ABB ACS880 Multi-Drive Fault & Warning Codes with Real Repair Cases

Introduction

ABB’s ACS880 Multi-Drive inverters are widely used in industrial automation for their reliability, flexibility, and high-performance motor control. However, like any advanced system, these drives can encounter various operational issues—often indicated through fault or warning codes. Understanding these codes is essential for efficient troubleshooting and repair. In this article, we’ll break down some of the most common fault and warning codes found in ACS880 Multi-Drive modules, along with real-world repair cases to help maintenance teams and engineers identify problems and restore functionality quickly.

What is ABB ACS880?

The ABB ACS880 series is widely used in industries such as oil and gas, mining, metallurgy, chemicals, cement, power, material handling, pulp and paper, woodworking, and marine. With a power range of 0.55 to 5600 kW and common voltage levels including 380V, 500V, and 690V, these inverters play a crucial role in driving various industrial processes.

However, due to prolonged operation and harsh working environments in these factories, the inverters may experience different levels of faults.

Repair Case: ABB ACS880 Multi-Drive Inverter Module

Model: ACS880-104-0440A-5
Power: 250 kW
Fault Phenomenon: Alarm 2340
Detection Results: Faulty drive board and IGBT module

01 Initial Detection and Insulation Check

Upon preliminary inspection, Alarm Code 2340 was confirmed. This alarm indicates a possible short circuit within the motor cable or motor, or internal damage to the inverter. To narrow down the cause, the insulation of both the motor and cable must be thoroughly inspected. Ensure there are no signs of damage or moisture, as this could lead to short circuiting.

02 Inverter No-Load Test and Replacement of Faulty Component

To further isolate the issue, disconnect the motor and start the inverter independently. Observe whether the alarm persists. If the alarm continues even without the motor connected, it suggests a higher likelihood of internal inverter failure. Upon identifying damaged components, replace the faulty drive board and IGBT module with new, compatible parts. Ensure that the replacements meet the specifications required for the ABB ACS880 series inverter.

03 Disassembly and Inspection

If the no-load test indicates a potential internal fault, proceed with disassembling the inverter. Focus on examining the drive board and IGBT module, as these are common components affected by short circuits and overcurrent. Carefully inspect the drive board for any signs of burnout or damage. Simultaneously, check the IGBT module for cracks, burnout, or any other physical damage.

04 Reassembly and Testing

Once the faulty components have been replaced, reassemble the inverter. Ensure that all connections are correctly made and securely fastened to avoid any further issues.

05 Reconnect the motor and conduct a load test

During this test, monitor key parameters such as motor current, output frequency, and output voltage. For example, typical readings could be a motor current of 76A, an output frequency of 22.73 Hz, and an output voltage of 174V. Compare these readings with the specifications provided by ABB to ensure proper function and performance.

Common Fault Handling for ABB ACS880 Series

01 Alarm 2340 - Short Circuit indicates a short circuit in the motor cable or motor, or internal damage to the inverter. The troubleshooting steps including check the insulation of the motor and cable for any signs of damage or moisture, and confirm the inverter's condition by starting it without connecting the motor. If the alarm persists, it suggests internal inverter damage.

02 Alarm 2310 – Overcurrent occurs when the output current exceeds the internal fault limit, usually 150% of the motor's rated current. The troubleshooting steps including check if the load is too heavy for the motor's capacity. For first-time use, verify the parameter settings to ensure they are correctly configured for the application.

03 Alarm 2330 - Ground Fault indicates grounding leakage or a severe imbalance in the three-phase output. The troubleshooting steps including two types, such as, for external faults, carefully check the insulation of the motor and motor cables, for internal faults, send the inverter for professional repair.

04 Alarm 3210 – Overvoltage signifies overvoltage in the DC bus (intermediate circuit). The troubleshooting steps including check the power supply for any abnormalities or fluctuations. If the alarm occurs upon power-up, the power board may be damaged and should be inspected. Monitor for overvoltage during deceleration or shutdown to prevent damage to the inverter.

