ABB ACS150, ACS355, ACS580 VFD Error Codes: Diagnostics & Resistors

ABB ACS150, ACS355, ACS580 Error Codes: Physical Origins and Explanations

When abnormal conditions occur in a motor drive system, ABB variable frequency drives (VFDs) of the ACS150, ACS355, and ACS580 series automatically block the output power stages and display a corresponding fault code. This crucial action prevents the thermal destruction of output IGBT modules and safeguards the motor stator windings. From our experience at the Kiev warehouse, more than 75% of technical support tickets are caused by external system factors rather than VFD hardware failures. These factors include improperly tuned acceleration/deceleration ramps, mains supply voltage sags, or deteriorated motor insulation. Below is a detailed technical analysis of the critical fault codes most commonly encountered during commissioning and daily operation.

Analysis of Fault F_0001 / 2310 (OVERCURRENT)

Fault F_0001 (on micro drives ACS150 and machinery drives ACS355) and code 2310 (on general purpose industrial drives ACS580) indicate that the VFD output current has exceeded the hardware trip threshold (typically 1.6 to 2.0 times the rated VFD output current). The physical root causes include:

• Short Circuit in Load: failure of the motor winding insulation (inter-turn short circuit) or a short between phase conductors in the output motor cable.
• Excessive Acceleration Rate: high inertia of the driven load combined with too short an acceleration time configured in VFD parameters.
• Mechanical Binding: locked motor rotor or high friction/clogging in the mechanical load (pump impeller, conveyor belt).

Diagnostic Procedure: Begin by disconnecting the motor cable from the VFD output terminals U, V, and W. Attempt to start the VFD without the motor connected. If the fault recurs immediately, the output IGBT power module is shorted or the current sensors are damaged. If the drive starts successfully without a load, inspect the motor cable and winding insulation using a megohmmeter (insulation resistance to ground must be at least 10 MOhms). To resolve overcurrent issues during starting, increase the acceleration time using parameter 2202 ACCELER TIME 1 (on ACS150/355) or parameter 23.11 Acceleration time 1 (on ACS580).

Analysis of Fault F_0002 / 3210 (OVERVOLTAGE)

Fault F_0002 or code 3210 indicates that the voltage on the intermediate direct current link (DC bus capacitor bank) has exceeded the critical hardware safety limit. This limit is approximately 420 VDC for 220V VFD models and 840 VDC for 380V models. The primary physical cause of this fault is regenerative motor operation.

When the VFD output frequency drops faster than the rotor of the motor slows down (due to high load inertia), the motor begins to act as an asynchronous generator. The motor converts mechanical kinetic energy into electrical energy and pumps it back into the VFD. Because the VFD input stage is an uncontrolled diode bridge rectifier, it cannot feed this energy back into the AC utility mains. The energy accumulates in the DC bus capacitors, causing a rapid voltage rise.

Diagnostic Procedure: Extend the deceleration time limit using parameter 2203 DECELER TIME 1 (on ACS150/355) or parameter 23.12 Deceleration time 1 (on ACS580). Ensure that the automatic overvoltage controller is active by configuring parameter 2608 OVERVOLT CTRL to 1 (ENABLED) on ACS355, or verify that parameter 30.30 Overvoltage control is set to Enabled on ACS580. If your industrial application requires rapid deceleration, you must install an external dynamic braking resistor.

Analysis of Fault F_0006 / 3220 (UNDERVOLTAGE)

Fault F_0006 or code 3220 occurs when the DC bus voltage falls below the minimum operating threshold (approximately 162 VDC for single-phase 220V models and 360 VDC for three-phase 380V models). Common technical causes include:

• AC Utility Voltage Sags: momentary drops or dropouts in the incoming mains supply voltage under load.
• Input Phase Loss: loss of one of the incoming power phases at terminals R, S, T.
• Hardware Charging Circuit Failure: burnt soft-charge charging resistor or a faulty internal bypass relay/contactor.

Diagnostic Procedure: Measure the actual AC line voltage directly at the VFD input terminals under load. Inspect the contacts of the input circuit breaker and the main line contactor. Ensure the undervoltage controller is active — parameter 2006 UNDERVOLT CTRL (on ACS150/355) or parameter 30.31 Undervoltage control (on ACS580). If the incoming supply voltage is stable under load but the drive trips on startup with no motor connected, it indicates internal damage to the soft-charge circuit (burnt resistor or failed relay).

Analysis of Fault F_0021 / 3381 (OUTPUT PHASE LOSS)

Fault F_0021 or code 3381 indicates that the VFD has detected an imbalance in the output current phases U, V, and W, or a complete absence of current flowing in one of the phases during run state. Common root causes include:

• Motor Cable Open Circuit: a broken conductor in the motor cable or a loose screw terminal on the VFD output block or motor terminal box.
• Motor Winding Defect: an internal open circuit or phase burnout within the electric motor stator.
• Low Motor Load/Capacity: If the connected motor rating is significantly lower than the VFD capacity, the output current may fall below the detection threshold of the VFD current sensors.

Diagnostic Procedure: Verify the tightness of all terminal screws on VFD output connections and inside the motor terminal block. Measure the phase-to-phase winding resistance directly from the VFD output terminal side. The resistance values between pairs U-V, V-W, and W-U must be perfectly balanced. If you are running a very small motor for testing purposes, you can temporarily disable this protection via parameter 3026 MOTOR PHASE LOSS (set to 0 = DISABLE on ACS355) or parameter 31.19 Motor phase loss (set to No action on ACS580).

