Page 1 — ABB general performance drives ACS580MV UCU primary control program Troubleshooting manual...
Page 2 Manuals and quick guides for I/O extension modules, fieldbus adapters, etc. You can find manuals and other product documents in PDF format on the Internet. See http://www.abb.com/motors&drives. For manuals not available in the Document library, contact your local ABB representative.
Page 5: Table Of Contents
Software loading to ACS580MV converter ........
Page 6 ACS580MV data analyzer ........
Page 7 Table of contents 7 KP1249 Fuse of PM control power loop failure causes control hub missing power mod- ule fault ..............172 KP1692 MOSFET failure causes control board power failed .
Page 8 8 Table of contents...
Page 9: Introduction To The Manual
Safety instructions Follow all safety instructions delivered with the drive. • Only ABB Service and ABB certified service partners are allowed to service the drive and change any of the parameters described in this manual. • Read the complete safety instructions before you install, commission, or use the drive.
Page 10: Target Audience
10 Introduction to the Manual Target audience This manual is intended for ABB Service and ABB certified service partner personnel who commission and troubleshoot the drives. Contents of the manual This manual contains the following chapters: • Software: describes procedures for loading the Loading of the Control software/firmware to all parts of control hardware.
Page 11: Terms And Abbreviations
Introduction to the Manual 11 Terms and abbreviations Term/abbreviation Definition Type of PLC used as IO controller in ACS580MV drives AC500 or AC500eco Type of control panel used with ACS580MV drives ACS-AP-W Analog input; interface for analog input signals Analog output; interface for analog output signals...
Page 12: Cybersecurity Disclaimer
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference,...
Page 13: Loading Of The Control Software
Loading of the Control Software What this chapter contains This chapter contains the description of equipment, tools and procedures for downloading software to all parts of control hardware in the ACS580MV converter. Warnings WARNING! Only ABB Service and ABB certified service partners are allowed to service the drive.
Page 14: Preparing The Sw Loading
Drive composer pro ver. 1.9 or newer DriveStartup ver. 5.0 or newer (recommended ver. is 5.2 or newer available in DriveStartup installer) DriveStartup step definitions for ACS580MV (contained in the ZHDRE loading package) TeraTerm Tera Term PC tool (available at Software loading to ACS580MV converter ...
Page 15 Loading of the Control Software 15 1. Switch off the control power. 2. Remove the daughter boards DB2 and DB3. 3. Connect XILINX platform cable USB II to X5 connector on control hub 4. Switch on the control power 5. Run PROG_MHDCH.bat batch file to program the control hub. Following window will open: 6.
Page 16 16 Loading of the Control Software screen will stay longer with the following message:...
Page 17: Loading Cvmi2 Firmware
Loading of the Control Software 17 Downloading of the control hub takes 3-4 minutes. 7. When the downloading is over following screen will show: press any key to exit. 8. Turn off the control power. 9. Remove the XILINX platform cable USB II. 10.
Page 18 18 Loading of the Control Software 1. Switch off the control power. 2. Connect XILINX platform cable USB II to X1301 connector on CVMI2. 3. Switch on the control power. 4. Run PROG_LXES.bat batch file to program the CVMI2. Following window will open: 5.
Page 19: Loading Io Controller (Ac500Eco) Software
Loading of the Control Software 19 6. When the downloading is over following screen will show: Press any key to exit. 7. Turn off the control power . 8. Remove the XILINX platform cable USB II.  Loading IO controller (AC500eco) software IO controller software version can be checked in parameter 81.7 IO controller version.
Page 20 20 Loading of the Control Software Note: Only MC502 SD card can be used. This is not the same SD card which is plugged into the UCU. 2. Switch off the control power 3. Install SD card adapter (MC503) into CPU PM55x 4.
Page 21: Loading The Io Controller (Ac500Eco) Software (Ac500 V3 Cpu)
Loading of the Control Software 21  Loading the IO controller (AC500eco) software (AC500 V3 CPU) 1. Save the following files and folders to the SD card (TA5350 and MC5102) root folder. Files can be found in the loading package (folder \04_IOController SW).
Page 22 22 Loading of the Control Software 2. Start Drive loader 2 and select the file LP_FirmwareUpgrade.lp from the ZHDRE release package (folder \01_UCON SW). Select ACS580 for the drive type and wait until the tool identifies the connection to the drive. Click “Download”...
Page 23: Loading The Acs-Ap-W Assistant Panel Firmware
HW version is defined by the first letter of serial number in the bar code sticker. Other way to check panel type and revision is to hold down the “?” key in panel power up. Appropriate info with mentioned information appears ACS580MV SW compatibility table then. Refer to the for the compatibility between UCON software and panel firmware.
Page 24 Safety instruction Obey the instructions given in chapter 1 and chapter 12 Maintenance ACS580MV hardware manual of the . If you ignore them, injury or death, or damage to the equipment can occur. Before starting to work on the drive, make sure: •...
Page 25 Loading of the Control Software 25 2. Check the port of the USB to FO serial cable on your PC (Control panel -> System -> Device Manager): 3. Open the “Tera Term” PC tool and set the serial port to the one where Serial to POF link cable is connected (COM19 in the example here).
Page 26 26 Loading of the Control Software 4. Connect the auxiliary +5.5V power supply cable (part of the USB-POF link cable) to +5.5V power supply connector on the power module. After that the DSP of the power module will boot up. After the DSP boots up the Tera Term receives information from DSP:...
Page 27 Loading of the Control Software 27 5. After Tera Term displays the text “Type ‘e’ to erase flash:” just press letter “e” on the keyboard. 6. Open the File menu and chose “Send file”:...
Page 28 28 Loading of the Control Software Select the PEBB1_CellController.bin file from the ZHDRE loading package (folder \02_PowerModule SW). Important: Make sure to select the option “Binary”! If not selected, the software download will fail.
Page 29 Loading of the Control Software 29 7. Press “Open” to start the download:...
