June 2025 – Page 3

Posted on 2025年6月11日2025年6月12日 by baiyuzhan

Intelligent Ventilation Control System Solution Based on Longi 900 Series VFD and RKC PID Controller with Carbon Monoxide Feedback

1. Application Background and Industry Pain Points

In enclosed or semi-enclosed environments such as underground parking lots, automobile repair workshops, welding workshops, paint booths, and other industrial sites, harmful gases like carbon monoxide (CO), emitted from vehicle exhaust, fuel combustion, or industrial processes, can accumulate over time. This presents a health risk to workers and affects the quality of air. Therefore, an intelligent, automated ventilation control system is needed to monitor and regulate air circulation in real time.

Traditional ventilation systems mostly run at fixed speeds, which are simple but result in high energy consumption, low efficiency, and slow response to fluctuating CO concentrations. To address these issues, this solution designs an intelligent ventilation system based on Longi 900 Series Variable Frequency Drives (VFD) and RKC PID controllers for automatically adjusting fan speed using PID closed-loop control, ensuring good air quality in a variety of settings.

Frequency Conversion Automatic Exhaust System

2. System Components and Working Principles

1. Key Components

Module Category	Product Selection	Function Description
VFD (Variable Frequency Drive)	Longi 900 Series VFD	Controls fan speed, adjusts airflow rate automatically
PID Controller	RKC CH102 or REX-C100	Receives CO sensor input and outputs control signals (4-20mA)
Carbon Monoxide Sensor	ZE25-CO (Winsen)	Detects CO concentration in real time, outputs analog signals
Ventilation Equipment	Centrifugal Fan or Duct Fan	Regulates exhaust air according to VFD adjustments
Control Panel	Custom-made	Displays status, allows manual/automatic switch

2. Control Logic and Operation Principles

(1) CO Concentration Detection

The CO sensor (e.g., Winsen ZE25-CO) continuously monitors the CO concentration in the air, typically outputting a 4-20mA analog signal. When the concentration exceeds a set threshold, it triggers subsequent control actions.

(2) PID Controller Adjustment

The RKC PID Controller compares the actual CO concentration with the set target concentration (e.g., 30ppm) and calculates the required adjustment signal using proportional-integral-derivative (PID) logic. It then outputs a control signal (4-20mA).

(3) VFD Speed Regulation

The Longi 900 Series VFD receives the analog control signal from the PID controller and adjusts the fan motor speed accordingly. For example, if the CO concentration is high, the PID controller will instruct the VFD to increase the speed, thereby increasing the airflow for faster exhaust.

(4) Feedback and Protection

The system continuously monitors CO concentration, and when it exceeds a safe level, the fan speed is increased automatically. Once the concentration drops back to a safe level, the fan speed is reduced to the minimum. This process optimizes energy use while ensuring the safety of workers.

3. Longi 900 Series VFD Advantages

Feature	Description
PID Control Support	Built-in PID control parameters for automatic regulation based on external input
Flexible Analog Input Interfaces	Supports 0-10V, 4-20mA, and other input signals, adaptable to various control needs
High Reliability	Multiple protection features including overload, overvoltage, and overheat safeguards
Energy Efficiency	Wide speed regulation range (0-500Hz), enabling precise fan speed adjustments to reduce energy consumption
Ease of Maintenance	User-friendly interface, easy to maintain, and extend device lifespan

4. Suggested System Configuration

Name	Model	Quantity	Description
VFD	Longi 900 Series 900-0015G3 (1.5kW)	1 unit	Drives the fan, adjusts speed according to PID control signals
PID Controller	RKC CH102	1 unit	Receives CO sensor signal, outputs control signal (4-20mA)
CO Sensor	Winsen ZE25-CO	1 unit	Detects CO concentration, outputs analog signal
Fan and Motor	YVF2 1.5kW + Centrifugal Fan	1 set	Core of the system, performs exhaust tasks
Control Panel	Custom-made	1 unit	Includes operation buttons, display indicators, emergency stop

Suggested Parameter Settings

For Longi 900 Series VFD, the following parameters are recommended:

Parameter	Description	Suggested Value
F0-00	Command Source	1 (External Terminal Control)
F0-01	Main Frequency Source	2 (AI1)
F5-02	PID Feedback Source	1 (Analog Input)
F5-08	Sensor Type	1 (4-20mA)
F5-01	PID Setpoint	30ppm (Reference Value)
F0-04/05	Acceleration/Deceleration Time	5-10s

5. System Deployment and Maintenance Recommendations

1. Installation and Layout

Sensor Installation: CO sensors should be installed in central locations or at the end of exhaust ducts, approximately 1.5-2 meters above the floor, to ensure complete area monitoring.
PID Controller: Should be installed in a location visible to the operator for easy adjustment of parameters.
VFD and Fan Installation: VFD should be installed in an electrical control cabinet with adequate ventilation, avoiding high temperatures and humidity.

2. System Debugging and Operation

Before powering up, verify that the wiring is correct, especially ensuring that the VFD output terminals (U/V/W) are not connected to the mains.
Set the RKC PID Controller:
- Setpoint (SV) to 30ppm.
- Control mode to PID, output signal set to 4-20mA.
After connecting the CO sensor, adjust PID parameters (proportional, integral, and derivative gains) for optimal system response.

3. Maintenance and Upkeep

Equipment	Maintenance Task	Frequency
CO Sensor	Zero-point calibration and functionality check	Every 6 months
PID Controller	Output signal and display check	Every 12 months
VFD	Heat sink cleaning and electrical check	Every 12-18 months
Fan Motor	Lubrication and current measurement	Every 3-6 months

6. System Upgrades and Expansion Recommendations

1. Remote Communication Module

The Longi 900 Series VFD supports Modbus RTU communication. Add a remote communication module for cloud-based monitoring, data logging, and alarm notifications, enabling more advanced smart management.

2. Multi-Region Control

For large workshops or parking lots, deploy multiple independent ventilation units, each with its own CO sensor, to control fan speeds regionally, optimizing energy use.

3. Integration of Particulate Matter (PM2.5/PM10) Sensors

Expand the system to monitor and control particulate pollution, ensuring air quality across various industrial processes.

4. Lighting System Integration

Incorporate lighting control, turning on both the lights and the ventilation system when personnel enter a room, and turning them off after a delay once they exit, further reducing energy consumption.

7. Conclusion and Value Proposition

With the Longi 900 Series VFD, RKC PID Controllers, and CO Sensor Integration, this system enables automatic fan speed adjustment to ensure air quality and worker safety. By utilizing energy-efficient, smart control, this solution meets the needs of environments like workshops, parking garages, and industrial sites, and provides significant benefits in terms of energy savings, safety, and environmental health.

This system is an ideal solution for maintaining high standards of air quality while optimizing energy use in industrial facilities.

Posted on 2025年6月11日2025年6月12日 by baiyuzhan

Multi-Speed Control via S1/S2/S3 Terminals on INVT Goodrive20 VFD

In industrial automation, multi-speed control is a practical and efficient method to handle varying load requirements using a Variable Frequency Drive (VFD). This article provides a step-by-step guide on configuring the INVT Goodrive20 series VFD to implement 3-wire (S1, S2, S3) multi-speed operation, suitable for up to 8 preset speed levels.

1. Control Principle

The Goodrive20 supports up to 16 speed levels, selectable through combinations of digital input terminals (S1 to S4). Each terminal acts as a binary bit, and the combination determines which speed level is active.

Using S1, S2, and S3, we can implement 8 speed levels (0–7):

S3	S2	S1	Speed Segment	Frequency Parameter
0	0	0	Segment 0	`P10.00`
0	0	1	Segment 1	`P10.01`
0	1	0	Segment 2	`P10.02`
0	1	1	Segment 3	`P10.03`
1	0	0	Segment 4	`P10.04`
1	0	1	Segment 5	`P10.05`
1	1	0	Segment 6	`P10.06`
1	1	1	Segment 7	`P10.07`

Adding S4 (set as Multi-speed terminal 4) will expand the system to 16 segments (P10.00 ~ P10.15).

