Category: Siemens

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1. Fault Definition and Background

The “F30004” fault is a common error code in the SINAMICS G120C series of Siemens inverters. It indicates:

• Power unit: Overtemperature heatsink AC inverter

In other words, the temperature of the power module’s heatsink has exceeded the permissible threshold. When the heatsink temperature reaches a warning level (typically around 5°C below the fault threshold), the inverter will raise an alarm (A05000). If the temperature continues to rise, it will escalate into fault F30004, leading to an immediate shutdown.

2. Possible Causes of F30004

Based on official documentation and field experience, the core causes of F30004 can be categorized as:

1. Cooling Fan Failure
   • Internal fans may become jammed, damaged, or run at reduced speed, preventing effective heat dissipation.
2. Blocked or Poor Heatsink Ventilation
   • Dust accumulation or airflow obstruction can significantly reduce the cooling capacity of the heatsink.
3. High Ambient Temperature
   • According to the manual, the intake air temperature for air-cooled drives should not exceed 42°C. Exceeding this temperature will increase thermal stress.
4. Overload or High System Load
   • The drive may be continuously running at high torque or with excessive mechanical load, leading to heat buildup in the power module.
5. Excessively High Pulse Frequency (Switching Frequency)
   • While high switching frequency improves output wave quality, it also increases internal power loss and heating.
6. Sensor or Parameter Issues
   • Although rare, a malfunctioning temperature sensor or incorrect settings may lead to false overheating detection.

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3. Diagnostic Steps for F30004

Upon encountering an F30004 fault, follow this step-by-step diagnostic procedure:

1. Check for Preceding Warnings

Use the BOP/IOP panel or engineering software to check if warning A05000 appeared before the F30004 fault. This can confirm if the fault was due to gradual overheating rather than an instant anomaly.

2. Inspect the Cooling Fan

• Listen for fan noise or visually inspect fan rotation.
• Remove the fan to check for blockages or dust.
• Replace the fan module if it shows signs of failure or aging.

3. Evaluate Ambient and Ventilation Conditions

• Measure the internal cabinet or intake air temperature.
• Clean all dust and obstruction near the heatsink or vent path.
• Improve ventilation or consider adding a cabinet cooling fan or air conditioning unit if needed.

4. Check Load Conditions

• Verify whether the motor is running with excessive load or mechanical resistance.
• Inspect parameter settings such as p0640 or p1341 (current limits).
• If operating near thermal limits for extended periods, reduce load or increase cooldown intervals.

5. Reduce Pulse Frequency

• Use parameter p1800 to lower the switching frequency.
• Avoid unnecessarily high values that can accelerate heat generation.

6. Validate Temperature Sensor

• Read diagnostic values such as r2124 and r0037.
• Replace the sensor or disable overheating fault response if the sensor is faulty.

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4. Solutions and Preventive Measures

4.1 Immediate Fixes

• Let the inverter cool down before clearing the fault.
• Verify all hardware and environmental factors before restarting.
• Reset the fault using the control panel or via software tools.

4.2 Long-Term Prevention

1. Routine Maintenance
   • Clean the inverter regularly, especially the heatsink, fan blades, and air filters.
2. Temperature Monitoring and Thermal Management
   • Install a cabinet temperature sensor and configure automatic cooling triggers.
3. Fan Replacement Strategy
   • Implement predictive maintenance based on fan usage hours or set a replacement schedule.
4. Optimize Load and Parameters
   • Avoid long-term high torque operations.
   • Set appropriate acceleration/deceleration times.
5. Adjust Switching Frequency Wisely
   • Do not set p1800 too high unless required by motor or application.
6. Configure Redundant Monitoring (if applicable)
   • Some models support backup temperature detection or allow disabling fault response under certain safety-controlled conditions.

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5. Conclusion and Insights

The F30004 fault in SINAMICS G120C is essentially a protective shutdown triggered by thermal overload. It’s often the result of long-term thermal stress rather than sudden failure. The key principles in addressing it are:

• Diagnose Systematically: Start from fan, environment, load, parameters, and sensors.
• Recover Cautiously: Clear the fault only after ensuring proper cooling and safe conditions.
• Prevent Proactively: Use regular maintenance, parameter tuning, and environmental control.

Unlike faults caused by short circuits or ground failures, thermal faults may seem benign at first, but repeated F30004 events can severely degrade inverter life or lead to power module damage. Preventive measures and automated monitoring are essential to ensure long-term reliable operation.

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6. Additional Recommendations

1. Install a temperature probe in the cabinet to monitor in real-time;
2. Activate pre-warning thresholds to raise an alarm before reaching F30004;
3. Monitor for F30035 (intake overtemperature) as it often occurs alongside F30004;
4. Entrust trained professionals to replace internal fans or disassemble power modules.

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This in-depth analysis of fault code F30004 aims to help users not only resolve current errors but also establish best practices in long-term inverter maintenance. For advanced technical assistance, consult Siemens’ certified support service.

