5093 Rating ID mismatch Fault in ABB ACS880 Drive

5093 Rating ID mismatch Fault in ABB ACS880 Drive indicates that the hardware of the drive (Power Unit) does not match the Rating ID stored in the Control Unit (ZCU/BCU) memory.

 

ACS880 Fault Guide: Rating ID Mismatch

Fault 5093
Definition: The hardware of the drive (Power Unit) does not match the Rating ID stored in the Control Unit (ZCU/BCU) memory.

The ACS880 is a modular drive. The Control Unit contains the "brain" (firmware and parameters), while the Power Unit contains the "muscle" (IGBTs and rectifiers). Each power module has a specific Rating ID. If the Control Unit expects a 100HP drive but finds a 50HP power module, it triggers Fault 5093 to prevent hardware damage.

When does this happen? This fault is most common after replacing a Control Unit (ZCU/BCU) or a Power Module with a spare part that was previously used in a drive of a different capacity.

Common Causes

• Control Unit Swap: Installing a new or used ZCU/BCU without properly configuring the drive software to match the power module.
• Incorrect Firmware: Loading firmware that is intended for a different frame size or voltage rating.
• Corrupted NVM: The Non-Volatile Memory on the memory unit (SD Card/Memory plug) has become corrupted or was taken from a different drive.
• Multi-Module Disconnect: In large drives with multiple inverter modules, a communication failure between the BCU and one of the modules can cause an ID mismatch.

ATTENTION: Incorrectly forcing a Rating ID update on a drive that truly has mismatched hardware can lead to catastrophic failure or fire. Always verify the physical nameplate of the power module before proceeding.

How to Fix Fault 5093

1. Verify Hardware via Parameter 07.01

Check Parameter 07.01 (Drive Rating ID) using the control panel. Compare this value to the physical nameplate on the side of the drive module. If they do not match, the software configuration is incorrect.

2. Update the Rating ID (Requires Drive Composer)

If you have replaced a control unit, you must "marry" it to the power unit. This usually requires ABB Drive Composer PC Tool:

• Connect your PC to the drive via USB or Ethernet.
• In Drive Composer, navigate to the System Info or Hardware tab.
• Use the "Rating ID" update tool (often requires specialized access levels or a "loading package" from ABB) to set the correct ID for your frame size.

3. Check the Memory Unit

Ensure the ZMU (Memory Unit) is correctly seated in the Control Unit. If you replaced the Control Unit but didn't move the original ZMU over, the drive will have the "factory default" ID, which will likely clash with your specific power module.

4. Inspect Fiber Optic Links (Large Frame Sizes)

For drives using a BCU (Inverter Control Unit) and multiple modules, check the fiber optic cables connecting the BCU to the modules. A dirty or broken fiber can cause the BCU to "lose" a module, resulting in a Rating ID error.

Summary Checklist

• Is the Control Unit new? Yes → Requires ID programming.
• Was the ZMU moved from the old unit? No → Move it to keep settings and ID.
• Is the firmware correct for the frame size? Check 07.05 (Firmware Version).

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