Complete Guide to ABB ACS150 Drive Fault Codes & Troubleshooting

-

Complete troubleshooting guide for ABB ACS150 drive fault codes. Find the full list of ACS150 error codes, common causes, and how to reset your ABB VFD.

ABB ACS150 Drive Fault Codes

 

If you are working with industrial automation, you likely know that the ABB ACS150 micro drive is a highly reliable component used in a wide variety of machinery. However, like all Variable Frequency Drives (VFDs), it can occasionally experience operational issues. When a problem occurs, the drive will stop and display an error code to help you identify the root cause.

To help you minimize equipment downtime, we have compiled a comprehensive guide to ABB ACS150 drive fault codes. Below, you will find a complete list of error codes, what they mean, and standard troubleshooting steps.

Understanding ABB ACS150 Faults and Alarms

Before diving into the list, it is important to understand the difference between an alarm and a fault on your ABB VFD:

  • Faults: These are severe issues that cause the drive to trip and stop the motor immediately to protect the equipment. The red LED will light up, and the panel will display a fault code (e.g., F0001).
  • Alarms: These are warnings that indicate an abnormal condition. The drive will usually continue to run, but the issue should be addressed before it turns into a hard fault.

Complete List of ABB ACS150 Drive Fault Codes

Below is the complete troubleshooting list for ACS150 VFD error codes. Search for your specific code to find the cause and the recommended solution.

Code Cause & Solution
A2001
OVERCURRENT
Cause: Output current limit controller is active.

Solution:

1. Check motor load.
2. Check acceleration time (parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2).
3. Check motor and motor cable (including phasing).
4. Check ambient conditions.
A2002
OVERVOLTAGE		 Cause: DC overvoltage controller is active.

Solution:

1. Check deceleration time (parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2).
2. Check input power line for static or transient overvoltage.
A2003
UNDERVOLTAGE		 Cause: DC undervoltage controller is active.

Solution: Check input power supply.
A2004
DIRLOCK		 Cause: Change of direction is not allowed.

Solution: Check parameter 1003 DIRECTION settings.
A2006
AI1 LOSS		 Cause: Analog input AI1 signal has fallen below limit defined by parameter 3021 AI1 FAULT LIMIT.

Solution:

1. Check fault function parameter settings.
2. Check for proper analog control signal levels.
3. Check connections.
A2009
DEVICE OVERTEMP		 Cause: Drive IGBT temperature is excessive. Alarm limit is 120 °C.

Solution:

1. Check ambient conditions.
2. Check air flow and fan operation.
3. Check motor power against drive power.
A2010
MOTOR TEMP		 Cause: Motor temperature is too high (or  appears to be too high) due to  excessive load, insufficient motor  power, inadequate cooling or  incorrect start-up data.

Solution:

1. Check motor ratings, load and cooling.
2. Check start-up data.
3. Check fault function parameter settings.
4. Let motor cool down.
5. Ensure proper motor  cooling: Check cooling fan, clean cooling  surfaces, etc.
A2011
UNDERLOAD		 Cause: Motor load is too low due to, for  example, release mechanism in driven equipment.

Solution:

1. Check for problem in driven equipment.
2. Check fault function parameter settings.
3. Check motor power against drive power.
A2012
MOTOR STALL		 Cause: Motor is operating in stall region  due to, for example, excessive load or insufficient motor power.

Solution:

1. Check motor load and drive ratings.
2. Check fault function parameter settings.
A2013
AUTORESET		 Cause: Automatic reset alarm.

Solution: Check parameter group 31 AUTOMATIC  RESET settings.
A2017
OFF BUTTON		 Cause: Drive stop command has been  given from control panel when  local control lock is active.

Solution:

1. Disable the local control mode lock by 1606 LOCAL LOCK and retry.
A2018
PID SLEEP		 Cause: Sleep function has entered the sleeping mode.

Solution: See parameter group 40 PROCESS PID  SET 1.
A2023
EMERGENCY
STOP		 Cause: Drive has received emergency stop command and ramps to stop according to ramp time defined by parameter 2208 EMERG DEC TIME.

Solution:

1. Check that it is safe to continue operation.
2. Return emergency stop push button to normal position.
A2026
INPUT
PHASE
LOSS		 Cause: Intermediate circuit DC voltage is oscillating due to missing input power line phase or blown fuse. Alarm is generated when DC voltage ripple exceeds 14% of nominal DC voltage.

