Category: Siemens

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

Introduction

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

G130 physical picture

Fault Analysis

F30025 (Overheating)

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

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

F30005 (Overload)

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

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

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

FAULT F30005

Mechanisms of Fault Occurrence

Faults Occurring at Power-On

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

Faults Occurring During Operation

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

G130 internal physical image

Solutions

Optimizing Parameter Adjustments

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

Reducing Load Rates

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

Ensuring Adequate Ventilation

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

Fault Repair

Handling Faulty Current Sensors

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

Repairing Drive Boards

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

Checking Current Detection Circuits

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

Practical Maintenance Case

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

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

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

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

G130 power board

Conclusion

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

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Debugging ideas and methods of Siemens G120 VFD PM240

As an important part of Siemens automation solutions, Siemens G120 series inverters are designed for high-performance applications. This series of inverters not only supports a wide range of motor types (including asynchronous motors, synchronous motors and servo motors), but also has excellent dynamic response capabilities and a rich set of functions, which can meet various needs from simple speed control to complex positioning control.

In the field of industrial automation, Siemens G120 series inverters are widely used in various motor control applications due to their high performance, high reliability and easy integration. This article combines multiple professional materials to provide engineers with a detailed Siemens G120 series inverter commissioning guide to help everyone better master the commissioning skills of this key equipment.

A、 BOP-2 operation panel description

The BOP-2 basic control interface is cleverly placed at the top of the control module. It plays a key role in inverter commissioning, operating status monitoring, and specific parameter configuration. This operation panel is unique and adopts a dual-line display design: the upper line focuses on displaying the specific values of the parameters, which is intuitive and clear; the lower line corresponds to the clear name of the parameters, which is convenient for users to quickly identify and operate. It is particularly worth mentioning that BOP-2 allows users to easily copy the various parameters of the inverter to the operation interface, and when necessary, easily download these parameters in batches to the inverters of the same series, greatly improving work efficiency and data management flexibility.

  • As shown in Figure 1, the BOP2 operation interface of the G120 inverter is detailed, and its main components include:

1. Motor Monitoring: This area focuses on real-time status monitoring of the motor, ensuring that users can instantly obtain key indicators of motor operation.

2. Control Operations: This section provides direct control of the inverter and the connected motor, allowing users to flexibly adjust the operating status.

3. Fault Diagnosis Area (Diagnostic Analysis): Specially used to identify and display possible system errors or abnormal conditions, so as to quickly locate the problem and handle it.

4. Parameter Settings: This area allows users to adjust and optimize the inverter parameters according to actual needs to achieve the best working performance and efficiency.

5. Setup Configuration: Focuses on the configuration management of the inverter itself, including network settings, security parameters, etc., to ensure stable operation of the equipment and compliance with safety standards.

6. Extra Features: Provides a series of additional practical functions or advanced settings to meet specific applications or user preferences.

（B）The hardware layout of the operation panel is equipped with multiple intuitive and easy-to-use buttons, as shown in Figure 2, including:

1. Escape key (ESC): used to exit the current operation or return to the previous menu.

2. Confirm button (OK): Execute the current selection or confirm the modified settings.

3. Mode switch key (HAND/AUTO): allows the user to easily switch between manual control mode and automatic operation mode.

4. Direction control keys (↑/↓): Used to move the cursor up and down in the menu and select the desired option.

5. Green start button: represents the command to start the motor safely, ensuring that the motor is started under safe conditions.

6. Red stop button: used to immediately stop the motor in an emergency to ensure the safety of personnel and equipment.

This design not only improves the convenience of operation, but also enhances the user’s ability to control the operating status of the inverter.

B、Quick debug mode operation

When starting up the inverter for the first time, the first step is to reset its parameters to factory settings. By navigating to the “setup” menu and confirming the “reset” operation, a selection box will pop up, showing the two options of “no” and “yes”. After explicitly selecting “yes” and confirming, the inverter will automatically initialize and return to the default configuration state. This step is to eliminate all existing motor-related configurations, ensure a pure test environment, avoid any potential unnecessary parameters from interfering with the normal operation of the inverter and motor on the test bench, and lay a stable foundation for subsequent debugging.

