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WARNING! Do not attempt any work on a powered ACS800. Follow the Safety Instructions as mentioned in the Hardware Manual !

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

This document contains some information about ACS800 fault messages and possible root causes of the faults. Document is meant to give additional information for fault tracing of the drive. If more information is needed contact technical support.

Before calling or sending email to the Support Line following information is good to be available: type of the unit e.g. ACS800-02-0320-3 serial number e.g. 1013500356 description how and when fault/problem occurs, actions done and how often this fault occurs what is the application

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Table of contents

Drive units ____________________________________________________________________3

DC Overvoltage ____________________________________________________________________3 Earth Fault ________________________________________________________________________6 FLT (x_x) _________________________________________________________________________7 I/O Communication Fault ____________________________________________________________7 No Communication (18) ____________________________________________________________8 Overcurrent _______________________________________________________________________9 PPCC Link Fault __________________________________________________________________12 PP Overload ______________________________________________________________________14 Supply Phase ______________________________________________________________________15

Fieldbus _____________________________________________________________________16 DSU ________________________________________________________________________17

Earth fault ________________________________________________________________________17 Other fault________________________________________________________________________18 Phase missing _____________________________________________________________________18

Instruction when a whole R2-R4 drive should be changed under warranty________________19

Fault Tracing _____________________________________________________________________20

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Drive units
ACS800 Temp

Possible reason The internal thermal model calculates that the maximum IGBT temperature has been reached. Decrease the load.

Action

Improve the inverter cooling by lowering the ambient temperature (e.g airconditioning unit). Replace CT. Check the measured current of each CT when the drive is not running by means of the parameters 160.1 to 160.3.

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DC Overvoltage

Possible reason Deceleration time is too short.

Action Set longer ramp time or use brake unit. Use Coasting Stop to Stop Function (if applicable). Resistance of the Braking Resistor is too high.

Parameter 2005 overvoltage controller disabled and there is no brake unit or TSU/ISU. Supply voltage too high

Disable controller only when using brake unit or TSU/ISU. Check mains for static or transient overvoltage.

Faulty Braking Chopper

Check Braking Chopper and Breaking Resistors.

Internal Fault Earth fault in IT (floating network) Incorrect inverter type

Replace xINT-board. Check there is no earth fault in supply. Compare the rating plate of the drive and configuration of the sw from CDP panel (drive) or par. 112.7 and 101.2 *1) Parameter 112.7 must show SRxxxx_x with ACS800 drives and SFxxxx_x with ACS600 drives. If wrong letters are shown, software must be re-loaded to RMIO. Disconnect common mode capacitors from the gnd *2)

EMC- boards are connected in IT network.

*1) See Parameter settings for ACS800 Single drive from ACS800 IHMM / Software / Instructions /

RMIO configuration instructions.

*2) See ACS800 Product Notice 1: ACS800 01 Units: Modifications to the RFI Filtering when used in the IT (ungrounded) Networks from ACS800 IHMM / Support / Hints and Product Notice.

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DC Undervoltage

Possible reason Too low input voltage

Action Check input fuses and the OESA is closed. Measure the input and DC voltage in stop, start and running (with multimeter or from actual signals). Check phase voltages of the supply.

Incorrect inverter type

Compare the rating plate of the drive and configuration in the sw from CDP panel (drive) or par. 112.7 and 101.2 *1) Check cabling between AINP and rectifier bridges. Check the cable between +DC-bus bar and AINT-board. Replace a rectifier bridge. Replace AINP-board. Replace xINT- board.

Internal fault

*1) See Parameter settings for ACS800 Singledrive from ACS800 IHMM / Software / Instructions / RMIO configuration instructions.

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Earth Fault / Current Unbalance

Possible reason Motor cable or motor is damaged.

Action Megger the motor and motor cable. Disconnect motor cables and run the drive in scalar control => if the drive does not trip its OK.

Long motor cables or high stray capacitance to the ground. Power factor correction capacitors or surge absorbers. Internal fault.

Use*1) output chokes. Check earth fault trip level Check there are no power factor correction capacitors or surge absorbers in the motor cable. See tips from ACS 600 Earth Fault Protection Service Manual *2). Replace xINT-board. Replace Current Transducer Replace xPBU-board if used. Replace all optic fibres between AINTs and NPBU.

