Author: baiyuzhan

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How to conduct load testing on VFD drive circuits to solve the problem of normal no-load and load failure?

The voltage amplitude of the six driving pulses outputted by the driving circuit meets the requirements. For example, measuring the amplitude of the positive excitation pulse voltage in the AC range is about 14V, and the amplitude of the negative cutoff voltage is about 7.5V (different models may vary). After the above inspection of the driving circuit, most maintenance personnel believe that the machine can be installed, but an extremely important inspection step – the inspection of the current (power) output ability of the driving circuit! Many VFDs that we believe have been repaired normally will still expose more hidden faults during operation, leading to a certain repair rate.

VFD operates normally under no-load or light load, but after carrying a certain load, it may experience motor vibration, output voltage phase deviation, frequency jump OC faults, etc.
Cause of malfunction: A. Insufficient output capacity of the power supply current (power) of the driving circuit; B、 The driving IC or the post amplifier of the driving IC is inefficient, and the output internal resistance increases, resulting in insufficient voltage or current amplitude of the driving pulse; C. IGBT is inefficient, with increased internal resistance and increased pressure drop in the conduction tube.

The proportion of failures caused by reason C is not high, and is limited by the conditions of the maintenance department, such as the inability to provide rated load testing for the frequency converter. But for the hidden faults caused by reasons A and B, we can use the method of increasing the load on the driver to expose them and then repair them, which can reduce the repair rate to the lowest level.
The normal opening of IGBT requires not only sufficient excitation circuit amplitude, such as+12V or above, but also sufficient driving current to ensure its reliable opening, or to ensure its conduction under a certain low internal resistance. The essence of the causes of faults A and B mentioned above is that due to the insufficient power output capability of the driving circuit, although the IGBT can be turned on, it cannot be in a good low conductivity internal resistance state, resulting in output phase deviation, severe motor vibration, and frequency jump OC faults.

Let’s conduct a more in-depth analysis of the control characteristics of IGBT and identify the root cause of the fault.

I. Control characteristics of IGBT:
The common perception is that IGBT devices are voltage-controlled devices, which require a certain level of excitation voltage for gate bias control, without the need to draw excitation current. In low-power circuits, only digital gate circuits can drive MOS-type insulated gate field effect transistors. As an IGBT, the input circuit happens to have the characteristics of a MOS-type insulated gate field effect transistor, and can therefore also be considered a voltage-controlled device. This perception is actually biased. Due to structural and process reasons, a junction capacitance called Cge is formed between the gate and emitter junctions of the IGBT tube, which controls the turn-on and turn-off of the IGBT tube. In fact, the charging and discharging control of Cge is responsible for the control of the turn-on and turn-off of the IGBT tube. The +15V excitation pulse voltage provides a charging current path for Cge, which turns on the IGBT; the -7.5V negative pulse voltage “forcibly pulls out the charged charge” on Cge, which plays a role in rapidly neutralizing the charged charge, and turns off the IGBT.
Assuming that the IGBT tube only controls the on-off switching of a DC circuit with a zero operating frequency, and after the Cge is fully charged at one time, there is almost no need for charging and discharging control, it is reasonable to describe the IGBT tube in this circuit as a voltage control device. However, the problem is that the IGBT tube in the output circuit of the frequency converter operates at a frequency of several kHz, and its gate bias voltage is also a pulse voltage with a frequency of several kHz! On the one hand, for such high-frequency signals, the capacitive impedance exhibited by Cge is relatively small, resulting in a large charging and discharging current. On the other hand, to make the IGBT turn on reliably and quickly (striving to make the tube have a small internal resistance), it is necessary to provide as large a driving current (charging current) as possible within the allowable operating range of the IGBT. For the control of turn-off, it is also the same. It is necessary to provide a low-resistance (ohmic) external discharge circuit to discharge the charge on the gate-emitter junction capacitor very quickly!
As we all know, capacitors are energy storage components that do not consume power themselves, and are called capacitive loads. However, just like the principle of power transmission and distribution lines, in addition to the power supply having to provide reactive current (reactive power) for capacitive components, which increases the power capacity of the power supply, the reactive current inevitably brings losses in line resistance (line loss)! The power loss of the drive circuit mainly concentrates on the gate resistance and the conduction internal resistance of the final amplifier tube. We often see that the output stage of the drive circuit, especially for high-power VFDs, is actually a power amplifier circuit, often consisting of medium-power or even high-power transistors, several watts of gate resistance, and other components, indicating that the drive circuit of IGBT consumes a certain amount of power and needs to output a certain current.
From the above analysis, it can be seen that the IGBT tube used in the VFD output circuit should be a current or power drive device, rather than a pure voltage control device

II. The last testing content before installation:
To minimize the rate of rework, after conducting comprehensive testing on the drive circuit in sections 3 and 4, do not miss the inspection of the drive circuit’s load-bearing capacity.
The method is as follows:

Measurement circuit for driving circuit with load capacity

The above diagram shows the driving circuit of the U-phase upper arm of DVP-1 22kW Delta VFD. The GU and EU in the figure are pulse signal output terminals, which are externally connected to the G and E poles of the IGBT. When repairing the drive board, it has been disconnected from the main circuit. The dashed box represents the external measurement circuit. After powering on the power supply/driver board, in conjunction with start and stop operations, a DC 250mA current range is connected in series at points m and n, and an external measuring resistor of 15 Ω 3W forms a circuit to detect the current output capability of each drive circuit. The starting state is measured, and five output current values are all around 150mA, with one output current only 40mA. The reason for the OC trip after installation and operation is precisely because the driving capability of this drive circuit is greatly insufficient! In the shutdown state, the measured current output capacity of each negative voltage power supply is about 50mA, and the negative voltage power supply capacity is normal.
Connecting RC in series plays a current limiting role, and the principle of its value is to select resistance and power values that are equal to the gate resistance (the parameter value of DR45 in the above figure) to make the detection effect obvious.
After testing the power output capability of the driving circuit, it can be determined that the driving circuit is completely normal. During the testing process of connecting the drive circuit to the main circuit, please first use a low-voltage 24V DC power supply to power the inverter circuit. After testing the drive circuit and inverter circuit to be normal, restore the normal power supply to the inverter circuit. If there is no low-voltage DC power supply at hand, at least two 45W light bulbs or 2A fuse tubes should be connected in series in the inverter power supply circuit. After the machine is tested normally, the original power supply of the inverter circuit should be connected!
The above power on detection of the driving circuit is carried out after disconnecting from the main circuit (IGBT). When the whole machine is connected, the input and input sides of the driving circuit must not be measured. Interference signals may be introduced due to human body induction and meter probes, causing IGBT to be triggered and conduct incorrectly, resulting in module explosion!

The insufficient output capability of the driving circuit is caused by two reasons:
A、 The power supply capacity is insufficient. Under no-load conditions, when we detect the output positive and negative voltages, they often reach the normal amplitude requirements. Even under load (such as after connecting to IGBT), although the instantaneous charging capacity of Cge is insufficient, due to the short charging time, we often cannot measure the low voltage drop of the power supply. Without resistive loads, this hidden fault can hardly be detected! The common fault in the circuit is the loss of capacitance of the filtering capacitor, as shown in DC41 in the figure above. Due to the drying up of the electrolyte inside the electrolytic capacitor during long-term operation, its capacity has decreased from a few hundred microfarads to several tens of microfarads, and even to a few microfarads. In addition, there may be inefficient rectifier tubes, such as an increase in forward resistance, which can also cause insufficient power output capacity;
B、 The internal output circuit of the driving IC is poor, or the internal resistance of the rear amplifiers DQ4 and DQ10 increases due to conduction. If there is no low drop in the power supply voltage after load testing, and the output voltage of T250 is detected to be low, it is a T250 defect. Otherwise, replace components such as DQ4 and DQ10. The phenomenon of increased resistance values such as DR40 and DR45 is relatively rare.
It should be noted that the insufficient positive excitation voltage only manifests as severe motor vibration, output voltage phase deviation, frequent OC faults, and other phenomena. Although it may cause overcurrent in the DC component of the motor winding, it poses a danger to the module structure that cannot be put into operation and the signal will burst. The loss of the negative cutoff voltage (caused by a fault in the negative pressure power supply circuit, which blocks the negative gate bias circuit) indicates that it is normal when powered on. When the start button is pressed, the IGBT inverter module will emit a “pop” sound and immediately burst into failure! Why is this?

III. Hazards of IGBT cut-off negative pressure circuit open circuit:
Except for the damage caused by sudden short circuit of the load during full speed operation, the harm of all faults such as overcurrent, overload, and undervoltage is far less than the harm of open circuit of gate bias circuit to IGBT. Speaking of this, maintenance personnel will deeply understand that they should not suffer too much from such losses.
During the maintenance process, the gate resistor DR45 was missed, and during the installation process, only the trigger plug of the upper arm IBGT1 was carelessly inserted, forgetting to connect the lower arm IGBT trigger terminal, resulting in the IGBT2 drive signal introduction terminal being vacant. After power on, the start signal is not activated, and there is no problem. Once the start signal is activated, there is no discussion, and the module is damaged. In my long-term maintenance work, I have developed a habit of stopping for a while before starting the operation after powering on, and observing whether the drive pulse output terminal is properly connected. After checking that each connection is intact, press the start button again. I often feel that this slight point is of great importance – the driving circuit and inverter output circuit are both in a normal state, and only one signal terminal of the driving pulse is missing, which will inevitably cause serious damage to the IGBT module and driving circuit again, resulting in all previous efforts being wasted!

Equivalent diagram of IGBT junction capacitance

Just like bipolar devices – transistors, three wire components inevitably form three equivalent capacitors inside, while the Cge inside IGBTs is not parasitic, but formed by process and structure. Let’s not bother with Cce capacitors. The two capacitors, Ccg and Cge, can have a destructive effect on IGBT.
The above diagram shows the situation when the triggering terminal of the lower arm IGBT is open circuit. After power on, IGBT1 can maintain a reliable cut-off state by applying a negative cut-off voltage to the G and E poles due to the connection of the driving circuit. The reckless input of the frequency converter operation signal causes IGBT1 to be driven by a forward excitation pulse voltage and turn on. The C pole of IGBT2, the U terminal, immediately jumps to a DC high voltage of+530V. This jump voltage provides a charging return circuit for the Ccg and Cge capacitors. During the turning on period of IGBT1, IGBT2 is also driven by this charging current, and it is almost simultaneously turned on. The common connection of the two tubes forms a short circuit to the+530V power supply at the P and N terminals. With a loud bang, both tubes explode! If the signal terminal of the upper tube is empty and the lower tube is connected to the driving circuit, the conduction of the lower tube will also cause damage to both tubes for the same reason.
Assuming that there is a gate bypass resistor connected in parallel on the G and E poles of IGBT2 (such as the R side in the IGBT1 gate control circuit), it will form a bypass effect on the charging current mentioned above, and the possibility of the two transistors sharing the same circuit will be reduced. Assuming that during the conduction period of the upper tube, there is a cut-off negative pressure of about 7V between the G and E terminals of the lower tube, and the positive charging current is neutralized and absorbed by the gate negative bias, which is far from reaching the amplitude required to turn on the IGBT, then IGBT2 is safe. This is also why negative pressure is added to the control circuit of IGBT.
For frequency converters using IPM intelligent inverter modules, the driving power supply is often a single power supply without providing negative pressure. Is that the case?
From a design perspective, the shorter the lead of the IGBT drive signal, the better, in order to reduce the inductance effect of the lead; There should be a small resistance circuit between the E and E poles of the IGBT to fully bypass the interference signal current. The IPM module, driver circuit, and inverter main circuit are integrated inside the module, and the wiring between the driver circuit and IGBT is extremely short. According to data, even the gate resistance is omitted to reduce the wiring impedance. In the off state, IGBT ensures that the gate is in a low impedance grounded state, effectively preventing misleading conduction caused by interference signals, thus eliminating the need for negative power supply.

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Maintenance ideas and methods for VFD switching power supply

The switching power supply circuit of VFD can be completely simplified into the circuit model shown in the diagram, and the key elements in the circuit are included. And any complex switching power supply, after removing the branches, will still have a backbone like the one shown in the picture. In fact, in maintenance, it is necessary to have the ability to simplify complex circuits, and to identify these main threads in the seemingly disorderly extension of circuits. To learn from the skilled chef of Jieniu, train yourself that there is no overall switch power circuit in front of your eyes, only the direction of the various parts and veins – oscillation circuit, voltage stabilization circuit, protection circuit, and load circuit, etc.

Take a look at how many veins there are in the circuit.

  1. 1.Oscillation circuit: The leakage source and R4 of the main windings N1 and Q1 of the switching transformer are the paths for the working current of the power supply; R1 provides starting current; The self powered windings N2, D1, and C1 form the power supply voltage for the oscillating chip. The normal operation of these three links is a prerequisite for the power supply to oscillate.

Of course, the 4-pin external timing components R2, C2, and PC1 chip itself of PC1 also constitute a part of the oscillation circuit.

  1. 2,.Voltage stabilizing circuit: The+5V power supply of N3, D3, C4, etc., and components such as R7-R10, PC3, R5, R6 constitute the voltage stabilizing control circuit.

Of course, the PC1 chip and peripheral components R3 and C3 on pins 1 and 2 are also part of the voltage stabilization circuit.

3.Protection circuit: The PC1 chip itself and the 3-pin peripheral component R4 form an overcurrent protection circuit; The parallel D2, R6, and C4 components on the N1 winding form the protection circuit of the IGBT; In essence, the voltage feedback signal of the voltage stabilizing circuit, the voltage stabilizing signal, can also be regarded as a voltage protection signal. However, the content of protecting the circuit is not limited to the protection circuit itself. The initiation and control of the protection circuit are often caused by abnormalities in the load circuit.

  1. 4.Load circuit: N3 and N4 secondary windings and subsequent circuits are all load circuits. The abnormality of the load circuit will involve the protection circuit and the voltage stabilizing circuit, causing the two circuits to make corresponding protection and adjustment actions.

The oscillation chip itself participates in and constitutes the first three circuits. If the chip is damaged, all three circuits will strike together. The maintenance of three or four circuits is carried out under the premise that the chip itself is normal. In addition, like playing chess, we should use a global perspective and systematic approach to diagnose faults, and see the essence through phenomena. If there is a stop vibration fault, it may not be caused by damage to the oscillation circuit components. It may be a voltage stabilization circuit fault or an abnormal load circuit, which causes the internal protection circuit of the chip to start controlling and stops the output of PWM pulses. It is not possible to completely isolate each circuit for maintenance, and the appearance of a faulty component may exhibit the effect of “pulling one engine and moving the whole body”.

The oscillation chip itself participates in and constitutes the first three circuits. If the chip is damaged, all three circuits will strike together. The maintenance of three or four circuits is carried out under the premise that the chip itself is normal. In addition, like playing chess, we should use a global perspective and systematic approach to diagnose faults, and see the essence through phenomena. If there is a stop vibration fault, it may not be caused by damage to the oscillation circuit components. It may be a voltage stabilization circuit fault or an abnormal load circuit, which causes the internal protection circuit of the chip to start controlling and stops the output of PWM pulses. It is not possible to completely isolate each circuit for maintenance, and the appearance of a faulty component may exhibit the effect of “pulling one engine and moving the whole body”.