Page 30 30 Loading of the Control Software 8. Once the download is successfully finished the following message will be shown: 9. Close the Tera Term PC tool. Disconnect the USB-POF link cable and +5.5V power supply cable, and reconnect the original POF link. Proceed to the next power module.
Page 31: Fault Tracing
In addition to that, troubleshooting procedures that are only allowed for ABB Service or ABB certified service partners are described in this chapter. If it is not possible to resolve a problem using information from this chapter, the ABB support line should be contacted.
Page 32: Pure Events
32 Fault tracing the Drive composer PC tool. Only the codes of warnings/faults are available over fieldbus. Warnings do not need to be reset; they stop showing when the cause of the warning ceases. Warnings do not latch and the drive will continue to operate the motor.
Page 33: Other Data Loggers
PC tool. (The fault data is not accessible through the control panel). All fault data loggers are copied to the SD card and can be analyzed later using ACS50MV Data analyzer PC tool (see Using ACS580MV Data Analyzer). 01.07 Motor current 01.10...
Page 34: Warning Messages
Check control hub daughter boards modules' (PM) states that is (or replace). not valid. Check PM SW version and update if required. Contact your local ABB representative. A190 Low frequency Low frequency operation It's better to stop the drive rather than operation within 2Hz lasts more than running it with low frequency.
Page 35 Check for proper delta/star connection of the motor. Check overload settings for the motor and settings for this alarm function (contact your local ABB representative). A284 Drive Overload Alarm Current is high either on Check that the motor parameters in...
Page 36 Check for an earth fault in motor or motor cables by measuring the insulation resistances of motor and motor cable. If no earth fault can be detected, contact your local ABB representative.
Page 37 Check the auxiliary code. See actions temperature excessive. for each code below. Temperature above warning Check ambient conditions. limit Thermistor damaged Contact your local ABB representative for control unit replacement. A5EA Measurement circuit Problem with internal Contact your local ABB representative. temperature temperature measurement For software version 2.00.0.3 and...
Page 38 38 Fault tracing Code Warning Cause What to do (hex) A684 SD card Check the auxiliary code. See actions Error related to SD card used for all the codes below. to store data on UCU No SD card Insert a compatible, writable SD card into the SD CARD slot of the UCU SD card write-protected SD card unreadable...
Page 39 A6FA Trial mode active The drive is running in trial Contact ABB support line to get a valid mode. After the trial mode license key. has expired the drive will trip Enter a valid license key in parameters immediately and license 96.71 License key part 1...
Page 40 If you are not sure if the settings in the license key are correct contact your local ABB representative and provide the auxiliary code. A6FE...
Page 41 Fault tracing 41 Code Warning Cause What to do (hex) 00 0001 Communication with module Check that the module is properly failed. seated in its slot. Check that the module and the slot connector is not damaged. Try installing the module into another slot.
Page 42 Check cable connections. Check if communication master is able to communicate. A7C2 FBA B Cyclical communication Contact your local ABB representative. communication between drive and fieldbus adapter module B or Programmable warning: WARNING! FBA B 50.32 FBA B comm loss...
Page 43 Fault tracing 43 Code Warning Cause What to do (hex) A801 High frequency High frequency injection Check if PM motor is non-salient type. injection polarity starting polarity Check parameter settings in group 77. search time-out identification is over the defined time limit. Drive will stop after warning displayed.
Page 44 44 Fault tracing Code Warning Cause What to do (hex) A88C Device clean Warning generated by an on- Check the event log for an auxiliary time timer code. Check the source of the warning A88D DC capacitor corresponding to the code: Programmable warnings: A88E Cabinet fan...
Page 45 Fault tracing 45 Code Warning Cause What to do (hex) A985 External warning 5 Fault in external device 5 Check the external device. 31.09 Check setting of parameter (Editable message text) Programmable warning: External event 5 source 31.09 External event 5 source 31.10 External event 5 type...
Page 46 1 to 0. 0001 - MCB open status just change from 0 to 1. B68B SW internal Software is gathering This is an internal ABB information, information information. needed for debugging purposes. Auxiliary code indicates memory address of the function where exception occured.
Page 47 Fault tracing 47 Code Warning Cause What to do (hex) B690 Drive charged This event is shown each Pure event - only appears in the event time the drive is charged. log for diagnostic purposes. B691 Drive starting This event is shown each Pure event - only appears in the event time the drive is starting.
Page 48 48 Fault tracing Code Warning Cause What to do (hex) B704 Sync to mains This event is shown each Pure event - only appears in the event command time sync to mains log for diagnostic purposes. command is received. B6B3 Par changed Event shows a parameter Aux code shows which parameter has...
Page 49 Fault tracing 49 Code Warning Cause What to do (hex) B6B5 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase U2 while sync current has exceeded the The code indicates which threshold internal fault limit while sync. has been exceeded.
Page 50 50 Fault tracing Code Warning Cause What to do (hex) B6B6 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase V2 while sync current has exceeded The code indicates which threshold internal has been exceeded. fault limit while sync. 1 - inverter overcurrent 2 - hardware overcurrent (95% of the maximum measureble current)
Page 51 Fault tracing 51 Code Warning Cause What to do (hex) B6B7 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase W2 while sync current has exceeded The code indicates which threshold internal fault limit while sync. has been exceeded.
Page 52 52 Fault tracing Code Warning Cause What to do (hex) B6BA PM HB2 short circuit The desaturation detection Check the event log for an auxiliary turn off while sync of the IGBTs in HB2 (half code. The code indicates which PM is bridge 2) of a power module affected.
Page 53 (door air inlet filter pads, fan primary phase is operation). approaching temperature Check overload settings for limit. transformer (contact your local ABB representative). E202 Trafo phase V1 The winding temperature of Check cooling of the transformer temperature high...
Page 54 55 FBA B data in failure. Alarm is activated 56 FBA B data out (changes allowed according to selection in only by ABB authorized personnel). 50.32 FBA B parameter Note: Make sure that up to maximum comm loss func of two fieldbus extension modules are used on the UCU.
