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Does ABB’s ACS880 drive require ZMU-02 to be used?

The ABB ACS880 drive does not necessarily require the ZMU-02 storage card to operate. The ZMU-02 card is primarily used to provide additional storage space for saving specific configuration parameters, and it is often used in applications that require storing large amounts of programs or advanced functions (e.g., multi-drive networking, complex control strategies, etc.).

ZMU-02

Role of the ZMU-02 Storage Card:

  1. Storing Parameters and Programs: The ZMU-02 card can be used to store the drive’s parameter settings, control programs, or fault logs. In applications where frequent adjustments or multiple preset configurations are needed, the ZMU-02 card becomes useful.
  2. Program Upgrades and Backup: The ZMU-02 card can also serve as a tool for program upgrades or backing up data. If the drive needs firmware updates or parameter changes, the storage card can make the process more convenient.
ACS880 NZ2000

Is the ZMU-02 Card Required?

  1. Standard Models: For most standard applications or regular ACS880 drives, the ZMU-02 card is not required for basic operation. The drive itself can operate normally with manual parameter adjustments and control, without the need for additional storage.
  2. Specialized Models or Specific Requirements: If the ACS880 model is part of a more specialized application or requires more advanced functionality (e.g., storing large amounts of configuration data, multiple programs, or updates), the ZMU-02 card might be necessary. This is especially true in multi-drive setups or when managing configurations across multiple devices.
  3. Different Model Requirements: Some specific ACS880 models may indeed require the ZMU-02 card for operation, particularly in complex applications. It is best to consult the specific model’s documentation or application manual to determine whether the storage card is required.

Conclusion:

The ZMU-02 storage card is not mandatory for all ACS880 drives. Standard models typically do not require it, but in certain specialized or advanced applications, the card may be necessary. It’s advisable to check the specific model and application manual to confirm whether the storage card is needed.

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Schneider ATV310 Series Inverter User Manual Guide

I. Introduction to Operating Panel Functions and Password Settings

The Schneider ATV310 series of inverters come equipped with an intuitive operating panel that facilitates various settings and operations. The operating panel includes a display screen, multiple buttons, and indicator lights. The display screen shows current parameters and status, while the buttons are used for navigation and parameter setting.

ATV310 is not working when powered on

Password Setting and Unlocking

To ensure device security, the ATV310 inverter supports password locking. Users can restrict access to the inverter by setting a password.

  • Setting a Password: Enter the “Configuration Mode” (ConF), select the “999 HMI Password” parameter, enter the desired password (ranging from 2 to 9999) using the navigation keys, and press the confirm button to save.
  • Unlocking the Inverter: If the inverter is locked, enter the “Configuration Mode”, select the “999 HMI Password” parameter, enter the password, and press the confirm button to unlock. If the password is forgotten, contact Schneider Electric technical support.
ATV310 actual terminal wiring diagram

Accessing Full Menu Functions and Storing/Restoring Parameters

The ATV310 inverter offers a comprehensive range of parameter settings. Users can access the full menu via the “Configuration Mode” (ConF).

  • Accessing the Full Menu: In the “Configuration Mode”, use the navigation keys to select the “FULL” submenu to access the complete list of parameters.
  • Storing Parameters: After completing parameter settings, select “101 Store Customer Parameter Settings” and press the confirm button to save the current configuration.
  • Restoring Factory Defaults: To reset the inverter to its factory default settings, select “102 Factory/Restore Customer Parameter Settings” and then press the confirm button and select “64”.
ATV310 displays normally

II. Setting the External Terminal Operating Mode

The ATV310 inverter supports the external terminal control mode, allowing users to achieve forward, reverse, high-speed, and low-speed functions through the LI1, LI2, LI3, and LI4 logic input terminals.

Wiring and Parameter Settings

  1. Wiring:
    • Connect the LI1, LI2, LI3, and LI4 terminals to the corresponding outputs of the external controller.
    • Ensure all wiring is secure and compliant with safety regulations.
  2. Parameter Settings:
    • Enter the “Configuration Mode” (ConF) and select the “Control Menu” (400-).
    • Set the “Control Type” (201) to “3-Wire Control” (01).
    • Set the “Logic Input Type” (203) to “Positive Logic” (00) to ensure high-level activation.
    • Set the “Given Channel 1” (401) to “Remote Display” (01) to receive speed commands via the external controller.
    • Set the “Command Channel 1” (407) to “Terminal” (01) to receive control commands through the LI1-LI4 terminals.
    • In the “Input/Output Menu” (200-), assign functions to LI1, LI2, LI3, and LI4:
      • LI1: Forward (L1H)
      • LI2: Reverse (L2H)
      • LI3: High Speed (L3H)
      • LI4: Low Speed (L4H)
    • In the “Speed Limit Menu” (512-), set the specific frequency values for high speed (512.2) and low speed (512.0).

High and Low Speed Frequency Given

The high and low speed frequencies can be given via the analog or digital outputs of the external controller. If using an analog output, connect the AI1 terminal to the analog output of the external controller and set the AI1 type and range in the “Input/Output Menu” (200-). If using a digital output, directly control high and low speeds through the LI3 and LI4 terminals.

III. Fault Code Analysis and Troubleshooting

The ATV310 inverter features advanced fault diagnosis. When a fault occurs, the corresponding fault code will be displayed on the screen. Users can take appropriate measures based on the code.

Common Fault Codes and Solutions

  • F001 Precharge Fault: Possible causes include faulty charging relays or damaged charging resistors. The solution is to check connections, confirm the stability of the main power supply, and contact Schneider Electric technical support if necessary.
  • F010 Overcurrent Fault: May be caused by incorrect parameter settings, excessive load, or mechanical lockup. The solution is to check parameter settings, adjust motor/drive/load dimensions, inspect mechanical device status, and connect motor reactors.
  • F011 Inverter Overheat Fault: May be caused by excessive load, poor ventilation, or high ambient temperature. The solution is to check motor load, inverter ventilation, and ambient temperature, and wait for the inverter to cool down before restarting.
  • F013 Motor Overload Fault: Triggered by excessive motor current. The solution is to check motor thermal protection settings and motor load, and adjust parameters if necessary.
  • F014/F015 Output Phase Loss Fault: May be caused by poor motor connections or faulty output contactors. The solution is to check motor connections and output contactor status.

