Category: Industrial control technology

Debugging, application, and maintenance techniques for industrial control products，Such as Variable speed driver(VSD),Variable frequency driver(VFD),Industrial touch screen,Programmable Logic Controller(PLC),Servo Driver,servo motor,servo amplifier,Servo Controller,etc.

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The characteristics of ACS355 inverter,abb acs355 fault codes list,acs355 manual fault

Introduction to the Features of ABB VFD ACS355 Series

The ABB VFD ACS355 series represents a significant advancement in variable frequency drive technology, offering a range of features that are tailored for optimal performance and ease of use. Here are some key characteristics of this series:

  1. Compact and Efficient Design: The ACS355 series is designed for space-saving installation, making it ideal for applications where space is at a premium. Despite its compact size, it packs a punch in terms of performance, delivering efficient motor control for a wide range of industrial applications.
  2. User-Friendly Interface: The series boasts an intuitive control panel with a clear display, allowing for easy navigation and setup. This user-friendly interface reduces the learning curve for operators, enhancing productivity and minimizing downtime.
  3. Advanced Motor Control: The ACS355 series incorporates advanced motor control algorithms that ensure precise speed and torque control. This ensures optimal performance of the connected motor, resulting in improved process efficiency and reduced energy consumption.
  4. Robust and Reliable: Designed for harsh industrial environments, the ACS355 series features a robust construction that can withstand dust, moisture, and temperature fluctuations. This ensures reliable operation and extended service life, even in demanding conditions.
  5. Flexible Connectivity: The series offers a range of connectivity options, including built-in Ethernet and fieldbus interfaces, enabling easy integration into existing automation systems. This flexibility simplifies system design and reduces installation costs.
  6. Comprehensive Protection Features: The ACS355 series incorporates a range of protective features, such as overcurrent, overvoltage, and thermal protection, to safeguard the drive and connected motor against potential damage. This enhances system reliability and reduces maintenance requirements.

In summary, the ABB VFD ACS355 series offers a compelling combination of compact design, user-friendliness, advanced motor control, robustness, flexible connectivity, and comprehensive protection features. These characteristics make it an ideal choice for a wide range of industrial applications where reliable and efficient motor control is essential.

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.

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ABB DRIVE ACS510 Constant Pressure Water Supply Control One to Two Scheme, Wiring and Parameter Settings

Take advantage of ABB’s ACS510 VSD for seamless multi-pump pressure control. With its advanced PFC application macro, you can effortlessly manage up to 7 pumps while ensuring consistent pressure regulation. This powerful feature eliminates the need for a separate constant pressure water supply controller, simplifying your system design. By implementing the SPFC macro, you can enjoy the added benefit of reducing stress on your pumps and power grid through gentle soft-start sequences. Consider SPFC as an enhanced version of PFC, providing superior control and reliability for your critical applications.

According to your description, DL6 is used for start commands, DL1 and DL2 for PFC control. SA1, SA2, and SA3 are three-position switches, with the middle position as stop. When manually operating at rated frequency, the switch is set to the right, and when the automatic allow signal is present, the switch is set to the left. The connections at 19, 21 and 22, 24 are connected to the relay terminals below the VFD, corresponding to the normally open contacts of RO1 (Relay 1) and RO2 (Relay 2).

The difference between PFC and SPFC:

In automatic mode with PFC: When SA2 and SA3 are set to the automatic position and the power is turned on, relay 1 on the inverter engages, which causes KM1 to engage and the motor M1 to start operating at variable frequency. If the frequency reaches the start-up frequency +1, the auxiliary motor is engaged, and relay 2 on the inverter engages, causing KM3 to engage and motor M2 to start operating at rated frequency. With PFC in automatic mode, it is possible to switch pumps at regular intervals.

In automatic mode with SPFC: When SA1 and SA2 are set to the automatic position and the power is turned on, relay 1 on the inverter engages, which causes KM1 to engage and the motor M1 to start operating at variable frequency. When the frequency reaches the start-up frequency +1, relay 1 is first disengaged and then relay 2 is engaged, causing KM4 to engage and motor M2 to start operating at variable frequency. Simultaneously, relay 1 re-engages to cause KM2 to engage and motor M1 to operate at rated frequency. With SPFC in automatic mode, it is not possible to switch pumps at regular intervals.

