Tag: Industrial Automation

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ACS530 VFD 5098 Alarm Fault Analysis and Troubleshooting

ACS530 VFD 5098 Alarm Fault Analysis and Troubleshooting

When working with ABB’s ACS530 series VFDs (Variable Frequency Drives), encountering specific fault alarms such as the 5098 alarm can be a concern. While the ACS530 series manual may not directly mention this alarm code, by referencing the manual of its similar ACS580 series VFDs, also from ABB, we can gain insight into the 5098 alarm and apply that knowledge to troubleshooting the ACS530 series.

Physical picture of ACS530 with fault number 5098

I. Understanding the 5098 Alarm

In the ACS580 series, the 5098 alarm indicates “I/O Communication Lost,” signifying a failure in communication with the standard I/O (Input/Output) devices. This usually occurs when there is an issue with the communication link between the VFD’s I/O terminal board (where analog inputs like AI1 reside) and the main board. Similarly, in the ACS530 series, the 5098 alarm likely indicates a communication issue as well.

II. Possible Causes of the Fault

  1. Power Issues:
    • The 10V or 24V power supply on the I/O terminal board may be abnormal, leading to unstable or failed communication.
    • There may be short circuits, open circuits, or poor connections in the power lines.
  2. Hardware Connection Problems:
    • Connections between the I/O terminal board and the main board may be loose, have cold solder joints, or be corroded.
    • Terminals may have aged due to prolonged use, resulting in poor contact.
  3. Communication Module Failure:
    • The VFD’s I/O communication module may be damaged, preventing proper communication with the I/O terminal board.
  4. Software or Configuration Issues:
    • The VFD’s software configuration may have errors, affecting communication protocols or parameter settings.
    • Despite similarities in design and software between the ACS530 and ACS580 series, subtle differences in configuration may lead to unexpected alarms in the ACS530 under certain conditions.
Physical picture of ABB inverter ACS530

III. Fault Troubleshooting Steps

To address the 5098 alarm in the ACS530 VFD, follow these troubleshooting steps:

  1. Check Power Supplies:
    • Use a multimeter to verify the 10V and 24V power supplies on the I/O terminal board are functioning correctly.
    • Inspect power lines for completeness, shorts, or open circuits.
  2. Inspect Hardware Connections:
    • Disconnect all connections related to the I/O terminal board, reconnect them securely, and ensure they are tight.
    • Examine the connections between the I/O terminal board and the main board for looseness, cold solder joints, or corrosion, and make necessary repairs.
  3. Assess Communication Module:
    • If possible, test replacing the I/O communication module with an identical one to determine if it’s faulty.
  4. Reset and Restart:
    • Attempt to reset the VFD to clear the alarm.
    • If resetting fails, power off the VFD, wait for a while, and then power it back on to eliminate any software-related communication issues.
  5. Contact Technical Support:
    • If none of the above steps resolve the issue, contact ABB’s technical support team or a professional service provider for further diagnosis and repair.

IV. Conclusion

Despite the ACS530 series VFD manual’s lack of direct mention of the 5098 alarm, referencing similar ACS580 series documentation and contextual analysis enables understanding the likely fault type and appropriate troubleshooting methods. In practice, consider all potential causes

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POWTRAN PI500 Series Current Vector Inverter: User Guide & Essential Features

This comprehensive guide covers the key features and essential operations of the POWTRAN PI500 Series high-performance current vector inverter, including parameter adjustment via the panel, start/stop control through terminals, external potentiometer debugging mode configuration, and multi-speed settings.

VFD panel operation method of POWTRAN

1. Adjusting Parameters via the Inverter Panel

To adjust parameters using the inverter’s keypad, follow these steps:

  • Enter Menu: Press the PRG key to enter the parameter setting mode.
  • Select Parameter Group: Use the arrow keys to select the desired function parameter group (e.g., F0 group for basic function parameters).
  • Select Function Code: Within the selected group, use the arrow keys to choose the function code you wish to modify.
  • Adjust Parameter Value: Use the increment/decrement keys to adjust the parameter value or enter a new value directly with the numeric keys.
  • Save Settings: After making changes, press ENTER to confirm and save your settings.

