ABB ACH550-UH HVAC User manual

ACH550-UH User’s Manual 1-281

Diagnostics

Warning! Do not attempt any measurement, parts replacement or other service

procedure not described in this manual. Such action will void the warranty, may

endanger correct operation, and increase downtime and expense.

Warning! All electrical installation and maintenance work described in this chapter

should only be undertaken by qualified service personnel. The Safety instructions on

the first pages of this manual must be followed.

Diagnostic displays

The drive detects error situations and reports them using:

• The green and red LED on the body of the drive

• The status LED on the control panel (if the HVAC control panel is attached to the

drive)

• The control panel display (if the HVAC control panel is attached to the drive)

• The Fault Word and Alarm Word parameter bits (parameters 0305 to 0309). See

Group 03: ACTUAL SIGNALS on page 1-87.

The form of the display depends on the severity of the error. You can specify the

severity for many errors by directing the drive to:

• Ignore the error situation.

• Report the situation as an alarm.

• Report the situation as a fault.

Red – faults

The drive signals that it has detected a severe error, or fault, by:

• Enabling the red LED on the drive (LED is either steady on or blinking).

• Setting an appropriate bit in a Fault Word parameter (0305 to 0307).

• Overriding the control panel display with the display of a fault code.

• Stopping the motor (if it was on).

The fault code on the control panel display is temporary. Pressing any of the

following buttons removes the fault message: MENU, ENTER, UP button or DOWN

button. The message reappears after a few seconds if the control panel is not

touched and the fault is still active.

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Diagnostics

Flashing green – alarms

For less severe errors, called alarms, the diagnostic display is advisory. For these

situations, the drive is simply reporting that it had detected something “unusual.” In

these situations, the drive:

• Flashes the green LED on the drive (does not apply to alarms that arise from

control panel operation errors).

• Sets an appropriate bit in an Alarm Word parameter (0308 or 0309). See Group

03: ACTUAL SIGNALS on page 1-87 for the bit definitions.

• Overrides the control panel display with the display of an alarm code and/or

name.

Alarm messages disappear from the control panel display after a few seconds. The

message returns periodically as long as the alarm condition exists.

Correcting faults

The recommended corrective action for faults is:

• Use the Fault listing table below to find and address the root cause of the

problem.

• Reset the drive. See Fault resetting on page 1-287.

Fault listing

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

1OVERCURRENT Output current is excessive. Check for and correct:

• Excessive motor load.

• Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and

2205 ACCELER TIME 2).

• Faulty motor, motor cables or connections.

2DC OVERVOLT Intermediate circuit DC voltage is excessive. Check for and correct:

• Static or transient overvoltages in the input power supply.

• Insufficient deceleration time (parameters 2203 DECELER TIME 1 and

2206 DECELER TIME 2).

• Verify that overvoltage controller is ON (using parameter 2005).

3DEV OVERTEMP Drive heatsink is overheated. Temperature is at or above limit.

R1…R4 & R7/R8: 115 °C (239 °F)

R5/R6: 125 °C (257 °F)

Check for and correct:

• Fan failure.

• Obstructions in the air flow.

• Dirt or dust coating on the heat sink.

• Excessive ambient temperature.

• Excessive motor load.

4SHORT CIRC Fault current. Check for and correct:

• A short-circuit in the motor cable(s) or motor.

• Supply disturbances.

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Diagnostics

5RESERVED Not used.

6DC UNDERVOLT Intermediate circuit DC voltage is not sufficient. Check for and correct:

• Missing phase in the input power supply.

•Blownfuse.

• Undervoltage on mains.

7AI1 LOSS Analog input 1 loss. Analog input value is less than AI1FLT LIMIT (3021).

Check for and correct:

• Source and connection for analog input.

• Parameter settings for AI1FLT LIMIT (3021) and 3001 AI<MIN FUNCTION.

8AI2 LOSS Analog input 2 loss. Analog input value is less than AI2FLT LIMIT (3022).

Check for and correct:

• Source and connection for analog input.

• Parameter settings for AI2FLT LIMIT (3022) and 3001 AI<MIN FUNCTION.

9MOT TEMP Motor is too hot, based on either the drive’s estimate or on temperature

feedback.

• Check for overloaded motor.

• Adjust the parameters used for the estimate (3005…3009).