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Siemens SIMODRIVE 611 is a modular, high-performance servo/spindle drive system widely used in CNC machines, automated production lines, high-speed machining centers, and other industrial applications. The system comprises a power module (rectifier/regenerative unit), drive modules (UM/FM), and control interface units, forming a complete motion control solution.

This article provides a comprehensive analysis of the SIMODRIVE 611 system, covering its functional description, standard wiring methods, parameter setting and commissioning steps, common fault diagnosis, and practical maintenance tips.

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I. Functional Overview of SIMODRIVE 611 System

1. Power Module (E/R Module)

• Model example: 6SN1146-1BB00-0EA1, a rectifier + regenerative feedback module.
• Main function: Converts 3-phase AC power (380V480V) into DC link voltage (typically 540V600V DC), and feeds back braking energy to the grid during motor deceleration.
• Features fault indication lights (RED/GREEN/YELLOW), supports pre-charging, DC discharge, and electronic monitoring.

2. Drive Modules

• Includes UM (Universal Module) and FM (Spindle Module).
• Responsible for controlling the motion of servo/spindle motors, including speed, torque, and position regulation.

3. Control Interface Modules

• Provide signal handling for PROFIBUS, analog I/O, power/enable feedback, encoder feedback, and more.

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II. Wiring Methods and Interface Descriptions

1. Power Module Wiring

• Input: 3-phase AC supply 3AC 380~480V
• Output: DC-Link voltage connected to drive modules
• X111 terminal block wiring:
  • T48-112-9: Checks whether the DC bus is charged
  • T63-9 / T64-9: Controls power enable for the drive module
  • Terminals T74/T73: Startup signal status (Open/Closed determines power state)
  • T5.1 / T5.2 / T5.3: Motor over-temperature, braking resistor, and drive fault alarm inputs

2. Wiring Precautions

• X181 port terminals NS1-NS2 must be shorted; otherwise, the system will not power up
• Never connect wires while the module is powered on
• Discharge circuits should be used to safely eliminate residual DC bus voltage

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III. Parameter Setting and Commissioning

SIMODRIVE 611 parameters are configured using Siemens’ SimoCom U software tool.

1. Required Tools

• SimoCom U software (Windows compatible)
• Communication cable (RS232 or USB-to-RS232 converter)
• Connect to the module via X471 communication port

2. Parameter Setup Procedure

1. Establish communication between PC and module
2. Read the current parameter set
3. Configure essential parameters:
   • Power module identification (Pn1)
   • Encoder type and feedback (Pn11~Pn13)
   • Current limits, acceleration/deceleration times (Pn30, Pn35, etc.)
   • Alarm thresholds (voltage, current, temperature)
4. Save settings and reboot the system for changes to take effect

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IV. Fault Diagnosis and Maintenance Tips

SIMODRIVE 611 features comprehensive fault diagnostics through LED indicators and signal terminals. Voltage and logic signal checks can quickly help pinpoint issues.

1. LED Status Indicators

• RED: Electronic hardware fault (e.g., DC bus failure, power fault)
• YELLOW: Pre-charging or module not ready
• GREEN: System is operating normally

2. Common Fault Cases

Case 1: T48-112-9 Not Conducting

• Symptom: DC bus voltage is only 27V after power-on, green LED is lit
• Possible causes: NS1-NS2 on X181 not shorted, pre-charge failure, protection not cleared

Case 2: T63-9 / T64-9 Not Conducting

• Symptom: Drive module inactive
• Troubleshooting: Manually short T63-9 and T64-9; if no response, check control board or upstream enable signal

Case 3: Constant RED Light

• Symptom: Module powered but no output
• Troubleshooting: Verify terminal shorts, drive connections, and presence of critical alarm codes

3. Maintenance Tips

• Diagnosis order: Check low-voltage logic terminals first (e.g., X111), then inspect if DC bus voltage is established
• Use a multimeter for voltage and continuity checks (especially at control terminals)
• Use a T20 Torx screwdriver to disassemble modules—avoid using incorrect tools
• Wait at least 5 minutes after power-off before performing any service work due to high residual voltage

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V. Conclusion

SIMODRIVE 611 is a robust and well-designed industrial drive system. Its power modules not only rectify three-phase AC to DC but also provide regenerative feedback capability, making it highly efficient. For optimal performance and safe maintenance, correct parameter configuration, proper wiring, and methodical troubleshooting are essential.

This article aims to provide engineers and maintenance personnel with a complete overview of SIMODRIVE 611’s operation and diagnostics. For advanced customization or onsite support, please consult Siemens-certified service providers or original factory support.

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1. Introduction

The SINAMICS G120 frequency converter series by Siemens is widely used in industrial automation for its modular structure, flexible control modes, and robust diagnostics. However, during operation, users may occasionally encounter fault codes such as F30001, which can interrupt production or system functionality. This article provides an in-depth explanation of the F30001: Power Unit Overcurrent fault, covering its causes, field-level troubleshooting, internal repair tips, and preventive strategies.

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2. Meaning of Fault Code F30001

Definition

F30001 refers to a severe fault in the power module:

“Overcurrent detected by power unit. Output is shut off immediately to protect internal components.”