CODE NAME SET VALUE NOTES
9902 APPLIC MACRO 15=SPFC control
1002 EXT2 COMMANDS 6=DI6 VSD startup command
1102 EXT1/EXT2 SEL 7=EXT2
1106 REF2 SELECT 19=PID1OUT After SPFC takes effect, 1106 defaults to 19 and does not require adjustment
1401 RELAY OUTPUT 1 31=PFC control
1402 RELAY OUTPUT 2 31=PFC control
1403 RELAY OUTPUT 3 4=FAULT
1601 RUN ENABLE 6=DI6
2008 MAXIMUM FREQ 50HZ
2202 ACCELER TIME 1 15S Set according to actual situation
2203 DECELER TIME 1 15S Set according to actual situation
3104 AR OVERCURRENT 1=ENABLE
4001 GAIN（PID) 1.5-2
4002 INTEGRATION TIME（PID) 2.5
4009 100% VALUE ” Defines (together with 4008) the scaling Set according to actual situation
applied to the PID controller’s actual values”
4010 SET POINT SEL 0=keypad – Control panel provides reference.
4016 ACT1 INPUT 1=AI1 is ACT1(Remote transmission meter）；2=AI2 is ACT1(Pressure sensor）
4022 SLEEP SELECTION 7=INTERNAL
4023 PID SLEEP LEVEL 38HZ Set according to actual situation
4024 PID SLEEP DELAY 30S
4025 WAKE-UP DEV 2.5
8118 AUTOCHNG INTERV 1h
8119 AUTOCHNG LEVEL 85%
8120 INTERLOCKS 1=DI1 Enables the Interlock function
8123 PFC ENABLE 1 = ACTIVE – Enables PFC control
8127 MOTORS 2 After SPFC takes effect, it defaults to 2, and there is no need to adjust the two pumps

The parameters mentioned in this article use SPFC macros, and PFC is also similar, except that the macro parameter is 7.VSDs such as ACS550 and ACS355 should also be able to achieve constant pressure water supply frequency converter control through similar operations. Please refer to their technical manuals for details, or contact us for guidance

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Debugging of ABB VFD for ACS800 Enhancement

A. Motor Auto-tuning (Quick Debugging Steps)

  1. Power On: Ensure the system is powered on.
  2. Input Initialization:
    • Press PAR to select the language. Set 99.1 to ENGLISH.
    • Choose the application macro. Set 99.2 to CRANE.
    • Determine if parameters should be reset to factory defaults. Set 99.3 to YES or NO.
    • Select the motor control mode in 99.4: DTC (Direct Torque Control) or SCALAR.
    • Enter the rated voltage in 99.5 V.
    • Input the rated current in 99.6 A.
    • Specify the rated frequency in 99.7 HZ.
    • Set the motor’s rated speed in 99.8 RPM.
    • Define the motor’s rated power in 99.9 KW.
  3. Motor Identification Run:
    • Proceed to motor identification by selecting 99.10.
    • Generally, choose ID MAGN (the motor won’t rotate).
    • For STANDARD mode (motor rotates), the motor must be disconnected from the equipment.
    • In REDUCED identification mode (motor rotates), the motor remains connected.
    • After selecting the identification mode, a “WARNING” signal may appear.
    • Press the start button to begin motor identification. This process can be stopped at any time using the stop button.
    • Once the motor identification is complete, press RESET to enter actual signal display mode.
  4. Motor Direction Check: Verify the motor’s rotation direction using the control panel.
  5. Input Speed Limits and Acceleration/Deceleration Times: Enter the necessary parameters.

