Category: Industrial control technology

Debugging, application, and maintenance techniques for industrial control products，Such as Variable speed driver(VSD),Variable frequency driver(VFD),Industrial touch screen,Programmable Logic Controller(PLC),Servo Driver,servo motor,servo amplifier,Servo Controller,etc.

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In-depth Analysis of ABB ACS510 Inverter Alarm 2015 PFC Interlock Fault and Solutions

1. Introduction

In modern industrial automation systems, the inverter (VFD) plays a crucial role in controlling speed, constant pressure water supply, fan control, and other applications. However, during actual operation, inverters often encounter various types of alarms that affect system stability and operational efficiency. Among these alarms, Alarm 2015 – PFC Interlock Fault, is a common issue in ABB ACS510 inverters, especially in applications where PFC control functionality (pump-fan control) is used.

This article will conduct an in-depth analysis of the root causes of Alarm 2015 in ABB ACS510 inverters, explain the working principle of PFC interlock functionality, and provide practical troubleshooting steps. By combining inverter control logic, parameter configurations, and field wiring, we will explore effective solutions to this alarm issue. This article aims to help readers thoroughly understand the mechanisms behind PFC interlock faults and how to address them, ensuring stable operation of the inverter system.

Alarm 2015 - PFC Interlock

2. Overview of Alarm 2015 PFC Interlock Fault

1. Meaning and Trigger Conditions of Alarm 2015

Alarm 2015 is a typical alarm code in ABB ACS510 inverters, indicating a PFC Interlock fault. When the system detects that the interlock condition is not satisfied, the inverter will stop the motor and display Alarm 2015 on the control panel. This alarm code is primarily used in multi-pump constant pressure water supply systems and other similar applications, ensuring that the switching order and status of motors are properly controlled to prevent system conflicts or equipment damage.

The triggering conditions for PFC interlock alarms are usually as follows:

  • Abnormal Interlock Input Signals: When the interlock signals received by the inverter (via digital inputs such as DI4, DI5, DI6, etc.) do not meet the expected conditions, the inverter considers a conflict or fault and triggers Alarm 2015.
  • Motor Status Conflicts: If one pump is running and the inverter attempts to start another pump without releasing the interlock condition, the alarm will be triggered.
  • Incomplete Equipment Switching: During automatic switching, if relevant devices (such as the bypass contactor, auxiliary relays, etc.) do not properly disconnect, the interlock signal will not reset, causing the inverter to detect an inconsistency and generate the alarm.

Alarm 2015 indicates that the inverter has not correctly recognized or executed the interlock logic, and it typically involves issues with wiring, parameter configuration, or the status of the equipment.

2. Overview of PFC Control Function

The PFC (Pump Fan Control) function is a commonly used control mode in ABB inverters for applications such as constant pressure water supply. It adjusts the operating frequency of the pumps and switches between variable frequency and fixed frequency operation to achieve automatic switching and load balancing between multiple pumps. In order to ensure the safe and stable operation of the system, the PFC function typically relies on interlock mechanisms to ensure that the switching of the inverter and the fixed frequency power supply, as well as the start and stop status of the pumps, are coordinated.

In systems using PFC control, the inverter monitors the operating status of multiple pumps and uses digital inputs (DI) and relay outputs (RO) to determine when to start or switch motors and adjust the system’s operational status in real-time. If any of these signals are abnormal or the equipment status does not match, the inverter will generate Alarm 2015.

The core purpose of the PFC interlock function is to prevent two pumps from running simultaneously under inappropriate conditions, avoiding equipment damage or energy loss. Its proper operation depends on correct wiring, reasonable parameter configuration, and the integrity of the equipment.

