ABB ACS100 Fault Codes and Alarm Help

From the ABB service manual I compiled a list of the ACS100 Fault codes or ACS100 Alarm codes, ACS100 Error codes, or whatever you like to call them. There's a lot of good information here regarding problem solving and clearing alarms on the ACS100. This list or errors will help you solve problems fast.

Alarm and Fault displays: The seven-segment display unit of control panel indicates alarms and faults using codes "ALxx" or "FLxx", where xx is the corresponding alarm or fault code. Alarms 1-6 arise from button operation.

Green LED blinks for AL10-16, meaning that the ACS 100 cannot fully follow the control commands. The faults are indicated by red LED.

The alarm and fault messages disappear by pressing MENU, ENTER or the arrow buttons of the control panel. The message will reappear after a few seconds if the keypad is not touched and the alarm or fault is still active. Last fault code is stored into parameter 102. This fault memory can be cleared from the control panel by pressing UP and DOWN buttons simultaneously in parameter set mode.

Resetting Faults (or alarms):

Faults that are indicated by a red blinking LED are reset by turning the power off for a while. Other faults (indicated by red static LED) can be reset either from the control panel, by digital input, or switching the supply voltage off for a while. When the fault has been removed, the motor can be started. The ACS100 can be configured to automatically reset certain faults. (This would be done with parameter 505 AUTO RESET which I don't cover here)

OK with that being said, here are the ACS100 faults/alarms to hopefully give you ACS100 troubleshooting help:

ACS100 ALARM CODE LIST

• CF 0 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 1 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 2 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 3 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 4 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 5 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 6 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 7 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 8 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• CF 9 Position of configuration switch S1. Certain parameters can be modified only when S1 = 0.
• AL 1 Parameter upload/download failed.
• AL 2 Operation not allowed while start is active.
• AL 3 Operation not allowed in remote or local control.
• AL 4 REVERSE button disabled. Parameter 208 (Dir Lock) is active.
• AL 5 Panel START button disabled.
• DI configuration is 3-wire and DI2 is open.
• AL 6 Operation not allowed. Parameter 503 (Param Lock) is active.
• AL10* Overcurrent controller active. Only shown only if parameter 506 is set to 1 (Yes).
• AL11* Overvoltage controller active.Only shown only if parameter 506 is set to 1 (Yes).
• AL12* Undervoltage controller active. Only shown only if parameter 506 is set to 1 (Yes).
• AL13 Reserved. Contact supplier.
• AL14 Reverse command attempted in remote control (REM), while parameter 208 (Dir Lock) is active.
• AL15 Reserved. Contact ABB Motor supplier.
• AL16 Reserved. Contact ABB Motor supplier.

ACS100 FAULT CODE LIST

Please Note that Faults (*) with red blinking LED are reset by turning the power off and on. The other faults are reset by pressing the START/STOP button. And here's the fault codes:

• FL 1 Overcurrent: Possible mechanical problem or Acc and/or Dec times may be too small.
• FL 2 DC overvoltage: Input voltage too high or Dec time may be too small.
• FL 3 ACS 100 overtemperature: Ambient temperature too high or Severe overload.
• FL 4 * Fault current: output earth fault or short circuit.
• FL 5 Output overload.
• FL 6 DC undervoltage.
• FL 7 Analogue input fault. (See parameter 501.)
• FL 8 Motor overtemperature. (See parameter 502.)
• FL 9 Panel disconnected from drive in local control. Note! If FL 9 is active when the power is turned off, the ACS100 will start in remote control (REM) when the power is turned back on.
• FL10 Parameters inconsistent. Check that AI min (fmin) is not greater than AI max (fmax).
• FL11 * DC bus ripple too large. Check supply.
• FL12 Reserved. Contact ABB motor/drive supplier.
• FL13 * Hardware error. Contact ABB motor/drive supplier.
• FL14 * Hardware error. Contact ABB motor/drive supplier.
• FL15 * Analogue input out of range. Check AI level.
• FL16 * Hardware error. Contact ABB motor/drive supplier.
• FL17 * Hardware error. Contact ABB motor/drive supplier.
• FL18 * Hardware error. Contact ABB motor/drive supplier.
• FL19 * Hardware error. Contact ABB motor/drive supplier.
• Full display blinking - Serial link failure or Bad connection between the control panel and the ACS100.