Page 55 Fault tracing 55 Code Warning Cause What to do (hex) E211 INU cooling fan 4 Temperature relay Check wiring of fan 4 temperature warning integrated in INU cooling fan contacts (open circuit, loose 4 has opened. A redundant terminals). Check if fan is mechanically fan group is activated.
Page 56 E219 IO Controller version IO Controller SW version Upgrade IO Controller SW (Contact 81.07 IO incompatible (shown in parameter your local ABB representative). Controller version ) is lower than the expected value 81.08 (shown in parameter IO Controller version required...
Page 57 MB has already opened and motor can is inhibited by MB open be controlled on VSD mode directly. status. E235 Sync to VSD not Sync to VSD functionality Contact your local ABB represenative support isn’t supported currently. and pay attention to ABB latest released version.
Page 58 / deceleration time (for scalar control) or 25.02 speed proportional gain (for vector control) to stabilize motor speed. Contact ABB support if problem cannot be solved E238 RMS sync overtime 1 minute after...
Page 59: Fault Messages
Check control hub daughter boards that is not valid. (or replace). Check PM SW version and update if required. Contact your local ABB representative. 2110 Trafo overcurrent The transformer primary Check the event log for an auxiliary current has exceeded code.
Page 60 2281 Calibration Measured offset of output Try performing the current calibration phase current measurement again (Contact your local ABB or difference between representative). output phase U2 and W2 current measurement is too big (the values are updated during current calibration).
Page 61 Check for an earth fault in motor or motor cables by measuring the insulation resistances of motor and motor cable. If no earth fault can be detected, contact your local ABB representative. 2340 Short circuit Short-circuit in motor Check motor and motor cable.
Page 62 62 Fault tracing Code Fault Cause What to do (hex) 2350 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase U2 current has exceeded The code indicates which threshold internal fault limit. has been exceeded. 1 - inverter overcurrent 2 - hardware overcurrent (95% of the maximum measureble current) 3 - motor overcurrent...
Page 63 Fault tracing 63 Code Fault Cause What to do (hex) 2351 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase V2 current has exceeded The code indicates which threshold internal fault limit. has been exceeded. 1 - inverter overcurrent 2 - hardware overcurrent (95% of the maximum measureble current) 3 - motor overcurrent...
Page 64 64 Fault tracing Code Fault Cause What to do (hex) 2352 Motor overcurrent The instantaneous motor Check the event log for auxiliary code. phase W2 current has exceeded The code indicates which threshold internal fault limit. has been exceeded. 1 - inverter overcurrent 2 - hardware overcurrent (95% of the maximum measureble current) 3 - motor overcurrent...
Page 65 PM has code. The code indicates which PM is undershot the minimum affected. level. Contact your local ABB representative. 3233 PM +5V power supply The +5V power supply of a Check the event log for an auxiliary fault PM has failed.
Page 66 66 Fault tracing Code Fault Cause What to do (hex) 3239 PM diode open PM rectifier's diode open Check the event log for an auxiliary circuit circuit is detected. code. The code indicates which PM is affected. Replace the faulty PM. 20.02 Ext1 start trigger 3280 Standby timeout...
Page 67 Fault tracing 67 Code Fault Cause What to do (hex) 35.02 Measured temperature 1 has Check the value of parameter 4981 External temperature Measured temperature 1 exceeded fault limit. Check the cooling of the motor (or (Editable message text) other equipment whose temperature is being measured).
Page 68 68 Fault tracing Code Fault Cause What to do (hex) 5013 PM charging relay The voltage across the Check the event log for an auxiliary not closed charging relay contact of a code. The code indicates which PM is PM is larger than it would be affected.
Page 69 The feedback is not between converter and grid contactor. correct 3s after command is Check grid contactor. given. Measurement circuit Problem with internal Contact your local ABB representative. 5094 temperature temperature measurement of the drive. Emergency OFF Emergency OFF button on...
Page 70 What to do (hex) 607A Trial mode expired The entered license key of Contact ABB support line to get a valid the drive is not valid and the license key. trial mode time has expired. Enter a valid license key in parameters 96.71 License key part 1...
Page 71 Check PM SW version and update if required. Replace the PM (if always the same PM gives the fault). Contact your local ABB representative. 6111 PM undefined fault An undefined fault code from Check the event log for an auxiliary a PM has been received.
Page 72 Application file incompatible Note: This fault cannot be reset. 64A3 Application loading or corrupted Check the event log for the auxiliary code and contact your local ABB representative. The memory unit was Contact your local ABB representative. 64B0 Memory unit detached detached when the control unit was powered.
Page 73 Internal SSW fault 2 Internal fault. Reboot the control unit (using parameter 96.8 Control board boot) or by cycling power. If the problem persists, contact your local ABB representative. Operating system error Note: This fault cannot be reset. 64E1 Kernel overload Contact your local ABB representative.
Page 74 74 Fault tracing Code Fault Cause What to do (hex) Use of saved control panel The control panel reference can only 7083 Panel reference reference in multiple control be saved for one reference type at a conflict modes attempted. time. Consider the possibility of using a copied reference instead of saved reference (see the reference selection parameter).
Page 75 53 FBA A data out Check cable connections. Check if communication master is able to communicate. Cyclical communication Contact your local ABB representative. 7520 FBA B communication between drive and fieldbus Programmable fault: adapter module B or 50.32 FBA B comm...
Page 76 76 Fault tracing Code Fault Cause What to do (hex) 7540 CVMI2 There is communication Check communication wiring from communication lost error between UCON and UCU to CVMI2 board. CVMI2 board. Check power supply wiring of CVMI2 board. Replace the CVMI2 board. Typical auxiliary code: F010: UCON is rebooted while CVMI2 board is still power-on.
Page 77 The winding temperature of Check cooling of the transformer E100 Trafo phase U1 the indicated transformer (door air inlet filter pads, fan overtemperature primary phase has exceeded operation). the temperature limit. Check overload settings for the transformer (contact your local ABB representative).
Page 78 (door air inlet filter pads, fan overtemperature primary phase has exceeded operation). the temperature limit. Check overload settings for the transformer (contact your local ABB representative). The winding temperature of Check cooling of the transformer E102 Trafo phase W1 the indicated transformer...
