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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Analysis and Solutions for Overheating Alarm 2010 or Fault Code F009 in ABB ACS510 Series Drives

Introduction
ABB ACS510 series drives are widely used in industrial automation to control various types of motors. Overheating alarms (2010) and fault codes (F009) are common issues that relate to motor overheating. If not addressed promptly, these issues can lead to motor or drive damage. This article will explain the mechanisms behind overheating alarms 2010 and fault code 9 in detail and offer solutions to address them.

ACS510 alarm 2010 physical picture

1. Overview of the Alarm and Fault

When the ABB ACS510 series drive detects that the motor temperature exceeds safe limits, it may display an overheating alarm (2010) or a fault code (F009). The key difference between these two is:

  • Overheating Alarm 2010: The drive detects that the motor temperature is higher than the set threshold, issuing a warning but allowing the drive to continue running, giving the user time to intervene.
  • Fault Code 9: The motor temperature rises to a critical level, and the drive shuts down to prevent further damage to the motor or drive.

2. Mechanism of Overheating Alarms and Faults

In traditional motor temperature protection systems, thermal resistors (PTC or NTC) are used to directly monitor the motor’s internal temperature. When the motor exceeds a set temperature, the resistance value of the thermal resistor changes, and the drive detects this, triggering alarms or shutdowns. However, in the ABB ACS510 series, there is no direct connection to the motor’s thermal resistor. Instead, the drive uses a sophisticated thermal model algorithm to estimate the motor temperature.

1. The Relationship Between Motor Current and Temperature

The motor current is a key factor in determining the motor’s temperature during operation. Generally, the higher the current, the greater the heat generated in the motor windings due to resistive losses (I²R losses). However, the relationship between current and temperature is not linear. The temperature rise in the motor also depends on:

  • Thermal time constant: The rate at which the motor heats up and cools down is affected by its thermal time constant. Even if the current increases suddenly, the motor temperature doesn’t immediately rise to dangerous levels because the motor has thermal inertia. Similarly, cooling takes time once the motor is stopped.
  • Cooling efficiency: The effectiveness of motor cooling also influences temperature changes, especially when running at low or zero speed. At low speeds, cooling is less effective, and the temperature tends to rise faster.

2. Thermal Model Algorithm in the Drive

The ABB ACS510 drive estimates motor temperature based on the actual current, time, and set parameters, even without direct temperature sensor input.

  • Parameter 3005 (Motor Thermal Protection): This parameter enables or disables motor thermal protection. When enabled, the drive estimates the motor’s temperature based on current and time.
  • Parameter 3006 (Motor Thermal Time Constant): This defines the motor’s thermal time constant, determining how quickly the motor heats up or cools down. The longer the time constant, the slower the temperature rise, and vice versa.
  • Parameter 3007 (Zero Speed Cooling Factor) and 3009 (Full Speed Cooling Factor): These parameters influence how the motor cools at low and high speeds, respectively. Since motor cooling fans often rely on motor speed, cooling is less effective at low speeds, making the motor more prone to overheating.

The drive uses these parameters to determine if the motor is at risk of overheating. When the current is high for an extended period, the drive accumulates the thermal load, and once the temperature estimate reaches the threshold, it triggers either an alarm (2010) or a fault (9).

3. Solutions for Resolving the Fault

When an overheating alarm (2010) or fault code (9) occurs, the following steps can be taken to troubleshoot and resolve the issue:

1. Check the Motor Load and Operating Conditions

First, verify if the motor is overloaded. A motor running at high load or full load for an extended time will heat up quickly. If the load exceeds the motor’s rated capacity, reduce the load or stop the motor temporarily to allow it to cool down.

2. Check Drive Parameter Settings

  • Parameters 3005 to 3009: Ensure that these parameters are correctly configured, particularly the motor thermal time constant (3006) and cooling factors (3007, 3009). If the motor often runs at low speed, adjust the cooling factors to improve temperature estimation accuracy.
  • Overload Protection Settings: Make sure that overload protection is correctly enabled to prevent the motor from running under excessive load for extended periods.

3. Inspect the Drive and Motor Cooling Systems

The drive includes thermal resistors to monitor its internal temperature. If the cooling system fails, such as if the cooling fan malfunctions, the heat sink becomes clogged, or the ambient temperature is too high, this can affect both the drive and motor cooling.

  • Clean the heat sink and check the fan: Regularly clean the heat sink and ensure the cooling fan operates correctly for optimal heat dissipation.
  • Improve the working environment: Ensure that the drive and motor are in a well-ventilated area to avoid high ambient temperatures.

4. Check Cables and Connections

Inspect the cables between the motor and drive for damage or poor connections. Faulty cables can cause irregular currents, which may lead to overheating alarms.

5. Monitor and Maintain the System

For motors and drives running for long periods, regularly monitor their operation, logging key data like current and temperature. Adjust drive parameters according to the actual operating conditions to keep the system running within safe temperature limits.

4. Conclusion

Overheating alarms (2010) and fault code (F009) in the ABB ACS510 series drives are primarily triggered by the internal thermal model, which estimates the motor temperature based on current and runtime. This model eliminates the need for a direct motor thermal resistor connection while providing effective motor temperature monitoring and alarm functionality to prevent motor damage.

