slow, jog).
- PID Control: If you want to control blower pressure or airflow precisely, set C01.00=3 (Process Closed Loop) and configure the PID parameters in Group 07 along with a feedback sensor signal on VI.
- Jog: Use C03.11 for jog frequency, and assign a DI (e.g., FOR or DIx) to “jog function.”

V. Using a PLC / Touch Screen / Industrial PC (If Needed)

PLC Selection
- For simpler requirements (start/stop, speed reference, minimal I/O), choose a low-end PLC (e.g., Hailipu, Delta, Xinje, Mitsubishi FX1S/FX3U, etc.).
- For more comprehensive linkage (e.g., multi-station synchronization, multi-step speeds, fault interlocks), select a mid-range PLC with sufficient I/O.
- Communication: The HLP-C100 features RS485 (Modbus RTU). If your PLC has RS485, you can connect them directly with twisted-pair wiring. Through PLC registers, you can read/write the inverter’s operating status, fault info, frequency commands, etc.
Touch Screen / HMI / Industrial PC
- If you need HMI operation, you can choose a 7” or 10” screen (e.g., Weintek, Kinco, Hailipu HMI) integrated with the PLC. Alternatively, the HMI can connect directly to the inverter over Modbus RTU.
- In the HMI configuration software, set the inverter station address, baud rate, and parity (matching C08.31, C08.32, C08.33) for reading and writing the inverter’s registers. This allows remote start/stop, speed setting, alarm monitoring, parameter/recipe management, etc.
- The same applies to an industrial PC, which can connect via serial RS485 or via a USB/RS232-to-RS485 converter.
Wiring and Precautions
- RS485 Interface: Inverter terminals RS+ and RS- correspond to the PLC’s D+ and D-. Make sure to include the 120 Ω termination resistor if required (move jumper J1 on the inverter to ON or add an external resistor).
- For multiple inverters on one bus, assign distinct addresses (C08.31) and ensure the same baud rate (C08.32) and data format (C08.33).

VI. Wiring and Control Diagram Examples (Dashed-Line Version)

Below is an example for a three-phase 380 V supply, with external push-button start/stop and analog speed control:

              Three-phase AC380V
       R ——┐
       S ——┤—— [Circuit Breaker] ——> [HLP-C100 Inverter] ——> U ——> Blower Motor
       T ——┘                                         V
                                                   W
            PE ————————————> Protective Ground


Digital Control:
   +24V (From PLC or external supply) —— Start Button (NO) ——> FOR (inverter)
                                      —— Stop Button (NC) ——> DI1 (inverter)
   Inverter GND —————————————————————> +24V Supply GND

Analog Signal:
   PLC AO(0–10V) ——> VI (inverter)
   PLC AGND       ——> GND (inverter)

Relay Output (optional):
   FA-FB-FC (FB is common; FA normally closed, FC normally open)
   ——> PLC input or alarm indicator

RS485 Communication (optional):
   PLC D+ ——> RS+  (inverter)
   PLC D- ——> RS-  (inverter)
   Common: PLC COM ——> COM (inverter)

If you only wish to use the inverter’s built-in keypad for start/stop and speed adjustment, there is no need for external push buttons—just ensure C00.40 (HAND Key), C00.42 (AUTO Key) are enabled (default). For speed reference, set C03.15=21 (panel potentiometer).

VII. Conclusion

Advantages of This Scheme:
- You can flexibly adjust the blower motor speed (frequency) as required by the desiccant packaging process.
- Via external push buttons or PLC/HMI, you can seamlessly switch between automatic and manual control, improving efficiency and convenience.
- The inverter includes robust built-in protection features to safeguard both the motor and itself.
Optional and Extended Features:
- If your machine requires multi-station linkage or advanced remote monitoring, choose a more capable PLC/HMI and leverage RS485 (Modbus RTU) for centralized control.
- If harmonic interference is severe, add an input reactor or EMI filter.
- For rapid braking or high-inertia loads, you can configure a brake unit and suitable brake resistor.
- If the ambient temperature exceeds 40 °C, derate the inverter or use enhanced cooling to ensure reliable operation.

By following the principles of correct model selection, standardized wiring, and proper parameter configuration, you can fully harness the speed-regulating advantages of the HLP-C100, thereby enhancing the performance and stability of your desiccant packaging machine.