Note: Some parameters cannot be modified during operation and require the inverter to be stopped first. Always consult the manual thoroughly before adjusting parameters.

Wiring Diagram of POWTRAN PI500

2. Starting and Stopping the Inverter via Terminals

To control the inverter’s start and stop via external terminals, follow these configuration steps:

  • Set Command Source: Set F0.11 (Command Source Selection) to “1” (Terminal Control) to enable external terminal operation.
  • Assign Terminal Functions: Use F1 group function codes (e.g., F1.00, F1.01) to assign specific input terminals (e.g., DI1, DI2) for forward, reverse, stop, and other functions.
  • Wiring: Connect the external control signal wires correctly to the designated input terminals based on your settings.

To start the inverter, apply a closure signal to the forward terminal (e.g., DI1). To stop, apply a stop signal to the stop terminal (which may be DI2, depending on your configuration) or disconnect the forward signal.

External potentiometer analog quantity given wiring diagram of PI500

3. Setting External Potentiometer Adjustment Mode

To configure the inverter for external potentiometer adjustment, follow these steps:

  • Configure AI1 Input:
    • Wiring: Connect the external potentiometer’s output to the inverter’s AI1 and GND terminals.
    • Set Input Range: Adjust F1.12 (AIC1 Minimum Input) and F1.14 (AIC1 Maximum Input) based on the potentiometer’s output range to ensure the inverter interprets the signals correctly.
  • Select Frequency Source: Set F0.03 (Main Frequency Source Setting) to “2” (Analog AI1 Setting) to use the AI1 input signal as the frequency reference.
  • Start Adjustment: Once configured, rotating the external potentiometer will adjust the inverter’s output frequency.
Multi speed functional wiring diagram of PI500

4. Introduction to Multi-speed Functionality

The multi-speed feature enables preset speed profiles, allowing quick switching between them via external signals.

  • Preset Speeds: Use E1 group function codes (E1.00 to E1.15) to set up to 16 different speed segments, each representing a percentage of the maximum frequency.
  • Assign Terminal Functions: Allocate input terminals (e.g., S1, S2, S3, S4) through F1 group function codes to select between the multi-speed segments based on their combinational states.
  • Set Acceleration/Deceleration Times: Customize acceleration and deceleration times for seamless speed transitions using parameters like F0.13 to F0.15.
  • Choose Speed Switching Method: Optionally, utilize external signals (high-speed pulses, communication signals) for dynamic speed segment switching.

To utilize the multi-speed feature, manipulate the allocated external terminals or transmit corresponding control signals. The inverter will then adjust its operating frequency according to the activated speed segment.

Notes:

  • Ensure speed segment settings align with the motor and inverter’s capabilities.
  • Carefully consider the mechanical load’s response to acceleration and deceleration when setting these times.

By following these configurations, you can flexibly manage the inverter’s speed to meet various process demands, while also benefiting from the manual’s detailed guidance for troubleshooting and maintaining optimal performance.

To learn more about the usage of PI500 VFD, you can download its manual from Google Drive or contact our service：https://drive.google.com/file/d/1zCUn1w6h9rEkvbP0yPJ1qAA5–T7axBt/view?usp=sharing

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KAIZ Series AC Servo Drive User Manual: Comprehensive Guide for Selection, Installation, Operation, and Troubleshooting

I. JOG Jogging Operation Process

The JOG mode allows users to directly control the start, stop, and reverse of the servo motor through buttons, commonly used for manual debugging and positioning. Below are the specific steps for JOG jogging operation:

