Author: baiyuzhan

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ZTE ZXDU68 Series Integrated Power Supply User Manual Guide

I. Product Overview and System Configuration

1.1 Product Introduction

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.
ZXDU power panel image

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.
    • DC Distribution: 4 primary load shedding circuits, 2 secondary load shedding circuits, 2 battery inputs.
    • 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

  1. Installation Environment: The equipment should be placed in a dry, well-ventilated environment with a temperature range of -5℃~45℃.
  2. 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.
  3. 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:

  1. AC Distribution Unit:
    • Function: Mains access, lightning protection, and standby output distribution.
    • Key Components: C-class lightning protector, D-class lightning protection box, AC input circuit breaker.
  2. Rectifier Group:
    • Function: Converts AC to -48V DC, supports hot-swappable.
    • Indicator Lights: Green “IN” indicates normal input, green “OUT” indicates normal output.
  3. DC Distribution Unit:
    • Function: Distributes DC power to loads and batteries, supports primary/secondary load shedding protection.
    • Key Components: Load fuses, battery fuses, DC lightning protection box.
  4. Monitoring Unit:
    • Function: Data acquisition, parameter setting, and alarm management.
    • Core Boards: PSU (Power Management), RSB (Rectifier Signal), SCB (Signal Conversion).

3.2 Working Principle

  • 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).
Picture inside ZXDU power cabinet

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

  1. 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.
  2. 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:
  3. 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

  1. Startup Steps:
    • Disconnect load and battery fuses → Close AC input circuit breaker → Start rectifiers → Close standby output → Restore load.
  2. 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 TypeHandling Method
AC Power FailureActivate backup oil machine power supply and check mains recovery.
Rectifier FaultReplace the faulty rectifier and ensure N+1 redundancy.
Low Battery VoltageCheck battery capacity settings and initiate equalization charging to repair.
DC Output OvervoltageCheck 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.

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Application Scheme of OUke Inverter GD320 in Roller Shutter Equipment

I. Overview

This scheme aims to apply the Ouke inverter GD320 to roller shutter equipment to achieve precise control of the motor. Combining the technical data of the Lingshida inverter and the application requirements of the roller shutter equipment, this scheme details the motor application positions, wiring methods, parameter settings, and PLC control schemes.

Working images of Ouke inverter GD320

II. Motor Application Positions and Functions

In roller shutter equipment, motors are mainly used in the following positions and functions:

  1. Opening/Closing Function:
    • The motor drives the lifting of the shutter to open and close it.
    • Position: The motor is usually installed at one end of the shutter shaft and drives the shaft to rotate through a transmission device.
  2. Limit Function:
    • The motor works with limit switches to ensure that the shutter stops accurately at predetermined positions when opening and closing.
    • Position: Limit switches are installed at the top and bottom of the shutter track.
  3. Safety Protection Function:
    • The motor cooperates with infrared protection devices. When an obstacle is detected, the motor stops or reverses to avoid crushing.
    • Position: Infrared protection devices are installed on both sides or the bottom of the shutter.
  4. Emergency Stop Function:
    • In an emergency, the motor power supply is cut off through an emergency stop button or password switch, causing the shutter to stop immediately.
    • Position: Emergency stop buttons or password switches are installed in easily accessible positions.

III. Wiring Methods

  1. Main Circuit Wiring
    • Power Wiring: Connect the three-phase power supply (L1, L2, L3) to the inverter’s RST terminals.
    • Motor Wiring: Connect the motor’s UVW terminals to the inverter’s UVW terminals.
    • Precautions:
      • Ensure that the power supply and motor phase sequences are consistent to avoid motor reversal.
      • Check if the wire ends are secure after wiring to avoid poor contact.
  2. Control Circuit Wiring
    • Control Signal Wiring:
      • Start/Stop Signal: Connect the start button and stop button to the inverter’s FWD and REV terminals, respectively.
      • Speed Signal: If external speed adjustment is needed, connect a potentiometer or analog signal output from the PLC to the inverter’s AI terminal.
      • Limit Switch Signal: Connect the upper and lower limit switches to the inverter’s LI1 and LI2 terminals, respectively.
    • Precautions:
      • The control circuit should use shielded wires to avoid electromagnetic interference.
      • The control circuit and main circuit should be wired separately to ensure safety.
  3. Grounding Wiring
    • Reliably ground the grounding terminals of the inverter and motor to ensure equipment safety.

IV. Parameter Settings

  1. Basic Parameter Settings
    • Pr000: Password
      • Set to 000 to unlock parameters.
    • Pr001: Operating Frequency Setting
      • Set to 50Hz (adjust according to the motor’s rated frequency).
    • Pr002: Operating Control Mode
      • Set to 1 (terminal command control).
  2. Motor Parameter Settings
    • Pr003: Main Frequency Setting Method
      • Set to 1 (analog input).
    • Pr004: Base Frequency
      • Set to 50Hz (consistent with the motor’s rated frequency).
    • Pr005: Maximum Output Voltage
      • Set to 380V (adjust according to the motor’s rated voltage).
  3. Acceleration/Deceleration Time Settings
    • Pr006: Acceleration Time 1
      • Set to 10s (adjust according to actual needs).
    • Pr007: Deceleration Time 1
      • Set to 10s (adjust according to actual needs).
  4. Limit Switch Settings
    • Pr008: Upper Limit Frequency
      • Set to 50Hz (consistent with the motor’s rated frequency).
    • Pr009: Lower Limit Frequency
      • Set to 0Hz.
    • Pr010: Electronic Thermal Relay Action Selection
      • Set to 1 (electronic thermal relay action).
  5. PID Control Settings (if needed)
    • Pr011: PID Setpoint
      • Set according to actual needs.
    • Pr012: PID Feedback Value
      • Set according to actual needs.
    • Pr013: PID Proportional Gain
      • Adjust according to actual needs.
    • Pr014: PID Integral Time
      • Adjust according to actual needs.
    • Pr015: PID Derivative Time
      • Adjust according to actual needs.