2. Wiring Overview

The terminals S1, S2, and S3 are digital input ports capable of receiving NPN or PNP signals from external switches, PLC outputs, or push buttons. By default, the control system uses an internal +24V supply, and the digital signals return to the PW common terminal.

3. Parameter Setup

Step 1: Set frequency source to Multi-Speed

P00.06 = 6   // Selects Multi-Speed as the frequency reference

Step 2: Assign S1, S2, S3 as Multi-Speed Inputs

Navigate to group P05, and configure input terminal functions:

Parameter	Description	Value
P05.00	S1 terminal function	16 (Multi-speed terminal 1)
P05.01	S2 terminal function	17 (Multi-speed terminal 2)
P05.02	S3 terminal function	18 (Multi-speed terminal 3)

If S4 is used:

P05.03 = 19 // S4 = Multi-speed terminal 4

Step 3: Configure Frequency Values for Each Segment

Set the desired frequency for each segment using parameters P10.00 ~ P10.07:

Parameter	Segment	Example Value
P10.00	0	5.00 Hz
P10.01	1	10.00 Hz
P10.02	2	15.00 Hz
P10.03	3	20.00 Hz
P10.04	4	25.00 Hz
P10.05	5	30.00 Hz
P10.06	6	35.00 Hz
P10.07	7	40.00 Hz

You may adjust values according to your application needs. Each value must be ≤ P00.03 (Max Output Frequency).

4. Operation Conditions & Notes

The VFD must be running (Run command active) for multi-speed changes to take effect.
Transitions between speed levels will follow acceleration/deceleration ramp settings.
The default logic mode is NPN (sinking). If using PNP (sourcing) inputs, adjust the U-type jumper on the terminal board.
Independent acceleration/deceleration times per segment can be configured in P10.16 ~ P10.31.
If signal changes are sluggish, verify the input filter time via P07.10.

5. Example Configuration (3-bit 8-Speed Control)

P00.06 = 6        // Frequency source = Multi-speed
P05.00 = 16       // S1 = Multi-speed terminal 1
P05.01 = 17       // S2 = Multi-speed terminal 2
P05.02 = 18       // S3 = Multi-speed terminal 3

P10.00 = 5.00     // Segment 0
P10.01 = 10.00    // Segment 1
P10.02 = 15.00    // Segment 2
P10.03 = 20.00    // Segment 3
P10.04 = 25.00    // Segment 4
P10.05 = 30.00    // Segment 5
P10.06 = 35.00    // Segment 6
P10.07 = 40.00    // Segment 7

6. Conclusion

The Goodrive20 VFD’s multi-speed functionality provides a robust method for achieving stepwise speed control using simple external switches or digital outputs. It is ideal for applications such as conveyors, fans, and pumps. With the correct parameter setup and terminal wiring, you can enable a highly flexible speed selection system without needing complex PLC programming.

Posted on 2025年6月10日2025年6月12日 by baiyuzhan

Implementation Plan for Automated Control System of Mooncake Production Line

Based on Longi 900 Series Inverter and Mitsubishi FX3U PLC

1. Project Background

Mooncakes are a traditional Chinese delicacy with cultural significance, especially during the Mid-Autumn Festival. With increasing market demand for quality, production capacity, and hygiene standards, traditional manual production methods have become inadequate. Therefore, building an efficient, stable, and intelligent automated mooncake production system is crucial.

This project proposes an automation control system integrating the Mitsubishi FX3U PLC, Weintek HMI, and Rongji 900 series inverter to manage the entire mooncake manufacturing process—from dough and filling feeding, encrusting, pressing, forming, tray loading, baking, cooling, to final packaging. The system aims to provide a flexible, reliable, and cost-effective solution for small to medium-sized food manufacturers.

Schematic Diagram of Mooncake Production Line

2. Detailed Workflow and Production Line Principle

2.1 Overall Operating Principle

The mooncake production line consists of a series of interconnected machines controlled by PLC logic, frequency inverters, and HMI interfaces. Key mechanisms include:

Synchronization of multiple machines via conveyor belts;
Detection of workpiece positions using photoelectric sensors;
Speed control of motors via inverters for precise encrusting, molding, and tray feeding;
Time-sequenced logic from the PLC ensures no process conflicts;
Real-time monitoring and parameter setting via HMI.

2.2 Detailed Workflow Breakdown

Stage	Description
1. Raw Material Feeding	Dough and filling are independently fed via hoppers. Dough is delivered using screw or belt feeders, while filling (e.g., lotus paste, egg yolk) is fed by twin-screw or extrusion pumps.
2. Encrusting	An automatic encrusting machine proportionally wraps dough around the filling. Three synchronized feeding systems ensure consistent weight and shape of each mooncake ball.
3. Molding and Pressing	Mooncake balls are first shaped by a vibrating pre-former, then enter the press system. The top-down mold structure creates floral patterns and sets thickness using pneumatic or servo mechanisms.
4. Conveying & Alignment	Molded mooncakes are neatly aligned by guide rails and pushed into baking trays using mechanical pushers. The process is synchronized to avoid overlaps or gaps.
5. Baking	Multi-zone tunnel ovens provide accurate heat distribution (e.g., upper/lower heat). Temperature sensors and alarms ensure safe operation. Advanced models may include vision-based feedback control.
6. Cooling	After baking, mooncakes cool for 5–10 minutes via mesh-belt forced-air systems. Adjustable air speed/direction ensures even cooling, with flipping mechanisms for underside exposure.
7. Inspection	Metal detectors and weight checkers remove defective or foreign-object-containing products.
8. Packaging	Qualified mooncakes are guided by robotic arms or channels into packaging machines for automatic wrapping, sealing, coding, and boxing. The system synchronizes with the conveyor line via PLC signals.

This line typically supports 50,000 to 200,000 pieces/day with a throughput of 60–120 pieces per minute and easily accommodates various flavors and sizes.

3. System Architecture

3.1 Mitsubishi FX3U PLC

Manages all I/O signals (e.g., sensors, buttons, alarms);
Includes main program, interrupt routines, and PID modules for real-time operation;
MODBUS-compatible for seamless communication with Rongji inverters;
Expandable with high-speed counting modules for precise positioning.

3.2 Rongji 900 Series Inverter

Drives dough feeders, encrusters, mold presses, tray pushers, etc.;
Supports VF and SVC modes for high torque at low speeds;
Built-in PID for closed-loop control (e.g., pressure in mold presses);
Multi-speed (F4) support with 8-step preset frequencies;
Rich I/O terminals for flexible integration.

3.3 Weintek HMI (e.g., TK6071iQ)

Communicates with PLC via RS-232 or MODBUS-RTU;
Enables menu control, recipe switching, alarms, and statistics;
Supports USB recipe import/export and data logging for quality control.

4. Sample Control Logic

Encrusting Module

DI1: Start signal
AI1: Speed reference (from HMI or upper system)
DO1: Completion signal to trigger the next stage

Molding Module

PLC monitors position sensor and triggers press motor;
Rongji 900 inverter reads pressure sensor input via AI and uses PID to maintain consistent pressing force.

Tray Loading Module

PLC controls solenoid valves and pushers based on production rhythm;
Light sensors detect tray availability;
System halts and alarms when trays are missing.

5. Advantages of Longi 900 Series Inverter

The longi 900G3 inverters demonstrated the following key strengths in this project:

Strong Low-Speed Torque: 150% torque at 0.5Hz ensures stable encrusting and precise tray loading;
Flexible Control Modes: VF and SVC switching adapts to fast feeding and slow pressing tasks;
Built-in PID: Reduces PLC workload and hardware requirements;
Compact and Cost-Effective: Ideal for upgrading production lines in small/medium food factories;
Simple, Reliable Communication: Easy-to-configure MODBUS registers speed up commissioning.

6. Conclusion

This automation system combines Mitsubishi FX3U PLC, Rongji 900 inverters, and Weintek HMI to create a comprehensive, efficient, and stable mooncake production solution. It features flexible parameter settings, smooth operation, high productivity, and easy scalability and maintenance.

