ABB DCS Drive Faults (DCS800)

[dave2]

Don't want to sound pushy but I'm looking for a quick response... I'm getting a fault: F552 on an ABB DCS800 drive. Came on suddenly and I have to resolve this quick. if anyone has info on ABB DCS drive faults, please post!
Thanks,
Dave

[drives-technician]

Here's a general list of ABB faults and alarms for the DCS drive manual, they should pertain to all these models:

DCS800-EP1-0020-05, DCS800-EP2-0025-05, DCS800-EP1-0045-05, DCS800-EP2-0050-05, DCS800-EP1-0065-05, DCS800-EP2-0075-05, DCS800-EP1-0090-05, DCS800-EP2-0100-05, DCS800-EP1-0125-05, DCS800-EP2-0140-05, DCS800-EP1-0180-05, DCS800-EP2-0200-05, DCS800-EP1-0230-05, DCS800-EP2-0260-05, DCS800-EP1-0315-05, DCS800-EP2-0350-05,  DCS800-EP1-0405-05, DCS800-EP2-0450-05, DCS800-EP1-0470-05, DCS800-EP2-0520-05, DCS800-EP1-0610-05, DCS800-EP2-0680-05, DCS800-EP1-0740-05, DCS800-EP2-0820-05,
DCS800-EP1-0900-05, DCS800-EP2-1000-05, DCS800-EP2-1010-05

Here's the ABB DCS Fault List:

• F501 - Auxiliary Undervoltage Limit
  The auxiliary voltage is too low at terminal X99 on PIN-4 or POW-4 Board.


• F502 - Armature Overcurrent
  The armature current exceeds the overcurrent limit.


• F503 - Armature Overvoltage
  The armature voltage exceeds the overvoltage limit


• F504 - Converter Overtemperature
  The drive internal temperature exceeds the temperature limit.


• F505 - Residual current detection
  The drive has detected a ground fault.


• F506 - Motor 1 Overtemperature
  The motor 1 temperature exceeds the temperature limit.


• F507 - Motor 1 Overload
  Motor overloaded based on calculated thermal curve.


• F508 - Input/Output Board Not Found or Faulty
  The drive cannot communicate with a previously known option board such as COM-8x, RAIO, RDIO, IOB-2, IOB-3, RTAC, or DSL-4.


• F509 - Motor 2 Overtemperature
  The motor 2 temperature exceeds the temperature limit.


• F510 - Motor 2 Overload
  The motor 2 current exceeds the overload limit.


• F512 - Mains Low Voltage
  The mains voltage is below the fault limit or the mains voltage is below the alarm limit for an excessive amount of time


• F513 - Mains Overvoltage
  The mains voltage is above the fault limit for more than 10 seconds.


• F514 - Mains Not in Sync
  The synchronization with the mains frequency has been lost.


• F515 - Motor 1 Field Supply (Exciter) Overcurrent
  The field current is above the fault limit.


• F516 - Motor 1 Field Supply (Exciter) Communication Loss
  DSL-Link communication between the drive and the field supply (Exciter) has stopped for a time longer than the fault limit.


• F517 - Armature Current Ripple
  Current ripple on the DC output exceeds the limit. This is often an indication that one or more thyristors is not working or a fuse is blown.


• F518 - Motor 2 Field Supply (Exciter) Overcurrent M
  The field current is above the fault limit.


• F519 - Motor 2 Field Supply (Exciter) Communication Loss
  DSL-Link communication between the drive and the field supply (Exciter) has stopped for a time longer than the fault limit.


• F521 - Field Exciter Missing (Selected Motor)
  One or more field supply (exciter) faults is present for the motor currently selected (M1 or M2), including: (for M1) F515, F516, F529, F537 and/or F541; (for M2) F518, F519, F530, F538 and/or F542.


• F522 - Speed Feedback (Selected Motor)
  Speed feedback from a tachometer or encoder is continuously compared to EMF feedback while running. A fault indicates that the EMF was above a limit (30.15) while the motor speed was below a limit (30.14).


• F523 - External Fan Acknowledge Missing
  The Fan Acknowledge digital input was lost or was not set within 10 seconds.


• F524 - Main Contactor Acknowledge Missing
  The Main Contactor Acknowledge digital input was lost or was not set within 10 seconds.


• F525 - Type Code Mismatch
  On D1, D2, D3, or D4 modules, the current and voltage range of the type code setting is limited to 1000 Adc and 600 Vac. A fault indicates the existing setting is out of range.


• F526 - External Fault Via Digital Input
  The External Fault digital input was set


• F527 - Converter Fan Acknowledge Missing
  The Converter Fan Acknowledge digital input was lost or was not set within 10 seconds.


• F528 - Fieldbus Communications Loss
  Fieldbus Communications have been interrupted for a period longer than a time limit after the first data set from the overriding control has been received.


• F529 - Motor 1 Field Supply (Exciter) not OK
  A fault was detected by the motor 1 field supply (exciter) during its self diagnosis or there was a power failure in field supply 1.


• F530 - Motor 2 Field Supply (Exciter) not OK
  A fault was detected by the motor 2 field supply (exciter) during its self diagnosis or there was a power failure in field supply 2.