  1. Connect Control Signals:
    • Ensure that the control signal cable CN1 of the servo driver is correctly connected to the corresponding controller or manual operation panel.
    • Set the Servo Enable (SON) to OFF, CCW Drive Inhibit (FSTP) and CW Drive Inhibit (RSTP) both to ON, or disable the drive inhibit function using parameter PA20.
  2. Power On the Control Circuit:
    • Turn on the control circuit power supply of the servo driver (note that the main circuit power supply should remain off for now).
    • The display of the servo driver will light up. Check for any alarm messages, and if any, inspect the connection wiring.
  3. Set Control Mode:
    • Enter the parameter setting interface and set the Control Mode Selection (Parameter No. 4) to JOG mode (value 3).
  4. Power On the Main Circuit:
    • After confirming no alarms or abnormalities, turn on the main circuit power supply.
    • Set the Servo Enable (SON) to ON, and the motor will enter an excited state but remain at zero speed.
  5. Perform JOG Operation:
    • In JOG mode, press and hold the Up key (↑) to make the motor run forward at the preset JOG speed (set in Parameter No. 22); release the key, and the motor will stop and remain at zero speed.
    • Press and hold the Down key (↓) to make the motor run reverse at the preset JOG speed; release the key, and the motor will stop and remain at zero speed.
Standard wiring method for servo position control mode

II. Position Mode Operation Process

The position mode allows users to control the precise position of the servo motor by sending position commands. Here are the specific steps for position mode operation:

  1. Set Basic Parameters:
    • Ensure the Servo Enable (SON) is set to OFF, and CCW Drive Inhibit (FSTP) and CW Drive Inhibit (RSTP) are both set to ON.
    • Enter the parameter setting interface and set the Control Mode Selection (Parameter No. 4) to Position Mode (value 0).
    • According to the output signal method of the controller, set Parameter No. 14 (Position Command Pulse Input Mode) and the appropriate electronic gear ratio (No. 12 and No. 13).
  2. Connect Position Command Signals:
    • Connect the position controller’s output signals to the corresponding position command input terminals of the servo driver (e.g., CN1-22/5/14/23 pins).
  3. Power On and Start:
    • Turn on both the control circuit and main circuit power supplies. After confirming no alarms or abnormalities, set the Servo Enable (SON) to ON, and the motor will enter an excited state.
    • Operate the position controller to send position commands to the servo driver, driving the motor to move precisely to the designated position.
Standard wiring method for servo speed control mode

III. Speed Mode Operation Process

The speed mode allows users to control the rotation speed of the servo motor by sending speed commands. Here are the specific steps for speed mode operation:

  1. Set Basic Parameters:
    • Ensure the Servo Enable (SON), Speed Selection 1 (SC1), and Speed Selection 2 (SC2) are all set to OFF, and CCW Drive Inhibit (FSTP) and CW Drive Inhibit (RSTP) are also OFF, or use parameters for direct control.
    • Enter the parameter setting interface and set the Control Mode Selection (Parameter No. 4) to Speed Mode (value 1).
    • Set the internal speed parameters No. 24 to No. 27 as needed.
  2. Connect Speed Command Signals:
    • Connect the output signals of the speed controller to the speed command input terminals of the servo driver (e.g., through control terminal CN2 or internal speed selection).
  3. Power On and Start:
    • Turn on both the control circuit and main circuit power supplies. After confirming no alarms or abnormalities, set the Servo Enable (SON) to ON, and the motor will enter an excited state.
    • Operate the speed controller to send speed commands to the servo driver, driving the motor to rotate at the commanded speed.

IV. Fault Codes and Solutions

  1. Err-01: IPM Module Fault
    • Cause: Circuit board failure, low supply voltage, damaged motor insulation, etc.
    • Solution: Check the driver connections, confirm normal supply voltage, and replace the faulty driver or motor.
  2. Err-03: OCU Overcurrent
    • Cause: Short circuit in U, V, W phases of the driver, poor grounding.
    • Solution: Check the driver connections, ensure proper grounding, and replace the faulty driver.
  3. Err-07: Encoder Fault
    • Cause: Incorrect encoder wiring, encoder damage, or faulty cable.
    • Solution: Check encoder wiring, replace the encoder or cable.
  4. Err-08: Speed Deviation
    • Cause: Excessively high input command pulse frequency, improper acceleration/deceleration time constants.
    • Solution: Correctly set the input pulse frequency and acceleration/deceleration time constants, check encoder status.
  5. Err-09: Position Deviation
    • Cause: Incorrect position command, encoder damage.
    • Solution: Check position commands and encoder status, reset position parameters.