In practical use, adjusting drive parameters, performing regular maintenance, and controlling the motor load are key to preventing and resolving such issues. Through this analysis, electricians and technicians can better understand the mechanisms behind overheating alarms and faults, take appropriate measures to resolve them, and ensure the safe operation of both the motor and drive.

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Operation Guide for LS Electric VFD LSLV-S100 Series User Manual

  1. Introduction to VFD Panel Functions
    Panel Composition
    The panel of the LS Electric VFD LSLV-S100 series consists of the following main parts:
LS S100 VFD Operation Panel Function Diagram

Display: Shows operating status, parameter information, fault indications, etc.
Keys:
RUN: Forward start key; pressing it starts the VFD in forward rotation.
REV: Reverse start key; pressing it starts the VFD in reverse rotation.
STOP/RESET: Stop/reset key; used to stop the VFD or reset faults.
Up/Down Arrow Keys: Used to increase or decrease values during parameter setting.
Left/Right Arrow Keys: Used to navigate between parameter groups or codes.
ENT: Enter key; used to confirm parameter settings or enter a function menu.
ESC: Multi-function key; can be set to move to the initial position, jog operation, switch between local/remote operation, etc.
SET/RUN Indicator: Indicates whether the VFD is in setting mode or running status.
FWD/REV Indicators: Indicate whether the VFD is in forward or reverse rotation, respectively.
Accessing Function Menus
Navigating Parameter Groups: Use the left/right arrow keys to move between different parameter groups.
Parameter Setting: Enter a parameter group, use the up/down arrow keys to select a specific parameter, press ENT to enter editing mode, and press ENT again to confirm the setting.
Jog Operation: If set to jog mode, press the ESC key, and then use the RUN and REV keys for jog operation.

  1. Terminal Start and Potentiometer Speed Control
    Wiring Instructions
    To achieve terminal start and potentiometer speed control, wire as follows:

Forward Start Terminal: Connect the forward start signal (e.g., FX terminal) of the control circuit to the P1 (or specified) terminal of the VFD.
Reverse Start Terminal: Connect the reverse start signal (e.g., RX terminal) of the control circuit to the P2 (or specified) terminal of the VFD.
Stop Terminal: Connect the stop signal of the control circuit to one of the multifunction input terminals of the VFD (e.g., a terminal set for stop function).
Potentiometer Wiring: Connect the three terminals of the potentiometer to the V1 terminal (voltage input), GND (ground), and VR terminal (reference voltage) of the VFD, respectively.
Parameter Setting
Operation Command Method: In the drive group (dr), set the drv parameter to Fx/Rx-1 or Fx/Rx-2 to select the terminal start mode.
Frequency Setting Method: In the basic function group (bA), set the Freq Ref Src parameter to V1 to select potentiometer speed control.
Multifunction Terminal Setting: In the input terminal function group (In), set terminals such as P1, P2 for forward and reverse start functions, and set the required stop terminal for stop function.

  2. VFD Initialization Setting
    To initialize VFD parameters, follow these steps:
LS Power VFD LSLV-S100 Series Control Terminal Diagram

Enter the drive group (dr) parameters.
Locate the dr.93 parameter (parameter initialization).
Press ENT to enter editing mode.
Use the up/down arrow keys to set the value to 9 (full initialization).
Press ENT again to confirm the setting.
The VFD will restart and apply the default parameter settings.

  1. Fault Code Analysis and Solutions
    Reading Fault Codes
    When a fault occurs in the VFD, a corresponding fault code will be displayed. You can view the fault code on the display of the panel or enter the protection function group (Pr) to view detailed fault information through related parameters.

Common Fault Codes and Solutions
OC (Overcurrent): Check if the motor is overloaded, if the motor cable is short-circuited, or if the output terminals have poor contact.
OV (Overvoltage): Check if the input voltage is too high, if the deceleration time is too short, or if the braking resistor is functioning properly.
UV (Undervoltage): Check if the input power supply is stable and if the voltage is within the allowed range.
OH (Overheat): Check if the ambient temperature around the VFD is too high or if the cooling fan is working normally.
EF (External Fault): Check if the external control circuit is normal or if there is an external fault signal input.
Solutions typically include adjusting parameter settings (e.g., increasing deceleration time, setting appropriate current limits, etc.), checking and repairing wiring issues, and replacing faulty components. When dealing with faults, always disconnect the power supply of the VFD to ensure safety.

This operation guide covers the main panel functions, wiring and parameter settings for terminal start and potentiometer speed control, initialization settings, and fault code analysis and solutions of the LS Electric VFD LSLV-S100 series. We hope this guide helps you better use and maintain this series of VFDs.

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Guide for the User Manual of Haishida HSD260 Series VFD

I. Introduction to the Operation Panel Functions

The Haishida HSD260 series VFD’s operation panel offers a variety of functions, enabling users to conveniently set, monitor, and control the VFD’s operation. The following are the main function introductions of the operation panel:

HSD260 VFD Operation Panel Function Diagram
  1. Display Settings

To set the display to show actual current instead of frequency, you need to access the parameter setting interface via the PRG key and adjust the relevant function codes. The specific steps are as follows:

Enter parameter settings: Press the PRG key to enter the P-group function parameter setting interface.
Select display parameter: Use the ▲ (increment) and ▼ (decrement) keys to find and select the parameter you want to display, such as U0-04 (output current).
Confirm and exit: Press the ENTER key to confirm your selection and exit the parameter setting interface via the PRG key. The operation panel will now display the value of the selected parameter.

