This scheme aims to apply the Lianchuang High-Tech LC400E inverter to the unwinding and slitting machine. By precisely controlling the motor speed and torque, it achieves automation and efficient operation of core functions such as unwinding, cutting, and rewinding. The scheme covers motor function analysis, wiring methods, parameter settings, function realization, and auxiliary equipment selection to ensure the efficiency and stability of the unwinding and slitting machine’s production.
II. Analysis of the Unwinding and Slitting Machine Structure and Motor Configuration
Equipment Functions The unwinding and slitting machine is used to cut wide rolls of materials into multiple narrow rolls. Its core functions include unwinding, cutting, and rewinding.
Motor Configuration
Unwinding Motor: Controls the unwinding speed of the parent roll and requires constant tension to prevent material slack or breakage.
Rewinding Motor: Controls the winding of narrow materials and requires tension adjustment according to the roll diameter (trapezoidal tension).
Cutting Motor: Drives the cutting components and requires precise speed control.
Control Requirements Tension control is the core requirement. It needs to achieve constant tension during unwinding and trapezoidal tension during rewinding through motor torque control.
III. Key Features of the LC400E Inverter
High-Performance Vector Control: Supports precise speed and torque control to meet tension synchronization requirements.
Multi-Mode Control: Terminal control, analog input, and multi-speed settings to adapt to different working conditions.
Safety Protection: Functions such as overvoltage, overcurrent, and motor protection ensure equipment safety.
Communication Capabilities: Supports Modbus communication (RS232/RS485) for easy integration with PLC/HMI.
Adjustable Parameters: Acceleration/deceleration time, PID control, and other parameters can be flexibly adjusted.
Specifications: Power range from 0.75 kW to 500 kW, with output current reaching 63 A for models like G022/T4, suitable for the motor requirements of the unwinding and slitting machine.
IV. Application Positions of the LC400E in the Unwinding and Slitting Machine
Unwinding Motor: Torque control mode to maintain constant tension.
Rewinding Motor: Speed/torque control mode to support trapezoidal tension adjustment.
Cutting Motor: Speed control mode to ensure cutting accuracy. Application Suggestions: Configure multiple inverters according to the number of motors, such as one for the unwinding motor and one for the rewinding motor.
V. Wiring Methods
Main Circuit Wiring
Connect the input terminals (R, S, T) to the three-phase power supply and the output terminals (U, V, W) to the motor. Connect the PE terminal to the ground.
Refer to the LC400E manual for wire size specifications (e.g., for a 22 kW model, the input is 100 A, and the output is 63 A).
Safety Protection: Install an emergency stop button and set inverter protection parameters.
Tension Control: Prioritize the installation of tension sensors to ensure control accuracy.
Multi-Motor Synchronization: Coordinate through the PLC to avoid uneven tension.
Environmental Requirements: Install the inverter in a well-ventilated and dry environment, away from dust and moisture.
X. Summary
This scheme achieves high-precision speed and tension control through the application of the LC400E inverter in the unwinding and slitting machine, combined with PLC and HMI for automated operation. Key measures include:
Adopting constant tension and trapezoidal tension control for the unwinding and rewinding motors, respectively.
Using standard wiring methods and key parameter settings to ensure system stability.
Selecting Siemens/Mitsubishi equipment to achieve efficient automated control. This scheme can significantly improve the production efficiency of the unwinding and slitting machine, reduce operation difficulty and fault risks, and is suitable for the roll material processing industry.
The rotary cutting machine is an essential piece of equipment in the woodworking industry, primarily used to peel logs into thin veneer sheets, which are widely applied in the production of plywood, furniture, and decorative materials. To achieve efficient and precise processing, the rotary cutting machine relies on the coordinated operation of multiple motors, including the main spindle motor for log rotation, the cutting blade motor for veneer cutting, the conveyor belt motor for veneer output, and the feed motor for controlling cutting thickness. These motors require precise speed and torque control to ensure processing quality and production efficiency. As a versatile electrical device capable of flexibly controlling motor operation, the inverter plays a critical role in the rotary cutting machine.
This article provides a detailed explanation of how to apply the Mobeck MT110 inverter to various motor control aspects of a rotary cutting machine, covering functional analysis, inverter selection, wiring design, parameter settings, and the integration of PLC and touchscreen systems. Through a well-designed and implemented solution, the rotary cutting machine can achieve efficient, stable, and automated operation, meeting the demands of modern woodworking processes.
Functional Analysis of the Rotary Cutting Machine
The primary task of a rotary cutting machine is to process logs into veneer sheets, involving log fixation and rotation, cutting by the blade, veneer output, and precise control of cutting thickness. Below is a detailed analysis of the main motor functions in a rotary cutting machine:
1. Main Spindle Motor (Rotation Function)
Function: The main spindle motor drives the log to rotate, serving as the core power component of the rotary cutting machine.
Characteristics: It requires high power, typically ranging from 5.5 kW to 15 kW (depending on the machine size), and needs stable speed output while allowing dynamic speed adjustments based on processing requirements.
Control Requirements: The inverter must support vector control mode to ensure high torque output at low speeds and be capable of receiving external speed reference signals (e.g., from a PLC or potentiometer).
2. Cutting Blade Motor (Cutting Function)
Function: This motor drives the cutting blade to peel the rotating log into veneer sheets.
Characteristics: The power typically ranges from 3 kW to 7.5 kW, with speed adjustments required based on veneer thickness, and stable torque support during cutting.
Control Requirements: The inverter needs fast start/stop capabilities and precise speed control, often requiring synchronization with the main spindle motor.
3. Conveyor Belt Motor (Conveying Function)
Function: It ensures the smooth output of cut veneer sheets, maintaining production continuity.
Characteristics: The power is relatively low, typically between 0.75 kW and 2.2 kW, with speed needing to match the cutting rhythm.
Control Requirements: The inverter should support simple speed regulation and may need to operate in coordination with the cutting blade motor.
4. Feed Motor (Feed Function)
Function: It controls the feed speed of the cutting blade or log, directly determining the veneer thickness.
Characteristics: The power is low (0.75 kW to 1.5 kW), and it can be either an asynchronous motor or a servo motor, requiring high-precision speed control.
Control Requirements: If using an asynchronous motor, the inverter must support high-precision speed regulation and accept external analog signal inputs; if using a servo motor, a dedicated servo drive is required.
5. Other Auxiliary Motors
Function: These include motors for clamping devices, chip removal fans, etc., used to assist the processing operation.
Characteristics: The power is low (0.37 kW to 1.5 kW), with simple control requirements, typically needing only basic start/stop functions.
From the above analysis, it is clear that the motor control requirements of a rotary cutting machine are diverse. The main spindle and cutting blade motors demand high-performance control, while the conveyor belt and feed motors prioritize speed stability and precision. The Mobeck MT110 inverter, with its flexible control modes and rich functionality, is an ideal choice to meet these requirements.
Application Scheme of Mobeck MT110 Inverter
1. Inverter Application Positions
Based on the functional characteristics of the rotary cutting machine, the Mobeck MT110 inverter can be applied to the following key motor positions:
Main Spindle Motor: Use the MT110 inverter for vector control to ensure stable log rotation.
Cutting Blade Motor: Use the MT110 inverter for speed control, synchronized with the main spindle motor.
Conveyor Belt Motor: Use the MT110 inverter for simple speed regulation.
Feed Motor: If an asynchronous motor is used, the MT110 inverter can provide high-precision speed control; if a servo motor is used, a separate servo drive is required.
2. Inverter Selection
Assuming a medium-sized rotary cutting machine with the following motor power configuration:
Main Spindle Motor: 7.5 kW
Cutting Blade Motor: 5.5 kW
Conveyor Belt Motor: 1.5 kW
Feed Motor: 1.1 kW (asynchronous motor)
Based on the motor power and load characteristics, the following Mobeck MT110 inverter models are selected:
Main Spindle Motor: MT110-7.5kW (rated power 7.5 kW, 380V three-phase)
Cutting Blade Motor: MT110-5.5kW (rated power 5.5 kW, 380V three-phase)
Conveyor Belt Motor: MT110-1.5kW (rated power 1.5 kW, 380V three-phase)
Feed Motor: MT110-1.1kW (rated power 1.1 kW, 380V three-phase)
When selecting the inverter, ensure that its rated capacity is slightly higher than the motor power to provide a margin for potential overload conditions.
3. Wiring Design
The following uses the main spindle motor (7.5 kW) MT110 inverter as an example to detail the wiring method. The wiring for other motors is similar, with adjustments based on power and control requirements.
(1) Main Circuit Wiring
Power Input: Connect the three-phase 380V power supply to the inverter’s R, S, and T terminals.
Motor Output: Connect the inverter’s U, V, and W terminals to the three-phase input of the main spindle motor.
Grounding: Connect the inverter’s grounding terminal and the motor’s grounding terminal to the ground wire to ensure electrical safety.