Switching power supply circuits often exhibit the following three typical fault phenomena (combined with Figures 3 and 9):
A、 The secondary load supply voltage is 0V. After the frequency converter is powered on, there is no response, and there is no indication on the operation display panel. The measured voltage of 24V and 10V at the control terminal is 0V. If the charging resistance or pre charging circuit of the main circuit is intact, it can be determined that there is a switch power supply fault. The maintenance steps are as follows:

1.First, use the resistance measurement method to measure whether there is any breakdown or short circuit phenomenon in switch Q1, and whether there is an open circuit in the current sampling resistor R4. The easily damaged component of the circuit is the switch tube. When it is damaged, R4 will increase in resistance or open circuit due to impact. The G-pole series resistor and oscillation chip PC1 in Q1 are often damaged by strong electrical shocks and need to be replaced simultaneously; Check for short circuits in the load circuit and eliminate them.

2.If the damaged parts are replaced or there are short circuited components that have not been detected, a power on inspection can be conducted to further determine whether the fault is in the oscillation circuit or the voltage stabilizing circuit.

Inspection method:
a、 First, check if there is an open circuit in the starting resistor R1. After normal operation, use an 18V DC power supply to directly power on pins 7 and 5 of UC3844 to separately power on the oscillation circuit. Measure that pin 8 should have a 5V voltage output; The 6 pins should have a voltage output of about 1V. The oscillation circuit is basically normal, and the fault is in the voltage stabilizing circuit;
If the voltage output of pin 8 is 5V, but the voltage of pin 6 is 0V, check the external R and C timing components of pins 8 and 4, and the peripheral circuit of pin 6;
If the voltage measured on pins 8 and 6 is 0V, the UC3844 oscillation chip is broken and needs to be replaced.

b、 Power on UC3844 separately and short circuit the input side of PC2. If the circuit vibrates, it indicates that the fault is in the peripheral circuit of the input side of PC2; The circuit still does not vibrate, check the PC2 output side circuit.

B、 Intermittent oscillation occurs in the switching power supply, where a “hiccup” or “squeaking” sound can be heard, or a “hiccup” sound cannot be heard, but when the display panel is operated, it lights up and turns off. This is a typical fault characteristic caused by abnormal load circuit, resulting in power overload and triggering overcurrent protection circuit action. The abnormal increase in load current causes a significant increase in the excitation current of the primary winding, forming a voltage signal of more than 1V at the current sampling resistor R4, which activates the internal current detection circuit of UC3844 and causes the circuit to stop vibrating; The overcurrent signal on R4 disappears, and the circuit starts vibrating again. This cycle repeats, causing intermittent oscillations in the power supply.

Inspection method:
a、 Measure the resistance values at both ends of the power supply circuit C4 and C5. If there is a short circuit, it may be due to a short circuit in the rectifier diodes D3 and D4; Observe the appearance of C4 and C5 for any bulging or liquid spraying, and remove them for inspection if necessary; There is no abnormality in the power supply circuit, which may be due to a short circuit fault component in the load circuit;
b、 Check the power supply circuit for any abnormalities, power on, and use the troubleshooting method to troubleshoot each power supply one by one. If the power supply terminal of the fan is unplugged, the switch power supply works normally, and the operation display panel displays normally, it indicates that the 24V cooling fan has been damaged; If the+5V power supply connector is unplugged or the power supply copper foil is cut off, and the switch power supply is working normally, it indicates that there are damaged components in the+5V load circuit.

C、 The supply voltage of the load circuit is too high or too low. The oscillation circuit of the switching power supply is normal, but the problem lies in the voltage stabilizing circuit.

The output voltage is too high, and the components of the voltage stabilizing circuit are damaged or inefficient, resulting in insufficient feedback voltage amplitude. Inspection method:
a、 Connect a 10k resistor in parallel to the output terminal of PC2, and the output voltage drops back. The output side voltage stabilizing circuit of PC2 is normal, and the fault lies in both the PC2 itself and the input side circuit;
b、 Parallel connection of a 500 Ω resistor on R7 results in a significant drop in output voltage. The optocoupler PC2 is in good condition, but the fault is low efficiency of PC3 or a change in the value of the external resistor component of PC3. On the contrary, it is PC2 defect.
If the load supply voltage is too low, there are three possible faults: 1. The load is too heavy, causing a decrease in output voltage; 2. Poor components of the voltage stabilizing circuit result in excessive voltage feedback signals; 3. The switch tube is inefficient, causing insufficient energy exchange in the circuit (switch transformer).

Inspection and repair methods:
a、 Remove the load circuits of the power supply branch one by one (note! Do not disconnect the load circuit by opening the power supply rectifier tube of that branch, especially the+5V power supply circuit with a voltage stabilizing feedback signal! The disappearance of the feedback voltage signal will cause abnormal increase in output voltage of each branch, and burn out large areas of the load circuit!) Determine whether the voltage drop is caused by excessive load; If the circuit returns to normal after cutting off a certain power supply, it indicates that the switching power supply itself is normal. Check the load circuit; Low output voltage, check the voltage stabilizing circuit.
b、 Check the resistance components R5-R10 of the voltage stabilizing circuit, and there is no change in value; Replace PC2 and PC3 one by one. If everything is normal, it indicates that the replacement components are inefficient and the internal resistance of conduction increases.
c、 If replacing PC2 and PC3 is ineffective, the fault may be low efficiency of the switch tube, or there may be problems with the switch and excitation circuit, which does not rule out the low efficiency of the internal output circuit of UC3844. Replace high-quality switch tubes and UC3844.

For general faults, the above troubleshooting methods are effective, but not necessarily 100% effective. If there are no abnormalities in the oscillation circuit, voltage stabilization circuit, or load circuit, but the circuit still has low output voltage, intermittent oscillation, or simply no response, this situation may occur. Don’t worry for now, let’s delve deeper into the cause of the circuit malfunction to help identify the faulty component as soon as possible. What other reasons can cause the circuit to not vibrate when the intermittent oscillation or stoppage of the circuit is not caused by the starting and stabilizing circuits?

(1) The R, D, and C circuits with parallel connection at both ends of the main winding N1 serve as a peak voltage absorption network, providing a discharge path for the magnetic field energy stored in the transformer during the switching period (reverse current channel of the switching tube), protecting the switching tube from overvoltage breakdown. When D2 or C4 experiences severe leakage or breakdown short circuit, the power supply is equivalent to adding a heavy load, causing the output voltage to drop significantly. U3844 lacks power supply, and the internal undervoltage protection circuit is activated, leading to intermittent oscillation of the circuit. Due to the parallel connection of components on the N1 winding, it is difficult to detect a short circuit and is often overlooked;
(2) Some switch mode power supplies have a protection circuit with an input power supply voltage (high voltage). Once the circuit itself malfunctions, the circuit will experience a false overvoltage protection action and the circuit will stop vibrating;
(3) Poor current sampling resistance, such as pin oxidation, carbonization, or increased resistance, can lead to an increase in voltage drop, resulting in false overcurrent protection and causing the circuit to enter an intermittent oscillation state;
(4) The rectifier diode D1 of the self powered winding is inefficient, and the forward conduction internal resistance increases, causing the circuit to fail to vibrate. Replacement testing is required;
(5) The quality factor of the switch transformer is reduced due to mold and moisture in the winding, and the original model transformer is used for replacement testing;
(6) The parameters of the R1 oscillation circuit vary, but no abnormalities are detected in the measurement, or the switching tube is inefficient. At this time, the circuit is checked and found to be normal, but it does not vibrate.

Repair method:
Change the existing parameters and status of the circuit to expose the fault! Try reducing the resistance value of R1 (not less than 200k Ω) so that the circuit can vibrate. This method can also be used as one of the emergency repair methods. Invalid, replace switch tube, UC3844, switch transformer test.
The output voltage is always slightly higher or lower, and cannot reach the normal value. Unable to detect any abnormalities in the circuit or components, almost all components in the circuit were replaced. The output voltage value of the circuit is still in a “barely and barely” state, sometimes seeming to work “normally”, but it makes people feel uneasy, as if they are neurotic, and I don’t know when an “abnormal performance” will occur. Don’t give up, adjust the circuit parameters to make the output circuit reach its normal value and reach its working state, so that we can rest assured. There are several reasons for the variation of circuit parameters:

  1. a、 Transistors are inefficient, such as a decrease in the amplification factor of the transistor, an increase in the internal resistance of conduction, an increase in the forward resistance of the diode, and a decrease in the reverse resistance;
  2. b、 The related dielectric loss, frequency loss, etc. of capacitors that cannot be measured with a multimeter;
  3. c、 Aging and parameter drift of transistors and chip devices, such as decreased light transfer efficiency of optocouplers;
  4. d、 Inductive components, such as switch transformers, have reduced Q values, etc;
  5. e、 The resistance variation of resistive components is not significant.
  6. f、 There are several factors involved in the above 5 reasons, forming a “comprehensive effect”.
  7. The “current” state of a circuit formed by various reasons is a “pathological” state. Perhaps we need to change our maintenance approach. Traditional Chinese medicine has a “dialectical treatment” theory, and we also need to use it. The next prescription is not to target a specific component, but to “regulate” the entire circuit, making it from “pathological” to “normal”. Just like this, the illness was treated with confusion and confusion.
  8. Repair method (slight adjustment of component values):

(1) Low output voltage:
a、 Increase R5 or decrease R6 resistance value; b、 Reduce the resistance values of R7 and R8 or increase the resistance values of R9.
(2) High output voltage:
a、 Reduce R5 or increase R6 resistance value; b、 Increase the resistance values of R7 and R8 or decrease the resistance values of R9.
The purpose of the above adjustments is to thoroughly inspect the circuit and replace inefficient components before proceeding. The purpose is to adjust the relevant gain of the stabilizing feedback circuit, so that the pulse duty cycle of the oscillation chip output changes, the energy storage of the switching transformer changes, and the output voltage of the secondary winding reaches the normal value, and the circuit enters a new “normal balance” state.
Many seemingly irreparable and difficult faults were repaired with ease after adjusting one or two resistance values.

During maintenance, attention should be paid to the following issues: 1. During the inspection and repair process of the switching power supply, the power supply to the IGBT module of the three-phase output circuit should be cut off to prevent abnormal driving power supply and damage to the IGBT module; 2. When repairing faults with high output voltage, it is even more important to cut off the+5V power supply to the CPU motherboard to avoid abnormal or high voltage damage to the CPU, resulting in the CPU motherboard being scrapped. 3. Do not interrupt the voltage stabilizing circuit, as it will cause an abnormal increase in output voltage! 4. The diodes in switch mode power supply circuits, used for rectification and protection, are both high-speed diodes or Schottky diodes and cannot be replaced by ordinary IN4000 series rectifier diodes. 4. After the switch tube is damaged, it is best to replace it with the original model. With such a developed network, the source of goods is not a problem and can generally be purchased. Many things can be purchased at cheap prices on Taobao, pay attention to quality!

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Communication Application of Mitsubishi FX2NPLC and Mitsubishi VFD ModbusRTU Protocol

Modbus is a serial communication protocol invented by Modicon for the communication between its PLC and the host. Its physical layer adopts asynchronous serial standards such as RS232 and 485. Due to its openness, it is widely adopted by PLC and RTU manufacturers. The Modbus communication method adopts a master-slave query corresponding mechanism. Only when the master station sends a query, the slave station can provide a response, and the slave station cannot actively send data. The master station can send queries to a certain slave station or broadcast information to all slave stations. The slave station only responds to queries sent to it separately, and does not respond to broadcast messages. There are two transmission methods for MODBUS communication protocol: RTU mode and ASCII mode. The Mitsubishi 700 series frequency converter can use the ModbusRTU communication protocol from the RS-485 terminal for communication operation and parameter settings.

Object:

  1. Mitsubishi PLC: FX2N+FX2N-485-BD
  2. Mitsubishi frequency converter: F700 series, A700 series.
    The two are connected through Ethernet cables, as shown in the following figure.

Connection diagram between FX2N-485-BD and n VFDs

1、 Setting up Mitsubishi frequency converters
When communicating between PLC and frequency converter, the communication specifications must be set in the frequency converter. After each parameter initialization setting, the frequency converter needs to be reset or the power supply of the frequency converter needs to be turned on and off.
Parameter Number Name Setting Value Description
Pr331 communication station number 1 sets the frequency converter station number to 1
Pr332 communication speed 96, set communication speed to 9600bps
Pr334 parity check stop bit length 2 even check, stop bit length 1 bit
Pr539 communication verification time 9999 does not perform communication verification
Pr549 protocol selection 1 ModbusRTU protocol
Pr551 PU mode operation right selection 2 PU operation mode operation right as PU interface
When communicating with ModbusRTU protocol, Pr551 must be set to 2, Pr340 is set to a value other than 0, Set Pr79 to 0, 2, or 6. When using the RS-485 terminal for ModbusRTU protocol communication, it must be running in NET network mode.

2、 Settings of Mitsubishi PLC
Set communication format D8120
The setting value of D8120 is 0C87, which means the data length is 8 bits, the parity stop bit is 1 bit, the baud rate is 9600pbs, and there is no header or terminator.
After modifying the D8120 settings, ensure that the PLC power is turned on and off once.

3、 Communication program
The partial PLC program that uses ModbusRTU protocol to communicate with the frequency converter is as follows:

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Converting 0-10VDC to 4-20mA for Robust Signal Transmission in Water Supply Systems

In variable frequency water supply control systems, remote pressure gauges play a crucial role in monitoring and maintaining consistent pressure levels. These gauges often exhibit resistance values ranging from 100 to 500 ohms, which correspond to a continuous pressure range, such as 0-10 MPa. Traditionally, this variable resistance can be utilized by series connecting a larger resistor and applying a 0-10V signal. This setup produces a continuously varying voltage that is suitable for frequency converters, PLCs, and other control devices. However, in practical engineering applications, 4-20mA signals are preferred over 0-10V due to their enhanced resistance to interference. Consequently, converting resistance or voltage signals into 4-20mA signals becomes essential for reliable transmission and control.

To address this need, several frequency converter manufacturers have developed specialized water supply signal acquisition boards. These boards are not limited to constant pressure water supply systems and can be applied across various industrial scenarios. Below, we explore three conversion circuits that serve as valuable learning resources and references.

One notable solution is a water supply substrate R/I conversion circuit board designed by a leading frequency converter manufacturer. This board effectively transforms the resistance changes from a remote pressure gauge into a 4-20mA current signal, which is then fed into the control terminal. By comparing this signal with a预设 pressure value, the frequency converter automatically adjusts its output frequency to ensure constant pressure in the water supply network.

The 4-20mA signal source circuit essentially functions as a constant current source with high internal resistance. The output current remains consistent, regardless of the external load resistance. Within this circuit, T2 and T3 form two constant current source circuits: T2 acts as a “fixed” constant current source, while T3 operates as a “variable” one.

