Acs800 Fault Tracing 5zx2n

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ABB Industrial drives, ACS800

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eLearni ng

Fault tracing

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Objectives

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After completing this module, you will be able to 

Explain the functions of ACS800 diagnostics



Find information on how to trace alarms and signals with the fault logger, data logger and data words



Explain what kind of material exists and where to find it



Get help for the fault tracing when needed

Help

Fault tracing 

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

Systematic fault tracing –

Logical iteration, step by step

–

Make notes of fault tracing actions

–

Use application and other drawings

Is the fault in the drive? –

Application characteristics

–

External devices 

Supply



PLC, relays, etc

Help

Fault tracing

Fault tracing principles Drive “alive”?

Yes

No Check supply voltages and main circuit

supplying net

Indications (CDP, leds, DriveWindow2, etc)

Fault location?

drive

drive

Fault location?

other systems

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drive supply Check supplying network

See supply mo dule manuals

See drive hard ware manuals

See drive firm ware manuals

Check PLC, moto r, cabling, etc

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Fault tracing | Fault tracing principles

Main circuit quick check US

UC

V ~

V =

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 



Resistance of each input/output phase against the dc-link +/-

Fault tracing | Fault tracing principles

Back Help

Supply modules manuals 



Links to ACS800 supply modules manuals in ABB Library: –

ACS800-204 IGBT Supply Modules Hardware Manual

–

ACS800 IGBT Supply Control Program 7.x Firmware Manual

–

ACS800-207 Cabinet-installed IGBT Supply Unit Hardware Manual

–

ACS800-404 Thyristor Supply Modules 's Manual

–

's Manual: ACS800-407 and ACS800-807 Cabinet-installed Thyristor Supply Units (TSU) (639 to 5991 kW)

–

ACS800-307 and ACS800-507 Cabinet-installed Diode Supply Unit 's manual

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Diode Supply Modules ACS800-304 and ACS800-704 's manual

–

ACA 635 IGBT Supply Sections 260 to 4728 kVA, ACS 800-17 Line-Side Converter 120 to 1385 kVA 's manual

DSU on-site tester

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ACS800 IHMM / 02 Manuals & Guides / General Manuals / ACS800-304 and ACS800-704 Modules On-Site Tester, 's Guide

Fault tracing | Fault tracing principles

Drive hardware manuals

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Links to ACS800 hardware manuals in ABB Library: –

ACS800-01/U1 Hardware Manual

–

ACS800-02/U2 Hardware Manual

–

ACS800-04/04M/U4 Hardware Manual

–

ACS800-04 Drive Modules Hardware Manual, (0.55 to 132 kW)

–

ACS800-11/U11 Drives Hardware Manual (5.5 to 110 kW)

–

ACS800-07 (45 to 560 kW) Hardware Manual

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ACS800-07 (500 to 2800 kW) Hardware Manual

–

ACS800-17 Drives (55 to 2500 kW / 75 to 2800 HP), Hardware Manual

–

ACS800-31/U31 Hardware Manual

–

ACS800-37 Drives (55 to 2700 kW / 75 to 3000 HP), Hardware manual

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ACS800-104 Inverter Modules, Hardware Manual

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ACS800-107 (1.5 to 5340 kW) Cabinet-built Inverter Units Hardware Manual

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ACS800-607 Brake Units Hardware Manual

–

ACS800-67 Wind Turbine Drives for Asynchronous Slip Ring Generators Hardware Manual

–

ACS800-07LC Drives Hardware Manual

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Fault tracing | Fault tracing principles

Drive firmware manuals - basic

Back Help next page

Links to basic ACS800 firmware manuals in ABB Library 

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

Single drive: –

Firmware Manual, Standard Application Program 7.x

–

Permanent Magnet Synchronous Machine Drive Application ProgramSupplement to Firmware Manual for ACS800 Standard Application Program 7.x

Multidrive: –

ACS800 System Application Program 7.x Firmware Manual

–

ACS 600/800 PMSM Drive Application ProgramSupplement to Firmware Manual System Application Program 7.x