As a key drive component, the Longi inverter stands out for its excellent performance and affordability—making it not only ideal for this project, but also highly recommended for other food processing lines such as pastry, frozen food, and beverage packaging.

Posted on 2025年6月7日2025年6月9日 by baiyuzhan

What Does “REnt” and “rEAd0” Mean on Delta VFD-VE Inverter? Full Explanation and Solutions

Delta’s VFD-VE series inverters are widely used in various industrial automation applications for their stable performance and advanced vector control (FOC) capabilities. However, users may encounter some English prompts on the operator panel during operation, such as “REnt” or “rEAd0”, which can be confusing, especially for first-time users.

This article explains the meaning of these two prompts, the reasons why they appear, and how to properly handle or exit these states. By the end of this guide, you’ll be equipped to interpret the panel messages correctly and operate your Delta VFD-VE more efficiently.

1. Overview of the VFD-VE Control Panel

The Delta VFD-VE operator panel features a 4-digit LED display and several functional buttons for mode switching, programming, and motor control. The key components include:

RUN: Starts the motor
STOP/RESET: Stops operation or resets faults
PU: Toggles between panel (PU) and external (EXT) control
MODE: Switches display modes or exits menus
PROG/DATA: Enters or confirms parameter settings
Arrow keys: Scroll through parameters and values

During operation or configuration, the panel may display messages such as “REnt” or “rEAd0”. Let’s explore their meanings.

2. What Does “REnt” Mean?

2.1 Meaning:

“REnt” stands for Remote Enable Terminal.

This message indicates that:

The inverter is currently in External Control Mode (EXT).
A valid remote enable signal has been received from the multi-function input terminals (e.g., MI1).
The inverter is in a “standby” state, ready to run, but the external “RUN” command has not yet been issued.

2.2 When It Appears:

“REnt” usually appears when:

Parameter P00.20 = 2 (Start/Stop command source is external terminal).
One of the MI (multi-input) terminals is configured as a Run Enable input (e.g., MI1 = 03).
The control circuit is powered, and the inverter is waiting for the “Run” signal.

2.3 How to Handle:

This is not a fault. No action is required if you intend to control the inverter remotely.

To run the inverter from external terminals:

Ensure the RUN enable input (e.g., MI1) is active (closed contact or ON signal).
Assign another terminal (e.g., MI2) as the RUN command (Forward or Reverse).
Verify that all input logic is configured properly in parameter group P05.

2.4 Switch to Panel (PU) Mode:

If you prefer controlling the inverter from the panel:

Press the PU key to change to panel control.
Press RUN to start the motor.
Check parameters:
- P00.20 = 0 (Start command from PU)
- P00.21 = 0 (Frequency source from PU)

3. What Does “rEAd0” Mean?

3.1 Meaning:

“rEAd0” means Read Parameter Group 0.

This message appears when the user enters the programming mode by pressing the PROG/DATA key. It indicates that parameter group 0 (P00) is currently selected for reading or editing.

3.2 When It Appears:

You’ll see “rEAd0” when:

You press the PROG/DATA button to access parameter settings.
The inverter is waiting for you to choose which parameter group you want to enter.

Main parameter groups on VFD-VE include:

Group	Description
P00	Main control settings
P01	Acceleration/deceleration and limits
P02	Input terminal assignments
P09	Protection settings
P99	System configuration and reset

3.3 How to Navigate:

Use the UP/DOWN arrows to select other groups (e.g., P01, P09).
Press RIGHT arrow to enter the group.
Use UP/DOWN arrows to browse parameters (e.g., 00.00, 00.01).
Press PROG/DATA to view or modify a value.
Press PROG/DATA again to confirm.

3.4 Exit Programming Mode:

Press the MODE key to return to the main display screen.

4. Common Misunderstandings and Tips

Misconception: “REnt” means “Return”

Many users mistakenly think REnt = Return, but in Delta inverters, it clearly stands for Remote Enable, indicating readiness to receive a run command via external terminal.

Misconception: “rEAd0” indicates a fault

“rEAd0” simply shows that you’re accessing parameter group 0. It’s a normal prompt, not an error or alarm.

5. Summary Table

Display	Meaning	Is It a Fault?	Recommended Action
REnt	Remote enable received	❌ No	Wait for external RUN signal or switch to PU
rEAd0	Reading parameter group 0	❌ No	Browse or edit parameters using arrows

6. Best Practices

Familiarize yourself with parameter groups, especially P00, P01, and P05.
Set P00.20 and P00.21 properly based on control preference (PU or EXT).
Use PROG/DATA and MODE keys wisely to enter/exit programming mode.
Use P99.01 to restore factory settings if needed.

7. Conclusion

Understanding messages like “REnt” and “rEAd0” on the Delta VFD-VE inverter panel is crucial for proper operation and maintenance. These prompts help users know the current control mode and parameter status, and recognizing them allows for smoother commissioning and troubleshooting.

Posted on 2025年6月6日2025年6月6日 by baiyuzhan

ACS850 Inverter Fault “03:58A” On-site Troubleshooting and Maintenance Guide

Introduction

The ABB ACS850 inverter is a widely used AC motor control device in the industrial sector, renowned for its high flexibility and reliability. However, when the inverter displays the fault code “03:58A”, it may indicate an issue with the Encoder Interface Module (FEN-XX) or the communication between the encoder and the inverter, leading to equipment shutdown. This document provides detailed instructions on how to diagnose and repair this fault on-site, including checking physical connections, testing hardware, adjusting parameters to support encoder-less operation, as well as maintenance and preventive measures. By following a systematic approach, technicians can quickly locate the problem and restore equipment operation.

Meaning of Fault Code “03:58A”

The fault code “03:58A” is not explicitly listed in the standard ACS850 fault code list (as per the ABB ACS850 manual) and may be a specific error code for the FEN-XX module or a non-standard display on the user interface. Based on user descriptions, this fault is related to the FEN-XX module and encoder connection. Possible causes include:

Physical Connection Issues: Loose encoder cables, damaged cables, or poor connector contact.
Hardware Failure: Damage to the FEN-XX module, encoder, or inverter communication interface.
Parameter Configuration Errors: Mismatch between the encoder module configuration expected by the inverter and the actual hardware.
Power Supply Problems: Unstable supply voltage affecting the communication channel.

Understanding these potential causes helps in formulating an effective diagnostic strategy.

On-site Diagnostic Steps

When the ACS850 displays the fault code “03:58A”, technicians should follow these steps for diagnosis:

1. Check Physical Connections

Steps:

Confirm that the FEN-XX module (e.g., FEN-01, FEN-11, or FEN-21) is firmly inserted into slot 1 or slot 2 of the inverter.
Inspect the encoder cable for breaks, wear, or corrosion.
Ensure that connectors are not loose or have poor contact.

Tools: Screwdriver, multimeter (for testing cable continuity).

Precautions: Disconnect power and follow lockout/tagout procedures to ensure safety.

2. Check for Hardware Damage

Steps:

Inspect the inverter, FEN-XX module, and encoder for signs of burning, capacitor bulging, or other electrical stress.
If possible, test with a spare, known-good module or encoder.

Tip: Record any abnormalities (such as burn marks or odors) for further analysis.

3. Verify Parameter Settings

Steps:

90.01 Enc Module Sel: Should be set to 0 (None) if no encoder is used.
90.02 Encoder 2 Sel: Set to 0 (None) if no second encoder is present.
90.05 Enc Cable Fault: Set to 0 (No) to avoid fault alarms when no encoder is used.

Access the parameter menu using the control panel or DriveStudio software.

Check parameters related to the encoder module:

Confirm that the control mode (parameter 40.01) matches the current hardware configuration.
Reference: ABB ACS850 firmware manual.

4. Test the Module and Inverter

Steps:

If the fault disappears, the issue may be with the module or its connection.
If the fault persists, check the inverter’s communication interface.

Remove the FEN-XX module and attempt to run the inverter:

Replace the current module with a known-good FEN-XX module and observe if the fault is resolved.