  1. Start/Stop Operations

Start: Press the RUN key to start the VFD. If the command source (P0-02) is set to the operation panel, pressing the RUN key will start the VFD.
Stop: Press the RUN key again to stop the VFD. If the VFD is in a fault state, pressing the RUN key can also reset the fault.

  1. Parameter Adjustment

Enter parameter settings: Press the PRG key and use the ▲ (increment) and ▼ (decrement) keys to select the function code you need to adjust.
Modify parameter values: Press the SHIFT key to select the digit you want to modify, then use the ▲ (increment) and ▼ (decrement) keys to adjust the parameter value.
Save and exit: After making changes, press the ENTER key to save the settings and exit the parameter setting interface via the PRG key.

HSD260 VFD Control Circuit Wiring Diagram

II. Terminal Start and Potentiometer Speed Control Wiring and Control Terminals

  1. Terminal Start

To achieve terminal start, you need to correctly wire the control terminals and set the corresponding function codes. Below is a simple example of three-wire start wiring:

Wiring Example:
DI1 (Forward Start): Connect to the start button (normally open)
COM: Common terminal
DI2 (Stop): Connect to the stop button (normally closed)

Parameter Settings:
P0-02: Command source selection, set to 1 (terminal command channel)
P4-00: DI1 terminal function selection, set to 1 (forward operation)
P4-01: DI2 terminal function selection, set to 9 (fault reset)
P4-11: Terminal command mode, set to 2 (three-wire mode)

  1. Potentiometer Speed Control

When using a potentiometer for speed control, you need to correctly wire the potentiometer to the VFD’s analog input terminals and set the corresponding function codes. Below is an example of potentiometer speed control wiring:

Wiring Example:
+10V: Connect to the variable resistor terminal of the potentiometer
AI1: Connect to the other end of the potentiometer
GND: Connect to the common terminal of the potentiometer

Parameter Settings:
P0-03: Main frequency source selection, set to 2 (AI1)
Ensure the potentiometer’s resistance range matches the VFD’s input requirements

err18 fault

III. VFD Fault Analysis and Solutions

  1. ERR01: Inverter Unit Protection

Fault Analysis: This fault is usually caused by short circuits in the VFD’s output circuit, excessively long motor and VFD wiring, or overheated modules.
Solution:
Check and eliminate peripheral faults.
Install reactors or output filters.
Check for blocked air ducts and ensure the fan is working properly.
Ensure all connections are properly inserted.
If the problem persists, seek technical support.

  1. ERR02: Acceleration Overcurrent

Fault Analysis: This fault may be caused by grounding or short circuits in the VFD’s output circuit, vector control without motor parameter tuning, or too short an acceleration time.
Solution:
Eliminate peripheral faults.
Perform motor parameter tuning.
Increase the acceleration time.
Adjust the manual torque boost or V/F curve.
Check that the voltage is within the normal range.

  1. ERR05: Acceleration Overvoltage

Fault Analysis: This fault may be caused by excessively high input voltage, external forces dragging the motor during acceleration, or too short an acceleration time.
Solution:
Adjust the voltage to the normal range.
Eliminate external forces or install braking resistors.
Increase the acceleration time.
Install braking units and resistors.

  1. ERR10: VFD Overload

Fault Analysis: This fault is usually caused by excessive load or undersized VFD selection.
Solution:
Reduce the load and check the motor and mechanical condition.
Select a VFD with a higher power rating.

  1. ERR15: External Device Fault

Fault Analysis: This fault is usually caused by external fault signals input through multifunction terminals DI.
Solution:
Reset the operation.
Check and eliminate faults in external devices.

  1. ERR18: Current Detection Fault

Fault Analysis: This fault may be caused by abnormal Hall devices or drive boards.
Solution:
Replace the Hall devices.
Replace the drive board.

By following this guide, you should be able to better understand and utilize the Haishida HSD260 series VFD. If you encounter any unresolved issues, it is recommended to contact Rongji Electromechanical Technology Co., Ltd. for technical assistance.

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EV510 VFD User Manual and Operation Guide for Oulu