• Check the temperature sensors and Group 35 parameters.

10 PANEL LOSS Panel communication is lost and either:

• Drive is in local control mode (the control panel displays HAND or OFF),

• Drive is in remote control mode (AUTO) and is parameterized to accept

start/stop, direction or reference from the control panel.

To correct check:

• Communication lines and connections

• Parameter 3002 PANEL COMM ERROR.

• Parameters in Group 10: START/STOP/DIR and Group 11:

REFERENCE SELECT (if drive operation is AUTO).

11 ID RUN FAIL The motor ID run was not completed successfully. Check for and correct:

• Motor connections

• Motor parameters 9905…9909

12 MOTOR STALL Motor or process stall. Motor is operating in the stall region. Check for and

correct:

• Excessive load.

• Insufficient motor power.

• Parameters 3010…3012.

14 EXTERNAL FLT 1 Digital input defined to report first external fault is active. See parameter

3003 EXTERNAL FAULT 1.

15 EXTERNAL FLT 2 Digital input defined to report second external fault is active. See parameter

3004 EXTERNAL FAULT 2.

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

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Diagnostics

16 EARTH FAULT Possible ground fault detected in the motor or motor cables. The drive

monitors for ground faults while the drive is running and while the drive is

not running. Detection is more sensitive when the drive is not running and

can produce false positives.

Possible corrections:

• Check for/correct faults in the input wiring.

• Verify that motor cable does not exceed maximum specified length.

• A delta grounded input power supply and motor cables with high

capacitance may result in erroneous error reports during non-running

tests. To disable response to fault monitoring when the drive is not

running, use parameter 3023 WIRING FAULT. To disable response to all

ground fault monitoring, use parameter 3017 EARTH FAULT.

17 UNDERLOAD Motor load is lower than expected. Check for and correct:

• Disconnected load.

• Group 37: USER LOAD CURVE.

18 THERM FAIL Internal fault. The thermistor measuring the internal temperature of the

drive is open or shorted. Contact your local ABB sales representative.

19 OPEX LINK Internal fault. A communication-related problem has been detected on the

fiber optic link between the OITF and OINT boards. Contact your local ABB

sales representative.

20 OPEX PWR Internal fault. Low voltage condition detected on OINT power supply.

Contact your local ABB sales representative.

21 CURR MEAS Internal fault. Current measurement is out of range. Contact your local ABB

sales representative.

22 SUPPLY PHASE Ripple voltage in the DC link is too high. Check for and correct:

• Missing mains phase.

•Blownfuse.

23 ENCODER ERR Not used (Available only with encoder and parameter Group 50).

23 ENCODER ERR The drive is not detecting a valid encoder signal. Check for and correct:

• Encoder presence and proper connection (reverse wired, loose

connection, or short circuit).

• Voltage logic levels are outside of the specified range.

• A working and properly connected Pulse Encoder Interface Module,

OTAC-01.

• Wrong value entered in parameter 5001 PULSE NR. A wrong value will

only be detected if the error is such that the calculated slip is greater

than 4 times the rated slip of the motor.

• Encoder is not being used, but parameter 5002 ENCODER ENABLE = 1

(ENABLED).

24 OVERSPEED Motor speed is greater than 120% of the larger (in magnitude) of 2001

MINIMUM SPEED or 2002 MAXIMUM SPEED. Check for and correct:

• Parameter settings for 2001 and 2002.

• Adequacy of motor braking torque.

• Applicability of torque control.

• Brake chopper and resistor.

25 RESERVED Not used as of the publication of this manual.

26 DRIVE ID Internal fault. Configuration Block Drive ID is not valid. Contact your local

ABB sales representative.

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

ACH550-UH User’s Manual 1-285

Diagnostics

27 CONFIG FILE Internal configuration file has an error. Contact your local ABB sales

representative.

28 SERIAL 1 ERR Fieldbus communication has timed out. Check for and correct:

• Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME).

• Communication settings (Group 51 or 53 as appropriate).

• Poor connections and/or noise on line.

29 EFB CONFIG

FILE Error in reading the configuration file for the embedded fieldbus.

30 FORCE TRIP Fault trip forced by the fieldbus. See the fieldbus User’s Manual.

31 EFB 1 Fault code reserved for the embedded fieldbus (EFB) protocol application.

These codes are not used as of the publication of this manual.