IV. Conclusion

The Schneider ATV310 series inverter user manual provides detailed operating instructions and parameter setting explanations, helping users quickly get started and fully utilize the inverter’s functions. Through this guide, users can understand the operating panel functions, password setting and unlocking methods, steps for setting the external terminal operating mode, and solutions for common fault codes, thereby more effectively using and maintaining the ATV310 inverter. In practical applications, users should set parameters reasonably according to specific needs and environmental conditions, and regularly check the device status to ensure long-term stable operation of the inverter.

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Fuji Frequency Converter FRENIC-Multi (FRN E1S) Series User Manual Guide

I. Introduction to the Operation Panel Functionality and Key Parameter Settings

1.1 Introduction to the Operation Panel Functionality

Fuji frequency converter E1S series operation panel function diagram

The Fuji Frequency Converter FRENIC-Multi (FRN E1S) series features an intuitive operation panel that allows users to easily monitor and control the operation of the frequency converter. The operation panel provides various functions such as setting operating frequencies, monitoring operating status, and configuring parameters.

Key Features of the Operation Panel:

  • LED Display: Displays various operating parameters such as output frequency, output current, and operating status.
  • UP/DOWN Keys: Used to adjust the set frequency.
  • RUN/STOP Keys: Used to start and stop the motor.
  • Mode Selection Keys: Allows switching between operation modes such as run mode, program mode, and alarm mode.

1.2 Setting the Electronic Thermal Relay Function

The electronic thermal relay function protects the motor from overheating by monitoring the output current of the frequency converter. To configure this function, the following parameters need to be set:

  • F10 (Thermal Relay Characteristic Selection): Selects the cooling system characteristic of the motor. Options include self-cooled motors with built-in fans and externally cooled motors.
  • F11 (Thermal Relay Action Value): Sets the current level at which the thermal relay will trip. This value should typically be set to around 100-110% of the motor’s rated current.
  • F12 (Thermal Time Constant): Sets the time it takes for the thermal relay to trip after the current exceeds the action value. This value depends on the motor’s thermal properties and the ambient operating conditions.

1.3 Configuring the Instantaneous Power Failure Restart Function

The instantaneous power failure restart function allows the frequency converter to automatically restart the motor after a temporary power outage. To enable and configure this function, the following parameters need to be set:

  • F14 (Instantaneous Power Failure Restart Selection): Enables or disables the instantaneous power failure restart function. Options include no restart (instant trip), no restart with reset on power restoration, restart at the frequency at the time of power failure (for general loads), and restart at the start frequency (for low-inertia loads).
  • H13 (Restart Waiting Time): Sets the time to wait after detecting a power failure before attempting to restart the motor. This helps to ensure that the residual voltage in the motor windings has decayed sufficiently to prevent inrush currents.
  • H14 (Frequency Ramp-Down Rate): Sets the rate at which the output frequency is reduced during restart to synchronize with the motor’s rotational speed and prevent excessive currents.
  • H16 (Instantaneous Power Failure Allowable Time): Sets the maximum time that can elapse after a power failure before the restart function is disabled.
Fuji frequency converter E1S standard wiring diagram

1.4 Selecting and Configuring the Terminal FM Function

The terminal FM provides an analog output signal that can be used to monitor various operating parameters of the frequency converter. To select and configure this function, the following steps are required:

  • F29 (Terminal FM Action Selection): Selects whether the terminal FM outputs a voltage signal (0-10V) or a pulse signal.
  • F30 (Output Gain): Adjusts the gain of the analog output signal. This allows scaling the output signal to match the input range of the monitoring equipment.
  • F31 (Function Selection): Selects the parameter to be monitored and output through the terminal FM. Options include output frequency, output current, output voltage, motor torque, load rate, and more.
  • F33 (Pulse Rate): When pulse output is selected, this parameter sets the pulse rate at 100% output.

By carefully configuring these parameters, users can fully utilize the advanced functionality of the Fuji FRENIC-Multi (FRN E1S) series frequency converter to optimize motor control and protect against potential faults.

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Panasonic Inverter VF200 Series User Manual Guide

Introduction

The Panasonic Inverter VF200 series is a powerful and flexible variable frequency drive (VFD) equipment widely used in the industrial automation field. This document aims to provide users with a detailed user guide to help them better understand and efficiently operate the VF200 series inverter.


Function diagram of Panasonic VF200 series inverter operation panel

1. Operation Panel Function Introduction, Parameter Upload, and Download

1.1 Operation Panel Function Introduction

The operation panel of the Panasonic Inverter VF200 series serves as the primary interface for user interaction. It features various functions and indicators to facilitate ease of use and monitoring.

  • Display Section: Displays output frequency, current, linear speed, set frequency, communication station number, abnormality content, various mode displays, and function setting data.
  • FWD/REV Indicators: Green indicators that show the forward/reverse operation status.
  • Panel Potentiometer: Used to set the operating frequency via the operation panel.
  • Alarm (ALM) Indicator: Red indicator that lights up in case of abnormalities or alarms.
  • RUN/STOP Buttons: Buttons to start/stop the inverter.
  • MODE Button: Toggles between various modes such as operation status display, frequency setting, rotation direction setting, control status monitoring, custom settings, function settings, and built-in memory settings.
  • SET Button: Used to switch modes, display data, and store settings.
  • ▲(UP) and ▼(DOWN) Buttons: Used to change data, output frequency, and set the rotation direction when operating via the panel.
VF200 picture

1.2 Uploading and Downloading Parameters

  • Uploading Parameters (CPY1): To upload the inverter’s functional parameters to the operation panel’s built-in memory, follow these steps:
    1. Stop the inverter.
    2. Press the MODE button four times to enter the function setting mode.
    3. Press the SET button.
    4. Use the ▲/▼ buttons to select “CPY1”.
    5. Press the SET button and set the value to “UPL”.
    6. Press the SET button again to start the upload process.
  • Downloading Parameters (CPY2): To download the parameters from the operation panel’s built-in memory to the inverter, follow these steps:
    1. Stop the inverter.
    2. Press the MODE button four times to enter the function setting mode.
    3. Press the SET button.
    4. Use the ▲/▼ buttons to select “CPY2”.
    5. Press the SET button and set the value to “dOL”.
    6. Press the SET button again to start the download process.