By following these steps and solutions, users can effectively operate the KaiZheng Servo C&B series servo driver in JOG mode, position mode, and speed mode, and promptly address potential fault codes for better Google indexing.

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External Terminal Start & Potentiometer Speed Control with Password Security and Fault Code Analysis on CDI-EM60 and EM61 Series Inverters from Hangzhou Delixi

The CDI-EM60 and EM61 series variable frequency drives (VFDs) from Hangzhou Delixi boast robust functionalities in industrial control applications. This article delves into the external terminal start and external potentiometer speed control features of these inverters, alongside an overview of their password security and fault code analysis capabilities.

I. External Terminal Start

Pictures of Hangzhou Delixi CDI-EM60 and EM61 series drivers

The CDI-EM60 and EM61 series VFDs support versatile starting methods, including keypad control, terminal control, and communication control. External terminal start is a popular and flexible method, triggering the inverter’s start and stop through external signals.

Setup Steps for External Terminal Start:

  1. Parameter Configuration:
    • Set the P0.0.03 (Operation Control Mode Selection) to 1 for terminal control.
    • Adjust other relevant parameters such as acceleration/deceleration times and frequency sources as needed.
  2. Wiring:
    • Connect external control signals to the corresponding input terminals of the inverter (e.g., DI1, DI2).
    • Ensure compatibility between the external signal source (e.g., pushbuttons, relay contacts) and the inverter input terminals.
  3. Testing:
    • Power on and test if the external control signals correctly trigger the inverter’s start and stop.
    • Fine-tune parameters for a smooth start-up process.

Precautions:

  • Ensure external control signals adhere to the inverter’s electrical specifications.
  • Regularly inspect wiring for secure connections to prevent control failures.
Delixi VFD CDI-EM60 and EM61 External Terminal Control Wiring Diagram

II. External Potentiometer Speed Control

External potentiometer speed control adjusts the inverter’s output frequency by rotating an external potentiometer, thereby regulating motor speed.

Setup Steps for External Potentiometer Speed Control:

  1. Parameter Configuration:
    • Set the P0.0.04 (Frequency Source Selection) to 2 (Keypad Potentiometer) or 1 (External Terminal VF1, if connecting the potentiometer to VF1).
    • Adjust parameters like maximum frequency and acceleration time to suit speed control requirements.
  2. Wiring:
    • Connect the wiper, fixed terminal, and variable terminal of the potentiometer to the corresponding inverter terminals (e.g., VF1, GND).
    • Ensure the potentiometer’s electrical specifications match the inverter’s input requirements.
  3. Testing:
    • Rotate the potentiometer and observe if the inverter’s output frequency varies accordingly.
    • Adjust the potentiometer’s rotation range and inverter parameters for optimal speed control.

Precautions:

  • Regularly check potentiometer connections for reliability to prevent speed instability.
  • Avoid sudden disconnection or short-circuiting of potentiometer wiring during inverter operation.

III. Password Settings and Decoding

The Delixi inverters offer password protection to restrict unauthorized parameter modifications.

Password Setup:

  1. Access the Password Menu:
    • Navigate through the inverter’s keypad to the parameter setting interface.
    • Locate the password-related function code (e.g., P5.0.20) and enter the password setup menu.
  2. Enter the Password:
    • Input a custom 5-digit password.
    • Confirm the password and save changes before exiting the setup menu.

Password Decoding and Recovery:

  • Decoding: Enter the correct password to lift password protection and regain full inverter control.
  • Password Recovery: If forgotten, contact the inverter supplier or manufacturer for unlocking or password reset.

IV. Fault Code Analysis

During operation, the Delixi inverters may display fault codes indicating the device’s status and fault types.