32 EFB 2

33 EFB 3

34 MOTOR PHASE Fault in the motor circuit. One of the motor phases is lost. Check for and

correct:

• Motor fault.

• Motor cable fault.

• Thermal relay fault (if used).

• Internal fault.

35 OUTPUT WIRING Possible power wiring error detected. When the drive is not running it

monitors for an improper connection between the drive input power and the

drive output. Check for and correct:

• Proper input wiring – line voltageis NOT connected to drive output.

• The fault can be erroneously declared if the input power is a delta

grounded system and motor cable capacitance is large. This fault can be

disabled using parameter 3023 WIRING FAULT.

36 INCOMP

SWTYPE

The drive cannot use the software.

• Internal Fault.

• The loaded software is not compatible with the drive.

• Call support representative.

37 CB OVERTEMP Drive control board is overheated.

Check for and correct:

• Excessive ambient temperatures

• Fan failure.

• Obstructions in the air flow.

101 SERF CORRUPT Error internal to the drive. Contact your local ABB sales representative and

report the error number.

102 RESERVED

103 SERF MACRO

104 RESERVED

105 RESERVED

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

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Diagnostics

201 DSP T1

OVERLOAD Error in the system. Contact your local ABB sales representative and report

the error number.

202 DSP T2

OVERLOAD

203 DSP T3

OVERLOAD

204 DSP STACK

ERROR

205 RESERVED

(obsolete)

206 OMIO ID ERROR

207 EFB LOAD ERR

1000 PAR HZRPM

LIMITS

Parameter values are inconsistent. Check for any of the following:

• 2001 MINIMUM SPEED > 2002 MAXIMUM SPEED.

• 2007 MINIMUM FREQ > 2008 MAXIMUM FREQ.

• 2001 MINIMUM SPEED / 9908 MOTOR NOM SPEED is outside proper range

(> 50)

• 2002 MAXIMUM SPEED / 9908 MOTOR NOM SPEED is outside proper range

(> 50)

• 2007 MINIMUM FREQ / 9907 MOTOR NOM FREQ is outside proper range

(> 50)

• 2008 MAXIMUM FREQ / 9907 MOTOR NOM FREQ is outside proper range

(> 50)

1001 PAR PFAREFNG Parameter values are inconsistent. Check for the following:

• 2007 MINIMUM FREQ is negative, when 8123 PFA ENABLE is active.

1002 RESERVED

(Obsolete)

1003 PAR AI SCALE Parameter values are inconsistent. Check for any of the following:

• 1301 AI 1 MIN > 1302 AI 1 MAX.

• 1304 AI 2 MIN > 1305 AI 2 MAX.

1004 PAR AO SCALE Parameter values are inconsistent. Check for any of the following:

• 1504 AO 1 MIN > 1505 AO 1 MAX.

• 1510 AO 2 MIN > 1511 AO 2 MAX.

1005 PAR PCU 2 Parameter values for power control are inconsistent: Improper motor

nominal kVA or motor nominal power. Check for the following:

• 1.1 < (9906 MOTOR NOM CURR * 9905 MOTOR NOM VOLT * 1.73 / PN) < 3.0

• Where: PN= 1000 * 9909 MOTOR NOM POWER (if units are kW)

or PN= 746 * 9909 MOTOR NOM POWER (if units are HP, e.g. in US)

1006 EXT ROMISSING Parameter values are inconsistent. Check for the following:

• Extension relay module not connected and

• 1410…1412 RELAY OUTPUTS 4…6 have non-zero values.

1007 PAR

FBUSMISSING

Parameter values are inconsistent. Check for and correct:

• A parameter is set for fieldbus control (e.g. 1001 EXT1 COMMANDS = 10

(COMM)), but 9802 COMM PROT SEL = 0.

1008 PAR

PFAWOSCALAR

Parameter values are inconsistent – 9904 MOTOR CTRL MODE must be = 3

(SCALAR: SPEED), when 8123 PFA ENABLE is activated.

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

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Diagnostics

Fault resetting

The ACH550 can be configured to automatically reset certain faults. Refer to

parameter Group 31: Automatic Reset.

Warning! If an external source for start command is selected and it is active, the

ACH550 may start immediately after fault reset.

Flashing red LED

To reset the drive for faults indicated by a flashing red LED:

• Turn off the power for 5 minutes.

