ABB ACS580 General Purpose Drive

The drive has detected an excessive current flow to the motor, exceeding its operational limits. This typically indicates an overload condition, mechanical binding, or a short circuit in the motor or cabling, potentially leading to motor or drive damage if left unaddressed.

An earth (ground) fault or significant current unbalance has been detected in the motor circuit, specifically within the motor itself or its connecting cables. This is a critical safety hazard and can cause severe damage to equipment or pose a risk of electric shock.

The drive has detected a loss of one or more phases in the incoming AC power supply. This condition reduces the drive's power capability and can lead to instability, protective tripping, or damage to internal components if operation continues unregulated.

The drive has detected an incorrect input power or motor cable connection, or an earth fault. This includes scenarios where an input power cable is inadvertently connected to the drive's motor connection terminals, posing a significant electrical safety risk and potential damage to the drive or motor.

The DC link voltage within the drive has exceeded its safe operating limit. This commonly occurs due to regenerative energy from the motor (e.g., during rapid deceleration) that cannot be dissipated, or an excessive input supply voltage. Prolonged overvoltage can damage the drive's internal components.

The DC link voltage within the drive has dropped below its minimum operational threshold. This is typically caused by a loss or dip in the incoming AC supply voltage or an issue with the drive's internal power supply rectification. Continued operation with undervoltage can lead to unstable motor control or drive malfunction.

The drive has detected a loss of one or more phases between its output terminals and the connected motor. This typically results from a broken cable, loose connection, or open circuit protection, which can lead to motor instability, overheating, or failure if ignored.

The drive's internal components (e.g., power module, heatsink) have exceeded their safe operating temperature limit. This indicates insufficient cooling or an overload, which can lead to reduced lifespan and premature failure of the drive if not corrected.

An external temperature sensor (sensor 1) has detected that the monitored equipment (e.g., motor winding) has exceeded its programmed temperature limit. This fault protects external components from overheating and potential damage, which could lead to critical system failure.

An external temperature sensor (sensor 2) has detected that the monitored equipment (e.g., motor bearing) has exceeded its programmed temperature limit. This fault protects external components from overheating and potential damage, which could lead to critical system failure.

The Safe Torque Off (STO) function is active, meaning both STO signals (IN1 and IN2) are switched off or lost, causing the drive to trip. This is a critical safety function that stops the motor for safety. The drive will not start until both STO signals are restored and all faults are reset.

The drive has received a request from the PLC via Fieldbus Adapter (FBA A) that it cannot fulfill because the requested functionality is either unavailable or not activated. This indicates a discrepancy between the PLC program's expectations and the drive's current configuration, preventing proper fieldbus control.

A communication break has occurred in the embedded fieldbus (EFB) communication link. This means the drive has lost its connection with the fieldbus master, leading to a loss of control and monitoring capabilities via the EFB, which can halt automated processes.

The embedded fieldbus (EFB) configuration file could not be read by the drive. This indicates a potential issue with the EFB's internal software or memory where its settings are stored, preventing it from initializing or operating correctly.

The parameter settings for the embedded fieldbus (EFB) are inconsistent or incompatible with the selected protocol. This prevents the EFB from establishing a stable connection or communicating effectively, leading to operational errors.

The embedded fieldbus (EFB) protocol firmware could not be loaded, or there is a version mismatch between the EFB protocol firmware and the main drive firmware. This critical error prevents the EFB from functioning, thus disabling fieldbus communication.

This is a generic fault reserved for the embedded fieldbus (EFB) protocol application, indicating an unspecified error within the EFB communication stack or protocol execution. The precise cause and resolution are dependent on the specific fieldbus protocol implemented.

This is another generic fault reserved for the embedded fieldbus (EFB) protocol application, indicating an unspecified error within the EFB communication stack or protocol execution. Like EFB fault 2, its exact meaning is dependent on the specific fieldbus protocol in use.

An internal fault indicating an overflow in a 32-bit text table within the drive's memory. This typically points to an internal software anomaly or a memory management issue. If unaddressed, it could lead to unpredictable drive behavior or further system faults.

An internal fault indicating an overflow related to an internal text file within the drive's memory. This is usually indicative of a software bug or a transient memory allocation issue. Continued occurrence can compromise drive stability.

