ABB ACS480 Betriebsanleitung

—

ABB GENERAL PURPOSE DRIVES

ACS480

Fault tracing

Troubleshooting

Fault tracing 01

Fault tracing

What this chapter contains

The chapter lists the warning and fault messages including possible causes and

corrective actions. The causes of most warnings and faults can be identified and

corrected using the information in this chapter. If not, contact an ABB service

representative. If you have a possibility to use the Drive composer PC tool, send the

Support package created by the Drive composer to the ABB service representative.

Warnings and faults are listed below in separate tables. Each table is sorted by

warning/fault code.

Safety

WARNING! Only qualified electricians are allowed to service the drive. Read

the instructions in chapter Safety instructions at the beginning of the Hardware

manual of the drive before working on the drive.

Indications



Warnings and faults

Warnings and faults indicate an abnormal drive status. The codes and names of

active warnings and faults are displayed on the control panel of the drive as well as in

the Drive composer PC tool. Only the codes of warnings and faults are available over

fieldbus.

Warnings do not need to be reset; they stop showing when the cause of the warning

ceases. Warnings do not trip the drive and it will continue to operate the motor.

02 Fault tracing

Faults latch inside the drive and cause the drive to trip, and the motor stops. After the

cause of a fault has been removed, the fault can be reset from a selectable source

(Menu - Primary settings - Advanced functions - Reset faults manually (Reset

faults manually from:) on the panel; or parameter 31.11 Fault reset selection) such

as the control panel, Drive composer PC tool, the digital inputs of the drive, or

fieldbus. Reseting the fault creates an event 64FF Fault reset. After the reset, the

drive can be restarted.

Note that some faults require a reboot of the control unit either by switching the power

off and on, or using parameter 96.08 Control board boot – this is mentioned in the

fault listing wherever appropriate.



Pure events

In addition to warnings and faults, there are pure events that are only recorded in the

event log of the drive. The codes of these events are included in the Warning

messages table on page (388).



Editable messages

For external events, the action (fault or warning), name and the message text can be

edited. To specify external events, select Menu - Primary settings - Advanced

functions - External events.

Contact information can also be included and the text edited. To specify contact

information, select Menu - Primary settings - Clock, region, display - Contact info

view.

Warning/fault history



Event log

All indications are stored in the event log with a time stamp and other information.

The event log stores information on

• the last 8 fault recordings, that is, faults that tripped the drive or fault resets

• the last 10 warnings or pure events that occurred.

See section Viewing warning/fault information on page 387.

Auxiliary codes

Some events generate an auxiliary code that often helps in pinpointing the problem.

On the control panel, the auxiliary code is stored as part of the details of the event; in

the Drive composer PC tool, the auxiliary code is shown in the event listing.

Fault tracing 03



Viewing warning/fault information

The drive is able to store a list of the active faults actually causing the drive to trip at

the present time. The drive also stores a list of faults and warnings that have

previously occurred.

For each stored fault, the panel shows the fault code, time and values of nine

parameters (actual signals and status words) stored at the time of the fault. The

values for the latest fault are in parameters 05.80...05.88.

For active faults and warnings, see

•Menu - Diagnostics - Active faults

•Menu - Diagnostics - Active warnings

•Options - Active faults

•Options - Active warnings

• parameters in group 04 Warnings and faults (page 161).

For previously occurred faults and warnings, see

•Menu -Diagnostics - Fault & event log

• parameters in group 04 Warnings and faults (page 161).

The event log can also be accessed (and reset) using the Drive composer PC tool.

See Drive composer PC tool user’s manual (3AUA0000094606 [English]).

QR code generation for mobile service application

A QR code (or a series of QR codes) can be generated by the drive for display on the

control panel. The QR code contains drive identification data, information on the

latest events, and values of status and counter parameters. The code can be read

with a mobile device containing the ABB service application, which then sends the

data to ABB for analysis. For more information on the application, contact your local

ABB service representative.

To generate the QR code, select Menu - System info - QR code.

Note: If a control panel which does not support QR code generation (version older

than v.6.4x) is used, the QR code menu entry will disappear totally and will not be

available any longer either with control panels supporting the QR code generation.

04 Fault tracing

Warning messages

Note: The list also contains events that only appear in the Event log.