I. Introduction to Operation Panel Functions

Schematic diagram of EV510 VFD operation panel
  1. Panel Diagram and Indicator Descriptions
    Panel Diagram: The VFD operation panel typically includes a display screen, confirm button, stop/reset button, potentiometer adjustment, multifunction button, menu button, function indicators, run button, increase/decrease buttons, and shift button.
    Indicator Status:
    RUN/TUNE: Light off indicates stop, light on indicates operation.
    FWD/REV: Light off indicates normal operation, light on indicates reverse operation.
    TRIP: Light off indicates normal operation, slow flashing indicates motor self-learning (1 time/second), fast flashing indicates fault (4 times/second).
  2. Setting to Display Actual Speed Instead of Frequency
    To display actual speed instead of frequency, the monitoring parameter needs to be adjusted.
    Enter the parameter setting interface through the operation panel, locate the d0-19 feedback speed (Hz) function code, and set its value to the relevant parameter for displaying actual speed. The specific parameter value may vary depending on the VFD model and settings. Please refer to the function parameter table and monitoring parameter summary in the manual.
  3. Start, Stop, and Parameter Adjustment Button Operations
    Start: Press the run button (RUN) to start the VFD.
    Stop: Press the stop/reset button (STOP/RESET) to stop the VFD operation. In fault state, this button can also be used for reset.
    Adjust Parameters:
    Press the menu button (MENU) to enter the parameter setting menu.
    Use the increase/decrease buttons and shift button to select the parameter to be adjusted.
    Press the confirm button to enter the parameter modification state, then use the increase/decrease buttons and shift button again to adjust the parameter value.
    After adjustment, press the confirm button to save the settings and exit.
EV510 VFD physical picture

II. Terminal Start and Potentiometer Speed Adjustment Wiring and Parameter Settings

  1. Terminal Start Wiring
    Control Terminals: Typically, digital input terminals such as S1 (forward operation) and S2 (reverse operation) are used for start control.
    Wiring Method: Connect external control signals (such as buttons, relay contacts, etc.) to S1 and the common terminal COM for forward start; connect to S2 and the common terminal COM for reverse start.
  2. Potentiometer Speed Adjustment Wiring
    Control Terminals: Use analog input terminals such as AI1 and AI2 for potentiometer speed adjustment.
    Wiring Method: Connect the sliding end of the potentiometer to the analog input terminal (such as AI1), and connect the fixed ends to +10V and GND (common ground) respectively.
  3. Parameter Settings
    Start Parameters:
    Set P0-02 operation command channel to 1 (terminal command channel).
    According to the wiring, set P4-00 S1 terminal function selection to 1 (forward operation), and P4-01 S2 terminal function selection to 2 (reverse operation).
    Speed Adjustment Parameters:
    Set P0-03 main frequency source A command selection to 2 (AI1), indicating that AI1 terminal is used for frequency setting.
    According to the potentiometer wiring and speed adjustment requirements, set parameters such as P4-13 AI curve 1 minimum input, P4-15 AI curve 1 maximum input, P4-14 AI curve 1 minimum input corresponding setting, and P4-16 AI curve 1 maximum input corresponding setting to define the correspondence between potentiometer output voltage and frequency.
EV510E VFD Sstandard wiring diagram

III. VFD Fault Analysis and Solution

  1. Common Faults and Causes
    Overcurrent Fault: May be caused by motor stalling, overload, improper parameter settings, etc.
    Overvoltage Fault: May be caused by excessive input voltage, short deceleration time, damaged braking resistor, etc.
    Undervoltage Fault: May be caused by insufficient input voltage, power supply failure, etc.
    Overheating Fault: May be caused by high ambient temperature, poor VFD heat dissipation, excessive load, etc.
  2. Solutions
    Overcurrent Fault: Check if the motor is stalled or overloaded, adjust the load or increase the VFD capacity; check if the parameter settings are reasonable, such as acceleration time, deceleration time, etc.
    Overvoltage Fault: Check if the input voltage is normal, adjust the deceleration time or add a braking resistor; check if the braking resistor is damaged or poorly wired.
    Undervoltage Fault: Check if the input power supply is normal, and ensure that the power supply voltage is within the allowable range.
    Overheating Fault: Improve the VFD heat dissipation conditions, such as increasing ventilation, cleaning dust, etc.; reduce the load or increase the VFD capacity; check if the parameter settings are reasonable, such as carrier frequency, etc.
  3. Fault Troubleshooting Steps
    Observe Indicators: Initially judge the fault type based on the indicator status.
    View Fault Records: Enter the VFD fault record interface to view the type and occurrence time of the most recent fault or faults.
    Check External Wiring: Ensure that all external wiring is correct and free from looseness or short circuits.
    Adjust Parameter Settings: According to the fault type and cause, appropriately adjust the VFD parameter settings.
    Contact After-sales Service: If the fault cannot be resolved independently, contact the VFD manufacturer or professional maintenance personnel for repair.

Through the above steps, users can effectively use the Oulu EV510 VFD, including operation panel functions, terminal start and potentiometer speed adjustment wiring and parameter settings, as well as fault analysis and solutions.

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INVT Servo SV-DA200 Series Manual User Guide

I. Implementation of Servo JOG Jogging Operation

Implementation Process

Servo JOG (Jogging) operation allows users to manually control the servo motor for short, small movements, primarily used for debugging or precise positioning. The following are the specific steps to implement servo JOG operation:

1. Hardware Connection

  • Connect the Servo Motor: Ensure the servo motor is properly connected to the servo drive, and check that all connecting cables are secure.
  • Control Signal Wiring: According to the CN1 terminal wiring diagram for the DA200 series servo drive, connect the control signal wires to the corresponding CN1 terminals on the servo drive. For JOG operation, typically, servo enable (SON), direction control (e.g., POT, NOT), and jog signal lines need to be connected.

