ABB DCS880 Warning AF90 Autotuning Fault

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Getting the AF90 Autotuning fault on your ABB DCS880 DC drive? Learn how to decode XXXXYYYY AUX codes and fix failures in field, armature, and speed controller tuning.

ABB DCS880 Warning AF90 Autotuning Fault

 

Commissioning an ABB DCS880 DC drive requires several "Autotuning" steps to ensure the drive understands the electrical and mechanical characteristics of the motor. If you see Warning AF90, it means one of these tuning routines or assistants started but did not finish successfully.

The AF90 code is an informative warning. To clear it, you must either complete the tuning process successfully or manually override the warning by holding the Reset button (or digital input reset) for more than 3 seconds. However, simply clearing the warning doesn't fix the underlying reason why the tuning failed. Here is how to decode the error and get your drive tuned correctly.

The Key to Success: Decoding the AUX Code

The AF90 warning provides an 8-digit AUX code (format XXXXYYYY). This code is your roadmap to the solution. The first four digits (XXXX) tell you which test failed, and the last four (YYYY) tell you why it failed.

Step 1: Identify the Autotuning Type (XXXX)

  • 0001: Field current autotuning
  • 0002: Armature current autotuning
  • 0003: Speed feedback assistant
  • 0004: Speed controller autotuning
  • 0007: Thyristor test

Common Failures and Solutions

1. Field Current Tuning Issues (XXXX = 0001)

If your field current tuning is failing, check the following YYYY codes:

  • 00010005: No field exciter selected. Check Parameter 99.07 to ensure the correct field exciter type is selected.
  • 00010007 - 0001000A: The measured field current isn't reaching the reference. This usually means the field circuit is open or interrupted. Check your wiring and field fuses.
  • 00010002: The motor is turning. For field tuning, the motor must be at a standstill.

2. Armature Current Tuning Issues (XXXX = 0002)

This is the most critical tuning step for DC motor control.

  • 00020004: Armature current is set to zero in Parameter 99.11. You must enter the motor's nominal nameplate current first.
  • 00020006 / 00020008: Armature circuit or voltage measurement wiring is wrong. Check terminals C1/D1 and the connection to the SDCS-PIN board.
  • 00020007: No load connected. While some tuning requires no load, the armature circuit must be electrically complete.

3. Speed Controller & Feedback Issues (XXXX = 0003 or 0004)

Speed tuning requires the motor to actually spin, which introduces more variables.

  • 00030002 / 00040003: Speed limitation. Check Parameters 30.11 and 30.12. If your max speed limits are set too low, the drive cannot reach the speeds required for the tuning routine.
  • 00040009 / 00030003: Voltage limitation. If your mains supply is low or Parameter 99.12 (Nominal Voltage) is set incorrectly, the drive may not be able to provide enough armature voltage to reach the necessary tuning speed.
  • 0004000B: Drive is not in Speed Control mode. Verify Parameter 19.01.

4. Premature Stop (YYYY = 0001)

Regardless of the test type, if the last four digits are 0001, the process was interrupted. This happens if:

  • The "Stop" button was pressed.
  • The "On" or "Run" enable signal was dropped.
  • A different fault occurred during the test.

Pro-Tips for Successful Autotuning

  • The 3-Second Reset: If you are stuck in a loop and just need to move the motor manually, hold the Reset button for 3 seconds. This clears the AF90 warning.
  • Check Thyristors: For large drives (H5–H8), if performing a thyristor test (0007), ensure 99.11 (Nominal Current) is set to at least 50A, or the test may fail to detect the SCRs.
  • Acceleration Times: If the motor fails to reach base speed during tuning (Code 0004000C), try decreasing Parameter 23.12 (Acceleration Time 1) to allow the drive to use more torque during the ramp.

Summary Checklist

  1. Write down the full 8-digit AUX code.
  2. Verify motor nameplate data in Group 99.
  3. Ensure all safety interlocks and "Run Enables" are high and stable.
  4. Check that the motor is physically able to rotate (if required by the test).
  5. Ensure your voltage and speed limits (Group 30) aren't strangling the drive.

 

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