The circuit is powered by a 12V DC voltage from the CPU motherboard, which undergoes isolation and filtering through D1 and C4 before reaching the Vcc1 water supply substrate. Further processing by R1 and TL431 converts Vcc1 into a 2.5V reference voltage. This voltage is then used in conjunction with the TL431, operational amplifier circuit (comprising R2, Z2, and the internal resistance of the remote pressure gauge), and the T2 circuit to create a constant current circuit of approximately 4.9 mA.

The resistance changes in the remote pressure gauge are translated into voltage variations across the Z2 resistor. This pressure signal is subsequently input into the second-stage operational amplifier circuit (pins 5 and 6) via R3. The T3 circuit forms the “variable” constant current source, where changes in the gauge’s internal resistance are converted into signal voltage inputs for the operational amplifier. This stage, with deep negative feedback (an amplification factor of 1), maintains a constant current source circuit. The output current is directly dependent on the gauge’s internal resistance.

For enhanced protection, Z1 and Z3 are voltage-embedded protection diodes at the signal input and output terminals. Typically, the internal resistance of the frequency converter’s current input terminals is 250 ohms.

Alternatively, dedicated signal conversion chips, such as the AD694, simplify the conversion process. These chips require only a current-limiting resistor and a transistor to accurately convert 0-10V signals to 4-20mA. With the control terminal of the frequency converter powered by a 24V supply, these chips offer excellent anti-interference performance.

A third option involves constructing a 0-10V/4-20mA signal conversion circuit using an operational amplifier circuit and discrete components. However, this approach necessitates two power supplies and initial output current adjustments, making it less practical and less commonly used.

In conclusion, converting 0-10VDC to 4-20mA signals is crucial for ensuring robust and interference-resistant transmission in water supply control systems. The described circuits and solutions provide effective means of achieving this conversion, catering to various industrial applications and requirements.

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Analysis of Zero Position Adjustment for Incremental Optoelectronic Encoder for Initial Position Detection of Permanent Magnet Synchronous Motor Rotors

The mainstream servo motor position feedback components include incremental encoders, absolute encoders, rotary transformers, etc. The vector control of permanent magnet AC servo drive requires a position feedback component to provide the position information of the rotor D-axis of the permanent magnet motor to the servo driver. After the position feedback component is installed with the motor, it is necessary to obtain the position relationship between the rotor magnetic pole axis (D) axis and the motor A-phase axis through the position feedback component before the driver starts vector control. Taking an incremental photoelectric encoder as an example, the encoder provides the position increment and zero position Z signal information to the controller’s main control chip, and uses these three sets of signals to determine the motor position of the motor. In actual use, the incremental photoelectric encoder also provides three additional sets of UVW signals for roughly determining the initial position of the rotor D-axis during motor startup. The rising edge of the encoder U signal and the rising edge of the Z trigger signal are generally aligned. The problem is that when the encoder is installed on the motor shaft, it may be fixed at a certain position of 360 degrees relative to the motor A-phase axis (after the motor winding stator is assembled). If the angle at this position is not known, the position information of the D-axis of the motor rotor cannot be determined using the output signal of the incremental photoelectric encoder, and vector control of the motor cannot be completed. Therefore, it is necessary to obtain this position signal through certain adjustment methods, which can be called electrical angle phase initialization, encoder zero position adjustment or alignment.

The physical significance of the signals of incremental encoders and the concept of axis position of permanent magnet synchronous motors

1. The A-phase axis of the motor and the orientation of the magnetic field

A permanent magnet motor is composed of three phase winding coils that are energized to form a rotating magnetic field, which is carried to the rotor poles equipped with rotor magnetic steel for rotation. The three phase windings form their own spatial magnetic potential vectors, and these three magnetic potentials combine to form a rotating magnetic potential vector: Figure 1 is a schematic diagram of the axial section layout of the motor winding. The A phase coil head is A-tail X, the B phase coil head is B-tail Y, and the C phase coil head is C-tail Z, connected in a star shape. XYZ is connected together, and the “+” and “-” in the ABC small circle represent the positive direction of the motor current of each phase equivalent coil (flowing from the beginning). When each phase coil is energized with a positive current, the arrows in the diagram are A and B according to the right-hand rule when the positive direction current is applied to the right hand direction. The direction of the magnetic potential (field) of A, B, and C when the positive direction current is applied to the three-phase coil, i.e. the respective axes of A, B, and C.

Assuming that when phase A flows in (positive direction) 1A, the current flowing out from phases B and C is -0.5A each (negative sign indicates opposite to the specified positive direction), as shown in Figure 2, the actual current at the coil edge of AZBXCY is+1+0.5-0.5-1-0.5+0.5 when unfolded counterclockwise along the cross-section. It can be seen that there are continuous positive current directions in the 180 degree electrical angle area along the circumference, and the other 180 continuous negative current directions are symmetrically distributed. The direction of the magnetic potential field determined by the right-hand rule in Figure 2 is the arrow direction shown in Figure 2, that is, the synthesized magnetic field is on the A-phase axis.

When powering on phases B and C, the current flows from phase B to phase C, as shown in Figure 3. The direction of the three-phase magnetic field is 90 degrees ahead of the axis of phase A.

2. The physical meaning of each output signal of the incremental photoelectric encoder

The commonly used incremental photoelectric encoder is a type of encoder with simple magnetic pole positioning function, which has two sets of output information: one set of information is A, B, Z; The other group is U, V, W, used to detect the position of magnetic poles, with absolute information function. Among them, A and B are basic signals, which can be processed to conveniently determine the direction and speed of motor rotation; Z pulses are used for reference positioning, with a phase difference of 120 degrees between the U, V, and W pulses. The number of pulses per revolution is consistent with the number of pole pairs of the motor. The use of U, V, and W signals can serve as a starting point for rough measurement of rotor position. After the motor starts, the precise angular position is obtained from signals A and B.

3. A deeper understanding of encoder output signals and motor position signals

A permanent magnet synchronous motor using an incremental photoelectric encoder as a position detection component must have its precise initial position measured when the system is first powered on. Because in the permanent magnet motor drive system, the position detection and initial positioning of the motor rotor are the basic conditions for system composition and operation, as well as the necessary conditions for vector control decoupling. Only when the rotor position of a permanent magnet synchronous motor can be accurately known, can the permanent magnet synchronous motor be equivalently transformed into an equivalent model on the dq coordinate system according to a series of equations in vector control. The system can control the permanent magnet synchronous motor using a control method similar to that of a separately excited DC motor, thus achieving the performance requirements of a servo transmission system composed of separately excited DC motors. In the driving system that uses an incremental photoelectric encoder to measure the position of the motor, the initial position of the motor needs to be detected first after the system is powered on. The initial position of the motor not only affects the positioning accuracy of the servo system, but also has a certain impact on the fast starting performance of the motor.

Taking a permanent magnet synchronous motor as an example, Figure 4 is the simplest diagram of the position relationship between the stator winding, magnetic steel, and HALL of the motor, with the rotor magnetic poles rotating uniformly counterclockwise. At the position shown in the diagram, the stator coil phase A crosses the zero point. If the DC brushless motor has a maximum output power when the current and back electromotive force are in the same phase due to 120 degrees conduction, and the U-phase voltage switch tube is delayed by 30 degrees of electrical angle conduction, the installation position of the HALL should be rotated counterclockwise over 30 degrees of electrical angle. The three sets of signal encoding outputs of the HALL output of a DC brushless motor reflect the motor position signal. The 360 degree electrical angle space is evenly divided into six consecutive spaces, each occupying 60 degrees of electrical angle.

The UVW signal of the encoder is similar to the DC brushless HALL signal, so it can also play this role
What is the difference between the function and the HALL output signal? Three HALLs have been installed by
On the three-phase axis shown in Figure 1, the three-phase HALL output signal not only reflects the rotor position signal, but also
The information also includes the three-phase axis of the stator, so that the position information of the stator and rotor can be communicated
By matching with HALL, the angle and position information of the rotor relative to the stator axis can be found. When
After the encoder is installed, the UVW signal of the photoelectric encoder is input on the encoder disk
If a position sensor similar to HALL is placed on the encoder disk (actually
Similarly, when the zero position of the rotor magnetic potential (transition position between N and S poles) is rotated past this position
The U-phase signal of the photoelectric encoder undergoes a jump, and the rising edge of the U-phase signal can reflect the magnetic field of the rotor
The position of the polar axis (D-axis) triggers the rising edge of the Z-signal (encoder zero position) and the U-signal
The rising edge of the signal is consistent, so the Z trigger signal can reflect the position of the rotor’s D-axis at that time. The problem is,
The rising edge of the U-phase signal of the photoelectric encoder can reflect the position of the rotor magnetic pole axis (D-axis), when
The position of the rotor magnetic pole axis (D-axis) and the motor winding when the photoelectric encoder emits a Z signal pulse
The angle between the A-phase axes (compensation angle parameter in TI PMSM 3.1 routine QEP module)
The number is CalibratedAngle, but it needs to be converted to the pulse number of the photoelectric encoder.
4.Correction of the angle between the encoder Z signal and the motor A phase axis position
After the installation of the photoelectric encoder, when the rotor rotates, the position where the z signal is triggered may be in the range of
At a fixed angle of 360 degrees electrical angle with the A-phase axis of the motor as the reference zero point, so Compared to the HALL output signal, there is a missing link, which is the failure to phase the UVW signal with A Corresponding axes. This requires finding out this angle, which is usually achieved through the soft Correct the parts.

As shown in Figure 5, a two channel oscilloscope is used to observe the opposite potential of A and the contact of the encoder Z signal The time relationship of the generator position is determined by making the motor rotate at a constant speed and connecting three resistors with equal resistance values to form a star Then connect the three resistors connected in a star pattern to the UVW three-phase winding of the motor Line. In the figure, R is the external resistance, La, Lb, and Lc are the three-phase inductance of the motor stator, Ra Rb and Rc are the three-phase resistances of the motor stator, because the resistance of the motor stator is usually very small, as long as If the external resistance R is large enough, the stator resistance is ignored.

Use an oscilloscope to observe the output of motor A phase By focusing on the star type resistor, obtain the back electromotive force waveform of motor phase A.The period of the opposite electromotive force of motor A and the encoder Z signal and back electromotive force can be obtained from the oscilloscope The time difference between the zero crossing point of the waveform from low to high can be used to obtain the motor A phase axis and encoder Z signal

The angle difference of the number is:

The period T of the opposite electromotive force from motor A and the waveform of the encoder Z signal and the back electromotive force from low to high The time difference between zero crossing can be used to calculate the corrected number of pulses, and the encoder zero can be corrected through software The phase relationship with the axis of stator A.

Installation of encoder and adjustment or alignment of encoder zero position

The above detailed description describes the method of correcting the angle between the encoder zero point and the stator A phase axis. In practice Many manufacturers in production directly align the zero point of the encoder when installing it, and the back electromotive force decreases from low to low There are two methods for crossing the zero point position: one is to cross the zero point from low to high with the opposite electromotive force of A Position alignment, another method is to align with the zero crossing point of the back electromotive force of the AB line from low to high.

1.Align the U-phase signal of the encoder (encoder zero point) with the zero point of the motor electrical angle A opposite to the zero crossing position of the electromotive force
a. Use a DC power source to apply a DC current smaller than the rated current to the UVW winding of the motor,
A in, BC out, as shown in Figure 2, orient the motor shaft to a balanced position;
b. Observe the U-phase signal and Z-signal of the encoder using an oscilloscope;
c. Adjust the relative position between the encoder shaft and the motor shaft;
d. While adjusting, observe the encoder U-phase signal jump edge and Z-signal until Z-signal
The signal is stable at a high level (where the normal state of the Z signal is low), and the encoder is locked
The relative position relationship with the motor;
e. Twist the motor shaft back and forth, and after letting go, if the motor shaft returns to the balance position freely each time,
If the Z signal can stabilize at a high level, then alignment is effective.

2.Align the U-phase signal of the encoder (encoder zero point) with the zero point of the motor electrical angle, i.e. the zero crossing position of the AB line back electromotive force
a. Apply a DC power supply to the AB winding of the motor with a DC current less than the rated current,
A in, B out, orient the motor shaft to a balanced position;
b. Observe the U-phase signal and Z-signal of the encoder using an oscilloscope;
c. Adjust the relative position between the encoder shaft and the motor shaft;
d. While adjusting, observe the encoder U-phase signal jump edge and Z-signal until Z-signal
The signal is stable at a high level (assuming that the normal state of the Z signal is low), locking the encoder and
The relative position relationship of the motor;
e. Twist the motor shaft back and forth, and after letting go, if the motor shaft returns to the balance position freely each time,
If the Z signal can stabilize at a high level, then alignment is effective

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Abb Acs580 Fault Code 7122,What does this fault code mean and how can it be reset?

The ACS580 stands as an upgraded iteration compared to the previous ABB ACS550 inverter, boasting enhanced functionalities like vector control. Its versatile applications cover a wide range. Internally, the ACS580 exhibits a distinct circuit structure from its predecessor, the ACS550. In the course of ACS580 usage, encountering various faults and alarm scenarios is common. However, the fault codes and alarms differ significantly from those of the ACS550, necessitating reference to the ACS580 firmware manual for troubleshooting.

In practical scenarios, some fault codes encountered with the ACS580 may not be documented in the manual, presenting a unique challenge. This situation often leaves many electrical engineers puzzled. For instance, a typical fault code such as “7122” cannot be located in any of the ACS580 manuals. Below, you’ll find a table detailing fault codes for the ACS580.

In the provided table, we notice adjacent fault codes like 7121 and 7181, yet codes like 7122, 7123, 7124, and so forth are conspicuously absent. When faced with such a scenario, how does one determine the meaning of abb acs580 fault code 7122?

Those familiar with the internal hardware structure of the ACS580 inverter understand that the high-power mainboard of the ACS580 closely resembles that of the ACS880. In pursuit of clarity, we consulted the firmware manual for the ACS880 and searched its fault code table, only to find no mention of code 7122, as displayed below:

It’s evident that although there are some differences in the fault code listings between the ACS580 and ACS880, the explanations for the fault alarm content are nearly identical as long as the codes match. This demonstrates that many fault code contents in ABB inverters can be cross-referenced within a series. However, it’s regrettable that even in the ACS880’s code table, an explanation for “7122” cannot be found.

Finding ourselves in a predicament, with neither inverter providing an explanation for fault code “7122,” what can we do next?

Upon further exploration, we recall that ABB also offers a compact low-power inverter called the ACS150, which shares hardware and software structures similar to the ACS550. Considering this, the upgraded version of the ACS150 should be the ACS180. We swiftly locate the firmware manual for the ACS180 and navigate to the vicinity of the fault code table. To our amazement, a miracle unfolds, as depicted in the table below:

The table clearly indicates that “7122” is an overload alarm, further specifying that it’s caused by excessively high motor current. Besides verifying if the motor is genuinely overloaded, it’s also necessary to inspect parameters 35.51, 35.52, 35.53, 35.55, and 35.56. Upon comparing these parameters in the ACS580 firmware manual, astonishingly, they closely resemble those in the ACS180. Parameter 35.51 defaults to 110%, but in such cases, it can be adjusted higher, say 150%. However, this adjustment necessitates ensuring that the motor hardware is in good condition and the motor power meets the on-site load requirements.