1.3 Setting and Eliminating Passwords

  • Setting a Password:
    1. Stop the inverter.
    2. Press the MODE button four times to enter the function setting mode.
    3. Use the ▲/▼ buttons to navigate to parameter P150.
    4. Press the SET button to display the current password.
    5. Use the ▲/▼ buttons to set a new password (range: 0000-9999).
    6. Press the SET button to save the password.
  • Eliminating a Password:
    1. Stop the inverter.
    2. Press the MODE button four times to enter the function setting mode.
    3. Use the ▲/▼ buttons to navigate to parameter P150.
    4. Press the SET button to display the current password.
    5. Set the password to “0000” using the ▲/▼ buttons.
    6. Press the SET button to eliminate the password.

1.4 Restoring Parameter Initialization

To restore the inverter’s parameters to their factory default settings, follow these steps:

  1. Stop the inverter.
  2. Press the MODE button four times to enter the function setting mode.
  3. Use the ▲/▼ buttons to navigate to parameter P151.
  4. Press the SET button to display the current setting.
  5. Set the value to “3” using the ▲/▼ buttons.
  6. Press the SET button to restore the parameters to their factory defaults.
Panasonic VF200 inverter control terminal wiring diagram

2. External Terminal Control for Forward/Reverse Rotation and PWM Frequency Control

2.1 Forward/Reverse Rotation Control via External Terminals

To achieve forward/reverse rotation control via external terminals, connect the relevant control signals to the designated terminals on the inverter.

  • Terminal Configuration:
    • SW1-SW5 (Control Circuit Terminals 4-8): These terminals can be configured to control forward/reverse rotation, start/stop, and other functions.
    • Configuration Steps:
      1. Stop the inverter.
      2. Enter the function setting mode by pressing the MODE button four times.
      3. Navigate to parameters P036-P040 using the ▲/▼ buttons.
      4. Set the desired function (e.g., forward/reverse, start/stop) to the corresponding terminal using the ▲/▼ buttons.
      5. Press the SET button to save the settings.

2.2 PWM (Pulse) Frequency Control

To control the inverter’s output frequency via PWM signals, follow these steps:

  • Terminal Configuration:
    • Terminal 7 (SW4) and Terminal 8: These terminals are used to receive PWM frequency control signals.
    • Configuration Steps:
      1. Stop the inverter.
      2. Enter the function setting mode by pressing the MODE button four times.
      3. Navigate to parameter P087 using the ▲/▼ buttons.
      4. Set the value to “1” to enable PWM frequency control.
      5. Press the SET button to save the setting.
      6. Connect the PWM signal source to terminals 7 and 8 according to the wiring diagram provided in the manual.
  • Additional Settings:
    • P088: Sets the number of PWM cycles to average for frequency calculation.
    • P089: Sets the PWM signal period.

By following this guide, users can effectively utilize the Panasonic Inverter VF200 series, leveraging its advanced features and flexible control options to meet various industrial automation needs.

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User Guide and E-04 Fault Meaning and Solution for NSA2000 Series Inverters from Nengshi

I. Introduction to the Operation Panel of the Nengshi NSA2000 Series Inverters

Basic wiring diagram of NS2000 frequency converter

The operation panel of the Nengshi NSA2000 series inverters features intuitive and powerful control functions, capable of meeting the demands of various industrial applications. The main function keys on the operation panel include:

  • RUN: The inverter run key, used to start the inverter.
  • REV/JOG: The reverse/jog key, which can be set to reverse or jog functions according to parameters.
  • STOP/RST: The stop/reset key, used to stop the inverter or reset it in case of a fault.
  • PRG: The mode switch key, used to switch the working mode of the operation panel.
  • ENTER: The confirmation key, used to confirm the current status or store parameters.
  • ▲/▼: The data modification keys, used to modify function codes or parameter values.
  • SHIFT: The data bit switch key, used to select the bit to be modified when modifying data.

How to Restore Factory Settings (Initialize Parameters)

  1. With the inverter in the stopped state, press the PRG key to enter the parameter query mode.
  2. Press the PRG key again to enter the parameter modification mode.
  3. Use the ▲/▼ keys to select the function parameter F3.01.
  4. Press the ENTER key to enter the parameter modification state.
  5. Set the parameter value to 1 and press the ENTER key to confirm, restoring the inverter to factory settings.

How to Set Passwords and Parameter Write Protection Functions, and How to Eliminate Passwords

  1. Setting a Password: Modify the function parameter F3.03 to set a 4-digit numeric password within the range of 0000-9999.
  2. Parameter Write Protection: Function parameter F3.02 is used to set parameter write protection, allowing choices between allowing modification of all parameters, only allowing modification of frequency settings, or prohibiting modification of all parameters.
  3. Eliminating a Password: Reset the value of function parameter F3.03 to 0 to eliminate password protection.

Function and Setting Method of Jump Frequencies

Jump frequencies are used to avoid the mechanical resonance points of load devices, preventing equipment damage or performance degradation due to resonance. The setting method is as follows:

  1. Use the ▲/▼ keys to select function parameters F2.36F2.37F2.38F2.39F2.40, and F2.41, which are used to set the three jump frequencies and their corresponding jump ranges.
  2. Press the ENTER key to enter the parameter modification state, use the ▲/▼ keys to set the desired jump frequencies and ranges.
  3. After setting, press the ENTER key to confirm.