The control panel or PC tool, configured as the active control location, has ceased communication with the drive. This results in a loss of local control and monitoring capabilities, potentially stopping the drive or preventing startup.

Communication between an I/O module and the drive's control unit is not working properly. This fault can lead to unreliable or non-functional digital/analog inputs and outputs, affecting connected sensors, actuators, and overall process control.

A fieldbus or other option module installed in the drive's option slot is not supported by the drive's firmware or hardware. This module will not function, and its presence might cause conflicts or prevent proper drive operation.

An overvoltage condition has been detected on an Analog Input (AI) of an I/O module. The AI automatically switches to voltage mode from mA mode as a protective measure. If the high signal level persists, it could damage the input circuit or lead to inaccurate process feedback.

The configuration of an I/O module is either not supported or contains illegal settings. This prevents the I/O module from operating as intended, leading to incorrect I/O behavior or non-functionality of connected devices.

The drive has tripped due to a motor stall condition. This fault is triggered when the motor current exceeds the stall current limit, and the output frequency or speed is below its set limit for a configured time. This indicates a severe overload or mechanical blockage, which can cause significant motor or drive damage if persistent.

A short circuit has been detected within the brake chopper circuit, specifically occurring when an earth fault condition is also present and the brake chopper is active. This is a severe fault that can lead to rapid destruction of the brake chopper power components and poses a safety risk due to high current flow.

An analog input signal has gone outside the predefined minimum or maximum limits. This fault is programmable and prevents the drive from operating with out-of-range sensor feedback, which could lead to incorrect control, erratic behavior, or damage to connected equipment.

This programmable fault is triggered by the signal supervision function 1, indicating that a monitored signal (defined in parameter 32.07) has violated its configured supervision criteria (defined in parameter 32.06). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

This programmable fault is triggered by the signal supervision function 2, indicating that a monitored signal (defined in parameter 32.17) has violated its configured supervision criteria (defined in parameter 32.16). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

This programmable fault is triggered by the signal supervision function 3, indicating that a monitored signal (defined in parameter 32.27) has violated its configured supervision criteria (defined in parameter 32.26). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

This programmable fault is triggered by the signal supervision function 4, indicating that a monitored signal (defined in parameter 32.37) has violated its configured supervision criteria (defined in parameter 32.36). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

This programmable fault is triggered by the signal supervision function 5, indicating that a monitored signal (defined in parameter 32.47) has violated its configured supervision criteria (defined in parameter 32.46). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

This programmable fault is triggered by the signal supervision function 6, indicating that a monitored signal (defined in parameter 32.57) has violated its configured supervision criteria (defined in parameter 32.56). This helps in detecting abnormal conditions of critical internal or external signals, preventing unintended operation or damage.

An external device configured as External Event 1 (parameters 31.01 and 31.02) has generated a fault. This indicates a problem with equipment or sensors outside the drive's direct control, potentially impacting the entire system's operation and requiring immediate attention.

An external device configured as External Event 2 (parameters 31.03 and 31.04) has generated a fault. This indicates a problem with equipment or sensors outside the drive's direct control, potentially impacting the entire system's operation and requiring immediate attention.

An external device configured as External Event 3 (parameters 31.05 and 31.06) has generated a fault. This indicates a problem with equipment or sensors outside the drive's direct control, potentially impacting the entire system's operation and requiring immediate attention.

The drive has detected an earth (ground) fault or current unbalance in the motor or motor cable, but it is configured to issue a warning rather than trip. While allowing continued operation, this indicates a potentially developing safety issue or insulation degradation that requires immediate attention before it escalates to a full fault.

An auxiliary cooling fan, typically connected to the control board, is either stuck, disconnected, or has failed. This compromises the supplemental cooling for the drive's internal components, potentially leading to overheating warnings or faults if the thermal conditions worsen, especially in high ambient temperatures or loads.

The drive's hardware setup is in the process of initializing. This is a normal startup phase; however, if this warning persists, it might indicate a hang in the initialization sequence. This can prevent the drive from entering a ready state for operation.

The drive's hardware is undergoing its initialization process. While typically a brief startup event, persistent initialization can signal a deeper issue with the drive's hardware or firmware. The auxiliary code might provide more context on the specific stage of initialization.