B. Parameter Configuration – Optimized for Google SEO

  1. Set parameter 10.1 to DI1 for brake acknowledgment digital input.
  2. Leave parameter 10.2 as NOT SEL for zero-position digital input.
  3. Parameter 10.3 remains NOT SEL for deceleration digital input.
  4. Parameter 10.4 is NOT SEL for rapid stop digital input.
  5. Parameter 10.5 is NOT SEL for power-on acknowledgment digital input.
  6. Keep parameter 10.6 as NOT SEL for synchronization request digital input.
  7. Set parameter 10.7 to EXT DI1.1 for chopper fault digital input.
  8. Configure parameter 10.8 to DI2 for the second speed level digital input.
  9. Set parameter 10.9 to DI5 for the third speed level digital input.
  10. Parameter 10.10 is set to DI6 for the fourth speed level digital input.
  11. Parameters 10.11 to 10.15 and 10.17, 10.18 remain NOT SEL.
  12. Set parameter 10.16 to DI-1L for fault reset digital input.
  13. Parameter group 13 deals with analog input signals. No need for modification.
  14. Set parameter 14.1 to BRAKE LIFT for relay output 1.
  15. Configure parameter 14.2 to WATCHDOG-N for relay output 2.
  16. Parameter 14.3 is set for relay output 3 to indicate a FAULT-N signal. When a fault occurs, the relay releases, and during power-on, the fault relay engages.
  17. Parameter group 15 covers analog output signals. No modifications required.
  18. Parameter group 16 deals with password settings. No need to change.
  19. Parameter group 20 defines limit values:
    • Parameter 20.1: Minimum speed for the operating range.
    • Parameter 20.2: Maximum speed for the operating range.
    • Parameter 20.3: Maximum output current.
    • Parameter 20.4: Maximum positive output torque.
    • Parameter 20.5: Maximum negative output torque.
    • Parameter 20.6: DC overvoltage controller.
    • Parameter 20.7: DC undervoltage controller.
    • Parameter 20.8: Minimum frequency for the operating range.
    • Parameter 20.9: Maximum frequency for the operating range.
    • Parameters 20.10 to 20.13 relate to analog inputs but are not detailed here.
  20. Parameter 21.1 is not to be changed.
  21. Set parameter 21.2 for the field excitation time, approximately 4 times the motor’s rated KW (in milliseconds).
  22. Parameter group 23 covers speed control gains, integral and derivative times, motor slip, etc. Generally left unchanged.
  23. Parameter group 24 deals with torque build-up time. Typically not modified.
  24. Parameter group 26 allows compensation voltage setting for the motor (only in SCALAR mode).
  25. Parameter group 27 configures the braking chopper:
    • Set parameter 27.1 to ON for brake chopper control.
    • Parameter 27.2 is set to FAULT to activate overload protection for the braking resistor.
    • Enter the actual value for the braking resistor in parameter 27.3.
    • Set the time constant for the braking resistor in parameter 27.4 to 300S.
    • Define the maximum continuous braking power for the resistor in parameter 27.5.
    • Set the control mode for the brake chopper control to AS GENERATOR in parameter 27.6.
  26. Parameter group 28 deals with motor modeling. Typically not modified.
  27. Parameter group 30 covers fault functions. Generally left unchanged.
  28. Parameter group 50 configures encoder values:
    • Set the number of encoder pulses in parameter 50.1.
    • Define the calculation method for encoder pulses in parameter 50.2.
    • Parameter 50.3 is set to FAULT for encoder fault action.
    • Set the encoder monitoring delay time in parameter 50.4 (avoid setting to 0).
    • Parameter 50.5 determines the encoder feedback usage, typically set to TRUE.
  29. Parameter group 60 handles the switch between local and external operation.
  30. Parameter groups 61 and 62 deal with speed monitoring. Generally not modified.
  31. Parameter group 63 covers torque monitoring. Typically left unchanged.
  32. Parameter group 64 is for crane mode:
    • Set parameter 64.1 to TRUE for STAND ALONE mode.
    • Parameter 64.10 is configured to STEPJOYST or STEPRADIO.
    • Parameters 64.13 to 64.16 define the speeds for the four speed levels (as a percentage of rated speed).
  33. Parameter group 65 deals with motor field current settings. Generally not modified.
  34. Parameter group 66 covers torque verification, typically left unchanged.
  35. Parameter group 67 configures brake control:
    • Set the brake application time to 0.5S in parameter 67.1.
    • Define the brake fault delay as 0.5S in parameter 67.2.
    • Parameters 67.3 to 67.10 are not detailed but can be set as needed.
  36. Parameter group 68 is for power optimization, typically not modified.
  37. Parameter group 69 defines the maximum speed and acceleration/deceleration times.
  38. Parameter group 98 activates optional modules.
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ACS800 Variable Speed Drive (VSD) Debugging Steps

I. Basic Local Control Process for ACS800 VSD

Ensure that the air switch is closed and the contactor is energized.
Press the LOC/REM key to switch to local control mode.
Press the FAR key to enter the parameter setting interface. Use the double arrow keys to navigate to the 99 parameter group, then use the single arrow keys to select item 04. Press ENTER to confirm. Here, you can choose between DTC mode (suitable for most cases) or SCALA mode. After selecting, press ENTER to save or ACT to exit.
Press the ACT key to return to the main operation interface.
Press the REF key, use the up/down arrow keys to input the desired parameter value, and then press ENTER to confirm.
Press the start key to begin operating the VSD.
To replace the displayed actual signal, follow these steps:
a. Press the ACT key to enter signal display mode.
b. Select the row you want to change and press ENTER.
c. Use the arrow keys to browse and select a new signal (such as actual motor speed – SPEED, transmission output frequency – FREQ, etc.).
d. Press ENTER to confirm the change or ACT to exit.