Page 79 MCB protection relay settings if required. Check MCB control wiring between ACS580MV and MCB. E115 INU cooling fan 2 Temperature relay Check wiring of fan 2 temperature fault...
Page 80 80 Fault tracing Code Fault Cause What to do (hex) E116 INU cooling fan 3 Temperature relay Check wiring of fan 3 temperature fault integrated in INU cooling fan contacts (open circuit, loose 3 has opened. terminals). Check if fan is mechanically blocked or makes excessive noise (bearing problem).
Page 81 Fault tracing 81 Code Fault Cause What to do (hex) The winding temperature of Check cooling of the motor. E125 Motor phase W1 the indicated motor phase overtemperature Check fault limit setting for the motor has exceeded the 84.09 Motor winding temperature temperature limit.
Page 82 Check contactor control wiring between ACS580MV and contactor. The inductor temperature Check cooling of the inductor. E144 Inductor has exceeded the overtemperature temperature limit.
Page 83: What This Chapter Contains
This fault is triggered by Check signal of 7.11 Cpu usage. If it is FA90 STO diagnostics internal diagnostic. Look at very high, Contact your local ABB failure auxiliary code of this fault: representative. Axu code = 1: The check sum...
Page 84: Terms And Abbreviations
84 Fault tracing...
Page 85: Service Level Parameters
End user access level are not listed in this manual, although some of them are referenced. For more details on the End user level ACS580MV primary control program firmware manual parameters refer to Parameters can be viewed and edited using operator panel ACS-AP-W or Drive composer PC tool.
Page 86: Parameter Listing
(In the following table, shown on the same row as the parameter name) The default value of a parameter for the Factory macro. For information on macro- ACS580MV primary control specific parameter values, see chapter Application macros in program firmware manual...
Page 87 Service Level Parameters 85 Voltage reserve; flux braking; IR compensation. 97 Motor control Motor configuration settings. 99 Motor data...
Page 88 86 Service Level Parameters Parameter listing Name/Value Description Def/FbEq1 01 Actual value Basic signals for monitoring the drive. All parameters in this group are read-only unless otherwise noted. 1.165 Voltage RMS deviation between grid and motor. Voltage RMS deviation % of grid -10.00...10.00 1 = 1% 1.166...
Page 89 Service Level Parameters 87 Name/Value Description Def/FbEq1 05.14 Communication Selects the communication link of message counter or FigBus counter link error counter displayed in parameters and 05.142. 05.141 selector Note: This parameter is visible only for AINF2, AINFB and AINF6 targets. FigBus Shows the message counter and error counter for UART- communication between fieldbus module and control...
Page 90 88 Service Level Parameters Name/Value Description Def/FbEq1 10.102 RO2 toggle counter Counts number of times relay output RO2 changed states. To reset the counter, in control panel depress the Reset key for at least three seconds. 0…4294967295 Number of times RO2 changed states. 1 = 1 10.103 RO3 toggle counter...
Page 91 Service Level Parameters 89 Name/Value Description Def/FbEq1 17.07 Control hub DI Contains the values of digital inputs that are used 0b00000 force data instead of the electrical statuses if selected in parameter 17.06. Bit 0 is the forced value for control hub DI1. Bit / Name / Information 0: DI1 1: DI2...
Page 92 90 Service Level Parameters Name/Value Description Def/FbEq1 21.32 Flystart frequency Minimum frequency/speed used during speed scan in 0.1 p.u. flystart. If the motor speed is still not found when the frequency reference gets smaller than this parameter, the flystart continues the speed scan with negative sign or ends the speed scan depending on the option selected in parameter 21.34: 21.34 Flystart reverse enable...
Page 93 Service Level Parameters 91 Name/Value Description Def/FbEq1 0 … 10 NoUnit 1 = 1 NoUnit 21.39 Flystart Iq ctrl Ki Integral gain of the PI controller used to control Iq current 0.05 during flystart. NoUnit 0 … 1 NoUnit 1 = 1 NoUnit 21.204 Starting freeze time Starting inhibit from last stop or fault to make motor 5000ms...
Page 94 92 Service Level Parameters Name/Value Description Def/FbEq1 Name Description Load type est done Estimation of quadratic torque coefficient and frictional torque is done. Inertia est done Estimation of moment of inertia is done. 26 Torque reference chain Service-level parameters for torque reference chain. Parameters 26.90 …26.101 configure the acceleration damping function.
Page 95 Service Level Parameters 93 Name/Value Description Def/FbEq1 0.000 … 32767.000 Filtered rate of actual speed change. 1 = 1 rpm/s rpm/s 26.97 Acceleration filter Defines the acceleration filter reduction value. When reduction actual speed changes faster than the bypass limit (par. 26.96), the first filter is bypassed and the filtering time of the second and third filters are divided by this value.
Page 96 94 Service Level Parameters Name/Value Description Def/FbEq1 0 … 1200 V 1 = 1 V 30.57 Ridethrough DC link Ridethrough DC Link control level [V]. During the 900 V control level ridethrough the DC Link is controlled to this level. 0 …...
Page 97 Service Level Parameters 95 Name/Value Description Def/FbEq1 Ramp stop 31.37 Parameters 31.37 Ramp stop supervision 31.38 Ramp supervision 01.29 Speed change delay, together with stop supervision rate , provide a supervision function for normal (ie. non- emergency) ramp stopping. The supervision is based on either •...
Page 98 96 Service Level Parameters Name/Value Description Def/FbEq1 34 Protections Drive protection functions. Note: For motor related quantities specified in p.u., if no special note is given, the base value is Motor nominal current defined in parameter 99.6. For grid related quantities specified in p.u., if no special note is given, the base value is Rated input current defined by license key (can be seen in parameter 30.41).
Page 99 Note: If the Trafo overcurrent happens during charging on a de-rated R4 drive then this parameter can be increased above the default value. Contact the ABB support line for the exact settings. This is only valid for de-rated R4 drives! 0 …...