Main Circuit Wiring Diagram (Text Description):
Power Supply (380V Three-Phase)
L1 ---- R
L2 ---- S
L3 ---- T
|
|---- Ground Terminal ---- Ground
|
U ---- Motor U Phase
V ---- Motor V Phase
W ---- Motor W Phase
|
|---- Motor Ground Terminal ---- Ground
(2) Control Circuit Wiring
The control terminals of the MT110 inverter include digital inputs (DI), analog inputs (AI), and relay outputs (RO). Using the main spindle motor control as an example:
Start/Stop Control:
DI1 (Forward Start): Connect to the PLC output point (e.g., Y0) to control inverter start via the PLC.
DI2 (Stop): Connect to the PLC output point (e.g., Y1) to control inverter stop via the PLC.
COM: Common terminal, connected to the PLC’s common terminal.
Speed Reference:
AI1 (Analog Input): Connect to the PLC’s analog output module (0-10V signal) for speed regulation.
GND: Analog ground, connected to the PLC’s analog ground.
Fault Output:
RO1A/RO1B (Relay Output): Connect to the PLC input point (e.g., X0) to detect inverter faults.
Control Circuit Wiring Diagram (Text Description):
Using the main spindle motor (7.5 kW) MT110 inverter as an example, the key parameter settings are listed below. Assuming the MT110 inverter’s parameter numbering is similar to that of a general-purpose inverter, the settings are as follows:
P0.03 (Control Mode): Set to 1 (Vector Control without PG), suitable for the high torque requirements of the main spindle motor.
P0.04 (Run Command Source): Set to 1 (Terminal Control), using DI1/DI2 for start/stop control.
P0.06 (Frequency Reference Source): Set to 2 (AI1 Analog Input), using the PLC’s 0-10V signal to set the speed.
P1.00 (Motor Rated Power): Set to 7.5 (7.5 kW).
P1.01 (Motor Rated Voltage): Set to 380 (380V).
P1.02 (Motor Rated Frequency): Set to 50 (50 Hz).
P1.03 (Motor Rated Speed): Set to 1460 (assuming a 4-pole motor, approximately 1460 rpm at 50 Hz).
P2.00 (Acceleration Time): Set to 5 (5 seconds) to avoid startup shock.
P2.01 (Deceleration Time): Set to 5 (5 seconds) to ensure smooth stopping.
P5.00 (DI1 Function): Set to 1 (Forward Run).
P5.01 (DI2 Function): Set to 2 (Stop).
P6.00 (Relay Output Function): Set to 1 (Fault Output).
Parameter settings for other motors should be adjusted based on their specific functions:
Cutting Blade Motor: Set acceleration/deceleration time to 3 seconds to accommodate fast start/stop requirements.
Conveyor Belt Motor: Use V/F control (P0.03=0) to simplify control logic.
Feed Motor: Requires high-precision speed control, so adjust the gain and offset parameters of AI1 (e.g., P4 group parameters).
Parameter Settings Example Table:
Parameter No.
Description
Main Spindle Motor
Cutting Blade Motor
Conveyor Belt Motor
Feed Motor
P0.03
Control Mode
1 (Vector)
1 (Vector)
0 (V/F)
1 (Vector)
P0.04
Run Command Source
1 (Terminal)
1 (Terminal)
1 (Terminal)
1 (Terminal)
P0.06
Frequency Reference Source
2 (AI1)
2 (AI1)
2 (AI1)
2 (AI1)
P1.00
Motor Rated Power (kW)
7.5
5.5
1.5
1.1
P2.00
Acceleration Time (s)
5
3
2
2
P2.01
Deceleration Time (s)
5
3
2
2
5. PLC and Touchscreen Selection and Application
(1) Selection
To achieve automated control of the rotary cutting machine, a PLC and touchscreen are required:
PLC: Recommend the Siemens S7-200 SMART series (e.g., CPU 224XP), which supports analog input/output and offers strong scalability.
Touchscreen: Recommend the Siemens KTP400 Basic (7-inch), which supports communication with the PLC via Profinet and provides an intuitive operation interface.
(2) PLC Program Design
The PLC is responsible for coordinating the operation of each motor, with the main functions including:
Start/Stop Control: Use PLC output points (e.g., Y0, Y1) to control the DI1/DI2 of each inverter, enabling motor start/stop.
Speed Regulation: Use the PLC’s analog output module (0-10V) to control the inverter’s AI1, dynamically adjusting each motor’s speed.
Synchronization Control: Calculate the speed ratio between the main spindle motor and the cutting blade motor through the program to ensure consistent cutting thickness.
Fault Detection: Use the inverter’s relay output (RO1A/RO1B) to send fault signals to the PLC input point (e.g., X0), triggering an alarm.
VAR
Start_Main : BOOL; // Main Spindle Motor Start Signal
Stop_Main : BOOL; // Main Spindle Motor Stop Signal
Speed_Main : REAL; // Main Spindle Motor Speed (0-10V)
Start_Feed : BOOL; // Feed Motor Start Signal
Stop_Feed : BOOL; // Feed Motor Stop Signal
Speed_Feed : REAL; // Feed Motor Speed (0-10V)
Start_Conveyor : BOOL; // Conveyor Belt Motor Start Signal
Stop_Conveyor : BOOL; // Conveyor Belt Motor Stop Signal
Speed_Conveyor : REAL; // Conveyor Belt Motor Speed (0-10V)
END_VAR
// Main Spindle Motor Control
IF Start_Main AND NOT Stop_Main THEN
Inverter_Main.CommandWord := 16#83; // Run Forward
Inverter_Main.FrequencyReference := Speed_Main * 5; // 0-10V corresponds to 0-50Hz
ELSE IF Stop_Main THEN
Inverter_Main.CommandWord := 16#80; // Stop
END_IF
// Feed Motor Control
IF Main_Spindle_At_Speed AND Start_Feed AND NOT Stop_Feed THEN
Inverter_Feed.CommandWord := 16#83;
Inverter_Feed.FrequencyReference := Speed_Feed * 5;
ELSE IF Stop_Feed THEN
Inverter_Feed.CommandWord := 16#80;
END_IF
// Conveyor Belt Motor Control
IF Cutting_In_Progress AND Start_Conveyor AND NOT Stop_Conveyor THEN
Inverter_Conveyor.CommandWord := 16#83;
Inverter_Conveyor.FrequencyReference := Speed_Conveyor * 5;
ELSE IF Stop_Conveyor THEN
Inverter_Conveyor.CommandWord := 16#80;
END_IF
(3) Touchscreen Interface Design
The touchscreen is used for parameter settings and operation status monitoring, with the main interfaces including:
Main Interface: Displays the operation status (running/stopped), current speed (Hz), and fault status of each motor.
Parameter Setting Interface: Sets the target speed of each motor (via PLC AO output) and veneer thickness (via feed motor speed adjustment).
Alarm Interface: Displays inverter fault information (e.g., overload, overheating) and provides a reset button.
6. Safety Considerations
To ensure the safe operation of the equipment, the following precautions should be observed:
Electrical Safety: Ensure reliable grounding of the inverter and motor to prevent electrical leakage risks.
Operational Safety: Set an emergency stop button on the touchscreen, allowing the PLC to stop all inverters simultaneously.
Overload Protection: Enable overload protection in the inverter parameters (e.g., P9 group parameters) to prevent motor overheating.
Maintenance Safety: Regularly inspect the inverter’s cooling fan and wiring terminals to ensure long-term operational stability.
Conclusion
Through the above scheme, the Mobeck MT110 inverter can fully meet the control requirements of a rotary cutting machine:
Main Spindle Motor: Achieves smooth log rotation with adjustable speed, ensuring processing continuity.
Cutting Blade Motor: Operates synchronously with the main spindle motor, ensuring cutting quality.
Conveyor Belt Motor: Provides stable veneer output, with speed matching the cutting rhythm.
PLC and Touchscreen: Enable automated control and human-machine interaction, enhancing equipment efficiency and ease of operation.
The advantages of this scheme lie in its modular design and flexibility, allowing users to adjust motor power, inverter models, and control parameters based on actual needs. Additionally, the integration of a PLC and touchscreen enables the rotary cutting machine to achieve a higher level of automation, significantly improving production efficiency and product quality.
I. Functional Requirements Analysis of the Washing Machine
The washing machine is primarily used for efficient cleaning of various workpieces. Its core functional requirements include:
Washing Pump Drive: A high-power motor is required to drive a high-pressure water pump for strong water jetting.
Conveyor Belt Control: Drive the conveyor belt to achieve continuous workpiece transportation.
Rotary Brush Control: Drive the rotary brush to perform mechanical scrubbing on the workpiece surface.
Air-Drying System: Drive the fan to quickly dry the cleaned workpieces.
Status Monitoring and Protection: Real-time monitoring of motor operation status is required, with overload, overvoltage, and other protection functions.