This is a protective measure triggered when the output current exceeds the safe limit of the power module (typically IGBT modules), preventing hardware damage.

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Internal Detection Mechanism

The converter continuously monitors the output current of each phase (U, V, W). The fault is triggered under these conditions:

• Phase current exceeds the hardware threshold.
• Significant imbalance between the output phases.
• Motor stall or sudden torque demands exceed current capacity.
• Control loop errors cause false current surges.

Diagnostic parameter r0949 can be used to identify the affected phase (0=unknown, 1=U, 2=V, 3=W, 4=DC bus current).

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3. Common Causes of F30001

A. Load-Side Problems

• Motor winding short circuit or insulation breakdown.
• Damaged or incorrectly connected output cables.
• Motor blocked, causing high inrush current.
• Converter powered on without connecting a load (not supported in some configurations).

B. Parameter Misconfiguration

• Acceleration/deceleration time too short (p1120/p1121).
• Incorrect motor parameters (p0300, p0310) lead to wrong current ratings.
• Overcurrent response time (e.g. p0974) set too aggressively.

C. Power Supply Issues

• Unstable or unbalanced 3-phase input.
• Contactors dropping voltage momentarily.
• Absence of line reactors leading to high inrush current.

D. Internal Hardware Failures

• Damaged IGBT power modules.
• Current sensing circuitry failure.
• Loose connections or dry solder joints on the driver board.

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4. On-Site Troubleshooting and Recommendations

Step 1: Basic Electrical Checks

• Use an insulation tester to verify that motor windings have no shorts to ground (usually >1MΩ).
• Inspect cables for mechanical damage, aging, or moisture.
• Verify correct wiring (star or delta) per motor nameplate.

Step 2: Optimize Control Parameters

• Extend acceleration time (p1120) to 5–10 seconds.
• Correct the motor’s rated current value (p0310).
• Perform motor identification (p1910 = 1) before first start-up.
• Avoid no-load testing on some modules.

Step 3: Reset and Re-Test

• Clear the fault on the operator panel or through fieldbus.
• Re-energize and monitor output behavior.
• If fault reoccurs, move to deeper diagnostics.

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5. Internal Hardware Inspection (For Qualified Personnel Only)

⚠️ WARNING: Wait at least 5 minutes after power-off to allow DC bus capacitors to discharge.

Disassembly & Inspection:

• Open the PM240 cover and check for signs of damage or burn marks.
• Measure resistance between U/V/W and DC terminals to detect IGBT short circuits.
• Visually inspect drive board connectors and test points for cold joints or oxidation.
• If possible, swap power modules or control boards for cross-verification.

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6. Preventive Maintenance Tips

Task	Frequency
Clean dust and vents	Monthly
Tighten terminal connections	Quarterly
Check cable insulation	Semi-annually
Monitor current values (r0051)	Continuously
Configure tolerant protection	Initial setup

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7. Conclusion

F30001 is a typical fault in SINAMICS G120 that stems from overcurrent events. With proper analysis, parameter optimization, and electrical inspection, most such issues can be resolved at the field level. Technicians must understand not only the electrical behavior of the load but also how the inverter monitors and reacts to current flow.

If the issue persists after external causes are ruled out, contacting our technical support or replacing the power module may be necessary to ensure safety and long-term reliability.

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Operation Panel Function Introduction

The Basic Operation Panel (BOP) of the Siemens V20 frequency converter serves as the primary interface for user interaction, integrating multiple critical functions. It provides real-time monitoring of key parameters including operating frequency, output current, and DC bus voltage, displayed on a high-brightness LED screen with two-line readability up to 1.5 meters. The membrane keypad design includes six functional keys:

• OFF1 Stop Key: Initiates ramp stop by single press, decelerating the motor to stop according to preset deceleration time (P1121).
• Start/Reverse Key: Controls motor start/stop in manual mode, with long-press (2 seconds) for direction reversal.
• Multi-Function Key (M): Navigates menus, confirms parameter edits, switches display screens, and initiates bit editing when combined with OK key.
• OK Key: Enables mode switching, rapid parameter confirmation, and password entry (long-press for 3 seconds).
• Direction Keys: Traverses menu hierarchy, adjusts parameter values, and fine-tunes frequency settings; scrolls fault history in alarm state.
• Fault Reset Key: Integrated with OK key functions through combination operations.

The panel adopts a three-level menu structure with four main modules: Operation Status, Parameter List, Fault Records, and System Settings. In parameter editing mode, bit-by-bit modification is supported with rapid saving via OK key. Notably, the BOP supports offline parameter backup through dedicated interfaces.

Parameter Initialization and Security Settings

Parameter Initialization Procedure

The Quick Commissioning function enables parameter reset and basic configuration:

1. Enter P0010=1 commissioning mode
2. Configure motor parameters (P0304-P0311)
3. Select connection macro (Cn001 for terminal control or Cn002 for communication control)
4. Set application macro (e.g., P1300=20 for fan/pump loads)
5. Execute P3900=1 to complete calculations

This process automatically configures over 20 core parameters including ramp functions and overload protection, reducing commissioning time by 60% compared to traditional methods.