II. Realization of Terminal Forward/Reverse Control and External Potentiometer Frequency Control Functions

Terminal Forward/Reverse Control

Terminal forward/reverse control is achieved by controlling the on/off states of the FWD and REV terminals. The parameters that need to be set include:

  • F0.04: Operation command channel selection, set to 1 to control via terminals.
  • F4.06: FWD/REV terminal control mode, select the appropriate control mode according to actual needs (such as two-wire or three-wire mode).

In terms of wiring, connect the external control switches to the FWD and REV terminals respectively, and ensure that the common terminal COM is correctly connected.

External Potentiometer Frequency Control

The external potentiometer frequency control function allows users to change the output frequency of the inverter by adjusting the resistance value of an external potentiometer. The parameters that need to be set include:

  • F0.01: Frequency setting channel selection, set to 0 to use the potentiometer on the operation panel.
  • If using an external potentiometer, set F0.01 to 4 (VCI analog setting) or 5 (CCI analog setting), and configure the input range of VCI or CCI (F5.00-F5.03) according to actual conditions.

In terms of wiring, connect the three terminals of the external potentiometer to the VCI (or CCI), GND, and +10V (or 0V) terminals of the inverter.

E-04 FAULT

III. Meaning and Handling of E-04 Fault

Meaning of E-04 Fault

The E-04 fault indicates overvoltage during the acceleration process of the inverter. This is usually caused by abnormal grid voltage, restarting a rotating motor, or excessively short deceleration time.

Handling Method

  1. Check the Input Power Supply: Ensure that the grid voltage is stable and meets the operating requirements of the inverter.
  2. Avoid Restarting a Rotating Motor: If it is necessary to start a rotating motor, set it to DC brake start.
  3. Extend the Deceleration Time: Appropriately extend the deceleration time of the inverter based on actual conditions to reduce overvoltage.

Fault Repair

If the above methods cannot resolve the E-04 fault, further inspection and repair of the inverter may be required. It is recommended to contact professional after-sales service personnel or a technical support team for troubleshooting and repairs. During the repair process, ensure that the power supply to the inverter is cut off and operate in accordance with relevant safety regulations.

Conclusion

The Nengshi NSA2000 series inverters feature a rich set of operation panel functions. Through reasonable parameter settings and wiring configurations, various control functions can be realized. When handling E-04 faults, first check the input power supply and the operating status of the inverter, and take corresponding measures based on actual conditions. If further repairs are needed, it is recommended to contact a professional technical support team. Through proper use and maintenance, the Nengshi NSA2000 series inverters will provide users with stable and reliable variable frequency speed regulation solutions.

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User Guide for GSK DAP03 Spindle Drive Unit and Troubleshooting for Err-11

I. Display Menu and Status Monitoring

1.1 Operation and Settings of the Display Menu

GSK DAP03 Spindle Drive Unit Standard Wiring Diagram

The GSK DAP03 spindle drive unit is equipped with a 6-digit LED digital tube for displaying various statuses and parameters. Users can operate the display menu and monitor statuses through the following steps:

Status Monitoring: Users can press corresponding buttons to select different monitoring statuses. For example, pressing the “+” or “-” button can flip through different monitoring contents such as motor speed, current position, input/output terminal status, etc. The specific monitoring content can be selected by setting parameter PA3, and the content displayed after power-on can also be set according to this parameter.

Parameter Setting: In parameter setting mode, users can adjust parameter values using the “+” and “-” buttons, and save the settings by pressing the “Confirm” button. Note that after modifying certain key parameters, a parameter write operation (EE-SEt) is required to ensure the changes take effect.

1.2 Settings for Status Monitoring

Status monitoring allows users to view various statuses of the drive unit in real-time, such as motor speed, position, alarm codes, etc. Users can select the specific monitoring content by setting parameter PA3. For example, setting PA3 to “0” will display motor speed by default after power-on; setting it to “1” will monitor the low five-digit pulse count of the current motor position, and so on.

II. Manual and Inching Control

2.1 Manual Control

In manual control mode, users can directly control the motor’s forward and reverse rotation as well as acceleration and deceleration using the “+” and “-” buttons on the operation panel. The specific steps are as follows:

  • Set PA4=2 to select manual operation mode.
  • Set PA33=1 to enable forced enable (not dependent on external enable signals).
  • Enter the manual operation menu and control the motor using the “+” and “-” buttons. Pressing the “+” button accelerates the motor, pressing the “-” button decelerates it, and releasing the buttons allows the motor to maintain its current speed.

2.2 Inching Control

Inching control allows users to briefly run the motor at a preset speed. The specific steps are as follows:

  • Set PA4=3 to select inching operation mode.
  • Set PA21 to the desired inching speed (e.g., 300 represents 300 RPM).
  • Set PA33=1 to enable forced enable.
  • Enter the inching operation menu and press the “+” or “-” button to start the motor in forward or reverse rotation. The motor stops when the button is released.
DAP03 spindle drive unit and CN connection diagram

III. Position and Speed Control Modes

3.1 Position Control Mode

In position control mode, users control the motor’s precise position through pulse commands. The specific wiring and parameter settings are as follows:

Wiring: Connect the PULS+, PULS-, SIGN+, SIGN- terminals of the CN1 interface to receive position commands.

Parameter Settings:

  • Set PA4=0 to select position mode.
  • Set PA12 (position pulse command multiplication factor) and PA13 (position pulse command division factor) as needed to calculate the electronic gear ratio.
  • Set PA14 to select the pulse command mode (e.g., pulse + direction).

3.2 Speed Control Mode

In speed control mode, users can control the motor’s speed through analog voltage commands or internal digital commands. The specific wiring and parameter settings are as follows:

Analog Voltage Command Control:

  • Wiring: Connect the VCMD+, VCMD- terminals of the CN1 interface to receive analog voltage commands.
  • Parameter Settings: Set PA4=1 and PA22=1 to select analog command speed mode, and set PA42 to the motor speed corresponding to 10V analog input.