II. V5-H Inverter Selection and Configuration
Based on the power requirements of each functional module of the washing machine, the following V5-H inverter models are selected:
Functional Module
Motor Type
Power Range
Inverter Model
Washing Pump
Three-phase asynchronous motor
7.5-11kW
V5-H-11K
Conveyor Belt
Three-phase asynchronous motor
1.5-2.2kW
V5-H-2.2K
Rotary Brush
Three-phase asynchronous motor
2.2-3.7kW
V5-H-3.7K
Air-Drying System
Three-phase asynchronous motor
1.5-2.2kW
V5-H-2.2K
III. Control Circuit Design
1. Main Circuit Wiring
Washing Pump Motor:
Connect the inverter output terminals (U/T1, V/T2, W/T3) to the washing pump motor.
Connect the braking unit DC output terminal (Ө) to the braking resistor (for rapid shutdown).
Conveyor Belt Motor:
Connect the inverter output terminals (U/T1, V/T2, W/T3) to the conveyor belt motor.
Rotary Brush Motor:
Connect the inverter output terminals (U/T1, V/T2, W/T3) to the rotary brush motor.
Air-Drying System Motor:
Connect the inverter output terminals (U/T1, V/T2, W/T3) to the fan motor.
2. Control Circuit Wiring
Start/Stop Control:
Connect the PLC output points to the inverter multi-function input terminals (X1-X7) to achieve remote start/stop.
Speed Regulation:
Connect the PLC analog output (0-10V) to the inverter analog input terminal (AI1) to achieve stepless speed regulation.
Status Feedback:
Connect the inverter multi-function output terminals (Y1, Y2/DO) to the PLC input points to feedback operation status.
Fault Protection:
Connect the inverter fault output terminal to the PLC input point to achieve fault alarming.
Inverter fault output terminal → PLC input point (I0.2)
IV. Parameter Setting and Optimization
1. Basic Parameter Setting
Parameter Group
Parameter Name
Setting Value/Range
Description
P0.03
Control Mode Selection
1 (Vector Control 1)
Suitable for heavy-duty applications such as washing pumps
P0.04
Frequency Command Method
1 (AI1 Voltage Command)
Regulate speed through PLC analog output
P0.05
Maximum Operating Frequency
50Hz
Set according to motor rated frequency
P0.08
Acceleration Time
5s
Adjust according to load characteristics
P0.09
Deceleration Time
5s
Adjust according to load characteristics
2. Advanced Parameter Setting
Parameter Group
Parameter Name
Setting Value/Range
Description
P8.00
PID Control Selection
1 (Enable PID)
Used for closed-loop control of temperature, pressure, etc.
P8.01
Proportional Gain
2.0
Adjust according to system response
P8.02
Integral Time
10s
Adjust according to system stability
P8.03
Derivative Time
0.1s
Adjust according to system damping
P5.01
Multi-function Input Terminal X1
15 (Forward Start)
Define terminal function
P5.02
Multi-function Input Terminal X2
16 (Reverse Start)
Define terminal function
P7.01
Multi-function Output Terminal Y1
32 (Running)
Define output status
P7.02
Multi-function Output Terminal Y2
33 (Fault Output)
Define fault output
3. Motor Parameter Auto-Tuning
Set P9.15=1 to activate the motor parameter auto-tuning function.
Input rated voltage, current, speed, and other parameters according to the motor nameplate.
Optimize vector control performance after auto-tuning is complete.
V. Collaborative Control of PLC and Inverter
1. PLC Selection
Model: Siemens S7-1200 CPU 1214C DC/DC/DC
Features:
14 digital input points, 10 digital output points.
2 analog input channels, 1 analog output channel.
Supports Modbus RTU communication protocol.
2. Control Program Logic
Washing Pump Control:
Regulate inverter output frequency through PID algorithm based on pressure sensor feedback.
Achieve constant pressure water supply to improve washing efficiency.
Conveyor Belt Control:
Achieve precise positioning through pulse encoder feedback of position information.
Automatically adjust conveyor belt speed according to workpiece size.
Rotary Brush Control:
Control rotary brush start/stop through a timer to achieve intermittent scrubbing.
Adjust rotary brush speed according to workpiece material.
Air-Drying System Control:
Automatically adjust fan speed according to ambient temperature.
Achieve energy-efficient operation.
PLC Program Flowchart:
Start → Initialization → Read Sensor Data → Execute PID Algorithm → Output Control Signal → Monitor Status → Fault Handling → End
VI. Human-Machine Interface Design
1. Touch Screen Selection
Model: Kunlun Tongtai TPC7062KS
Features:
7-inch TFT LCD display with a resolution of 800×480.
Supports Modbus RTU communication protocol.
Provides a rich library of graphics and controls.
2. Interface Design
Main Interface:
Display the washing machine’s operation status, motor speeds, temperature, pressure, and other parameters.
Provide manual/automatic mode switching buttons.
Parameter Setting Interface:
Allow users to modify key parameters such as PID parameters, acceleration/deceleration time, and frequency limits.
Provide parameter saving and restoration functions.
Fault Alarm Interface:
Display fault type, occurrence time, and handling methods.
Provide fault confirmation and reset buttons.
Touch Screen Interface Diagram:
[Main Interface]
Operation Status: Running
Washing Pump Speed: 30Hz
Conveyor Belt Speed: 0.5m/s
Rotary Brush Speed: 15r/min
Temperature: 40℃
Pressure: 0.5MPa
[Manual/Automatic Switching Button]
[Parameter Setting Interface]
PID Proportional Gain: 2.0
PID Integral Time: 10s
Acceleration Time: 5s
Deceleration Time: 5s
Frequency Limit: 50Hz
[Save Parameters Button] [Restore Default Button]
[Fault Alarm Interface]
Fault Type: Overload Alarm
Occurrence Time: 2025-04-06 10:00:00
Handling Method: Check motor load, reduce operating frequency
[Confirm Fault Button] [Reset Button]
VII. System Integration and Debugging
1. System Integration
Connect the PLC, inverter, and touch screen through the Modbus RTU bus.
Configure communication addresses for each device to ensure efficient data exchange.
2. System Debugging
No-Load Debugging:
Check whether the rotation direction and speed of each motor are consistent with the design.
Verify the stability and response speed of the PID control algorithm.
Load Debugging:
Test the system’s stability and reliability under different load conditions.
Adjust parameters to optimize washing effect and energy-saving performance.
Fault Simulation:
Simulate faults such as overload and overvoltage to verify the reliability of protection functions.
Test the real-time performance of fault alarming and reset functions.
VIII. Conclusion
This solution achieves efficient and stable operation of the washing machine through the vector control technology and rich I/O interfaces of the V5-H inverter. Combined with the collaborative control of the PLC and touch screen, it improves the system’s automation level and operational convenience. Through parameter auto-tuning and PID algorithm optimization, it further enhances the washing effect and energy-saving performance. This solution can be widely applied in the cleaning of automobile parts, industrial components, and other fields, with broad market prospects.
The Chuanken SCKR1 series soft starter is a powerful digital soft-start solution designed for motors ranging from 11 kW to 850 kW. This guide provides a detailed explanation of the operation panel functions, parameter initialization, parameter copying to another soft starter, password setup and removal, external terminal start mode, bypass control implementation, wiring methods for main and control circuits (including schematic diagrams, with real images preferred if available), key parameters, and fault codes with their meanings and troubleshooting steps. This will help users operate the device efficiently and safely.
1. Functions of the Operation Panel (Keyboard, HMI)
The operation panel (HMI) of the SCKR1 series soft starter is the core interface for user interaction, offering parameter configuration, status monitoring, and fault diagnosis. Below are its main functions (refer to PAGE16, 6.1 Operation Panel):
Display Screen:
Shows real-time status (e.g., current, power, motor temperature) and programming details.
Parameter 8D allows selection between real-time current or motor power display.
The bottom half of the screen can switch between options like soft starter status, motor temperature, current, and power using the “▲” and “▼” buttons.
Button Functions:
Menu Navigation Keys (▲/▼): Switch between menu options, parameters, or adjust parameter values.
MENU Key: Enter menu or parameter editing mode, save parameter changes (includes STORE function).
EXIT Key: Exit menu or parameter editing, cancel unsaved changes.
ALT Key: Used with F1/F2 to access function logs or debugging tools.
F1/F2 Shortcut Keys: Quick access to common tasks (functions defined by parameters 8B and 8C).
L/R Key: Switch between Local and Remote control modes.
Status LED Indicators:
Ready: Steady on indicates motor stopped and starter ready; blinking indicates waiting for restart delay or temperature check.
Run: Steady on indicates motor running at full voltage; blinking indicates starting or stopping.
Trip: Steady on indicates starter tripped; blinking indicates warning state.
Local: Steady on indicates local control mode; off indicates remote control mode.
If all LEDs are off, it indicates no control voltage.
Synchronization Function:
The operation panel syncs with the soft starter’s parameters. If a different panel is inserted, a confirmation message appears, allowing the user to copy parameters from the panel to the starter or vice versa.
2. How to Initialize Parameters
Initializing parameters ensures the soft starter matches the motor (refer to PAGE7, 3.1 Setting Procedure Summary):
Preparation:
Ensure no power voltage is applied before connecting cables.