*1) see Maximum Motor Cable length on ACS600/ACS800 DU/DT Filter Selection Guide and NOCHxxxx, AOCHxxxx du/dt Filters Installation Guide from ACS800 IHMM / Manuals & Guides / General manuals and ACS800 IHMM / Manuals & Guides / System Control and Option Manuals *2) See ACS 600 Earth Fault Protection Service Manual from Service Hints of ACS600 SingleDrive In-House Maintenance Manual. NOTE! All the functions described in the manual are not directly applicable with ACS800.

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FLT (x_x)

Possible reason (F1_47) Flash memory (F2_X) Processor or memory

Action Replace RMIO-board, inform Supportline Replace RMIO-board, inform Supportline

I/O Communication Fault

Possible reason A Communication error has occurred on the I/O Link.

Action Check the connections of the fibre optic cables on the I/O Link Check a correspondence between parameter settings and HW configuration on the I/O Link (all I/O Modules). Check*1) a correspondence between parameter settings and HW configuration, when Pulse Encoder Module (NTAC) is connected to CH1.

Electromagnetic interference.

Check for proper earthing of the equipment. Check for highly emissive components nearby.

Internal fault

Replace option module. Replace the fibre optic cables on the I/O Link. Replace RDCO module Replace AIMA-board Replace RMIO-board.

*1) if the Pulse Encoder Module is connected to CH1 instead of CH2, par. 70.03 CH1 BAUDRATE the Communication Speed must be changed to 4 Mbits.

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No Communication (18)

Possible reason (8) = Panel Link between RMIO-board and control panel is faulty (4) = Panel type is not compatible with the version of the drive application program. (1-4) = Internal fault

Action Check the Panel Link connections. Check the Panel type and the version of the drive application program. Replace RMIO-board. Replace CDP 312R Panel.

Possible reason (3) = Internal fault

Action Check *1) setting of par. 16.09 CTRL BOARD SUPPLY. Check the external +24VDC supply for voltage dips.

*1) See ACS800 Product Notice 2 / ACS800 Units: External +24 V Powering of the RMIO Board from ACS800 IHMM

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Overcurrent

Possible reason Sudden load change or stall Closing contactor in output Motor connection is wrong (Star / Delta)

Action Check the load, the motor current and mechanics of the system If output contactor is used, stop modulation at first and then close the contactor. Check motor voltage and its connection from the rating plate and compare with values of parameter group 99. Check the load and increase ramp times. Caused by speed ref: Check that the speed reference does not oscillate (par. 122.2 speed ref 3). Caused by torque ref: Check that the torque referencies do not oscillate (par. 137.3 torq used ref, 122.10 torq ref1 and 122.11 torq ref2). Caused by overcompensation in a speed response: Check the speed controller parameter settings. (Autotune does not bring a satisfactory result in some cases). Caused by Too high Feedback filtering time (par.121.9): See ACS 600 Speed Controller Tuning hint from IHMM *1). Caused by wrong value of the encoder pulses: Check the waveform of the pulses and the pulse numbers from the 155.2 encoder pulse nr. Caused by Motor Model: Check correct motor data from motor name plate and compare to group 99.

Too short ramp times, so that overcurrent controller does not have enough time to grip. Oscillation in motor speed / torque.

Output short circuit: Damaged motor cable(s) or damaged motor.

Check motor and cable insulations. Disconnect motor cables and run the drive in scalar control => if the drive does not trip its OK.

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Possible reason Output earth fault in TN-S (grounded network) Wrong motor and drive dimensioning.

Action Check and megger motor(s) and cables. Check the value of the motor nominal current is inside 1/6* par 112.2 2* par 112.2. Measure output current, torque and limit word.