II. Data Upload and Download Operations

To upload set motor parameters to the CDP-312 panel:

Verify that item 98.02 is set to FIELDBUS and item 98.07 is set to ABB DRIVES.
Switch to local control mode (LOC).
Press the FUNC key to access the function menu.
Use the arrow keys to navigate to the UPLOAD function and press ENTER to execute the upload.
If you need to move the control panel, ensure it is in remote control mode first.
To download data from the control panel to the drive unit:

Connect the control panel containing the uploaded data.
Ensure you are currently in local control mode.
Press the FUNC key to access the function menu.
Navigate to the DOWNLOAD function and press ENTER to execute the download.
III. Achieving PLC and VSD PROFIBUS-DP Communication

After confirming that the communication module is installed and the DP network cable is correctly connected, follow these steps to set the parameters:

In local mode, use FAR and the arrow keys to enter parameter settings.
Set 98.02 to FIELDBUS to activate the RPBA-01 communication module.
Set 98.07 to ABB DRIVES to determine the communication protocol.
Configure items 10.01, 10.02, and 10.03 as needed to define the external control source.
Set 16.01 to YES to allow operation.
Select the fault reset signal source for 16.04.
From 11.01 to 11.08, set the source of the control word and given value.
In items 22.01 to 22.03, define acceleration/deceleration time and stop function.
For the 51 group of parameters, configure according to the fieldbus adapter module’s settings.
Adjust the actual signal transmission content in the 92 group as needed.
IV. Additional Parameter Setting Reference (Not Currently Used)

This section provides guidance on setting speed limits, protection functions, and parameter locking for future reference.

Note: Before making any parameter changes, ensure you fully understand their impact and consult a professional if necessary.

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How to adjust the power rating of ABB’s ACS510/ACS550/ACS350/ACS355/ACH550 VFDs

With ABB’s ACS510/ACS550/ACS350/ACS355 VFDs, you can easily adjust the power rating through a straightforward process. Whether you want to upgrade a 1.1KW VFD to 5.5KW or vice versa, this flexibility allows you to set the power rating according to your needs. This feature is particularly useful when you have a limited number of VFD main boards, such as SMIO-01C, and need to adapt them to different power ranges. With this adjustment, you can ensure seamless operation even if a VFD in a different power range fails. These are not mentioned in the ABB AC drives PDF manual

  1. How to access and modify parameters:
    Open the parameter table, navigate to the deepest level of parameters, such as 0102, or any other displayed parameters. For example, if it says 9905, then hold the UP (arrow up), DOWN (arrow down), and RETURN (the button on the upper left next to LOC) buttons simultaneously for 3 seconds. You will notice a flash on the screen, and the top line of the screen should show “PARAMETERS+”.
  2. Expanding parameter groups:
    After that, exit and re-enter the parameter groups. Now, you will notice that the number of parameter groups has expanded from the original 99 to a maximum of 120. Navigate to parameter group 105.
  3. Modifying power capacity:
    To modify the relevant power capacity, follow these steps:
    • Find and modify parameter 10509. Change 105.09 to the desired current value and modify the corresponding power value accordingly (make sure it matches theVFD label. For example, if your inverter model is ACS510-01-017A-4, change it to 0174H; for ACS510-01-031A-4, change it to 0314H).
    • Set 10502 to 1 and confirm.
    • Set 10511 to 4012 and confirm.
    Please note that the order of modifications is crucial. If you make a mistake, you may need to start over.
  4. Verifying parameter changes:
    Finally, re-enter the parameter table and check if parameter 3304 (transmission capacity) has been correctly modified.
    To improve SEO performance, here are the optimized suggestions for the above text:

How to access and modify parameters:
Open the parameter table, navigate to the deepest level of parameters, such as 0102, or any other displayed parameters. For example, if it says 9905, then hold the UP (arrow up), DOWN (arrow down), and RETURN (the button on the upper left next to LOC) buttons simultaneously for 3 seconds. You will notice a flash on the screen, and the top line of the screen should show “PARAMETERS+”.

Expanding parameter groups:
After that, exit and re-enter the parameter groups. Now, you will notice that the number of parameter groups has expanded from the original 99 to a maximum of 120. Navigate to parameter group 105.

Modifying power capacity:
To modify the relevant power capacity, follow these steps:

Find and modify parameter 10509. Change 105.09 to the desired current value and modify the corresponding power value accordingly (make sure it matches the VFD label. For example, if your inverter model is ACS510-01-017A-4, change it to 0174H; for ACS510-01-031A-4, change it to 0314H).
Set 10502 to 1 and confirm.
Set 10511 to 4012 and confirm.
Please note that the order of modifications is crucial. If you make a mistake, you may need to start over.