Complete physical installation and control cable connections (see wiring section).
Initialization Steps:
Step 1: Apply control voltage (A1, A2 terminals, 220-440 VAC).
Step 2: Set date and time:
Press “ALT” + “TOOL” to enter the “Tool” menu.
Use “▲/▼” to navigate to the “Date/Time” screen.
Press “ENTER” to enter edit mode.
Use “▲/▼” to adjust date and time values, press “ENTER” to save.
Step 3: Quick setup (for common applications):
Press “MENU” to enter the main menu.
Use “▲/▼” to select “Fast Setting,” press “ENTER” to access.
Find your application in the list, press “ENTER” to start setup.
Step 4: If no matching application, use the standard menu:
Return to the main menu, select “Standard Menu.”
Navigate to “Motor Data 1,” edit parameter 1A (motor rated current) to match the motor nameplate.
Step 5: Press “EXIT” multiple times to exit the menu.
Notes:
For advanced applications, refer to “Extended Menu” (PAGE31) and parameter descriptions (PAGE35).
Use the built-in simulation tool (3.3 Simulation Tool) to verify wiring and control logic.
3. How to Copy Parameters to Another Soft Starter
The operation panel supports parameter copying for easy configuration of multiple devices (refer to PAGE16, 6.1 Operation Panel):
Steps:
Step 1: Save parameters to the operation panel on the source soft starter:
Press “MENU,” enter “Load/Save Settings” (PAGE35).
Select “Save to Display,” press “ENTER” to save.
Step 2: Remove the panel and insert it into the target soft starter.
Step 3: When the target device detects the new panel, it displays “New Display Detected”:
Use “▲/▼” to select “Display to Starter.”
Press “MENU” to confirm; parameters will be copied to the target starter.
Notes:
If parameters don’t take effect, the target device loads default values; check compatibility.
Ensure both devices are of the same model to avoid parameter conflicts.
Studies indicate that frequency converters can be applied to the feeding, pre-milling, trimming, and polishing functions of edge banding machines, improving efficiency and quality.
Evidence suggests that frequency converters require integration with PLCs and touchscreens for automated control, with parameter settings adjusted based on motor characteristics.
It appears that wiring and parameter configuration can be complex, necessitating professional technical support to ensure safe operation.
Background and Functional Analysis
Edge banding machines are essential woodworking equipment in furniture manufacturing, with primary functions including pre-milling, gluing, feeding, pressing, cutting, trimming, and polishing. Frequency converters (Variable Frequency Drives, VFDs) enable precise motor speed control, optimizing the efficiency and accuracy of these processes. Based on the specific requirements of edge banding machines, frequency converters can be applied to the feeding motor, pre-milling motor, trimming motor, and polishing motor.
Application Scheme Overview
The application scheme for frequency converters includes motor allocation, wiring methods, parameter settings, and control system design. Research shows that the feeding motor typically operates at 50 Hz, while pre-milling and polishing motors require high-frequency operation (e.g., 185 Hz and 190 Hz), and the trimming motor supports coarse and fine trimming modes (80 Hz and 102 Hz). Additionally, a PLC (e.g., Siemens S7-1200) and a touchscreen (e.g., Weinview MT8071iE) can achieve automated control and parameter adjustment, which seems particularly important for enhancing operational convenience.
Unexpected Detail: Complex Wiring and Safety Considerations
An unanticipated detail is that frequency converter wiring involves power input (R, S, T), motor output (U, V, W), and control terminals (DI1-DI5, AI1, etc.), requiring proper grounding (PE) to prevent electrical leakage. Parameter settings necessitate motor auto-tuning, and initial commissioning may require professional technical support, adding to the implementation complexity.
Detailed Research Report: Frequency Converter Application and Control Scheme Design in Edge Banding Machines
Introduction
Edge banding machines are indispensable in furniture manufacturing, performing processes such as pre-milling, gluing, feeding, pressing, cutting, trimming, and polishing. Frequency converters (VFDs) significantly enhance the operational efficiency, machining quality, and energy savings of edge banding machines by adjusting motor speeds. This report designs a frequency converter application scheme based on the specific functions of an edge banding machine, covering motor allocation, wiring methods, parameter settings, and control system selection, aiming to provide comprehensive technical guidance.
Functional Analysis of Edge Banding Machines
Based on a typical edge banding machine model (e.g., IGOLDENCNC KT-468), its main functions include:
Pre-milling: Trims the edge of the panel to ensure flatness.
Gluing: Applies hot-melt glue to the panel edge for bonding the edge band.
Feeding and Pressing: Feeds the panel steadily via a conveyor belt and presses the edge band onto the panel.
Cutting: Cuts off excess edge band.
Trimming: Includes coarse and fine trimming to level the edge band with the panel.
Scraping: Smooths the edge band, removing burrs.
Polishing: Enhances the surface finish of the edge band.
From the operational requirements, feeding demands stable low-speed operation, pre-milling and polishing require high-speed operation, and trimming needs multi-speed switching. These characteristics highlight the critical role of frequency converters in precise motor speed control.
Frequency Converter and Motor Allocation
Based on the functional modules of the edge banding machine and the number of frequency converters (four converters shown in the image), the motor allocation scheme is as follows:
Converter 1 (F 50.0 Hz): Controls the feeding motor, operating at a lower frequency (50 Hz) for stable operation.
Converter 2 (F 185 Hz): Controls the pre-milling motor, requiring high-speed operation (approximately 10,000 RPM or more).
Converter 3 (F 102 Hz): Controls the trimming motor, supporting coarse trimming (80 Hz) and fine trimming (102 Hz).
Converter 4 (F 190 Hz): Controls the polishing motor, requiring high-speed operation (approximately 10,000 RPM or more).
The cutting motor and gluing motor may be directly controlled by relays, as their speed requirements are lower.
Wiring Scheme Design
Frequency converter wiring includes power input, motor output, and control terminal wiring. Using the INVT frequency converter as an example, the details are as follows:
Power and Motor Wiring
Power Input: R, S, T connect to a three-phase 380V power supply, with PE grounded.
Motor Output: U, V, W connect to the motor’s three-phase lines, with PE grounded.
Wiring Diagram (Text Description):
Power Input: R ---- [Converter R]
S ---- [Converter S]
T ---- [Converter T]
PE --- [Converter PE]
Motor Output: [Converter U] ---- U (Motor)
[Converter V] ---- V (Motor)
[Converter W] ---- W (Motor)
[Converter PE] --- PE (Motor Ground)
Control Terminal Wiring
Control terminals receive external signals (e.g., PLC outputs). The specific wiring is as follows:
Feeding Motor Converter: DI1 connects to PLC Y0 (start/stop), DI2 to PLC Y1 (forward/reverse), AI1 to a potentiometer (0-10V speed adjustment).
Pre-milling Motor Converter: DI1 connects to PLC Y2 (start/stop), DI2 to PLC Y3 (high/low speed).
Trimming Motor Converter: DI1 connects to PLC Y4 (start/stop), DI2 to PLC Y5 (coarse/fine trimming).
Polishing Motor Converter: DI1 connects to PLC Y6 (start/stop).
Control Terminal Wiring Diagram (Text Description):
Implementation Results: Stable feeding (30-50 Hz), high-speed pre-milling and polishing (185-190 Hz), multi-speed trimming, and automated control enhance operational convenience.
Precautions: Ensure motor parameter matching, reliable grounding, motor auto-tuning during initial commissioning, and proper dustproofing and heat dissipation during installation.
Conclusion
Through the above scheme, frequency converters significantly improve the production efficiency and machining quality of edge banding machines. Wiring and parameter settings require professional support, while the integration of PLC and touchscreen enables automated control.
The ABB ACH580 series inverters are specifically designed for HVAC (Heating, Ventilation, and Air Conditioning) systems, renowned for their high efficiency, energy savings, and reliable operation. However, in practical applications, the FAULT 3181 error code may appear, affecting the normal operation of the system. This article will provide a detailed analysis of the nature of FAULT 3181, its generation mechanisms, on-site inspection steps, and specific repair strategies.
What is FAULT 3181?
In the ABB ACH580 series inverters, FAULT 3181 is typically associated with wiring or grounding faults in the main circuit. This fault code indicates that the inverter has detected electrical issues in the power input or motor output circuit, triggering its protection mechanism. According to the technical documentation, FAULT 3181 usually points to abnormal electrical connections in the main circuit, such as loose wiring, short circuits, or improper grounding. This fault is designed to prevent equipment damage or safety hazards and requires timely diagnosis and handling.
Generation Mechanisms of FAULT 3181
The occurrence of FAULT 3181 may involve the following mechanisms:
Loose or Poor Wiring Connections If the power or control wires in the main circuit are not securely connected, it may lead to voltage fluctuations or signal interruptions. The inverter detects these anomalies and triggers fault protection.