Power factor correction capacitors or surge absorbers. Encoder connection Uncorrect motor data Incorrect inverter type

Check there are no power factor correction capacitors or surge absorbers in the motor cable. Check encoder, encoder cables (including phasing) and xTAC module. Check correct motor data from motor rating plate. Compare the rating plate of the drive and configuration in the sw from CDP panel (drive) or par. 112.7 and 101.2 *2) Check motor nominal cos fii value from hidden parameters *3). Check *4) flat cable connections Check and replace fibreoptic cable Check or replace current transducers *5) Check output current, torque and limit word *6) See Overcurrent or Motor Temperature Fault with Scalar Control hint from IHMM *7)

Uncorrect motor nominal cos fii No communication between RMIO- RINT / AINT- and AGDR boards Overcurrent in Scalar Control

LD (GTO) mode is ON LD (GTO) mode is OFF Functioning of the contactor used in the auxiliary control circuit for e.g motor heating or motor external fan control Internal fault

Change the LD mode OFF (par.149.9) See Long Distance Mode Hint from IHMM *8) Relocate the contactor. Equip the contactor with surge suppressor. Check or replace current transducers *4). Replace xINT-board. Check the flat cables are connected properly. Replace all optic fibers between INTs and xPBU (if parallel connected). Replace xPBU-board if used (if parallel

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Possible reason connected).

Action

*1) See Hint15 ACS 600 Speed Controller Tuning from Service Hints of ACS600 SingleDrive InHouse Maintenance Manual. *2) See Parameter settings for ACS800 Singledrive from ACS800 IHMM / Software / Instructions. *3) Compare cos fii values from the motor name plate and par. 110.7 MOTOR_NOM_COS_FII. If there are big differences, set the above-mentioned parameter by changing first par. 110.5 POWER_IS_GIVEN to COS FII. Note that you have to perform the Motor Identification Run after changing any motor data. *4) See ACS800 HW Hint 4 / ACS800 Units: PPCC Link - Short Circuit - Overcurrent fault caused by inadequate flat cable connection from ACS800 IHMM / Support / Hints and product notice. *5) See Hint38 How to Check ACS 600 Current Transducers from Service Hints of ACS600 SingleDrive In-House Maintenance Manual. *6) If there is oscillation in the torque and the motor current uses 191.29 Scalar stab gain to stabilize the system. If the current limit of the drive is active, increase the current limit level or decrease load. Note that the drive trips easier to overcurrent in scalar control than in DTC in case of current limitation. *7) See Hint43 Overcurrent or Motor Temperature Fault with Scalar Control under Service Hints in the ACS600 SingleDrive In-House Maintenance Manual. *8) See Hint Long Distance Mode in ACS 600 under Fault Tracing in the ACS 600 MultiDrive InHouse Maintenance Manual Air-cooled.

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PPCC Link Fault

Possible reason No communication between RMIO- RINT / AINT- and AGDR boards

Action Check the flat cable connections *1) or Check the fibre optic cables are connected between RMIO - AINT-boards (+xPBU if parallel connected) and replace if needed. Check that DC-bus voltage is alive. Check that parameter 112.16 corresponds actual setup. *2)

Functioning of the contactor used in the auxiliary control circuit for e.g motor heating or motor external fan control Inverter hardware failure

Relocate the contactor. Equip the contactor with surge suppressor. Replace xINT board. Check all connections from xINT (some connection can overload the xINT-board Check*3) and replace current transducers. Check and replace IGBT-modules *4) Check and replace APOW. Check and replace xPBU. Check all flat cable connections. Check all connections from APOW (some connection can overload the APOW-board)

Incorrect inverter type

Compare the rating plate of the drive and configuration in the sw from CDP panel (drive) or par. 112.7 and 101.2 *5) Replace NPBU-4x with APBU-42 in ACS80007 units with parallel connected R8i inverters.

Disturbance of pulse branching unit

*1) See ACS800 HW Hint 4 / ACS800 Units: PPCC Link - Short Circuit - Overcurrent fault caused by inadequate flat cable connection from ACS800 IHMM / Support / Hints and product notice *2) See ACS800 SW Hint x / XXXXXX from ACS800 IHMM / Support / Hints and product notice *3) See hint38 How to Check ACS 600 Current Transducers under Service Hints in the ACS600 SingleDrive In-House Maintenance Manual.

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*4) See Replacing the IGBT module of ACS800-02 frame R7 drive 7 or replacing the IGBT modules of ACS800-02 frame R8 drive under ACS800 IHMM / Support / Service Instructions and Manuals *5) See Parameter settings for ACS800 Singledrive under ACS800 IHMM / Software / Instructions / RMIO configuration instructions

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PP Overload

Possible reason The temperature difference between heat sink (cool environment) and IGBT module is too high (driven in max current).