Diagnostics Table for ABB Variable Frequency Drive Fault Codes

For convenience, we have compiled the main faults of the ACS150, ACS355, and ACS580 series in a single technical summary table:

Power Stage Diagnostics: Diode Test on Rectifier and IGBT Modules

If the ABB VFD trips on F_0001 / 2310 overcurrent continuously even with the motor cable disconnected, or if the main input circuit breaker trips immediately upon applying utility power, the VFD has likely suffered a destructive breakdown of its power semiconductor modules. From our experience, a primary evaluation of the power section can be completed directly on-site using a standard digital multimeter in diode test mode.

Before proceeding with any electrical tests, disconnect all input and output power wiring, and wait at least 15 to 20 minutes for the intermediate DC link capacitors to discharge fully. Use a DC voltmeter to verify that the voltage between the VFD UDC+ and UDC- terminals has dropped below 36 VDC.

To inspect the power section of ABB frequency converters, follow this testing sequence:

1. Input Rectifier Bridge Test: Set the multimeter to diode test mode. Place the red probe on the negative DC bus terminal UDC-, and touch the black probe to the input utility terminals R, S, T (or L1, L2, L3) one by one. The meter should display a forward voltage drop of 300 to 700 mV (indicating healthy forward diode junction bias). Next, move the black probe to the positive DC bus terminal UDC+ (or BRK+), and touch the red probe to terminals R, S, T sequentially — the meter must show 300 to 700 mV again. Reverse the probe polarities: reverse measurements in both steps must indicate open circuit (displaying O.L).
2. Output IGBT Inverter Stage Test: Keeping the meter in diode test mode, place the red probe on the negative DC bus terminal UDC-, and touch the black probe to the output motor terminals U, V, W (or T1, T2, T3) one by one. The meter should display a forward voltage drop of the IGBT freewheeling diodes within 300 to 700 mV. Next, move the black probe to the positive DC bus terminal UDC+ (or BRK+), and touch the red probe to terminals U, V, W sequentially — the meter must display a similar drop of 300 to 700 mV. Reverse the probe polarities: reverse measurements must indicate open circuit (O.L).

Any measurement reading near 0 Ohms or a continuous audible beep from the meter indicates a destructive thermal breakdown of the semiconductor junction. A reading of O.L in both forward and reverse directions indicates a blown, open-circuited semiconductor junction. In both scenarios, the VFD power circuit board must be sent for professional repair.

CRITICAL SAFETY WARNING FOR COMMISSIONING ENGINEERS:

It is strictly prohibited to connect any measuring equipment, sensor, or oscilloscope that shares common ground with the utility network via a standard 3-pin power plug, to the low-voltage logic ground terminals GND (such as terminals 11, 16, or 19 by default) while simultaneously attempting to take measurements on the VFD high-voltage power terminals or the negative DC bus terminal UDC-.

The high-voltage UDC- bus is at a high negative potential with respect to the incoming phases and mains earth. Connecting the low-voltage logic GND on the control board to the UDC- bus or mains ground via the grounding lead of test instruments triggers an instantaneous thermal explosion on the micro-controller board, completely destroying the gate driver isolation barriers, microprocessors, and logic circuits. This failure voids all manufacturer warranty options.

Dynamic Braking and Resistor Selection Guidelines

Dynamic braking is employed to prevent F_0002 / 3210 overvoltage faults in cyclic industrial operations with heavy load inertia or when rapid stopping is critical (e.g. industrial centrifuges, hoists, exhaust fans). During motor deceleration, the regenerative energy is directed to an external dynamic braking resistor where it is safely dissipated as heat.

The physical integration of dynamic braking in ABB frequency converters depends on the specific drive series:

• ABB ACS150 and ACS355: These VFDs feature a built-in dynamic braking chopper in all frame sizes. The dynamic braking resistor must be connected directly to the power terminals R+ and R-.
• ABB ACS580: A built-in dynamic braking chopper is only integrated in smaller models within frame sizes R1 to R3 (covering ratings up to 22 kW depending on model supply voltage). The resistor connects directly to terminals R+ and R-. For larger frame sizes (R4 to R9), an external dynamic braking chopper (brake unit) must be purchased and wired into the high-voltage DC bus terminals UDC+ and UDC-.

To activate and configure the VFD dynamic braking chopper, adjust the following parameters:

• On ACS150 and ACS355 series: Set parameter 3010 BU CHOPPER CTRL to 1 (ENABLED WITH THERMAL OVERLOAD protection). This setting enables the VFD to calculate the thermal profile of the resistor, protecting it from thermal runaways. If using a resistor without a thermal switch, you can select option 2 (ENABLED WITHOUT THERMAL protection), but note that this increases the risk of resistor overheating.
• On ACS580 series: Navigate to parameter 30.10 Braking chopper enable and select Enabled with thermal protection. Ensure that the resistor parameters (nominal resistance and nominal power rating) are entered in Group 30 parameters to allow accurate drive overload modeling.

To protect the built-in braking chopper from overload damage, the connected dynamic braking resistor resistance must not be lower than the minimum limit specified by ABB. Our engineering team has calculated the recommended dynamic braking resistor values for standard motor ratings from 0.75 to 5.5 kW:

To choose and procure the correct dynamic braking hardware, visit our catalog section: braking resistors.

Conclusion and Professional Technical Support

Proper diagnostic evaluation and isolation of fault codes on ABB ACS150, ACS355, and ACS580 series drives minimizes industrial downtime. Adhering to the standard IGBT power circuit testing procedure using our digital multimeter guide helps safeguard your VFD from expensive control board damage. If you encounter any configuration difficulties or detect a semiconductor junction breakdown, our engineers at the Kiev warehouse are always ready to provide expert assistance, on-site diagnostics, or quick replacements. To select a new VFD, browse our primary catalog section: frequency converters, or view our dedicated manufacturer section: ABB frequency converters, where we stock the complete series range backed by official manufacturer warranties.