Short Circuits Short circuits in the main circuit, such as those caused by damaged cable insulation or incorrect wiring, may result in overcurrent. The ACH580 has built-in overcurrent protection, and it will immediately shut down and display FAULT 3181 when abnormal current is detected.
Grounding Issues Grounding faults are a common cause of FAULT 3181. Poor grounding connections or the presence of grounding loops may lead to leakage currents or electrical noise, triggering the protection mechanism.
Cable Damage Physical damage (such as cut or worn cables) may expose conductors, leading to short circuits or accidental grounding. This is particularly common in long-term operation or harsh environments.
Incorrect Parameter Configuration Improper inverter parameter settings (such as mismatched motor ratings) may exacerbate electrical issues, ultimately manifesting as FAULT 3181.
On-Site Inspection Steps
To accurately diagnose FAULT 3181, it is recommended to follow these on-site inspection steps:
Safety Preparation Disconnect the inverter power supply and implement the Lockout-Tagout (LOTO) procedure. Use a multimeter to confirm that the equipment is completely de-energized.
Visual Inspection Inspect the power and control wires and grounding connections in the main circuit for signs of looseness, corrosion, or physical damage. Check the inverter casing for dust, moisture, or other environmental factors that may affect electrical performance.
Electrical Testing Use a multimeter to measure the voltage at the input terminals to ensure it falls within the rated range. Check for phase imbalance or phase loss. Perform insulation resistance testing on the cables to detect short circuits or grounding faults. Test the grounding resistance to ensure it meets electrical specifications.
Grounding Verification Check that the grounding wires are securely connected without breaks or looseness. Use a grounding tester to confirm the integrity of the grounding path.
Parameter and Log Review Access the inverter’s fault logs via the control panel or ABB Drive Composer tool to check for other related error codes. Verify that key parameters match the actual application and ensure correct configuration.
Environmental Assessment Check the environmental conditions at the installation location, such as temperature, humidity, and vibration levels, to ensure compliance with operational requirements.
Specific Repair Strategies
Based on the inspection results, the following repair measures can be taken:
Tighten Connections If loose wiring is found, tighten the terminals according to the manufacturer’s recommended torque values to ensure good contact.
Replace Damaged Cables If the cables have physical damage or insulation failure, replace them with new cables that meet the specifications.
Repair Grounding Issues If grounding is poor, clean the grounding contact points and reconnect them to ensure the grounding resistance meets standards.
Address Short Circuits If a short circuit is found, use a multimeter to trace the fault point and repair or replace the damaged components.
Adjust Parameters If parameter configuration is incorrect, refer to the ACH580 manual to adjust the settings or restore factory defaults and reconfigure.
Reset and Test After repairs, reset the inverter and conduct a trial run to observe whether the fault is cleared.
Preventive Measures Develop a regular maintenance plan to check wiring and grounding conditions and clean dust inside the equipment. Train operators to ensure proper installation and maintenance.
If the above steps do not resolve the issue, it may indicate a more serious internal fault in the inverter. In such cases, it is recommended to contact ABB technical support for professional repair or component replacement.
Conclusion
FAULT 3181 is a common error in ABB ACH580 series inverters related to wiring or grounding faults in the main circuit. Through systematic on-site inspections, including visual observation, electrical testing, and parameter review, the root cause of the problem can be accurately identified. Repair strategies include tightening connections, replacing components, optimizing grounding, and adjusting parameters. Regular maintenance and correct installation are key to preventing such faults. If the issue is complex, ABB’s technical support will provide further assistance to ensure the normal operation of the ACH580, safeguarding the stability and efficiency of the HVAC system.
The Hilectro HI300 series servo system is a high-performance servo drive widely used in industrial automation, renowned for its high precision and reliability. However, in practical applications, the fault code “Er050” may occur. This article provides a detailed analysis of the meaning of the “Er050” fault, its causes, as well as on-site inspection, handling, and specific maintenance methods to help technicians quickly restore equipment operation and summarize preventive measures to reduce the occurrence of similar faults.
1. Meaning of Er050 Fault
In the Hilectro HI300 series servo system, the “Er050” fault code indicates Software Overcurrent. This is a protective mechanism triggered when the servo drive’s software detects that the current value exceeds the preset safety threshold. Unlike hardware overcurrent (such as “Er056”), “Er050” is primarily detected and alarmed by software algorithms, usually related to control parameters, feedback signals, or external wiring issues. When this fault occurs, the system stops running and displays “Er050” on the digital display, accompanied by related indicator lights (such as “RDY” or “VCC”) lighting up, prompting the operator to take action.
2. Causes of Er050 Fault
The occurrence of “Er050” is not due to a single reason but is the result of multiple potential issues. The common causes are as follows:
Excessive Current Loop PI Parameters The current control of the servo system relies on a Proportional-Integral (PI) controller, adjusted through parameters such as proportional gain (Kp, typically corresponding to CI.00) and integral gain (Ki, typically corresponding to CI.02). If these parameters are set too high, the controller may overreact to current changes, causing current fluctuations to exceed the normal range and trigger the software overcurrent protection.
Short Circuit or Grounding on the Motor Output Side A short circuit in the motor’s internal windings or a ground fault in the output cable can cause a sharp increase in current. The software detects this anomaly and immediately alarms to protect the drive and motor.
Encoder Wiring Issues The encoder provides feedback on the motor’s position and speed. If the encoder wiring is loose, disconnected, or short-circuited, the servo system cannot accurately obtain feedback data, leading to current control instability and eventually causing an overcurrent fault.
Incorrect Motor Parameter Settings The servo drive needs to be precisely controlled based on the motor’s electrical parameters (such as inductance Ls). If the parameter configuration does not match the actual motor, the drive may output incorrect current commands, resulting in overcurrent.
Environmental or Power Supply Interference Power supply voltage fluctuations or high ambient temperatures may affect current stability. Especially under long-term operation or harsh conditions, the software may misjudge it as overcurrent.
These causes may interact with each other. For example, an encoder fault may lead to current control errors, which in turn amplify the impact of PI parameters, ultimately triggering “Er050.”
3. On-Site Inspection and Handling Methods
When the equipment displays “Er050,” technicians need to follow a systematic inspection process to quickly identify the problem and take preliminary measures. The specific steps are as follows:
1. Check Current Loop Parameters
Operation Method: Use the servo drive’s control panel or host computer software to enter the parameter setting interface and check the values of current loop parameters (such as CI.00 and CI.02).
Judgment Standard: If the parameter values are significantly higher than the recommended range (refer to the equipment manual), it may be the cause of the fault.
Handling Measures: Gradually reduce the Kp and Ki values (recommended to adjust by 10%-20% each time), save the settings, restart the system, and observe if the fault is resolved.
2. Check Motor Insulation and Wiring
Operation Method: Turn off the power and wait for the capacitor to discharge (about 5-10 minutes). Use a multimeter or insulation resistance tester to measure the insulation resistance between motor phases and to ground.
Judgment Standard: The normal insulation resistance should be greater than 10MΩ. If it is lower, it indicates a short circuit or grounding.
Handling Measures: Inspect the motor cables and terminals, repair or replace damaged parts.
3. Check Encoder Wiring
Operation Method: Ensure the encoder cable connections are secure and the shielding is properly grounded. Use a multimeter to test the continuity of the lines or an oscilloscope to observe the feedback signal waveform.
Judgment Standard: Signal interruption or abnormal waveform (such as excessive noise) indicates an encoder fault.
Handling Measures: Tighten loose connectors or replace damaged cables.
4. Check Motor Parameters
Operation Method: Verify the motor parameters set in the drive (such as inductance Ls) against the motor nameplate or manual data.
Judgment Standard: Significant parameter deviations may be the cause of the fault.
Handling Measures: Correct the parameters based on the actual motor data, save, and test.
5. Environmental and Power Supply Check
Operation Method: Use a voltmeter to measure the stability of the input power supply (380V-480V) and check the temperature and ventilation inside the control cabinet.
Judgment Standard: Voltage fluctuations exceeding the standard (±10%) or high temperatures (>40°C) may cause faults.
Handling Measures: Install a voltage stabilizer or improve cooling conditions.
4. Specific Maintenance Recommendations
Based on the on-site inspection results, take the following targeted maintenance measures:
Parameter Adjustment If the PI parameters are too large, gradually reduce the values of CI.00 and CI.02, testing after each adjustment to observe the system response. Avoid excessive reduction that may lead to control instability.
Wiring Repair For encoder or motor wiring issues, tighten loose connectors or replace damaged cables. Ensure the shielding is properly grounded to reduce electromagnetic interference.
Component Replacement
Motor Fault: If insulation tests show a short circuit or grounding, replace the motor or repair the insulation.
Encoder Damage: Replace with the same model encoder and recalibrate the system.
Hardware Maintenance If internal current sensors or power modules (such as IGBT) are suspected to be faulty, have a professional inspect and possibly replace the damaged components.
Safety Operations Ensure the power is off and capacitors are discharged before maintenance. Use insulated tools and protective equipment. If the issue is complex, contact Hilectro technical support with the serial number and fault details for guidance.