Other Common Alarms and Warnings

01 Alarm 3130 - Input Phase Loss indicates a loss of one or more input phases to the inverter. Alarms related to high temperatures in various IGBT modules and power units.

Fault Codes: 

4290 Fault: Module Temperature Too High
42F1 Fault: Inverter IGBT Temperature Too High
4310 Fault: Power Unit Module Temperature Exceeds Limit
4380 Fault: Excessive Temperature Difference Between Different IGBTs
7192 Fault: Brake IGBT Over-Temperature

Warning Codes

A4A9 Warning: Inverter Module Temperature Too High
A4B9 Warning: Power Unit Temperature Too High
A4B1 Warning: Excessive Temperature Difference Between IGBTs of Different Phases
A4B2 Warning: Excessive Temperature Difference Between the Environment and the Drive Module PCB
A4F6 Warning: IGBT Temperature Too High
A79C Warning: Brake IGBT Over-Temperature

02 No Display Issues which check for blown fuses or tripped circuit breakers. If these are not the cause, inspect the power board for damage.

Unique Fault Alarm Codes for ABB ACS880 Series

01 Fan Faults

Fan malfunctions are a frequent issue in inverters, often indicated by specific fault codes. Codes A581 and A582, along with 5080 and 5081, are all associated with problems in the cooling fan system. The cooling fans play a vital role in maintaining the inverter's optimal operating temperature. When these fans fail or encounter issues, it can lead to overheating, which in turn may cause performance degradation or even permanent damage to the inverter. Regular maintenance and prompt replacement of faulty fans are key to preventing overheating-related damage.

02 Failure to Pass Self-Test

Another significant problem that can occur is the inverter's inability to pass its self-diagnostic test. When this happens, the panel typically displays a loading icon and remains stuck, unable to transition to the main system interface. This self-test is a critical step in the inverter's startup process, designed to verify that all internal components and systems are functioning correctly. It may involve checking the inverter's firmware, inspecting internal connections, or testing individual components

03 Memory Card Faults

Memory card-related faults are also not uncommon in inverters. Fault codes FB11, FB12, FB13, and FB14 all indicate issues with the memory card or its communication with the inverter. The memory card in an inverter serves several important functions, such as storing configuration settings, logging operational data, and facilitating communication with external systems. Resolving memory card faults may involve replacing the memory card, tightening connections, or updating the inverter's firmware to ensure proper communication.

In summary, the ABB ACS880 series of inverters is a vital component in various industrial processes. However, due to prolonged use and harsh conditions, these inverters may experience faults. By understanding common alarms and troubleshooting steps, maintenance personnel can quickly diagnose and repair issues. 
Additionally, recognizing unique fault alarm codes can facilitate targeted repairs, minimizing downtime and ensuring the reliability of industrial drive systems. Regular maintenance and inspection are crucial to prevent faults and extend the lifespan of ABB ACS880 inverters.

FAQ

Q1: What is the difference between a fault code and a warning code in ABB ACS880?
A1: A fault code indicates a critical error that stops the drive from operating, requiring immediate action. A warning code signals a potential issue or operating condition that should be addressed but does not immediately halt the system.

Q2: What are some common fault codes in the ACS880 Multi-Drive?
A2: Common fault codes include F001 (Overcurrent), F002 (DC Overvoltage), F004 (Earth Fault), and F010 (Inverter Overtemperature), among others.

Q3: Can I clear fault codes without fixing the issue?
A3: You may be able to temporarily reset the fault, but without resolving the underlying problem, the error is likely to recur. Always address the root cause before clearing the code.

Q4: Where can I find a full list of ABB ACS880 codes?
A4: The complete list is available in the official ABB ACS880 firmware manual, but this article summarizes the most common ones with repair context.

Q5: What tools are useful for diagnosing ACS880 errors?
A5: ABB’s Drive Composer software, diagnostic LEDs on the control panel, and error history logs are all useful tools for identifying and analyzing faults.