How to Troubleshoot ABB ACS560 Warning 2310 Overcurrent

Getting the ABB ACS560 Warning 2310? This alarm signals an overcurrent condition. Learn how to diagnose motor shorts, check mechanical jams, and optimize your VFD settings.

 

In the ABB ACS560 drive, Warning 2310 is a clear signal that the drive is sensing an Overcurrent condition. This means the motor is drawing more current than the drive’s programmed limit, or the drive has detected a sudden surge that threatens the integrity of its internal power module (IGBTs).

While an overcurrent warning is often a precursor to a full "Fault" trip, it gives you a window of time to investigate before the drive shuts down your entire process. Here is how to track down the source of the excess current.

Why Does Warning 2310 Trigger?

When the ACS560 monitors output current, it compares the actual motor draw against the limits you defined in the drive's parameters. Common triggers include:

• Sudden Load Spike: A mechanical jam, bearing seizure, or a massive increase in load (e.g., a pump hitting a closed valve).
• Short Circuit: A partial short in the motor cable, the motor junction box, or the internal motor windings.
• Aggressive Acceleration: Trying to speed up a high-inertia load (like a heavy fan or flywheel) faster than the motor can handle.
• Parameter Mismatch: Incorrect motor nominal values (Group 99) causing the drive to miscalculate its own current limits.

Step-by-Step Troubleshooting Guide

1. The "Disconnected" Drive Test

The fastest way to determine if the issue is the drive itself or the motor circuit:

• Disconnect the motor output cables (U, V, W) from the drive.
• Start the drive in a "no-load" condition.
• If the Warning 2310 persists with no motor connected, the drive’s internal power module has a short circuit, and the drive likely needs replacement.
• If the warning goes away, your drive hardware is healthy, and the problem is definitely in your cables or motor.

2. Inspect the Motor and Cables

If the drive passed the disconnected test, move to the field:

• Megger Test: Use an insulation tester to check the motor cables and windings. A breakdown in insulation (even if it's not a dead short yet) will cause current leakage that triggers a 2310 warning.
• Check Terminations: Open the motor junction box. Look for signs of moisture, loose wires, or carbon tracking where phases might be arcing to ground or to each other.

3. Check Mechanical Load

• Does the driven equipment move freely by hand?
• If you are running a pump, check if the discharge valve is accidentally closed. If you are running a conveyor, check for blockages.

4. Review Acceleration Parameters

If your electrical and mechanical systems are fine, you may simply be asking too much of the drive:

• If the warning 2310 only appears during start-up, check your Acceleration Time (Parameter 23.12). Increasing this time helps the drive ramp up the motor without hitting the current limit.
• Verify Parameter 99.06 (Motor nominal current). If this is set lower than the actual motor's full-load current, the drive will trigger warnings prematurely.

How to Reset the Warning

A "Warning" is often self-clearing once the current levels return to a normal range. If it escalates to a full "Fault" trip:

1. Clear the mechanical jam or fix the damaged cable.
2. Press the [Reset] button on your ACS560 control panel.
3. Monitor current (Parameter 01.07) during the next start to ensure it stays below the nominal rating.

Maintenance Tip

If you see Warning 2310 frequently, check the cleanliness of your motor cooling fins. A motor running at high temperatures has higher winding resistance, which can contribute to higher current draw. Keeping the motor cool is often the "hidden" fix for recurrent overcurrent alarms.