Verifying parameter changes:
Finally, re-enter the parameter table and check if parameter 3304 (transmission capacity) has been correctly modified.

Just a reminder, the process of changing the power above has only been changed to the power of the ABB drive motherboard(SMIO-01C). The power of the drive board has not been changed, although it shows that it can be expanded. In fact, if the power of the power board has not been changed, the actual output power of the variable frequency drive (VFD) has not changed. At the same time, this method is only applicable to ACS510/ACS550/ACS350/ACS355/ACH550 VFDs and is not suitable for ACS800 series inverters. If you would like to know the power modification method for ACS800 inverters, please contact us directly.

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The circuit principle and modification and exchange method of frequency inverter transformer

The current transformers used in frequency inverter circuits, except for a few early products that used traditional transformers wound with through core inductor coils, are often integrated sealed current transformers made of Hall elements and pre current detection circuits (let’s call them electronic current transformers) in mature circuits. They are divided into standard and non-standard types, and the standard type uses specialized molded products in the market. For example, a 10A/1V current transformer generates a 1V signal voltage output for every 10A current in the circuit. Non standard type, designed and customized by the frequency converter manufacturer, cannot be used interchangeably. When damaged, it is generally necessary to replace the same model product provided by the original manufacturer. Of course, with deeper maintenance efforts, different models of current transformers can also be used for emergency repair or improvement, and later replaced.
Electronic current transformers often use some type of sealant for curing, which can cause damage and cannot be restored once removed. What kind of circuits are inside and whether they can be repaired or replaced, causing a lot of speculation. When I was repairing a Fuji frequency inverter, I replaced it with the main board of the TECO frequency inverter. When it was necessary to adjust the A/V ratio of the electronic current transformer, it had to be adjusted by the internal circuit of the transformer. Only then did I make up my mind and use a knife, a saw, and a lot of effort to dissect and map the internal circuits of the current transformers of these three types of frequency inverters. It was hard won.

An electronic current transformer is actually a circuit for a current/voltage converter. The Taian 7.5kW inverter current transformer circuit has a certain representativeness. The main body of the current transformer is also a circular hollow magnetic ring. The U, V, and W output lines of the frequency inverter pass through the iron core magnetic ring as the primary winding (small power models usually pass through multiple turns), and the magnetic ring generates magnetic field lines that vary in density with the output current of the frequency inverter. This magnetic ring has a gap in which a Hall element with four lead terminals is embedded. Hall elements are packaged in sheet form, and the magnetic field lines of the magnetic ring pass through the packaging end face of the Hall element, which is also known as the magnetic field line collection area (or magnetic induction surface). Hall elements convert changes in magnetic field lines into induced voltage outputs. The circuit consists of Hall elements and a precision dual operational amplifier circuit 4570. A constant current of mA (about 3-5mA) level must be added to the operation of the Hall element, and 4570A should be connected as a constant current source output mode to provide the mA level constant current required for the normal operation of the Hall element (the working current of the Hall element in this circuit is about 5.77 mA), which should be added to pins 4 and 2 of the Hall element; The induced voltage that varies with the output current at pins 1 and 3 of the Hall element is applied to the input terminals 2 and 3 of 4570b. Three pins are embedded in the reference voltage (zero potential point), and the change in input voltage of two pins is amplified and output by one pin (current detection signal). Electronic current transformers often have four terminal components, with two terminals supplying power to internal amplifiers of+15V and -15V, the other two terminals serving as signal output terminals, one terminal grounded, and one terminal serving as signal OUT terminal+ In addition to providing power for the dual operational amplifier IC4570, 15V and -15V are further stabilized by 6V to form a zero potential point introduced into the three pins of 4570. When the frequency converter is in a shutdown state, the ground measurement OUT point should be 0V. During operation, it will output an AC signal voltage below 4V in proportion to the output current.

After the electronic current transformer is damaged, it outputs a higher positive or negative DC voltage during static state (when the frequency inverter is shut down), which is mostly due to damage to the internal operational amplifier. Power on self-test of the frequency inverter, which displays a fault code (sometimes without a code in the manual), the frequency inverter will refuse to start or even parameter operation!
The current transformer circuit of TECO 3.7kW frequency converter uses a programmable operational amplifier chip. I have not yet found the model of this chip, but through modification tests, some characteristics of the circuit have been identified. According to the experiment, pin 2 is the constant current power supply terminal, pins 3 and 4 are the input terminals of the differential amplifier, and pin 13 is the signal output terminal. When short circuiting the solder gaps of pins 11, 12, and 13 step by step, the amplification factor shows a decreasing trend; When opening the circuit step by step, the amplification factor increases. This can adjust the amplification factor of the chip, making it easier to match frequency converters with different power outputs. I successfully applied the current transformer to a 45kW Fuji frequency Inverter by taking corresponding measures.
The voltage detection and current detection signals of the frequency converter may be applied by the program to control the output three-phase voltage and current – when the detection signal changes, the output three-phase voltage and current also change accordingly. When repairing or modifying the original circuit, be careful not to change the original circuit parameters. It is still recommended to use original accessories to repair the frequency converter while maintaining the original circuit form.