Code

(hex) Warning / Aux. code Cause What to do

64FF Fault reset A fault has been reset from the

panel, Drive composer PC tool,

fieldbus or I/O.

Event. Informative only.

A2A1 Current calibration Current offset and gain

measurement calibration will

occur at next start.

Informative warning. (See parameter

99.13 ID run requested.)

A2B1 Overcurrent Output current has exceeded

internal fault limit.

In addition to an actual

overcurrent situation, this

warning may also be caused

by an earth fault or supply

phase loss.

Check motor load.

Check acceleration times in parameter

group 23 Speed reference ramp (speed

control), 28 Frequency reference chain

(frequency control). Also check

parameters 46.01 Speed scaling, 46.02

Frequency scaling and 46.03 Torque

scaling.

Check motor and motor cable (including

phasing and delta/star connection).

Check for an earth fault in motor or motor

cables by measuring the insulation

resistances of motor and motor cable.

See chapter Electrical installation,

section Checking the insulation of the

assembly in the Hardware manual of the

drive.

Check there are no contactors opening

and closing in motor cable.

Check that the start-up data in parameter

group 99 Motor data corresponds to the

motor rating plate.

Check that there are no power factor

correction capacitors or surge absorbers

in motor cable.

A2B3 Earth leakage 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 for an earth fault in motor or motor

cables by measuring the insulation

resistances of motor and motor cable.

See chapter Electrical installation,

section Checking the insulation of the

assembly in the Hardware manual of the

drive. If an earth fault is found, fix or

change the motor cable and/or motor.

If no earth fault can be detected, contact

your local ABB representative.

Fault tracing 05

A2B4 Short circuit Short-circuit in motor cable(s)

or motor.

Check motor and motor cable for cabling

errors.

Check motor and motor cable (including

phasing and delta/star connection).

Check for an earth fault in motor or motor

cables by measuring the insulation

resistances of motor and motor cable.

See chapter Electrical installation,

section Checking the insulation of the

assembly in the Hardware manual of the

drive.

Check there are no power factor

correction capacitors or surge absorbers

in motor cable.

A2BA IGBT overload Excessive IGBT junction to

case temperature. This

warning protects the IGBT(s)

and can be activated by a short

circuit in the motor cable.

Check motor cable.

Check ambient conditions.

Check air flow and fan operation.

Check heatsink fins for dust pick-up.

Check motor power against drive power.

A3A1 DC link overvoltage Intermediate circuit DC voltage

too high (when the drive is

stopped).

Check the supply voltage setting

(parameter 95.01 Supply voltage). Note

that the wrong setting of the parameter

may cause the motor to rush

uncontrollably, or may overload the brake

chopper or resistor.

Check the supply voltage.

If the problem persists, contact your local

ABB representative.

A3A2 DC link undervoltage Intermediate circuit DC voltage

too low (when the drive is

stopped).

A3AA DC not charged The voltage of the intermediate

DC circuit has not yet risen to

operating level.

A490 Incorrect temperature

sensor setup

Temperature cannot be

supervised due to incorrect

adapter setup.

Check the settings of temperature source

parameters 35.11 and 35.21

A491 External temperature

(Editable message text)

Measured temperature 1 has

exceeded warning limit.

Check the value of parameter 35.02

Measured temperature 1.

Check the cooling of the motor (or other

equipment whose temperature is being

measured).

Check the value of 35.13 Temperature 1

warning limit.

A492 External temperature

(Editable message text)

Measured temperature 2 has

exceeded warning limit.

Check the value of parameter 35.03

Measured temperature 2.

Check the cooling of the motor (or other

equipment whose temperature is being

measured).

Check the value of 35.23 Temperature 2

warning limit.

A4A0 Control board

temperature

Control unit temperature is too

high.

Check the auxiliary code. See actions for

each code below.

(none) Temperature above warning

limit

Check ambient conditions.

Check air flow and fan operation.

Check heatsink fins for dust pick-up.

1 Thermistor broken Contact an ABB service representative

for control unit replacement.

Code

(hex) Warning / Aux. code Cause What to do

06 Fault tracing

A4A1 IGBT overtemperature Estimated drive IGBT

temperature is excessive.

Check ambient conditions.

Check air flow and fan operation.