Further investigation reveals that the ACS180 inverter does include parameter 35.56, whereas the ACS580 does not offer this parameter as an option. Interestingly, setting parameter 35.56 to 0 can effectively disable motor overload alarms, effectively masking fault code 7122.

This indicates that the hardware and software of ABB’s drives—ACS180, ACS580, and ACS880—are essentially the same. Perhaps their underlying programs are identical, and they merely display different series and functionalities through specific settings. Fault code 7122 and the hardware detection function are present in each inverter model, but in the ACS580 and ACS880, the hardware circuitry suppresses it. However, if there’s an issue with the hardware circuitry, such as poor contact or breakage in the connection between the mainboard and the drive board, it may trigger fault code 7122 directly, with no apparent means of suppression, and the fault alarm details may not be found in the inverter’s manual.

Conclusion: When fault codes like 7122 appear on ACS580 or ACS880 inverters, it’s usually indicative of an internal hardware circuit problem. In such cases, removing the inverter, checking the connections and plugs, and clearing dust may resolve the issue. If this doesn’t suffice, it’s likely that a component on the board is faulty, requiring the inverter to be repaired.

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Characteristics of ACS800 Drivers, abb acs800 troubleshooting manual

The ACS800 inverter, produced by ABB, is an advanced industrial frequency converter with several unique features that make it highly favored in the industrial control and drive sectors.

Firstly, the ACS800 inverter boasts a wide power range, from kilowatts to megawatts, suitable for various scales and complexities of industrial applications. This flexibility enables the ACS800 to meet the needs of different industries and applications, from small production lines to large factories.

Secondly, the ACS800 inverter exhibits outstanding performance and stability. It employs advanced control algorithms and technologies to achieve precise speed and torque control, ensuring stable and reliable equipment operation. Whether in harsh industrial environmental conditions or demanding production processes, the ACS800 performs exceptionally well.

Furthermore, the ACS800 inverter offers extensive features and options. It supports multiple communication interfaces for integration with various control systems, enabling flexible remote control and monitoring. Additionally, the ACS800 provides various protection functions, such as overload protection, short-circuit protection, and overvoltage protection, effectively safeguarding the safe operation of equipment and production systems.

The ACS800 inverter also emphasizes energy efficiency and environmental protection. By optimizing energy utilization and efficiency, the ACS800 can reduce energy consumption and production costs while minimizing environmental impact, in line with sustainable development requirements.

In conclusion, the ACS800 inverter, with its wide application range, excellent performance, rich features, and eco-friendly energy-saving characteristics, is an ideal choice for industrial control and drive applications. It not only improves production efficiency and quality but also reduces operating costs, creating greater value for users.Below is the ABB ACS800 troubleshooting manual.

Warning or Fault Message On The Panel Display Of ABB ACS800

An indication of an abnormal drive status appears as a warning or fault message on the panel display. You depend on the abb acs800 troubleshooting manual,Utilizing this information, most causes of warnings and faults can be identified and rectified. Should you encounter challenges beyond your expertise, do not hesitate to reach out to us for assistance.When you encounter a malfunction in the ABB ACS800 drive, you can also directly refer to this manual:

https://drive.google.com/file/d/1xIHyXqzHP-my4EsTVidbco33lgYWFXH5/view?usp=sharing

