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 ACS 1000 Medium voltage drives

Troubleshooting manual Software version: MSAH44xx classic Release date: 05/21/2013 3BHS539545 ZAB E40 Rev.-

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ABB reserves all rights to this document. Misuse, in particular duplication and forwarding to third parties, is not permitted. This document has been checked with due care and attention. However, should the user find any errors, these should be reported to ABB. ABB aims to maintain the most modern standard, therefore, entries in this manual may differ from the actual product.

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Troubleshooting manual

Table of contents

Troubleshooting manual..................................................................................................... 5 Faults .................................................................................................................................... 7 Alarms .............................................................................................................................. 105

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Troubleshooting manual

Troubleshooting manual If information is required beyond the instructions in this manual, contact ABB as follows: ABB Switzerland Ltd Medium Voltage Drives CH-5300 Turgi, Switzerland Phone:+41 844 845 845 Fax:+41 58 589 2984 [email protected]

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Faults Panel text

Meaning of message

Possible causes

AnInpCalib

Analog input calibration: Automatic Automatic calibration of analog calibration of analog inputs was not inputs could not be carried out successful. successfully because one of the analog input values is higher than 0.5 mA.

Hints for rectification

Fault class ARU

Fault class INU

Analog input wires have to be disconnected for the calibration. Retry calibration.

Parameter

Bit

9.07

B12

9.07

B02

Defective IOEC.

AutoRestart

Drive trip because auto-restart sequence takes too long.

Depends on the fault that initiated the auto-restart sequence.

The auto-restart function is enabled with P31.01.

Wrong parameter setting

Check reason for auto restart attempts. Check related parameters.

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FC2

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Panel text

Meaning of message

Possible causes

Hints for rectification

Aux Fan 1/2

Auxiliary fans of water cooling system: auxiliary fan 1/2 failure. For details see P41.06 RedAuxFanInstall.

Auxiliary fan thermal protection relay has been tripped.

Check thermal relay setting.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.05

B05

9.02

B08

Check fan phase currents. Faulty components or wiring. Check components and wiring.

Affected internal connections: D13- Auxiliary fan M13 has a thermal IOEC1 (X11/5, X11/6) for AuxFan1, protection relay Q13 with a normally closed auxiliary contact. DI9-IOEC4 (X12/7, X12/8) for AuxFan2.

This supervision cannot be deactivated in the SW.

Behavior of redundant cooling fan is set with P41.06 RedAuxFanInstall: 0 = no redundant fan is installed 1 = redundant fan is installed Default setting is 0 BChopDiscr

BCU was switched on but no feedback was received

Fiber optic link INT to BCU IGCT interrupted.

The status of the signal can be read from - P09.02, Bit08 (FaultWord2)

Fiber optic link CDU to INT interrupted.

Check fiber optic links.

Not Appl.

FC2

Check IGCT status LEDs on GUSP. Check current setting of CDU.

BCU IGCT (-V4501, -V4504) not switching. Wrong current setting on CDU.

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Panel text

Meaning of message

Possible causes

Hints for rectification

BChopGUSP

BCU GUSP3 failure.

Aux power failure.

Check auxiliary supply, batteries and fuses.

The status of the signal can be read from - P09.02, Bit06 (FaultWord2)

Faulty fiber optic link.

Check auxiliary supply wiring.

GUSP failure.

Check fiber optic cables and connections.

Short circuit in BCU circuit

Short circuit inside the BCU.

Check diodes and IGCTs.

The status of the signal can be read from - P09.02, Bit07 (FaultWord2)

Short circuit on braking resistor.

Check braking resistor.

Incorrect setting on CDU.

Check CDU settings.

BChopShort

3BHS539545 ZAB E40 Rev.-

Faults Fault class ARU

Not Appl.

Fault class INU

FT

Parameter

Bit

9.02

B06

9.02

B07

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Panel text

Meaning of message

Possible causes

Brg DE Mlos

Motor bearing temperature Loss of measurement signal. measurement at driven end: loss of analog input. Defective temperature probe.

Hints for rectification

Check measurement circuit, refer to the electrical diagram for terminal identification.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.01

B10

Check components and wiring. Motor bearing temperature is a 4...20 mA analog input signal. BrgDE Mlos alarm is activated when measuring signal drops below 2 mA. Connection: AI02-IOEC3 (X31.3, X32.3) (IOEC3 has to be activated by setting P75.01 to YES).

Faulty components or wiring. Check parameter settings. Communication problem with IOEC3.

Check the analog inputs on IOEC3. Check IOEC3 DIP-switch setting according to wiring diagram.