V. PLC Control Scheme

  1. PLC Selection
    • Choose a PLC with analog and digital outputs, such as Siemens S7-200 SMART.
  2. PLC and Inverter Wiring
    • Analog Output: Connect the PLC’s analog output module to the inverter’s AI terminal to adjust motor speed.
    • Digital Output: Connect the PLC’s digital output module to the inverter’s FWD, REV, LI1, LI2, and other terminals to control motor start, stop, and limits.
  3. PLC Programming
    • Manual Control Program:
      • Control motor start, stop, and forward/reverse rotation through buttons.
      • Program example (ladder diagram):复制代码| I0.0 (Start Button) |---|---|---| Q0.0 (Inverter FWD)| I0.1 (Stop Button) |---|---|---| Q0.1 (Inverter REV)
    • Automatic Control Program:
      • Detect obstacles through sensors or infrared protection devices and control motor stop or reverse.
      • Program example (ladder diagram):复制代码| I0.2 (Infrared Sensor) |---|---|---| Q0.2 (Inverter LI1)| I0.3 (Lower Limit Switch)|---|---|---| Q0.3 (Inverter LI2)
  4. Communication Settings (if needed)
    • If more complex control functions are required, communication between the PLC and inverter can be achieved through the RS-485 interface.
    • Set the inverter’s communication parameters, such as baud rate, data bits, stop bits, etc., to ensure consistency with the PLC.

VI. Conclusion

This scheme details the application of the Ouke inverter GD320 in roller shutter equipment, including motor application positions, wiring methods, parameter settings, and PLC control schemes. Through reasonable wiring and parameter settings, precise control of roller shutter equipment can be achieved, improving equipment stability and safety. If further customization or optimization of the scheme is needed, adjustments can be made based on actual equipment requirements.

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User Manual Guide for Lingshida Inverter LSD-C7000 Series

Introduction

As a high-performance vector inverter, the Lingshida LSD-C7000 series is widely used in industrial drive applications. This guide aims to provide users with an in-depth understanding of the inverter’s operation panel functions, parameter settings, external control, and troubleshooting, ensuring efficient and safe operation of the equipment.

I. Operation Panel Functions and Key Parameter Settings

1.1 Introduction to Operation Panel Functions

The LSD-C7000 series inverter’s operation panel integrates a variety of function keys and status indicators, including:

  • Function Keys: RUN (run), STOP (stop), JOG (jog), PU/EXT (operation mode switch), SET (confirm), MODE (mode selection), etc.
  • Status Indicators: RUN (green, running status), STOP (red, stop status), F/R (forward/reverse indication), ALARM (fault alarm), etc.
  • Display Screen: Real-time display of set frequency, output current, voltage, power, speed, and other key parameters.
LSD-C7200

1.2 Factory Reset of Parameters

When needing to reset the inverter parameters, follow these steps:

  1. Enter programming mode: Press the MODE key to select parameter setting mode (usually displayed as “Pr” or “P”).
  2. Set the reset parameter: Enter Pr001=11111 (specific reset code) via the numeric keys.
  3. Confirm execution: Press the SET key to confirm, and the inverter will automatically restart and restore all parameters to their factory defaults.

1.3 Password Setting and Access Restrictions

  • Password Setting:
    • Set a 4-digit password (range: 0-65535) via parameter Pr800.
    • After setting, accessing protected parameters (such as Pr001-Pr800) requires entering the password.
  • Password Elimination: Set Pr800 to 0 to remove password protection.
  • Access Restrictions: By setting Pr800 to an odd or even number, access permissions for different parameters can be controlled hierarchically.

II. External Terminal Control and Speed Regulation Configuration

2.1 Forward/Reverse Control Wiring and Parameter Settings

  • Wiring Method:
    • Connect external switch or relay contacts to the inverter control terminals S1 (forward) and S2 (reverse) respectively.
    • Ensure that the control circuit uses shielded wires to avoid electromagnetic interference.
  • Parameter Settings:
    • Pr006=1: Select terminal control mode.
    • Pr301=1 (forward function), Pr302=2 (reverse function): Assign terminal control logic.

2.2 Potentiometer Speed Regulation Wiring and Parameter Settings

  • Wiring Method:
    • Connect the potentiometer output terminal to the inverter’s analog input terminal FV, and connect it to GND.
    • It is recommended to use a 10kΩ linear potentiometer to obtain smooth speed regulation.
  • Parameter Settings:
    • Pr004=1: Select analog input as the frequency command source.
    • Pr203=100% (gain), Pr204=0% (offset): Calibrate the potentiometer output range.

III. Fault Code Analysis and Solutions

3.1 Common Fault Codes and Their Meanings

Fault CodeFault NamePossible Causes
Uv1UndervoltageInput voltage is below 70% of rated value
OCOvercurrentMotor overload, short circuit, or parameter setting error
OL1Motor OverloadProlonged overload operation
SPInput Phase LossPower supply phase loss or loose wiring
SPOOutput Phase LossMotor winding damage or poor contact

3.2 Fault Handling Procedures

  1. Uv1/SP Handling:
    • Check if the power supply voltage is within the rated range (e.g., 380V±15%).
    • Ensure that the terminal connections are secure to avoid poor contact.
  2. OC/OL1 Handling:
    • Reduce the load or adjust the acceleration time parameter (e.g., Pr005).
    • Check the motor insulation to rule out winding short circuits.
  3. SPO Handling:
    • Test the motor winding resistance and repair open or short circuits.
    • Check the inverter output contactor contacts to ensure reliable conduction.
LSD-C7000 standard wiring diagram

IV. Comprehensive Usage Suggestions

4.1 Regular Maintenance Items

  • Clean the Heat Sink: Clean the heat sink dust quarterly to prevent overheating.
  • Parameter Backup: Regularly back up parameter settings via the operation panel or dedicated software.
  • Capacitor Inspection: Test the DC bus capacitor capacity every two years, and replace it if it is below 80%.

4.2 Safe Operation Practices

  • Grounding Protection: Ensure reliable grounding of the inverter and motor, with a grounding resistance ≤4Ω.
  • Prohibited Operations: Do not disconnect the control cable during operation to avoid signal interference causing misoperation.
  • Environmental Adaptation: Avoid prolonged operation in environments with humidity >90% or temperature >45℃.

Through this guide, users can fully grasp the core operation and troubleshooting skills of the LSD-C7000 series inverter. It is recommended to combine the actual working conditions of the equipment and refer to the electrical schematic diagram in the manual for in-depth debugging to fully utilize the equipment’s performance. For complex faults, contact Lingshida’s technical support team promptly for professional guidance.