Note: Record the results of each test to trace the source of the problem.

5. Check Power Supply Stability

Steps:

Use a multimeter to measure the supply voltage to the inverter and module, ensuring it meets specifications (e.g., 230V or 400V).
Check for voltage fluctuations or interruptions that may affect communication.

Recommendation: Use an uninterruptible power supply (UPS) or voltage stabilizer to improve stability.

Parameter Adjustment for Encoder-less Operation

If the application does not require an encoder, the ACS850 can operate using sensorless vector control or V/f control. These modes rely on internal algorithms to estimate motor speed without encoder feedback, suitable for applications with lower precision requirements. Below are the key parameters to adjust:

Parameter Number	Parameter Name	Recommended Setting	Description
90.01 Enc Module Sel	Encoder Module Selection	0 (None)	Disable encoder module
90.02 Encoder 2 Sel	Secondary Encoder Selection	0 (None)	Disable second encoder
90.05 Enc Cable Fault	Encoder Cable Fault	0 (No)	Avoid fault alarms when no encoder is used
19.02 Speed to Sel	Speed Source Selection	0 or 2 (Estimated)	Use internal speed estimation
40.01 Control Mode	Control Mode Selection	1 (V/f control) or 3 (Sensorless vector control)	Select appropriate control mode
33.02 Superv1 Act	Supervision 1 Actual Value	Speed rpm	Use estimated speed value instead of encoder value

Operational Notes:

V/f Control (Parameter 40.01 = 1): Suitable for applications with low speed precision requirements.
Sensorless Vector Control (Parameter 40.01 = 3, depending on firmware version): Provides better low-speed performance but requires correct setup of motor parameters (such as rated voltage, current, frequency).
Switching to encoder-less mode may reduce control precision at low speeds, which should be evaluated based on application requirements.

Specific parameter values may vary by firmware version; it is recommended to refer to the ABB ACS850 firmware manual.

Determining the Fault Source

To accurately determine whether the fault originates from the inverter, encoder, or interface module, perform the following tests:

1. Inverter Test

Method: Remove all option modules and attempt to run the inverter.

Results:

If the fault code “03:58A” disappears, the issue may be with the FEN-XX module or its connection.
If the fault persists, there may be an issue with the inverter’s communication interface.

2. Module Test

Method: Replace the current FEN-XX module with a known-good module and restart the inverter.

Results:

If the fault disappears, the original module may be damaged.
If the fault persists, check the cable or inverter.

3. Cable Test

Method: Use a multimeter or cable tester to check the continuity and correct wiring of the encoder cable and module connection cable.

Results: Replace the cable if a break or short circuit is found.

4. Diagnostic Parameter Check

Method: Check parameter group 08 (Alarms & Faults) for any other communication errors or hardware fault indications.

Tool: Control panel or DriveStudio software.

Maintenance and Replacement

Based on the diagnostic results, take the following maintenance measures:

1. Repair Loose Connections

Refasten loose cables or connectors to ensure good contact.
Clean connectors to remove dust or corrosion.

2. Replace Damaged Cables

Replace damaged cables with shielded cables of the same specifications to reduce electromagnetic interference.
Ensure cable length and wiring comply with ABB recommended standards.

3. Replace Faulty Modules

If the FEN-XX module or encoder is damaged, replace it with a compatible model (e.g., FEN-01, FEN-11, or FEN-21).
After replacement, reconfigure relevant parameters (such as 90.01, 90.02).

4. Inverter Repair

If the issue is with the inverter itself, contact ABB technical support for repair or replacement.
Do not attempt to repair internal components of the inverter unless you are a certified technician.

Safety Precautions

Power Disconnection: Disconnect power and wait for capacitors to discharge (usually 5 minutes) before touching any internal components.
Protective Gear: Wear insulating gloves and safety glasses.
Lockout/Tagout: Follow lockout/tagout procedures to prevent accidental startup.
Grounding Check: Ensure the equipment is properly grounded to reduce electromagnetic interference.

Preventive Measures

To prevent similar faults from recurring, it is recommended to:

Regular Maintenance: Inspect cables, connectors, and modules every 6 months.
Firmware Updates: Keep the inverter firmware up to date to fix known issues.
Parameter Backup: Use DriveStudio to back up parameter settings for quick restoration.
Environmental Control: Ensure the inverter operates in an environment that meets temperature, humidity, and cleanliness requirements (refer to the ABB ACS850 hardware manual).

Conclusion

The ACS850 inverter fault code “03:58A” may be related to the Encoder Interface Module (FEN-XX) or encoder communication issues. By checking physical connections, testing hardware, adjusting parameters for encoder-less operation, technicians can quickly resolve the problem. Determining the fault source (inverter, encoder, or module) is a critical step, requiring a combination of physical inspection and parameter analysis. If the issue is complex, contacting technical support is advisable. Regular maintenance and proper configuration can significantly reduce the occurrence of such faults, ensuring reliable operation of industrial systems.

Posted on 2025年6月5日2025年6月6日 by baiyuzhan

Shihlin SS2 Inverter “ou0” Fault: Analysis and Solutions

Introduction

In the field of industrial automation, Variable Frequency Drives (VFDs) are essential for controlling motor speed and torque. The Shihlin SS2 series inverter is widely recognized for its efficiency and reliability across various industrial applications. However, like any electronic device, it may encounter faults, one of which is the “ou0” fault—a common issue that can lead to downtime and affect productivity. This article provides an in-depth analysis of the “ou0” fault, its causes, and detailed solutions to help users restore normal operation swiftly.

What Is the “ou0” Fault?

The “ou0” fault code typically indicates that the inverter has detected an excessively high DC bus voltage, a condition known as overvoltage. The DC bus is a critical component in the inverter that converts AC input into DC before inversion. When the DC bus voltage exceeds the safety threshold, the inverter triggers a protective mechanism, displaying “ou0” and halting operation to prevent damage to internal components like the IGBT module. On the Shihlin SS2 inverter’s control panel, “ou0” is usually shown in red, accompanied by an abnormal status of the operation indicator light.

Common Causes of the “ou0” Fault

Overvoltage faults can stem from multiple factors, with the following being the most prevalent:

High Input Voltage
If the AC input voltage exceeds the inverter’s rated range (typically 380V ±15%), the DC bus voltage rises accordingly. Grid fluctuations, poor power quality, or external disturbances like lightning strikes can contribute to this issue.
Regenerative Energy Feedback
During motor deceleration, especially with high-inertia loads (e.g., CNC machines or heavy machinery), the motor can act as a generator, feeding energy back to the inverter. If the deceleration time is too short or there is no mechanism to dissipate this energy, the DC bus voltage spikes.
Component Aging or Failure
DC bus capacitors play a vital role in absorbing and stabilizing voltage. Aging or damaged capacitors may fail to perform, leading to voltage fluctuations. Additionally, faults in the rectifier or inverter modules can also cause overvoltage.
Improper Parameter Settings
A deceleration time set too short is a frequent misconfiguration, causing regenerative energy to accumulate rapidly. Other parameters, such as voltage regulation settings, may also impact voltage stability.
External Factors
- Excessively long cables or degraded insulation can introduce voltage interference or leakage.
- Environmental conditions like high temperatures or dust accumulation may affect the inverter’s cooling and performance.