Red LED

To reset the drive for faults indicated by a red LED (on, not flashing), correct the

problem and do one of the following:

• From the control panel, press RESET

• Turn off the power for 5 minutes.

Depending on the value of 1604, FAULT RESET SELECT, the following could also be

used to reset the drive:

• Digital input

• Serial communication

When the fault has been corrected, the motor can be started.

1009 PAR PCU1 Parameter values for power control are inconsistent: Improper motor

nominal frequency or speed. Check for both of the following:

•1<(60 * 9907 MOTOR NOM FREQ / 9908 MOTOR NOM SPEED < 16

• 0.8 < 9908 MOTOR NOM SPEED /

(120 * 9907 MOTOR NOM FREQ / Motor Poles) < 0.992

1010 PAR PFA

OVERRIDE

Both the override mode and PFA are activated at the same time. These

modes are mutually incompatible, because PFA interlocks cannot be

observed in the override mode.

1011 PAR OVERRIDE

PARS

Overeride is enabled, but parameters are incompatible. Verify that 1701 is

not zero, and (depending on 9904 value) 1702 or 1703 is not zero.

1012 PAR PFA IO 1 IO configuration is not complete – not enough relays are parameterized to

PFA. Or, a conflict exists between Group 14, parameter 8117, NR OF AUX

MOT, and parameter 8118, AUTOCHNG INTERV.

1013 PAR PFA IO 2 IO configuration is not complete – the actual number of PFA motors

(parameter 8127, MOTORS) does not match the PFA motors in Group 14 and

parameter 8118 AUTOCHNG INTERV.

1014 PAR PFA IO 3 IO configuration is not complete – the drive is unable to allocate a digital

input (interlock) for each PFA motor (parameters 8120 INTERLOCKS and

8127 MOTORS).

Fault

Code

Fault Name In

Panel Description and Recommended Corrective Action

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Diagnostics

History

For reference, the last three fault codes are stored into parameters 0401, 0412,

0413. For the most recent fault (identified by parameter 0401), the drive stores

additional data (in parameters 0402…0411) to aid in troubleshooting a problem. For

example, parameter 0404 stores the motor speed at the time of the fault.

To clear the fault history (all of the Group 04, Fault History parameters):

1. Using the control panel in Parameters mode, select parameter 0401.

2. Press EDIT.

3. Press UP and Down simultaneously.

4. Press SAVE.

Correcting alarms

The recommended corrective action for alarms is:

• Determine if the Alarm requires any corrective action (action is not always

required).

•UseAlarm listing below to find and address the root cause of the problem.

Alarm listing

The following table lists the alarms by code number and describes each.

Alarm

Code Display Description

2001 OVERCURRENT Current limiting controller is active. Check for and correct:

• Excessive motor load.

• Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and

2205 ACCELER TIME 2).

• Faulty motor, motor cables or connections.

2002 OVERVOLTAGE Over voltage controller is active. Check for and correct:

• Static or transient overvoltages in the input power supply.

• Insufficient deceleration time (parameters 2203 DECELER TIME 1 and

2206 DECELER TIME 2).

2003 UNDERVOLTAGE Under voltage controller is active. Check for and correct:

• Undervoltage on mains.

2004 DIR LOCK The change in direction being attempted is not allowed. Either:

• Do not attempt to change the direction of motor rotation, or

• Change parameter 1003 DIRECTION to allow direction change (if

reverse operation is safe).

2005 I/OCOMM Fieldbus communication has timed out. Check for and correct:

• Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME).

• Communication settings (Group 51 or 53 as appropriate).

• Poor connections and/or noise on line.

ACH550-UH User’s Manual 1-289

Diagnostics

2006 AI1 LOSS Analog input 1 is lost, or value is less than the minimum setting.

Check:

• Input source and connections

• Parameter that sets the minimum (3021)

• Parameter that sets the Alarm/Fault operation (3001)

2007 AI2 LOSS Analog input 2 is lost, or value is less than the minimum setting.

Check:

• Input source and connections

• Parameter that sets the minimum (3022)

• Parameter that sets the Alarm/Fault operation (3001)

2008 PANEL LOSS Panel communication is lost and either:

• Drive is in local control mode (the control panel displays HAND or

OFF), or

• Drive is in remote control mode (AUTO) and is parameterized to

accept start/stop, direction or reference from the control panel.