Fault tracing | Fault tracing principles

Drive firmware manuals - applications

Back Help previous page

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Links to application specific ACS800 firmware manuals in ABB Library: –

Cascade Generator Control Program for ACS800-67 Wind Turbine Drive Firmware ManualACS800 Center Winder / Unwind Application Program, Firmware Manual

–

Supplement, Centrifuge Control Application Program for ACS 800 Firmware Manual

–

ACS800 Center Winder / Unwind Application Program, Firmware Manual

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ACS800 Common Converter Control Application (CCCA) 7.x Firmware Manual

–

ACS800 CraneDrive Control ACC 800 Crane Application Program 7.2

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Supplement for ACS 800 Extruder Control Application Program

–

Inline Application Program, Application Software Manual

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Master/Follower Application Guide for ACS800 Standard Appl. Program

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ACS800 Motion Control Application Program 7.x Firmware Manual

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ACS600/ACS800 Firmware Manual Multi Block Programming Application 7.x

–

ACS800 Adaptive Program Application Guide

–

ACS800 P and ESP (W631) Application Program Firmware Manual

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Firmware Manual for ACS800 Pump Control Application Program 7.1

–

ACS800 Rod Pump Light Application Program Firmware Manual

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Supplement, Slew Control Application Program

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Firmware Manual for ACS 800 Spinning Control Application Program 7.x

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Firmware Manual, Application Program Template 7.x for ACS800 Frequency Converters

–

Firmware Manual, for Test Bench Application Program, Supplement

–

Supplement for Traverse Control Application Program 7.x

Fault tracing | Fault tracing principles

Checking the other systems 

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



Upper level controls –

PLC

–

Application controller

–

Check signals, status words

Scalar mode –

Motor + cable

–

Pulse encoder

Other sensors –

Pressure, flow, etc.

–

Temperature (PTC, Pt100,...)

Back Help

Help

ACS800 diagnostics 

Software and hardware functions –

Signals 

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–

Alarms and signals –

Fault indications

–

Actual values

–

Status words



Fault logger



Data loggers



APBU logger

Indicators 

Boards



Displays



Other indicators

Help

Board indications 

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

Drive contains warning and fault LEDs on 

ADPI board



NLMD led display



DSSB board



Supply and drive module front



RMIO board



AINT board

A fault indication LED normally stays lit after the fault is detected

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Board indications

ADPI board

Help

Help

Board indications

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NLMD 

ACS800 multidrive



Led display, 3 status LEDs –

Ready

–

Run

–

Fault

Help

Board indications

RMIO board

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

Two status LEDs –

Green = auxiliary power on

–

Red = fault

Help

Board indications

AINT board 

Four status LEDs –

V204 (green) 

–

V309 (red) 

–

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driving permission bits are set

V310 (green) 

–

aux. power ok

prevention of unexpected start active

V311 (green) 

voltage to gate drivers ok

Help

Board indications

GINT board 

Status LED

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–

15 Vdc supply active

Help

Board indications

DSSB board indications 

Diode supply system board 



DSU module front 

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Fault indication LEDs

Fault indication LEDs

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Indicators

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

Other indicators –

Relays

–

Fuses

–

Lamps

–

etc.

Help

Warnings and faults 

ACS products use a two-level protection system –

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–

Warning 

Lower level



Generated by the drive or control

Fault 

Higher level



Generated by the drive

Warnings and faults

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Fault history 

Faults and warnings are stored with the time stamp



Fault logger collects 64 latest faults



16 of the latest faults are stored in power off

Help

Help

Warnings and faults | Fault history

Fault logger 



Reading the fault logger contents –

CDP312 control

–

DriveWindow 2.x

Alarm and fault codes –

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–

Firmware manuals 

ABB Library



ACS800 IHMM Lotus Notes

More details in drive type specific learning modules

LINKS TO ONLINE DOCUMENTS

DriveWindow 2 's Manual Links will open in a new window

Warnings and faults | Fault history

Viewing and resetting - CDP312 

View and reset the fault history with control

1. Enter the Actual Signal Display Mode 2. Enter the Fault History Display 3. Select the next or previous fault/warning 4. Clear the Fault History