WARNING CAUSE WHAT TO DO
ACS800 TEMP (4210)
3.08 AW 1 bit 4		 Drive IGBT temperature is excessive. Fault trip limit is 100%. Check ambient conditions. Check air flow and fan operation.
Check heatsink fins for dust pick-up. Check motor power against unit power.
AI < MIN FUNC (8110)
3.09 AW 2 bit 10
(programmable Fault Function 30.01)		 Analogue control signal is below minimum allowed value due to incorrect signal level or failure in control wiring. Check for proper analogue control signal levels.
Check control wiring.
Check Fault Function parameters.
AD [message] Message generated by an EVENT block in the Adaptive Program. Consult the documentation or author of the Adaptive Program.
BACKUP USED (FFA3) PC stored backup of drive parameters is downloaded into use. Wait until download is completed.
BATT FAILURE (5581)
3.18 AW 5 bit 15		 APBU branching unit memory backup battery error caused by
– incorrect APBU switch S3 setting
– too low battery voltage.		 With parallel connected inverters, enable backup battery by setting actuator 6 of switch S3 to ON.
Replace backup battery.
BC OVERHEAT (7114)
3.18 AW 5 bit 3		 Brake chopper overload Stop drive. Let chopper cool down.
Check parameter settings of resistor overload protection function (see parameter group 27 BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that drive supply AC voltage is not excessive.
BRAKE ACKN (FF74)
3.16 AW 4 bit 3		 Unexpected state of brake acknowledge signal See parameter group 42 BRAKE CONTROL.
Check connection of brake acknowledgement signal.
BR OVERHEAT (7112)
3.18 AW 5 bit 2		 Brake resistor overload Stop drive. Let resistor cool down.
Check parameter settings of resistor overload protection function (see parameter group 27 BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
CALIBRA DONE (FF37) Calibration of output current transformers is completed. Continue normal operation.
CALIBRA REQ (FF36) Calibration of output current transformers is required. Displayed at start if drive is in scalar control (parameter 99.04) and scalar fly start feature is on (parameter 21.08). Calibration starts automatically. Wait for a while.
WARNING CAUSE WHAT TO DO
COMM MODULE (7510)
3.08 AW 1 bit 12
(programmable Fault Function 30.18, 30.19)		 Cyclical communication between drive and master is lost. Check status of fieldbus communication. See chapter Fieldbus control, or appropriate fieldbus adapter manual.
Check parameter settings:
– group 51 COMM MODULE DATA (for fieldbus adapter)
– group 52 STANDARD MODBUS (for Standard Modbus Link).
Check Fault Function parameters. Check cable connections.
Check if master can communicate.
DC BUS LIM (3211)
3.18 AW5 bit 9
(programmable Fault Function 30.23)		 Drive limits torque due to too high or too low intermediate circuit DC voltage. Informative alarm
Check Fault Function parameters.
EARTH FAULT (2330)
3.08 AW 1 bit 14
(programmable Fault Function 30.17)		 Drive has detected load unbalance typically due to earth fault in motor or motor cable. Check there are no power factor correction capacitors or surge absorbers in motor cable.
Check that there is no earth fault in motor or motor cables:
– measure insulation resistances of motor and motor cable.
If no earth fault can be detected, contact your local ABB representative.
ENC CABLE (7310)
3.31 AW 6 bit 3
(programmable Fault Function 50.07)		 Pulse encoder phase signal is missing. Check pulse encoder and its wiring.
Check pulse encoder interface module and its wiring.
ENCODER A<>B (7302)
3.09 AW 2 bit 4		 Pulse encoder phasing is wrong: Phase A is connected to terminal of phase B and vice versa. Interchange connection of pulse encoder phases A and B.
ENCODER ERR (7301)
3.08 AW 1 bit 5		 Communication fault between pulse encoder and pulse encoder interface module and between module and drive Check pulse encoder and its wiring, pulse encoder interface module and its wiring, parameter group 50 ENCODER MODULE settings.
FAN OTEMP (FF83)
3.16 AW 4 bit 0		 Excessive temperature of drive output filter fan. Supervision is in use in step-up drives. Stop drive. Let it cool down. Check ambient temperature.
Check fan rotates in correct direction and air flows freely.
HW RECONF RQ (FF38) Inverter type (e.g. sr0025_3) has been changed. Inverter type is usually changed at factory or during drive implementation. Wait until alarm POWEROFF! activates and switch control board power off to validate inverter type change.
WARNING CAUSE WHAT TO DO
ID DONE (FF32) Drive has performed motor identification magnetisation and is ready for operation. This warning belongs to normal start-up procedure. Continue drive operation.
ID MAGN (FF31) Motor identification magnetisation is on. This warning belongs to normal start-up procedure. Wait until drive indicates that motor identification is completed.
ID MAGN REQ (FF30) Motor identification is required. This warning belongs to normal start-up procedure. Drive expects user to select how motor identification should be performed: By Identification Magnetisation or by ID Run. Start Identification Magnetisation by pressing Start key, or select ID Run and start (see parameter 99.10).
ID N CHANGED (FF68) Drive ID number has been changed from 1. Change ID number back to 1. See chapter
Control panel.
ID RUN (FF35) Motor identification Run is on. Wait until drive indicates that motor identification Run is completed.
ID RUN SEL (FF33) Motor Identification Run is selected, and drive is ready to start ID Run. This warning belongs to ID Run procedure. Press Start key to start Identification Run.
IN CHOKE TEMP (FF81)
3.18 AW 5 bit 4		 Excessive input choke temperature Stop drive. Let it cool down. Check ambient temperature.
Check that fan rotates in correct direction and air flows freely.
INV CUR LIM (2212)
3.18 AW 5 bit 8
(programmable Fault Function 30.23)		 Internal inverter current or power limit has been exceeded. Reduce load or increase ramp time.
Limit inverter actual power or decrease line- side converter reactive power generation reference value (parameter 95.06 LCU Q PW REF).
Check Fault Function parameters.
INV DISABLED (3200)
3.18 AW 5 bit 6		 Optional DC switch has opened while unit was stopped. Close DC switch.
Check AFSC-0x Fuse Switch Controller unit.
WARNING CAUSE WHAT TO DO
INV OVERTEMP (4290)
3.31 AW 6 bit 0		 Converter module temperature is excessive. Check ambient temperature. If it exceeds 40°C, ensure that load current does not exceed derated load capacity of drive. See appropriate hardware manual.
Check that ambient temperature setting is correct (parameter 95.10).
Check converter module cooling air flow and fan operation.
Cabinet installation: Check cabinet air inlet filters. Change when necessary. See appropriate hardware manual.
Modules installed in cabinet by user: Check that cooling air circulation in cabinet has been prevented with air baffles. See module installation instructions.
Check inside of cabinet and heatsink of converter module for dust pick-up. Clean when necessary.
IO CONFIG (FF8B)
(programmable Fault Function 30.22)		 Input or output of optional I/O extension or fieldbus module has been selected as signal interface in application program but communication to appropriate I/O extension module has not been set accordingly. Check Fault Function parameters.
Check parameter group 98 OPTION MODULES.
MACRO CHANGE (FF69) Macro is restoring or User macro is being saved. Wait until drive has finished task.
MOD BOARD T (FF88)
09.11 AW 3 bit 14		 Overtemperature in AINT board of inverter module. Check inverter fan.
Check ambient temperature.
MOD CHOKE T (FF89)
09.11 AW 3 bit 13		 Overtemperature in choke of liquid cooled R8i inverter module. Check inverter fan.
Check ambient temperature. Check liquid cooling system.
MOT CUR LIM (2300)
3.18 AW 5 bit 10
(programmable Fault Function 30.23)		 Drive limits motor current according to current limit defined by parameter 20.03 MAXIMUM CURRENT. Reduce load or increase ramp time.
Increase parameter 20.03 MAXIMUM CURRENT value.
Check Fault Function parameters.
MOTOR STALL (7121)
3.09 AW 2 bit 9
(programmable Fault Function 30.10)		 Motor is operating in stall region due to e.g. excessive load or insufficient motor power. Check motor load and drive ratings. Check Fault Function parameters.
MOTOR STARTS (FF34) Motor Identification Run starts. This warning belongs to ID Run procedure. Wait until drive indicates that motor identification is completed.
WARNING CAUSE WHAT TO DO
MOTOR TEMP (4310)
3.08 AW 1 bit 3
(programmable Fault Function 30.04…30.09)		 Motor temperature is too high (or appears to be too high) due to excessive load, insufficient motor power, inadequate cooling or incorrect start-up data. Check motor ratings, load and cooling. Check start-up data.
Check Fault Function parameters.
MOTOR 1 TEMP
(4312)
3.16 AW 4 bit 1		 Measured motor temperature has exceeded alarm limit set by parameter 35.02. Check value of alarm limit.
Check that actual number of sensors corresponds to value set by parameter.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
MOTOR 2 TEMP
(4313)
3.16 AW 4 bit 2		 Measured motor temperature has exceeded alarm limit set by parameter 35.05. Check value of alarm limit.
Check that actual number of sensors corresponds to value set by parameter.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
MOT POW LIM (FF86)
3.18 AW 5 bit 12
(programmable Fault Function 30.23)		 Drive limits motor power according to limits defined by parameters 20.11 and 20.12. Informative alarm
Check parameter 20.11 P MOTORING LIM and 20.12 P GENERATING LIM settings.
Check Fault Function parameters.
MOT TORQ LIM (FF85)
3.18 AW 5 bit 11
(programmable Fault Function 30.23)		 Drive limits motor torque according to calculated motor pull-out torque limit and minimum and maximum torque limits defined by parameters 20.13 and 20.14. Informative alarm
Check parameter 20.13 MIN TORQ SEL and
20.14 MAX TORQ SEL settings. Check Fault Function parameters.
If LIMIT WORD 1 bit 0 TORQ MOTOR LIM
is 1,
– check motor parameter settings (parameter group 99 START-UP DATA)
– ensure that ID run has been completed successfully.
PANEL LOSS (5300)
3.09 AW 2 bit 13
(programmable Fault Function 30.02)		 Control panel selected as active control location for drive has ceased communicating. Check panel connection (see appropriate hardware manual).
Check control panel connector.
Replace control panel in mounting platform. Check Fault Function parameters.
POINTER ERROR (FFD0) Source selection (pointer) parameter points to non existing parameter index. Check source selection (pointer) parameter settings.
->POWEROFF! (FF39) Inverter type (e.g. sr0025_3) has been changed. Inverter type is usually changed at factory or during drive implementation. Switch control board power off to validate inverter type change.
WARNING CAUSE WHAT TO DO
PPCC LINK (5210)
3.06 FW 2 bit 11		 Fibre optic link to INT board is faulty. Check fibre optic cables or galvanic link. With frame sizes R2-R6 link is galvanic.
If RMIO is powered from external supply, ensure that supply is on. See parameter 16.09 CTRL BOARD SUPPLY.
Check signal 03.19. Contact ABB representative if any of faults in signal 3.19 are active.
PPCC LINK xx INT board fibre optic connection fault in inverter unit of several parallel connected inverter modules. xx refers to inverter module number. Check connection from inverter module Main Circuit Interface Board, INT to PPCC Branching Unit, PBU. (Inverter module 1 is connected to PBU INT1 etc.)
Check signal 03.19. Contact ABB representative if any of faults in signal 3.19 are active.
(5210)
3.06 FW 2 bit 11 and
4.01
PP OVERLOAD (5482)
3.18 AW 5 bit 5		 Excessive IGBT junction to case temperature. This can be caused by excessive load at low frequencies (e.g. fast direction change with excessive load and inertia). Increase ramp time. Reduce load.
REPLACE FAN (4280)
3.18 AW 5 bit 0		 Running time of inverter cooling fan has exceeded its estimated life time. Replace fan.
Reset fan run time counter 01.44.
RUN ENABLE (FF8E)
3.06 FW 2 bit 4		 No Run enable signal received. Check setting of parameter 16.01. Switch on signal or check wiring of selected source.
SLEEP MODE (FF8C)
3.16 AW 4 bit 4		 Sleep function has entered sleeping mode. See parameter group 40 PID CONTROL.
START INHIBI (FF7A)
AW 1 bit 0		 Safe torque off function has been activated while drive was stopped.
Or: Optional start inhibit hardware logic is activated.		 Close Safe torque off function switch. If switch is closed and warning is still active, check power supply at ASTO board input terminals. Replace ASTO board.
Or: Check start inhibit circuit (AGPS board).
START INTERL (FF8D) No Start Interlock signal received. Check circuit connected to Start Interlock input on RMIO board.
SYNCRO SPEED (FF87)
3.18 AW 5 bit 1		 Value of motor nominal speed set to parameter
99.08 is not correct: Value is too near synchronous speed of motor. Tolerance is 0.1%. This warning is active only in DTC mode.		 Check nominal speed from motor rating plate and set parameter 99.08 exactly accordingly.
WARNING CAUSE WHAT TO DO
TEMP DIF xx y (4380)
4.01 FAULTED INT INFO		 Excessive temperature difference between several parallel connected inverter modules. xx (1…12) refers to inverter module number and y refers to phase (U, V, W). Check cooling fan. Replace fan.
Check air filters.
Alarm is indicated when temperature difference is 15°C. Fault is indicated when temperature difference is 20°C.
Excessive temperature can be caused e.g. by unequal current sharing between parallel connected inverters.
THERMISTOR (4311) Motor temperature is excessive. Motor thermal protection mode selection is TEMP SENSOR. Check motor ratings and load. Check start-up data.
3.08 AW 1 bit 2
(programmable Fault Function 30.04…30.05)		 Check thermistor connections to digital input DI6.
T MEAS ALM (FF91)
3.08 AW 1 bit 6		 Motor temperature measurement is out of acceptable range. Check connections of motor temperature measurement circuit. See chapter Program features for circuit diagram.
UNDERLOAD (FF6A) Motor load is too low due to e.g. release mechanism in driven equipment. Check for problem in driven equipment. Check Fault Function parameters.
3.09 AW 2 bit 1
(programmable Fault Function 30.13)
USER L CURVE (2312)
3.18 AW 5 bit 13		 Integrated motor current has exceeded load curve defined by parameters in group 72 USER LOAD CURVE. Check parameter group 72 USER LOAD CURVE settings.
Reduce load.
WARNING CAUSE WHAT TO DO
DOWNLOADING FAILED Download function of panel has failed. No data has been copied from panel to drive. Make sure panel is in local mode.
Retry (there might be interference on link). Contact ABB representative.
DRIVE IS RUNNING DOWNLOADING NOT POSSIBLE Downloading is not possible while motor is running. Stop motor. Perform downloading.
NO COMMUNICATION (X) Cabling problem or hardware malfunction on Panel Link Check Panel Link connections.
Press RESET key. Panel reset may take up to half a minute, please wait.
(4) = Panel type not compatible with drive application program version Check panel type and drive application program version. Panel type is printed on panel cover. Application program version is stored in parameter 33.02.
NO FREE ID NUMBERS ID NUMBER SETTING NOT POSSIBLE Panel Link already includes 31 stations. Disconnect another station from link to free ID number.
NOT UPLOADED DOWNLOADING NOT POSSIBLE No upload function has been performed. Perform upload function before downloading. See chapter Control panel.
UPLOADING FAILED Upload function of panel has failed. No data has been copied from drive to panel. Retry (there might be interference on link). Contact ABB representative.
WRITE ACCESS DENIED PARAMETER SETTING NOT POSSIBLE Certain parameters do not allow changes while motor is running. If tried, no change is accepted, and warning is displayed.
Parameter lock is on.		 Stop motor, then change parameter value.
Open parameter lock (see parameter 16.02).
FAULT CAUSE WHAT TO DO
ACS800 TEMP (4210)
3.05 FW 1 bit 3		 Drive IGBT temperature is excessive. Fault trip limit is 100%. Check ambient conditions. Check air flow and fan operation.
Check heatsink fins for dust pick-up. Check motor power against unit power.
ACS TEMP xx y (4210)
3.05 FW 1 bit 3 and 4.01		 Excessive internal temperature in inverter unit of several parallel connected inverter modules. xx (1…12) refers to inverter module number and y refers to phase (U, V, W). Check ambient conditions. Check air flow and fan operation.
Check heatsink fins for dust pick-up. Check motor power against unit power.
AI < MIN FUNC (8110)
3.06 FW 2 bit 10
(programmable Fault Function 30.01)		 Analogue control signal is below minimum allowed value due to incorrect signal level or failure in control wiring. Check for proper analogue control signal levels.
Check control wiring.
Check Fault Function parameters.
AD [message] Message generated by an EVENT block in the Adaptive Program. Consult the documentation or author of the Adaptive Program.
BACKUP ERROR (FFA2) Failure when restoring PC stored backup of drive parameters. Retry.
Check connections.
Check that parameters are compatible with drive.
BC OVERHEAT (7114)
3.17 FW 5 bit 4		 Brake chopper overload Let chopper cool down.
Check parameter settings of resistor overload protection function (see parameter group 27 BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that drive supply AC voltage is not excessive.
BC SHORT CIR (7113)
3.17 FW 5 bit 2		 Short circuit in brake chopper IGBT(s) Replace brake chopper.
Ensure brake resistor is connected and not damaged.
BRAKE ACKN (FF74)
3.15 FW 4 bit 3		 Unexpected state of brake acknowledge signal See parameter group 42 BRAKE CONTROL.
Check connection of brake acknowledgement signal.
BR BROKEN (7110)
3.17 FW 5 bit 0		 Brake resistor is not connected or it is damaged.
Resistance rating of brake resistor is too high.		 Check resistor and resistor connection.
Check that resistance rating meets specifications. See appropriate drive hardware manual.
FAULT CAUSE WHAT TO DO
BR OVERHEAT (7112)
3.17 FW 5 bit 3		 Brake resistor overload Let resistor cool down.
Check parameter settings of resistor overload protection function (see parameter group 27 BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that drive supply AC voltage is not excessive.
BR WIRING (7111)
3.17 FW 5 bit 1		 Wrong connection of brake resistor Check resistor connection.
Ensure brake resistor is not damaged.
CHOKE OTEMP (FF82) Excessive temperature of drive output filter. Supervision is in use in step-up drives. Let drive cool down.
Check ambient temperature.
Check filter fan rotates in correct direction and air flows freely.
COMM MODULE (7510)
3.06 FW 2 bit 12		 Cyclical communication between drive and master is lost. Check status of fieldbus communication. See chapter Fieldbus control, or appropriate fieldbus adapter manual.
(programmable Fault Function 30.18, 30.19) Check parameter settings:
– group 51 COMM MODULE DATA (for fieldbus adapter), or
– group 52 STANDARD MODBUS (for Standard Modbus Link).
Check Fault Function parameters.
Check cable connections.
Check if master can communicate.
CTRL B TEMP (4110)
3.06 FW 2 bit 7		 Control board temperature is above 88°C. Check ambient conditions. Check air flow.
Check main and additional cooling fans.
CURR MEAS (2211) Current transformer failure in output current measurement circuit Check current transformer connections to Main Circuit Interface Board, INT.
CUR UNBAL xx (2330) Drive has detected excessive output current unbalance in inverter unit of several parallel connected inverter modules. This can be caused by external fault (earth fault, motor, motor cabling, etc.) or internal fault (damaged inverter component). xx (1…12) refers to inverter module number. Check there are no power factor correction capacitors or surge absorbers in motor cable.
3.05 FW 1 bit 4 and 4.01 Check that there is no earth fault in motor or motor cables:
(programmable Fault Function 30.17) – measure insulation resistances of motor and motor cable.
If no earth fault can be detected, contact your local ABB representative.
DC HIGH RUSH (FF80) Drive supply voltage is excessive. When supply voltage is over 124% of unit voltage rating (415, 500 or 690 V), motor speed rushes to trip level (40% of nominal speed). Check supply voltage level, drive rated voltage and allowed voltage range of drive.
FAULT CAUSE WHAT TO DO
DC OVERVOLT (3210)
3.05 FW 1 bit 2		 Excessive intermediate circuit DC voltage.
DC overvoltage trip limit is 1.3 × 1.35 × U1max, where U1max is maximum value of supply voltage range. For 400 V units, U1max is 415 V. For 500 V units, U1max is 500 V. For 690 V units, U1max is 690 V. Actual voltage in intermediate circuit corresponding to the
supply voltage trip level is 728 V DC for 400 V units, 877 V DC for 500 V units, and
1210 V DC for 690 V units.		 Check that overvoltage controller is on (parameter 20.05).
Check supply voltage for static or transient overvoltage.
Check brake chopper and resistor (if used). Check deceleration time.
Use coast-to-stop function (if applicable).
Retrofit frequency converter with brake chopper and brake resistor.
DC UNDERVOLT (3220)
3.06 FW 2 bit 2		 Intermediate circuit DC voltage is not sufficient due to missing supply voltage phase, blown fuse or rectifier bridge internal fault.
DC undervoltage trip limit is 0.6 × 1.35 × U1min, where U1min is minimum value of supply voltage range. For 400 V and 500 V units,
U1min is 380 V. For 690 V units, U1min is 525 V. Actual voltage in intermediate circuit corresponding to supply voltage trip level is
307 V DC for 400 V and 500 V units, and 425 V DC for 690 V units.		 Check main supply and fuses.
EARTH FAULT (2330)
3.05 FW 1 bit 4
(programmable Fault Function 30.17)		 Drive has detected load unbalance typically due to earth fault in motor or motor cable. Check there are no power factor correction capacitors or surge absorbers in motor cable.
Check that there is no earth fault in motor or motor cables:
– measure insulation resistances of motor and motor cable.
If no earth fault can be detected, contact your local ABB representative.
ENC CABLE (7310)
3.33 FW 6 bit 2
(programmable Fault Function 50.07)		 Pulse encoder phase signal is missing. Check pulse encoder and its wiring.
Check pulse encoder interface module and its wiring.
ENCODER A<>B (7302) Pulse encoder phasing is wrong: Phase A is connected to terminal of phase B and vice versa. Interchange connection of pulse encoder phases A and B.
ENCODER ERR (7301)
3.06 FW 2 bit 5		 Communication fault between pulse encoder and pulse encoder interface module and between module and drive Check pulse encoder and its wiring, pulse encoder interface module and its wiring and parameter group 50 ENCODER MODULE settings.
EXTERNAL FLT (9000)
3.06 FW 2 bit 8
(programmable Fault Function 30.03)		 Fault in external device. (This information is configured through one of programmable digital inputs.) Check external devices for faults.
Check parameter 30.03 EXTERNAL FAULT.
FAULT CAUSE WHAT TO DO
FORCED TRIP (FF8F) Generic Drive Communication Profile trip command See appropriate communication module manual.
GD DISABLED (FF53) AGPS power supply of parallel connected R8i inverter module has been switched off during run. X (1…12) refers to inverter module number. Check Prevention of Unexpected Start-up circuit.
Replace AGPS board of R8i inverter module.
ID RUN FAIL (FF84) Motor ID Run is not completed successfully. Check maximum speed (parameter 20.02). It should be at least 80% of motor nominal speed (parameter 99.08).
IN CHOKE TEMP (FF81)
3.17 FW 5 bit 5		 Excessive input choke temperature Stop drive. Let it cool down. Check ambient temperature.
Check that fan rotates in correct direction and air flows freely.
INT CONFIG (5410)
03.17 FW 5 bit 10		 Number of inverter modules is not equal to original number of inverters. Check status of inverters. See signal 04.01 FAULTED INT INFO.
Check fibre optic cables between APBU and inverter modules.
If Reduced Run function is used, remove faulted inverter module from main circuit and write number of remaining inverter modules into parameter 95.03 INT CONFIG USER. Reset drive.
INV DISABLED
03.17 FW 5 bit 7
(3200)		 Optional DC switch has opened while unit was running or start command was given. Close DC switch.
Check AFSC-0x Fuse Switch Controller unit.
INV OVERTEMP (4290)
3.17 FW 5 bit 13		 Converter module temperature is excessive. Check ambient temperature. If it exceeds 40°C, ensure that load current does not exceed derated load capacity of drive. See appropriate hardware manual.
Check that ambient temperature setting is correct (parameter 95.10).
Check converter module cooling air flow and fan operation.
Cabinet installation: Check cabinet air inlet filters. Change when necessary. See appropriate hardware manual.
Modules installed in cabinet by user: Check that cooling air circulation in cabinet has been prevented with air baffles. See module installation instructions.
Check inside of cabinet and heatsink of converter module for dust pick-up. Clean when necessary.
Reset and restart after problem is solved and let converter module cool down.
FAULT CAUSE WHAT TO DO
I/O COMM ERR (7000)
3.06 FW 2 bit 6		 Communication error on control board, channel CH1
Electromagnetic interference		 Check connections of fibre optic cables on channel CH1.
Check all I/O modules (if present) connected to channel CH1.
Check for proper earthing of equipment. Check for highly emissive components nearby.
LINE CONV (FF51) Fault on line side converter Shift panel from motor side converter control board to line side converter control board.
See line side converter manual for fault description.
MOD BOARD T (FF88) Overtemperature in AINT board of inverter module. Check inverter fan.
Check ambient temperature.
MOD CHOKE T (FF89) Overtemperature in choke of liquid cooled R8i inverter module. Check inverter fan.
Check ambient temperature. Check liquid cooling system.
MOTOR PHASE (FF56)
3.06 FW 2 bit 15
(programmable Fault Function 30.16)		 One of motor phases is lost due to fault in motor, motor cable, thermal relay (if used) or internal fault. Check motor and motor cable. Check thermal relay (if used).
Check Fault Function parameters. Disable this protection.
MOTOR STALL (7121)
3.06 FW 2 bit 14
(programmable Fault Function 30.10…30.12)		 Motor is operating in stall region due to e.g. excessive load or insufficient motor power. Check motor load and drive ratings. Check Fault Function parameters.
MOTOR TEMP (4310)
3.05 FW 1 bit 6
(programmable Fault Function 30.04…30.09)		 Motor temperature is too high (or appears to be too high) due to excessive load, insufficient motor power, inadequate cooling or incorrect start-up data. Check motor ratings and load. Check start-up data.
Check Fault Function parameters.
MOTOR 1 TEMP
(4312)
3.15 FW 4 bit 1		 Measured motor temperature has exceeded fault limit set by parameter 35.03. Check value of fault limit.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
MOTOR 2 TEMP
(4313)
3.15 FW 4 bit 2		 Measured motor temperature has exceeded fault limit set by parameter 35.06. Check value of fault limit.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
NO MOT DATA (FF52)
3.06 FW 2 bit 1		 Motor data is not given or motor data does not match with inverter data. Check motor data parameters 99.04…99.09.
FAULT CAUSE WHAT TO DO
I/O COMM ERR (7000)
3.06 FW 2 bit 6		 Communication error on control board, channel CH1
Electromagnetic interference		 Check connections of fibre optic cables on channel CH1.
Check all I/O modules (if present) connected to channel CH1.
Check for proper earthing of equipment. Check for highly emissive components nearby.
LINE CONV (FF51) Fault on line side converter Shift panel from motor side converter control board to line side converter control board.
See line side converter manual for fault description.
MOD BOARD T (FF88) Overtemperature in AINT board of inverter module. Check inverter fan.
Check ambient temperature.
MOD CHOKE T (FF89) Overtemperature in choke of liquid cooled R8i inverter module. Check inverter fan.
Check ambient temperature. Check liquid cooling system.
MOTOR PHASE (FF56)
3.06 FW 2 bit 15
(programmable Fault Function 30.16)		 One of motor phases is lost due to fault in motor, motor cable, thermal relay (if used) or internal fault. Check motor and motor cable. Check thermal relay (if used).
Check Fault Function parameters. Disable this protection.
MOTOR STALL (7121)
3.06 FW 2 bit 14
(programmable Fault Function 30.10…30.12)		 Motor is operating in stall region due to e.g. excessive load or insufficient motor power. Check motor load and drive ratings. Check Fault Function parameters.
MOTOR TEMP (4310)
3.05 FW 1 bit 6
(programmable Fault Function 30.04…30.09)		 Motor temperature is too high (or appears to be too high) due to excessive load, insufficient motor power, inadequate cooling or incorrect start-up data. Check motor ratings and load. Check start-up data.
Check Fault Function parameters.
MOTOR 1 TEMP
(4312)
3.15 FW 4 bit 1		 Measured motor temperature has exceeded fault limit set by parameter 35.03. Check value of fault limit.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
MOTOR 2 TEMP
(4313)
3.15 FW 4 bit 2		 Measured motor temperature has exceeded fault limit set by parameter 35.06. Check value of fault limit.
Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling surfaces, etc.
NO MOT DATA (FF52)
3.06 FW 2 bit 1		 Motor data is not given or motor data does not match with inverter data. Check motor data parameters 99.04…99.09.
FAULT CAUSE WHAT TO DO
POWERF INV xx (3381)
3.17 FW 5 bit 9 and		 INT board powerfail in inverter unit of several parallel connected inverter modules. xx (1…12) refers to inverter module number. Check that INT board power cable is connected.
Check that POW board is working correctly.
4.01 Replace INT board.
PPCC LINK (5210)
3.06 FW 2 bit 11		 Fibre optic link to INT board is faulty. Check fibre optic cables or galvanic link. With frame sizes R2-R6 link is galvanic.
If RMIO is powered from external supply, ensure that supply is on. See parameter 16.09 CTRL BOARD SUPPLY.
Check signal 03.19. Contact ABB representative if any of faults in signal 3.19 are active.
PPCC LINK xx INT board fibre optic connection fault in inverter unit of several parallel connected inverter modules. xx refers to inverter module number. Check connection from inverter module Main Circuit Interface Board, INT to PPCC Branching Unit, PBU. (Inverter module 1 is connected to PBU INT1 etc.)
Check signal 03.19. Contact ABB representative if any of faults in signal 3.19 are active.
(5210)
3.06 FW 2 bit 11 and
4.01
PP OVERLOAD (5482)
3.17 FW 5 bit 6		 Excessive IGBT junction to case temperature. This fault protects IGBT(s) and it can be activated by short circuit at output of long motor cables. Check motor cables.
SC INV xx y Short circuit in inverter unit of several parallel Check motor and motor cable.
(2340)
3.05 FW 1 bit 0, 4.01		 connected inverter modules. xx (1…12) refers to inverter module number and y refers to
phase (U, V, W).		 Check power semiconductors (IGBTs) of inverter module.
and 4.02
SHORT CIRC Short-circuit in motor cable(s) or motor Check motor and motor cable.
(2340) Check there are no power factor correction
3.05 FW 1 bit 0 and capacitors or surge absorbers in motor cable.
4.02
Output bridge of converter unit is faulty. Contact ABB representative.
SLOT OVERLAP (FF8A) Two option modules have same connection interface selection. Check connection interface selections in group 98 OPTION MODULES.
START INHIBI (FF7A)
3.03 bit 8		 Safe torque off has been activated during motor run or motor start command has been given when Safe torque off is active.
Or: Optional start inhibit hardware logic is activated.		 Close Safe torque off switch. If switch is closed and fault is still active, check power supply at ASTO board input terminals. Replace ASTO board.
Or: Check start inhibit circuit (AGPS board).
SUPPLY PHASE (3130)
3.06 FW 2 bit 0		 Intermediate circuit DC voltage is oscillating due to missing supply voltage phase, blown fuse or rectifier bridge internal fault.
Trip occurs when DC voltage ripple is 13% of DC voltage.		 Check main supply fuses.
Check for main supply imbalance.
FAULT CAUSE WHAT TO DO
TEMP DIF xx y (4380)
3.17 FW 5 bit 8 and 4.01		 Excessive temperature difference between several parallel connected inverter modules. xx (1…12) refers to inverter module number and y refers to phase (U, V, W). Check cooling fan. Replace fan.
Check air filters.
Alarm is indicated when temperature difference is 15°C. Fault is indicated when temperature difference is 20°C
Excessive temperature can be caused e.g. by unequal current sharing between parallel connected inverters.
THERMAL MODE (FF50) Motor thermal protection mode is set to DTC for high-power motor. See parameter 30.05.
THERMISTOR (4311) Motor temperature is excessive. Motor thermal protection mode selection is TEMP SENSOR. Check motor ratings and load. Check start-up data.
3.05 FW 1 bit 5
(programmable Fault Function 30.04…30.05)		 Check thermistor connections to digital input DI6.
UNDERLOAD (FF6A) Motor load is too low due to e.g. release mechanism in driven equipment. Check for problem in driven equipment. Check Fault Function parameters.
3.05 FW 1 bit 8
(programmable Fault Function 30.13…30.15)
USER L CURVE (2312)
3.17 FW 5 bit 11		 Integrated motor current has exceeded load curve defined by parameter group 72 USER LOAD CURVE. Check parameter group 72 USER LOAD CURVE settings.
After motor cooling time specified by parameter 72.20 LOAD COOLING TIME has elapsed, fault can be reset.
USER MACRO (FFA1)
3.07 SFW bit 1		 No User Macro saved or file is defective. Create User Macro.