The Safe Torque Off (STO) function is active, meaning the safety circuit signal(s) connected to the STO connector have been lost or removed. Depending on parameter 31.22, this can be a warning when STO is intentionally activated, or an indication of an unintended safety circuit issue. The drive will prevent motor rotation for safety.

A problem has been detected with the internal temperature measurement circuit of the drive. This means the drive may be unable to accurately monitor the temperatures of critical components (e.g., IGBTs, power supply board), which could lead to undetected overheating and damage if left unresolved. The auxiliary code provides specific location details of the issue.

This is a programmable warning indicating a motor stall condition. The motor current has exceeded the defined stall current limit, while the output frequency or speed is below its respective limit for a set duration. This suggests the motor is overloaded or mechanically constrained, potentially leading to overheating if not addressed.

The drive has detected that all three output phases are disconnected from the motor. This can occur due to an open motor circuit, open switches, or faulty cabling, preventing the drive from controlling the motor and potentially causing damage to the drive if it attempts to operate into an open circuit.

A general fault has been detected within the brake resistor circuit. This may indicate an open circuit, incorrect resistance, or an inability to dissipate regenerative energy, which could lead to DC link overvoltage and a drive trip.

A short circuit has been detected in the brake resistor or a fault within the brake chopper itself. This condition prevents the safe dissipation of regenerative energy and can lead to damage to the brake chopper components, potentially causing further drive faults.

The temperature of the brake resistor has exceeded its configured warning limit (parameter 43.12). Continuous operation under this condition will lead to premature failure of the resistor and inability to dissipate regenerative energy, risking DC link overvoltage.

One or more critical parameters related to the brake resistor's data (such as resistance value, thermal time constant, or maximum continuous power) are either incorrect or not properly configured. This prevents the drive from accurately managing and protecting the brake resistor, risking damage during braking operations.

The Insulated Gate Bipolar Transistor (IGBT) within the brake chopper has exceeded its internal temperature warning limit. This indicates excessive heat generation due to sustained braking, inadequate cooling, or an overdriven chopper, risking damage to the power components and potentially causing drive failure.

The drive's built-in or extension I/O module is not detected or improperly connected. This configuration failure can lead to loss of control, inability to read inputs, or activate outputs, rendering the drive's control functions inoperable.

An external device configured as External Event 1 (parameters 31.01 and 31.02) has generated a warning. This indicates a potential issue with external equipment or sensors that should be investigated, though it may not cause an immediate drive trip. Addressing warnings proactively prevents escalation to faults.

An external device configured as External Event 2 (parameters 31.03 and 31.04) has generated a warning. This indicates a potential issue with external equipment or sensors that should be investigated, though it may not cause an immediate drive trip. Addressing warnings proactively prevents escalation to faults.

An external device configured as External Event 3 (parameters 31.05 and 31.06) has generated a warning. This indicates a potential issue with external equipment or sensors that should be investigated, though it may not cause an immediate drive trip. Addressing warnings proactively prevents escalation to faults.

An external device configured as External Event 4 (parameters 31.07 and 31.08) has generated a warning. This indicates a potential issue with external equipment or sensors that should be investigated, though it may not cause an immediate drive trip. Addressing warnings proactively prevents escalation to faults.

An external device configured as External Event 5 (parameters 31.09 and 31.10) has generated a warning. This indicates a potential issue with external equipment or sensors that should be investigated, though it may not cause an immediate drive trip. Addressing warnings proactively prevents escalation to faults.

The drive's season configuration for scheduled operations contains an error where a season is set to start before a previous one. This logical inconsistency will prevent proper execution of time-based functions, potentially causing the system to operate outside of desired schedules.

The automatic tuning routine for the speed controller did not complete successfully, potentially due to interruption or incorrect prerequisites. This prevents the drive from optimally controlling motor speed, leading to poor performance, instability, or inefficient operation.

An asymmetric loss of one of the Safe Torque Off (STO) signals has occurred (e.g., IN1 lost while IN2 is present). This is interpreted as a malfunction in the safety circuit and causes the drive to trip. The drive will not start until both STO signals are restored and all related faults are reset.

An asymmetric loss of one of the Safe Torque Off (STO) signals has occurred (e.g., IN2 lost while IN1 is present). This is interpreted as a malfunction in the safety circuit and causes the drive to trip. The drive will not start until both STO signals are restored and all related faults are reset.