  • Err01: Overcurrent During Constant Speed. Possible causes include output circuit shorts or load surges. Inspect and resolve issues before restarting the inverter.
  • Err02: Overcurrent During Acceleration. Might stem from motor/circuit shorts or inadequate acceleration time. Adjust parameters or check wiring.
  • Err04: Overvoltage During Constant Speed. Verify input voltage and bus voltage readings.
  • Err07: Module Fault. Could indicate inverter module damage, requiring replacement or professional service.
  • Err10: Motor Overload. Check for motor blockage or excessive loads, adjust motor protection parameters, or reduce the load.

Consulting the inverter manual’s fault code table enables swift troubleshooting and ensures uninterrupted production.

In conclusion, the CDI-EM60 and EM61 series VFDs from Hangzhou Delixi excel in industrial control with their versatile starting mechanisms, precise speed regulation, robust security features, and intuitive fault diagnosis. Mastering these functionalities optimizes device performance and enhances operational safety.

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Understanding and Resolving FAULT 7086 Alarm in ACS380 and ACS Series (ACS180, ACS530, ACS580, ACS880) Inverters

Introduction

When using ABB’s ACS series inverters, including ACS180, ACS530, ACS580, and ACS880, users may encounter the FAULT 7086 alarm code, which is not explicitly mentioned in the manuals for these models. This article delves into the reasons behind this alarm and provides comprehensive solutions to help users quickly identify and resolve the issue.

Fault 7086 of ABB drive

Background of FAULT 7086 Alarm

Although the operation manuals for ACS180, ACS530, ACS580, and ACS880 do not directly mention FAULT 7086, the explanation for this alarm code is found in the ACS380 (specifically designed for crane applications) manual. FAULT 7086 indicates “AI Overvoltage in I/O Module,” meaning that an overvoltage has been detected at the analog input (AI) port.

Cause Analysis

AI Port Overvoltage: When the input voltage at the AI port exceeds the set upper limit (typically 10VDC or a configurable value such as 7.5VDC), the inverter triggers the FAULT 7086 alarm to protect internal circuits from damage.

AI Signal Mode Change: If the AI signal level exceeds the acceptable range, the inverter may attempt to automatically switch the AI to voltage mode. If this fails, it will trigger the alarm.

Circuit Board Component Issues: Although the circuit board designs of ACS180, ACS530, ACS580, and ACS880 differ, they share a core control system. Issues with the mainboard, drive board connections, or related components can also lead to unexpected FAULT 7086 alarms.

The posistion of I/O module

Solutions

1.Check AI Voltage:

（1）Use a multimeter to measure the actual input voltage at the AI port and confirm if it exceeds the set upper limit.

（2）Adjust the AI port’s voltage upper limit setting, if necessary, to suit the current operating 2.environment.

（1）Inspect External Connections:

Verify that the external signal source for the AI port is normal, with no abnormal fluctuations or damage.

（2）Check the connection cables and plugs for the AI port to ensure they are securely connected and free from looseness.

3.Examine Circuit Boards and Modules:

（1）If suspecting a circuit board or module failure, first inspect the cables and plugs between the mainboard and drive board, cleaning dust and ensuring good contact.

（2）If possible, try replacing suspected circuit boards or modules to verify if the issue is resolved.

4.Refer to Relevant Documentation:

（1）Although the ACS180, ACS530, ACS580, and ACS880 manuals do not directly mention FAULT 7086, refer to the ACS380 manual for more information on handling AI overvoltage.

（2）Contact our technical team for free technical consultation and assistance

5.Reset the Inverter:

After ruling out external hardware issues, attempt to reset the inverter to see if the alarm clears.

I/O extension module of acs380

Conclusion

The FAULT 7086 alarm in ACS series inverters, including ACS180, ACS530, ACS580, and ACS880, can occur under specific circumstances not directly mentioned in their manuals. By thoroughly analyzing the alarm’s background and causes, and implementing appropriate solutions, users can effectively identify and resolve the issue. During the process, ensure safe operation and back up important data to prevent unexpected losses.

