Fault Finding

ABB Drives ACS600 TROUBLE SHOOTING 3AFE
Operating Instruction 00241985_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/TIITTANEN JUKKA
ACS600 02.Dec 2003 NURMIMÄKI JOUNI B 1 / 12
This document contains some information about ACS600 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. ACS607 1380 6
• 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
DC Overvoltage ________________________________________________________________2
DC Undervoltage _______________________________________________________________3
Earth Fault ___________________________________________________________________4
I/O Communication Fault________________________________________________________5
No Communication (1…8) _______________________________________________________6
Overcurrent ___________________________________________________________________7
PPCC Link Fault ______________________________________________________________10
Short Circuit _________________________________________________________________11
Supply Phase _________________________________________________________________12
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 Disable controller only when using brake unit
disabled and there is no brake unit or or TSU/ISU.
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 NINT-board.
Earth fault in IT (floating network) Check motor and motor cables.
EMC- boards are connected in IT netvork. Disconnect common mode capasitor from the
gnd. See hints XXX.
DC Undervoltage
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 inverter.
Internal fault Replace a rectifier bridge.

Replace NINP-board.
Check cabeling between NINP and D/T-
bridges.
Replace NINT.
Earth Fault
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.
Too long motor cables (with earthed network). Use*1) output chokes.
Power factor correction capacitors or surge Check there are no power factor correction
absorbers. capacitors or surge absorbers in the motor
cable.
Internal fault. Study ACS 600 Earth Fault Protection

Service Manual *2).
Check the flat cables are connected properly.
Replace NINT-board.
Replace Current Transducer or Earth Fault
Transducer.
Replace NPBU-board if used.
Replace NRFC-board.
Replace all optic fibers between NINTs and
NPBU.
*1) see Maximum Motor Cable length on Installation Guide for du/dt filters from Support Material
of ACS600 SingleDrive In-House Maintenance Manual.
*2) See ACS 600 Earth Fault Protection Service Manual from Service Hints of ACS600
SingleDrive In-House Maintenance Manual.
I/O Communication Fault
A Communication error has occurred on the Check the connections of the fibre optic cables
I/O Link. 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 the fibre optic cables on the I/O Link.
Replace NIOC- or NAMC-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)
(6-8) = Panel Link between NIOC-board and Check the Panel Link connections.
CDP311 control panel is faulty or Panel Link
between NAMC-board and CDP312 control
panel is faulty.
(4) = Panel type is not compatible with the Check the Panel type and the version of the
version of the drive application program. drive application program.
CDP312 Panel does not communicate with
SW version 3.x or earlier.
CDP311 Panel does not communicate with
SW version 5.x or later.
(1-4) = Internal fault Replace NAMC-board.

Replace NIOC-board if sw 3.0 or older is used.
Replace CDP 31x Panel.
Overcurrent
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 name plate and compare to values in
group 99 of the drive.
Too short ramp times, so that overcurrent Check the load and increase ramp times.
controller does not have enough time to grip.
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) Check motor and cable insulation’s.
or damaged motor.
Disconnect motor cables and run the drive in
scalar control => if the drive does not trip it’s
OK.
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.
Power factor correction capacitors or surge Check there are no power factor correction
absorbers. capacitors or surge absorbers in the motor
cable.
Encoder connection Check encoder, encoder cables (including

phasing) and NTAC module.
Uncorrect motor data Check correct motor data from motor name
plate.
Uncorrect inverter data Check correct inverter data from parameters in

groups 112 and 190. Compare values to the
values of NAMC changing instructions in IHMM
*2).
Uncorrect motor nominal cos fii Check motor nominal cos fii value from hidden
parameters *3).
Internal fault in the ACS600 Single Drive Check or replace current transducers *4).
Replace NINT-board.
Overcurrent in Scalar Control Check output current, torque and limit word *5)
Check or replace current transducers *4)
See Overcurrent or Motor Temperature Fault
with Scalar Control hint from IHMM *6)
Calibration current trip limit too low with high Update software version to ASXX5260 or
speed motors. newer.
Kuhnke relay type UF3G-230VACN / UF3G- See ACS 600 MultiDrive Fault Tracing Hint
110VACN is used in the fan supervision circuit. 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 Relocate the contactor.