3. Root Cause Analysis of Alarm 2015 Triggering

1. Wiring Issues in the Control Circuit

According to ABB inverter design logic, Alarm 2015 is typically triggered by abnormal interlock input signals (DI4, DI5, DI6, etc.). Improper wiring or equipment failures can lead to the loss or incorrect reception of these signals, causing Alarm 2015 to be triggered. Common wiring issues include:

  • Incorrect Wiring of Contact Auxiliary Contacts: The PFC control function depends on the auxiliary contacts (normally closed contacts) of the contactors to monitor the motor’s operational status. If the wrong type of contact (normally open) is used, or if the auxiliary contacts of the contactors do not reset properly, this can result in abnormal DI input signals and trigger the alarm.
  • Failure to Correctly Feed Back Digital Input Signals: DI4, DI5, and other digital input signals should be connected through normally closed auxiliary contacts of contactors and thermal relay contacts. If these contacts are omitted or not securely connected, it may result in the loss of interlock signals and trigger Alarm 2015.

2. Unstable Relay Output Signals

The PFC control function in ABB ACS510 inverters relies on relay outputs (RO1, RO2, RO3, etc.) to control the starting and stopping of motors. If the relay output signals are unstable or configured incorrectly, Alarm 2015 can be triggered. Common issues with relay outputs include:

  • Conflicting Relay Output Signals: In some system designs, RO1 and RO2 may be used to control the start and stop of two pumps. If these two relay outputs conflict and prevent the pumps from switching in the expected order, Alarm 2015 will be triggered.
  • Relay Contact Failure: If the normally open or normally closed contacts of a relay are damaged due to wear or malfunction, they may fail to operate properly, causing the interlock circuit to remain open or closed, triggering the alarm.

3. Parameter Configuration Issues

Alarm 2015 can also be caused by issues in the inverter’s parameter configuration. Below are some possible parameter-related problems that may lead to the alarm:

  • Incorrect Configuration of Interlock Parameters: In PFC control, parameters 8120 (INTERLOCKS) and 8121 (REG BYPASS CTRL) control the startup and switching of interlock logic. If these parameters are configured incorrectly, the inverter may not correctly recognize interlock signals, triggering Alarm 2015.
  • Unreasonable Automatic Switching Interval: If the automatic switching interval (parameter 8118) is set too short or too long, the system may become unstable during switching, triggering the alarm. The switching interval should be adjusted according to the actual load and system requirements.

4. Equipment Status Conflicts

If there is a fault with a pump or it does not stop as expected, Alarm 2015 can also be triggered. Common equipment status conflicts include:

  • Pump Not Stopping: If a pump that is running has not completely stopped, or if the bypass contactor has not disconnected, the inverter will not be able to start a new pump, triggering Alarm 2015.
  • Equipment Fault: If a pump experiences an overload or fault, the inverter will detect this and automatically stop, displaying Alarm 2015.
ACS510 PFC Macro External Terminal Wiring Diagram

4. Solutions to Alarm 2015

1. Check Wiring and Hardware

First, check the wiring in the control circuit to ensure that all auxiliary contacts, thermal relay contacts, and contactor contacts are connected correctly to the appropriate DI input terminals. The common wiring checks are as follows:

  • Check DI4 and DI5 Wiring: Ensure that DI4 (variable-speed pump interlock) and DI5 (auxiliary pump interlock) are connected in series with the normally closed auxiliary contacts of the bypass contactor and thermal relay contacts, ensuring that DI is “ON” when the pumps are not running.
  • Check Relay Output Signals: Check whether the relay output contacts (RO1, RO2, RO3) are functioning correctly and whether they can start and stop the pumps according to the actual load status.

2. Adjust Parameter Configuration

Next, check the relevant parameter settings in the inverter, particularly the following key parameters:

  • Check Parameter 8120 (INTERLOCKS): Ensure that this parameter is set to an appropriate value, typically 4, meaning that the interlock signals are distributed from DI4.
  • Check Parameter 8121 (REG BYPASS CTRL): This parameter controls the bypass function for the variable-speed pump. Ensure it is set to match the field requirements. If bypass control is not needed, set this parameter to 0.
  • Check Parameter 8118 (Automatic Switching Interval): Adjust the automatic switching interval according to the system’s load requirements to avoid frequent or prolonged switching that could cause instability.