Internal Digital Command Control:

  • Wiring: Connect the SP0, SP1, SP2, etc., terminals of the CN1 interface to select preset speeds.
  • Parameter Settings: Set PA4=1 and PA22=0 to select internal command speed mode, and set the speeds for each segment through PA24 to PA30.

3.3 Electronic Gear Ratio Setting

The electronic gear ratio is used to convert input commands into the motor’s actual movement. The calculation formula is:

G = (ZM × CD × δ × CR × PA13) / (PA12 × ZM × L)

Where ZM and ZD are the gear ratios at the screw end and motor end (both are 1 when directly connected), L is the screw lead, C is the motor encoder’s number of lines, δ is the system’s minimum output command unit, and CR and CD are the multiplication and division factors for the upper machine’s commands. Users need to set PA12 and PA13 according to the actual mechanical structure to achieve the desired electronic gear ratio.

IV. Common Alarm Codes and Troubleshooting

The GSK DAP03 spindle drive unit displays corresponding alarm codes when abnormalities are detected. Below are some common alarm codes, their meanings, and troubleshooting methods:

  • Err-1: The spindle motor speed exceeds the set value. Possible causes include abnormal encoder feedback signals, improper acceleration/deceleration time settings, etc. Troubleshooting methods include checking encoder connections, adjusting acceleration/deceleration time parameters, etc.
  • Err-5: Motor overtemperature alarm. Possible causes include no temperature detection device inside the motor, overload, etc. Troubleshooting methods include setting PA73=1 to disable the alarm, reducing the load, etc.
  • Err-9: Abnormal motor encoder signal feedback. Possible causes include poor encoder signal wire connections, damaged encoders, etc. Troubleshooting methods include checking encoder connections, replacing encoders, etc.
GSK spindle servo DAP03 experiences ERR-11 fault

V. Err-11 Alarm Code Meaning and Troubleshooting

The Err-11 alarm code indicates a fault in the intelligent power module (IPM) inside the drive unit. The IPM is a core component of the drive unit, responsible for converting DC power into AC power to drive the motor. When the IPM detects abnormalities or damage, it triggers the Err-11 alarm.

Possible Causes:

  • IPM Overheating: Long-term high-load operation or poor heat dissipation may cause the IPM to overheat, leading to failure.
  • Short Circuit or Overload: Short circuits in the motor or power lines, as well as motor overload operation, can damage the IPM.
  • Power Voltage Fluctuations: Unstable power voltage may cause abnormal IPM operation or even damage.
  • IPM Quality Issues: In rare cases, the IPM may have manufacturing defects or early failure.

Troubleshooting Methods:

  • Check Power Voltage: Ensure stable input power voltage that meets the drive unit’s voltage requirements. If the power voltage fluctuates significantly, consider installing a voltage stabilizer.
  • Check Motor and Wiring: Disconnect the motor from the drive unit and check for short circuits or grounding faults in the motor and wiring. Use tools such as a multimeter to perform resistance and insulation tests to ensure the wiring is intact.
  • Improve Heat Dissipation: Ensure the drive unit’s cooling fan is working properly and the heatsink is clean of dust. In high-temperature or harsh environments, consider adding additional cooling measures, such as installing fans or lowering the ambient temperature.
  • Replace the IPM: If the above steps fail to solve the problem, it may be due to IPM failure. In this case, contact the supplier or manufacturer to purchase and replace the IPM. When replacing, ensure power is off, and the new module is compatible with the old one.
  • Contact Technical Support: If the problem persists, it is recommended to contact GSK’s technical support team for assistance. They can provide more professional fault diagnosis and repair advice.

Notes:

  • When dealing with any faults related to electrical equipment, always cut off the power first to ensure personal safety.
  • If you do not have relevant professional knowledge and skills, do not attempt to repair the drive unit or IPM yourself. Incorrect operations may lead to further equipment damage or safety hazards.

By following the above steps, you should be able to diagnose and solve the Err-11 alarm issue in the GSK DAP03 spindle drive unit. If the problem persists, seek help from professional technicians.

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User Manual Guide for Convo Inverter FSCG05 Series

I. Introduction to Operating Panel Functions and Initialization Settings

1. Operating Panel Function Introduction

The Convo FSCG05 series inverters come equipped with an intuitive operating panel that offers extensive functionalities for parameter setting, monitoring, and control.

2. Factory Default Initialization Settings
Function diagram of CONVO inverter CVF-G5 panel

To restore the inverter to its factory default settings, you need to modify specific parameters. The key parameter to be set is b-11 (Parameter Initialization). Here’s how to do it:

  • Parameter and Settingb-11 = 1
  • Procedure:
    1. Access the advanced parameter mode by setting b-0 = 2.
    2. Navigate to b-11 and set its value to 1.
    3. Save the setting and restart the inverter to apply the factory defaults.
3. Copying and Downloading Parameters via Operating Panel

Copying Parameters:

  • Procedure for KP51B Keypad:
    1. Set the source inverter to parameter copy mode by pressing EnterStopDownEnter sequentially.
    2. Remove the keypad from the source inverter and insert it into the target inverter.
    3. Initiate the parameter download to the target inverter by pressing EnterStopDownDown sequentially.
  • Procedure for KP51S Keypad (due to limited memory, parameters need to be copied in two batches):
    • For copying B and L parameters: Press EnterStopDownDownEnter.
    • For copying H and E parameters: Press EnterStopDownStopDown.
    • To copy all B, L, H, and E parameters, follow the above steps for each batch.

Downloading Parameters:

  • Simply reverse the above steps to download parameters from the keypad to an inverter.

II. Terminal Control for Forward/Reverse Rotation and Potentiometer Speed Regulation

CONVO frequency converter SCG05 multi machine RS485 communication synchronization function diagram
Setting Parameters for Terminal Control
  • Forward/Reverse Rotation Control:
    • Set b-3 to select the control mode (e.g., 1 for external terminal control with keyboard stop disabled).
    • Configure the function of terminals X1, X2, FWD, and REV via parameters like L-47 to L-53 based on your control requirements.
  • Potentiometer Speed Regulation:
    • Set b-1 to 0 to use the potentiometer on the operating panel for speed control.
    • No additional parameter settings are required if using the panel potentiometer exclusively.