Diagnosing the “ou0” Fault

To accurately identify the cause of the “ou0” fault, a systematic diagnostic approach is recommended:

Check Input Voltage
Use a multimeter to measure the three-phase input voltage of the inverter, ensuring it falls within the Shihlin SS2 series’ rated range (typically 380V ±15%). If the voltage is too high or fluctuates significantly, investigate grid stability or external interference.
Review Deceleration Time Settings
Access the inverter’s parameter settings through the control panel and check the deceleration time parameter (possibly P.02, as per the manual). If the deceleration time is too short (e.g., 2 seconds), consider extending it to 5 seconds or more to reduce regenerative energy buildup.
Inspect DC Bus Capacitors
If possible, use a capacitance tester to measure the DC bus capacitors’ capacitance and equivalent series resistance (ESR). Aging capacitors may show reduced capacitance or physical damage (e.g., bulging or leakage). Replace them if necessary.
Evaluate Load Characteristics
Determine if the load is high-inertia (e.g., heavy machinery or fans). High-inertia loads generate significant regenerative energy during deceleration, potentially requiring additional braking equipment.
Inspect Cables and Grounding
Ensure the output cable length does not exceed the recommended limit (typically 50 meters) and check the cable insulation for integrity. Verify that the inverter is properly grounded to avoid electrical noise or static interference.
Use Diagnostic Tools
If the inverter supports communication features, connect diagnostic software to view detailed fault logs. Record the operating condition during the fault (e.g., acceleration, deceleration, or constant speed) for further analysis.

Solutions

Based on the diagnosis, the following measures can resolve the “ou0” fault:

Adjust Deceleration Time
Extending the deceleration time is a simple and effective way to address regenerative energy issues. Access the parameter settings via the control panel and adjust the deceleration time (e.g., P.02) from a short duration (like 2 seconds) to 5 seconds or longer, depending on the load characteristics.
Install a Braking System
For high-inertia loads, installing a braking resistor and braking unit is highly recommended. The braking resistor dissipates excess regenerative energy as heat, preventing the DC bus voltage from rising beyond the protection threshold. Ensure the resistor matches the inverter model, as specified in the Shihlin SS2 manual.
Stabilize Input Voltage
If the grid voltage is unstable, consider installing a voltage regulator or reactive power compensation device. A line reactor can also help filter high-order harmonics, improving power quality.
Replace Faulty Components
If the capacitors or other internal components are damaged, they should be replaced by a qualified technician. Ensure the power is disconnected and safety protocols are followed during replacement.
Optimize Environmental Conditions
Ensure the inverter is installed in a well-ventilated, temperature-controlled environment. Regularly clean the heat sink and fan to prevent dust buildup that could impair cooling.
Reset Parameters
If parameter settings may be incorrect, reset the inverter to factory defaults (often by holding the “STOP/RESET” key while powering on, as per the manual). Reconfigure the necessary parameters afterward.

Preventive Measures

To prevent the recurrence of the “ou0” fault, consider the following:

Regular Maintenance: Inspect the inverter’s capacitors, connectors, and cooling system every 6-12 months to ensure optimal condition.
Monitor Power Quality: Use a power quality analyzer to periodically check the input voltage stability and address potential issues early.
Optimize Parameter Settings: Adjust acceleration and deceleration times to match the load characteristics, ensuring compatibility with the application.
Install Protective Equipment: In lightning-prone areas, install surge protection devices to safeguard the inverter from transient overvoltage.

Case Study

In a manufacturing plant, a Shihlin SS2 inverter controlling a CNC machine frequently reported the “ou0” fault during rapid deceleration. Technicians first measured the input voltage, confirming it was within 380V ±10%, ruling out power supply issues. They then reviewed the parameters and found the deceleration time set to 2 seconds, which was too short. After extending it to 5 seconds, the fault ceased. To further enhance reliability, the plant installed a braking resistor, effectively managing the regenerative energy from the high-inertia load. This case highlights the importance of proper parameter adjustments and hardware upgrades in resolving the “ou0” fault.

Conclusion

The “ou0” fault in the Shihlin SS2 inverter is typically an overvoltage issue caused by factors like input voltage anomalies, regenerative energy buildup, or component failure. Through systematic diagnosis (e.g., checking voltage, adjusting parameters, installing braking systems), users can effectively address the issue. Regular maintenance and optimized settings are key to preventing future faults. If the problem persists, professional technical support is advised to ensure safe and reliable operation.

Common Overvoltage Fault Codes and Solutions

Below is a summary of typical overvoltage faults in inverters for reference:

Fault Code	Description	Possible Causes	Solutions
OV1	Overvoltage during acceleration	High input voltage, short acceleration time	Extend acceleration time, check input voltage
OV2	Overvoltage at constant speed	Regenerative energy buildup, capacitor failure	Check capacitors, install braking unit
OV3	Overvoltage during deceleration	Short deceleration time, high-inertia load	Extend deceleration time, install braking resistor
OU	General overvoltage alarm	High DC bus voltage, external interference	Check voltage, address cable issues, install lightning protection

Note: The Shihlin SS2 may use “ou0” to denote overvoltage, which should be confirmed with the specific manual.

Posted on 2025年6月4日2025年6月5日 by baiyuzhan

What’s the matter with the FF8E warning appearing on the ABB ACS800 series frequency converter, and how can it be resolved?

Introduction

The ABB ACS800 series frequency converter is a robust solution widely used in industrial applications, supporting a power range from 0.75 to 7500 horsepower. However, one common issue users may encounter is the FF8E warning, which signals that the drive has not received the “Run Enable” signal required for operation. This article provides a detailed exploration of the FF8E warning, its causes, diagnostic steps, and solutions, drawing from official documentation and practical insights to guide users effectively.

Understanding the FF8E Warning

The FF8E warning, classified as a “Run Enable” alert in the ACS800 series, indicates that the drive has not detected the necessary signal to start or continue motor operation. This signal serves as a safety and control mechanism, typically provided by an external device such as a PLC, control panel, or through fieldbus communication. When this signal is missing, the drive cannot operate, potentially disrupting production. The root causes of the FF8E warning generally fall into categories like parameter misconfiguration, wiring issues, or, less commonly, hardware faults.

Causes of the FF8E Warning

Based on ABB documentation and online discussions, the FF8E warning can be attributed to several potential causes:

Parameter Configuration Issues
- Incorrect Parameter 16.01 (RUN ENABLE) Setting: This parameter defines the source of the run enable signal. If misconfigured, the drive will fail to detect the signal.
  - Setting Options:
    - YES: Internal enable, no external signal required.
    - DI1-DI12: Signal provided via a specified digital input, which must be active.
    - COMM.CW: Signal provided via fieldbus communication, requiring active communication.
- Signal Not Active: Even with the correct setting, if the digital input is not energized or the communication control word is not sent, the warning will persist.
- Communication Failure: When set to COMM.CW, any interruption in fieldbus communication or failure to send the correct control word can trigger the FF8E warning.
Wiring Issues
- Poor 24VDC Contact: Unstable 24VDC power supply at pins 8 and 11 of the socket (e.g., due to loose contacts or corrosion) can disrupt the digital input signal.
- Faulty Signal Source Wiring: Loose or damaged wiring for the run enable signal source can prevent the signal from reaching the drive.
Hardware Issues
- Mainboard or Digital Port Circuit Failure: Though rare, a damaged mainboard or digital port circuit can prevent the drive from detecting the signal. This is typically considered only after ruling out other causes.
- Optional I/O Module Misconfiguration: If using extended I/O modules, improper configuration can lead to signal transmission failures.

Diagnostic and Resolution Steps

To effectively address the FF8E warning, users should follow these systematic steps:

Verify Parameter 16.01 Settings
- Using the drive’s control panel or a parameter configuration tool, confirm that parameter 16.01 aligns with the intended control method. For instance, if using a digital input, set it to the corresponding DI number; if using fieldbus, set it to COMM.CW.
- Refer to the ACS800 Standard Control Program Firmware Manual (pages 42 and 252) for detailed parameter descriptions.
Validate the Run Enable Signal
- Digital Input: Check if the specified digital input (e.g., DI1-DI12) is active. This can be verified via the control panel or by measuring the voltage at the input terminal with a multimeter.
- Communication Control: If using COMM.CW, ensure the fieldbus (e.g., Modbus or Profibus) connection is active and the control word (Main Control Word 03.01, bit 3) is correctly sent.
Inspect Wiring
- Focus on the 24VDC supply at pins 8 and 11 of the socket, ensuring secure contact with no looseness, corrosion, or contamination.
- Check the wiring of the run enable signal source for continuity, ensuring there are no open circuits or shorts.
Check Optional I/O Modules
- If the drive uses extended I/O modules, verify the settings in parameter group 98 (OPTION MODULES) to ensure the module is correctly configured and active.
Hardware Inspection
- If the above steps fail, a hardware issue may be present. Open the drive and inspect the mainboard and digital port circuits for visible damage or poor connections.
- Replacing the mainboard should be a last resort, pursued only after confirming a hardware fault, and ideally under guidance from ABB technical support.
Consult Official Documentation and Support
- Refer to the ACS800 Firmware Manual sections on “Start/Stop Control” and “Fault Tracing” for additional guidance.
- For complex issues, contact ABB technical support for professional assistance.