Access Control Mechanism

The V20 converter employs a hierarchical access management system:

• Access Level (P0003): Five levels from 0 (user-defined) to 4 (service)
• Parameter Group Locking: Restricts accessible parameter groups via P0004
• Password Protection: 4-digit password required for critical parameter modifications at expert level (3)

To remove password protection, downgrade P0003 to level 2 or below, or reset via service interface using specialized tools. Access restrictions can be applied to individual parameters, such as allowing P1080 (minimum frequency) adjustments while blocking P1120 (acceleration time) modifications.

External Control Implementation

Forward/Reverse Terminal Control

Utilizing digital input terminals (DI1-DI4) for direction control:

1. Wiring Configuration: Connect DI1 for forward command (24VDC) and DI2 for reverse command
2. Parameter Settings:
   • P0701=1 (DI1 as ON/OFF1 command)
   • P0702=2 (DI2 as reverse command)
   • P0700=2 (command source set to terminal control)
   • P1000=3 (frequency source set to analog input)

This configuration supports pulse commands for forward/reverse operations, automatically executing deceleration-stop-reverse acceleration sequence to prevent mechanical shocks.

Potentiometer Speed Control

Implementing analog input terminal (AI1) for stepless speed regulation:

1. Wiring Requirements: Connect 10kΩ linear potentiometer with mid-tap to AI1 (10V power supplied by converter)
2. Parameter Configuration:
   • P0756=2 (AI1 set to 0-10V voltage input)
   • P1000=2 (frequency source set to analog input)
   • P1080=5Hz (minimum frequency)
   • P1082=50Hz (maximum frequency)
   • P0759=0 (zero calibration)
   • P0760=100% (full-scale calibration)

Input filtering time (P0771) is recommended at 50ms to suppress interference pulses from contactor operations.

Fault Diagnosis and Resolution

Typical Fault Code Reference

Fault Code	Description	Possible Causes	Solutions
F1	Overcurrent	Motor cable short, short acceleration time	Check insulation, extend P1120
F3	Undervoltage	Power supply fluctuation, braking resistor short	Verify power quality, check R0001 resistor
F4	Converter Overheat	Poor ventilation, high pulse frequency	Clean air ducts, reduce P1800 carrier frequency
F12	Temp Sensor Fault	Temperature detection circuit open	Check T1/T2 terminal connections
F54	Motor I²t Overload	Prolonged overload operation	Reduce load, adjust P610 thermal time constant
F79	Motor Stall	Mechanical jamming, sudden load change	Check transmission, optimize P1237 stall detection time

Systematic Fault Handling

1. Fault Verification: Check current fault code and timestamp via BOP
2. Parameter Backup: Execute P0971=1 to prevent data loss during troubleshooting
3. Root Cause Analysis:
   • Electrical Issues: Measure terminal resistance (phase-to-phase insulation >1MΩ)
   • Mechanical Issues: Verify coupling alignment (allowable deviation <0.05mm)
   • Parameter Anomalies: Compare with P0005 parameter change history
4. Recovery Procedure:
   • Temporary Fix: Restore factory settings via P0970=1 (after backup)
   • Permanent Repair: Replace components or optimize control logic per fault code guidance

Maintenance and Optimization Recommendations

1. Preventive Maintenance:
   • Clean cooling fans every 2000 operating hours
   • Calibrate potentiometer linearity quarterly (error <2%)
   • Perform insulation resistance test annually (≥1MΩ@500VDC)
2. Energy Efficiency:
   • Enable P1300=20 fan/pump macro for automatic V/f² characteristic
   • Match P1120/P1121 ramp times with load inertia
   • Activate P3300=1 energy-saving mode for automatic frequency reduction at no-load
3. Communication Expansion:
   • Enable USS protocol via P2010[0]=1
   • Configure P2011=9.6kbps baud rate
   • Set Modbus address mapping using P2021-P2024

This guide is based on V20 firmware version V4.7.16. Always refer to the manual corresponding to your device’s firmware version. Execute parameter backup via P0971=1 before critical modifications and manage versions with P0970=2. For complex applications, use STARTER tool for offline programming and online monitoring.

1. Introduction & Scope

Siemens TIA Portal (V13–V19) leaves deep system traces during installation, including MSI product codes, Windows services, and drivers. Incomplete uninstallation causes version conflicts, GUID errors, and hardware issues (e.g., Code 19/45 for keyboards). This guide provides a fully automated, step-by-step solution to resolve these issues, covering:

• Deep component removal (programs, drivers, services, registry)
• Hardware error repair (Upper/Lower Filters)
• Pre/post-installation checks (media validation, license recovery)
• System health restoration (DISM/SFC/BCDEdit)
• Rollback scripts and error lookup tables

2. Pre-Uninstallation Preparation

2.1 Backup Critical Data

• Projects: Archive via TIA Portal’s “Archive” function (.zap13/14 files).
• Licenses: Export via Siemens Automation License Manager (ALM) to USB.