When encountering issues with your ACS800 inverter, it’s essential to follow proper troubleshooting procedures to address the problem effectively. Referencing the “ABB ACS800 troubleshooting manual” can provide invaluable guidance in diagnosing and resolving faults. Here are steps to handle ACS800 inverter faults:

  1. Identify the Fault Code: Upon encountering a fault, the ACS800 inverter typically displays a fault code on the panel display. Refer to the “ABB ACS800 troubleshooting manual” to interpret the specific fault code and understand its implications.
  2. Consult the Troubleshooting Manual: Once you’ve identified the fault code, consult the “ABB ACS800 troubleshooting manual” for detailed instructions on diagnosing and addressing the issue. The manual provides comprehensive troubleshooting procedures tailored to the ACS800 inverter’s specific components and functionalities.
  3. Follow Troubleshooting Steps: Follow the step-by-step troubleshooting steps outlined in the manual to systematically diagnose the fault. The manual offers insights into potential causes of the fault, along with recommended actions to resolve the issue promptly.
  4. Refer to Technical Support: In cases where troubleshooting efforts are unsuccessful or additional assistance is required, don’t hesitate to contact technical support. The “ABB ACS800 troubleshooting manual” serves as a valuable resource for technicians and support personnel, enabling them to provide informed assistance based on the specific fault encountered.
  5. Document and Learn: Throughout the troubleshooting process, document your observations, actions taken, and outcomes. This documentation can serve as a reference for future troubleshooting endeavors and contribute to continuous learning and improvement in managing ACS800 inverter faults.

By adhering to the guidance provided in the “ABB ACS800 troubleshooting manual” and following established troubleshooting procedures, you can effectively address faults encountered with your ACS800 inverter, minimizing downtime and ensuring optimal performance.

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In-depth Analysis of ABB VFD ACS355 Series Inverter: Features, Faults, and Alarm Codes

ABB VFD ACS355 Series Inverter: Technological Innovation and Feature Overview

ABB’s VFD ACS355 series of inverters, as a leading player in variable frequency drive technology, stands out for its superior performance, user-friendly interface, and high reliability, occupying a prominent position in numerous industrial applications. Below is an in-depth exploration of the core features of this series of inverters:

  1. Compact and Efficient Design Philosophy
    • Space Optimization: The compact design of the ACS355 series inverters significantly saves installation space, making them an ideal choice for environments with limited space.
    • High-Efficiency Performance: Despite their small size, the advanced control algorithms integrated within ensure efficient motor operation, suitable for a wide range of industrial applications.
  2. Intuitive and User-Friendly Interface
    • Smart Control Panel: Equipped with a high-brightness LED display and intuitive operation buttons, making parameter setting and monitoring simple and quick.
    • Customizable Interface: Users can customize the interface layout according to their actual needs, improving operational efficiency.
  3. Precise Motor Control Strategy
    • Vector Control: Supports high-precision vector control, enabling precise adjustment of motor speed and torque to meet performance requirements under various load conditions.
    • Adaptive Algorithm: The built-in adaptive algorithm automatically adjusts control parameters based on actual operating conditions, optimizing motor performance.
  4. Excellent Durability and Environmental Adaptability
    • Robust Enclosure Design: Made from high-strength materials, it effectively withstands dust, humidity, and temperature fluctuations in harsh industrial environments.
    • Wide Operating Temperature Range: A specially designed cooling system ensures stable operation of the inverter over a broad temperature range.
  5. Flexible Connectivity and Communication Options
    • Multiple Communication Interfaces: Built-in Ethernet, RS-485, and other communication interfaces facilitate seamless integration with PLCs, HMIs, and other devices.
    • Support for Open Protocols: Compatibility with Modbus, Profibus, and other open communication protocols enhances system interoperability and scalability.
  6. Comprehensive Protection Mechanisms
    • Multiple Protections: Integrated overcurrent, overvoltage, undervoltage, overheat, and other protection mechanisms ensure the safe operation of drives and motors.
    • Fault Early Warning: Real-time monitoring of key parameters provides early warning of potential faults, reducing downtime risks.

LED status description and alarm meaning

Where LED   off LED   lit and steady LED   blinking
On the front of
     the drive.
     If a control panel
     is attached to the
     drive, switch to
     remote control
     (otherwise a fault
     will be
     generated), and
     then remove the
     panel to be able
     to see the LEDs		 No power Green Power supply on
     the board OK		 Green Drive in an   alarm
     state
Red Drive in a   fault
     state. To reset
     the fault, press
     RESET from the
     control panel or
     switch off the
     drive power		 Red Drive in a   fault state.
     To reset the fault,
     switch off the drive
     power
At the top left
     corner of the
     assistant control panel		 Panel has no
     power or no
     drive
     connection.		 Green Drive in a   normal
     state		 Green Drive in an alarm
     state
Red Drive in a   fault
     state. To reset
     the fault, press
     RESET from the
     control panel or
     switch off the
     drive power		 Red 　





ABB Drives ACS355 Fault Codes List mamual,”Fault” means that the drive has experienced a serious malfunction, usually a hardware issue that needs to be removed for repair.