Check heatsink fins for dust pick-up.

Check motor power against drive power.

A4A9 Cooling Drive module temperature is

excessive.

Check ambient temperature. If it exceeds

40 °C/104 °F (IP21 frames R4

…

R9) or if

it exceeds 50 °C /122 °F (IP21 frames

…

R9), ensure that load current does

not exceed derated load capacity of

drive. For all P55 frames, check the

derating temperatures. See chapter

Technical data, section Derating in the

Hardware manual of the drive.

Check drive module cooling air flow and

fan operation.

Check inside of cabinet and heatsink of

drive module for dust pick-up. Clean

whenever necessary.

A4B0 Excess temperature Power unit module

temperature is excessive.

Check ambient conditions.

Check air flow and fan operation.

Check heatsink fins for dust pick-up.

Check motor power against drive power.

(1: U-phase, 2: V-phase, 3: W-phase, 4:

INT board, 6: Air inlet (sensor connected

to INT board X10), 7: PCB compartment

fan or power supply board, FA: Ambient

temperature).

A4B1 Excess temperature

difference

High temperature difference

between the IGBTs of different

phases.

Check the motor cabling.

Check cooling of drive module(s).

A4F6 IGBT temperature Drive IGBT temperature is

excessive.

Check ambient conditions.

Check air flow and fan operation.

Check heatsink fins for dust pick-up.

Check motor power against drive power.

A582 Auxiliary fan missing An auxiliary cooling fan (IP55

internal fan) is stuck or

disconnected.

Check the auxiliary code.

Check the auxiliary fan and connection.

Replace faulty fan.

Make sure the front cover of the drive is

in place and tightened. If the

commissioning of the drive requires that

the cover is off, this warning will be

generated even if the corresponding fault

is defeated. See fault 5081 Auxiliary fan

broken (page 400).

A5A0 Safe torque off

Programmable warning:

31.22 STO indication

run/stop

Safe torque off function is

active, ie safety circuit signal(s)

connected to connector STO is

lost.

Check safety circuit connections. For

more information, chapter The Safe

torque off function in the Hardware

manual of the drive and description of

parameter 31.22 STO indication run/stop

(page 244).

Check the value of parameter 95.04

Control board supply.

A5EA Measurement circuit

temperature

Problem with internal

temperature measurement of

the drive.

Contact your local ABB representative.

Code

(hex) Warning / Aux. code Cause What to do

Fault tracing 07

A5EB PU board powerfail Power unit power supply

failure.

Contact your local ABB representative.

A5ED Measurement circuit

ADC

Measurement circuit fault. Contact your local ABB representative.

A5EE Measurement circuit

DFF

Measurement circuit fault. Contact your local ABB representative.

A5EF PU state feedback State feedback from output

phases does not match control

signals.

Contact your local ABB representative.

A5F0 Charging feedback Charging feedback signal

missing.

Check the feedback signal coming from

the charging system.

A682 Flash erase speed

exceeded

The flash memory (in the

memory unit) has been erased

too frequently, compromising

the lifetime of the memory.

Avoid forcing unnecessary parameter

saves by parameter 96.07 or cyclic

parameter writes (such as user logger

triggering through parameters).

Check the auxiliary code (format XYYY

YZZZ). “X” specifies the source of

warning (1: generic flash erase

supervision). “ZZZ” specifies the flash

subsector number that generated the

warning.

A6A4 Motor nominal value The motor parameters are set

incorrectly.

Check the auxiliary code. See actions for

each code below.

The drive is not dimensioned

correctly.

0001 Slip frequency is too small. Check the settings of the motor

configuration parameters in groups 98

and 99.

Check that the drive is sized correctly for

the motor.

0002 Synchronous and nominal

speeds differ too much.

0003 Nominal speed is higher than

synchronous speed with 1 pole

pair.

0004 Nominal current is outside

limits

0005 Nominal voltage is outside

limits.

0006 Nominal power is higher than

apparent power.

0007 Nominal power not consistent

with nominal speed and

torque.

A6A5 No motor data Parameters in group 99 have

not been set.

Check that all the required parameters in

group 99 have been set.

Note: It is normal for this warning to

appear during the start-up and continue

until the motor data is entered.

A6A6 Voltage category

unselected

The voltage category has not

been defined.