2.2 Tool List

Tool	Purpose	Source
TIA Administrator	Uninstall same-version packages	TIA installation media
CleanUpTool	Official deep-clean script	Siemens FAQ #109482460
Revo Uninstaller	Advanced residual scanning	revouninstaller.com
PnPUtil/DevManView	Remove orphaned drivers	Windows ADK

3. Official Uninstallation Tools

3.1 TIA Administrator

1. Open Siemens.TiaAdmin.msi from installation media.
2. Filter “Installed” packages → Select TIA Portal version → Uninstall → Reboot.

3.2 CleanUpTool

1. Download CleanUp_TIA_Vxx.exe from Siemens FAQ.
2. Run as admin → Select target version → Reboot after completion.

4. PowerShell Script for Batch Uninstallation

powershell# C:\Cleanup_TIA_All.ps1$patterns = '*Totally Integrated Automation Portal*', '*SIMATIC*', '*TIA Admin*', '*PLCSIM*', '*WinCC*'$regPaths = 'HKLM:\SOFTWARE\Microsoft\Windows\CurrentVersion\Uninstall', 'HKLM:\SOFTWARE\WOW6432Node\...\Uninstall' $apps = foreach ($path in $regPaths) {  Get-ChildItem $path | ForEach-Object {    $displayName = (Get-ItemProperty $_.PSPath).DisplayName    if ($displayName -like $patterns) { $_ }  }} $apps | ForEach-Object {  Start-Process msiexec.exe -ArgumentList "/x $($_.PSChildName) /qn /norestart" -Wait}

Execution:

powershellSet-ExecutionPolicy Bypass -Scope Process -Force& C:\Cleanup_TIA_All.ps1

Reboot required after script completion.

5. Graphical Tools (Revo/Uninstall Tool)

• Revo Uninstaller:
  1. “Forced Uninstall” → Search “Totally Integrated Automation” → Delete all residues.
• Uninstall Tool:
  1. “Batch Mode” → Select Siemens software → “Deep Clean”.

6. Cleanup Legacy Drivers/Services/Registry

6.1 Remove Siemens Services

batchsc query type= service | findstr /I "Siemens SIMATIC TIA" > svc.txtfor /f %%s in (svc.txt) do (  sc stop %%s  sc delete %%s)

6.2 Fix Code 19/45 Keyboard Errors

1. Open regedit → Navigate to:HKLM\SYSTEM\CurrentControlSet\Control\Class\{4D36E96B-E325-11CE-BFC1-08002BE10318}
2. Delete UpperFilters/LowerFilters → Create a new multi-string value UpperFilters with kbdclass.

6.3 Remove Zombie Drivers

batchpnputil /enum-devices /problem > zombie.txtfor /f "skip=2 tokens=1,*" %%i in ('find "Problem" ^< zombie.txt') do (  pnputil /remove-device %%i /subtree /reboot)

7. System Health Check

batchdism /online /cleanup-image /restorehealth  # Repair component storesfc /scannow                                # Validate system filesbcdedit /enum {current}                     # Check for safeboot flags

To revert safeboot:

batchbcdedit /deletevalue {default} safebootbcdedit /deletevalue {default} safebootalternateshell

8. Reinstallation Guide

8.1 Media Validation

• Verify ISO integrity via SHA-256 checksum or use Siemens MediaCreator.

8.2 Silent Installation

batchStart.exe /isolog:"C:\TIAinstall.log" /silent

Check C:\ProgramData\Siemens\Automation\Logs\Setup.log for errors.

8.3 Reboot Nodes

Step	Reboot Required?	Notes
After CleanUpTool	✅	Free locked DLLs
Post-PowerShell script	✅	Windows Installer requirement
After STEP 7/WinCC/PLCSIM	✅	Register drivers

9. Troubleshooting Guide

Issue	Root Cause	Fix
“Detected older version”	Residual GUIDs	Run PowerShell script
Keyboard Code 19/45	Corrupted filters	Rebuild UpperFilters
OPC UA Service failure	Lingering trace services	Delete services + reinstall
CleanUpTool “reboot required”	Pending uninstalls	Restart

10. Automation & Best Practices

• Package scripts (PowerShell, service cleanup, .reg fixes) into a Git repo.
• Deploy via MDT/Intune for enterprise automation.
• Reduce reinstall time from 4 hours to 30 minutes.

Final Note: This guide synthesizes official documentation, field testing, and community fixes to eliminate TIA Portal reinstallation headaches. Always test scripts in a non-production environment first!

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Abstract
This article systematically examines a field case involving the co-occurrence of F30022 (Power Unit U_ce Monitoring Fault) and A7852 (External Alarm 3) in a G120L inverter used in a 315 kW water pump application. It delves into the fault mechanisms, provides a detailed eight-step troubleshooting process, outlines testing methods and replacement techniques for commonly damaged components, and summarizes five preventive maintenance points based on maintenance statistics.

I. Fault Phenomena and Code Interpretation

Fault Code F30022: Power Module U_ce Monitoring Triggered

Definition: The power unit continuously monitors the collector-emitter voltage (U_ce) during IGBT conduction. If an abnormal voltage waveform is detected, a hard fault is triggered, and the pulses are locked out.