CONVO is a brand under Bosch Rexroth,By following these steps and adjusting the specified parameters, you can effectively control the operation of your Convo FSCG05 series inverter, whether through the operating panel, external terminals, or by restoring factory settings. This user manual guide aims to provide a comprehensive reference for smooth and efficient inverter operation.

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Analysis and Solutions for Faults F30005 and F30025 in Siemens G130_G150 Series Frequency Converters

Introduction

Siemens G130 and G150 series frequency converters play a crucial role in industrial automation systems, and their stability and reliability are vital for the smooth operation of production processes. However, in practical applications, these converters may encounter various faults, with F30005 (overload) and F30025 (overheating) being two of the most common ones. This article aims to provide an in-depth analysis of the meanings and causes of these faults and offer corresponding solutions. Additionally, a practical maintenance case is presented to illustrate the complexity of fault handling and the strategies employed.

G130 physical picture

Fault Analysis

F30025 (Overheating)

The F30025 fault typically indicates that the power unit’s chip temperature is too high. This fault can be caused by various factors, including but not limited to:

  • Poor Heat Dissipation: Issues such as fan failure, obstructed ventilation, or excessively high ambient temperatures can prevent the power unit from effectively dissipating heat.
  • Overload Operation: Prolonged high-load operation generates significant heat within the power unit.
  • High Pulse Frequency: Operating at high frequencies increases the heat generation in the power unit.
fault F30025

F30005 (Overload)

The F30005 fault signifies an I2t overload in the power unit. Possible causes include:

  • Excessive Load: The motor or mechanical load exceeds the rated power of the frequency converter.
  • Unreasonable Operating Cycle: Continuous operation without sufficient cooling time for the frequency converter.
  • Improper Parameter Settings: Inappropriate settings for parameters such as acceleration and deceleration times, leading to excessive output current from the frequency converter.

Additionally, faults like overcurrent (F30001) and grounding (F30021) are also closely related to current detection and judgment, indicating output currents exceeding rated values and insulation damage to motors or cables, respectively.

FAULT F30005

Mechanisms of Fault Occurrence

Faults Occurring at Power-On

Faults that occur immediately upon power-on often point to hardware issues, such as damaged current sensors (transformers) or related detection circuit problems. These faults typically manifest as errors as soon as power is applied and are difficult to resolve through parameter adjustments.

Faults Occurring During Operation

Faults that arise during operation may be the result of a combination of factors, including load variations, ambient temperatures, and ventilation conditions. Such faults are usually addressed by optimizing parameters, reducing load rates, and improving ventilation conditions.

G130 internal physical image

Solutions

Optimizing Parameter Adjustments

  • Adjust Operating Cycles: Arrange the working and rest times of the frequency converter reasonably to avoid prolonged continuous operation.
  • Adjust Acceleration/Deceleration Times: Modify acceleration and deceleration times based on load characteristics to reduce the impact on the frequency converter.
  • Increase Preset Values for Electronic Thermal Protection: If the motor and frequency converter are not overloaded, the preset values for electronic thermal protection can be appropriately increased.

Reducing Load Rates

  • Check and Optimize Mechanical Loads: Ensure that mechanical loads operate within the rated power range of the frequency converter.
  • Adjust Gear Ratios: Where possible, adjust gear ratios to reduce the load on the motor axis.

Ensuring Adequate Ventilation

  • Regularly Clean Heat Sinks: Ensure that heat sink fins are free of dust and that fans are operating normally.
  • Improve Ventilation Conditions: Ensure that the frequency converter is installed in a well-ventilated location, away from direct sunlight and high-temperature environments.
ESM2000-9983

Fault Repair

Handling Faulty Current Sensors

  • Check Current Sensors: Use a multimeter to test the output of the current sensors for normality.
  • Replace Damaged Current Sensors: If a sensor is confirmed to be damaged, it should be promptly replaced with a compatible model.
  • Adopt Temporary Solutions: In emergencies, if only two current sensors are available, the frequency converter can be set to V/F control mode, but risks should be noted.

Repairing Drive Boards

  • Check Optocouplers on Drive Boards: Optocouplers are key components for detecting the voltage drop across switching transistors and should be replaced if damaged.
  • Rewire or Replace Faulty Components: If other components (such as resistors, capacitors) on the drive board are damaged, they should be rewired or replaced.

Checking Current Detection Circuits

  • Trace Current Signal Paths: From the current sensors to the frequency converter’s control circuit, gradually check each component along the signal path.
  • Use Oscilloscopes to Detect Signal Waveforms: Observe the waveforms of current signals through an oscilloscope to identify any abnormalities.
  • Repair or Replace Faulty Components: Based on the detection results, repair or replace faulty components.
G130 CPU board

Practical Maintenance Case

In actual maintenance, we encountered a typical case that fully demonstrated the complexity of concurrent F30005 and F30025 faults and their solutions. The frequency converter immediately displayed an F30025 fault upon power-on, and further operation (such as pressing the ↓ key) revealed an F30005 fault, indicating simultaneous issues of overheating and overload.

Upon thorough inspection, it was found that the root cause was a damaged current sensor. This frequency converter utilized three ESM2000-9922 current sensors, each with a maximum secondary side output current of 400mA, collectively responsible for monitoring the three-phase current output of the converter. According to Kirchhoff’s Current Law, the sum of currents entering a node at any moment should equal the sum of currents exiting the node. In a three-phase system, this means that the algebraic sum of any two phase currents must equal the negative of the third phase current. Therefore, theoretically, as long as two current sensors are functioning normally, the reading of the third sensor can be inferred from their data.