Page 100 98 Service Level Parameters Name/Value Description Def/FbEq1 34.05 Trafo over curr no If the transformer primary current exceeds this limit 0.5 p.u. 2113 Trafo no-load load trip level during charging the drive trips on fault overcurrent This condition is only checked after MCB has been closed until all power modules are ON (before the time defined in parameter 34.01 is elapsed).
Page 101 Service Level Parameters 99 Name/Value Description Def/FbEq1 34.17 Motor overcurrent The parameter is defined in [p.u.] with base value defined 1.3 p.u. trip level - Motor nominal current (Par99.6) Motor overcurrent protection reacts on the instantaneous values of the measured motor phase currents.
Page 102 100 Service Level Parameters Name/Value Description Def/FbEq1 34.24 Mot current sensor Maximum expected (allowed) measurement offset of the 0.4 mA offset motor current sensor. From this value the maximum expected (allowed) current measurement error is calculated in the software. If a measured motor phase current exceed this limit when the drive is not modulating 2353 Motor current sense fault the drive trips on fault...
Page 103 Service Level Parameters 101 Name/Value Description Def/FbEq1 34.36 Ground fault trip Maximum allowed amplitude of the motor common mode 500 V level voltage fundamental component. If the amplitude of the fundamental component in the motor common mode voltage exceeds this limit the drive trips on fault 3333 Ground fault.
Page 104 102 Service Level Parameters Name/Value Description Def/FbEq1 60.85 IEC D2D baud rate 8 mbps Defines the drive-to-drive (D2D) communication speed of DDCS channel selected with parameter 60.01 M/F communication port when parameter 60.03 M/F mode is one selections. 1 mbps 1 Megabit per second 2 mbps 2 Megabits per second...
Page 105 Service Level Parameters 103 Name/Value Description Def/FbEq1 77.22 CR: maximum Rotating frequency of motor current (frequency of stator 0.05 frequency reference magnetic field) is ramped and controller as maximum reference. 0 … 0.5 p.u. 1 = 1 p.u. 77.24 CR: freq rampup Ramping time for rotating frequency of motor current time from 0 max ref from 0 to maximum reference, the time will affect how...
Page 106 104 Service Level Parameters Name/Value Description Def/FbEq1 0 … 300 Hz 1 = 1 Hz 77.42 HFI-pos: injection Amplitude of the injected current for rotor position 0.25 current search. 0 … 0.25 p.u. 1 = 1 p.u. 77.61 HFI-pol: injection Frequency of the injected current for rotor polarity frequency search.
Page 107 Service Level Parameters 105 Name/Value Description Def/FbEq1 0 … 10000 ms 1 = 1 ms 78.21 Flux est controller Cutoff frequency of low pass filter of flux estimation filter cutoff freq controller. 0 … 500 Hz 1 = 1 Hz 78.22 Flux est controller Proportional gain of flux estimation controller.
Page 108 106 Service Level Parameters Name/Value Description Def/FbEq1 0…1000 ms 1 = 1 ms 79.03 Flux ctrl max limit Stator flux PI control max limit 10 p.u. 0…10 p.u. 1 = 1 p.u. 79.04 Flux ctrl min limit Stator flux PI control min limit 10 p.u.
Page 109 Service Level Parameters 107 Name/Value Description Def/FbEq1 79.25 Est. speed filter Estimated speed filter cutoff frequency 10 Hz cutoff freq 0…150 Hz 1 = 1 Hz 79.26 Compensation of Compensates phase delay of generated stator voltage -0.5 p.u. PWM phase delay due to PWM -5…5 p.u.
Page 110 108 Service Level Parameters Name/Value Description Def/FbEq1 0.0002…25 s 1 = 1 s 79.39 Fall time of rotor Fall time of rotor flux reference from 100% to 0% flux reference 0.00025…25 s 1 = 1 s 79.40 Rotor flux ref filter Cut-off frequency of low-pass filter of rotor flux reference 3 Hz cutoff freq 0…25 Hz...
Page 111 Service Level Parameters 109 Name/Value Description Def/FbEq1 Disable Enable 79.60 Current id filter id filter gain used in iq limit calculation of current limiter 0.0067 p.u. gain for scalar control 0…1 p.u. 1 = 1 p.u. 79.61 Energy balancing Energy balancing algorithm helps to keep the converter 10 p.u.
Page 112 Modbus communication. The total count is stored in this parameter. The PLC error counter is stored on the SD card and can be viewed using ACS580MV data analyzer tool. Internal PLC warnings and errors do not indicate any serious problem with PLC and are reset automatically.
Page 113 DC link is lower than the discharged level. WARNING! Make sure that all safety measures are in place ACS580MV when opening inverter cabinet door! Refer to hardware manual for instructions on safe handling.
Page 114 112 Service Level Parameters Name/Value Description Def/FbEq1 1 INU fan and 1 TRU 1 INU fan and 2 TRU fans 2 INU fans and 2 TRU fans 2 INU fans and 3 TRU fans 3 INU fans and 2 TRU fans 3 INU fans and 3 TRU fans 1 INU fan...
Page 115 Service Level Parameters 113 Name/Value Description Def/FbEq1 83.31 INU air pressure Time delay for monitoring of the air pressure (drop) 40 s monitoring delay inside inverter unit cabinet. time Different actions will apply in case of low and high pressure and depending on the availability of the redundant fans: 1.
Page 116 114 Service Level Parameters Name/Value Description Def/FbEq1 83.50 EC fan reference Speed reference for the inverter unit cooling fans given in 100% percentage of the maximum fan speed. Note: This parameter is effective only if the drive is equipped with EC cooling fans. 0 …...
Page 117 Service Level Parameters 115 Name/Value Description Def/FbEq1 87.11 AC500 CPU DI force Electrical status of digital inputs can be overridden, for 0b000000 selection example during testing. A bit in parameter 87.12 is provided for each digital input, and its value is applied whenever the corresponding bit in this parameter is set to 1.