auxiliary control circuit for e.g motor heating or
motor externl fan control Equip the contactor with surge suppressor.
Internal fault in the ACS600 MultiDrive See Fault tracing Hints from IHMM *9)
Replace all optic fibers between NINTs and
NPBU (if parallel connected).
Replace NPBU-board if used (if parallel
connected).
*1) See Hint15 ACS 600 Speed Controller Tuning from Service Hints of ACS600 SingleDrive In-
House Maintenance Manual.
*2) See NAMC-xx Parameter Setting instructions from Instructions to Exchange Parts section of
ACS600 SingleDrive In-House Maintenance Manual or from Software Hints of ACS 600 MultiDrive
In-House Maintenance Manual Air-cooled.
*3) Compare cos fii values from a motor name plate and par. 110.7 MOTOR_NOM_COS_FII.
If there are a 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 Hint38 How to Check ACS 600 Current Transducers from Service Hints of ACS600
*5) It there are 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.
*6) See Hint43 Overcurrent or Motor Temperature Fault with Scalar Control from Service Hints of
ACS600 SingleDrive In-House Maintenance Manual.
*7) See Hint ACS 600 MultiDrive Fault Tracing Hints Occassional Run Disabled / Start Inhibit HW
/ Overcurrent / Overvoltage / Encoder Faults from Fault Tracing of ACS 600 MultiDrive In-House
Maintenance Manual Air-cooled.
*8) See Hint Long Distance Mode in ACS 600 from Fault Tracing of ACS 600 MultiDrive In-House
Maintenance Manual Air-cooled.
*9) See Hint Fault tracing hints of parallel connected MultiDrive inverters from ACS 600 MultiDrive
In-House Maintenance Manual Air-cooled.
PPCC Link Fault
No communication between NAMC- and NINT- Check the fibre optic cables are connected
boards between NAMC - NINT-boards (+NPBU if
parallel connected) and replace if needed.
Check the DC is alive.
Incorrect value of INT-boards between Check*1) correct amount of INT-boards from

Software and Hardware. parameter 190.19.
Inverter hardware failure Replace NINT-board.

Check the NXPP-01 is connected correctly
(Note! mark C30 must be down).
Check and replace NGDR-boards.
Check*2) and replace current transducers.
Check and replace NPOW.
Check and replace NPBU.
Check all flat cable connections.
Check all connections from NPOW (some
connection can overload the NPOW-board)
Incorrect value of Software version with a Check*3) Inverter Hardware Type from
hardware between parallel and non-parallel software version (par. 3301 or 0401) and
units (application software 5.2XX or earlier). download software with correct loading
commands.
Functioning of the contactor used in the Relocate the contactor.

auxiliary control circuit for e.g motor heating or
motor externl fan control Equip the contactor with surge suppressor.
*1) See Instructions to NAMC-boards from Instructions to Exchange Parts of ACS600 SingleDrive
In-House Maintenance Manual.
*2) See hint38 How to Check ACS 600 Current Transducers from Service Hints of ACS600
*3) see Inverter HW (symbol3) in ACS600 SW Loading Instructions from SW Loading Packages
of ACS600 SingleDrive In-House Maintenance Manual or from Firmware Manual for System
Application Program.
Short Circuit
Damaged motor cables or damaged motor Check motor and cable insulation’s.
Check motor windings.
Output earth fault Check motors and cables
Internal fault Check there is no external object inside drive.

Check*1) or replace NGDR boards.
Check*2) or replace Power Plate Module.
Replace NINT- or NXPP-boards.
Replace NGPS-board.
*1) See Instruction for NGDR-tester from Service Manuals of ACS600 SingleDrive In-House
Maintenance Manual
*2) See Checking and Replacing a Power Plate Service manual from Service Manuals of ACS600
SingleDrive In-House Maintenance Manual
Supply Phase
One input phase is missing Check fuses and installation, measure the
supply voltages from terminal.
Supply net disturbance Check for mains supply imbalance.

Increase DC ripple limit value. Max value is
20%. Increasing the DC ripple will decrease
the life time of DC capasitors.
Oscillation problem under heavy load See*1) Service Hints from IHMM if SW 3.x is
used.
Check the load.
Internal fault Replace a rectifier bridge

Replace NINP-board
Check cabeling between NINP and D/T-
bridges.
Check the DC-capasitors.
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 NINT’s are broken.
*1) see hint38 Oscillation Problem of ACS600 under Heavy Load from Service Hints of ACS600

Fault Finding

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Fault Finding

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ABB Drives ACS600 TROUBLE SHOOTING 3AFE

Operating Instruction 00241985_B.DOC

Dept. Project Status Date Author Status Revision Page

• type of the unit e.g. ACS607 1380 6

• serial number e.g. 1013500356

• what is the application

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Supply voltage too high Check mains for static or transient

Faulty Braking Chopper Check Braking Chopper and Breaking

Internal Fault Replace NINT-board.

Earth fault in IT (floating network) Check motor and motor cables.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Internal fault Replace a rectifier bridge.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Internal fault. Study ACS 600 Earth Fault Protection

Dept. Project Status Date Author Status Revision Page

I/O Communication Fault

Possible reason Action

Electromagnetic interference. Check for proper earthing of the equipment.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

(1-4) = Internal fault Replace NAMC-board.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Closing contactor in output If output contactor is used, stop modulation at

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Encoder connection Check encoder, encoder cables (including

Uncorrect inverter data Check correct inverter data from parameters in

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

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Functioning of the contactor used in the Relocate the contactor.

Dept. Project Status Date Author Status Revision Page

PPCC Link Fault

Possible reason Action

Incorrect value of INT-boards between Check*1) correct amount of INT-boards from

Inverter hardware failure Replace NINT-board.

Functioning of the contactor used in the Relocate the contactor.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Output earth fault Check motors and cables

Internal fault Check there is no external object inside drive.

Dept. Project Status Date Author Status Revision Page

Possible reason Action

Supply net disturbance Check for mains supply imbalance.

Internal fault Replace a rectifier bridge

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