How to Troubleshoot ABB ACS580 Fault 42F1 IGBT Temperature?

Getting the ABB ACS580 Fault 42F1? This "IGBT Temperature" fault indicates your VFD is overheating. Learn how to diagnose cooling fans, heatsink buildup, and ambient conditions.

 

The ABB ACS580 is built for reliability, but its internal power electronics—the IGBTs (Insulated Gate Bipolar Transistors)—are highly sensitive to heat. If your drive trips with Fault 42F1 (IGBT Temperature), it has detected that the internal temperature of the power module has exceeded safe operating limits.

This is a protective trip. If the drive were to continue operating in this state, the power transistors would likely suffer permanent thermal failure. Here is how to investigate your cooling system and restore stable operation.

Why Does Fault 42F1 Trigger?

This fault occurs when the drive’s thermal sensors measure heat levels that the cooling system cannot manage. Common causes include:

• Cooling Fan Failure: The internal fan that pulls air across the heatsink has stalled or burned out.
• Clogged Airflow: Dust, manufacturing debris, or oil buildup has created a "blanket" on the heatsink fins, blocking air passage.
• Cabinet Ventilation: The drive is mounted in a sealed cabinet that lacks adequate exhaust or air conditioning, causing the drive to "breathe" its own hot exhaust air.
• Extreme Ambient Conditions: The temperature inside your facility is pushing the drive to the limit of its design specification.
• Drive Overload: The motor is drawing current near or above the drive’s maximum rating, generating heat faster than it can be removed.

Step-by-Step Troubleshooting Guide

Safety Warning: Always disconnect all power and wait at least 5 minutes for the DC bus capacitors to discharge before opening the drive. Use a multimeter to verify zero voltage before touching any internal components.

1. Inspect the Cooling Fan

The fan is the most common point of failure.

• With power applied (and the drive in "Ready" or "Run" mode), check if the fan is rotating.
• If the fan is silent or not spinning, inspect it for physical obstructions.
• If the fan is clear of debris but still won't start, the fan motor has likely failed and requires replacement.

2. Clean the Heatsink

If the fan is working but the drive still runs hot, the cooling path is likely restricted.

• Inspect the aluminum heatsink fins. If they are packed with dust, grease, or textile fibers, use low-pressure compressed air to blow them out (ensure you are blowing dust out of the drive, not deeper into it).
• Check the cabinet air intake and exhaust filters. Replace them if they are heavily soiled.

3. Check Ambient Temperature

The ACS580 is typically rated for operation up to 40°C–50°C (depending on load). If the cabinet temperature is consistently higher than this, the drive will eventually trip on a thermal fault.

• Measure the temperature inside the cabinet at the drive's intake point. If it’s near 50°C, you must add cabinet cooling fans or an air conditioning unit.

4. Verify Load and Sizing

Is the drive struggling to keep up?

• Check the drive’s output current (Parameter 01.07) against the nominal current rating on the drive's nameplate.
• If the drive is running at 100% current capacity for long durations, it generates significant heat. You may need to consider a larger drive if your process demand has increased.

How to Reset Fault 42F1

1. Allow for Cooling: A "hot" drive will trip again immediately if you try to restart it. Let the heatsink cool down for at least 15–20 minutes.
2. Reset: Once the drive temperature has returned to a safe range, press the [Reset] button on the control panel.
3. Test: Run the motor and observe the drive's internal temperature parameter (if available in your drive settings) to ensure it stabilizes.

Maintenance Tip

If you see a 42F1 fault, check the drive's total runtime. Most cooling fans have a service life of 30,000 to 50,000 hours. If your ACS580 has been running 24/7 for 5+ years, it is highly recommended to perform a preventative fan replacement before the next hot season begins.