2. Parameter Settings

  • Set the Motor Model: Use parameter P0.001 to set the correct motor model to ensure the drive can recognize the connected motor.
  • Configure JOG-related Parameters:
    • Jogging Speed: Set the jogging speed through parameter P0.05, typically in units of r/min.
    • Digital Input Configuration: In the P3.xx series of parameters, configure the digital input functions for servo enable (SON), forward jog (e.g., FJOG), reverse jog (e.g., RJOG), and other related inputs as needed.

3. Software Operation

  • Enable the Servo: Activate the servo drive by providing a valid signal to the servo enable terminal (SON).
  • Execute JOG Operation: Apply a forward jog (FJOG) or reverse jog (RJOG) signal, and the servo motor will move at the set jogging speed. Control the duration of the jog signal to manage the motor’s movement distance.

Precautions

  • Ensure safety during JOG operations to prevent accidental movements that could cause harm.
  • Check all connecting cables and parameter settings to ensure correct operation.
SV-SD200 Position Mode Standard Wiring Diagram

II. Servo Positioning via External Pulses in Position Control Mode

Implementation Process

In position control mode, precise servo positioning through external pulse signals is a common application. The following are the implementation steps:

1. Hardware Connection

  • Pulse Signal Lines: Connect the pulse signal lines to the pulse input terminals on the servo drive (e.g., PULS+, PULS- on CN1). Depending on requirements, direction signal lines (SIGN+, SIGN-) may also need to be connected.
  • Encoder Feedback Lines (if required): If encoder feedback is used, connect the encoder cables correctly to the corresponding terminals on the servo drive.

2. Parameter Settings

  • Control Mode Selection: Set parameter P0.03 to 0 for position control mode.
  • Pulse Input Configuration:
    • Configure the pulse input form (e.g., differential input or open-collector output) and direction signal settings.
    • Set the electronic gear ratio (e.g., P0.25, P0.26) to convert external pulses into actual motor shaft movements.
  • Position Control-related Parameters:
    • Adjust position loop gains (e.g., P2.02) and other control parameters as needed.
    • Configure software limits (e.g., P0.35, P0.36) to prevent exceeding safe travel ranges.

3. Software Operation

  • Send Pulse Signals: Transmit pulse signals to the servo drive via an upper computer, PLC, or other control system. The number of pulses determines the motor’s movement distance, while the pulse frequency controls the motor’s speed.
  • Monitor Status: Use the servo drive’s display panel or upper computer software to monitor the servo motor’s actual position and speed.

Precautions

  • Ensure pulse signal quality and stability to prevent positioning inaccuracies due to signal interference.
  • Adjust control parameters according to actual needs to achieve optimal control performance.

III. Fault Code Meanings and Solutions

Common Fault Codes and Solutions

  • Er10-4: Emergency Stop
    • Meaning: The emergency stop signal is active.
    • Solution: Check if the emergency stop button or related input signal lines have been triggered accidentally, clear the fault, and re-enable the servo.
  • Er22-0: Position Deviation Fault
    • Meaning: The actual position deviates significantly from the command position.
    • Solution: Inspect the mechanical transmission components for jams or loose connections, adjust position loop gains and other control parameters as needed.
  • Er25-1: Overcurrent Fault
    • Meaning: The motor current exceeds the rated value.
    • Solution: Check if the motor is overloaded, adjust speed or torque loop gains, and ensure the power supply voltage is stable.
  • Er13-1: Undervoltage Fault
    • Meaning: The main circuit supply voltage is too low.
    • Solution: Verify the power supply voltage, troubleshoot line faults, or adjust the power supply voltage.

Precautions

  • When encountering fault codes, first consult the fault code table for specific meanings and then follow the corresponding solutions for troubleshooting.
  • If faults cannot be resolved, promptly contact technical support or professional maintenance personnel for assistance.

By following the steps and precautions outlined above, users can effectively implement INVT Servo DA200 series JOG jogging operation, position control using external pulses, and fault diagnosis and resolution.

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Schneider VFD ATV630（altivar 630）: Analysis and Troubleshooting of Input Phase Loss and NLP Faults

The Schneider VFD ATV630（altivar 630） is a crucial device in the field of industrial automation, and its stable operation is vital for the efficiency of production lines. However, in practical applications, the ATV630 VFD may sometimes encounter Input Phase Loss and No Line Power (NLP) faults. This article will provide a detailed analysis of the causes of these two faults and corresponding troubleshooting methods.

Schneider inverter fault NLP

I. Input Phase Loss Fault

  1. Fault Phenomenon

The Input Phase Loss fault typically manifests as the VFD detecting a lack of one or more phases in the input power supply, leading to the inability of the VFD to operate normally.

  1. Causes

Power supply issues: Incorrect power supply connected to the VFD, such as connecting a single-phase power supply to a three-phase VFD.
Blown fuse: The fuse on the input side of the VFD may trip due to overcurrent or short circuit.
Unbalanced load: Unbalanced three-phase load may also result in phase loss faults.
Hardware failure: The internal detection circuit of the VFD may malfunction.
3. Troubleshooting Methods

Check power connection: Ensure that the VFD is connected to the correct three-phase power supply with stable voltage.
Inspect fuse: Check the condition of the fuse on the input side and replace it if necessary.
Balance load: Adjust the load to ensure balanced three-phase loading.
Contact after-sales service: If internal VFD failure is suspected, contact the supplier for after-sales repair.