Set voltage category in parameter 95.01

Supply voltage.

Code

(hex) Warning / Aux. code Cause What to do

08 Fault tracing

A6A7 System time not set System time is not set. Timed

functions cannot be used and

fault log dates are not correct.

Set the system time manually or connect

the panel to the drive to synchronize the

clock. If basic panel is used, synchronize

the clock through the EFB or a fieldbus

module.

Set parameter 34.10 Timed functions

enable to Disabled to disable the timed

functions if they are not used.

A6B0 User lock is open The user lock is open. Close the user lock by entering an invalid

pass code in parameter 96.02 Pass

code. See section User lock (page 151).

A6D1 FBA A parameter

conflict

The drive does not have a

functionality requested by a

PLC, or requested functionality

has not been activated.

Check PLC programming.

Check settings of parameter groups 50

Fieldbus adapter (FBA).

A6E5 AI parametrization The current/voltage hardware

setting of an analog input does

not correspond to parameter

settings.

Check the event log for an auxiliary code.

The code identifies the analog input

whose settings are in conflict.

Adjust either the hardware setting (on the

drive control unit) or parameter

12.15/12.25.

Note: Control unit reboot (either by

cycling the power or through parameter

96.08 Control board boot) is required to

validate any changes in the hardware

settings.

A6E6 ULC configuration User load curve configuration

error.

Check the auxiliary code (format XXXX

ZZZZ). “ZZZZ” indicates the problem

(see actions for each code below).

0000 Speed points inconsistent. Check that each speed point (parameters

37.11…37.15) has a higher value than

the previous point.

0001 Frequency points inconsistent. Check that each frequency point

(37.20…37.16) has a higher value than

the previous point.

0002 Underload point above

overload point.

Check that each overload point

(37.31…37.35) has a higher value than

the corresponding underload point

(37.21…37.25).

0003 Overload point below

underload point.

A780 Motor stall

Programmable warning:

31.24 Stall function

Motor is operating in stall

region because of e.g.

excessive load or insufficient

motor power.

Check motor load and drive ratings.

Check fault function parameters.

A792 Brake resistor wiring Brake resistor short circuit or

brake chopper control fault.

For drive frames R6 or larger.

Check brake chopper and brake resistor

connection.

Ensure brake resistor is not damaged.

Code

(hex) Warning / Aux. code Cause What to do

Fault tracing 09

A793 BR excess

temperature

Brake resistor temperature has

exceeded warning limit defined

by parameter 43.12 Brake

resistor warning limit.

Stop drive. Let resistor cool down.

Check resistor overload protection

function settings (parameter group 43

Brake chopper).

Check warning limit setting, parameter

43.12 Brake resistor warning limit.

Check that the resistor has been

dimensioned correctly.

Check that braking cycle meets allowed

limits.

A794 BR data Brake resistor data has not

been given.

One or more of the resistor data settings

(parameters 43.08…43.10) is incorrect.

The parameter is specified by the

auxiliary code.

0000 0001 Resistance value too low. Check value of 43.10.

0000 0002 Thermal time constant not

given.

Check value of 43.08.

0000 0003 Maximum continuous power

not given.

Check value of 43.09.

A79C BC IGBT excess

temperature

Brake chopper IGBT

temperature has exceeded

internal warning limit.

Let chopper cool down.

Check for excessive ambient

temperature.

Check for cooling fan failure.

Check for obstructions in the air flow.

Check the dimensioning and cooling of

the cabinet.

Check resistor overload protection

function settings (parameters

43.06…43.10).

Check minimum allowed resistor value

for the chopper being used.

Check that braking cycle meets allowed

limits.

Check that drive supply AC voltage is not

excessive.

A7A2 Mechanical brake

opening failed

Status of mechanical brake

acknowledgement is not as

expected during brake open.

Check mechanical brake connection.

Check mechanical brake settings in

parameter group 44 Mechanical brake

control.

Check that acknowledgement signal

matches the actual status of brake.

A7AB Extension I/O

configuration failure

I/O module is not connected to

the device or parameterization

conflict with connected I/O

module.

Check that the I/O module is connected

to the device.

Check that no parameters are connected

to non-existing I/O parameters.

Code

(hex) Warning / Aux. code Cause What to do

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