3. Eliminate Equipment Faults

If the wiring and parameter configuration are correct, check the equipment status. The following methods can be used to check:

  • Check the Status of the Pump: Ensure that the pumps are completely stopped before switching, and that the bypass contactor has been disconnected.
  • Check for Pump Overload Protection: Ensure that the pump is not overloaded or faulty. If necessary, inspect and maintain the motors to eliminate faults that could trigger Alarm 2015.

4. Perform Simulation Tests

Perform manual tests to simulate different operating conditions and observe whether the inverter responds correctly without triggering an alarm. For example, manually control the input signals of DI4, DI5, and DI6 to see if the inverter starts the motors correctly and switches them without triggering Alarm 2015.

5. Conclusion

ABB ACS510 Inverter Alarm 2015 (PFC Interlock Fault) is a common fault in multi-pump constant pressure water supply systems. Through an analysis of Alarm 2015, we identified that the root cause is usually related to abnormal interlock signals, wiring issues, relay output conflicts, incorrect parameter configurations, or equipment faults. The solutions to this problem include checking control circuit wiring, adjusting parameter settings, eliminating equipment faults, and performing simulation tests.

By performing proper troubleshooting and making the necessary adjustments, Alarm 2015 can be effectively eliminated, ensuring the stable operation of the system. In future applications, operators should regularly check the control circuit, maintain the equipment, and ensure that the inverter operates stably to avoid recurring alarms.

I hope this article provides valuable assistance to ABB inverter users, helping them understand the causes of PFC interlock faults and how to address them.

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User Manual Guide for KRC9 Series Inverter (Koreachuan)

I. Detailed Explanation of Operation Panel Functions

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

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

2. Password Management

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

3. Parameter Access Permissions

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

4. Factory Parameter Management

  • Restore Factory Settings: Set PP-01 to 1 to reset parameters to factory defaults.
  • Backup/Restore Parameters: Set PP-01 to 4 to backup parameters, or to 501 to restore from backup.
KRC9 front image

II. External Control Setup Guide

1. External Terminal Forward/Reverse Control

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

2. External Potentiometer Speed Control

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

III. Fault Codes and Troubleshooting Solutions

1. Common Fault Codes

Fault CodeDescriptionPossible Causes
Err02Acceleration OvercurrentOutput circuit grounded/shorted
Err03Deceleration OvercurrentOutput circuit grounded/shorted
Err04Steady-state OvercurrentOutput circuit grounded/shorted
Err05Acceleration OvervoltageInput voltage too high
Err06Deceleration OvervoltageOvervoltage suppression settings improper

2. Troubleshooting Process

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

IV. Conclusion

KRC9 side image

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

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Application Scheme of Parker 590+ DC Drive in Blow Molding Machines

I. Introduction

Blow molding machines are critical equipment for producing hollow plastic products (such as PE bottles and containers). The process involves several steps, including extrusion, clamping, blow molding, cooling, and mold opening. The Parker 590+ DC drive, with its precise speed and torque control capabilities, is particularly well-suited for controlling DC motors in blow molding machines. This document elaborates on how to apply the 590+ drive to a PE material blow molding machine, covering motor functions, wiring schemes, parameter settings, control system integration, and textual descriptions of electrical wiring diagrams and control schematics.

II. Analysis of Motor Functions in Blow Molding Machines

The process flow of a blow molding machine (especially for PE material extrusion blow molding) includes:

  • Extrusion: Plastic pellets are melted through the extruder screw to form a tubular parison.
  • Clamping: The mold closes, clamping the parison.
  • Blow Molding: Air is injected into the parison to expand and form the shape.
  • Cooling: The molded product is cooled.
  • Mold Opening: The mold opens, and the finished product is removed.