Action Run the drive with smaller current until the heat sink is warmed up.

Short Circuit

Possible reason Damaged motor cables or damaged motor

Action Check motor and cable insulations. Check motor windings.

Internal fault

Check there is no external object inside drive. Check or replace *1) IGBT modules. Replace xINT -boards. Replace xPBU-board if used. Replace AGPS-board. Check *2) flat cables are connected properly.

*1) See Replacing the IGBT module of ACS800-02 frame R7 drive 7 or replacing the IGBT modules of ACS800-02 frame R8 drive under ACS800 IHMM / Support / Service Instructions and Manuals *2) See ACS800 HW Hint 4 / ACS800 Units: PPCC Link - Short Circuit - Overcurrent fault caused by inadequate flat cable connection under ACS800 IHMM / Support / Hints and product notice

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Supply Phase

Possible reason One input phase is missing Supply net disturbance

Action Check fuses and installation, measure the supply voltages from input terminals. Check for mains supply imbalance. Increase par 145.4 DC ripple limit value. Max value is 20%. Increasing the DC ripple will decrease the lifetime of DC capacitors.

Oscillation problem under heavy load

Check the load Check parameter settings.

Internal fault

Replace xINT- board Replace the rectifier bridge Replace AINP-board Check cabling between AINP and rectifier bridge. Check the DC-capacitors. Check DC voltage measurement. In parallel connected drives check that the DC voltage is stabile when the drive is powered but not modulating. If the DC is not stabile one or more xINTs are broken.

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Fieldbus

Possible reason Communication cannot be established or communication parameters cannot be set when FB module of type Nxxx is used. FB status and Drive status word are not equal when FB module of type Rxxx is used.

Action Check par. 70.01 CH0 node address

Check the operation mode configuration (ABB DRIVES / GENERIC) on the FB master and par 98.07 in the drive.

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DSU
Earth fault
Possible reason Supply network is floating (IT) Action Disable earth fault supervision with dipswitches. Power off the board for at least 3 minutes. Install Bender. Motor cable or motor is damaged. Megger the motor and motor cable. Disconnect motor cables and run the drive in scalar control => if the drive does not trip its OK. Power factor correction capacitors or surge absorbers. Internal fault Check there are no power factor correction capacitors or surge absorbers in the motor cable. Check and replace current transformer(s). Check and replace flat cables. Replace DSMB-01 board Replace DSSB-01 board

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Other fault
Possible reason Emergency stop circuit opened Action Measure the input of connector X8:1 +24V :2 24V if not OK check following: Check emstop circuit Check fuses of connector X4 on DSSB board Check voltage polarity in input. Internal fault or charging not successful Check switch disconnector and auxiliary contacts. Check contactors and auxiliary contacts. Check cabling between DSAB - contactor Check and replace flat cables Replace DSSB board Replace DSMB-0X board

Phase missing
Possible reason AC fuse blown Loose input power terminal Internal fault Change AC fuse Check the connections and tightening torques Check and replace the fuse on DSAB-board Action

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When to change a whole R2-R4 drive under warranty

According to the ACS800 Warranty Directive1 frame R2-R4 units should be repaired by replacing the whole unit if the fault is on main circuit component. The purpose of this document is to help service engineer to locate the faulty component and then to do the right service action. If one of the following components causes the problem, then the drive should be repaired by using spare parts: Control panel CDP-312R Control panel connectors or control panel wiring RMIO-01 / RMIO-01C motor control board RMIO-option modules (RDCO-0x, RAIO-01, RDIO-01, RTAC-01, RDNA-01 or other fieldbus) RRFC-board filter board RVAR-board varistor board DC-capacitors (only in Frame R4) Fan Plastic front cover or other plastic parts Cable connection box If the fault is on one of the main circuit components or the frame of the drive is damaged then the problem should be selved by changing the whole unit. When ordering a whole drive under warranty it is possible that the unit delivered from Logistics Center will be different type. than the original one. Please see ACS800 Warranty Directive Appendix A for more information. Below is the list of components that require changing the whole unit: RINT-xxxx board RASI-board Power module (diode bridge, output bridge + brake), Frames R2-R3 Input bridge module, Frame R4 Output bridge, Frame R4 Brake module, Frame R4 Choke (DC choke in Frames R2-R3, AC choke in Frame R4) Module metal frame