Deep Dive into Parameter 16.01

Parameter 16.01 (RUN ENABLE) is central to resolving the FF8E warning. Below is a detailed breakdown:

Parameter Name	Default Setting	Function Description	Setting Options
16.01 RUN ENABLE	YES	Selects the source of the run enable signal, determining if the drive is allowed to operate	– YES: Internal enable, no external signal needed – DI1-DI12: Controlled via digital input – COMM.CW: Controlled via fieldbus

Key Notes:
- When using the Generic Drive protocol, set parameter 16.01 to “YES” to enable control via the fieldbus (Main Control Word 03.01, bit 3).
- The run enable signal must be active for the drive to respond to start commands, such as an ID Run.

Hardware Concerns: Mainboard and Digital Port Circuits

While the FF8E warning is typically caused by configuration or wiring issues, hardware faults—such as a damaged mainboard or digital port circuit—can also prevent signal detection. These issues are less common and should only be considered after exhausting other troubleshooting steps. Replacing the mainboard is a costly and complex solution, requiring professional guidance to avoid further damage or warranty issues.

Preventive Maintenance

To minimize the occurrence of FF8E warnings, consider the following preventive measures:

Regular Wiring Checks: Ensure all control signal wiring is secure, with no looseness or corrosion.
Environmental Monitoring: Maintain a clean, dry, and well-ventilated environment for the drive, avoiding dust buildup or overheating.
Firmware Updates: Regularly check for and install firmware updates from ABB to address potential bugs.
Parameter Documentation: Keep a record of parameter settings and changes for easier troubleshooting in the future.

Conclusion

The FF8E warning on the ABB ACS800 frequency converter indicates a missing run enable signal, often due to misconfigured parameter 16.01, poor 24VDC contact, or wiring issues. By systematically checking parameters, signals, wiring, and communication, most issues can be resolved. Hardware faults, such as mainboard or digital port circuit failures, are rare and should only be addressed after other possibilities are ruled out. Routine maintenance and proper configuration are key to ensuring the reliable operation of the ACS800 drive.

Posted on 2025年6月4日2025年6月4日 by baiyuzhan

ZK880-N Positive Control Inverter Three-Stage Speed Control Implementation Guide

SHZK ZK880N-5.5KW-3 Used Frequency Inverter 3PH 380V 5.5KW Disassembled, Fully Functional
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In the field of industrial automation control, inverters, as the core equipment for motor speed regulation, are widely used in various scenarios requiring graded speed regulation, such as fans, pumps, and conveyor belts. This article will take the ZK880-N positive control inverter as an example, combined with official technical documentation and practical application scenarios, to elaborate in detail on how to achieve three-stage speed control through DI digital input terminals, providing systematic guidance from hardware wiring to parameter settings.

I. Technical Principles of Three-Stage Speed Control

The essence of three-stage speed control is to preset the motor operating frequency into three different levels through the multi-stage speed instruction function of the inverter. Users can select the corresponding frequency band through external switch signals to realize the graded regulation of motor speed. The ZK880-N inverter uses digital input terminals (DI) as the trigger signal source, combined with function code parameter settings, to build a flexible and reliable multi-stage speed control system.

II. Hardware Wiring Implementation Steps

1. Terminal Function Definition

According to control requirements, the DI1-DI3 digital input terminals need to be configured as multi-stage speed control ports. Refer to the inverter terminal distribution diagram, with standard wiring terminals located in the control circuit interface area.

2. Wiring Specifications

Power Connection: Ensure that the main circuit power supply (R/S/T) and control circuit power supply (usually +24V) of the inverter are correctly connected.
DI Terminal Wiring:
- DI1: As the first-stage speed trigger terminal, it is recommended to connect a normally open contact switch.
- DI2: As the second-stage speed trigger terminal.
- DI3: As the third-stage speed trigger terminal.
- Common Terminal (COM): The signal common terminal for all DI terminals, which should be connected to the other end of the switch.

3. Wiring Precautions

The switch signal voltage range must comply with the DI terminal input specifications (5-30V DC).
It is recommended to use shielded twisted pair cables for signal transmission to avoid electromagnetic interference.
After wiring, use a multimeter to detect the insulation resistance between terminals to ensure there is no short circuit.

III. Detailed Explanation of Core Parameter Settings

The following function codes need to be configured through the operation panel or dedicated software:

1. DI Terminal Function Mapping

Function Code	Parameter Item	Setting Value	Function Description
F4-00	DI1 Function Selection	4	Multi-stage Speed 1 (corresponding to the first-stage speed)
F4-01	DI2 Function Selection	5	Multi-stage Speed 2 (corresponding to the second-stage speed)
F4-02	DI3 Function Selection	6	Multi-stage Speed 3 (corresponding to the third-stage speed)

2. Multi-Stage Speed Frequency Settings

Function Code	Parameter Item	Setting Value	Typical Application Scenarios
FC-00	Multi-stage Speed 1 Frequency	20Hz	Light load start/low-speed operation
FC-01	Multi-stage Speed 2 Frequency	35Hz	Normal working speed
FC-02	Multi-stage Speed 3 Frequency	50Hz	High-speed discharge/emergency acceleration

3. Operating Parameter Configuration

Function Code	Parameter Item	Recommended Value	Function Description
F6-00	Acceleration Time 1	8.0s	Transition time from first-stage to second-stage speed
F6-01	Deceleration Time 1	5.0s	Transition time from second-stage to first-stage speed
F6-02	Acceleration Time 2	12.0s	Transition time from second-stage to third-stage speed
F6-03	Deceleration Time 2	8.0s	Transition time from third-stage to second-stage speed
FC-16	Operation Instruction Selection	1	Terminal control mode
FC-17	Fault Reset Selection	1	Allow DI terminals to perform fault reset

IV. Realization of Three-Stage Speed Control Logic

1. Single Terminal Single-Stage Speed Mode

Only DI1 is closed: The motor operates at the frequency set by FC-00 (20Hz).
Only DI2 is closed: The motor operates at the frequency set by FC-01 (35Hz).
Only DI3 is closed: The motor operates at the frequency set by FC-02 (50Hz).

2. Combined Control Mode (Advanced Application)

Through function codes FC-03 to FC-07, combined stage speeds can be set:

DI1+DI2 closed: Execute the frequency set by FC-03 (reserved for extended stage speed).
DI2+DI3 closed: Execute the frequency set by FC-04 (reserved for extended stage speed).
Special application scenarios: Realize automatic stage speed switching logic through PLC programming.

V. Commissioning and Verification Process

1. No-Load Test Stage

Disconnect the motor load and only retain the inverter and dummy load.
Close the DI1-DI3 switches in turn to observe whether the output frequency is consistent with the set value.
Use an oscilloscope to detect the output voltage waveform and confirm there is no distortion.

2. Load Commissioning Stage

Gradually load to the rated load.
Test the current impact during stage speed switching (should be less than 1.5 times the rated current).
Verify whether the acceleration/deceleration time meets the process requirements.

3. Abnormal Handling Test

Simulate DI terminal signal adhesion fault.
Verify the effectiveness of the FC-17 fault reset function.
Test the reliability of overload protection (OL) action.

VI. Typical Application Cases

In a certain water plant’s constant pressure water supply system, the three-stage speed control of the ZK880-N inverter is adopted:

First-stage speed (25Hz): Maintain the basic pressure of the pipe network during night low-peak periods.
Second-stage speed (40Hz): Meet normal water demand during daytime water supply.
Third-stage speed (50Hz): Quickly supplement the pipe network pressure during peak water consumption periods.

