~3443202acs800 Trouble Shooting

ABB Drives

ACS800 TROUBLE SHOOTING

Operating Instruction

3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status

APPROVED/INGMAN KJELL

Revision

B

Page

1 / 22

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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

2 / 22

Table of contents

Drive units ____________________________________________________________________3

DC Overvoltage ____________________________________________________________________3

Earth Fault ________________________________________________________________________6

FLT (x_x) _________________________________________________________________________7

I/O Communication Fault ____________________________________________________________7

No Communication (1…8)____________________________________________________________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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

3 / 22

Drive units ACS800 Temp

Possible reason

Action

The internal thermal model calculates that the maximum IGBT temperature has been reached.

Decrease the load.

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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

4 / 22

DC Overvoltage

Possible reason

Action

Deceleration time is too short. 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 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.

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



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

5 / 22

DC Undervoltage

Possible reason

Action

Too low input voltage 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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

6 / 22

Earth Fault / Current Unbalance

Possible reason

Action

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.

Long motor cables or high stray capacitance to the ground.

Use*1) output chokes.

Check earth fault trip level

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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

7 / 22

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

I/O Communication Fault

Possible reason

Action

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

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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

8 / 22

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.

Possible reason

Action

(3) = Internal fault 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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

9 / 22

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).

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.


ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

10 / 22

Possible reason

Action

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.

Measure output current, torque and limit word.



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

Uncorrect motor data Check correct motor data from motor rating plate.


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

Check and replace fibreoptic cable

Overcurrent in Scalar Control 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)

LD (GTO) mode is ON Change the LD mode OFF (par.149.9)

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.

Equip the contactor with surge suppressor.

Internal fault 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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

11 / 22

Possible reason

Action connected).

*1) See Hint15 ACS 600 Speed Controller Tuning from Service Hints of ACS600 SingleDrive In-House 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 In-House Maintenance Manual Air-cooled.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

12 / 22

PPCC Link Fault

Possible reason

Action

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

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

Relocate the contactor.

Equip the contactor with surge suppressor.

Inverter hardware failure 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)


Disturbance of pulse branching unit Replace NPBU-4x with APBU-42 in ACS800-07 units with parallel connected R8i inverters.

*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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

13 / 22

*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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

14 / 22

PP Overload

Possible reason

Action

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

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

Short Circuit

Possible reason

Action

Damaged motor cables or damaged motor

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 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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

15 / 22

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



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

16 / 22

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.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

17 / 22

DSU Earth fault

Possible reason

Action

Supply network is floating (IT) 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.




Internal fault Check and replace current transformer(s).

Check and replace flat cables.

Replace DSMB-01 board

Replace DSSB-01 board

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

18 / 22

Other fault

Possible reason

Action

Emergency stop circuit opened 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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

19 / 22

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

1 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

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

20 / 22

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 customer’s 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

Possible reason

Action

No communication (x) Problem in panel communication CDP-312R, RMIO or cabling

Application Error (x) Problem in panel communication CDP-312R, RMIO sw

CTRL B TEMP RMIO temperature measurement shows too high value

RMIO

I/O Comm fault RMIO option slot communication RMIO, option modules

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

21 / 22

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

Fault

Possible reason

Action

Short Circuit IGBT broken or IGBT control circuit damaged, broken motor or motor cable

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.

Over / Undervoltage The voltage measurement gives values outside accepted range

Check parameter set-up and measure actual supply voltage and DC-voltage. If parameters and supply voltage are OK, change the whole drive.

Overcurrent Too big current measured, IGBT or RINT board broken, unsuitable motor or motor cable used or incorrect parameter setup of the 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.

Supply Phase Too much DC-ripple due to distorted network, wrong parameter setup or broken 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.

ACS800 TEMP or IN CHOKE TEMP

Temperature exceeds the limit due to measurement error, broken fan, blocked air circulation or broken component inside the 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.

Earth Fault Broken drive, motor or cable Check motor and cables. If no external reason is found then change the whole drive.

ABB Drives



3AFE 00308778_B.DOC

Dept.

Project

ACS800

Status Date

29.May 2006

Author

TIITTANEN JUKKA /D

Status


Revision

B

Page

22 / 22

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

Possible reason

Action

PPCC Link Communication between RASI and RMIO does not work properly

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.

~3443202acs800 Trouble Shooting

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Transcript of ~3443202acs800 Trouble Shooting