Abb Drives: Acs800 Trouble Shooting Operating Instruction 3afe

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

1 / 13

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

Table of contents

Drive units ____________________________________________________________________ 2 DC Overvoltage_____________________________________________________________________ 2 Earth Fault ________________________________________________________________________ 3 FLT (x_x)__________________________________________________________________________ 4 I/O Communication Fault ____________________________________________________________ 5 No Communication (1…8) ____________________________________________________________ 5 Overcurrent________________________________________________________________________ 6 PPCC Link Fault ___________________________________________________________________ 9 PP Overload ______________________________________________________________________ 10 Supply Phase ______________________________________________________________________ 11

Fieldbus _____________________________________________________________________ 12 DSU ________________________________________________________________________ 12 Earth fault ________________________________________________________________________ 12 Other fault________________________________________________________________________ 13 Phase missing _____________________________________________________________________ 13

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

2 / 13

Drive units 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.

Disable controller only when using brake unit or TSU/ISU.

Supply voltage too high

Check mains for static or transient overvoltage.

Faulty Braking Chopper

Check Braking Chopper and Breaking Resistors.

Internal Fault

Replace xINT-board.

Earth fault in IT (floating network)

Check there is no earth fault in 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)

EMC- boards are connected in IT network.

Disconnect common mode capacitors from the gnd *2)

*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.

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

3 / 13

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)

Internal fault

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.

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

Earth Fault

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 it’s OK.

Long motor cables or high stray capacitance to the ground.

Use*1) output chokes. Check earth fault trip level

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Possible reason

Revision

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A

4 / 13

Action

Power factor correction capacitors or surge absorbers.

Check there are no power factor correction capacitors or surge absorbers in the motor cable.

Internal fault.

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.

FLT (x_x)

Possible reason

Action

(F1_4…7) Flash memory

Replace RMIO-board, inform Supportline

(F2_X) Processor or memory

Replace RMIO-board, inform Supportline

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

5 / 13

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.

No Communication (1…8)

Possible reason

Action

(8) = Panel Link between RMIO-board and control panel is faulty

Check the Panel Link connections.

(4) = Panel type is not compatible with the version of the drive application program.

Check the Panel type and the version of the drive application program.

(1-4) = Internal fault

Replace RMIO-board. Replace CDP 312R Panel.

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Possible reason (3) = Internal fault

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6 / 13

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

Overcurrent

Possible reason

Action

Sudden load change or stall

Check the load, the motor current and mechanics of the system

Closing contactor in output

If output contactor is used, stop modulation at first and then close the contactor.

Motor connection is wrong (Star / Delta)

Check motor voltage and its connection from the rating plate and compare with values of parameter group 99.

Too short ramp times, so that overcurrent controller does not have enough time to grip.

Check the load and increase ramp times.

Oscillation in motor speed / torque.

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).

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Possible reason

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7 / 13

Action 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.

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

Check motor and cable insulation’s.

Output earth fault in TN-S (grounded network)

Check and megger motor(s) and cables.

Wrong motor and drive dimensioning.

Check the value of the motor nominal current is inside 1/6* par 112.2 – 2* par 112.2.

Disconnect motor cables and run the drive in scalar control => if the drive does not trip it’s OK.

Measure output current, torque and limit word. Power factor correction capacitors or surge absorbers.

Check there are no power factor correction capacitors or surge absorbers in the motor cable.

Encoder connection

Check encoder, encoder cables (including phasing) and xTAC module.

Uncorrect motor data

Check correct motor data from motor rating plate.

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 *2)

Uncorrect motor nominal cos fii

Check motor nominal cos fii value from hidden parameters *3).

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

Check *4) flat cable connections

Overcurrent in Scalar Control

Check or replace current transducers *5)

Check and replace fibreoptic cable

Check output current, torque and limit word *6) See Overcurrent or Motor Temperature Fault with Scalar Control hint from IHMM *7) LD (GTO) mode is ON

Change the LD mode OFF (par.149.9)

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Possible reason

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8 / 13

Action

LD (GTO) mode is OFF

See Long Distance Mode Hint from IHMM *8)

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

Relocate the contactor.

Internal fault

Check or replace current transducers *4).

Equip the contactor with surge suppressor.

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 connected). *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 a 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 use 191.29 Scalar stab gain to stabilize system. If the current limit of the drive is active, increase 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 from Service Hints of ACS600 SingleDrive In-House Maintenance Manual. *8) See Hint Long Distance Mode in ACS 600 from Fault Tracing of ACS 600 MultiDrive In-House Maintenance Manual Air-cooled.

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

9 / 13

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 the DC is alive.

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

Relocate the contactor.

Inverter hardware failure

Replace xINT -board.

Equip the contactor with surge suppressor.

Check all connections from xINT (some connection can overload the xINT-board Check*2) and replace current transducers. Check and replace IGBT-modules *3) 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 *4)

*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 hint38 How to Check ACS 600 Current Transducers from Service Hints of ACS600 SingleDrive In-House Maintenance Manual. *3) See Replacing the IGBT module of ACS800-02 frame R7 drive 7 or replacing the IGBT modules of ACS800-02 frame R8 drive from ACS800 IHMM / Support / Service Instructions and Manuals *4) See Parameter settings for ACS800 Singledrive from ACS800 IHMM / Software / Instructions / RMIO configuration instructions

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

10 / 13

PP Overload

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

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

Short Circuit

Possible reason Damaged motor cables or damaged motor

Action Check motor and cable insulation’s. 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 from 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 from ACS800 IHMM / Support / Hints and product notice

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

11 / 13

Supply Phase

Possible reason

Action

One input phase is missing

Check fuses and installation, measure the supply voltages from input terminals.

Supply net disturbance

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 xINT’s are broken.

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

12 / 13

Fieldbus

Possible reason

Action

Communication cannot be established or communication parameters cannot be set when FB module of type Nxxx is used.

Check par. 70.01 CH0 node address

FB status and Drive status word are not equal when FB module of type Rxxx is used.

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

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 it’s OK.

Power factor correction capacitors or surge absorbers.

Check there are no power factor correction capacitors or surge absorbers in the motor cable.

Internal fault

Check and replace current transformer(s). Check and replace flat cables. Replace DSMB-01 board Replace DSSB-01 board

ABB Drives Dept.

Project

Status Date

ACS800 02.Dec 2003

ACS800 TROUBLE SHOOTING

3AFE

Operating Instruction

00308778.DOC

Author

Status

NURMIMÄKI JOUNI

APPROVED/TIITTANEN JUKKA

Revision

Page

A

13 / 13

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

Action

AC fuse blown

Change AC fuse

Loose input power terminal

Check the connections and tightening torques

Internal fault

Check and replace the fuse on DSAB-board