Actual bearing temperature can be read from P80.02 BEARING TEMP DE (via AI02-IOEC3). Measurement loss detection is activated only if P81.10 AI2 MINIMUM IO3 is set to 1 (1 = 4 mA / 2 V). Reaction to measurement loss can be set to NONE, ALARM or SOFT STOP with P35.01 BEARING TEMP PROTECTION DE.

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Panel text

Meaning of message

Possible causes

Hints for rectification

BrgNDE Mlos

Motor bearing temperature measurement at non driven end: loss of analog input.

Loss of measurement signal.

Check measurement circuit, refer to the electrical diagram for terminal identification.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.01

B09

Defective temperature probe. Check components and wiring.

Motor bearing temperature is a 4...20 mA analog input signal. BrgNDE Mlos alarm is activated when measuring signal drops below 2 milliamps. Connection: AI03-IOEC3 (X31.4, X32.4) (IOEC3 has to be activated by setting P75.01 to YES).

Check parameter settings. Check the analog inputs on IOEC3. Check IOEC3 DIP-switch setting according to wiring diagram.

Actual bearing temperature can be read from P80.03 BEARING TEMP NDE (via AI03-IOEC3). Measurement loss detection is activated only if P81.16 AI03 MINIMUM IO3 is set to 1 (1 = 4 mA / 2 V). Reaction to measurement loss can be set to NONE, ALARM or SOFT STOP with P35.04 BEARING TEMP PROTECTION NDE.

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Panel text

Meaning of message

Possible causes

Hints for rectification

BrgTemp DE

Motor bearing temperature at the driven end too high.

Motor bearing temperature at the driven end exceeds trip level.

Check the true temperature.

Affected customer connection: AI02-IOEC3 (X31.3, X32.3) (IOEC3 has to be activated by setting P75.01 to YES).

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.01

B12

Check the scaling and the IOEC3 DIP-switch setting. Refer to motor documentation for further instructions on fault finding.

Actual bearing temperature can be read from P80.02 BEARING TEMP DE (via P80.06 AI02-IOEC3). Reaction to overtemperature can be set to NONE, ALARM or SOFT STOP with P35.01 BEARING TEMP PROTECTION DE. Bearing temperature alarm and trip levels: P35.02 BEARING TEMP DE ALARM L P35.03 BEARING TEMP DE TRIP L Scaling of analog inputs used for DE motor bearing temperature measurement is set with parameters: P81.08 AI2 HIGH VALUE (IOEC3) P81.09 AI2 LOW VALUE (IOEC3) P81.10 MINIMUM AI2 (IOEC3) P81.11 FILTER AI2 (IOEC3) P81.12 AI2 INVERT (IOEC3) P81.13 AI2 OFFSET (IOEC3)

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Panel text

Meaning of message

Possible causes

Hints for rectification

BrgTemp NDE

Motor bearing temperature at the non driven end too high (FCB).

Motor bearing temperature at the non driven end exceeds trip level.

Check the true temperature.

Affected customer connection: AI03-IOEC3 (X31.4, X32.4) (IOEC3 has to be activated by setting P75.01 toYES).

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.01

B11

Check the scaling and the IOEC3 DIP-switch setting. Refer to motor documentation for further instructions on fault finding.

Actual bearing temperature can be read from P80.03 BEARING TEMP DE (via P80.07 AI03-IOEC3).

Reaction to overtemperature can be set to NONE, ALARM or SOFT STOP with P35.04 BEARING TEMP PROTECTION NDE. Bearing temperature alarm and trip levels: P35.05 BEARING TEMP NDE ALARM L P35.06 BEARING TEMP NDE TRIP L Scaling of analog inputs used for NDE motor bearing temperature measurement is set with parameters: P81.14 AI3 HIGH VALUE (IOEC3) P81.15 AI3 LOW VALUE (IOEC3) P81.16 MINIMUM AI3 (IOEC3) P81.17 FILTER AI3 (IOEC3)

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 Panel text

Troubleshooting manual Meaning of message

Possible causes

Hints for rectification

Buchholz relay trip (transformer protection).

Check the transformer.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.02

B03

P81.18 AI3 INVERT (IOEC3) P81.19 AI3 OFFSET (IOEC3) Buchholz

Transformer: external Buchholz supervision Connections: DI05-IOEC3 (IOEC3 has to be activated by setting P75.01 to YES), terminals X11.9, X11.10. The status of the digital inputs can be checked with P80.09. Activation of the protection is done with parameters: P36.05 TrafoBuchholzProt

Check wiring and parameter settings. The gas generated during a fault in an oil-cooled transformer is Refer to transformer documentation for further collected in the gas relay, which is instructions on fault finding. located in a tube between the oil conservator and the main tank. The gas will displace the oil in the relay and a minor gas generation will cause the closing of the alarm contact. If a substantial amount of gas is generated or the oil level drops, first the alarm contact will close, followed by the tripping contact. Unusual oil flow from the transformer into the oil conservator will cause the immediate closing of the tripping contact. If the trip is active, the transformer is immediately disconnected from the grid (MCB opens).