However, this substitution scheme carries risks in practical operation, requiring that the three-phase currents and voltages output by the frequency converter remain relatively balanced and that the angle between the currents is close to the ideal 120°. Furthermore, since this frequency converter supports vector control, precise current measurement is crucial. Therefore, when adopting this temporary substitution scheme, we had to switch the converter’s operating mode from vector control to V/F control to avoid damaging the IGBT module due to inaccurate current calculations.

During the specific operation, we removed the damaged current sensor and reconnected the remaining two sensors. Then, through the frequency converter’s parameter setting interface, we changed its operating mode to V/F control. After these steps, although the frequency converter could be started and operated, the current values displayed on the screen were slightly lower than the actual values. In emergencies, this makeshift solution can temporarily restore the functionality of the frequency converter and ensure the continuity of the production process. However, in the long run, we still recommend replacing the damaged current sensor as soon as possible and restoring the frequency converter to its original vector control mode to ensure its performance and accuracy.

G130 power board

Conclusion

Although F30005 and F30025 faults are common in Siemens G130 and G150 series frequency converters, they can be effectively prevented and resolved through reasonable parameter adjustments, load reduction, improved ventilation conditions, and prompt fault repairs. In practical applications, targeted measures should be taken based on specific situations to ensure the stable operation of the frequency converters. Meanwhile, through meticulous inspections and flexible strategies, we can identify the key to solving problems and ensure the long-term reliable operation of the equipment.

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Schneider ATV303 Series Inverter User Guide and F014 Fault Resolution Method

I. Introduction to the ATV303 Series Inverter Operation Panel

The Schneider ATV303 series inverter’s operation panel (also known as the display terminal or HMI) features an intuitive interface, allowing users to easily set parameters, monitor operational status, and troubleshoot errors. The primary functions of the operation panel include:

  • Display Screen: Displays the current status, parameter values, error messages, etc., of the inverter.
  • Navigation Buttons: Used to navigate between menus and parameters, and to adjust parameter values.
  • Mode Button: Switches between “Given” (rEF), “Monitor” (MOn), and “Configuration” (ConF) modes.
  • Stop/Reset Button: Stops motor operation or resets faults under certain conditions.
  • Run Button: Starts motor operation.
ATV303 INVERTER  F014 FAULT

Setting and Removing Passwords

To prevent unauthorized access, users can set a password for the inverter. Here’s how:

  1. Enter “Configuration” mode (ConF).
  2. Select the “Maintenance” menu (900-).
  3. Locate the “HMI Password” parameter (999).
  4. Enter the desired password value (range: 2-9999) and press the “Confirm” button to save.

To remove the password, simply set the “HMI Password” parameter (999) to “OFF”.

Restoring Factory Settings

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

  1. Enter “Configuration” mode (ConF).
  2. Select the “Store/Restore Parameter Sets” menu.
  3. Set the “Factory/Restore Customer Parameter Settings” parameter (102) to “64”. The inverter will restart automatically and apply the factory settings.
Schneider inverter ATV303 control terminal wiring diagram

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

Terminal Forward/Reverse Control

To achieve motor forward/reverse control via the inverter’s control terminals, follow these setup and wiring steps:

  1. Parameter Settings:
    • Enter “Configuration” mode (ConF).
    • Select the “Input/Output” menu (200-).
    • Set the “Control Type” parameter (201) to “2-wire control” or “3-wire control”.
    • For “2-wire control”, configure the “2-wire Control” parameter (202), e.g., “Forward Priority”.
    • Set the “Reverse” parameter (503) to specify which logic input terminal controls reversal (e.g., LI2H for LI2 high level reversal).
  2. Wiring:
    • Connect the motor forward control terminal (e.g., LI1) to the forward control signal source.
    • Connect the motor reverse control terminal (e.g., LI2, based on parameter settings) to the reverse control signal source.
    • Ensure all control signal sources are passive dry contacts or provide appropriate level signals.

External Potentiometer Speed Regulation

To regulate inverter speed using an external potentiometer, configure the following parameters and connect the corresponding terminals:

  1. Parameter Settings:
    • Enter “Configuration” mode (ConF).
    • Select the “Control” menu (400-).
    • Set the “Given Channel 1” parameter (401) to “183” to receive speed input via analog input AI1.
    • Set the “AI1 Type” parameter (204.0) to “Voltage” or “Current” based on the external potentiometer’s output type.
    • For current output, also set the “0% AI1 Current Ratio Parameter” (204.1) and “AI1 Current Calibration Parameter 100%” (204.2).
  2. Wiring:
    • Connect the external potentiometer’s output terminal to the inverter’s analog input terminal AI1.
    • Connect the external potentiometer’s power terminals (if needed) to the inverter’s +5V and COM terminals, or provide an external power supply.

III. F014 Fault Resolution Method

F014 Fault Overview

The F014 fault indicates that one phase is missing from the inverter’s output to the motor. This fault can cause abnormal motor operation or even damage to the motor and inverter.

Mechanism of Occurrence

The primary mechanisms behind the output phase loss fault include:

  1. Loose or Poor Output Terminal Connections: Loose or poor contact between the inverter output terminals and motor connection terminals may prevent the transmission of electrical energy in one phase.
  2. Motor or Cable Faults: Internal motor winding damage or cable breaks can also lead to output phase loss.
  3. Inverter Internal Faults: Damage to power devices or control circuit faults within the inverter can cause output phase loss.

Repair Method

To resolve the F014 fault, follow these troubleshooting steps:

  1. Check Output Terminal Connections: Verify that the connections between the inverter output terminals and motor connection terminals are secure and free from loose or poor contacts.
  2. Inspect the Motor and Cable: Use a multimeter or other tool to check the continuity of the motor windings and cables, ensuring there are no breaks or shorts.
  3. Examine the Inverter Internals: If the above checks are clear, the fault may lie within the inverter. Disassemble and inspect the inverter for damaged power devices or control circuit faults, and perform necessary repairs or replacements.
  4. Re-execute Autotuning: After ruling out hardware faults, re-execute the inverter’s autotuning process to ensure correct parameter settings and normal motor operation.