Page 118 116 Service Level Parameters Name/Value Description Def/FbEq1 87.41 AC500 E P2 DI force Electrical status of digital inputs can be overridden, for 0b000000 selection example during testing. A bit in parameter 87.42 is provided for each digital input, and its value is applied whenever the corresponding bit in this parameter is set to 1.
Page 119 15Min ~ 60Min 1minute 95.90 PM Sub-capacitor When the sub-capacitor of ACS580MV power module is 480V overvoltage 1 bigger than this value, the drive will trip will ‘PM Sub Capacitor Overvoltage1’ fault. Note: This fault detection only active during capacitor reforming period.
Page 120 Name/Value Description Def/FbEq1 95.91 PM Sub-capacitor When the sub-capacitor of ACS580MV power module is 450V overvoltage 2 bigger than this value and last for Par 95.92 seconds, the drive will trip with ‘PM Sub Capacitor Overvoltage2’ fault. Note: This fault detection only active during capacitor reforming period.
Page 121 Service Level Parameters 119 Name/Value Description Def/FbEq1 95.94 DC unbalance During capacitor reforming process, if ‘PM DC unbalance 0x0000 status word 2 Warning’ is active, this status word indicates which power module in phase B report this warning, if have. Name Description 1 = Power module B1 report the ‘PM DC unbalance Waring’...
Page 122 120 Service Level Parameters Name/Value Description Def/FbEq1 95.95 DC unbalance During capacitor reforming process, if ‘PM DC unbalance 0x0000 status word 3 Warning’ is active, this status word indicates which power module in phase C report this warning, if have. Name Description 1 = Power module C1 report the ‘PM DC unbalance Waring’...
Page 123 Service Level Parameters 121 Name/Value Description Def/FbEq1 Enable Enable Power module software force download. 95.102 Min DC Volt Req Minimum DC link voltage required to start Power Module 900V Force DL software force download. It is only possible to start PM software force download process when the minimum cell dc link voltage is bigger than this value.
Page 124 122 Service Level Parameters Name/Value Description Def/FbEq1 Site commission complete. 96.84 Commissioning Finish commission steps. Pure event – only appears in the step complete event log for diagnostic purpose. Commission steps Aux.code(Hex): 0001 - SW downloading complete 0002 - License key refreshed 0003 - Motor parameters filled 0004 - App para setting complete 0005 - Common para setting complete...
Page 125 Service Level Parameters 123 Name/Value Description Def/FbEq1 SW downloading complete License key refreshed Motor parameters filled App para setting complete Common para setting complete Ctrl supply monitoring testing Door interlock monitoring testing MCB Testing Overriding system communication testing Master Follower Setting Remote Connectivity...
Page 126 124 Service Level Parameters Name/Value Description Def/FbEq1 MAU parameter setting SBU MB setting SBU MSS setting SBU ctrl interface checking MAU ctrl interface checking Sync bypass test (without load) Sync bypass test (with load) 96.20 Disable parameter Disables parameter flash saving when drive is running. flash saving while Typically, flash saving occurs before every start running...
Page 127 Service Level Parameters 125 Name/Value Description Def/FbEq1 97.44 SBU motor During synchronizing bypass process, SBU motor 2.5 p.u. overcurrent trip overcurrent trip level will replace motor overcurrent trip level level. 0 … 10 p.u. 1 = 1 p.u. 97.45 SBU motor phase During synchronizing bypass process, SBU motor phase 0.05 p.u.
Page 128 126 Service Level Parameters Name/Value Description Def/FbEq1 98.29 PM motor control Enable or Disable PM motor control parameters, Disable parameters refresh 78.05 D axis current controller p-gain, 78.06 D axis current controller integral time const, 78.09 Q axis current controller p-gain, 78.10 Q axis current controller integral time const, 78.22 Flux est controller p-gain, 78.23 Flux est controller integral time const,...
Page 129: Using Acs580Mv Data Analyzer
SD card in UCU. ACS580MV data analyzer ACS580MV data analyzer allows the user to view event logger, fault data logger and continuous monitoring logger files stored in SD card. The SD card installed in UCU allows for storing of big amount of data, so the records of drive...
Page 130: Menu Bar
Help  File menu File menu allows to open a data folder and to exit the ACS580MV data analyzer session. File menu consists of the following commands: • Select Data Folder: Allows the user to open a top folder containing all logged data.
Page 131: View Menu
• Manual: Displays ACS580MV data analyzer user manual as a PDF. Event logger To open data folder, proceed as follows: 1. In the ACS580MV data analyzer main menu, click File and then click Select Data Folder. Figure: ACS580MV data analyzer...
Page 132 Note: The user must select the top folder that contains LOGS and MONITOR folders with event logs, fault data logger and continuous monitor logger files. The ACS580MV data analyzer processes all the files in the selected folder and its sub-folders and extract all the information.
Page 133 Using ACS580MV Data Analyzer 133 Figure: ACS580MV data analyzer When the user selects an event in a list, the event type (fault or alarm), code and name with related help text are displayed in the top right pane. 3. In the status strip, click Export All in the drop-down list to export the event .txt...
Page 134: Fault Data Logger
134 Using ACS580MV Data Analyzer  Fault data logger Fault data logger displays the time plots of corresponding fault data logger. The user can select parameters to be displayed on graphs by checking and unchecking the check box next to parameter.
Page 135 Using ACS580MV Data Analyzer 135 Settings 1. In the status strip, click Settings in the drop-down list to change the settings of the time plot. Figure: Time plot settings...
Page 136: Continuous Monitoring Logger
136 Using ACS580MV Data Analyzer 2. In the Settings window, select the required time plots by selecting the check box. Figure: Settings 3. Select the desired option in Legends Alignment drop-down list to align the time plot parameter signals. Alignment Alignment allows the user to align the parameter signal list in the time plot data logger.
Page 137 Using ACS580MV Data Analyzer 137 date to view the time plot. All monitored drive parameters are grouped in several groups (called CML plots) that can be selected by right clicking on the graph area. To display or hide some of the parameters in the graph, check boxes next to parameter numbers can be used.