Physical picture of ATV630 VFD

II. NLP Fault

  1. Fault Phenomenon

The NLP fault indicates that the VFD has no main power supply voltage, i.e., the VFD does not detect main power input.

  1. Causes

Main power not connected: Only the 24V power supply is provided to the control terminals of the VFD, but the main circuit power supply is not connected.
Low voltage: The main circuit voltage is lower than the rated voltage of the VFD.
Hardware failure: The rectifier section of the VFD or components for detecting voltage may malfunction.
DC reactor not connected: For some high-power VFDs, if the DC reactor is not correctly connected, it may also lead to NLP faults.
3. Troubleshooting Methods

Check main power: Use a multimeter to check if the input voltage of the main circuit is normal.
Measure DC voltage: Use the DC range of the multimeter to measure the voltage between the PA/+ and PC/- terminals to ensure that the DC bus voltage is normal. If it is low, there may be a fault in the rectifier section of the VFD.
Check monitoring menu: View the main power supply voltage in the monitoring menu. If it is abnormal, it may be due to a failure of the internal voltage detection components of the VFD.
Inspect DC reactor: For VFDs equipped with a DC reactor, ensure that it is correctly connected.

III. Preventive Measures
To avoid similar issues, it is recommended to regularly maintain and inspect the VFD to ensure it is in good working condition. Specific measures include:

Regularly check power connections: Ensure that power connections are secure without looseness or corrosion.
Monitor voltage changes: Regularly monitor changes in power supply voltage to ensure it remains stable within the range allowed by the VFD.
Balance load: Arrange the load reasonably to avoid problems caused by unbalanced three-phase loading.
Professional repair: For complex faults, contact a professional VFD repair service provider for handling.

In summary, when the Schneider VFD ATV630（altivar 630） encounters Input Phase Loss and NLP faults, the causes should be analyzed first, followed by troubleshooting and repair according to the corresponding methods. Meanwhile, regular maintenance and inspections can effectively prevent the occurrence of similar faults, ensuring the stable operation of the VFD.

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Operating Instructions for Invt IPE100 Series Engineering Inverter Manual

I. Introduction to Operation Panel Functions

The Invt IPE100 Series Engineering Inverter is equipped with an intuitive and user-friendly operation panel, featuring the following key functions:

  1. PRC/ESC (Program/Escape Key): Used to enter or exit the primary menu and delete quick parameters. This key facilitates menu navigation and parameter management during programming or debugging.
  2. DATA/ENT (Enter Key): Navigates through menu screens level by level and confirms parameter settings. It is essential for making and modifying parameter settings.
  3. ↑ (Up Key): Increments data or function codes. Used to conveniently increase numerical values when adjusting parameters.
  4. ↓ (Down Key): Decrements data or function codes. Corresponds to the Up Key for decreasing parameter values.
  5. 》/SHIFT (Shift Key): Cycles through display parameters in both stop and run display modes. During parameter modification, it selects specific digits for editing, providing flexibility in parameter editing.
  6. RUN (Run Key): Initiates inverter operation in keyboard control mode. It is a primary control for the inverter’s running state.
  7. STOP/RST (Stop/Reset Key): Halts inverter operation during runtime. In fault alarm states, it resets faults regardless of function code P7.04 settings.
  8. QUICK/JOG (Quick/Jog Key): Its function is determined by function code P7.03. When P7.03=0, it activates jogging mode (keyboard control only); when P7.03=1, it toggles between forward and reverse rotation (keyboard control only). Simultaneous pressing of RUN and STOP/RST keys initiates a free stop.
Operation Panel Function Diagram of Invt IPE100 Inverter

II. Terminal Start and External Potentiometer Speed Control Setup

  1. Parameter Settings:
    • P0.00=2: Selects V/F control mode, suitable for most general-purpose motors.
    • P0.01=1: Enables terminal command mode for inverter start/stop control.
    • P0.02=1: Selects analog input A1 for speed command, allowing speed regulation via an external potentiometer.
  2. Motor Parameter Input:
    • Enter the following parameters based on the motor nameplate: P2.00 (motor type), P2.01 (motor rated power), P2.02 (motor rated frequency), P2.03 (motor rated speed), P2.04 (motor rated voltage), and P2.05 (motor rated current).
  3. Wiring Instructions:
    • Connect one end of the start switch (or stop switch) to inverter terminal S1 and the other end to terminal COM (ground). Shorting S1 and COM activates the inverter.
    • Connect the wiper of the potentiometer to terminal AI1, and the potentiometer ends to terminals +10V and GND, respectively. Turning the potentiometer clockwise accelerates the inverter, while turning it counterclockwise decelerates it.
External Wiring Diagram of Invt IPE100 Inverter