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ABB PSTX Series Soft Starter User Guide

The ABB PSTX series soft starter is an advanced device in the field of industrial motor control, integrating intelligent operation and multiple control functions. This guide will provide a detailed introduction to the functions of the operation panel (HMI), parameter initialization, parameter copying, password setting and removal, external terminal start mode, bypass control, wiring methods, key parameters, and the meanings and solutions of fault codes based on user needs, helping users fully master the usage skills of the PSTX.

I. Detailed Explanation of Operation Panel (HMI) Functions

The PSTX soft starter is equipped with an intuitive human-machine interface (HMI), which enables device status monitoring, parameter setting, and fault diagnosis through the display screen and buttons. Below are the specific functions of the operation panel:

1. Display Screen

  • Real-time Data Display: Displays the motor’s operating status, including parameters such as current, voltage, and power factor.
  • Fault Prompt: Displays fault codes and brief descriptions for quick diagnosis.
  • Menu Navigation: Displays multi-level menus, allowing users to browse setting options.

2. Button Functions

  • Navigation Keys (Up, Down, Left, Right): Used to move the cursor in the menu or adjust parameter values.
  • Confirm Key (Enter): Confirms selections or saves settings.
  • Return Key (Esc): Exits the current menu or cancels operations.
  • Reset Key (Reset): Clears fault status or restarts the device.
  • Start/Stop Key (some models): Directly controls the motor’s start and stop (in local mode).

3. Operation Methods

  • Enter the Main Menu: Press the “Menu” key (or long-press the navigation key, depending on the model).
  • Navigate to the Desired Function: Use the up and down keys to select modules such as “Basic Settings”, “Protection Settings”, or “Diagnostic Information”.
  • Modify Parameters: After selecting a parameter, press the “Enter” key to enter the editing mode. Use the navigation keys to adjust the value and press “Enter” again to save.
    For detailed operation instructions of the HMI, refer to Chapter 6 “Human-Machine Interface” in the manual. It is recommended that users familiarize themselves with the button layout to improve operation efficiency.

II. Parameter Initialization

Parameter initialization is used to restore the PSTX soft starter to its factory default settings, which is applicable for debugging or resetting after a fault. The operation steps are as follows:

  1. Enter the HMI main menu and select “System Settings”.
  2. Navigate to “Reset to Factory Defaults”.
  3. Press the “Enter” key to confirm, and the screen will prompt “Confirm reset?”.
  4. Press the “Enter” key again, and the device will reset all parameters and restart.
    Note: Initialization will clear all user settings. It is recommended to back up the parameters first (see “Parameter Copying” below).
PSTX Manual ABB Soft Starter Standard Wiring Diagram

III. Copying Parameters to Another Device

The PSTX supports copying parameters from one soft starter to another device, facilitating batch configuration. There are two methods:

1. Copying via HMI

  • Backup Parameters:
    • Enter the “System Settings” menu and select “Parameter Backup”.
    • Press the “Enter” key to save the current parameters to the internal memory.
  • Restore Parameters:
    • On the target device, enter the “System Settings” menu and select “Parameter Restore”.
    • Press the “Enter” key to load the backup parameters and restart the device after completion.

2. Copying via PSTX Configurator Software

  • Export Parameters:
    • Connect the soft starter to the computer using a USB or communication interface.
    • Open the PSTX Configurator software and read the device parameters.
    • Select “Export” and save as a parameter file (.prm format).
  • Import Parameters:
    • Connect the target device and open the software.
    • Select “Import”, load the parameter file, and write it to the device.

IV. Password Setting and Removal

The PSTX provides a password protection function to prevent unauthorized parameter modifications.

1. Set Password

  • Enter “System Settings” → “User Access”.
  • Select “Set Password”.
  • Enter a 4-digit password (e.g., “1234”) and press “Enter” to confirm.
  • Enter the same password again for verification. The password will take effect after successful saving.

2. Remove Password

  • Enter the “User Access” menu and select “Disable Password”.
  • Enter the current password and press “Enter” to confirm.
  • After the password is cleared, the device will return to an unprotected state.
    Tip: If the password is forgotten, contact ABB technical support to reset it using administrator privileges.
PSTX is working

V. External Terminal Start Mode

The PSTX supports controlling the motor’s start and stop through external terminals, which is suitable for PLC or manual switch control.

1. Wiring

  • Start Terminal (Start): Connect to the “Start” pin of the control terminal block (usually marked as “1”).
  • Stop Terminal (Stop): Connect to the “Stop” pin (usually marked as “2”).
  • Common Terminal (COM): Connect to the common terminal of the control power supply.

2. Configuration

  • Enter the “Control Settings” menu in the HMI.
  • Set the “Control Mode” to “External Terminal”.
  • Save the settings and exit.

3. Operation

  • Close the switch between the “Start” terminal and “COM”, and the motor will start.
  • Close the switch between the “Stop” terminal and “COM”, and the motor will stop.

VI. Bypass Control Implementation

Bypass control connects the power supply directly through a bypass contactor after the motor reaches full speed, bypassing the soft starter to reduce energy consumption.

1. Wiring

  • Bypass Contactor: Connect to the bypass output terminals of the soft starter (marked as “Bypass” or “BP”).
  • Main Circuit: Connect the main contacts of the bypass contactor in parallel between the input (L1, L2, L3) and output (T1, T2, T3) of the soft starter.

2. Configuration

  • Enter the “Function Settings” menu in the HMI.
  • Enable “Bypass Mode”.
  • Set the “Bypass Delay”, usually 0.5-2 seconds, to ensure the motor is at full speed before switching.

3. Working Principle

  • When starting, the soft starter controls the motor’s acceleration.
  • After reaching full speed, the PSTX outputs a signal to close the bypass contactor, and the motor is directly powered by the power supply.

VII. Wiring Methods

1. Main Circuit Wiring

The main circuit connects the power supply and the motor. The schematic diagram is as follows (based on Chapter 4 of the manual):

复制代码Power Input       Soft Starter       MotorL1 ----+------[ L1  T1 ]------+---- M1L2 ----+------[ L2  T2 ]------+---- M2L3 ----+------[ L3  T3 ]------+---- M3       |                       |       +--------[ PE ]---------+---- GND
  • L1, L2, L3: Three-phase power input.
  • T1, T2, T3: Motor output.
  • PE: Grounding terminal.

