Tag: ABB ACS580 FAULT CODE

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In-depth Analysis and Solution for FAULT 5681 on ABB ACS580 Series Inverters

The ABB ACS580 series inverters are crucial components in industrial automation, renowned for their efficiency and reliability. However, users may encounter various faults during operation, with FAULT 5681 being a particularly common one related to communication issues. This article provides an in-depth analysis of FAULT 5681, specifically addressing the differences between PS communication and PU communication, as well as the impact of parameter 95.04 on this fault, and offers detailed solutions.

Overview of FAULT 5681

FAULT 5681 indicates a communication error detected between the drive control unit and the power unit, preventing the device from functioning properly. Notably, while the manual may refer to “PU communication issues,” the operator panel might display “PS communication issues,” leading to confusion. In reality, PS communication and PU communication represent two distinct communication protocols and interfaces in ABB inverters.

  • PS Communication: Utilizes a serial communication interface (RS485) for point-to-point communication, suitable for smaller systems with its simplicity and directness.
  • PU Communication: Based on TCP/IP protocol and Ethernet interface, PU communication caters to larger systems, offering higher flexibility and scalability.
ACS580 normal working status display

Fault Analysis

  1. Misunderstanding of Communication Types: Users must clarify that the “PS communication issues” displayed on the operator panel do not equate to “PU communication issues” mentioned in the manual. FAULT 5681 specifically refers to issues within PS communication.
  2. Control Unit Power Supply: Parameter 95.04 governs the power supply method (internal 24V or external 24V) for the control unit. Instability or incorrect settings can directly affect communication stability, triggering FAULT 5681.
  3. Communication Line Faults: Improper connections, shorts, or opens in the RS485 communication lines can interrupt communication.
  4. Power Unit Failure: Damage to the power unit itself may prevent the control unit from detecting its status, leading to communication faults.

Solutions

  1. Clarify Communication Types:
    • Confirm that the fault indeed pertains to PS communication and understand the distinction between PS and PU communication to avoid confusion.
  2. Inspect and Adjust Control Unit Power Supply:
    • Check and confirm parameter 95.04 settings. For external power supply, verify the stability and connection of the external 24V power source. For internal supply, ensure the internal power module functions correctly.
    • Adjust or replace the power source if settings are incorrect or power is unstable, and restart the device to test communication recovery.
  3. Examine Communication Lines:
    • Thoroughly inspect the RS485 communication line connections, including interface plugs and line quality, ensuring no shorts, opens, or poor contacts.
    • Use a multimeter to test line continuity and replace damaged lines or connectors as needed.
  4. Verify Power Unit Status:
    • Suspect power unit failure? Use professional tools to diagnose its operation.
    • Replace or repair the power unit if damaged, coordinating with ABB service for assistance.
  5. Restart the Device:
    • After completing checks and adjustments, restart the device to restore communication. Monitor communication status changes during restart.
  6. Consult Professional Technical Support:
    • If issues persist, contact ABB’s technical support team for detailed troubleshooting and resolution strategies.

Conclusion

FAULT 5681, a prevalent communication issue in ABB ACS580 series inverters, stems from misunderstandings about communication types, control unit power supply issues, faulty communication lines, or power unit malfunctions. By distinguishing between PS and PU communication, inspecting and adjusting control unit power supply, thoroughly checking communication lines, verifying power unit status, timely restarting devices, and seeking professional help when needed, users can effectively resolve this fault. Prompt action ensures uninterrupted production line operations.

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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.