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Brake unit circuit diagram and repair ideas

When the speed of the load motor exceeds the output speed of the frequency inverter due to inertia or some other reason, the motor enters the “dynamic” state from the “electric” state, causing the motor to temporarily become a generator. The reverse generated energy of a load motor, also known as regenerative energy.

Some special machinery, such as mining elevators, winches, high-speed elevators, etc., when the electric motor decelerates, brakes, or lowers a heavy load (ordinary large inertia loads, deceleration and parking process), due to the potential energy and potential energy of the mechanical system, the actual speed of the frequency inverter can exceed the given speed of the frequency inverter. The phase of the induced current in the motor winding is ahead of the induced voltage, resulting in capacitive current, The diodes connected in parallel at both ends of the IGBT in the inverter circuit of the frequency converter and the energy storage capacitors in the DC circuit precisely provide a path for this capacitive current. The electric motor generates excitation electromotive force due to capacitive excitation current, which self excites and generates electricity, returning energy to the power supply. This is the process by which an electric motor converts mechanical potential energy into electrical energy and feeds it back to the power grid.

This regenerative energy is rectified by diodes parallel to the inverter circuit of the frequency inverter and fed into the DC circuit of the frequency converter, causing the voltage of the DC circuit to rise from around 530V to 600-700V or even higher. Especially during the process of decelerating and stopping under high inertia loads, it occurs more frequently. This sharp increase in voltage may cause significant voltage and current surges or even damage to the energy storage capacitor and inverter module of the inverter main circuit. Therefore, the braking unit and braking resistor (also known as the braking unit and braking resistor) are often essential components or preferred auxiliary components of the frequency converter. In low-power frequency converters, the braking unit is often integrated into the power module, and the braking resistor is also installed inside the body. But for high-power frequency converters, braking units and braking resistors are selected according to the load operation situation. The CDBR-4030C braking unit is one of the auxiliary configurations of the frequency inverter.

Regardless of the specific circuit, we can first imagine it from the control principle. The so-called braking unit is an electronic switch (IGBT module) that, when turned on, connects the braking resistor (RB) to the DC circuit of the frequency inverter to quickly consume the reverse power generation energy of the motor (converted into heat and dissipated in the ambient air), in order to maintain the voltage of the DC circuit within the allowable value. There is a DC voltage detection circuit that outputs a brake action signal to control the on and off of electronic switches. In terms of performance, when the DC circuit voltage of the frequency converter rises to a certain value (such as 660V or 680V), the switch is turned on to connect the braking resistor RB to the circuit until the voltage drops below 620V (or 620V), and then the switch is turned off, which is also feasible. Anyway, the braking unit has RB’s current limiting function and there is no risk of burning out. If its performance is further optimized, a voltage/frequency (or voltage/pulse width) conversion circuit will be controlled by a voltage detection circuit to control the on/off of the IGBT module in the braking unit. When the voltage of the DC circuit is high, the working frequency of the braking unit is high or the conduction cycle is long. When the voltage is low, the opposite is true. This type of pulse braking has much better performance than direct on/off braking. In addition, with the overcurrent protection and heat dissipation treatment of the IGBT module, this should be a high-performance braking unit circuit.

The CDBR-4030C braking unit is not very optimized in terms of structure and performance, but the actual application effect is still acceptable. The internal electronic switch is a dual tube IGBT module, and the gate and emitter of the upper tube are not used for short circuiting. Only the lower tube is used, which is somewhat wasteful. A single tube IGBT module can be used. The protective circuit is a combination of electronic circuits and mechanical trip circuits. The manufacturer has modified the internal structure of the QF0 air circuit breaker, changing it from leakage trip to trip when the module overheats. Temperature detection and action control are composed of a temperature relay, Q4, and KA1. When the module temperature rises to 75 º C, KA1 action triggers a trip, QF1 trips, and the power supply of the braking unit is turned off, thereby protecting the IGBT module from being burned out due to overcurrent or overheating to a certain extent.
The power supply of the detection circuit (as shown in the figure below) is obtained by reducing the power resistance, stabilizing the voltage with a voltage regulator, and filtering the capacitor, providing a 15V DC power supply.
The faults of the braking unit mainly occur in the control power supply circuit, manifested as open circuit of the step-down resistor, breakdown of the voltage regulator, etc; In addition, due to the introduction of 530V DC high voltage in the DC circuit of the frequency converter, the insulation of the circuit board decreases due to moisture, resulting in high voltage discharge and burning of copper foil strips in large areas of the circuit, as well as short circuits in the integrated blocks of the control circuit. Due to the fact that all circuit boards are coated with black protective paint, the connection and direction of the copper foil strips cannot be clearly seen, which also brings some inconvenience to maintenance.