After completing the reset, there is no need to perform a power-off restart operation. Jump directly to the “parameter” interface, where you will see two options: “standard” and “expert”. Select to enter the “standard” level, first set P10=1, and then accurately configure various related parameters based on the motor nameplate information and refer to Table 1.

Then, set the P1900 parameter to 1 to start the dynamic self-learning process of the motor. Then, adjust P10 back to 0. Press the “esc” key to return to the main interface, and then tap the “HANDAUTO” key. The hand icon representing the manual mode will appear on the screen. At this time, use the ↑ key to manually set the target speed of the motor. The recommended setting value is about 50 rpm. Then, press the green motor start button, and the motor will enter the self-learning state. During this period, the screen will display the “MOTID” logo, and the motor and inverter may make some noises, which are all normal reactions.

When the motor identification and self-learning process is successfully completed, the error message X that may have existed will automatically disappear, indicating that the motor’s rapid commissioning phase has been successfully completed. At this point, the user can flexibly set the motor speed through the BOP-2 operation panel to achieve manual control of the rotation without having to power off again.

It is worth noting that in order to ensure that all settings are saved, it is necessary to re-enter the “standard” mode after completing the settings and set the P971 parameter to 1. This step is crucial because it ensures that the configured parameters can be retained even after the inverter is powered off and restarted, avoiding the frequent flashing of the inverter green light RDY (indicating that the parameters are not set correctly, affecting the operation of the motor), while also ensuring that the motor can continue to accept manual control. In addition, during the motor self-learning period, please maintain a proper distance to prevent accidents.

C、Quick debugging mode graphic specific operation process

The key to achieving quick start-up and stable operation of the motor lies in the accurate configuration of a series of core parameters, including the performance setting of the motor, the selection of the inverter command receiving source, and the clarification of the speed control source. This series of operations together builds an efficient and convenient motor commissioning process. With the help of BOP-2 (Basic Operation Panel) for quick commissioning, the specific steps can be summarized as follows:

During the quick commissioning process, if parameter P1900 is configured to a non-zero value, after the commissioning is completed, the inverter will immediately trigger the A07991 alarm message, clearly indicating that the motor data identification process has been activated and is in standby state, waiting for further start instructions. This step is an important part of ensuring the matching degree between the motor and the inverter and optimizing performance. Users should refer to Section 5.2 “Static Identification” in the inverter manual to understand the details and precautions of this process in detail so as to smoothly perform subsequent operations.

D、Specific method flow for setting parameters

Through the BOP-2 interface, users can easily adjust various parameters. The specific operations are located in the “PARAMS” (parameter setting) or “SETUP” (configuration) menu. Simply modify the required parameter value.

1. Select parameter number:

2.To modify a parameter value:

E、BOP-2 Manual Mode

F、Upload parameters from VFD to BOP-2 panel

G、Download parameters from BOP-2 panel to VFD

H、Main parameter settings

I、Communication parameter settings

After the motor acceleration debugging process is successfully completed, the next step is the key step of the communication configuration link. Entering the “parameter” interface, two major paths are presented in front of you: one is “standard” (standard mode), which is suitable for basic and broad needs; the other is “expert” (expert mode), which unlocks deeper customization and extended parameter options. When you step into the “expert” hall, you need to accurately adjust the parameters closely related to communication and other advanced settings one by one according to the carefully prepared Table 3 (parameter configuration guide). It is worth noting that there is no need to touch the P10 parameter (that is, the start switch P10=1 for motor quick debugging) at this time, because it has been properly set in the previous debugging stage, laying a solid foundation for the subsequent communication configuration.

After completing the setting of all parameters, the next necessary maintenance step is to power off the inverter and then restart the device. When restarting the inverter, in order to ensure that the system is stable and smoothly transitions to the new configuration state, the recommended restart interval should not be shorter than one minute. This waiting time gives the system enough buffering and reset opportunities.

During the period when the inverter is powered off, you can make full use of the time to carefully check the configuration of the inverter on the OPC (operation control panel or host control system), including but not limited to the serial port number, baud rate setting and device address confirmation. These steps are crucial to ensure seamless connection of the communication link.