2. Control Circuit Wiring

The control circuit is used for signal input and output. The schematic diagram is as follows:

复制代码Control Power       Soft Starter Control Terminals+24V ----+----[ COM ]           |----[ Start ]----[ Switch ]         |----[ Stop  ]----[ Switch ]         |----[ Fault ]----[ Alarm ]GND -----+----[ GND  ]
  • Start/Stop: Connect to external switches or PLCs.
  • Fault: Fault signal output, used for external indication.
    Note: Refer to Chapter 4 of the manual for wiring photos to ensure accuracy.

VIII. Important Parameter Settings

The following are the key parameters of the PSTX and their functions:

Parameter NameFunctionRecommended Value
Start TimeControls the motor’s acceleration time2-20 seconds
Current LimitLimits the start current multiple2-4 times the rated current
Overload ProtectionSets the overload threshold1.1-1.5 times the rated current
Stop TimeControls the deceleration stop time5-30 seconds
Bypass DelayTime to switch to bypass after full speed0.5-2 seconds

Setting Method: Enter the “Basic Settings” menu, adjust each parameter item by item, and save.

IX. Fault Codes and Solutions

The PSTX prompts problems through fault codes. The following are common codes and their solutions:

Fault CodeMeaningSolution
F001Motor OverloadCheck if the load exceeds the limit and adjust the overload protection parameters
F002Soft Starter OverheatingClean the fan and improve ventilation conditions
F003Power Phase Sequence ErrorCheck the wiring order of L1, L2, L3
F004Output Short CircuitCheck the motor and wiring to eliminate the short circuit point
F005Communication FaultCheck the communication cable and settings

Troubleshooting Steps:

  1. Record the fault code and refer to Chapter 11 of the manual.
  2. Check the wiring, load, or cooling based on the prompt.
  3. After repair, press the “Reset” key to clear the fault.

X. Summary

Through this guide, users can fully master the operation panel functions, parameter management, control mode settings, wiring methods, key parameter configuration, and fault handling techniques of the ABB PSTX series soft starter. It is recommended to use this guide in conjunction with the manual (document number: 1SFC132081M2001) to ensure the safe and efficient operation of the device.

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Application Solution of VACON 100 HVAC Inverter in Chemical Metering Pumps

I. Application Scenario and Function Analysis

The main functions of chemical metering pumps include:

  • Precise Flow Control: Achieve quantitative delivery of chemicals by adjusting the pump’s rotational speed.
  • Start/Stop Control: Ensure smooth start and stop of the pump to avoid pressure surges.
  • Pressure/Flow Feedback Regulation: Adjust the pump speed in real-time based on sensor feedback.
  • Fault Protection: Automatic shutdown in case of overload, over-temperature, under-load, etc.
  • Remote Monitoring and Operation: Realize automated operation through fieldbus or external controllers.

The VACON 100 HVAC inverter is suitable for these requirements. It supports multiple control methods (digital input, analog input, fieldbus), has built-in HVAC application macros, fault diagnosis functions, and rich parameter settings, which can well meet the control requirements of chemical metering pumps.

Specific Functional Positions in the Application

  • Main Drive Motor: Drives the metering pump and controls its rotational speed to regulate the flow rate.
  • Auxiliary Motor (if any): Used for the cooling system or stirring device (depending on the process requirements).
    The following design focuses on a single main drive motor. If an auxiliary motor is required, it can be expanded according to similar logic.
Working site of the metering pump

II. Hardware Selection

  1. Motor Selection
    • Type: Three-phase asynchronous motor (commonly used in metering pumps). The power is selected according to the pump’s load requirements, such as 0.75 kW or 1.5 kW.
    • Voltage: Match the inverter’s power supply voltage, such as 380 – 480 V (common industrial standard).
    • Protection Level: The chemical environment may be corrosive, so it is recommended to choose a motor with an IP55 or higher protection level.
  2. Inverter Selection
    • Model: VACON 100 HVAC. The rated current should be greater than the motor’s full-load current (e.g., for a 1.5 kW motor with a current of about 3.5 A, choose a model with a rated current ≥ 4 A).
    • Power Supply: 380 – 480 V three-phase AC (refer to Section 7.1.2 of the installation manual).
  3. External Devices
    • PLC: Select Siemens S7 – 1200 (such as 1214C) for logic control and data processing.
    • Touch Screen: Siemens HMI TP700 Comfort for parameter setting and running status display.
    • Sensors:
      • Flow Sensor: Outputs a 4 – 20 mA analog signal for flow feedback.
      • Pressure Sensor: Outputs a 4 – 20 mA analog signal for pressure monitoring.
    • Relay: 24 V DC for controlling the start/stop signals.

III. Wiring Scheme

Refer to Section 7.2.1 of the installation manual and relevant sections of the application manual for information on the control terminals of the VACON 100 HVAC inverter. The following is the wiring design for the chemical metering pump:

  1. Power and Motor Wiring
    • Power Input: Connect to the L1, L2, L3 terminals of the inverter (three-phase 380 V).
    • Motor Output: Connect to the U, V, W terminals of the inverter and then to the three-phase motor.
    • Grounding: Connect the PE terminal of the inverter to the grounding terminal of the motor to ensure grounding complies with the EN61800 – 5 – 1 standard (refer to Section 1.3 of the installation manual).
  2. Control Terminal Wiring
    Refer to the technical information of the standard I/O board in Section 7.2.1 of the installation manual:
TerminalFunctionWiring Description
1+10V Reference VoltageNot used
2AI1+ (Analog Input 1)Connect to the flow sensor (positive pole of 4 – 20 mA output)
3AI1- (Analog Input 1 Ground)Connect to the flow sensor (negative pole of 4 – 20 mA output)
4AI2+ (Analog Input 2)Connect to the pressure sensor (positive pole of 4 – 20 mA output)
5AI2- (Analog Input 2 Ground)Connect to the pressure sensor (negative pole of 4 – 20 mA output)
624V Auxiliary VoltageSupply power to relays or sensors (if needed)
7GNDControl signal ground
8DI1 (Digital Input 1)Connect to the PLC output (start signal)
9DI2 (Digital Input 2)Connect to the PLC output (stop signal)
10DI3 (Digital Input 3)Connect to the external emergency stop button (normally closed contact)
11CM (Common Terminal A)Common ground for DI1 – DI3
1224V Auxiliary VoltageNot used
13GNDNot used
18AO1+ (Analog Output 1)Connect to the PLC input (output frequency feedback, 0 – 10 V)
19AO1- (Analog Output Ground)Common ground for analog output
ARS485 AConnect to the RS485 A terminal of the PLC
BRS485 BConnect to the RS485 B terminal of the PLC