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Application of S87C196MH (MC) microcontroller in inverter mainboard

1. Pinout of the 80-pin S87C196MH (MC) microcontroller in SMD package:

2. Introduction to the structure and functions of the S87C196MH (MC) microcontroller:

The controller is a 16-bit microcontroller produced by Intel. It is widely used in inverter products due to its powerful functions and high versatility.

The internal circuit includes arithmetic logic unit (RLU), registers, internal A/D converter, PWM generator, event processing array (EPA), three-phase to complement SPWM output generator, watchdog, clock and interrupt control circuits, etc. The internal structure schematic is as follows:

 The S87C196MH (MC) microcontroller uses CHMOS technology, has an operating temperature of -40 º C–85 º C, supports 16KB EPROM, and when the crystal oscillation frequency is 16MHz, it only takes 1.75 μs to complete 16-bit by 16-bit multiplication . It is suitable for the rapidity requirements of the control system. There are 7 I/O ports, and each port pin is multifunctional.

The register array has 512B, which is divided into low 256B and high 256B. The low 256B can be used as 256 accumulators during ALU operation, and the high 256B is used as register RAM. The high 256B can also be switched to 256B with accumulator function through unique window technology. The microcontroller has 13 10-bit/8-bit high-speed A/D converters inside, and the conversion time can be set between 1.39-40.2 μs . The A/D can also be used as a programmable comparator to generate an interrupt when the input crosses a threshold level.

The event processing array (EPA) mainly performs input and output functions. In input mode, the EPA monitors the changes in the input pin signal and records its time value when the event occurs. This process is called capture. In output mode, when the timer matches a stored time value, the output pin is set, cleared or triggered. Both capture and compare events can generate normal service processes or interrupts. There are 4 capture/compare modules and 4 compare modules.

EPA also contains two 16-bit bidirectional timer/counters T1 and T2. T1 can be timed according to an external clock source. In this working mode, EPA can directly process two pulse signals with a 90 ° phase difference output by the position sensor (such as a photoelectric encoder) to monitor the speed and direction of the motor.

External event processing server (PTS). The controller has two types of interrupt systems: programmable interrupt controller and PTS. The programmable interrupt can be set to PTS interrupt service mode. PTS has several micro-instruction coded hardware interrupt service processes, which can work in parallel with the CPU and can complete data block transfer, process multi-channel A/D conversion, control serial communication and other functions.

The S87C196MH (MC) microcontroller has a three-phase complementary SPWM waveform generator built in, which directly outputs six SPWM signals through the P6 port. The driving current can reach 20 mA and the driving frequency can reach 8MHz. Each SPWM signal can be independently programmed and the dead zone interlock time can be set.

3. Application of S87C196MH (MC) in INVT inverter motherboard:

（1） Power supply, clock, reset, etc. Pins that meet the basic working conditions of the microcontroller.

（2） Pins for processing digital and analog signals at the control terminals. The start, stop and speed control of the inverter, as well as the monitoring of the working status, are all carried out through the control terminals. The input and output signals of the control terminals directly enter the microcontroller pins.

The output of the analog signal of the inverter control terminal actually comes from the PWM0 (P6 I/O port) pin of the microcontroller. The actual output is a width-modulated pulse signal, which is converted into an analog voltage signal by the subsequent circuit.

（3）Switching control signal, control of charging contactor (relay control), control of cooling fan and reset control of drive circuit (release its fault lock state).

  （5）Processing of various detection and protection signals:

（6） Processing of other functional pins

Some pins are connected to ground, +5V, or +5V via a pull-up resistor according to their functions. Some pins are left unused.

    The specific functions of each pin of the S87C196MH (MC) microcontroller have been explained in detail above. In troubleshooting, the cause of the fault can also be determined and the fault location can be found based on the level status of the relevant pins.

For example, if the signal input of a certain terminal of the inverter is invalid, measure whether there is a 0-5V voltage change on the corresponding pin of the CPU , and then quickly determine whether it is a terminal input circuit fault or a CPU fault.