How to Fix Fault FF61 (ID Run) on ABB ACS560 Drives

Fixing ABB ACS560 Fault FF61: Why Your ID Run Failed

You’ve just installed a brand new ABB ACS560, entered your motor data, and hit the start button to begin the ID Run (Identification Run). Instead of the motor humming to life, the drive trips and displays Fault FF61.

 

If this is happening to you, don't worry. Fault FF61 simply means the drive was unable to complete its internal "handshake" with the motor. Let’s look at why this happens and how to get your commissioning back on track.

What is an ID Run and Why Does FF61 Happen?

Before the ACS560 can control a motor efficiently, it needs to create a mathematical model of that motor. It measures things like stator resistance and magnetic flux. This is the ID Run.

Fault FF61 occurs when the drive starts this process but encounters an error that prevents it from finishing. It’s essentially the drive saying, "The measurements I'm getting from this motor don't make sense based on the data you gave me."

Common Causes of FF61 on the ACS560

• Incorrect Motor Data: The most common cause. If the Amps, kW, or RPM entered in Group 99 don't match the motor nameplate, the ID run will fail.
• Motor Not Connected: If there is an isolator switch open between the drive and the motor, or a blown fuse, the drive "sees" an open circuit.
• Mechanical Load: If the motor is coupled to a heavy load (like a gearbox or a full pump) and cannot rotate freely during a "Standard" ID run.
• Interrupted Signal: If the "Enable" or "STP" signal is lost during the run, the drive will abort and throw FF61.

How to Fix Fault FF61: Step-by-Step

1. Double-Check Parameter Group 99

Go to the Primary Settings or Parameter Group 99 (Motor Data). Check these five values against the motor nameplate:

• 99.06 Motor Nominal Current (Amps)
• 99.07 Motor Nominal Voltage (Volts)
• 99.08 Motor Nominal Frequency (Hz)
• 99.09 Motor Nominal Speed (RPM)
• 99.10 Motor Nominal Power (kW)

Tip: Even a small typo in the RPM or Amps can cause an FF61 trip.

2. Verify the Motor Connection

Ensure all three phases (U, V, W) are connected securely at both the drive and the motor terminal box. If you have an output contactor or a local safety switch, make sure it is closed before you start the ID run.

3. Choose the Right ID Run Type

In Parameter 99.13, you have different options for the ID Run:

• Normal/Standard: The motor needs to rotate freely (uncoupled from the load).
• Reduced: Use this if you cannot uncouple the load but still need high accuracy.
• Still: Use this if the motor cannot rotate at all. Note that "Still" is less accurate than "Normal."

If you were trying a "Normal" run with the load attached, switch to "Still" or uncouple the motor and try again.

4. Check for "Safe Torque Off" (STO)

If the STO circuit opens during the ID run, the drive will stop immediately. Ensure your emergency stop buttons are pulled out and the STO terminals have a solid 24V signal.

How to Restart the Process

1. Clear the FF61 fault by pressing the Reset button on the keypad.
2. Correct your motor data in Group 99.
3. Change Parameter 99.13 to the desired ID Run mode again.
4. Press the Start button (usually the green button) within a few seconds to begin the process.

Summary

The ABB ACS560 Fault FF61 is rarely a sign of a broken drive. 90% of the time, it is either a data entry error in Group 99 or the motor being held back by a mechanical load. Verify your nameplate data, ensure the motor can spin (or use the "Still" ID run), and you'll be up and running in no time!