Wiring Diagram (Text Description)

  • Power Input:
    • L1 —- [Inverter L1]
    • L2 —- [Inverter L2]
    • L3 —- [Inverter L3]
  • Motor Output:
    • [Inverter U] —- [Motor U]
    • [Inverter V] —- [Motor V]
    • [Inverter W] —- [Motor W]
  • Grounding:
    • [Inverter PE] —- [Motor PE] —- [Grounding Wire]
  • Control Signals:
    • [PLC DO1] —- [DI1] (Start)
    • [PLC DO2] —- [DI2] (Stop)
    • [Emergency Stop Button] —- [DI3]
    • [Flow Sensor +] —- [AI1+]
    • [Flow Sensor -] —- [AI1-]
    • [Pressure Sensor +] —- [AI2+]
    • [Pressure Sensor -] —- [AI2-]
    • [AO1+] —- [PLC AI1] (Frequency Feedback)
    • [AO1-] —- [GND]
    • [A] —- [PLC RS485 A]
    • [B] —- [PLC RS485 B]

IV. Parameter Setting

The following parameter settings are based on the application manual and the requirements of the chemical metering pump. Use the start-up wizard and HVAC application macro of the VACON 100 for configuration.

  1. Start-up Wizard Settings (Refer to Page 4 of the Application Manual)
    • Language: Select Chinese.
    • Time: Set the current time (e.g., 14:30:00).
    • Date: Set the current date (e.g., 15.10.2023).
    • Application Macro: Select the HVAC application macro.
  2. Key Parameter Settings
Parameter NumberParameter NameSetting ValueDescription
P1.1Minimum Frequency10 HzEnsure the minimum running speed of the pump
P1.2Maximum Frequency50 HzMatch the rated frequency of the motor (typical value)
P3.1.1Motor Rated Voltage380 VSet according to the motor nameplate
P3.1.2Motor Rated Current3.5 ASet according to the motor nameplate
P3.3.1Control Mode1 (Frequency Control)Use frequency control mode
P3.5.1.1DI1 Function1 (Start)DI1 controls start
P3.5.1.2DI2 Function2 (Stop)DI2 controls stop
P3.5.1.3DI3 Function6 (External Fault)DI3 is used for emergency stop
P3.6.1AI1 Signal Range1 (4 – 20 mA)Flow sensor input
P3.6.2AI2 Signal Range1 (4 – 20 mA)Pressure sensor input
P3.7.1AO1 Function1 (Output Frequency)Output frequency feedback to the PLC
P3.14.1Overcurrent ProtectionEnabledProtect the motor and pump
P3.14.2Overload ProtectionEnabledPrevent motor overload
  1. PID Control Settings (Flow Regulation)
    • P3.9.1: Enable PID Control = 1
    • P3.9.2: Setpoint Source = 0 (Fixed value, input from the touch screen)
    • P3.9.3: Feedback Value Source = AI1 (Flow Sensor)
    • P3.9.4: Proportional Gain = 2.0 (Adjust according to actual debugging)
    • P3.9.5: Integral Time = 1.0 s (Adjust according to actual debugging)

V. Control System Design

  1. System Architecture
    • PLC: Responsible for logic control, sensor signal processing, and communication with the inverter.
    • Touch Screen: Display running status (rotational speed, flow rate, pressure) and set the target flow rate.
    • Inverter: Execute motor rotational speed control, receive PLC instructions, and sensor feedback.
    • Sensors: Provide real-time flow rate and pressure data.
  2. Control Logic
    • Start/Stop:
      • The PLC controls the inverter’s start/stop through DI1/DI2.
      • The emergency stop button triggers DI3, and the inverter stops immediately.
    • Flow Regulation:
      • The touch screen inputs the target flow rate value, and the PLC transmits it to the inverter via RS485.
      • The inverter adjusts the motor rotational speed through PID regulation based on the feedback from AI1 (flow sensor).
    • Pressure Monitoring:
      • AI2 (pressure sensor) monitors the pipeline pressure. If it exceeds the set range (e.g., > 5 bar), the PLC issues a stop command.
    • Fault Handling:
      • When the inverter detects a fault (e.g., overcurrent, fault code 1), it notifies the PLC via RS485, and the touch screen displays the fault information.

Control Schematic Diagram (Text Description)

  • [Touch Screen] —- [RS485] —- [PLC]
    • | |
    • | |—- [DO1] —- [DI1] (Start)
    • | |—- [DO2] —- [DI2] (Stop)
    • | |—- [AI1] —- [AO1] (Frequency Feedback)
    • | |—- [RS485] —- [Inverter A/B]
  • [Flow Sensor] —- [AI1+/-]
  • [Pressure Sensor] —- [AI2+/-]
  • [Emergency Stop Button] —- [DI3]
  • [Inverter U/V/W] —- [Motor]
Vacon inverter in field use

VI. Implementation Steps

  1. Installation and Wiring:
    • Connect the power supply, motor, and control signals according to the wiring scheme.
    • Ensure reliable grounding to avoid electromagnetic interference.
  2. Parameter Configuration:
    • Initialize using the start-up wizard on the inverter panel.
    • Input the above parameters and save the settings.
  3. PLC and Touch Screen Programming:
    • Write the start/stop logic and PID control program for the PLC.
    • Design the touch screen interface, including flow rate setting, running status, and fault alarms.
  4. Debugging:
    • Manually test the start/stop functions.
    • Adjust the PID parameters to ensure stable flow rate.
    • Simulate faults to verify the protection functions.
  5. Operation and Optimization:
    • After long-term operation, fine-tune the parameters according to the actual working conditions.

VII. Precautions

  • Safety: Do not touch the internal circuits of the inverter after it is powered on (refer to Section 1.2 of the installation manual).
  • EMC: The chemical environment may have interference, so adjust the EMC jumpers (refer to Section 6.3 of the installation manual).
  • Support: If you encounter any problems, you can contact us.