Solution:

1. Check input power line fuses.
2. Check for input power supply imbalance.
3. Check fault function parameter setting.
4. This is a programmable fault function, check parameter 3016 SUPPLY PHASE
A5011  Cause: Drive is controlled from another source.
Solution: Change drive control to the local control mode.
A5012  Cause: Direction of rotation is locked.

Solution: Enable change of direction. See parameter 1003 DIRECTION.
A5013  Cause: Panel control is disabled because start inhibit is active.

Solution:

1. Start from the panel is not possible. Reset the emergency stop command or remove the 3-wire stop command before starting from the panel.
2. Check parameters 1001 EXT1 COMMANDS, 1002 EXT2 COMMANDS and 2109 EMERG STOP SEL.
A5014 Cause: Panel control is disabled because of drive fault.

Solution: Reset drive fault and retry.
A5015  Cause: Panel control is disabled because the local control mode lock is active.

Solution: Deactivate the local control mode lock and retry. See parameter 1606 LOCAL LOCK.
A5019 Cause: Writing non-zero parameter value is prohibited.

Solution: Only parameter reset is allowed.
A5022  Cause: Parameter is write protected.

Solution: Parameter value is read-only and cannot be changed.
A5023 Cause: Parameter change is not allowed, when drive is running.

Solution: Stop drive and change parameter value.
A5024  Cause: Drive is executing task.

Solution: Wait until task is completed.
A5026 Cause: Value is at or below minimum limit.
A5027 Cause: Value is at or above maximum limit.
A5028 Cause: Invalid value
A5029  Cause: Memory is not ready.

Solution: Retry.
A5030  Cause: Invalid request
A5031  Cause: Drive is not ready for operation, for example, due to low DC voltage.

Solution: Check input power supply.
A5032 Cause: Parameter error.
F0001
OVERCURRENT 		 Cause: Output current has exceeded trip level. Overcurrent trip limit for drive is 325% of drive nominal current.

Solution:

1. Check motor load.
2. Check acceleration time (parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2).
3. Check motor and motor cable (including phasing).
4. Check ambient conditions. Load capacity decreases if installation site ambient temperature exceed 40 °C. 
F0002
DC OVERVOLT		 Cause: Excessive intermediate circuit DC voltage. DC overvoltage trip limit is 420 V for 200 V drives and 840 V for 400 V drives.

Solutions:
1. Check that overvoltage controller is on (parameter 2005 OVERVOLT CTRL).
2. Check brake chopper and resistor (if used). DC overvoltage control must be deactivated when brake chopper and resistor are used.
3. Check deceleration time (parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2).
4. Check input power line for static or transient overvoltage.
5. Retrofit frequency converter with brake chopper and brake resistor.
F0003
DEV OVERTEMP		 Cause: Drive IGBT temperature is excessive. Fault trip limit is 135 °C.

Solution:

1. Check ambient conditions.
2. Check air flow and fan operation.
3. Check motor power against drive power.
F0004
SHORT CIRC 		 Cause: Short circuit in motor cable(s) or motor

Solution:

1. Check motor and motor cable.
F0006
DC UNDERVOLTAGE 		 Cause: Intermediate circuit DC voltage is not sufficient due to missing input power line phase, blown fuse, rectifier bridge internal fault or too low input power.

Solution:

1. Check that undervoltage controller is on (parameter 2006 UNDERVOLT CTRL).
2. Check input power supply and fuses.
F0007
AI1 LOSS		 Cause: Analog input AI1 signal has fallen below limit defined by parameter 3021 AI1 FAULT LIMIT.

Solution:

1. Check fault function parameter settings.
2. Check for proper analog control signal levels.
3. Check connections.
F0009
MOT OVERTEMP		 Cause: Motor temperature is too high (or appears to be too high) due to excessive load, insufficient motor power, inadequate cooling or incorrect start-up data.

Solution:

1. Check motor ratings, load and cooling.
2. Check start-up data.
3. Check fault function parameter settings.
4. Let motor cool down. Ensure proper motor cooling:
5. Check cooling fan, clean cooling surfaces, etc.
F0012
MOTOR STALL		 Cause: Motor is operating in stall region due to, for example, excessive load or insufficient motor power.

Solution:

1. Check motor load and drive ratings.
2. Check fault function parameter settings.
F0014
EXT FAULT 1		 Cause: External fault 1 Check external devices for faults.

Solution:

1. Check fault function parameter setting.
F0015
EXT FAULT 2		 Cause: External fault 2

Solution:

1. Check external devices for faults.
2. Check fault function parameter setting.
F0016
EARTH FAULT		 Cause: Drive has detected earth (ground) fault in motor or motor cable.