CODE FAULT CAUSE WHAT TO DO
1 OVERCURRENT (2310)
     0305 bit 0		 Output current has exceeded trip level. 　
Sudden load change or stall. Check motor load and mechanics.
Insufficient acceleration   time. Check acceleration time (2202 and 2205).   Check the possibility of using vector control.
Incorrect motor data. Check that motor data (Group 99) is equal to motor rating plate   values. If using vector control, perform ID run (9910).
Motor and/or drive is too   small for the application. Check sizing.
Damaged motor cables,   damaged motor or wrong motor connection (star/delta). Check motor, motor cable and connections (including phasing).
Internal fault of the drive.   Drive gives an overcurrent fault after start command even when the motor is   not connected (use scalar control in this trial). Replace the drive.
High frequency noise in STO   lines. Check the STO cabling and remove the noise sources nearby.
2 DC OVERVOLT (3210)
     0305 bit 1		 Excessive intermediate circuit DC voltage. DC overvoltage trip   limit is 420 V for 200 V drives
     and 840 V for 400 V drives.		 　
Supply voltage is too high   or noisy. Static or transient overvoltage in the input power supply. Check input voltage level and check power line for static or   transient overvoltage
If the drive is used in a   floating network, DC overvoltage fault may appear In a floating network, remove the EMC screw from the drive.
CODE FAULT CAUSE WHAT TO DO
If the overvoltage fault appears during deceleration, possible causes are:
• Overvoltage controller disabled.
• Deceleration time is too short.
• Faulty or undersized braking chopper.		 • Check that overvoltage controller is on (parameter 2005 OVERVOLT CTRL).
• Check deceleration time (2203,
2206).
• Check brake chopper and resistor (if used). DC overvoltage control must be deactivated when brake chopper and resistor is used (parameter 2005 OVERVOLT CTRL). Retrofit drive with brake chopper and brake resistor.
0003 DEV OVERTEMP (4210)
0305 bit 2		 Drive IGBT temperature is excessive. The fault trip limit depends on the drive type and size.
Ambient temperature is too high. Check ambient conditions. See also section Derating on page 378.
Airflow through the inverter is not free. Check air flow and free space above and below the drive (see section Free space around the drive on page 34).
Fan is not working properly Check fan operation.
Overloading of the drive. 50% overload is allowed for one minute in ten minutes. If higher switching frequency (parameter 2606) is used, follow the Derating rules on page 378.
0004 SHORT CIRC (2340)
0305 bit 3		 Short-circuit in motor cable(s) or motor.
Damaged motor or motor cable. Check motor and cable insulation. Check motor winding
Internal fault of the drive. Drive gives an overcurrent fault after start command even when the motor is not connected (use scalar control in this trial). Replace the drive.
High frequency noise in STO lines. Check the STO cabling and remove the noise sources nearby.
0006 DC UNDERVOLT (3220)
0305 bit 5		 Intermediate circuit DC voltage is not sufficient. Check input power supply and fuses.
Undervoltage controller disabled. Check that undervoltage controller is on (parameter 2006 UNDERVOLT CTRL).
CODE FAULT CAUSE WHAT TO DO
Missing input power line phase. Measure the input and DC voltage during start, stop and running by using a multimeter or check parameter 0107 DC BUS VOLTAGE.
Blown fuse Check the condition of input fuses.
Rectifier bridge internal fault. Replace the drive.
0007 AI1 LOSS (8110)
0305 bit 6		 Analog input AI1 signal has fallen below limit defined by parameter
3021 AI1 FAULT LIMIT.
(programmable fault function 3001, 3021)
Analog input signal is weak or does not exist. Check the source and wire connections of the analog input.
Analog input signal is lower than fault limit. Check parameters 3001 AI<MIN FUNCTION and 3021 AI1 FAULT LIMIT.
0008 AI2 LOSS (8110)
0305 bit 7		 Analog input AI2 signal has fallen below limit defined by parameter
3022 AI2 FAULT LIMIT.		 .
(programmable fault function
3001, 3022)
Analog input signal is weak or does not exist. Check the source and wire connections of analog input.
Analog input signal is lower than fault limit. Check parameters 3001 AI<MIN FUNCTION and 3021 AI1 FAULT LIMIT.
CODE FAULT CAUSE WHAT TO DO
0009 MOT OVERTEMP (4310)
0305 bit 8
(programmable fault function 3005…3009 3504)		 Motor temperature estimation is too high.
Excessive load or insufficient motor power Check motor ratings, load and cooling.
Incorrect start-up data. Check start-up data.
Check fault function parameters
3005…3009.
Minimize IR compensation to avoid heating (parameter 2603 IR COMP VOLT).
Check frequency of the motor (low running frequency of motor with high input current can cause this fault).
Let the motor cool down. The necessary cooling time period depends on the value of parameter 3006 MOT THERM TIME. Motor
temperature estimation is counted down only when the drive is powered on.
Measured motor temperature has exceeded the fault limit set by parameter 3504 FAULT LIMIT. Check value of fault limit.
Check that actual number of sensors corresponds to value set by parameter 3501 SENSOR TYPE.
Let the motor cool down. Ensure proper motor cooling: Check the cooling fan, clean cooling surfaces, etc.
0010 PANEL LOSS (5300)
0305 bit 9
(programmable fault function 3002)		 Control panel selected as active control location for drive has ceased communicating. Check panel connection.
Check fault function parameters.
Check parameter 3002 PANEL COMM ERR.
Check control panel connector.
Refit control panel in mounting platform.
If the drive is in external control mode (REM) and is set to accept start/stop, direction commands or references through control panel:
Check group 10 START/STOP/DIR
and 11 REFERENCE SELECT
settings.
0011 ID RUN FAIL (FF84)
0305 bit 10		 Motor ID run is not completed successfully. Check motor connection.
Check start-up data (group 99 START- UP DATA).
Check maximum speed (parameter 2002). It should be at least 80% of motor nominal speed (parameter 9908).
Ensure ID run has been performed according to instructions in section ID run procedure on page 71.
CODE FAULT CAUSE WHAT TO DO
0012 MOTOR STALL (7121)
0305 bit 11
(programmable fault function 3010…3012)		 Motor is operating in stall region due to, eg, excessive load or insufficient motor power. Check motor load and drive ratings.
Check fault function parameters
3010…3012.
0014 EXT FAULT 1
(9000)
0305 bit 13
(programmable fault function 3003)		 External fault 1 Check external devices for faults.
Check parameter 3003 EXTERNAL FAULT 1 setting.
0015 EXT FAULT 2
(9001)
0305 bit 14
(programmable fault function 3004)		 External fault 2 Check external devices for faults.
Check parameter 3004 EXTERNAL FAULT 2 setting.
0016 EARTH FAULT (2330)
0305 bit 15
(programmable fault function 3017)		 Drive has detected earth (ground) fault in motor or motor cable. Check motor.
Check motor cable. Motor cable length must not exceed maximum specifications. See section Motor connection data on page 387.
Note: Disabling earth fault (ground fault) may damage drive.
Drive internal fault. Internal short-circuit may cause earth fault indication. This has happened if fault 0001 appears after disabling the earth fault. Replace the drive.
0017 UNDERLOAD (FF6A)
0306 bit 0
(programmable fault function 3013…3015)		 Motor load is too low due to, eg, release mechanism in driven equipment. Check for problem in driven equipment.
Check fault function parameters
3010…3012.
Check motor power against drive power.
0018 THERM FAIL (5210)
0306 bit 1		 Temperature of the drive exceeds the operating level of the thermistor. Check that the ambient temperature is not too low.
Drive internal fault. Thermistor used for drive internal temperature measurement is open or short-circuited Replace the drive.
0021 CURR MEAS (2211)
0306 bit 4		 Drive internal fault. Current measurement is out of range. Replace the drive.
CODE FAULT CAUSE WHAT TO DO
0022 SUPPLY PHASE (3130)
0306 bit 5
(programmable fault function 3016)		 Intermediate circuit DC voltage is oscillating due to missing input power line phase or blown fuse. Check input power line fuses and installation.
Check for input power supply imbalance.
Check the load.
Trip occurs when DC voltage ripple exceeds 14% of nominal DC voltage. Check fault function parameter 2619 DC STABILIZER.
0023 ENCODER ERR (7301)
0306 bit 6
(programmable fault function 5003)		 Communication fault between pulse encoder and pulse encoder interface module or between module and drive. Check pulse encoder and its wiring, pulse encoder interface module and its wiring and parameter group 50 ENCODER settings.
0024 OVERSPEED (7310)
0306 bit 7		 Motor is turning faster than 120% of the highest allowed speed due to incorrectly set minimum/maximum speed, insufficient braking torque or changes in load when using torque reference.
Operating range limits are set by parameters 2001 MINIMUM SPEED
and 2002 MAXIMUM
SPEED (in vector control) or 2007 MINIMUM FREQ and 2008 MAXIMUM FREQ
(in scalar control).		 Check minimum/maximum frequency settings (parameters 2001 MINIMUM SPEED and 2002 MAXIMUM SPEED).
Check adequacy of motor braking torque.
Check applicability of torque control.
Check need for brake chopper and resistor(s).
0027 CONFIG FILE (630F)
0306 bit 10		 Internal configuration file error Replace the drive.
0028 SERIAL 1 ERR
(7510)
0306 bit 11
(programmable fault function 3018, 3019)		 Fieldbus communication break Check status of fieldbus communication. See chapter Fieldbus control with embedded fieldbus on page 313, chapter Fieldbus control with fieldbus adapter on page 339 or appropriate fieldbus adapter manual.
Check fault function parameter 3018 COMM FAULT FUNC and 3019
COMM FAULT TIME settings.
Check connections and/or noise on the line.
Check if master can communicate.
0029 EFB CON FILE (6306)
0306 bit 12		 Configuration file reading error Error in reading the configuration files of the embedded fieldbus. See fieldbus user’s manual.
CODE FAULT CAUSE WHAT TO DO
0030 FORCE TRIP (FF90)
0306 bit 13		 Trip command received from fieldbus Fault trip was caused by fieldbus. See fieldbus user’s manual.
0034 MOTOR PHASE (FF56)
0306 bit 14		 Motor circuit fault due to missing motor phase or motor thermistor relay (used in motor temperature measurement) fault. Check motor and motor cable.
Check motor thermistor relay (if used).
0035 OUTP WIRING (FF95)
0306 bit 15
(programmable fault function 3023)		 Incorrect input power and motor cable connection (ie, input power cable is connected to drive motor connection). Possible power wiring error detected. Check that input power connections are not connected to drive output.
Fault can be declared if input power is delta grounded system and motor cable capacitance is large. This fault can be disabled by parameter 3023 WIRING FAULT.
0036 INCOMPATIBLE SW
(630F)
0307 bit 3		 Loaded software is not compatible. Loaded software is not compatible with the drive. Contact your local ABB representative.
0037 CB OVERTEMP (4110)
0305 bit 12		 Drive control board overheated. Fault given when measured temperature of the control board (indicated by signal 0150 CB TEMP) reaches 95 °C for an IP20 drive or 102 °C for an IP66 drive (ACS355-…+B063). Check for excessive ambient temperature.
Check for fan failure.
Check for obstructions in air flow.
Check the dimensioning and cooling of cabinet.
Parameter 3024 CB TEMP FAULT is set to enable with fault.
0044 SAFE TORQUE OFF
(FFA0)
0307 bit 4		 STO (Safe torque off) requested and it functions correctly.
Parameter 3025 STO OPERATION is set to react with fault.		 If this was not expected reaction to safety circuit interruption, check cabling of safety circuit connected to STO terminals X1C.
If different reaction is required, change value of parameter 3025 STO OPERATION.
Reset fault before starting.
0045 STO1 LOST (FFA1)
0307 bit 5		 STO (Safe torque off) input channel 1 has not de-energized, but channel 2 has. Opening contacts on channel 1 might have been damaged or there is a short-circuit. Check STO circuit cabling and opening of contacts in STO circuit.
CODE FAULT CAUSE WHAT TO DO
0046 STO2 LOST (FFA2)
0307 bit 6		 STO (Safe torque off) input channel 2 has not de-energized, but channel 1 has. Opening contacts on channel 2 might have been damaged or there is a short-circuit. Check STO circuit cabling and opening of contacts in STO circuit.
0101 SERF CORRUPT (FF55)
0307 bit 14		 Drive internal error. Replace the drive.
0103 SERF MACRO (FF55)
0307 bit 14
0201 DSP T1 OVERLOAD Drive internal error. If fieldbus is in use, check the
communication, settings and contacts.
(6100)
0307 bit 13		 Write down fault code and contact your local ABB representative.
0202 DSP T2 OVERLOAD
(6100)
0307 bit 13
0203 DSP T3 OVERLOAD
(6100)
0307 bit 13
0204 DSP STACK ERROR
(6100)
0307 bit 12
0206 CB ID ERROR (5000)
0307 bit 11		 Drive internal error. Replace the drive.
1000 PAR HZRPM (6320)
0307 bit 15		 Incorrect speed/frequency limit parameter setting Check parameter settings. Check that following applies:
• 2001 MINIMUM SPEED <
2002 MAXIMUM SPEED
• 2007 MINIMUM FREQ <
2008 MAXIMUM FREQ
• 2001 MINIMUM SPEED / 9908 MOTOR NOM SPEED, 2002 MAXIMUM SPEED / 9908 MOTOR NOM SPEED, 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ and
2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ are
within range.
CODE FAULT CAUSE WHAT TO DO
1003 PAR AI SCALE (6320)
0307 bit 15		 Incorrect analog input AI signal scaling Check parameter group 13 ANALOG INPUTS settings. Check that following applies:
• 1301 MINIMUM AI1 <
1302 MAXIMUM AI1
• 1304 MINIMUM AI2 <
1305 MAXIMUM AI2.
1004 PAR AO SCALE (6320)
0307 bit 15		 Incorrect analog output AO signal scaling Check parameter group 15 ANALOG OUTPUTS settings. Check that following applies:
• 1504 MINIMUM AO1 <
1505 MAXIMUM AO1.
1005 PAR PCU 2
(6320)
0307 bit 15		 Incorrect motor nominal power setting Check parameter 9909 MOTOR NOM POWER setting. Following must apply:
• 1.1 < (9906 MOTOR NOM CURR · 9905 MOTOR NOM VOLT · 1.73 / PN) < 3.0
Where PN = 1000 · 9909 MOTOR
NOM POWER (if units are in kW)
or PN = 746 · 9909 MOTOR NOM
POWER (if units are in hp).
1006 PAR EXT RO (6320)
0307 bit 15
(programmable fault function 3027)		 Incorrect relay output extension parameters Check parameter settings. Check that following applies:
• Output relay module MREL-01 is connected to drive. See parameter 0181 EXTENSION.
• 1402 RELAY OUTPUT 2, 1403 RELAY OUTPUT 3 and 1410 RELAY OUTPUT 4 have non-zero values.
See MREL-01 output relay module user’s manual (3AUA0000035974 [English]).
1007 PAR FBUSMISS (6320)
0307 bit 15		 Fieldbus control has not been activated. Check fieldbus parameter settings. See chapter Fieldbus control with fieldbus adapter on page 339.
1009 PAR PCU 1
(6320)
0307 bit 15		 Incorrect motor nominal speed/frequency setting Check parameter settings. Following must apply for induction motor:
• 1 < (60 · 9907 MOTOR NOM FREQ
/ 9908 MOTOR NOM SPEED) < 16
• 0.8 < 9908 MOTOR NOM SPEED / (60 · 9907 MOTOR NOM FREQ / 9913 MOTOR POLE PAIRS) < 0.992
Following must apply for permanent magnet synchronous motor:
• 9908 MOTOR NOM SPEED (60 · 9907 MOTOR NOM FREQ 9913 MOTOR POLE PAIRS) = 1.0
CODE FAULT CAUSE WHAT TO DO
1015 PAR USER U/F (6320)
0307 bit 15		 Incorrect voltage to frequency (U/f) ratio voltage setting. Check parameter 2610 USER DEFINED U1 … 2617 USER
DEFINED F4 settings.
1017 PAR SETUP 1
(6320)
0307 bit 15		 Only two of the following can be used simultaneously: MTAC- 01 pulse encoder interface module, frequency input signal or frequency output signal. Disable frequency output, frequency input or encoder:
• change transistor output to digital mode (value of parameter 1804 TO MODE = 0 [DIGITAL]), or
• change frequency input selection to other value in parameter groups
11 REFERENCE SELECT,
40 PROCESS PID SET 1,
41 PROCESS PID SET 2 and
42 EXT / TRIM PID, or
• disable (parameter 5002
ENCODER ENABLE) and remove MTAC-01 pulse encoder interface module.