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Diagnosis and Resolution of “Free Stop” Fault in ENC EDH2200 High-Voltage Inverter: Impact of S1# Function Configuration

Introduction

The ENC EDH2200 series high-voltage inverter is commonly used in industrial applications for motor control. However, during operation, it may enter a “free stop (emergency stop)” state due to faults, rendering it unable to restart. Based on an actual case, this article analyzes the causes of the inverter’s “free stop” fault, focusing on the impact of the input terminal S1# function configuration (P05.00), and summarizes solutions and preventive measures.

Fault Background

The inverter control panel (Attachment 5.jpg) displays an “actual alarm POFF state,” with operational parameters at 0 (input/output voltage 0V, current 0A, frequency 0Hz), indicating the system is in a non-operational state. The operation log (Attachment 1.jpg) shows S3# as “self-generated accident (total accident),” initially considered the root cause. However, after adjusting the S1# terminal function (P05.00) from “1: Lift given” to “0: No function,” the system returned to normal, and the inverter successfully restarted.

Emergency stop state

Fault Cause Analysis

Based on the operation log and the actual resolution process, the following is a detailed analysis of the fault causes:

  1. Impact of S1# Function Configuration
    • P05.00 (S1# function selection) was originally set to “1: Lift given,” likely used to receive signals from external devices (e.g., pump lift control signals).
    • If the external device fails to provide a correct signal (e.g., signal loss, abnormality, or interference), the system may misjudge it as a fault and trigger a protection mechanism, leading to “free stop.”
    • Changing P05.00 to “0: No function” removes S1# from control, and the system exits the protection state, indicating that the S1# configuration is the core issue.
  2. Correlation with S3# “Self-Generated Accident”
    • S3# (P05.02) displays “self-generated accident (total accident),” which may be a chain reaction triggered by S1# malfunction.
    • The inverter’s protection logic may be designed to trigger a total accident (S3#) and enter emergency stop mode when an abnormality is detected on a terminal (e.g., S1#).
  3. Possible External Factors
    • S1# may be connected to external devices (e.g., pumps or sensors). If the device malfunctions or there are wiring issues (e.g., loose connections, short circuits), it may cause signal abnormalities.
    • Environmental interference (e.g., electromagnetic interference) may also affect S1# signal transmission.
  4. Hardware and Parameter Configuration
    • Circuit board images (Attachments 3.jpg and 4.jpg) show relays K4/K5 and terminal connections. If S1#-related hardware is damaged, it may cause signal errors.
    • Improper configuration of P05 group parameters (input terminal function selection) may lead to system misjudgment.
Control circuit inside the high-voltage inverter cabinet

Resolution Process

  1. Problem Identification
    • The control panel displays “POFF state,” and the operation log shows S3# as “self-generated accident.” However, the “lift given” function of S1# raises concerns.
    • Referencing the P05 group parameter table (Attachment 6.jpg), it is confirmed that S1# (P05.00) is set to “1: Lift given.”
  2. Parameter Adjustment
    • Change P05.00 from “1” to “0” (no function) to remove S1# from control.
    • After adjustment, use the control panel’s “reset” function to clear the alarm.
  3. System Recovery
    • Press the “start” button, and the inverter successfully restarts with operational parameters returning to normal (voltage, current, frequency, etc., no longer 0).

Summary of Solutions

  • Core Solution Steps: Change P05.00 (S1# function) from “1: Lift given” to “0: No function,” remove S1#’s control function, clear the alarm, and restart the system.
  • Preventive Measures:
    • Check S1#’s wiring and external devices to ensure normal signal transmission.
    • Regularly maintain hardware to prevent loose connections or component damage.
    • Record parameter adjustments for future troubleshooting.

Unexpected Findings

  • The S3# “self-generated accident” record may only be a result, not the cause. The actual issue stems from the S1# configuration. This highlights the need to consider all relevant terminals and parameters when troubleshooting inverter faults, rather than focusing solely on alarm records.
  • The control panel brand is FLEXEM, while the inverter is ENC, which may involve terminological or logical differences. For example, the “POFF” state is defined in FLEXEM but not explicitly mentioned in the ENC manual.
EDH2200 terminal board

Table: Fault Causes and Solutions

Fault PhenomenonPossible CauseSolution
Free stop, unable to startS1# function (lift given) mis-triggerChange P05.00 to “0: No function”
S3# displays self-generated accidentChain reaction from S1# abnormal signalClear alarm after resolving S1# issue
System displays POFF stateProtection mechanism triggers power-offRestart system after clearing alarm
External device signal abnormalityLoose wiring or device faultCheck S1# wiring and external devices

Conclusion

The “free stop (emergency stop)” issue in the ENC EDH2200 high-voltage inverter is caused by improper configuration of the S1# terminal function (P05.00), potentially triggered by abnormal external signals. By changing the S1# function to “no function,” the system returns to normal. Users are advised to regularly check terminal wiring and external devices, optimize parameter configurations, and take preventive measures to avoid recurrence of similar issues.

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Analysis and Solutions for Fan Overheating Fault in ENC EDH2200 High-Voltage Inverter

Introduction

Variable Frequency Drives (VFDs) are critical devices for controlling motor speed and torque in modern industrial applications. However, fan overheating alarms are a common fault during inverter operation. This document provides a comprehensive analysis of the fan overheating alarm issue in the ENC EDH2200 series high-voltage inverter, covering its meaning, possible causes, solutions, and operational log analysis to guide users in troubleshooting and resolving the problem.

Fault Meaning

A fan overheating alarm indicates that the cooling fan of the inverter has exceeded its temperature threshold, potentially affecting normal device operation. As a key component for internal temperature control, the fan’s failure to cool the system effectively will lead to temperature rises, trigger protection mechanisms, and may even damage electronic components or cause system failures.
Key Detail: The operational log shows the alarm occurred at 13:34:02 on March 25, 2023, with a recovery time recorded as 14:31:58 on September 7, 2024. The abnormally long alarm duration requires urgent attention.