I believe the troubleshooting guide pertains to all these models:

• ACS50-01N-01A4-1
• ACS50-01N-02A2-1
• ACS50-01N-01A4-2
• ACS50-01N-02A2-2
• ACS50-01N-04A3-2
• ACS50-01N-07A6-2
• ACS50-01N-09A8-2
• ACS50-01E-01A4-1
• ACS50-01E-02A2-1
• ACS50-01E-01A4-2
• ACS50-01E-02A2-2
• ACS50-01E-04A3-2
• ACS50-01E-07A6-2
• ACS50-01E-09A8-2

Nice job!

ABB ACS50 Faults,  Errors, and Alarms

Guys here's a quick and easy guide for troubleshooting ACS50 faults, errors, alarms or whatever you want to call them. Straight from the manual, the troubleshooting guide is simple on these.

ACS50 has two status indication LEDs, visible through the front cover. If the drive detects a problem, the red LED will blink. After fixing the problem, reset by switching the start signal off. If start is off already, turn it first on and then off again. See the list below for the fault codes (= the number of LED blinks).

Remember the basics, Green LED On and Red LED off, ACS50 operates normally
Green LED On and Red LED Blinking means the protective function has been activated. The number of blinks indicates the fault code.

Green LED Blinking and Red LED Blinking means the ACS50 will reset automatically within 3 seconds. Warning! Motor starts, if the start signal is on so be aware of this.  Automatic reset will function if the AUTORESET is ON. This is configured using the DIP switches.

Ok here's the possible causes and what to do:

• 1. DC overvoltage. 1) Mains voltage is too high: Check supply. 2) Deceleration ramp time is too short compared to the load. Automatic reset will function if the AUTORESET is ON
• 2. DC undervoltage. Mains voltage is too low: Check supply. Automatic reset will function if the AUTORESET is ON
• 3. Output short circuit: Switch off the power and check the motor windings and motor cable.
• 4. Output overcurrent. 1) Acceleration time is too short compared to the load inertia: Increase ACC/DEC time with potentiometer. 2)Motor and drive sizes do not match: Check motor.
• 5. Reserved
• 6. Analogue input value is less than 4 mA/2 V. (*) Note: This supervision is active if AI OFFSET is ON.
• 7. Motor overload (I2t overload): 1) Check the load, and verify that the motor size is suitable for ACS50. 2) Verify that setting of MOTOR I NOM potentiometer is correct.
• 8. Inverter overload or excessive internal temperature: 1) Load is too high or 2) drive cooling is insufficient.
• 9. Other fault. Internal error. Turn power off and on again. If problem persists replace the unit

I'd personally like to hear from younger technicians here, engagement from young maintenance techs would light this place up. I think you can get a different perspective based on their age. The older technicians have built their experience in a whole different tech world so they see things differently.

Finding fault in a contactor is best done when it's de-energized but I have to admit, the contactor test with power applied is interesting if it's done safely.

I would prefer to do the power-on tests with a digital multimeter, with your gloves on, of course.

Cranes are a major safety concern, if I were you I'd just look towards upgrades and replacements when crane parts become obsolete

Are the cheap Pittsburg tools any good? Anybody have anything good to say about these? The general idea is that they're too cheap to be any good.

I think this part of the forum is not going to take off. Ebay has a lock on this end of things.

Yes or no to Free Run Stop? Inertia and stopping time is obviously the most critical aspect here.

The time it takes for an electric motor to come to a stop naturally depends on factors such as the inertia of the load, the motor size, and the operating conditions. In some cases, allowing the motor to stop freely may be acceptable if the stopping time is within safe limits.

Your brake will never fail if you don't use a brake at all. So it is a nice option if it is practical and safe.