Common Causes:

• Output phase-to-phase or phase-to-ground short circuits or motor winding breakdown.
• IGBT module internal breakdown (due to overheating, aging, or surge impacts).
• Loss of 24 V power supply to the gate drive or blown fuses on the circuit board.
• Interruption of the fiber-optic link between the Control Unit (CU) and Power Module (PM), leading to sampling loss.
• Improper system grounding, causing harmonic currents to return through the PE line and elevate the sampling ground potential.

Alarm Code A7852: External Alarm 3

Definition: A digital input is mapped via parameter p2117. When its status meets the trigger condition, the alarm is set. This does not shut down the power but only indicates an external interlock anomaly.

Typical Trigger Sources:

• Closure of fire/emergency stop circuits.
• Faults in cooling water pressure, oil station pressure, or PLC outputs.
• Loose terminals or poor shielding grounding leading to interference pulses.

When F30022 and A7852 occur simultaneously, it often indicates hardware defects in the power stage and an alarm state in the field interlock, requiring separate handling.

II. Eight-Step Systematic Troubleshooting Process

Step	Operation Points	Purpose and Acceptance Criteria
1	Power-off insulation test: Measure U/V/W→PE with a 500 V megohmmeter (≥ 5 MΩ)	Determine if motor/cable insulation is degraded
2	Phase-to-phase short circuit test: Remove motor terminals and measure U-V/V-W/U-W resistance (should equal rated value)	0 Ω indicates winding short circuit
3	IGBT diode measurement: Use a multimeter’s diode mode to measure forward and reverse	Bidirectional 0 Ω indicates module breakdown
4	Drive board 24 V verification: Check 24 V and 15 V supplies on the gate drive board	Lack of power supply may falsely trigger F30022
5	Fiber-optic link self-test: Check Rx/Tx indicators on CU and PM ends (should be constantly lit)	Dim or flickering lights indicate link interruption
6	Resolve A7852: View p2117 corresponding DI, short-circuit/disconnect to verify	Confirm the true source of the external alarm
7	No-load test run: Remove U/V/W and power up	If F30022 does not reoccur, the problem is on the motor side
8	Load retest: After replacing/repairing components, reconnect the motor for test run	r0947 shows no faults, and operation is stable

III. Practical Maintenance Case

Device Overview: G120L-315 kW + CU240E-2PN control unit driving a circulating water pump. First occurrence of F30022 + A7852 after 5 years of operation.

Initial On-site Screening: Megohmmeter reading of only 0.2 MΩ indicates insulation breakdown. Line-to-line resistance measurement of U-V at 0.3 Ω (should be 0.75 Ω) confirms motor short circuit.

Power Module Inspection: U-arm IGBT measures bidirectional 0 Ω, indicating hard breakdown. The same-side drive board’s 24 V fuse is blown.

Component Replacement: Replace 2×1700 C-rated IGBTs, rewire, replace the fuse, and clean the cooling channel.

Fiber-optic Reset: Re-plug the CU-PM POF; indicators return to a constantly lit state.

External Alarm Handling: p2117=1101, corresponding to DI4. Found that the fire interlock test line was not reset → restored, and A7852 disappeared.

Test Run and Delivery: First, a no-load test run, followed by a 50 Hz full-load test run for 1 hour. No alarms occurred; delivered to production.

IV. Component Prices and Typical Labor Hours Reference

Item	Price (CNY)	Labor Hours (h)	Notes
1700 C IGBT module ×2	11,800 ×2	—	Original parts
POF fiber-optic docking kit	260	—	2 m
24 V fuse + terminals	120	—	—
Maintenance labor	—	16 ×350 = 5,600	Includes disassembly, testing, debugging
Insulating materials/thermal maintenance	500	—	Cleaning + painting
Total	≈30,000	16	Completed within two working days

V. Five Key Points for Preventive Maintenance

1. Online Insulation Monitoring: Install an IDAX-M to issue an early warning when insulation drops below 2 MΩ.
2. Quarterly Thermal Cleaning: Use compressed air to blow out air ducts and check r0035 temperature rise. Immediately address any rise >10 K.
3. Standardized Power-Up Sequence: Turn on the main circuit first, followed by the 24 V control power supply to avoid false alarms due to premature power-up of the drive board.
4. Layered External Alarms: Digest external alarm signals within the PLC and connect only the total OK contact to the drive to reduce false stops.
5. Surge and Harmonic Suppression: Install a 690 VAC SPD + 3% reactor at the incoming line to reduce dv/dt impacts on the IGBTs.

VI. Conclusion

F30022 represents a “red alert” at the power stage level, while A7852 serves as a “yellow light” at the system level. When both codes occur simultaneously, it is essential to investigate both hardware and external interlocks. Through structured eight-step troubleshooting, rigorous component testing, replacement, and debugging, production can be restored for a 315 kW water pump within 48 hours. By implementing preventive measures such as insulation monitoring, thermal cleaning, grounding optimization, and surge/harmonic suppression, the risk of similar shutdowns can be significantly reduced. It is hoped that the cases and methodologies presented in this article will provide practical assistance to on-site maintenance engineers and serve as a reference for equipment managers in formulating preventive maintenance plans.