Through the automatic switching of stage speeds by pressure sensor signals, an energy-saving rate of 32% is achieved, and the pressure fluctuation range is controlled within ±0.02MPa.

VII. Maintenance and Optimization Suggestions

Regularly check the reliability of DI terminal wiring, and recommend tightening every six months.
Recheck the FC-00 to FC-02 parameter settings every quarter according to load characteristics.
Upgrade to the latest firmware version (currently V2.13) to obtain an optimized stage speed switching algorithm.
For impact loads, it is recommended to add an input reactor to improve power quality.

By following the above systematic implementation steps, users can efficiently achieve the three-stage speed control function of the ZK880-N inverter. In practical applications, it is necessary to combine specific process requirements and optimize parameters to achieve the best control effect. With the development of Industry 4.0, this inverter supports the Modbus-RTU communication protocol and can be integrated with the host computer system to achieve more intelligent stage speed scheduling management.

Posted on 2025年6月3日2025年6月3日 by baiyuzhan

Guide to Resolving Fault 2281: Current Measurement Calibration on ABB ACS580 Drives

Introduction

The ABB ACS580 is a robust and reliable Variable Frequency Drive (VFD) widely used in industrial applications for precise control of AC motors. However, like any complex electronic device, the ACS580 may encounter faults that require troubleshooting and maintenance. One common issue is “Fault 2281,” which is related to current measurement calibration. This document provides a detailed explanation of the causes of Fault 2281, the roles of parameters 99.13 and 99.14, and a step-by-step guide to resolving this fault, ensuring the drive returns to normal operation. This guide is designed to offer clear and practical solutions for technicians and engineers while ensuring operational safety and equipment efficiency.

What is Fault 2281?

Fault 2281 indicates an issue with the current measurement calibration of the ACS580 drive. This fault is typically triggered by the following reasons:

Excessive Measurement Offset: The measurement offset of the output phase currents exceeds the allowable range.
Interphase Discrepancy: The current measurement difference between output phases U2 and W2 is too large.
Incorrect Calibration Completion: The initial setup or previous calibration process may not have been executed correctly.
Hardware Issues: There may be faults in the current sensors, connecting cables, or the drive’s internal circuitry.
Environmental Interference: External factors such as temperature and electromagnetic interference may affect calibration stability.
Firmware Issues: The drive’s firmware version may be incompatible with the calibration requirements.

Fault 2281 is usually displayed on the drive’s display as “Fault 2281” with an auxiliary code (e.g., “0000 0003”), indicating the specific problem. Failing to resolve this fault may lead to inaccurate motor control, overheating, or equipment damage, making timely resolution crucial.

Why is Current Measurement Calibration Important?

Current measurement is one of the core functions of a VFD, directly affecting the drive’s performance and safety. Accurate current measurement serves the following purposes:

Device Protection: By monitoring the current, the drive can detect overloads, short circuits, or other anomalies and take protective measures (such as tripping or decelerating).
Performance Optimization: Precise current control ensures accurate motor torque regulation, suitable for applications requiring smooth operation.
Energy Efficiency: Reduces energy waste by adjusting motor speed according to load demands.
Diagnostic Support: Provides reliable current data for fault diagnosis and predictive maintenance.

If current measurement is not correctly calibrated, it may result in:

Torque control errors affecting motor performance.
Incorrect tripping or failure to trip, increasing the risk of equipment damage.
Inefficient operation, wasting energy.
Unreliable diagnostic data, complicating fault troubleshooting.

Therefore, regular calibration of the current measurement system is key to ensuring the efficient and reliable operation of the ACS580 drive.

Roles of Parameters 99.13 and 99.14

In the ACS580 drive, parameters 99.13 and 99.14 belong to the “Motor Parameters” group (Group 99) and are used to configure and execute Identification Run (ID Run), including current measurement calibration.

Parameter 99.14: Identification Run Condition

Parameter 99.14 is used to select the type of identification run. According to the provided documentation, the possible values for parameter 99.14 include:

Value	Description	English Translation
0	No identification operation	No identification operation
1	Standard identification operation	Standard identification operation
2	Simplified identification operation	Simplified identification operation
3	Static identification operation	Static identification operation
4	Reserved	Reserved
5	Current measurement calibration	Current measurement calibration
6	Advanced identification operation	Advanced identification operation

Setting parameter 99.14 to 5 indicates that the drive will perform current measurement calibration to adjust the internal current measurement system for accuracy.

Parameter 99.13: Identification Run Request

Parameter 99.13 is used to initiate the identification run. According to the ABB ACS580 firmware manual, this parameter allows the user to request the drive to execute an identification run, the specific type of which is defined by parameter 99.14. After setting parameter 99.13, the drive will perform the corresponding operation based on the setting in 99.14, such as current measurement calibration.

Synergy Between the Two Parameters

99.14 specifies the operation type (e.g., a value of 5 indicates current measurement calibration).
99.13 triggers the identification run, initiating the calibration process.

By correctly setting these two parameters, users can recalibrate the current measurement system to resolve Fault 2281.

Steps to Execute Current Measurement Calibration

Below are the detailed steps to resolve Fault 2281 by setting parameters 99.13 and 99.14 to execute current measurement calibration:

Ensure Safety
- Power Off: Disconnect the drive from the power source to ensure complete de-energization and avoid electrical hazards.
- Isolate the Motor: Ensure the motor has stopped and is disconnected from the load to prevent accidental startup.
- Check the Environment: Ensure the working environment is free from electromagnetic interference or extreme temperatures that could affect the calibration.
Access the Parameter Menu
- Control Panel: On the ACS580 drive’s control panel, press the “Menu” or “Parameters” button to enter the parameter setup mode.
- PC Tool: Use the ABB Drive Composer software to connect to the drive via the appropriate communication port and open the parameter setup interface.
Navigate to the Motor Parameters Group
- On the control panel, use the navigation buttons to scroll to “Motor Parameters” or Group 99.
- In Drive Composer, browse the parameter list to find Group 99 (Motor Data).
Set Parameter 99.14
- Locate parameter 99.14 (Identification Run Condition).
- Set its value to 5 (Current Measurement Calibration). Depending on the interface, this may involve selecting from a dropdown list or manually entering “5”.
Initiate the Identification Run
- Locate parameter 99.13 (Identification Run Request).
- Set this parameter to initiate the identification run. Typically, this involves selecting “Start ID Run” or entering a specific value (refer to the manual for specific operations).
Monitor the Calibration Process
- The drive will perform current measurement calibration, which may last from a few seconds to a minute, depending on the drive and motor configuration.
- Observe the control panel display for progress information or error messages.
Verify the Calibration Results
- After calibration is complete, check the drive’s display to confirm whether Fault 2281 has been cleared.
- Use an external current measurement device (such as a current clamp) to verify that the current values displayed by the drive match the actual values.
Save the Parameters
- Save the changed parameter settings to ensure they are retained after a power outage.
- On the control panel, this is usually done by selecting “Save” or “Confirm”; in Drive Composer, choose “Save Parameters”.

Troubleshooting Tips

If Fault 2281 persists after calibration, try the following methods:

Check Hardware Connections: Ensure the current sensors, motor cables, and terminal blocks are secure and free from loose connections or damage.
Check Hardware Integrity: Inspect the drive’s interior for physical damage or current sensor failures.
Verify Firmware Version: Ensure the drive’s firmware is up to date. The document mentions that versions below 99.7.3 may require calibration support from ABB Drives.
Refer to the Manual: Consult the ACS580 user manual’s troubleshooting section for specific meanings of auxiliary codes (such as 0000 0003).
Contact Technical Support: If the issue persists, contact technical support, providing the fault code, auxiliary code, and steps already attempted.