• F531 - Motor Stalled (Selected Motor)
  The measured speed is less than the stall speed and the torque is greater than the stall torque for a time greater than the stall time.


• F532 - Motor Overspeed (Selected Motor)
  The measured speed of the selected motor exceeded the respective overspeed limit.


• F533 - 12 Pulse Reversal Timeout
  On 12-pulse systems, armature current direction did not change for a period longer than a time limit after zero current has been detected.


• F534 - 12 Pulse Current Difference
  For systems configured for 12-pulse parallel operation, the current difference has exceed the limit for a period longer than the limit.


• F535 - 12 Pulse Communication
  On 12-pulse systems, DCS-Link communications between the master and the follower drive have been interrupted for a period longer than the limit.


• F536 - 12 Pulse Follower Failure
  A fault has been generated in the 12-pulse follower


• F537 - Motor 1 Field Supply (Exciter) ready lost
  Motor 1 field supply (exciter) has lost the ready-foroperation message while running. The AC supply voltage may be missing or no longer in sync.


• F538 - Motor 2 Field Supply (Exciter) ready lost
  Motor 2 field supply (exciter) has lost the ready-for operation message while running. The AC voltage may be missing or no longer in sync.


• F539 - Fast Current Rise
  The current through the drive has risen too quickly, exceeding the limit. This may be caused by a short circuit or incorrect tuning.


• F540 - SDCS-COM-8 Faulty
  The SDCS-COM-8 board is no longer operable


• F541 - Motor 1 Field Exciter Low Current
  The motor 1 field current is below the current limit for a period longer than a time limit.


• F542 - Motor 2 Field Exciter Low Current
  The motor 2 field current is below the current limit for a period longer than a time limit.


• F543 - SDCS-COM-8 Communication Loss
  Overriding control and/or master-follower communications through channel 0 or 2 of the COM-8 have been interrupted for a period longer than the limit.


• F544 - Peer to Peer, Master-Follower Communication Loss
  DCS-Link for fieldbus communications have been interrupted for a period longer than the limit.


• F545 - Application Load Failure
  The application program did not load correctly.


• F546 - Local Command Loss
  Communications have been interrupted with the control panel, Drive Window, or Drive Window light while in Local Control Mode.


• F547 - Hardware Failure
  Hardware failure has been detected.


• F548 - Firmware Failure
  Firmware failure has been detected or firmware did not load correctly.


• F550 - Parameter or Memory Card Read Error
  Reading the actual parameter set or a user parameter set from either flash or the Memory Card failed. Check that User1 and/or User2 have been saved properly using ApplMacro (99.08). Also check the SDCS-MEM-8 memory card. May also require replacing the SDCSCON-4 board.


• F551 - Analog Input Out of Range
  One of the analog input values is below the minimum limit.


• F552 - Mechanical Brake (Selected Motor)
  The acknowledge signal for brake open or brake engaged is missing for a period longer than the open or engage limit.


• F553 - Tachometer or Encoder Polarity (Selected Motor)
  Speed feedback polarity from a tachometer or encoder is continuously compared to EMF feedback polarity while running. A fault indicates that the two ran in opposite directions while the motor feedback speed and EMF speed were above absolute limits. If this occurred during start up, try reversing polarity of the motor or the tach/encoder. If this occurred while in production, the tach/encoder may be faulty.


• F554 - Tachometer Range (Selected Motor)
  The signal from the tachometer analog input has exceeded a limit. If this occurred during start up, connect the tach to the next higher voltage terminal on drive connector X3 terminals 1, 2 or 3.


• F556 - Torque Proving (Selected Motor)
  The TorqProvOK signal has not been set within a time limit after the RUN command (7.01 bit3) has been set.


• F557 - Reversal Time
  Armature current direction did not change for a period longer than a time limit after zero current was detected. For motors with high inductance (e.g., large motors) or if motor is high voltage compared to the mains voltage, try decreasing RevDly (43.14), then increasing the limit

Stay tuned for the DCS alarms...

[drives-technician]

And here's the ABB DCS Alarm List:

• A101 - Coast Stop (Off2) via Digital Input
  The Coast Stop (Off2) digital input is cleared.


• A102 - Emergency Stop (Off3) via Digital Input
  The Emergency Stop (Off3) digital input is cleared.


• A103 - DC Breaker Acknowledge Missing (Selected Motor)
  The DC Breaker Acknowledge digital input is cleared.


• A104 - Converter Overtemperature
  The drive internal temperature is within 5°C of the temperature limit.


• A105 - Dynamic Braking in progress
  For non-US dynamic braking, the DynBrakeAck input is set while in the ON state


• A106 - Motor 1 Overtemperature
  The motor 1 temperature exceeds the temperature limit.


• A107 - Motor 1 Overload
  The motor 1 current exceeds the overload limit.


• A109 - Motor 2 Overtemperature
  The motor 2 temperature exceeds the temperature limit.


• A110 - Motor 2 Overload
  The motor 2 current exceeds the overload limit.


• A111 - Mains Low Voltage
  The mains voltage is below the alarm limit.