Latest version of ACS800 Warranty Directive is always available in ACS800 In-House Maintenance Manual. See sections ACS800 IHMM / 01 General / Warranty for ABB or ACS800 IHMM / 01 General / Warranty for DAP

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Fault Tracing of small drives (frames R2-R4)

Engineer should always locate the faulty component before changing the whole unit. The steps of fault tracing must be described in detail in the warranty report. Following tables can be used as help when locating the faulty component. Many faults can be caused by incorrect parameter values. If there is a chance that someone has entered problematic settings, following simple procedure can be done: 1. Upload parameters to CDP-312R (see Firmware manual for instructions, section Control Panel) 2. Make an Application Restore (parameter 99.03 in Standard Application Program) for the drive. This will return the default settings. 3. If the fault disappeared then the fault was probably caused by incorrect parameter set-up. Then drive should be comissioned again by setting the parameters according to the customers application. 4. If the application restore does not remove the fault then there is probably a hardware fault in the drive. Continue fault tracing in order to find the faulty component. In case of following faults the unit should be repaired by using spare parts:

Fault No communication (x) Application Error (x) CTRL B TEMP I/O Comm fault

Possible reason Problem in panel communication Problem in panel communication RMIO temperature measurement shows too high value RMIO option slot communication

Action CDP-312R, RMIO or cabling CDP-312R, RMIO sw RMIO RMIO, option modules

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In case of following faults the unit should be repaired by changing the whole drive after possibility of external reason is ruled out

Fault Short Circuit

Possible reason IGBT broken or IGBT control circuit damaged, broken motor or motor cable

Action Rule out the motor cable or motor damage by running the unit in scalar motor cables disconnected. If the drive is still giving short circuit fault the whole unit should be changed. Check parameter set-up and measure actual supply voltage and DC-voltage. If parameters and supply voltage are OK, change the whole drive. Check parameter set-up, also ensure that the motor values are acceptable for the drive and inspect the insulation level of the motor and the motor cables. If all OK, change the whole drive. Check parameter set-up, rule out possibility of broken fuse, check that supply voltage is in balance. If all are OK, change the whole drive. Check parameter set-up. Ensure that all the fans are running and the air circulation is OK. If no external reason is found then change the whole drive. Check motor and cables. If no external reason is found then change the whole drive.

Over / Undervoltage

The voltage measurement gives values outside accepted range Too big current measured, IGBT or RINT board broken, unsuitable motor or motor cable used or incorrect parameter setup of the drive. Too much DC-ripple due to distorted network, wrong parameter setup or broken drive. Temperature exceeds the limit due to measurement error, broken fan, blocked air circulation or broken component inside the drive. Broken drive, motor or cable

Overcurrent

Supply Phase

ACS800 TEMP or IN CHOKE TEMP

Earth Fault

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In case of following faults the drive should be either repaired with spare parts or by repairing the whole drive. Defining the correct repair procedure requires some futher fault tracing

Fault PPCC Link

Possible reason Communication between RASI and RMIO does not work properly

Action 1. Check if external power supply used and parameter 16.09 is in Internal (default) value 2. RASI-board broken (change whole drive) 3. RMIO-board broken (change the RMIO) 4. Check cable/fibre and connections

Unit is dead

RMIO board does not wake up or internal 24V power does not work

1. Measure DC-voltage from terminals (if not normal => change the whole unit) 2. If DC-voltage is OK, measure internal power supply (24V) output (e.g. from RMIO terminal). If voltage is not 24V, unplug RMIO and fan and measure again. If 24V is now OK, either broken fan or RMIO overloads the power (=> repair with spare parts). If 24V is still not OK after unplugging fan and RMIO, change the whole drive.

More information about fault tracing can be found from other manuals and IHMM. This document is not a complete guide, which takes all variations into account. Local and Global Support Lines can be used for assistance.