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Panel text

Meaning of message

Possible causes

Hints for rectification

CH0 LinkErr

DDCS channel 0 (fieldbus) link error.

Interruption of communication in DDCS CH0 (fieldbus):

Check the fiber optic connections and cabling.

Connections: None, internal software supervision.

The DDCS communication on channel CH0 is broken.

The Distributed Drive Communication System (DDCS) is a communication protocol used between the AMC and an upper level controller or an external PLC, connected to an ACS1000 on channel CH0 with a fieldbus adapter.

The DDCS communication link on channel CH0 is not updated within a specified supervision time window.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.07

B10

Check fieldbus adapter.

The action in case of a communication error in CH0 can be selected with P70.05 CH0 ComLossControl. CH0 LinkErr can either be defined as alarm or as fault.

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Panel text

Meaning of message

Possible causes

Hints for rectification

CH2 LinkErr

DDCS channel 2 (master/follower) link error.

The DDCS communication on channel CH2 is broken.

Check the fiber optic connections.

Connections: None, internal software supervision.

The DDCS communication link on channel CH2 is not updated within a specified supervision time window.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.07

B11

9.06

B00

Check the master/follower parameter settings.

Channel 2 on the AMC is used for the master/follower link between the drives. The drive can be programmed to either be the master or the follower. The action in case of a communication error in CH2 can be selected with P70.14 CH2 ComLossControl. CH2 LinkErr can either be defined as alarm or as fault. ChargeCirc

Charging circuit fault. During the charging state the voltage in the intermediate DC link is supervised to detect any fault in the charging circuit. If the DC voltage level is reached too fast, or if an overvoltage situation occurs during charging, the circuit has a defective component.

IGCT or varistor defect: Short circuit of protection IGCTs (V3001, -V3002) Short circuit in varistors (-Z3001, Z3002)

Check IGCTs and varistors.

Defective DC link capacitor.

Check ADCVI scaling subprint.

Check DC link capacitors. Check parameter settings.

Wrong parameter setting. Wrong voltage measurement, e.g. scaling.

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Panel text

Meaning of message

Possible causes

Hints for rectification

Charging

Charging of DC link failed due to timeout. Maximum charging time exceeded.

Interrupted circuit

Check IGCTs and varistors

Wrong parameter setting

Check wiring and bus connections

Related parameters: P115.06 ChargeTime

CtrlBackSupp

Control aux. power supply backup voltage failure.

Fault class ARU

Fault class INU

Parameter

Bit

9.03

B14

9.06

B04

Check parameter settings

Control backup power supply is interrupted.

Connections: None, internal connection to DI04-IOEC1. Status can be checked with P08.08, Bit 3.

Faults

With UPS: battery is empty or missing.

Check the status of DI04-IOEC1 and consider the electrical diagram.

With UPS: check that batteries are healthy. Check the UPS modules. With Safeline: check the 3-phase supply. Check the power supply modules.

With Safeline: 3-phase aux. power is missing.

EPS: Check the status of backup batteries (starting from Software MSOH4100 and higher) .

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Panel text

Meaning of message

Possible causes

Hints for rectification

CtrlBackSupp

Control aux. power supply backup voltage failure.

Control backup power supply is interrupted.

Check the status of DI04-IOEC1 and consider the electrical diagram.

Connections: None, internal connection to DI04-IOEC1. Status can be checked with P08.08, Bit 3.

With UPS: battery is empty or missing.

Control aux. power supply voltage failure.

Control backup power supply is interrupted.

Connections: None, internal connection to DI08-IOEC1. Status can be checked with P08.08, Bit 7.

Fault class ARU

Fault class INU

Parameter

Bit

9.06

B04

9.06

B05

9.09

B07

With UPS: check that batteries are healthy. Check the UPS modules. With Safeline: check the 3-phase supply. Check the power supply modules.

With Safeline: 3-phase aux. power is missing.

CtrlSuppFail

Faults

With UPS: Interruption of 3-phase aux. power. With Safeline: Interruption of Safeline.

EPS: Check the status of backup batteries (starting from Software MSOH4100 and higher). Check the status of DI08-IOEC1 and consider the electrical diagram.