ABB Drives ACS355 Alarm Codes List mamual,The “alarm” message means that the drive only has a fault prompt. Generally, the normal state of the drive can be restored by resetting or powering off before powering on. However, users need to check why such warnings occur to avoid greater damage

CODE ALARM CAUSE WHAT TO DO
2001 OVERCURRENT
0308 bit 0
(programmable fault function 1610)		 Output current limit controller is active.
High ambient temperature.		 Check ambient conditions. Load capacity decreases if installation site ambient temperature exceeds 40 °C (104 °F). See section Derating on page 378.
For more information, see fault 0001 in Fault messages generated by the drive on page 359.
2002 OVERVOLTAGE
0308 bit 1
(programmable fault function 1610)		 DC overvoltage controller is active. For more information, see fault 0002 in Fault messages generated by the drive on page 359.
2003 UNDERVOLTAGE
0308 bit 2		 DC undervoltage controller is active. For more information, see fault 0006 in Fault messages generated by the drive on page 359.
2004 DIR LOCK
0308 bit 3		 Change of direction is not allowed. Check parameter 1003 DIRECTION
settings.
2005 IO COMM
0308 bit 4
(programmable fault function 3018, 3019)		 Fieldbus communication break Check status of fieldbus communication. See chapter Fieldbus control with embedded fieldbus on page 313, chapter Fieldbus control with fieldbus adapter on page 339 or appropriate fieldbus adapter manual.
Check fault function parameter settings.
Check connections.
Check if master can communicate.
2006 AI1 LOSS
0308 bit 5
(programmable fault function 3001, 3021)		 Analog input AI1 signal has fallen below limit defined by parameter 3021 AI1 FAULT LIMIT. For more information, see fault 0007 in Fault messages generated by the drive on page 359.
2007 AI2 LOSS
0308 bit 6
(programmable fault function 3001, 3022)		 Analog input AI2 signal has fallen below limit defined by parameter 3022 AI2 FAULT LIMIT. For more information, see fault in 0008 Fault messages generated by the drive on page 359.
2008 PANEL LOSS
0308 bit 7
(programmable fault function 3002)		 Control panel selected as active control location for drive has ceased communicating. For more information, see fault 0010 in Fault messages generated by the drive on page 359.
2009 DEVICE OVERTEMP
0308 bit 8		 Drive IGBT temperature is excessive. Alarm limit depends on the drive type and size. Check ambient conditions. See also section Derating on page 378.
Check air flow and fan operation.
Check motor power against drive power.
CODE ALARM CAUSE WHAT TO DO
2010 MOTOR TEMP
0308 bit 9
(programmable fault function 3005…3009 / 3503)		 Motor temperature is too high (or appears to be too high) due to excessive load, insufficient motor power, inadequate cooling or incorrect start-up data. For more information, see fault 0009 in Fault messages generated by the drive on page 359.
Measured motor temperature has exceeded alarm limit set by parameter 3503 ALARM LIMIT.
2011 UNDERLOAD
0308 bit 10
(programmable fault function 3013…3015)		 Motor load is too low due to, eg, release mechanism in driven equipment. Check for problem in driven equipment.
Check fault function parameters.
Check motor power against drive power.
2012 MOTOR STALL
0308 bit 11
(programmable fault function 3010…3012)		 Motor is operating in stall region due to, eg, excessive load or insufficient motor power. Check motor load and drive ratings. Check fault function parameters.
2013
1)		 AUTORESET
0308 bit 12		 Automatic reset alarm Check parameter group 31 AUTOMATIC RESET settings.
2018
1)		 PID SLEEP
0309 bit 1
(programmable fault function 1610)		 Sleep function has entered sleeping mode. See parameter groups 40 PROCESS PID SET 1… 41 PROCESS PID SET 2.
2019 ID RUN
0309 bit 2		 Motor Identification run is on. This alarm belongs to normal start-up procedure. Wait until drive indicates that motor identification is completed.
2021 START ENABLE 1 MISSING
0309 bit 4		 No Start enable 1 signal received Check parameter 1608 START ENABLE 1 settings.
Check digital input connections.
Check fieldbus communication settings.
2022 START ENABLE 2 MISSING
0309 bit 5		 No Start enable 2 signal received Check parameter 1609 START ENABLE 2 settings.
Check digital input connections.
Check fieldbus communication settings.
2023 EMERGENCY STOP
0309 bit 6		 Drive has received emergency stop command and ramps to stop according to ramp time defined by parameter 2208 EMERG DEC TIME. Check that it is safe to continue operation.
Return emergency stop push button to normal position.
CODE ALARM CAUSE WHAT TO DO
2024 ENCODER ERROR
0309 bit 7
(programmable fault function 5003)		 Communication fault between pulse encoder and pulse encoder interface module or between module and drive. Check pulse encoder and its wiring, pulse encoder interface module and its wiring and parameter group 50 ENCODER settings.
2025 FIRST START
0309 bit 8		 Motor identification magnetization is on. This alarm belongs to normal start-up procedure. Wait until drive indicates that motor identification is completed.
2026 INPUT PHASE LOSS
0309 bit 9
(programmable fault function 3016)		 Intermediate circuit DC voltage is oscillating due to missing input power line phase or blown fuse.
Alarm is generated when DC voltage ripple exceeds 14% of nominal DC voltage.		 Check input power line fuses.
Check for input power supply imbalance.
Check fault function parameters.
2029 MOTOR BACK EMF
0309 bit 12		 Permanent magnet synchronous motor is rotating, start mode 2 (DC MAGN) is
selected with parameter 2101 START FUNCTION,
and run is requested. Drive warns that rotating motor cannot be magnetized with DC current.		 If start to rotating motor is required, select start mode 1 (AUTO) with parameter 2101 START FUNCTION. Otherwise drive starts after motor has stopped.
2035 SAFE TORQUE OFF
0309 bit 13		 STO (Safe torque off) requested and it functions correctly.
Parameter 3025 STO OPERATION is set to react with alarm.		 If this was not expected reaction to safety circuit interruption, check cabling of safety circuit connected to STO terminals X1C.
If different reaction is required, change value of parameter 3025 STO OPERATION.
Note: Start signal must be reset (toggled to 0) if STO has been used while drive has been running.
1) Even when the relay output is configured to indicate alarm conditions (eg, parameter 1401
RELAY OUTPUT 1 = 5 (ALARM) or 16 (FLT/ALARM)), this alarm is not indicated by a relay output.

The basic control panel indicates control panel alarms with a code, A5xxx.It usually means that there is a problem with the motherboard or control panel,It usually means that there is a problem with the motherboard or control panel.

ALARM CODE CAUSE WHAT TO DO
5001 Drive is not responding. Check panel connection.
5002 Incompatible communication profile Contact your local ABB representative.
5010 Corrupted panel parameter backup file Retry parameter upload. Retry parameter download.
5011 Drive is controlled from another source. Change drive control to local control mode.
5012 Direction of rotation is locked. Enable change of direction. See parameter
1003 DIRECTION.
5013 Panel control is disabled because start inhibit is active. Start from panel is not possible. Reset emergency stop command or remove 3-wire stop command before starting from panel.
See section 3-wire macro on page 111 and parameters 1001 EXT1 COMMANDS, 1002 EXT2 COMMANDS and 2109 EMERG STOP SEL.
5014 Panel control is disabled because of drive fault. Reset drive fault and retry.
5015 Panel control is disabled because local control mode lock is active. Deactivate local control mode lock and retry. See parameter 1606 LOCAL LOCK.
5018 Parameter default value is not found. Contact your local ABB representative.
5019 Writing non-zero parameter value is prohibited. Only parameter reset is allowed.
5020 Parameter or parameter group does not exist or parameter value is inconsistent. Contact your local ABB representative.
5021 Parameter or parameter group is hidden. Contact your local ABB representative.
5022 Parameter is write protected. Parameter value is read-only and cannot be changed.
5023 Parameter change is not allowed when drive is running. Stop drive and change parameter value.
5024 Drive is executing a task. Wait until task is completed.
5025 Software is being uploaded or downloaded. Wait until upload/download is complete.
5026 Value is at or below minimum limit. Contact your local ABB representative.
5027 Value is at or above maximum limit. Contact your local ABB representative.
5028 Invalid value Contact your local ABB representative.
ALARM CODE CAUSE WHAT TO DO
5029 Memory is not ready. Retry.
5030 Invalid request Contact your local ABB representative.
5031 Drive is not ready for operation, eg, due to low DC voltage. Check input power supply.
5032 Parameter error Contact your local ABB representative.
5040 Parameter download error. Selected parameter set is not in current parameter backup file. Perform upload function before download.
5041 Parameter backup file does not fit into memory. Contact your local ABB representative.
5042 Parameter download error. Selected parameter set is not in current parameter backup file. Perform upload function before download.
5043 No start inhibit
5044 Parameter backup file restoring error Check that file is compatible with drive.
5050 Parameter upload aborted Retry parameter upload.
5051 File error Contact your local ABB representative.
5052 Parameter upload has failed. Retry parameter upload.
5060 Parameter download aborted Retry parameter download.
5062 Parameter download has failed. Retry parameter download.
5070 Panel backup memory write error Contact your local ABB representative.
5071 Panel backup memory read error Contact your local ABB representative.
5080 Operation is not allowed because drive is not in local control mode. Switch to local control mode.
5081 Operation is not allowed because of active fault. Check cause of fault and reset fault.
5083 Operation is not allowed because parameter lock is on. Check parameter 1602 PARAMETER LOCK
setting.
5084 Operation is not allowed because drive is performing a task. Wait until task is completed and retry.
5085 Parameter download from source to destination drive has failed. Check that source and destination drive types are same, ie, ACS355. See type designation label of the drive.
5086 Parameter download from source to destination drive has failed. Check that source and destination drive type designations are the same. See type designation labels of the drives.
ALARM CODE CAUSE WHAT TO DO
5087 Parameter download from source to destination drive has failed because parameter sets are incompatible. Check that source and destination drive information are same. See parameters in group 33 INFORMATION.
5088 Operation has failed because of drive memory error. Contact your local ABB representative.
5089 Download has failed because of CRC error. Contact your local ABB representative.
5090 Download has failed because of data processing error. Contact your local ABB representative.
5091 Operation has failed because of parameter error. Contact your local ABB representative.
5092 Parameter download from source to destination drive has failed because parameter sets are incompatible. Check that source and destination drive information are same. See parameters in group 33 INFORMATION.
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The characteristics, usage methods, parameter settings, and wiring of ABB drive ACS510 constant pressure water supply control

The control characteristics of ABB VFD ACS510 for water supply are as follows:

  1. High control precision and good stability: It provides powerful support for the automatic control of constant pressure water supply systems by achieving precise speed regulation, reduced starting current, power saving, high reliability, and jitter control.
  2. Simple design and easy operation: It adopts a visual interface design and an easy-to-operate keyboard controller. Through the intuitive operating interface, users can easily understand the working status of the VFD and more easily guide and maintain it.
  3. High reliability and strong safety: It has multiple protection functions such as overcurrent, overvoltage, and short circuit, and reduces mechanical vibration and noise of the motor, thereby reducing the maintenance cost of the motor and the safety risks for users.
  4. Perfect matching with fans and pumps: The enhanced PFC application can control up to 7 (1+6) water pumps and switch more pumps. The SPFC cyclic soft start function can adjust each pump sequentially, with a maximum of 6 water pumps, without the need for an additional PLC.
  5. Improving the safety of the system: The constant pressure frequency conversion water supply using ABB ACS510 improves the safety of equipment operation. The water supply system, with PLCs and VFDs, has stable and efficient intelligent integrated circuits with automatic detection, leakage protection, phase failure protection, and automatic alarm functions.
  6. Improving the performance of water supply systems: In the centrifugal pump parallel operation mode of water supply, if one of the centrifugal pumps fails, the thermal relay controlling this centrifugal pump can be set to failure. At this time, the corresponding frequency control cabinet will display that this centrifugal pump has failed, the fault light will turn on, and when the frequency conversion water supply system is running, it will skip the operation of the centrifugal pump and motor with the failure, improving the performance of water supply systems.

In summary, ABB VFD ACS510 has characteristics such as high precision, good stability, simple design, high reliability, strong safety, etc., improving the performance and safety of water supply systems.

One-to-one PID configuration:

ABB VFD one-to-one wiring
The one-to-one PID configuration is typically used to control a target variable, such as temperature, pressure, or flow rate, and regulate the output of the VFD using an input signal. For the one-to-one wiring of the ABB VFD, the following steps can be followed:

Determine the required input and output signals: A control signal input (such as analog input AI or digital input DI) is typically required to receive the control signal, and an output signal (such as analog output AO or digital output DO) is used to control the output frequency of the VFD.

Connect the input signal: Attach the control signal wire to the corresponding input terminals on the VFD. If using analog input, ensure that the resistance and potentiometer on the signal wire are set correctly. If using digital input, connect the signal wire to the corresponding DI terminals.

Connect the output signal: Attach the output frequency wire from the VFD to the corresponding output terminals. If using analog output, ensure that the resistance and potentiometer on the signal wire are set correctly. If using digital output, connect the signal wire to the corresponding DO terminals.

Set the VFD parameters: Configure the VFD parameters according to the control requirements. This includes setting the target frequency, maximum and minimum frequencies, acceleration time, and deceleration time, among others.

Debug and test: After completing the wiring and parameter settings, perform testing to ensure that the system is functioning properly. Check that the input signal is correctly controlling the output of the VFD and that the system is stable and operating under various conditions.

Actual wiring instructions for a one-to-one scenario

  1. 1.For voltage output instruments, such as a remote pressure gauge (range 0-10V), connect the three wires to terminals 4, 5, and 6 according to the labeling (internal resistance requirements: 1KΩ-10KΩ). Simultaneously, move the AI2 DIP switch in jumper J1 on the terminal block to the left (as shown in the diagram above). This signal represents the actual pressure feedback value.
    If it’s a current output pressure sensor, connect the two wires to terminals 5 and 6. Simultaneously, move the AI2 DIP switch in jumper J1 on the terminal block to the right (as shown in the diagram above).
  2. 2.Short-circuit terminals 11 and 12.
  3. 3.Connecting terminals 10 and 13 provides the start signal.

Parameter Settings:

99.02 6 = PID Control Macro
This parameter sets the control macro to PID, which means the device will use Proportional-Integral-Derivative control for precise regulation.

10.02 1 = DI1 Controls Start/Stop
This setting determines that Digital Input 1 (DI1) will be used to control the starting and stopping of the process or device.

11.02 7 = External 2
This parameter is likely referring to an external control source or input selection. “External 2” could be a specific configuration for an external signal or device.

13.04 20% (When the actual signal is 4-20mA or 2-10V)
This setting configures the input signal scaling. It indicates that when the incoming signal is within the range of 4-20mA or 2-10V, it will be interpreted as 20% of the full scale value.

16.01 0 – No start permissive signal required
This parameter indicates that no external permissive signal is needed to start the device or process. It’s set to 0, which means the start permissive signal is not required.

40.10 19 (Internal setpoint)
This parameter sets the internal setpoint to 19. The exact meaning of this value depends on the context and scaling of the system, but it typically represents a target value for the controlled variable.

40.11 Set pressure value (Percentage of the pressure gauge range, e.g., if the target is 8 kg and the range is 16 kg, set it to 50%)
This parameter is used to set the desired pressure as a percentage of the pressure gauge’s total range. In the example given, the target pressure is 8 kg out of a possible 16 kg range, so it’s set to 50%.

ABB Drives ACS510 One-to-Three Wiring

1.The feedback signal from the pressure sensor is of the current type. To align with this, configure J1 for current input by dialing the code to the right.

2.Establish a short circuit between pins 11 and 12.

3.Connecting pins 10 and 13 initiates the start signal.

4.For the interlocked startup of three pumps, establish connections between pin 10 and pins 16, 17, and 18 respectively.

5.Each of the three pumps should be wired to a separate relay, ensuring individual control.

VFD Parameter Settings

Parameter Set Value

99.02 6 = PID Control Macro

10.02 1 = DI1 Controls Start/Stop

11.02 7 = External 2

13.04 20% (When the actual signal is 4-20mA or 2-10V)

14.01 31 = PFC Control

14.02 31 = PFC Control

14.03 31 = PFC Control

16.01 0 – No start permissive signal required

40.10 19 (Internal setpoint)

40.11 Set pressure value (Percentage of the pressure gauge range, e.g., if the target is 8 kg and the range is 16 kg, set it to 50%)

81.17 2 = Number of auxiliary units

81.27 3 = Number of auxiliary units

Note: There seems to be a redundancy in the parameters 14.01, 14.02, and 14.03, all set to “PFC Control” and parameters 81.17 and 81.27 both referring to “Number of auxiliary units”. Please check if these are indeed distinct parameters or if some correction is needed. Additionally, ensure that the parameter names and values align with the specific model and manual of the frequency converter being used.