Solution:

1. Check motor.
2. Check motor cable.
3. Motor cable length must not exceed maximum specifications.

Note: Disabling earth fault (ground fault) may
damage drive.
F0017
UNDERLOAD		 Cause: Motor load is too low due to, for example, release mechanism in driven equipment.

Solution:

1. Check for problem in driven equipment.
2. Check fault function parameter settings.
3. Check motor power against drive power.
F0018
THERM FAIL		 Cause: Drive internal fault. Thermistor used for drive internal temperature measurement is open or short-circuited.

Solution: This hardware issue in drive need to repair or replace drive.
F0021
CURR MEAS 		 Cause: Drive internal fault. Current measurement is out of range.

Solution: This hardware issue in drive need to repair or replace drive.
F0022
INPUT PHASE
LOSS		 Cause: Intermediate circuit DC voltage is oscillating due to missing input power line phase or blown fuse. Fault trip occurs when DC voltage ripple exceeds 14% of nominal DC voltage.

Solution:

1. Check input power line fuses.
2. Check for input power supply imbalance.
3. Check fault function parameter setting.

F0026
DRIVE ID 		 Cause: Internal drive ID fault

Solution: This hardware issue in drive need to repair or replace drive.
F0027
CONFIG FILE 		 Cause: Internal configuration file error.

Solution: This hardware issue in drive need to repair or replace drive.
F0035
OUTPUT WIRING		 Cause: Incorrect input power and motor cable connection (that is input power cable is connected to drive motor connection).
Fault can be erroneously declared if drive is faulty or input power is delta grounded system and motor cable capacitance is large.

Solution:

1. Check input power connections.
2. Check input & output connection.
F0036
INCOMPATIBLE
SW		 Cause: Loaded software is not compatible.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0101
SERF CORRUPT 		 Cause: Corrupted Serial Flash chip file system.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0103
SERF MACRO 		 Cause: Active macro file missing from Serial Flash chip.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0201
DSP T1
OVERLOAD		 Cause: System error.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0202
DSP T2
OVERLOAD		 Cause: System error.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0203
DSP T3
OVERLOAD		 Cause: System error.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0204
DSP STACK
ERROR		 Cause: System error.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F0206
MMIO ID
ERROR 		 Cause: Internal I/O Control board (MMIO) fault.

Solution: There is an hardware or software issue in drive, need to repaur or replace drive.
F1000
PAR HZRPM 		 Cause: Incorrect speed/frequency limit parameter setting

Solution:

1. Check parameter settings.
2. Following must apply: 2007 MINIMUM FREQ < 2008 MAXIMUM FREQ,
3. 2007 MINIMUM FREQ/9907 MOTOR NOM FREQ and 2008 MAXIMUM FREQ/9907 MOTOR NOM FREQ are within range.
F1003
PAR AI SCALE 		 Cause: Incorrect analog input AI signal scaling

Solution:

1. Check parameter group 13 ANALOG INPUTS settings.
2. Following must apply: 1301 MINIMUM AI1 < 1302 MAXIMUM AI1.

 

How to Reset an ABB ACS150 Drive Fault

Once you have identified the fault using the list above and resolved the mechanical or electrical issue causing it, you will need to reset the drive to resume normal operation. Here is how you can clear the fault:

  1. Using the Control Panel: Press the RESET button on the integrated control panel.
  2. Digital Inputs: If your drive is wired for remote resetting, you can trigger the reset via the designated digital input.
  3. Power Cycle: If the fault will not clear via the keypad, safely turn off the main power supply to the drive. Wait for 5 minutes (allowing the DC bus capacitors to discharge) and turn the power back on.

Safety Warning: Never attempt to reset a fault and restart the drive without first investigating the root cause. Repeatedly resetting a drive under fault conditions can cause permanent damage to the VFD or the connected motor.

Best Practices to Prevent VFD Faults

Experiencing frequent ABB VFD error codes? Here are a few preventative maintenance tips to keep your ACS150 running smoothly:

  • Check Motor Cabling: Ensure all motor cables and connections are tight and free from moisture or short circuits.
  • Ensure Proper Ventilation: VFDs generate heat. Ensure the cooling fans are working and the drive's heatsink is free of dust and debris.
  • Monitor Load Changes: Frequent overcurrent or overvoltage faults can indicate mechanical binding in your application or incorrect acceleration/deceleration parameters.

Conclusion

Troubleshooting ABB ACS150 drive fault codes doesn't have to be a headache. By keeping this list handy, you can quickly diagnose issues, perform the necessary fixes, and get your machinery back online safely.

 

Comments

Post a Comment