5. Preventive Measures and Routine Maintenance
To prevent the recurrence of “Er050” faults, implement the following preventive measures:
Regular Inspections Check motor, encoder, and power supply wiring quarterly to ensure there is no looseness or aging.
Parameter Management Regularly back up parameter settings and monitor current waveforms during operation to ensure they are within normal ranges.
Environmental Optimization Keep the control cabinet clean and dry, install ventilation or dehumidification equipment to prevent overheating and moisture accumulation.
Personnel Training Train operators to recognize early anomalies (such as motor noise or overheating) and report them promptly for handling.
6. Conclusion
The “Er050” fault in the Hilectro HI300 series servo system, indicating software overcurrent, is a common protective alarm typically caused by excessive current loop parameters, wiring faults, or incorrect motor parameters. Through systematic on-site inspections (such as parameter verification, insulation testing, and encoder checks) and targeted maintenance (such as adjusting parameters or replacing components), technicians can effectively resolve the issue. Preventive maintenance and a deep understanding of the fault mechanisms are key to ensuring long-term stable operation of the equipment. We hope this article provides practical guidance for on-site operations. For further assistance, refer to the equipment manual or contact professional technical support.
The PROMPOWER Inverter PD310 Series is a powerful and versatile low-voltage inverter suitable for industrial automation scenarios that require high dynamic performance and a wide range of speed regulation. To help users better master its usage, this document provides a detailed English user guide based on the Russian user manual. The content covers the functions of the operation panel and related settings, external control implementation methods, and diagnostic and handling procedures for fault codes.
I. Introduction to Operation Panel Functions and Related Settings
The operation panel is the core tool for user interaction with the PD310 Series inverter. Through its keys and display, users can perform operations such as parameter viewing, modification, and device control. This section will introduce the functions of the operation panel in detail and explain how to restore factory settings for parameters, set and eliminate passwords, and set parameter access restrictions.
1.1 Introduction to Operation Panel Functions
The operation panel of the PD310 Series inverter includes a display and multiple function keys for displaying the running status and executing operations. According to Chapter 5 “Приступаем к работе” (Getting Started) of the manual, the main functions are as follows:
Display: Displays the current running status (such as frequency, voltage), parameter values, and fault codes.
Key Functions:
PRG (Programming Key): Enters or exits the programming mode to access the parameter setting menu.
ENTER (Confirm Key): Confirms parameter modifications or enters the next level of the menu.
UP (Up Key): Increases the parameter value or scrolls up the page.
DOWN (Down Key): Decreases the parameter value or scrolls down the page.
SHIFT (Shift Key): Switches between the parameter number and parameter value.
RUN (Run Key): Starts the inverter.
STOP/RESET (Stop/Reset Key): Stops the inverter operation or resets the fault status.
Operation Example: To modify a parameter, the user can press the PRG key to enter the programming mode, use the UP/DOWN keys to select the parameter number, press the ENTER key to enter the parameter value editing mode, use the UP/DOWN keys to adjust the value, and finally press the ENTER key to save.
1.2 Restoring Factory Settings for Parameters
To restore the inverter parameters to the factory default values, follow the steps in Section 5.3 “Сброс на заводские настройки” (Restoring Factory Settings) of the manual:
Press the PRG key to enter the programming mode.
Use the UP/DOWN keys to select the parameter group “F0”.
Press the ENTER key to enter the “F0” group.
Select the parameter “F0-00” (usually the factory reset parameter).
Press the ENTER key to enter the editing mode and set the value to “1” (indicating factory reset).
Press the ENTER key to confirm. The inverter will automatically restart, and the parameters will be restored to the factory values.
Note: This operation will clear all user settings. It is recommended to back up important parameters in advance.
1.3 Setting and Eliminating Passwords
The PD310 Series supports password protection to prevent unauthorized parameter modifications. The steps for setting and eliminating passwords are as follows:
Setting a Password:
Press the PRG key to enter the programming mode.
Select the parameter group “F0”.
Enter the parameter “F0-01” (password setting parameter).
Input a 4-digit password (e.g., 1234) and adjust the value using the UP/DOWN keys.
Press the ENTER key to confirm. The password setting takes effect.
The password must be entered the next time parameter access is required.
Eliminating a Password:
Press the PRG key to enter the programming mode.
Input the current password to unlock parameter access.
Enter the parameter “F0-01”.
Set the value to “0”.
Press the ENTER key to confirm. The password is cleared.
1.4 Setting Parameter Access Restrictions
To prevent accidental operations, the PD310 allows restricting access permissions for certain parameters. The specific operations are as follows:
Setting Access Restrictions:
Press the PRG key to enter the programming mode.
Select the parameter group “F0”.
Enter the parameter “F0-02” (access restriction setting).
Set the parameter value to the number of the parameter group to be restricted (e.g., set to “1” to restrict the F1 group).
Press the ENTER key to confirm. The restricted parameter group cannot be accessed or modified.
Lifting Access Restrictions:
Press the PRG key to enter the programming mode.
Input the password (if set) to unlock.
Enter the parameter “F0-02”.
Set the value to “0”.
Press the ENTER key to confirm. All parameter groups resume accessible status.
Through the above settings, users can flexibly manage parameter permissions and ensure system security.
II. External Control Implementation
The PD310 Series inverter supports motor forward/reverse control and speed regulation through external terminals. This section will introduce how to achieve external terminal forward/reverse control and external potentiometer speed regulation through wiring and parameter settings.
2.1 External Terminal Forward/Reverse Control
External terminal forward/reverse control is achieved through digital input terminals (DI) and the common terminal (COM). According to Section 4.5 “Клеммы управления” (Control Terminals) of the manual:
Wiring:
Forward Switch: Connect DI1 and COM terminals.
Reverse Switch: Connect DI2 and COM terminals.
Parameter Settings:
Press the PRG key to enter the programming mode.
Select the parameter group “F1”.
Set “F1-00” (control mode) to “1” (terminal control).
Set “F1-01” (DI1 function) to “1” (forward command).
Set “F1-02” (DI2 function) to “2” (reverse command).
Press the PRG key to exit.
Operation Mode: When DI1 is closed, the motor runs forward; when DI2 is closed, the motor runs reverse. If both DI1 and DI2 are closed simultaneously, the motor may stop (depending on the parameter configuration).
2.2 External Potentiometer Speed Regulation
External potentiometer speed regulation achieves speed adjustment through analog input terminals (AI). According to Section 4.5 of the manual:
Wiring:
Potentiometer Middle Tap: Connect to the AI1 terminal.
Potentiometer One End: Connect to the +10V terminal.
Potentiometer Other End: Connect to the GND terminal.
Parameter Settings:
Press the PRG key to enter the programming mode.
Select the parameter group “F2”.
Set “F2-00” (speed reference method) to “1” (AI1 analog input).
Set “F2-01” (AI1 minimum input) to 0V (minimum potentiometer voltage).
Set “F2-02” (AI1 maximum input) to 10V (maximum potentiometer voltage).
Set “F2-03” (AI1 minimum frequency) to 0Hz.
Set “F2-04” (AI1 maximum frequency) to 50Hz (or the maximum frequency required by the user).
Press the PRG key to exit.
Operation Mode: Rotating the potentiometer linearly adjusts the motor speed from 0Hz to 50Hz.
III. Fault Codes and Handling
The PD310 Series inverter may encounter faults during operation and prompt the user with fault codes. This section lists common fault codes and their meanings based on Section 6.1 “Коды ошибок” (Fault Codes) of the manual and provides handling methods.
3.1 Fault Code List
The following are common fault codes and their meanings (refer to page 201 of the manual):
For the above faults, the following are the recommended handling methods:
Err01 Short-circuit Protection:
Check if the motor and output lines are short-circuited.
Ensure correct wiring and eliminate grounding faults.
Err08/Err09/Err10 Overvoltage Faults:
Check if the input voltage is too high.
Confirm if the braking resistor is correctly connected or damaged.
Extend the acceleration/deceleration time parameters (F0 group).
Err11 Undervoltage:
Check if the power supply voltage is below the requirement.
Check if the power supply line connections are good.
Err12 Input Phase Loss:
Check if the three phases of the input power are complete.
Ensure secure wiring.
Err13 Output Phase Loss:
Check if the motor wiring is loose or disconnected.
Verify if the motor is normal.
Err14 Inverter Overload:
Reduce the load or replace with a higher-power inverter.
Check if the parameter settings are reasonable.
Err15 Motor Overload:
Check if the load exceeds the motor capacity.
Adjust the motor protection parameters (F5 group).
Err17 Inverter Overtemperature:
Check if the cooling fan is operating normally.
Clean the heat sink to ensure good ventilation.
Err21 External Fault:
Check if the external fault input terminal (DI) is triggered.
Eliminate the external fault source.
Err23 Communication Fault:
Check if the communication line connections are correct.
Verify if the communication parameters (F11 group) match.