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5. Return to Actual Signal Display Mode

Help

Alarms and signals

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Protection functions 

Preprogrammed Fault and warning functions



Programmable Fault and warning functions



Programmable Autoreset functions



See the Firmware manual for more details –

30 FAULT FUNCTIONS

–

31 AUTOMATIC RESET

Help

Warnings and faults | Functions

Preprogrammed functions

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

Examples of preprogrammed protection features 

Temperature



Overload



DC overvoltage



DC undervoltage



Overcurrent



Short circuit



Input phase loss



Temperature

Help

Warnings and faults | Functions

Programmable fault functions

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

Programmable action when a fault is detected (par group 30) –

No action

–

Warning indication

–

Fault tripping



Defined according to the application



Instructions can be found in the Firmware Manual –

ACS800 IHMM

–

ABB Library

Help

Warnings and faults | Functions | Programmable fault functions

Examples

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

Examples of programmable protection features 

loss



External fault



Motor stall



Underload



Motor phase loss

Help

Warnings and faults | Functions

Programmable autoreset functions

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

Parameter group 31 –

Automatic fault reset

–

Only for certain fault types



Not operational if the drive is in local control



Instructions can be found in the Firmware Manual –

ACS800 IHMM

–

ABB Library

Help

Warnings and faults | Functions | Programmable autoreset functions

Examples

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

Examples of programmable autoreset functions: 

Overcurrent



Overvoltage



Undervoltage



AI Signal < Minimum

Help

Help

Data logger 

ACS800 data logger

© Copyright 04/29/17 ABB. All rights reserved. - 30 -

–

Tool for analyzing drives state afterwards 

fault tripping



other abnormal operation

–

Memory buffer located in the drive RMIO board

–

Collects selected data according to selected triggering settings

–

Max. 2 loggers / drive (depends on sw)

–

Max. 6 variables (=channels) / logger

–

32700 samples / channel

Help

Data logger

Data logger control 

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

DriveWindow 2.x –

Setting up the logger

–

Reading the logger data

More details: –

Training module for tools

–

DriveWindow ’s manual 

ACS800 IHMM



ABB Library

LINKS TO ONLINE DOCUMENTS

DriveWindow 2 's Manual Links will open in a new window

Help

Drive signals

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

Can be followed from –

CDP312 control

–

Pc tool (DriveWindow, DriveDebug)

Help

Drive signals

CDP312 

Actual display –



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

Three selectable signals

Numerical form –

Decimal

–

Binary

–

Hexadecimal

ACS800 Firmware manual - Control –

ACS800 IHMM

–

ABB Library

Help

Drive signals

DriveWindow 2.x 

Numerical form –

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

Selectable formats

Graphical form –

6 selectable variables

–

Scaling, sample time

–

Buffering, zoom, cursor

LINKS TO ONLINE DOCUMENTS

DriveWindow 2 's Manual Links will open in a new window

Help

Drive signals

Useful signals

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

Speed –

Actual

–

Reference

–

Speed error = speed reference - speed actual



Output current



Power



Torque



DC link voltage



Status words

Help

Drive signals

Scaling 

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

How accurate is accurate enough? –

Horizontally, sample time

–

Vertically

Measured signal –

Range min...max

–

Time scale

Help

APBU datalogger 

Used for parallel connected inverter fault tracing



PPCS branching unit





APBU-44



APEB-84 extension board (if needed)

APBUDL tool software for data exchange 



Instructions for use –

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Analyzing in MS Excel

APBU datalogger ’s Manual 

ACS800 IHMM

Help

Product documentation Available product documentation 

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

ACS800 firmware and hardware manuals: –

ACS 800 IHMM Lotus Notes

–

ABB Library

ACS800 In-House Maintenance manual (IHMM): –

service hints

–

circuit diagrams

Help

Technical 

Drives Technical services –



Local ABB representative –

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Accurate, consistent, and responsive information and to our customers

More information on and remote services

LINKS TO ONLINE DOCUMENTS

Drive services s Links will open in a new window