To correct check:

• Communication lines and connections

• Parameter 3002 PANEL LOSS.

• Parameters in Groups 10 START/STOP/DIR and 11: REFERENCE

SELECT (if drive operation is AUTO).

2009 DEVICE

OVERTEMP

Drive heatsink is hot. This alarm warns that a DEVICE OVERTEMP fault

may be near.

R1…R4 & R7/R8: 100 °C (212 °F)

R5/R6: 110 °C (230 °F)

Check for and correct:

• Fan failure.

• Obstructions in the air flow.

• Dirt or dust coating on the heat sink.

• Excessive ambient temperature.

• Excessive motor load.

2010 MOT OVERTEMP Motor is hot, based on either the drive’s estimate or on temperature

feedback. This alarm warns that a Motor Underload fault trip may be

near. Check:

• Check for overloaded motor.

• Adjust the parameters used for the estimate (3005…3009).

• Check the temperature sensors and Group 35 parameters.

2011 UNDERLOAD Motor load is lower than expected. This alarm warns that a Motor

Underload fault trip may be near. Check:

• Motor and drive ratings match (motor is NOT undersized for the

drive)

• Settings Group 37: USER LOAD CURVE

2012 MOTOR STALL Motor is operating in the stall region. This alarm warns that a Motor

Stall fault trip may be near.

2013

(note 1)

AUTORESET This alarm warns that the drive is about to perform an automatic fault

reset, which may start the motor.

• To control automatic reset, use parameter Group 31: AUTOMATIC

RESET.

2014

(note 1)

AUTOCHANGE This alarm warns that the PFA autochange function is active.

• To control PFA, use parameter Group 81: PFA CONTROL

Alarm

Code Display Description

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Diagnostics

Note 1. Even when the relay output is configured to indicate alarm conditions (e.g. parameter

1401 RELAY OUTPUT 1 = 5 (ALARM) or 16 (FLT/ALARM)), this alarm is not indicated by a relay output.

2015 PFA INTERLOCK This alarm warns that the PFA interlocks are active, which means that

the drive cannot start the following:

• Any motor (when Autochange is used),

• The speed regulated motor (when Autochange is not used).

2016 Reserved

2017 OFF BUTTON Note 1.

2018

(note 1)

PID SLEEP This alarm warns that the PID sleep function is active, which means

that the motor could accelerate when the PID sleep function ends.

• To control PID sleep, use parameters 4022…4026 or 4122…4126.

2019 ID RUN Performing ID run.

2020 OVERRIDE This alarm warns that the Override function is active, which may start

the motor.

2021 START ENABLE 1

MISSING

This alarm warns that the Start Enable 1 signal is missing.

• To control Start Enable 1 function, use parameter 1608.

To correct, check:

• Digital input configuration.

• Communication settings.

2022 START ENABLE 2

MISSING

This alarm warns that the Start Enable 2 signal is missing.

• To control Start Enable 2 function, use parameter 1609.

To correct, check:

• Digital input configuration.

• Communication settings.

2023 EMERGENCY

STOP

Emergency stop activated.

2024 ENCODER ERROR The drive is not detecting a valid encoder signal. Check for and

correct:

• Encoder presence and proper connection (reverse wired, loose

connection, or short circuit).

• Voltage logic levels are outside of the specified range.

• A working and properly connected Pulse Encoder Interface Module,

OTAC-01.

• Wrong value entered in parameter 5001 PULSE NR. A wrong value

will only be detected if the error is such that the calculated slip is

greater than 4 times the rated slip of the motor.

• Encoder is not being used, but parameter 5002 ENCODER ENABLE =

1 (ENABLED).

2025 FIRST START Signals that a the drive is performing a First Start evaluation of motor

characteristics. This is normal the first time the motor is run after motor

parameters are entered or changed. See parameter 9910 (MOTOR ID

RUN) for a description of motor models.

2026 RESERVED Not used.

2027 USER LOAD

CURVE

This alarm warns that the condition defined by parameter 3701 USER

LOAD CMODE has been valid longer that half of the time difined by 3703

USER LOAD CTIME.

2028 START DELAY Shown during the Start delay. See parameter 2113 START DELAY.

Alarm

Code Display Description

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