The alarm for fan overheating

Possible Causes

  1. Excessive Ambient Temperature
    • The operating environment temperature exceeds the inverter’s default threshold of 75°C, causing the fan to run continuously for extended periods and overheat.
    • Manual Parameter: P08.27 sets the ambient temperature alarm threshold; verify if the actual temperature exceeds the limit.
  2. Fan Malfunction
    • Damage to the fan motor or obstruction of blades leads to insufficient cooling.
    • Manual Parameter: P23 group parameters (e.g., P23.20 and P23.21) control fan start/stop temperatures; these may fail if the fan malfunctions.
  3. Ventilation Blockage
    • Dust, debris, or internal accumulations block ventilation ports, impeding airflow.
    • Preventive Measure: Regularly clean the ventilation system.
  4. Overload
    • The connected load exceeds the inverter’s rated capacity, increasing heat generation and burdening the fan.
    • Solution: Ensure the load is within the inverter’s specifications.
  5. Improper Parameter Settings
    • Incorrect configuration of temperature control parameters results in inappropriate fan start/stop conditions.
    • Manual Parameter: Adjust P23.03 (overheat warning temperature 1, default 90°C) and P23.04 (default 110°C) based on actual conditions.

Solutions

  1. Check and Control Ambient Temperature
    • Measure the current ambient temperature and ensure it remains below the 75°C threshold.
    • If the temperature is too high, install air conditioning or improve ventilation (e.g., add exhaust fans).
  2. Maintain and Inspect the Fan
    • Ensure the fan operates normally and check for damage or wear to the motor and blades.
    • If a fault is detected, replace damaged components by referring to Section 8.5 of the manual.
    • Regularly clean the fan to remove dust or blockages.
  3. Optimize the Ventilation System
    • Ensure sufficient space around the inverter to meet ventilation requirements in the manual.
    • Clean ventilation ports and surrounding areas to prevent dust accumulation.
  4. Verify Load and Inverter Capacity
    • Check if the current load exceeds the inverter’s rated capacity; if so, reduce the load or upgrade the inverter.
    • Ensure compatibility between the motor and the inverter.
  5. Adjust Parameter Settings
    • Modify P23 group parameters based on actual needs (e.g., increase P23.03 to an appropriate value, but do not exceed 135°C).
    • Ensure P23.20–P23.23 settings align with actual operating conditions.

Operational Log Analysis

  • Key Log Entries:
    • March 25, 2023, 13:34:02: Fan overheating alarm triggered. Recovery time recorded as September 7, 2024, 14:31:58, indicating an abnormally long alarm duration that may not have been resolved promptly.
    • Multiple ambient temperature exceedance warnings (e.g., repeated records on February 7, 2024) support the hypothesis of excessive ambient temperature.
  • Unexpected Detail: Inconsistent dates in the log (recovery time later than the alarm time) suggest a potential error in the system’s logging mechanism.
    • Recommendation: Check the system clock and logging function to ensure data accuracy.
EDH2200

Conclusion

Resolving the fan overheating alarm in the ENC EDH2200 series high-voltage inverter requires a systematic investigation of potential causes and the implementation of the following measures to manage and prevent issues:

  • Control ambient temperature, maintain the fan, optimize ventilation, verify load, and adjust parameters.
    Regular maintenance and monitoring are critical to ensuring the long-term reliability of the inverter.

Key Highlight: Prioritize addressing the inconsistent dates in the operational log to avoid misdiagnosis caused by logging errors.

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SHZHD.V680 Variable Frequency Drive E-06 Fault Analysis and Solutions

1. Fault Overview

The E-06 fault indicates a deceleration overvoltage, a common issue that can occur during the deceleration process of the SHZHD.V680 variable frequency drive. When the output voltage exceeds the safe range during deceleration, the drive triggers a protection mechanism, leading to equipment shutdown or alarms. This fault is often related to motor load characteristics, parameter settings, and over-excitation control.

2. Fault Cause Analysis

  • Improper Over-Excitation Settings: Low over-excitation gain settings can cause the voltage to rise too quickly during deceleration.
  • Load Characteristics: Loads with high inertia can generate excessive reverse electromotive force during deceleration.
  • Unreasonable Parameter Settings: Short deceleration times can cause the voltage to rise too quickly during deceleration.
E-05

3. Solutions

3.1 Adjust Over-Excitation Gain
  • Parameter P3-10 (VF Over-Excitation Gain): Increase this value to better suppress voltage rise during deceleration. Recommended range: 0 ~ 200. Gradually increase based on actual conditions until the fault is resolved.
3.2 Optimize Deceleration Time Settings
  • Parameter P0-18 (Deceleration Time 1): Extend the deceleration time to make the deceleration process smoother. Gradually increase based on actual load characteristics until the fault is resolved.
3.3 Check Load Characteristics
  • If the load has high inertia, additional braking measures, such as adding a braking resistor or using a regenerative system, may be necessary during deceleration.
3.4 Check Motor and Drive Compatibility
  • Ensure that the motor and drive parameters are matched to avoid overvoltage issues due to mismatched parameters.

4. Precautions

  • Adjust parameters gradually to avoid introducing other issues.
  • Conduct trial runs after adjustments to confirm that the fault has been resolved.
  • If the problem persists, consult technical support or a professional repair technician for further diagnosis.
SHZHEND.V680

5. Conclusion

By appropriately adjusting the over-excitation gain, optimizing deceleration time settings, checking load characteristics, and ensuring motor and drive compatibility, the E-06 deceleration overvoltage fault in the SHZHD.V680 variable frequency drive can be effectively resolved. Proper parameter settings and regular maintenance are key to ensuring the efficient operation of the drive.

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In-Depth Analysis and Practical Guide to Horizontal Line Faults in Fuji Inverter G1S Series

As a key device in the field of industrial control, Fuji Inverter G1S series indicates fault states through different forms of horizontal lines on its operation panel. Based on extensive field cases and technical data, this article provides a comprehensive analysis of horizontal line faults (including the middle horizontal line “—-” and the upper and lower horizontal lines) and offers actionable diagnostic procedures and solutions.

I. Fault Patterns and Core Implications

1. Middle Horizontal Line “—-” Fault

Display Feature: The LED monitor displays four consecutive horizontal lines.
Core Implication:

  • PID Control Conflict: When J01=0 (PID control is not enabled), if the E43 parameter is forcibly set to display PID parameters, the system will return invalid data.
  • Communication Link Anomaly: Poor connection between the operation panel and the inverter body, such as damage to the shield layer of the extension cable or oxidation of the cable.