With UPS: check the 3-phase supply. Check the power supply modules. With Safeline: check the Safeline. Check the power supply modules. EPS: Check the supply to the EPS. Check the EPS.

CustSupSig1

Parameter group 48 allows the Customer supervision signal 1 customer to define his own (Fault Class 1, Fault Class 2 or supervision function. It is possible Soft Stop) has been activated. to define three different signals (CSS1.1 to CSS1.3) and their logical interconnection (OR or AND

Check customer supervision signal. Check group 48 settings. Check wiring according to wiring diagrams.

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 Panel text

Troubleshooting manual Meaning of message

Possible causes

Hints for rectification

Faults Fault class ARU

Fault class INU

Parameter

Bit

- gate). It is possible to invert those signals (high or low active). If NOT SEL is selected, the function is dis+D29abled. If ONLY STATUS is selected, only the status bit in P8.04 AUX STATUS WORD 4 will be set, no alarm or fault will be initiated. If ALARM is selected, only the alarm message CustSupSig1 will be displayed on the panel. No trip reaction is active. If SOFTSTOP, TRIP 1a or TRIP 1b is chosen, the drive stops according to selected trip reaction and the fault message CustSupSig1 will be displayed on the panel.

The status of the signal can be read from - P09.09, Bit 07 (Fault Class 1)

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Panel text

Meaning of message

Possible causes

CustSupSig2

Parameter group 48 allows the Customer supervision signal 2 customer to define his own (Fault Class 1, Fault Class 2 or supervision function. It is possible Soft Stop) has been activated. to define three different signals (CSS1.1 to CSS1.3) and their logical interconnection (OR or AND - gate). It is possible to invert those signals (high or low active).

Hints for rectification

Check customer supervision signal.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.09

B08

Check group 48 settings. Check wiring according to wiring diagrams.

If NOT SEL is selected, the function is dis+D29abled. If ONLY STATUS is selected, only the status bit in P8.04 AUX STATUS WORD 4 will be set, no alarm or fault will be initiated. If ALARM is selected, only the alarm message CustSupSig1 will be displayed on the panel. No trip reaction is active. If SOFTSTOP, TRIP 1a or TRIP 1b is chosen, the drive stops according to selected trip reaction and the fault message CustSupSig1 will be displayed on the panel. The status of the signal can be read from - P09.09, Bit 08 (Fault Class 1)

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Panel text

Meaning of message

Possible causes

Hints for rectification

Discharging

DC link discharge timeout. Maximum discharging time exceeded.

Faulty discharging circuit .

Isolate the drive and wait for discharging before closing grounding switch.

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.03

B10

9.04

B04

Wrong parameter settings. Related parameters: P115.05 DischargeTime P149.08 EarthIsolatorONVoltage

EarthIsoCtrl

Check discharging circuit. Faulty measurement. Check parameter settings.

Feedback signal from grounding Loose wiring. switch is missing while drive is in operation. This is considered to be Faulty IOEC. critical for personal safety and therefore the converter has tripped.

Check components and wiring. Check the status of DI10 and DI11-IOEC1 and consider the electrical diagram.

Connections: DI10-IOEC1, terminals X12.9, X12.10 Grounding Switch Open and DI11-IOEC1 terminals X13.1, X13.2 Grounding Switch Closed Status can be checked with P04.21, Bits 3 & 4. EarthIsoCtrl trip can not be deactivated by SW parameters.

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Panel text

Meaning of message

Possible causes

Hints for rectification

EmergOff

Trip due to emergency off.

Emergency off has been activated (locally or from overriding system).

Control cabinet door emergency button or customer emergency buttons has been activated (Check the tripping loop circuit and status of DI05-IOEC1) .

Connections: DI05-IOEC1, terminals X11.9, X11.10

Faults Fault class ARU

Fault class INU

Parameter

Bit

9.02

B12

9.09

B00

Check overriding control word 7.06 OCW bit 1 Off2 (only if P75.04 FBA Comm.Module set to DSET 1 or 10 R/W).

ExtAct1Lost

External actual signal 1 lost: actual signal 1 for PID-control macro drops below the minimum limit.

The PID actual signal 1 has dropped below 4 mA / 2 V.

Check measurement circuit, refer to the electrical diagram for terminal identification.

Loose wiring in the contol circuit. Connection: AI01-IOEC4, terminals X31.2, X32.2 (IOEC4 has to be Improper shield grounding of activated by setting P75.02 to wiring. YES). Power supply of sensor lost. Operation in case of actual value 1 (analog input signal AI01-IOEC4). Faulty IOEC. ExtAct1Lost fault is activated only if P86.04 (AI1 Minimum IO4) is set to 4 mA / 2 V and P40.15 (AI