The circuit consists of an LM393 integrated operational amplifier, a CD4081BE four input and gate circuit, and a 7555 (NE555) time base circuit. The control principle is briefly described as follows:

The DC circuit voltage of the frequency converter introduced by the P and N terminals is divided by the R1 to R7 resistor network and input to the 2 pins of LM339. The 3 pins of LM339 are connected to the set voltage after further voltage stabilization and RP1 adjustment through 15V control power supply. This voltage value is the set voltage of the braking action point. LED1 also serves as a power indicator light. As LM393 is an open collector output operational amplifier circuit, the output terminals of the two amplifiers are connected with pull-up resistors R13 and R14 to provide high-level output during braking action. The first stage amplification circuit is a hysteresis voltage comparator (sometimes also known as a hysteresis comparator), where D1 and R10 are connected to form a positive feedback circuit, providing a certain hysteresis voltage to make the set point voltage fluctuate with the output, avoiding frequent output fluctuations caused by comparing at one point. The second stage amplifier is a typical voltage comparator connection. In essence, the operational amplifier is used here as a switching circuit, without a linear amplification link, but as a switching output. The two-stage amplification circuit forms a phase inversion process for the signal, so that when the output voltage is higher than the set voltage, the circuit has a high-level output.
When LM393 is static, it is a high level output. This high level is superimposed on pin 3 of LM393 through D1 and R10, which “boosts” the voltage value of the braking action set point. When the input voltage of pin 2 (such as 660V DC circuit voltage between P and N) is higher than the voltage of pin 3, pin 1 changes from high level to low level; After the second stage of phase inversion processing, output a high-level signal to pin 1 of CD4081BE. Meanwhile, due to the low level of pin 1 of LM393, pin 3 also dropped from the raised voltage value to the set value. In this way, when the braking unit acts and connects the braking resistor between P and N, the voltage of P and N starts to fall from 660V and continues to fall until the voltage of pin 2 (580V between P and N) is lower than the set voltage value of pin 3. The circuit flips and the braking signal stops outputting, avoiding the unstable output caused by frequent circuit actions at 660V voltage.

The time base circuit 7555 is connected to a typical multi harmonic oscillator and outputs a pulse frequency voltage with a fixed duty cycle. In the LM393 voltage sampling circuit, the braking action signal is output – pin 1 of CD4081BE is a high level, and the high-level component of the rectangular pulse voltage output by the time base circuit 7555 is combined with the high-level signal of LM393, causing pin 3 of CD4081BE to generate a positive voltage pulse output. This pulse is then processed by the master/slave conversion switch, the second stage, and the gate switch circuit. After power amplification by Q1 and Q2 complementary voltage followers, it drives the electronic switch IGBT module.

When the master/slave control switch is turned to the upper end, this machine acts as the master, implements braking action, and transmits braking commands to other slaves through terminals OUT+and OUT -; When the master/slave control switch is turned to the lower end, this machine acts as a slave and receives braking signals from the main unit through terminals IN+and IN -. The signal is input into pin 6 of CD4081BE through optocoupler U5, and braking action is carried out based on the signal from the main unit.
The part of the circuit marked “What is the intention of this circuit” on the blueprint, let’s start from the circuit itself and try to understand the designer’s original intention. If my analysis is incorrect, I hope readers can correct it. Under normal conditions, when implementing a braking action, it can be seen that the braking signal output by U2 is a rectangular pulse sequence signal (this signal is added to pin 1 of U4), and the signal added to pin 2 of U4 through a step-down resistor at the PB terminal is exactly an inverted rectangular pulse sequence signal. At any moment, one of pins 1 and 2 of U4 is always a high level. For the “high out of low” characteristic of the OR gate, pin 3 of U4 always outputs a low level, Q3 is in the cut-off state, and the circuit implements normal braking action; Assuming that the output module has been continuously connected or has been broken down, the signal from the PB terminal to pin 2 of U4 is a DC low level, which is in phase or phase with the pulse signal from pin 1, resulting in an output of “two low and one high”. By driving Q3 through U8, the output signal of pin 3 of U2 is short circuited to ground, causing pin 8 of U2 to also be at a low level until pins 1 and 2 of U4 are completely locked to ground (low) level, and Q3 continues to enter a fully conductive state, completely blocking the braking signal output by U2. Power must be cut off to lift this blockade. But this protective blockade seems powerless and beyond the reach of the module itself in transient overcurrent conditions or faults in the Q1 and Q2 drive circuits themselves.