After the inverter restarts and runs stably, you will find that the communication between the inverter and OPC has been successfully established, and the data transmission between the two will become smooth and unimpeded, laying a solid foundation for the subsequent automated control process.

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Simplified Debugging Guide for Siemens 400 Series (420/430/440) VFD Drives

Simplified Debugging Guide for Siemens 400 Series (420/430/440) VFD Drives

Debugging a Siemens 400 series Variable Frequency Drive (VFD), specifically models 420, 430, and 440, can initially seem daunting due to the multitude of parameters and unfamiliar symbols on the operation panel. However, with a structured approach, even newcomers can quickly master the basics and get these drives running efficiently. This guide will outline a straightforward method for debugging, focusing on essential functions like start/stop control and frequency adjustment, along with some tips for PID operation and parameter adjustment.

Terminal connections of the Siemens 400 Series (420/430/440) VFD Drives

Initial Setup and Terminal Connections

Before diving into the parameter settings, ensure that the terminal wires are properly connected. For basic operation, you’ll need to connect five wires:

  1. Start/Stop Switch: Connect between terminals 5 and 9.
  2. Potentiometer for Frequency Adjustment: Short-circuit terminals 2 and 4, then connect wires from terminals 1, 3, and 4 to the potentiometer, with terminal 3 connected to the center head.
Operation Panel

Understanding Operation Panel Keys

The operation panel of the Siemens VFD is equipped with several keys that serve different functions:

  • Start/Stop Keys: Marked as 1 and 0, these control the run and stop operations.
  • Parameter Adjustment Keys: The P key enters parameter adjustment mode, while the up and down arrows navigate through the parameters. The P key also confirms selections and writes values.
  • Data Display/Reset Key: Press for 2 seconds to view operating data. It also serves as a return key after parameter adjustment and a reset button for fault shutdown.
  • Control Mode Switch Keys: The “Hand” key enables operation via the panel, while the “Auto” key switches to terminal control.
Operation Panel Keys

Quick Start Guide for New Machines

For newly manufactured machines, you can bypass extensive parameter adjustments by understanding the basic button functions and ensuring correct terminal connections. However, for used machines, it’s often simplest to initialize all parameters to their factory settings:

  • Set P0010=30
  • Set P0970=1

After entering these values, the drive will reset, which may take about three minutes.

Parameter access level

PID Operation Adjustment (440 Model)

For PID control, you’ll need to configure specific parameters:

  • P2200=1: Enables PID function, disables conventional frequency settings.
  • P2253: Selects the PID setting signal source (e.g., P2253=755 for analog input 1).
  • P2264: Selects the PID feedback signal source.

Multi-machine operations, such as PID one variable frequency with three power frequencies, require detailed adjustments according to the manual.

Tips for Parameter Adjustment

  • To access PID parameters, set P003=3 for expert-level parameters.
  • Adjust P004 to change specific parameter settings, such as P004=10 for frequency setting values.
  • Define digital terminal functions with P700=2 for digital input control.

Shortcuts and Precautions

  • Fault Reset: Set a terminal to 12 for reverse operation and fault reset.
  • Fixed Frequency Operation: Set a terminal to 15 for multi-stage speed control. Adjust P1000=33 for analog signal plus fixed frequency.
  • V/F Curve Adjustment: Customize the V/F curve with P1300 based on the load type (e.g., constant torque, variable torque).
parameter level

Inertial (Free) Parking Control

For applications requiring inertial parking, set P701=1 for forward start/stop and P702=3 for inertial parking. Connect terminals 5 and 6 in parallel and control via terminal 9.

Special Considerations for High-Power Motors

When starting high-power motors, Siemens VFDs may output a certain excitation current to magnetize the stator winding before the motor starts. This is not a malfunction but a feature to reduce starting current.

Conclusion

By following this structured approach, even those new to Siemens 400 series VFDs can quickly become proficient in their operation and debugging. Remember to consult the manual for detailed parameter descriptions and always initialize parameters for used machines to ensure a smooth start. With a basic understanding of the operation panel, terminal connections, and key parameters, you’ll be well-equipped to handle a variety of applications and control requirements.