Page 138 138 Using ACS580MV Data Analyzer Parameter list Parameter list shows which drive parameters are contained in each of the CML plots. Following CML plots are available: • Default • Transformer temperatures • IGBT temperatures (3 temperatures are measured) • Charging relay temperatures •...
Page 139: Drive Composer Support Package
The support package can be created by the user of the drive and emailed to ABB Support line for investigation. Support package is created in Drive composer PC tool by clicking on the icon in...
Page 140 140 Drive Composer Support Package figure below, a file SupportFiles.dcsupport is created and attached to the default email program installed in the PC. The file can also be saved manually. The support package contains following information from the drive: Parameter backup •...
Page 141 Drive Composer Support Package 141 Figure: Drive data available in support package Tripping faults in the event logger have a fault data logger attached (see Fault Tracing chapter for more details on the event logger and fault data logger). Fault data loggers can be seen in Online Monitor section of Drive composer.
Page 142 Figure: Exporting the fault data logger The data from the fault data logger are exported in .dcexp format. If Matlab is available, the data can be imported using ABB in-house script in the following way: log_data = read_dcexp(‘FileName.dcexp’). The script will plot the data in predefined format, like in the following figure.
Page 143 Drive Composer Support Package 143 Figure: Example of fault data logger data plotted using Matlab script...
Page 144 144 Drive Composer Support Package...
Page 145: Pof Link Test
POF Link Test 145 POF Link Test Contents of this chapter This chapter describes how to use the parameters that control the POF link power between Control Hub and Power Modules, in order to early detect communication problems. The service pass-code is required to have access to these parameters in parameter group 95 HW configuration.
Page 146: Link From Power Modules (Tx) To Control Hub (Rx)
146 POF Link Test the tests described in this chapter the counters should be observed only after completing the charging sequence of the drive. Link from power modules (TX) to control hub (RX) The POF transmitter power on the Power Module is controlled with the parameter 95.70 PM half optical power.
Page 147: What To Do In Case Tests Pof-1 Or Pof-2 Fail
POF Link Test 147 Observe the following parameters: • 70.12/32/52…, Hub RX comm err count A1/A2/A3 • 71.12/32/52…, Hub RX comm err count B1/B2/B3 … • 72.12/32/52…, Hub RX comm err count C1/C2/C3 … Test results PASS: the observed Hub RX comm err counters can have an initial value different from 0, but DO NOT have variation for more than 10 minutes ...
Page 148: Test Pof-4: Hub Tx Half Power
148 POF Link Test Observe the following parameters: • 70.5/25/45…, PM RX comm err count A1/A2/A3 … • 71.5/25/45…, PM RX comm err count B1/B2/B3 … • 72.5/25/45…, PM RX comm err count C1/C2/C3 … Test results PASS: the observed PM RX comm err counters can have an initial value different from 0, but DO NOT have variation for more than 10 minutes ...
Page 149: What To Do In Case Tests Pof-3 Or Pof-4 Fail
POF Link Test 149 instructions given in section What to do in case tests POF-3 or POF-4 fail be directly applied.  What to do in case tests POF-3 or POF-4 fail In case the test fail the following steps can be executed: 1.
Page 150 150 POF Link Test...
Page 151: Inspecting Power Modules
In order to detect a malfunction or a failed component in a power module, the tests described in this chapter shall be carried out. If tests identify a failure in the power module, perform investigation steps to solve the problems as recommended. ABB will also do further analysis and repair.
Page 152: Safety
Maintenance chapter 12 of the manual. If you ignore ACS580MV hardware them, injury or death, or damage to the equipment can occur. Before starting to work on the drive, make sure: • that the main and auxiliary power supply to the drive is switched off, locked out, and tagged out •...
Page 153: Measurement Steps
In this case replace it with a new power module and send the failed power module back to ABB for further analysis. 4. Check visually if the fuses (phase V and W if power module is R1-R6, Phase U and V if power module is R7-R9) on front side of power module are open.
Page 154: Measure The Resistance Of Fuses
Table 2 DC link resistance measurements - Healthy Power Module If the measured values differ from the allowed values in Table 2, replace with a new power module and send failed power module back to ABB for further analysis. Measuring the diodes of rectifier and IGBT ...
Page 155: Measuring Points
Inspecting Power Modules 155 If the measured values differ from the allowed values in Table 3, replace with a new power module and send failed power module back to ABB for further analysis.  Measuring points Figure 1: R1-R3 power module – Measuring points...
Page 156 156 Inspecting Power Modules Figure 3: R4-R6 power modules – Measuring points 2 Figure 4: R7-R9 power modules – Measuring points...
Page 157 Inspecting Power Modules 157 Figure 5: How to use the clip to access DC+ point (R1-R9) Figure 6: R1-R6 power modules main circuit diagram...
Page 158 158 Inspecting Power Modules Figure 7: R7 power module main circuit diagram...
Page 159 Inspecting Power Modules 159 Figure 8: R8 power module main circuit diagram...
Page 160 160 Inspecting Power Modules Figure 9: R9 power module main circuit diagram...
Page 161: Record Table
Inspecting Power Modules 161  Record Table Measurements - Healthy Power Module Converter serial number: Power module serial number: Power module material number: Power module HW release: Power module position: Visual Inspection 1 Warranty sticker is complete. 2 Serious mechanical deformation is observed. 3 Heatsink is dirty.
Page 162: How To Open The Power Module (Pebb)
162 Inspecting Power Modules How to open the power module (PEBB)  Preparation Before starting any work on the PEBB, please make sure safety rules have been applied, see as chapter Safety. Necessary tools Index Tool Type Cable cutter Sharp-nose plier Combination screwdriver T25 torx bit Protective gloves...
Page 163: Open The Power Module
Inspecting Power Modules 163  Open the Power Module Step 1: remove red marked screws and open the PEBB.
Page 164 164 Inspecting Power Modules Unscrew all red marked screws.
Page 165 Inspecting Power Modules 165 Step 2. Unplug the gate emitter connection. Step 3. Release output voltage cable from cable clamp. Step 4. Remove cable. Step 5. Separate HCB board and CB board from holder. Remove screws marked in red...