Motor Functions
Based on the blow molding process, the following motors are suitable for use with the 590+ DC drive:

  • Extruder Motor:
    • Function: Drives the screw to control plastic melting and extrusion speed.
    • Requirements: Precise speed control, smooth acceleration/deceleration, and overload protection.
    • Reason: PE materials require a stable extrusion speed to ensure uniform parison formation. Baumüller emphasizes the need for high torque and precise speed control in extruders.
  • Clamping Unit Motor:
    • Function: Controls the opening and closing of the mold.
    • Requirements: Rapid response and precise speed or position control.
    • Reason: Quick and accurate mold movements can improve production efficiency. Plastics Technology mentions the need for precise control in clamping systems.

Motor Specifications (Based on User Input)

  • Rated Voltage: 440V
  • Rated Current: 25.1A
  • Power: 15kW
  • Speed: 1500 rpm
  • Field Excitation: Field current not provided; assumed to use voltage control mode.
  • Assumption: The extruder motor uses the above specifications. The clamping unit motor specifications may differ (e.g., 10A, assumed value) and should be adjusted according to the actual nameplate.

III. Application Design of the 590+ DC Drive

  1. Application Positions and Functions
    • Extruder Motor
      • Control Mode: Speed Setpoint mode.
      • Function: Precisely control the screw speed to ensure uniform melting of PE materials; maintain stable extrusion through PID control; use Ramp function for smooth start-up and shutdown.
      • Implementation: The drive receives a 0-10V speed reference signal from the PLC and feeds back the actual speed through an encoder or DC generator.
    • Clamping Unit Motor
      • Control Mode: Speed Setpoint mode (or Position Control mode if supported).
      • Function: Control the rapid closing and opening of the mold; ensure precise movements and reduce mechanical shock.
      • Implementation: The drive receives open/close commands from the PLC and may use limit switches for position control.
  2. Wiring Scheme
    • Motor Connections
      • Extruder Motor: Connect the armature to the drive’s A1 (positive)/A2 (negative) terminals; if the field is internally powered, no connection is needed; if external, connect to FL1/FL2 terminals (refer to Eurotherm Manual).
      • Clamping Unit Motor: Same as above, to be confirmed based on actual motor specifications.
    • Control Signal Connections
      • Speed Reference: Connect the PLC analog output (0-10V) to the A4 terminal (ANIN3), ensuring signal shielding to reduce noise.
      • Start/Stop: Connect the PLC digital output to the C3 terminal (DIGN2 for start); connect the PLC digital output to the C4 terminal (DIGN3 for stop, or use a single signal).
      • Feedback: Connect the encoder to the drive’s encoder input terminals; connect the DC generator to the TB terminal.
      • Communication: Connect the P3 port to the PLC communication interface (e.g., RS-485) for data exchange.
    • Power Connections
      • Main Power: Connect the three-phase AC power (380V or matching voltage) to the L1/L2/L3 terminals.
      • Control Power: Connect 24V DC to the C9 (+24V)/C10 (0V) terminals.
    • Wiring Precautions
      • Use shielded cables to reduce electromagnetic interference.
      • Ensure proper grounding to comply with safety standards.
      • Refer to the wiring diagram in Appendix L of the manual.
  3. Parameter Settings
    • Extruder MotorParameter NameLabelSetting ValueRangeDefault ValueNotesARMATURE V CAL.201.03530.9800 to 1.10001.0000Voltage switch set to 425VCUR. LIMIT/SCALER15100.00%0.00 to 200.00%100.00%Corresponding to 25.1AMAIN CURR. LIMIT421100.00%0.00 to 200.00%200.00%Adjustable as neededFIELD CONTROL MODE209VOLTAGEVOLTAGE/CURRENTVOLTAGEVoltage control modeRATIO OUT/IN21090.00%0.00 to 100.00%90.00%Initial field voltage ratioSPEED FBK SELECT10ENCODERMultiple options-Assume using encoderMODE1Speed SetpointMultiple modes-Speed control modeRAMP RATE (Accel)25.0 seconds0.1 to 600.0 seconds-Smooth accelerationRAMP RATE (Decel)35.0 seconds0.1 to 600.0 seconds-Smooth deceleration