Handling Process: When a fault occurs, record the code and press the STOP/RESET key to reset. If the issue cannot be resolved, troubleshoot according to the above methods and contact PROMPOWER technical support if necessary.
Conclusion
Through this document, users can fully understand the operation and application of the PROMPOWER Inverter PD310 Series. The functions of the operation panel provide convenience for parameter management, and restoring factory settings, password protection, and access restrictions enhance system security. External terminal forward/reverse control and potentiometer speed regulation provide users with flexible control methods. The identification and handling methods for fault codes help quickly resolve issues and ensure stable equipment operation. This document aims to provide users with practical guidance and improve equipment usage efficiency.
The winding machine and its traverse system are primarily used to ensure that materials (such as paper, film, or wire) are neatly and evenly arranged on the reel during the winding process, preventing stacking or misalignment. The following sections detail the application of the inverter, including motor selection, wiring methods, parameter settings, control logic, and the integration of PLC, HMI, or industrial PC, based on the process equipment workflow.
1. Functional Analysis of the Winding Machine Traverse System
The traverse system of a winding machine typically requires the following functions:
Main Winding Motor: Drives the reel to rotate, completing the material winding process.
Traverse Motor: Drives the traverse device to move left and right, ensuring even material distribution on the reel.
Tension Control: Maintains constant material tension during winding to avoid stretching or slackening.
Speed Synchronization: The traverse motor’s movement speed must synchronize with the main winding motor’s speed to match the material winding speed.
Position Control: The traverse device must reciprocate based on the reel width, with left and right limit settings.
Start/Stop Control: Controls the start and stop of winding and traversing via external signals (e.g., buttons or PLC).
Fault Protection: Detects faults such as overload, phase loss, or overcurrent, stopping the system for protection.
A typical winding machine traverse device includes a main winding motor (driving the winding drum) and a traverse device (achieving left-right movement through a lead screw). We will use the 900 series frequency converters to control the main winding motor and the traverse motor.
2. Motor Selection and Function Assignment
2.1 Main Winding Motor
Function: Drives the reel to rotate, completing material winding.
Motor Selection: Based on the winding machine’s load and reel diameter, we assume a 4kW three-phase asynchronous motor (380V) is required. From the inverter model table on page 5 of the manual, we select the 900-0040G1 model (suitable for a 4kW motor, rated output current 18A).
Control Mode: Uses V/F control mode (ideal for scenarios with significant load variations like winding machines), adjusting speed via the inverter to control winding speed.
2.2 Traverse Motor
Function: Drives the traverse device to move left and right, achieving reciprocating motion via a lead screw mechanism.
Motor Selection: The traverse motor typically requires less power; we assume a 0.75kW three-phase asynchronous motor (380V) is needed. From the manual’s model table on page 5, we select the 900-0007M3 model (suitable for a 0.75kW motor, rated output current 2.5A).
Control Mode: Uses open-loop vector control mode (suitable for precise speed and direction control), managing the traverse motor’s forward/reverse rotation and speed via the inverter.
3. Inverter Wiring Design
3.1 Main Winding Motor Inverter (900-0040G1) Wiring
Power Input:
Inverter input terminals R, S, T connect to a three-phase 380V power supply.
Ground terminal PE connects to the ground wire for safety.
Motor Output:
Inverter output terminals U, V, W connect to the three-phase input of the main winding motor.
Control Terminal Wiring (refer to Chapter 3 of the manual, “Mechanical Installation and Electrical Connection”):
DI1 (Start/Stop Control): Connects to an external start button (normally open contact) to start/stop the main winding motor.
DI2 (Forward/Reverse): Connects to an external direction switch to control the main winding motor’s rotation direction (typically only forward rotation is needed for winding machines).
AI1 (Speed Reference): Connects to a potentiometer (0-10V) or PLC analog output to adjust the main winding motor’s speed.
DO1 (Operation Status Output): Connects to an indicator light or PLC input to output the inverter’s operating status.
+24V and COM: Used for the power supply and common terminal of the external control circuit.
3.2 Traverse Motor Inverter (900-0007M3) Wiring
Power Input:
Inverter input terminals R, S, T connect to a three-phase 380V power supply.
Ground terminal PE connects to the ground wire.
Motor Output:
Inverter output terminals U, V, W connect to the three-phase input of the traverse motor.
Control Terminal Wiring:
DI1 (Forward): Connects to the left limit switch (normally closed contact); when the traverse device reaches the left limit, it triggers to stop forward rotation.
DI2 (Reverse): Connects to the right limit switch (normally closed contact); when the traverse device reaches the right limit, it triggers to stop reverse rotation.
DI3 (Start/Stop Control): Linked to the main winding motor’s start/stop signal (via PLC or relay).
AI1 (Speed Reference): Receives a PLC analog output (0-10V) to set the speed, synchronized with the main winding motor.
DO1 (Operation Status Output): Connects to a PLC input to output the traverse motor’s operating status.
3.3 Wiring Diagram (Text Description)
Main Winding Motor Inverter Wiring Diagram:
Three-Phase Power 380V
| | |
R S T
| | |-------> Inverter (900-0040G1) Input Terminals R, S, T
PE-------------> Inverter PE Ground Terminal
Inverter Output U, V, W
| | |
U V W-------> Main Winding Motor (4kW)
Control Terminals:
External Start Button-------> DI1 - COM
Direction Switch-----------> DI2 - COM
Potentiometer (0-10V)------> AI1 - GND
Indicator Light------------> DO1 - COM
Traverse Motor Inverter Wiring Diagram:
Three-Phase Power 380V
| | |
R S T
| | |-------> Inverter (900-0007M3) Input Terminals R, S, T
PE-------------> Inverter PE Ground Terminal
Inverter Output U, V, W
| | |
U V W-------> Traverse Motor (0.75kW)
Control Terminals:
Left Limit Switch-----------> DI1 - COM
Right Limit Switch----------> DI2 - COM
Start/Stop Signal (PLC)-----> DI3 - COM
PLC Analog (0-10V)---------> AI1 - GND
PLC Input------------------> DO1 - COM
4. Parameter Settings
4.1 Main Winding Motor Inverter (900-0040G1) Parameter Settings
Referring to Chapter 5 of the manual, “Parameter Description,” set the following key parameters:
F0-00 (Command Source): Set to 1 (terminal control), using DI1 to control start/stop.
F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via the potentiometer.
F0-03 (Maximum Frequency): Set to 50Hz (adjust based on actual needs).
F0-09 (Motor Rated Frequency): Set to 50Hz.
F0-10 (Motor Rated Voltage): Set to 380V.
F1-00 (DI1 Function): Set to 1 (forward run).
F1-01 (DI2 Function): Set to 2 (reverse run).
F6-12 (Motor Overload Protection): Set to 150% (adjust based on motor rated current).
F7-00 (Communication Address): Set to 1 (if using PLC communication).
4.2 Traverse Motor Inverter (900-0007M3) Parameter Settings
F0-00 (Command Source): Set to 1 (terminal control), using DI1 and DI2 to control forward/reverse.
F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via PLC.
F0-03 (Maximum Frequency): Set to 30Hz (traverse motor speed is lower, adjust based on lead screw ratio).
F0-09 (Motor Rated Frequency): Set to 50Hz.
F0-10 (Motor Rated Voltage): Set to 380V.
F1-00 (DI1 Function): Set to 1 (forward run).
F1-01 (DI2 Function): Set to 2 (reverse run).
F1-02 (DI3 Function): Set to 5 (free stop), linked with the main winding motor.
F6-12 (Motor Overload Protection): Set to 150%.
5. Control Logic Design
5.1 Speed Synchronization Logic
The traverse motor’s speed must synchronize with the main winding motor’s speed. Assuming the reel diameter is (D), material thickness is (t), and reel speed is (n) (rpm), the material winding linear speed is: [ v = \pi \cdot D \cdot n ]
The traverse device’s movement speed (v_{\text{traverse}}) must match (v). Assuming the lead screw pitch is (p) and the traverse motor speed is (n_{\text{traverse}}), then: [ v_{\text{traverse}} = p \cdot n_{\text{traverse}} ]
Thus, the traverse motor speed should be: [ n_{\text{traverse}} = \frac{\pi \cdot D \cdot n}{p} ]
The PLC calculates (n_{\text{traverse}}) and outputs the corresponding frequency signal (0-10V) to the traverse inverter’s AI1 terminal.
5.2 Reciprocating Motion Control
The traverse device uses left and right limit switches to control reciprocating motion:
When the traverse device reaches the left limit, the left limit switch opens, DI1 signal fails, the inverter stops forward rotation, and DI2 triggers reverse rotation.
When the traverse device reaches the right limit, the right limit switch opens, DI2 signal fails, the inverter stops reverse rotation, and DI1 triggers forward rotation.
5.3 Tension Control
Tension control can be achieved by fine-tuning the main winding motor’s speed. For more precise tension control, a tension sensor can be added, with the PLC collecting tension signals to dynamically adjust the main winding motor’s speed.