Page 166 166 Inspecting Power Modules Yellow: charging relay Pink internal fuse: shall be always checked with multimiter for resistance; If fuse is open, needs to be reported to support line.
Page 167: Known Problems
Inspecting Power Modules 167 Known Problems Should help field service engineer to diagnose some ACS580MV top known problems on site so that ABB can provide customers with faster resolutions and better experiences.  KP1252 Arc inside charging relay causes power module fault...
Page 168 168 Inspecting Power Modules Figure 11: Arc inside relay How to identify the problem on site Fault Messages This failure happens at the very beginning of charging, but you may not detect the failure during charging phase sometimes. Because there is no feedback from relay, it really depends on how severe the arcing is.
Page 169 Inspecting Power Modules 169 Figure 13: Q802 exploded Figure 12: Q802 position 2. U605 or Q603 on control board burned, which is close to material label areas and could be observed after removing the cover of power module. (usually on R4 –...
Page 170: Kp1299 De-Lamination Of Fiber Optic Cause Communication Failure
After identifying the problem, we suggest that: 1. Send all available failure information (plus serial number of failed PCBA and power module) to support line for further double check. ABB can recheck if this power module is within the affected batch.
Page 171 Inspecting Power Modules 171 enormous pressure between the interface of two materials, and lead to delamination of fiber optic. Figure 16: Delamination of fiber optic under X-ray How to identify the problem on site Fault Message Delamination of fiber failure always happens with communication failure, below message can indicate that problem: 1.
Page 172: Ule Fault
172 Inspecting Power Modules Figure 18 shows, the interface of test pins which can be accessed from outside the PEBB to connect the USB cable for verification. If there is no red light after connecting the pins correctly to the USB cable, the fiber optic sender is damaged.
Page 173 Inspecting Power Modules 173 Fuse on HCB of power module open and cause control board cannot work. How to identify the problem on site Fault Messages Fuse on HCB was broken usually invite Control Hub Missing PM on site. Because of control board doesn’t work, so power module cannot communicate with control hub.
Page 174: Kp1692 Mosfet Failure Causes Control Board Power Failed
174 Inspecting Power Modules Left photos are PEBB0 frame, right photos are PEBB1 frames. Use multimeter plus and minus probes test two holders of fuse, the value should lower than 1 ohm. How to solve the problem on site If the fuse on HCB broken was the root cause, we suggest replace broken fuse and send all available failure information (plus serial number of failed PCBA and power module) to support line.
Page 175 Inspecting Power Modules 175 MOSFET short circuit usually happened between its gate and source. Short condition can cause the current in the loop increase and destroy multiple electronic components including the fuse on HCB. When fuse open is found on site, it should be verified if the MOSFET shorted, before replacing new fuse, otherwise the new fuse will be damaged again.
Page 176 176 Inspecting Power Modules MOSFET failure happens when the resistance is almost 0ohm. How to solve the problem on side After identifying the problem, we suggest that: 1. Send all available failure information (plus serial number of failed PCBA and power module) to support line for further double check.
Page 177: Kp1632 Failed Common Mode Choke On Hcb Is Leading To Malfunction Of Pebb
Inspecting Power Modules 177  KP1632 Failed common mode choke on HCB is leading to malfunction of PEBB Common mode choke short or open circuit on HCB usually occurs in the coil inside choke. There are two group of coils inside of choke, one group connect with pin1 and pin3, another group connect with pin2 and pin4.
Page 178 178 Inspecting Power Modules How to analyze Failure We can verify the choke’s function by measuring resistance using the multi- meter. Usually we can measure IGBT gate cables, black and white cable on IGBT gate terminal, to make sure the choke is ok or not. The resistance in there should be around 10Kohm.
Page 179: Flystart Troubleshooting
Flystart troubleshooting 179 Flystart troubleshooting Flystart troubleshooting Most of the problems during flystart will have a motor current as a consequence. To find out the root cause for a problem it is necessary to observe the time the overcurrent is occurring and previous conditions of the drive. More precisely, the following features should be identified：...
Page 180 180 Flystart troubleshooting • (If DT tool is used additionally observe currents in d and q axis:) • g_tMeas_125us.Idq[0] • g_tMeas_125us.Idq[1] The following table summarizes potential problems and describes troubleshooting measures. Note that for some problems several troubleshooting measures are proposed (sometime having opposite approach).
Page 181 Flystart troubleshooting 181 Issue Possible solution Reduce the time during which reference speed is kept constant. The transient time equals one rotor time constant and cannot be directly set by parameter. In order to change it set parameters 98.4 “Lm user” and 98.3 “Rr user” to achieve different values of rotor time constants.
Page 182 182 Flystart troubleshooting...
Page 183: Software Capacitor Reforming
Software capacitor reforming 183 Software capacitor reforming What this chapter contains This chapter contains short guideline for using ‘Capacitor reforming’ functionality. The service pass-code is required to have access to these parameters in parameter group 95 HW configuration. Capacitor reforming test The software capacitor reforming function can be used when below 2 conditions both fulfilled: 1.
Page 184: Capacitor Reforming Test Steps
184 Software capacitor reforming Capacitor reforming test steps 1. Preparation the drive. The drive should have no active faults and fulfill the condition to close MCB. 2. Set Par 95.88 Capacitor reforming test = Enable. (If possible, use Drive composer to monitor signal Par 95.93, Par 95.94, Par 95.95 and Par 95.96.). 3.
Page 185: Further Information
Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to abb.com/searchchannels. Product training For information on ABB product training, navigate to new.abb.com/service/training.

ABB ACS580MV Troubleshooting Manual

1 Introduction to the Manual

2 Loading of the Control Software

3 Fault Tracing

4 Service Level Parameters

5 Using ACS580MV Data Analyzer

6 Drive Composer Support Package

7 POF Link Test

8 Inspecting Power Modules

9 Flystart Troubleshooting

10 Software Capacitor Reforming

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