    • Clamping Unit Motor
      • Assume current is 10A; other parameters are similar.
    • Setting Steps
      • Enter the configuration mode via MMI (CONFIGURE ENABLE = ENABLED).
      • Set the above parameters, referring to the manual’s menu system.
      • Save the parameters (CONFIGURE ENABLE = DISABLED).
  4. Control System Integration
    • PLC Selection
      • Recommended: Siemens S7-1200 (compact, suitable for small and medium-sized blow molding machines) or S7-300 (suitable for large equipment).
      • Functions: Control the process flow (extrusion, clamping, blow molding, mold opening); send analog signals (speed reference) and digital signals (start/stop); receive feedback from the drive (speed, current, faults).
      • Modules: Analog output module (e.g., EM 231, 0-10V); digital output module (e.g., EM 222); communication module (e.g., RS-485).
    • HMI Selection
      • Recommended: Siemens KTP700 Basic or Allen-Bradley PanelView Plus.
      • Functions: Display extrusion speed, motor current, fault status; provide start/stop buttons, speed setting interface; alarm management.
      • Interface Example: The home page displays running status, speed, and current; the setting page adjusts extrusion speed and clamping speed; the alarm page displays drive fault codes.
    • Industrial PC (Optional)
      • Recommended: Siemens Simatic IPC477E or Beckhoff CX5130.
      • Functions: Recipe management (store parameters for different PE products); data logging (production data, fault logs).
      • Applicable Scenarios: Large production lines or when advanced automation functions are required.
    • Control Logic
      • PLC Program: The main cycle executes the process steps in sequence (extrusion → clamping → blow molding → cooling → mold opening); set the speed reference (e.g., 50%) when the extruder starts and activate the C3 terminal; stop by closing the C3 terminal and setting the speed to 0; send a close command (speed 100%) to the clamping unit before blow molding and an open command (speed -100% or reverse) after blow molding.
      • Example Logic (Textual Description)
        • Press the “Start” button: Output the speed reference (Q0.0, 0-10V) to A4; activate C3 (Q0.1, start).
        • Clamping phase: Output the clamping speed (Q0.2, 0-10V) to the clamping drive’s A4; activate the clamping C3 (Q0.3, start).
  5. Electrical Wiring Diagram and Control Schematic
    • Extruder Wiring Diagram (Textual Description)
      • [Three-phase power 380V] –> [L1/L2/L3] –> [590+ input terminals]
      • [24V DC power] –> [C9(+24V)/C10(0V)] –> [590+ control power]
      • [Extruder motor armature] –> [A1/A2] –> [590+ output terminals]
      • [Extruder motor field] –> [FL1/FL2] –> [590+ field terminals] (if external)
      • [PLC analog output 0-10V] –> [A4(ANIN3)] –> [590+ speed reference]
      • [PLC digital output] –> [C3(DIGN2)] –> [590+ start]
      • [PLC digital output] –> [C4(DIGN3)] –> [590+ stop]
      • [Encoder] –> [Encoder input] –> [590+ feedback]
    • Clamping Unit Wiring Diagram (Textual Description)
      • [Three-phase power 380V] –> [L1/L2/L3] –> [590+ input terminals]
      • [24V DC power] –> [C9(+24V)/C10(0V)] –> [590+ control power]
      • [Clamping motor armature] –> [A1/A2] –> [590+ output terminals]
      • [Clamping motor field] –> [FL1/FL2] –> [590+ field terminals] (if external)
      • [PLC analog output 0-10V] –> [A4(ANIN3)] –> [590+ speed reference]
      • [PLC digital output] –> [C3(DIGN2)] –> [590+ start]
      • [PLC digital output] –> [C4(DIGN3)] –> [590+ stop]
      • [Limit switch] –> [Digital input] –> [590+ position feedback]
    • Control Schematic (Textual Description)
      • [Operator] –> [HMI KTP700]
      • [HMI] –> [PLC S7-1200]
      • [PLC] –> [Analog output Q0.0] –> [Extruder 590+ A4]
      • [PLC] –> [Digital output Q0.1] –> [Extruder 590+ C3]
      • [PLC] –> [Analog output Q0.2] –> [Clamping 590+ A4]
      • [PLC] –> [Digital output Q0.3] –> [Clamping 590+ C3]
      • [Extruder 590+] –> [Extruder motor] –> [Screw]
      • [Clamping 590+] –> [Clamping motor] –> [Mold]
      • [PLC] –> [Other control] –> [Blow molding valve, cooling system]