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1. Introduction

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

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

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2. Definition and Background of Alarms 1080

2.1 Overview of the Trace Function

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

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

2.2 What Alarms 1080 Signifies

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

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

2.3 How It Differs from Fault Codes

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

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3. Common Causes and Scenarios

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

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

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4. Impact on System Operation

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

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

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5. Handling and Disabling Methods

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

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

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6. Common Questions and Answers

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

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

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

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

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7. Case Study

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

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

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8. Conclusion

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

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

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

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The Siemens SINAMICS S120/S150 drive systems are widely used in industrial automation for controlling electric motors. In this guide, we will explore the various features and operations of these systems, covering aspects such as the operation panel, parameter copying, initialization, password settings, parameter access control, and external control connections.

1. Introduction to the Operation Panel (BOP20)

The Basic Operator Panel (BOP20) is an essential interface for the SINAMICS S120 system, offering six buttons and a backlit display for operation. It is designed for simple and efficient interaction with the system, enabling the user to input parameters, display runtime status, and manage errors.

Key Features of BOP20:

• Control and Monitoring: It allows users to input parameters, monitor the system status, and reset faults.
• Access Control: Through the BOP20, users can set the access level, where higher access allows modification of more parameters.
• Error Handling: The panel displays alarms and errors, with options to acknowledge and reset them*2. Copying Parameters Between Drives**

Copying parameters from one drive to another is a common requirement when setting up multiple systems with the same configuration. This can be easily done using the BOP20 or through the expert parameter settings in the STARTER software.

To copy parameters from RAM to ROM:

1. Press and hold the “P” button for three seconds, or
2. Use parameters like p0009 = 0 and p0977 = 1 to initiate the copy .

This sures that all system parameters are consistent across devices and securely saved in non-volatile memory.

3. Parameter Initialization and Factory Reset

For initial setups or after a fault, it may be necessary to perform a full initialization or a factory reset. This can be done either by using the BOP20 or directly through software tools.

To reset the system:

1. Set parameter p0009 = 30 to perform a factory reset.
2. Ensure all components return to their default settings.

This procedure is essential for clearing incorrect configurations or preparing a device for deployment in a different setup.

4. Password Management

To protect the drive system’s settings from unauthorized changes, the S120 allows the user to set a password for configuration access. Passwords can be configured and removed using parameters in the system.

• Setting a Password: Input the desired password through parameter settings in the expert parameter list.
• Removing a Password: The password can be cleared by setting specific parameters (e.g., p9761 = 0) .

*5. Par

Access control is crucial for preventing unauthorized changes to system parameters. The S120 system allows for different levels of access, controlled via the BOP20 or the parameter configuration menu. By adjusting the parameter p0003, users can restrict access to certain critical parameters, ensuring that only qualified personnel can modify essential settings .

6. External Control: Forwarrse Rotation, Speed Control via Potentiometer

The SINAMICS S120 offers flexible options for integrating external devices, such as external switches and potentiometers, to control motor operations.

• Forward and Reverse Rotation: You can connect external terminals to control the motor’s direction. Specific parameters (P2589 and P2590) are used to define the command source for forward and reverse motion .
• Speed Control: For adjusting motor speexternal potentiometer, parameters such as P2585 and P2586 can be set to receive and process the analog signals from the potentiometer .

This flexibility ensures that the S120 can be tailorde range of industrial applications, offering both manual and automated control options.

7. Common Fault Codes and Troubleshooting

The S120 system is equipped with an extensive set of diagnostic tools to identify and address issues quickly. Some common fault codes include:

• F01650/F30650: This fault is triggered when the CRC check for Safety Integrated (SI) parameters fails .
• F01680/F30680: This indicates discrepancies in the safettion during operation .

To troubleshoot, ensure that parameters related to Safety Integrated ary configured and that any changes to the system are properly validated through the STARTER or BOP20 interface .

8. Conclusion

The SINAMICS S120 and S150 drives offer advanced feature control, with a user-friendly interface, flexible configuration options, and robust safety and diagnostic features. By understanding the operation panel, copying parameters, initializing settings, and configuring passwords and external control systems, users can ensure optimal performance and secure operation of their industrial automation systems. Additionally, being aware of the fault codes and how to address them will help maintain the system’s reliability and efficiency.

For more advanced configurations and troubleshooting, refer to the SINAMICS S120 Parameter Manual and the related documentation to fully leverage the capabilities of these systems.

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This guide incorporates the essential features of the SINAMICS S120 and S150 systems, as outlined in the manuals provided, and addresses user concerns regarding setup, security, control, and fault management.

1. Meaning of Error Code “r13000”

On Siemens SINAMICS S120 and S150 servo drives, error codes starting with “r” followed by five digits are used to indicate various issues. The “r13000” error code typically relates to feedback system problems in the closed-loop control mode. Specifically, this error may involve the following:

• Feedback Configuration or Signal Failure: The drive may not be receiving signals from the feedback device (e.g., encoder), causing the control system to lack necessary feedback information.
• Control Mode Conflict: If the drive is not configured for the appropriate control mode, the feedback system may fail to work correctly, triggering the “r13000” error.