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Repair process of driving circuit for 22kW Delta frequency Inverter

After checking the drive circuit of the 22kW Delta VFD Drive and replacing it with a new module, the OC will jump upon startup. The module is newly replaced, and all six drive pulses are working properly. I don’t think it should be. Still checking the measurement, the six negative pressures driving the IC during shutdown are all normal, and the six excitation voltages are also normal after startup. It is necessary to first determine whether the fault is caused by the driver IC or the module.

It is necessary to first test the load carrying capacity of the six drive ICs, that is, to measure the trigger current value of their output. Connect a 15 ohm resistor in series to the output terminal, and then connect a 15 ohm resistor in series to the probe to limit the circuit current to around 0.5A. After the start signal is activated, its current output capacity is measured, and it can still provide a dynamic current of about 150mA even when the original trigger circuit is connected normally. The driving circuit of the V-phase lower arm IGBT tube only outputs about 40mA of current, which obviously cannot meet the excitation requirements of the IGBT tube. The root cause of the OC fault lies in this!
There seems to be a misconception about the driving method of IGBT tubes, especially high-power IGBT tubes: IGBT tubes are voltage signal excitation devices, not current type excitation devices. The driving signal only needs to meet the voltage amplitude, without requiring too much current driving capability! I have previously analyzed that even IGBT tubes are essentially current driven devices!
The output signals of the driving ICs (PC929 and PC923) of the machine are amplified by a complementary voltage follower and then supplied to the triggering terminals of the module. The push-pull amplifier was originally a pair of field-effect transistors, but due to the lack of the original type of transistor on hand, it has now been replaced with transistor pairs D1899 and B1261. After modification testing, it should be able to meet the excitation requirements. Check the V-phase lower arm circuit. The resistance from pin 11 (pulse output pin) of PC929 to the subsequent power amplifier circuit was originally 100 ohms, but now it has changed to over 100k, causing D1899 to be unable to fully conduct and the output driving current to be too small. After replacing the resistor, the output current is normal. After replacing the power transistor, the base resistance was not measured, resulting in this phenomenon.
By the way, I measured the negative current supply capacity of the driving circuit when cutting off negative pressure output. The probe is still connected in series with a 15 ohm resistor, and each circuit is around 30mA.
This leads to the conclusion that measuring the output voltage of the driving IC is not as direct and effective as measuring its output current. And it can expose the root cause of the malfunction. When the internal resistance of the circuit output increases due to certain reasons, measuring the driving voltage is often normal, which masks the truth of insufficient driving current.

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Repair of 22kW HC1 drive module malfunction

A 22kW HC1 drive, the fuse of the inverter module power supply series connection is broken, and no other abnormalities are found in the main circuit measurement. After installation, first send the inverter power supply to 24V and jump EOCn, which means overcurrent during acceleration and short circuit on the motor side. Obviously, there is still a malfunction in the module or driver part. It seems that it’s not just about replacing insurance.

Dismantle and recheck the driver circuit board. It was found that there was no positive excitation pulse output in one of the driver circuits. The power amplifier tube (lower tube) of the driver circuit was found to have broken down, and the voltage terminal of the module trigger terminal was continuously embedded on the negative pressure. After replacing the amplifier tube, the pulse circuit is normal.
Install the machine, connect to 24V power supply, and power on to trip EfbS, which means the fuse is blown. Remove the 24V power supply and replace the original fuse terminals with light bulbs in series, which will emit strong light upon power transmission. But after removing the trigger terminal during power outage, the individual measurement module was normal; Install the insurance and connect the inverter circuit to a 24V power supply. Start the frequency converter, and when the frequency rises to around 5Hz, the ECOn will still trip. I’m not sure if it’s still a problem with the module or the driver circuit.
Recheck the positive and negative voltage and current of the drive output, both are normal. Possible module malfunction. Simply remove all three modules and place them on the workbench for power testing along with the driver board. After powering on, it was detected that the negative pressure on one arm was low, about 2V. Disconnect the trigger terminal, the negative pressure returns to normal value, insert the module trigger terminal, and the negative pressure decreases again. Confirmed that the module was indeed damaged, replaced with a new module, and the fault was repaired.