IV. Implementation Steps

  1. Wiring
    • Confirm the power supply voltage (380V or matching).
    • Connect the motor armature (A1/A2) and field (FL1/FL2, if needed).
    • Connect the control power (C9/C10).
    • Connect the PLC analog output to A4 and digital output to C3/C4.
    • Connect the feedback device (encoder or DC generator).
    • Connect the P3 port to the PLC communication interface.
  2. Parameter Setting
    • Enter the MMI and set CONFIGURE ENABLE = ENABLED.
    • Set parameters such as armature voltage, current limit, field control mode, etc.
    • Configure speed feedback and control mode.
    • Save the parameters and set CONFIGURE ENABLE = DISABLED.
  3. PLC and HMI Configuration
    • Write the process control program in the PLC.
    • Configure the HMI interface, adding status displays and control buttons.
    • Test the communication (PLC with the drive).
  4. Testing and Debugging
    • Power on and check the drive status (no alarms).
    • Start the extruder via the HMI and verify speed control.
    • Test the clamping unit’s opening and closing to ensure accurate movements.
    • Adjust parameters (e.g., Ramp time, PID gain) to optimize performance.

V. Precautions

  • Safety: Ensure power is disconnected before wiring and follow electrical safety standards.
  • Debugging: Test gradually to avoid motor overload or mechanical damage.
  • PE Material Characteristics: Ensure that the extrusion speed is coordinated with temperature control (refer to ScienceDirect).
  • Manual Reference: Detailed wiring and parameter settings should be consulted in the Eurotherm Manual.

VI. Conclusion

By applying the Parker 590+ DC drive to the extruder and clamping unit of a blow molding machine, precise motor control can be achieved, improving the production efficiency and quality of PE products. The wiring scheme ensures reliable signal transmission, parameter settings match motor requirements, and PLC and HMI integration enables automated control. This scheme is a general design and may require微调 (fine-tuning) based on specific equipment and processes in practical applications.

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User Manual Guide and DC BR Fault Analysis & Resolution for the Edley Inverter AS Series

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

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

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

Restoring Factory Default Parameters

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

  1. Press the PROG key to enter parameter setting mode.
  2. Use the UP/DOWN keys to find the CD52 parameter (regional version).
  3. Press the FUNC key to enter parameter modification mode.
  4. Use the UP/DOWN keys to set the CD52 parameter to USA (for the US version) or Eur (for the European version), then press the PROG key to save.
  5. Power off and restart the inverter. The parameters will be restored to factory defaults.
AS2-IPM

Setting and Removing Passwords

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

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

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

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

Setting Parameter Access Restrictions

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

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

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

Terminal Forward/Reverse Control

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

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

External Potentiometer Frequency Setting for Speed Regulation

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

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

III. DC BR Fault Analysis and Solution

Meaning of DC BR Fault

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

Possible Causes of the Fault

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

Solutions

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

IV. Conclusion

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

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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.

Fault 3181

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.

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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.”

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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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.