ABB ACS560 Standard Control Program Firmware

A failure has occurred in the current transformer within the output current measurement circuit. This means the drive cannot accurately monitor motor current, which is critical for protection and control, potentially leading to motor or drive damage if operation continues without proper current feedback.

The drive has detected a load unbalance, typically due to an earth fault in the motor or motor cable, or excessive output current unbalance in an inverter unit (for parallel connected modules). This condition poses a significant electrical safety risk, can lead to equipment damage, insulation breakdown, or fire, and indicates an internal fault if external causes are ruled out.

Excessive intermediate circuit DC voltage, exceeding the trip limit (e.g., 728 V DC for 400 V units). This fault often occurs during rapid deceleration of high inertia loads or due to problems with the braking system, posing a risk of damage to the drive's power components.

The drive is actively limiting torque due to the intermediate circuit DC voltage being either too high or too low. This is an informative alarm indicating the drive is attempting to protect itself from potentially damaging voltage conditions, which can lead to unstable operation or component stress if the underlying cause isn't addressed.

The intermediate circuit DC voltage is insufficient, typically due to a missing supply voltage phase, a blown input fuse, or an internal rectifier bridge fault. This condition prevents the drive from powering the motor correctly, leading to a shutdown or inability to start.

The control board temperature has exceeded 88°C, indicating a critical overheating condition. Sustained high temperatures can lead to unreliable drive operation, component damage, or premature failure of the control board, ultimately causing system shutdown.

The motor temperature is excessively high (or detected as such) due to factors like excessive load, insufficient motor power, inadequate cooling, or incorrect start-up data. This condition can severely degrade motor insulation, reduce motor lifespan, and lead to premature motor failure if left unresolved.

The measured temperature of motor 1 has exceeded the alarm limit defined by parameter 35.02. This indicates a potential overheating situation specific to this motor, which can lead to insulation degradation and reduced motor lifespan if not addressed.

The measured temperature of motor 2 has exceeded the alarm limit defined by parameter 35.05. This indicates a potential overheating situation specific to this motor, which can lead to insulation degradation and reduced motor lifespan if not addressed.

The control panel, which was selected as the active control location for the drive, has ceased communicating. This fault means the drive has lost its primary human-machine interface, preventing local control and monitoring, and potentially causing unintended drive behavior based on selected fault functions.

A communication error has occurred on control board channel CH1, typically caused by electromagnetic interference. This fault prevents the drive from communicating correctly with connected I/O modules, leading to loss of control or incorrect operation.

The brake resistor is incorrectly wired. This can lead to improper braking operation, potential damage to the resistor or drive, and ineffective energy dissipation during deceleration, creating unsafe operating conditions and poor speed control.

The brake resistor has overloaded and is experiencing excessive temperature. This condition indicates that the resistor is dissipating too much energy, potentially due to an incorrect braking cycle or excessive supply voltage, posing a risk of damage to the resistor and surrounding components.

The motor is operating in a stall region, indicating an excessive mechanical load or insufficient motor power for the applied task. Sustained stalling leads to rapid motor overheating, potential winding damage, and reduced motor lifespan.

A communication fault exists between the pulse encoder and its interface module, or between the module and the drive. This indicates a failure in the feedback loop crucial for precise motor control, potentially leading to uncontrolled motor movement, poor speed regulation, or system shutdown.

The pulse encoder phasing is incorrect, specifically Phase A is connected to the terminal for Phase B and vice versa. This wiring error will cause the drive to misinterpret motor direction and speed, leading to incorrect motor operation, instability, or immediate trips.

A pulse encoder phase signal is missing, indicating a problem with the encoder connection or the encoder itself. This will result in a loss of accurate motor speed and position feedback, causing erratic motor control or complete shutdown of the motor.

Cyclical communication between the drive and the master control system has been lost. This indicates a breakdown in fieldbus communication, which can lead to loss of control over the drive and the machinery it operates. Unresolved, this will prevent proper drive operation and could impact process stability.

An analogue input signal has fallen below its set minimum limit, which can cause the drive to react by either tripping or setting the speed to a predefined value. This warning indicates a potential loss of critical feedback or reference signal, which could lead to unsafe or unintended operation if not addressed.

A fault signal has been received from an external device, which is configured through one of the drive's programmable digital inputs. This indicates a problem in an external system or process that the drive is integrated with, often a safety interlock or monitoring system, requiring the drive to stop.

The inverter type (e.g., sr0025_3) has been changed, typically at the factory or during drive implementation. This fault indicates that the new configuration needs to be validated before the drive can operate correctly, requiring a specific power-off sequence.

The inverter type (e.g., sr0025_3) has been changed, typically at the factory or during drive implementation, and a power cycle is required to validate this change. This alarm prompts the user to switch off the control board power to finalize the hardware reconfiguration and allow the drive to operate with the new settings.

A fault has occurred on the line-side converter of the drive system. This indicates a problem with the input power stage that converts AC supply to DC bus voltage, potentially affecting the drive's ability to operate or drawing excessive current.

Motor data has either not been provided to the drive or the configured motor data does not match the inverter's capabilities. Incorrect or missing motor parameters can lead to suboptimal motor control, instability, and potential damage to both the motor and the drive.

One of the motor phases is lost, caused by a fault in the motor, motor cable, thermal relay (if used), or an internal drive fault. This condition leads to unbalanced motor currents, potentially causing motor overheating, vibration, and damage to the motor or drive.

The drive's supply voltage is excessive, exceeding 124% of the unit's voltage rating. When this occurs, the motor speed can rapidly accelerate (rush) to a trip level (40% of nominal speed), indicating a potentially damaging overvoltage condition for the drive and potentially the motor.

The output filter choke of the drive is experiencing excessive temperature. This supervision is active in step-up drives and points to inadequate cooling or excessive current through the choke, which can lead to overheating and potential damage to the filter components, impacting drive output quality.

The fan for the drive's output filter is experiencing excessive temperature. This typically occurs in step-up drives and indicates inadequate cooling, which can lead to overheating of the filter components and potential damage to the output filter if not resolved promptly.

The drive is limiting motor torque based on calculated motor pull-out torque and the minimum/maximum torque limits defined by parameters 20.13 and 20.14. This informative alarm indicates the drive is operating at its torque limits, potentially due to high load, incorrect motor parameters, or insufficient motor identification. Sustained operation at torque limits can hinder performance and prevent achieving desired output.

The drive is limiting motor power based on the limits defined by parameters 20.11 and 20.12. This is an informative alarm indicating the drive is operating at its power limits, potentially due to excessive load or conservative parameter settings. While not an immediate trip, sustained operation at limits can reduce efficiency or prevent desired performance.

An overtemperature condition has been detected on the AINT board of an inverter module. Prolonged operation at elevated temperatures can lead to accelerated degradation and eventual failure of critical electronic components on the board.

Overtemperature has occurred in the choke of a liquid-cooled R8i inverter module. Excessive heat in the choke can reduce its magnetic properties and potentially lead to insulation breakdown, compromising drive performance and safety.

A source selection (pointer) parameter has been configured to point to a non-existent parameter index. This indicates a configuration error in the drive's settings, which can lead to incorrect parameter referencing and potentially erratic or undefined drive behavior.