III. Inverter Fault Code Analysis and Troubleshooting

  1. Output Faults (OUT1, OUT2, OUT3): Correspond to faults in phases U, V, and W, respectively. Causes may include rapid acceleration, inverter unit issues, or IGBT internal damage. Check for strong interference from peripheral devices and ensure proper motor and cable connections.
  2. Overcurrent Faults (OC1, OC2, OC3): Correspond to overcurrent during acceleration, deceleration, and constant speed operation, respectively. Check for excessive motor load, motor blockage, or improper parameter settings.
  3. Overvoltage Faults (OV1, OV2, OV3): Correspond to overvoltage during acceleration, deceleration, and constant speed operation, respectively. Verify the power supply voltage and ensure proper functioning of braking resistors and braking units.
  4. Undervoltage Fault (UV): Indicates that the bus voltage is below the set value. Check the input power stability and power line connections.
  5. Overload Faults (OL1, OL2): Correspond to motor overload and inverter overload, respectively. Verify motor load and inverter cooling conditions.
  6. Phase Loss Faults (SPI, SPO): Correspond to input and output phase loss, respectively. Inspect power and motor wiring connections and motor condition.

These are the basic operating instructions and common fault code explanations for the Invt IPE100 Series Engineering Inverter. In practical applications, please adjust parameter settings and troubleshoot faults according to specific situations.

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User Guide for Inovance Inverters MD280 Series Manual

I. Introduction

The Inovance MD280 series inverter is a powerful and user-friendly universal inverter widely applied in various automation equipment such as textile, papermaking, and machine tools. This guide will detail the operation panel functions, terminal start/stop configuration, external potentiometer speed regulation settings, and fault code troubleshooting for the MD280 inverter.

Function diagram of Inovance Inverters MD280 operation panel

II. Operation Panel Functions and Usage

The MD280 inverter’s operation panel serves as the primary interface between the user and the inverter, providing functionality such as run, stop, reset, and speed adjustment.

  • RUN Key: Pressing this key starts the inverter.
  • STOP/RES Key: Used to stop the inverter or reset it in case of a fault.
  • Multi-Function Key (MF.K): Depending on the setting, this key can switch command sources, toggle between forward and reverse rotation, or initiate jogging.
  • Speed Adjustment Potentiometer (if equipped): Rotating the potentiometer directly adjusts the inverter’s output frequency for speed regulation.

The LED display on the panel shows the inverter’s operating status, frequency, current, and other parameters, facilitating real-time monitoring.

Inovance Inverters MD280 Control Circuit Wiring Diagram

III. Terminal Start/Stop and External Potentiometer Speed Regulation

The MD280 inverter supports start/stop control through external terminals and speed regulation using an external potentiometer. Here are the detailed setup and wiring instructions:

1. Terminal Start/Stop Configuration

First, set the control command source through the inverter parameters. Navigate to the inverter parameter settings and set F0-00 to “1” (terminal command channel). Then, configure the DI terminal functions using the F2 group parameters, for example:

  • Set F2-00 to “1” to assign DI1 as the forward run terminal.
  • Set F2-01 to “2” to assign DI2 as the reverse run terminal.
  • Set F2-04 to “8” to assign DI4 as the free stop terminal.

When wiring, connect the external start, stop buttons, or contactors to the DI1, DI2, and DI4 terminals (depending on specific requirements), ensuring the common terminals are connected to the inverter’s COM terminal.

Inovance Inverters MD280 Label

2. External Potentiometer Speed Regulation

The MD280 inverter supports analog speed regulation via the AI2 terminal using an external potentiometer. First, set the J2 jumper on the control board to “V” (voltage input mode). Then, connect the three pins of the external potentiometer to AI2, GND, and +10V (or an equivalent voltage source from an external power supply).

In the parameter settings, ensure F0-01 is set to “1” (AI1 analog input) or “2” (AI2 analog input), depending on which AI terminal the potentiometer is connected to. Additionally, configure the AI input minimum and maximum values, along with the corresponding output frequency range, using parameters F2-09 to F2-12.

IV. Fault Code Meanings and Solutions

During operation, the MD280 inverter may encounter various faults and display corresponding fault codes on the LED screen. Here’s an explanation and solution for ERR02:

ERR02: Acceleration Overcurrent

  • Meaning: The inverter detects an overcurrent during acceleration.
  • Possible Causes:
    • Excessive motor load.
    • Too short acceleration time setting.
    • Improper V/F curve configuration.
  • Solutions:
    • Check if the motor load exceeds the rated capacity and reduce the load if necessary.
    • Increase the acceleration time (adjust parameter F0-09).
    • Optimize the V/F curve settings by adjusting parameters like F1-05 (torque boost).
    • Inspect the motor and connecting cables for short circuits or ground faults.

By following these steps, you can effectively resolve the ERR02 fault encountered during MD280 inverter operation, ensuring stable equipment performance.

Inovance Inverters experiences Error02 fault

V. Conclusion

The Inovance MD280 series inverter, with its robust functionality and user-friendly operation, holds a significant position in various automation equipment. This guide aims to enhance your understanding of the inverter’s operation panel functions, terminal start/stop and external potentiometer speed regulation settings, as well as fault code troubleshooting. By mastering these concepts, you can fully leverage the inverter’s performance advantages, boosting production efficiency.

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In-depth Analysis and Solution for FAULT 5681 on ABB ACS580 Series Inverters

The ABB ACS580 series inverters are crucial components in industrial automation, renowned for their efficiency and reliability. However, users may encounter various faults during operation, with FAULT 5681 being a particularly common one related to communication issues. This article provides an in-depth analysis of FAULT 5681, specifically addressing the differences between PS communication and PU communication, as well as the impact of parameter 95.04 on this fault, and offers detailed solutions.