• A112 - Peer to Peer, Master-Follower Communication Loss
  DCS-Link or fieldbus communications have been interrupted for a period longer than the limit.


• A113 - SDCS-COM-8 Communication Loss
  Overriding control and/or master-follower communications through channel 0 or 2 of the COM-8
  have been interrupted for a period longer than the limit


• A114 - Armature Current Deviation
  Current reference differs from current actual by more than a limit for longer than a time limit. See alarm description in DCS800 Firmware Manual for what to check in the event of a fault.


• A115 - Tachometer Range (Selected Motor)
  If this alarm is present for longer than 10 seconds, the signal from the tachometer analog input exceeded a limit. If present for 10 seconds and then it clears, it is an indication that M1OvrSpeed (30.16) or M2OvrSpeed (49.21) has changed and a new tach fine tuning is required.


• A116 - Mechanical Brake (Selected Motor)
  Active only when BrakeFaultFunc (42.06) = CRANE, the acknowledge signal for brake engaged is missing for a period longer than the engage limit.


• A117 - Armature Current Ripple
  DC current ripple exceeds the limit. If this occurs during start up, then current controller gain may be set too high. Otherwise, this is often an indication that one or more thyristors is not working or a fuse is blown.


• A118 - Found New Application on Memory Card
  An application has been found on SDCS-MEM8 used with ControlBuilder.


• A119 - Application Mismatch between Drive and Memory Card
  The applications previously loaded to the drive and the one on the SDCS-MEM8 do not match.


• A120 - Overvoltage Protection Active
  The overvoltage protection unit, DCF506-xxxx-51 is active, so the controller is blocking the converter output.


• A121 - Autotuning Failed
  Autotuning has failed.


• A122 - Mechanical Brake (Selected Motor)
  Active only when BrakeFaultFunc (42.06) ? FAULT, the acknowledge signal for brake open or brake engaged is missing for a period longer than the open or engage limit. Or torque actual does not reach the torque limit, used, for example, for cranes with a hanging load.


• A124 - Speed Scaling Out of Range
  See: Motor 1: 50.01, 20.01, 20.02, 99.04 and Motor 2: 49.22, 49.03, 49.19, 49.20


• A125 - Speed Feedback (Selected Motor)
  Speed feedback from a tachometer or encoder is continuously compared to EMF feedback while running. A fault indicates that the EMF voltage was above a voltage limit (30.15) while the motor speed was below a speed limit (30.14). This usually indicates there is a problem with the tachometer or encoder.


• A126 - External Alarm via Digital Input
  The External Alarm digital input is set.


• A127 - Analog Input Out of Range
  One of the analog input values is below the minimum limit.


• A128 - Fieldbus Communications Loss
  Fieldbus Communications have been interrupted for a period longer than a time limit after the first data set from the overriding control has been received.


• A129 - Parameters Restored
  The parameters found in flash were invalid at power-up (checksum fault). All parameters were restored from the parameter backup.


• A130 - Local Command Loss
  Communications have been interrupted with the control panel, Drive Window, or Drive Window Light while in Local Control Mode


• A131 - Parameter Added
  A new firmware program with a different amount of parameters was downloaded. The new parameters are set to their default value.


• A132 - Parameter Setting Conflict
  The settings of some parameters are in conflict with each other.


• A133 - Retained Data Invalid
  The retained data was invalid at power-up; the backup data was used. Backup data reflects the status during the previous power-up. Retained data includes: fault logger data, Data1 (19.01) thru Data4 (19.04), I/O options (see group 98), parameters defined by means of DCS800 ControlBuilder when the RETAIN box is checked.


• A134 - Parameter Compatibility
  When downloading parameter sets or during powerup the firmware attempts to write the parameters. If setting of a parameter is not possible or not compatible, the parameter is set to default.


• A135 - Parameter Upload or download Failed
  The checksum verification failed following a parameter upload or download. Please try again


• A136 - Adaptive Program Task Time Not Set
  The task time for Adaptive Programming is not set when the user attempted to start it.


• A137 - Speed Not Zero
  Drive was restarted before the motor decelerated below the zero speed limit.


• A138 - Off2 (Coast Stop) Fieldbus
  Bit 1 from the main control word is not set, causing a start inhibit condition.


• A139 - Off3 (Emergency Stop) Fieldbus
  Bit 2 from the main control word is not set, causing an estop condition.


• A140 - Illegal Fieldbus Settings
  The fieldbus parameters in group 51 (fieldbus) are not set according to the fieldbus adapter or the device has not been selected.


• A141 - SDCS-COM8 Firmware Version Conflict
  Invalid combination of drive (SDCS-CON-4) firmware and SDCS-COM-8 firmware. Drive firmware 3.7 is compatible with SDCS-COM-8 firmware 1.80 or higher. See firmware release notes for complete compatibility list. Typically requires upgrading to a newer SDCSCOM-8 board


• A142 - Memory Card Missing
  A ControlBuilder application has been loaded in the drive but the memory card belonging to that application has not been found.


• A143 - Memory Card Failure
  The data found in the memory card was invalid (checksum fault).

[dave2]

Many thanks, it was just a simple braking issue.



Dave