Common Errors and How to Avoid Them

When performing calibration, avoid the following common errors:

Not Powering Off: Ensure the drive is powered off before adjusting parameters to prevent unexpected behavior or safety risks.
Incorrect Parameter Settings: Confirm that you are adjusting parameters 99.13 and 99.14 and that their values are correct (99.14 set to 5).
Skipping Verification: After calibration, check if the fault has been cleared and verify the accuracy of the current measurement.
Ignoring Hardware Issues: If calibration is ineffective, check for hardware issues such as loose connections or damaged sensors.

Conclusion

Current measurement calibration is a critical step in ensuring the efficient and reliable operation of the ABB ACS580 drive. Fault 2281 indicates that the current measurement system needs recalibration. By correctly using parameters 99.13 and 99.14 and following the steps provided in this document, you can effectively resolve this fault and restore the drive to normal operation. Regular maintenance and calibration checks help prevent similar issues, extend equipment life, and maintain production efficiency. For further assistance, refer to the official documentation or contact ABB technical support.

Appendix: Parameter 99.14 Value Table

Value	Description	English Translation
0	No identification operation	No identification operation
1	Standard identification operation	Standard identification operation
2	Simplified identification operation	Simplified identification operation
3	Static identification operation	Static identification operation
4	Reserved	Reserved
5	Current measurement calibration	Current measurement calibration
6	Advanced identification operation	Advanced identification operation

Posted on 2025年6月2日2025年6月2日 by baiyuzhan

Detailed Explanation of Shihlin SS2 Inverter E0 Fault: Causes, Solutions, and Preventive Measures

Introduction

Inverters are vital components in industrial automation, enabling precise control over motor speed and torque across various sectors, including manufacturing and energy. The Shihlin SS2 series inverter, manufactured by Shihlin Electric, is widely recognized for its reliability and performance. However, like any complex equipment, it may encounter faults during operation. One such issue is the E0 fault, which can be perplexing for users due to its specific triggering conditions. This article provides a comprehensive analysis of the E0 fault in the Shihlin SS2 inverter, detailing its meaning, causes, solutions, and preventive measures to assist users in restoring normal operation efficiently.

1. Meaning of the E0 Fault

According to the Shihlin SS2 Series Inverter Manual (version V1.07), the E0 fault is triggered under specific conditions related to the inverter’s parameter settings and operation mode. Specifically, when parameter P.75 (stop function setting) is set to 1, and the inverter is operating in a mode other than PU (panel operation mode) or H2 (high-frequency mode), pressing the stop button (labeled as “(20) key” in the manual) for 1.0 second causes the inverter to stop. The display shows “E0,” and all functions are disabled or reset. This behavior acts as a protective mechanism to prevent unintended operation or potential damage under these conditions.

Interestingly, the manual also lists E0 in the fault code table under “00(H00)” as “no fault” (无异常), which may indicate a different context, such as a default or reset state in fault logging. This dual reference suggests that E0’s meaning depends on the operational context, but the primary focus here is its association with the stop function and parameter P.75.

2. Causes of the E0 Fault

To effectively resolve the E0 fault, understanding its causes is essential. Based on the manual and related information, the following are the primary reasons for the E0 fault:

Parameter P.75 Configuration: Parameter P.75 governs the inverter’s stop behavior. When set to 1, it enables a deceleration stop function. In non-PU or non-H2 modes, pressing the stop button for 1 second triggers the E0 fault, as the inverter interprets this as an invalid operation under the current settings.
Operation Mode Restrictions: The E0 fault is specific to non-PU and non-H2 modes. PU mode allows direct control via the inverter’s control panel, while H2 mode may relate to specific high-frequency applications. Operating in external control mode (e.g., via external signals) with P.75 set to 1 increases the likelihood of triggering E0.
External STE/STR Command Interference: External start/stop commands (STE/STR) can conflict with the inverter’s settings. The manual notes that when E0 occurs, these external commands are canceled, suggesting that signal interference may contribute to the fault.
Operator Error: Inadvertently pressing the stop button for more than 1 second in an incompatible mode can trigger the E0 fault. This is particularly common during initial setup, debugging, or when operators are unfamiliar with the inverter’s operation.

It’s worth noting that earlier versions of the Shihlin SS2 manual (e.g., V1.01) describe E0 as a communication error related to parity check issues. This discrepancy indicates that fault code definitions may have evolved across manual versions, with V1.07 providing the most relevant information for modern SS2 inverters.

3. Solutions for the E0 Fault

Resolving the E0 fault involves a systematic approach to eliminate its triggers and restore normal operation. The following steps, derived from the manual (version V1.07), are recommended:

Cancel External STE/STR Commands:
- Inspect the inverter for any external start/stop (STE/STR) signals that may be interfering with its operation.
- Cancel these inputs to ensure no external commands conflict with the inverter’s settings. In program operation mode, manual signals typically do not require clearing, but verifying the absence of interference is critical.
Reset the Inverter:
- Locate the stop button (labeled “(20) key”) on the control panel.
- Press and hold it for at least 1.0 second to clear the E0 fault and reset the inverter to an operational state. This is a direct method recommended in the manual.
Check and Adjust Parameter P.75:
- Access the inverter’s parameter setting menu to review the value of P.75.
- If P.75 is set to 1 and this is not suitable for your application, change it to 0 (the factory default) or another appropriate value. Refer to section 5.33 of the manual for detailed guidance on adjusting P.75.
Verify Operation Mode:
- Ensure the inverter is operating in the correct mode (PU or H2, if required for your application).
- Switch to the appropriate mode to prevent the fault from recurring.
Perform a Parameter Reset:
- If the above steps do not resolve the issue, use parameters P.996 or P.997 to reset the inverter. These parameters can clear fault records or restore factory settings, as outlined in sections 5.78 and 5.80 of the manual.
Seek Professional Assistance:
- Persistent faults may indicate hardware issues (e.g., faulty motherboard or wiring errors) or complex configuration problems.
- Contact Shihlin Electric’s technical support team via their official website or arrange for the inverter to be inspected by the manufacturer.

The following table summarizes the causes and solutions for the E0 fault:

Possible Cause	Solution
P.75 set to 1, non-PU/H2 mode operation	Adjust P.75 to 0 or other values (manual section 5.33)
Stop button pressed for 1.0 second	Press stop button for 1.0 second to reset
External STE/STR command interference	Cancel external commands, check wiring
Hardware or configuration issues	Reset using P.996/P.997 or contact manufacturer

4. Preventive Measures for E0 Fault

To minimize the occurrence of E0 faults and ensure reliable inverter operation, consider the following preventive measures:

Proper Parameter Configuration:
- During installation and commissioning, thoroughly review the Shihlin SS2 Series Inverter Manual (version V1.07) to ensure parameters like P.75 are correctly set for your application.
- Avoid modifying parameters without understanding their functions to prevent unintended faults.
Regular Maintenance:
- Conduct periodic inspections of the inverter’s wiring, cooling system, and control panel to check for loose connections, dust buildup, or overheating.
- Regular maintenance reduces the risk of faults caused by environmental or mechanical issues.
Operator Training:
- Train all personnel operating the SS2 inverter on its proper use and fault-handling procedures.
- Ensure the manual is readily available for quick reference during operation or troubleshooting.
Power Supply Stability:
- Use voltage stabilizers or surge protectors to protect the inverter from power fluctuations, which can contribute to faults.
- A stable power supply is essential for long-term reliability.
Fault Monitoring and Logging:
- Maintain a record of all fault occurrences, including their conditions and resolutions.
- Regularly monitor the inverter’s performance to identify and address potential issues early.

5. Conclusion

The E0 fault in the Shihlin SS2 inverter, while initially confusing, can be effectively managed by understanding its association with parameter P.75 and specific operation modes. By following the outlined steps—canceling external STE/STR commands, resetting the inverter, adjusting P.75, and verifying the operation mode—users can typically resolve the fault quickly. Additionally, adopting preventive measures such as proper parameter setup, regular maintenance, operator training, power protection, and fault monitoring can significantly reduce the likelihood of E0 faults. For persistent issues, contacting Shihlin Electric’s technical support or arranging professional inspection is advisable. By implementing these strategies, users can ensure the stable and efficient operation of their SS2 inverters, maximizing performance in industrial applications.