2. Lower Horizontal Line “_ _ _ _” Fault

Display Feature: The motor stops after the command is triggered, and the panel displays an underscore.
Core Implication:

  • Insufficient DC Bus Voltage: The measured voltage is below DC400V (for 400V models), often caused by non-compliant input power specifications or excessive line voltage drop.
  • Missing Main Power Supply: The control power is on, but the main power circuit breaker is not closed.
  • Power Configuration Conflict: When H72=1, an abnormal main power supply is detected, such as DC power supply incorrectly connected to the AC input terminal.
G1S physical image

II. Standardized Diagnostic Procedures

Step 1: Quick Status Confirmation

  1. Power Supply Check:
    • Main Power Supply: Measure the voltage between L1-L2-L3 to confirm compliance with the inverter specifications (e.g., 400V ±10%).
    • Control Power Supply: Check the stability of the 24V auxiliary power supply to avoid OC3 alarms caused by fan shorts.
  2. Panel Operation Verification:
    • Perform a reset operation (long press the RST key) to observe if the fault can be cleared.
    • Read the communication error counter through parameter viewing mode (e.g., d001-d005).

Step 2: Layered Fault Location

Fault LayerInspection ItemTechnical Details
Communication LayerExtension CableUse a megohmmeter to measure the cable insulation resistance >10MΩ and check the continuity of the shield layer.
Power LayerDC BusMeasure the P(+)-N(-) voltage during startup and compare it with the value displayed on the operation panel (error should be <5%).
Control LayerParameter ConfigurationFocus on checking critical parameters such as J01 (PID control) and H72 (main power detection).

Step 3: In-Depth Hardware Inspection

  • Main Circuit Check:
    • Disconnect the main power supply and measure the resistance of the rectifier bridge and IGBT module to check for short circuits.
    • Check the connection status of the braking resistor to avoid OU1/OU2 overvoltage alarms.
  • Control Board Check:
    • Use an oscilloscope to monitor the PWM output waveform of the mainboard to confirm the integrity of the drive signal.
    • Perform a “hot swap” test on suspected faulty boards to locate the specific damaged component.

III. Practical Cases of Typical Faults

Case 1: Lower Horizontal Line Fault in a Plastic Extruder

Fault Phenomenon: The motor does not respond after the start command, and the panel displays a lower horizontal line.
Diagnostic Process:

  1. Measure the main power supply voltage at 380V (standard 400V), confirming excessive voltage drop.
  2. Check the DC bus voltage at 360V (standard ≥400V), locating insufficient voltage.
  3. Find an incorrect transformer tap setting, resulting in low input voltage.
    Solution:
  • Adjust the transformer tap setting to the 400V output position.
  • Install an APFC device to improve power quality.

Case 2: Middle Horizontal Line Fault in a CNC Machine

Fault Phenomenon: The panel displays “—-” after parameter modification.
Diagnostic Process:

  1. Find that E43 is mistakenly set to PID feedback value, while J01=0.
  2. Check the panel extension cable and find that the shield layer is worn at the cable tray.
    Solution:
  • Change E43 to frequency display mode.
  • Replace the shield cable and optimize the cable routing path.

IV. Preventive Maintenance Strategies

  1. Periodic Inspection Plan:
    • Daily: Visually inspect the panel display status and record the operating environment temperature and humidity.
    • Monthly: Measure the main power supply voltage, DC bus voltage, and calibrate PID control parameters.
    • Quarterly: Perform a main power supply power-off restart test and check the contacto r suction status.
  2. Spare Parts Management Optimization:
    • Establish a lifespan model for critical spare parts (e.g., IGBT modules, DC capacitors).
    • Sign an emergency supply agreement with suppliers to ensure a 48-hour response.
  3. Technology Upgrade Path:
    • Regularly upgrade firmware versions to utilize new algorithms for optimizing fault detection mechanisms.
    • Consider an overall upgrade to the G1S-P series for aging equipment (>5 years).
Fuji G1S display - malfunction

V. Technical Development Trends

With the development of industrial IoT technology, Fuji Inverter G1S series now supports remote monitoring and predictive maintenance functions. By integrating edge computing nodes, the following can be achieved:

  1. Real-time Fault Feature Extraction: Utilize AI algorithms to analyze waveform data and identify potential faults in advance.
  2. Cloud Expert Diagnosis: Upload fault data to the cloud platform for expert system solutions.
  3. Digital Twin Applications: Build a virtual model of the equipment to simulate fault scenarios and practice response drills.

Conclusion

Handling horizontal line faults in Fuji Inverter G1S series requires engineers to possess a solid knowledge of power electronics and a systematic diagnostic mindset. The standardized procedures and practical cases provided in this article enable users to quickly locate more than 80% of common faults. For complex issues, it is recommended to combine official technical documentation and dedicated diagnostic tools for in-depth analysis. Continuous technical training and knowledge updating are the keys to improving fault handling efficiency.

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In-Depth Analysis of Alarms 1080 (Trace Data Save) in Siemens SINAMICS S120 Drives

1. Introduction

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

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

alarms 1808

2. Definition and Background of Alarms 1080

2.1 Overview of the Trace Function

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

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

2.2 What Alarms 1080 Signifies

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

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

2.3 How It Differs from Fault Codes

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

3. Common Causes and Scenarios

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

  1. Manually Enabled Trace During Commissioning
    In many cases, an engineer sets up a Trace task in STARTER, TIA Portal, or directly on the panel to diagnose specific motor or drive behavior. For example, if you want to observe speed-loop responses or current-waveform patterns, you configure sampling frequency, trigger conditions, and the signals to track. As soon as the sampling finishes, the drive writes the data to storage, resulting in Alarms 1080.
  2. Automatic Background Trace
    Some drive configurations automatically initiate the Trace function for advanced monitoring or “fault logging.” When the system detects certain threshold conditions or a fault event, the drive begins collecting data. Once the event is captured, it proceeds to save it, displaying Alarms 1080 in the process.
  3. Leftover Trace Settings
    In some projects, the Trace function was used at one point but never deactivated. Even after the main commissioning is done, the drive may still be periodically recording data and subsequently saving it, inadvertently causing recurring Alarms 1080 messages. Though typically benign, these messages might raise questions among less-experienced personnel.
S120 drives

4. Impact on System Operation

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

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

5. Handling and Disabling Methods

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

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

6. Common Questions and Answers

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

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

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

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

7. Case Study

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

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

8. Conclusion

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

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

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