By following these steps, users can effectively resolve the F014 fault on the ATV303 series inverter and restore normal device operation. Regular inspections and maintenance of the inverter are recommended to prevent similar faults from occurring.

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Huayuan Inverter User Manual Usage Guide and ERR02 Fault Solution

I. Introduction to the Function of Huayuan Inverter G1 Series Operating Panel (Keyboard)

Function diagram of Huayuan inverter keyboard

Operating Panel Functionality

The Huayuan Inverter G1 Series operating panel integrates multiple functions to facilitate parameter setting, status monitoring, and fault diagnosis. The panel primarily consists of a 5-digit 8-segment LED display, 4 indicator lights, 8 buttons, and a rotary potentiometer.

  • LED Display: Shows output frequency, current, various parameter settings, and abnormal statuses.
  • Indicator Lights: Indicate the current operating mode (e.g., Hz, A, V).
  • Button Functions:
    • Rotary Potentiometer: Used to adjust numerical settings; clockwise rotation increases the value, while counterclockwise rotation decreases it.
    • Multifunction Button: Can be set to invalid, jog, or forward/reverse functions.
    • Program Button: Enters or exits the parameter menu.
    • Confirm Button: Enters the parameter menu and confirms current modifications.
    • Shift Button: Switches between running status monitoring data and shifts parameters during modification.
    • Run Button: Controls the start and stop of the inverter.
    • Stop/Reset Button: Stops the inverter or resets faults.
    • Up/Down Buttons: Increases or decreases function codes or values.
Huayuan Inverter G1 Series Wiring Diagram

Parameter Upload and Download

  • Parameter Upload: Copies the internal parameters of the inverter to the keyboard memory. Set function parameter P07.02=H.#1, press the “‖” button to start the upload, and “CoPy” will be displayed upon completion.
  • Parameter Download: Writes the parameters stored in the keyboard to the inverter. Set function parameter P07.02 to H.12 or H.13, press the “‖” button to start the download, and “LoAd” will be displayed upon completion.

Setting Open-Loop Vector Control (SVC) and Closed-Loop Vector Control (FVC) Modes

  • Open-Loop Vector Control (SVC):
    1. Set P00.00=1.
    2. Set motor parameters (P02.01~P02.05) according to the motor nameplate.
    3. Perform motor parameter tuning (P00.25=1 for static tuning, P00.25=2 for dynamic tuning).
  • Closed-Loop Vector Control (FVC):
    1. Set P00.00=2.
    2. Set motor parameters (P02.01~P02.05) according to the motor nameplate.
    3. Set encoder-related parameters (e.g., P20.00 sets the encoder line count, P20.02 enables the PG card encoder function).
    4. Perform motor parameter tuning (P00.25=1 for static tuning, P00.25=2 for dynamic tuning).

Initializing Parameters

  • By setting function parameter P00.26, you can choose to restore factory default parameters (excluding or including motor parameters).

II. External Terminal Control

Achieving Forward/Reverse Rotation and Potentiometer Speed Adjustment

Terminal Connections

  • Forward/Reverse Control:
    • For forward rotation, connect the DI1 terminal to the common terminal (COM).
    • For reverse rotation, connect the DI2 terminal to the common terminal (COM).
  • Potentiometer Speed Adjustment:
    • Connect the output end of the external potentiometer to AI1 or AI2, and the other end to the common terminal (COM).

Parameter Settings

  • Forward/Reverse Parameters:
    • Set P05.00 (DI1 function) = 1 (forward rotation) or 2 (reverse rotation).
    • Ensure P00.01 (command source selection) = 0 (keyboard control) or change it to 1 (terminal control) as needed.
  • Potentiometer Speed Adjustment Parameters:
    • Set P00.02 (main frequency source X selection) = 1 (AI1) or select other analog inputs as needed.
    • Ensure P05.59 (AI voltage or current selection) is set correctly (e.g., 00 indicates AI1 is a voltage input).
err02 fault

III. ERR02 Fault Solution

Meaning of ERR02 Fault

ERR02 indicates an “acceleration overcurrent fault,” meaning an overcurrent is detected during inverter acceleration.

Fault Causes and Solutions

  1. Grounding or Short Circuit in Inverter Output Circuit:
    • Check and eliminate grounding or short circuits in peripheral wiring.
  2. Vector Control Mode Without Parameter Tuning:
    • Ensure motor parameter tuning has been correctly performed (SVC or FVC mode).
  3. Too Short Acceleration Time:
    • Increase the acceleration time (P00.17 or P00.18).
  4. Inappropriate Manual Torque Boost or V/F Curve:
    • Adjust the manual torque boost (P04.01) or select an appropriate V/F curve (P04.00).
  5. Low Voltage:
    • Adjust the voltage to the normal range.
  6. Starting a Rotating Motor:
    • Choose speed tracking start or wait for the motor to stop before starting.
  7. Sudden Load Increase During Acceleration:
    • Eliminate sudden load increases or reassess the load condition.
  8. Undersized Inverter Selection:
    • Select an inverter with a higher power rating.

Repairing the Inverter

If the above methods cannot resolve the ERR02 fault, further inspection and repair of the inverter may be necessary:

  1. Check the Drive Board and Main Control Board:
    • Confirm that the drive board and main control board are functioning normally, and replace faulty components if necessary.
  2. Check the Hall Sensor:
    • Confirm that the Hall sensor is operating correctly, and replace it if damaged.
  3. Contact the Manufacturer or Professional Repair Service:
    • If the problem persists, it is recommended to contact the inverter manufacturer or a professional repair service for further inspection and repair.

Conclusion

The Huayuan Inverter G1 Series user manual provides a detailed operation guide and fault solution. By correctly setting parameters and using external terminal control, various functions of the inverter can be realized. For the ERR02 fault, the inverter can be restored to normal operation by troubleshooting and solving the problem step by step. When necessary, contacting the manufacturer or a professional repair service is crucial to ensuring reliable operation of the equipment.