Overview of FAULT 5681

FAULT 5681 indicates a communication error detected between the drive control unit and the power unit, preventing the device from functioning properly. Notably, while the manual may refer to “PU communication issues,” the operator panel might display “PS communication issues,” leading to confusion. In reality, PS communication and PU communication represent two distinct communication protocols and interfaces in ABB inverters.

  • PS Communication: Utilizes a serial communication interface (RS485) for point-to-point communication, suitable for smaller systems with its simplicity and directness.
  • PU Communication: Based on TCP/IP protocol and Ethernet interface, PU communication caters to larger systems, offering higher flexibility and scalability.
ACS580 normal working status display

Fault Analysis

  1. Misunderstanding of Communication Types: Users must clarify that the “PS communication issues” displayed on the operator panel do not equate to “PU communication issues” mentioned in the manual. FAULT 5681 specifically refers to issues within PS communication.
  2. Control Unit Power Supply: Parameter 95.04 governs the power supply method (internal 24V or external 24V) for the control unit. Instability or incorrect settings can directly affect communication stability, triggering FAULT 5681.
  3. Communication Line Faults: Improper connections, shorts, or opens in the RS485 communication lines can interrupt communication.
  4. Power Unit Failure: Damage to the power unit itself may prevent the control unit from detecting its status, leading to communication faults.

Solutions

  1. Clarify Communication Types:
    • Confirm that the fault indeed pertains to PS communication and understand the distinction between PS and PU communication to avoid confusion.
  2. Inspect and Adjust Control Unit Power Supply:
    • Check and confirm parameter 95.04 settings. For external power supply, verify the stability and connection of the external 24V power source. For internal supply, ensure the internal power module functions correctly.
    • Adjust or replace the power source if settings are incorrect or power is unstable, and restart the device to test communication recovery.
  3. Examine Communication Lines:
    • Thoroughly inspect the RS485 communication line connections, including interface plugs and line quality, ensuring no shorts, opens, or poor contacts.
    • Use a multimeter to test line continuity and replace damaged lines or connectors as needed.
  4. Verify Power Unit Status:
    • Suspect power unit failure? Use professional tools to diagnose its operation.
    • Replace or repair the power unit if damaged, coordinating with ABB service for assistance.
  5. Restart the Device:
    • After completing checks and adjustments, restart the device to restore communication. Monitor communication status changes during restart.
  6. Consult Professional Technical Support:
    • If issues persist, contact ABB’s technical support team for detailed troubleshooting and resolution strategies.

Conclusion

FAULT 5681, a prevalent communication issue in ABB ACS580 series inverters, stems from misunderstandings about communication types, control unit power supply issues, faulty communication lines, or power unit malfunctions. By distinguishing between PS and PU communication, inspecting and adjusting control unit power supply, thoroughly checking communication lines, verifying power unit status, timely restarting devices, and seeking professional help when needed, users can effectively resolve this fault. Prompt action ensures uninterrupted production line operations.

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Analysis and Solution for OC Alarm Code in ZONCN Inverter NZ200 Series

In industrial automation control systems, inverters serve as critical devices for power transmission control, and their stability and reliability are directly related to the continuous operation of production lines. The Zhongchen Inverter NZ200 series, as a high-performance option, may encounter specific alarm codes during operation, particularly the OC (Over-Current) alarm.

Normal display content on the operation panel when ZONCN VFD is working

For short-duration, high-current OC alarms in the NZ200 series, the primary causes generally stem from issues within the current detection circuit of the drive board or potential damage to the module itself. These alarms may recur even after a reset due to underlying issues. Typically, the root causes can be attributed to the following scenarios:

  1. Excessively Long Motor Cables: Long motor cables can introduce excessive leakage current, potentially triggering the OC alarm.
  2. Inadequate Cable Selection: Choosing marginal cable types can also result in higher leakage currents, especially under high load conditions.
  3. Loose Cable Connections and Damage: Loose cable connections or damaged cables can cause arcing effects when the load current surges, triggering the OC protection mechanism.

Recommended Solutions:

ZONCN inverter OC3 alarm
  • Inspect and Shorten Motor Cables: Review the cable length and ensure it meets the manufacturer’s recommendations. If possible, shorten the cable length to reduce leakage current.
  • Upgrade Cable Quality: Replace existing cables with higher-quality, appropriately rated ones to minimize leakage current issues.
  • Tighten Cable Connections and Check for Damage: Thoroughly inspect all cable connections for tightness and integrity. Replace any damaged cables immediately.
  • Monitor and Adjust Load Conditions: Keep track of load changes and adjust inverter settings accordingly to avoid excessive current surges.
  • Inspect and Replace Drive Board/Module: If the issue persists despite the above measures, consider replacing the drive board or entire inverter module, as the internal circuitry may have been damaged.

By addressing these potential causes and implementing preventive maintenance practices, operators can significantly reduce the likelihood of OC alarms in their Zhongchen Inverter NZ200 series, ensuring the smooth and reliable operation of their industrial automation systems.