6. PLC and HMI Selection and Application
6.1 Necessity of PLC and HMI
PLC: Recommended to implement speed synchronization, reciprocating motion control, tension control logic, and communication with the inverter.
HMI: Used for parameter setting, monitoring operating status (e.g., speed, tension, fault information), and operational control (start/stop, speed adjustment).
6.2 Model Recommendations
PLC: Siemens S7-1200 series (e.g., CPU 1214C DC/DC/DC)
Reason: Supports Modbus-RTU communication (compatible with the inverter), has sufficient I/O points (digital and analog), and is cost-effective.
Configuration: Includes analog input/output modules (for collecting tension signals and outputting speed reference signals).
HMI: Siemens KTP700 Basic (7-inch)
Reason: Compatible with S7-1200, supports Modbus communication, user-friendly interface, suitable for industrial environments.
6.3 PLC and Inverter Communication
Communication Method: Uses Modbus-RTU protocol (refer to Chapter 6 of the manual).
Settings:
Main winding inverter communication address (F7-00) set to 1, baud rate (F7-01) set to 19200bps, data format (F7-02) set to 8-E-1.
Traverse inverter communication address (F7-00) set to 2, with the same baud rate and data format.
PLC Program:
Reads the main winding inverter’s speed (register U0-00).
Calculates the traverse inverter’s target frequency and writes to register 0x01.
Monitors fault status (registers U0-51 to U0-71); if a fault occurs, the system stops.
6.4 HMI Interface Design
Main Interface: Displays main winding motor speed, traverse motor speed, material tension, and operating status.
Parameter Settings: Sets reel diameter, material thickness, lead screw pitch, maximum speed, etc.
Control Buttons: Start, stop, emergency stop, and speed adjustment (via slider).
7. Control Schematic (Text Description)
PLC (S7-1200)
|-------> RS485 Communication ------> Main Winding Inverter (Address 1)
|-------> RS485 Communication ------> Traverse Inverter (Address 2)
|
|-------> Analog Output -----> Main Winding Inverter AI1 (Speed Reference)
|-------> Analog Output -----> Traverse Inverter AI1 (Speed Reference)
|
|-------> Digital Input -----> Left Limit Switch
|-------> Digital Input -----> Right Limit Switch
|
|-------> Analog Input -----> Tension Sensor
HMI (KTP700)
|-------> Communicates with PLC for Display and Control
8. Implementation Steps
Installation: Follow Chapter 3 of the manual to install the inverter and motors, ensuring proper ventilation and secure wiring.
Wiring: Connect the power, motors, and control terminals as per the wiring diagrams above.
Parameter Settings: Set the inverter parameters as described in Section 4, and test motor operation.
PLC Programming: Write the speed synchronization and reciprocating motion control logic, and test communication functions.
HMI Configuration: Design the interface and test operational functions.
Commissioning: Start the winding machine, adjust speed and tension parameters, and ensure even traversing.
9. Precautions
Safety: Adhere to the safety precautions in Chapter 1 of the manual, ensuring reliable grounding and avoiding misoperation.
Motor Parameter Tuning: If using vector control, perform motor parameter auto-tuning (refer to Chapter 4 of the manual).
Fault Diagnosis: If overcurrent or overvoltage faults occur, refer to Chapter 7 of the manual for troubleshooting.
Through the above solution, the 900 Series Inverter can be effectively applied to the winding machine’s traverse system, achieving speed synchronization, reciprocating motion, and tension control. For more detailed PLC programming or HMI interface design, please feel free to contact us.
This translation maintains the technical accuracy and structure of the original article, with key points emphasized in bold as requested. Let me know if further adjustments are needed!
The ZTE ZXDU68 S601/T601 Series Integrated Power Supply is an intelligent unattended power system designed specifically for communication networks. It adopts a modular design, supports -48V DC output, and can be configured with up to 12 ZXD2400 (V4.0) 50A high-frequency switching rectifiers, achieving a total output current of 600A. The system features comprehensive monitoring capabilities and supports remote management, making it suitable for access networks, remote switching stations, mobile base stations, and other scenarios.
Key Features:
High Efficiency and Energy Saving: The rectifiers use active power factor correction (PFC) technology, with an input power factor >0.99 and efficiency >90%.
Intelligent Management: The centralized monitoring unit supports “Three Remotes” (remote measurement, remote signaling, remote control) functions, enabling real-time monitoring of voltage, current, temperature, and other parameters.
Flexible Expansion: Supports N+1 redundancy backup, and the rectifiers support hot-swappable, plug-and-play functionality.
Multiple Protections: Equipped with C-class, D-class, and DC lightning protection modules, and supports battery hierarchical load shedding protection.
1.2 Model and Configuration
Model Differences:
ZXDU68 S601: 2-meter-high cabinet, with space below for installing inverters or batteries.
ZXDU68 T601: 1.6-meter-high cabinet, with other functions identical to S601.
Standard Configuration:
AC Distribution: Single 100A input, 2 standby outputs.
Monitoring Unit: 1 set, supporting RS232/RS485 communication interfaces.
Rectifiers: 12 ZXD2400 (V4.0) rectifiers.
II. Safety Operation Guidelines
2.1 Safety Warnings
High Voltage Danger: Disconnect the power before operation and avoid working on live cables.
Anti-Static Measures: Wear an anti-static wrist strap and ground it before contacting circuit boards.
Tool Requirements: Use dedicated insulated tools and prohibit the use of non-standard tools.
2.2 Operation Precautions
Installation Environment: The equipment should be placed in a dry, well-ventilated environment with a temperature range of -5℃~45℃.
Wiring Specifications:
AC input must comply with three-phase five-wire or single-phase three-wire systems.
DC output must strictly distinguish polarity to avoid short circuits.
Maintenance Requirements: Regularly check the status of lightning protectors (window color), the tightness of cable connections, and the cleanliness of the cooling air ducts.
III. System Structure and Working Principle
3.1 System Structure
The ZXDU68 system consists of four core units:
AC Distribution Unit:
Function: Mains access, lightning protection, and standby output distribution.
AC Input: Mains power is distributed to rectifiers and standby outputs after lightning protection.
Rectification Conversion: Rectifiers convert AC to DC and output it in parallel to the DC distribution.
Battery Management: The monitoring unit automatically switches between float and equalization charging modes based on battery status, supporting temperature compensation.
Load Protection: When the battery voltage falls below the set threshold, the system performs hierarchical load shedding (primary load shedding and secondary load shedding).
IV. Monitoring Unit Operation Guide
4.1 Interface and Button Functions
Operation Interface:
LCD Display: Real-time display of voltage, current, and alarm information.
Buttons: ▲/▼ keys to switch menus, Enter key to confirm, Esc key to return.
Indicator Lights:
PWR (Power), RUN (Running), ALM (Alarm) status lights.
4.2 Main Function Operations
Information Query:
Path: Main Menu → 【Information】 → View DC output, battery status, AC input, etc.
Supports real-time data, historical alarm records, and discharge record queries.
Parameter Setting:
Float Charging Voltage: 53.5V (default), range 42.0V~58.0V.
Equalization Charging Cycle: 180 days (default), range 15~365 days.
Path: Main Menu → 【Control】 → Enter password (default 0000) → Set float charging voltage, equalization charging cycle, etc.
Key Parameters:
Alarm Handling:
Real-time alarms are displayed in the 【Alarm】 menu, with audio and visual alerts.
Historical alarms can be traced through the 【Records】 menu.
V. Routine Maintenance and Fault Handling
5.1 Routine Maintenance Process
Startup Steps:
Disconnect load and battery fuses → Close AC input circuit breaker → Start rectifiers → Close standby output → Restore load.
Shutdown Steps:
Disconnect load and battery fuses → Turn off rectifiers → Disconnect AC input.
5.2 Regular Inspection Items
Lightning Protectors: Check the window color of C-class lightning protectors (green is normal, red requires replacement).
Cooling System: Clean fan and air duct dust to ensure cooling efficiency.
Cable Connections: Check input/output terminals for looseness to avoid poor contact.
5.3 Common Fault Handling
Fault Type
Handling Method
AC Power Failure
Activate backup oil machine power supply and check mains recovery.
Rectifier Fault
Replace the faulty rectifier and ensure N+1 redundancy.
Low Battery Voltage
Check battery capacity settings and initiate equalization charging to repair.
DC Output Overvoltage
Check rectifier output voltage and replace abnormal modules.
VI. Appendix and Technical Support
6.1 Technical Specifications Quick Reference
Input Voltage: 80V~300V AC (phase voltage).
Output Voltage: -48V DC (range -42V~-58V).
Protection Rating: IP20, compliant with YD/T 1058-2000 standard.
Conclusion The ZTE ZXDU68 Series Integrated Power Supply provides stable power protection for communication networks with its intelligent design and high reliability. Users can maximize equipment efficiency and reduce operational risks by mastering the operation and maintenance points in this guide. It is recommended to participate in regular ZTE official training to obtain deeper technical support.