2. Possible Causes

Common causes for the “r13000” error code include:

1. Feedback Device Failure: The feedback sensor or encoder may be malfunctioning, leading to loss or abnormal signals.
2. Connection Issues: Loose, disconnected, or poor connections between the feedback device and the drive may be causing the error.
3. Incorrect Parameter Configuration: The drive’s parameters might not match the actual application, leading to a mismatch between the control mode and feedback system.
4. Hardware Failure: The drive itself may have a hardware issue, affecting the processing of feedback signals.

3. Solutions

To troubleshoot and resolve the “r13000” error, the following steps can be taken:

1. Check the Feedback Device: Verify that the feedback sensor or encoder is working properly and providing stable output signals.
2. Inspect the Connections: Check the cables connecting the feedback device to the drive, ensuring they are securely connected with no loose or disconnected wires.
3. Verify Parameter Configuration: Using tools such as TIA Portal, check the drive’s parameter settings to ensure they match the actual application, particularly parameters related to closed-loop control mode.
4. Review Error Logs: Use the drive’s diagnostic function to check the error logs for more detailed information on the fault.
5. Restart the Drive: After addressing the potential issues above, try restarting the drive to see if the error persists.
6. Contact Technical Support: If the issue is not resolved by the above methods, contact Siemens technical support for professional assistance.

4. Preventive Measures

To prevent the occurrence of the “r13000” error, the following preventive measures can be implemented:

1. Regular Maintenance: Perform routine checks and maintenance on feedback devices to ensure they are functioning properly.
2. Correct Parameter Configuration: Ensure that all parameters in the drive’s configuration match the actual application, avoiding issues caused by misconfiguration.
3. Training for Operators: Provide training for operators to familiarize them with the operation and maintenance of the drive, reducing human errors.
4. Use High-Quality Components: Use high-quality feedback devices and cables to minimize hardware failures.

5. Conclusion

The “r13000” error code is a common fault indication in Siemens SINAMICS S120 and S150 servo drives, typically related to feedback system issues in the closed-loop control mode. By analyzing potential causes and implementing corresponding solutions, this error can be effectively diagnosed and resolved. In practical applications, regular maintenance, correct parameter configuration, operator training, and the use of high-quality components can help reduce the occurrence of similar faults.

In Siemens SINAMICS S120 and S150 series drives, the F07802 fault code indicates that the rectifier unit or power module is not ready. This fault typically occurs during the drive’s startup process, signaling that the drive has not received a readiness feedback from the power module within the expected time frame. Understanding the meaning of this fault and its solutions is crucial for ensuring the drive operates correctly.

1. Fault Meaning

The F07802 fault code signifies that after the internal enable command, the drive has not received a readiness signal from the rectifier or power module. Possible causes include:

• Short Monitoring Time: The drive’s waiting period for the power module to become ready is insufficient, leading to a timeout.
• Absence of DC Bus Voltage: The DC bus voltage has not been established, preventing the power module from starting.
• Faulty Rectifier or Power Module: The associated components have hardware faults, rendering them inoperative.
• Incorrect Input Voltage Settings: The drive’s input voltage parameters are misconfigured, causing the power module to fail to start.

2. Fault Diagnosis and Solutions

To address the above potential causes, consider the following steps:

• Extend Monitoring Time (P0857): In the drive’s parameter settings, appropriately increase the monitoring time for the power module to ensure there is sufficient time during startup for the power module to become ready.
• Check DC Bus Voltage: Use a multimeter to measure the DC bus voltage, ensuring it is within the normal range. If the voltage is abnormal, inspect the DC bus wiring and connections for looseness or poor contact.
• Inspect Rectifier and Power Module: Examine the status indicators of the relevant components to confirm they are functioning correctly. If indicators are abnormal or absent, the components may need replacement.
• Verify Input Voltage Settings (P0210): In the drive’s parameter settings, confirm that the input voltage parameters match the actual supply voltage. Mismatched settings can prevent the power module from starting.

3. Preventive Measures

To prevent the occurrence of the F07802 fault, it is advisable to implement the following measures:

• Regular Maintenance: Periodically inspect the drive’s electrical connections and component statuses to promptly identify and address potential issues.
• Correct Parameter Configuration: Ensure all parameters, especially those related to voltage and monitoring time, are correctly configured in the drive’s settings.
• Stable Power Supply: Maintain a stable power supply system for the drive, avoiding voltage fluctuations or power outages.
• Operator Training: Provide regular training for operators to enhance their ability to identify and resolve drive faults.

4. Conclusion

The F07802 fault code is a common startup fault in Siemens SINAMICS S120 and S150 series drives. By appropriately extending the monitoring time, checking the DC bus voltage, verifying input voltage settings, and performing regular maintenance, this fault can be effectively prevented and resolved. During the troubleshooting process, always adhere to electrical safety protocols to ensure the safety of personnel and equipment.