Variable Frequency Drives

Troubleshooting

© ABB
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Safety First!
Adhere and comply with NFPA70E

 Service by qualified person only:

 Qualified person: One who has skills and knowledge related
to the construction and operation of the electrical equipment
and installations and has received safety training to
recognize and avoid the hazards involved.
 Procedural steps:
 Disconnect all power sources.

 Visually verify disconnection (when possible).

 Implement approved lock out / tag out procedure.

 Identify power sources (e.g., review drawings /

documentation).
 Confirm electrically safe status (e.g., voltmeter
measurement).
 Ground equipment as needed (e.g., capacitive energy
storage).

© ABB
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Safety First!
Remember:

An open disconnect, circuit

breaker or fuses is NOT a true
indication that the DC bus is not
charged!

As well, A DC bus indication lamp should be

verified. If the light is off, consider the light to
be in a failed state and verify the bus.

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Gather the Facts First

 VFD Fault / Trip

 Be reassured: The VFD is protecting itself and the equipment.

 Often the person reporting the condition has limited technical

expertise and this person is reporting what they see, hear or even
smell. They are not typically reporting the “problem.”

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Gather the Facts First
Ask Leading Questions and Listen

 Questions
 How long has it been installed and functional?

 Environment around the drive?

 Centrifugal or PD pump? Heavy duty or normal duty VFD? Part
number?
 What is the drive reporting in the form of fault messages?

 What time did this occur, has it previously tripped at this time or
process point?
 Did anything else trip?

 What other heavy load are you aware of starting?

 Any recording meters on the distribution or branch power?

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Hardware Troubleshooting
Proper Grounding

 Do NOT daisy chain grounding!

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Hardware Troubleshooting
Proper Grounding Termination

NO! Yes

* *Enclosure back Enclosure back

panel panel

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Hardware Troubleshooting
Proper Cable Routing

 Verify per installation manuals.

 For loose cables such as ones in a cable tray maintain a
minimum of 6 inches between input power, output power and the
controls, unless they have their own grounding shield such a
metal conduit.
 NEVER mix control and power.
 Issue – Electro Magnetic Interference (EMI).
 Problems that could happen:
 Control and or communication signals may not communicate
properly or inadvertently triggered signals.
 It is okay for cables to cross perpendicular to each other.
 Reference: IEEE 110-1999 Emerald Book; “IEEE Recommend
Practice for Powering and Grounding Electronic Equipment.”

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Troubleshooting
Output Cable Length

 Follow the VFD manual regarding cable length.

 Reflected Wave, First turn failure
 Line and load reactors vs. DV/DT filters.
 Impedance Values
 Issue: Ground fault tripping of the VFD.
 Motor ground.

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Troubleshooting
Will Not Start, Stop, Follow an Analog Signal or Pilots

 Verify that the E-Stop safety input is high (SIL2).

 Does the VFD have an enable input and a run directional
input?
 2 or 3 wire control enabled?
 Rising edge on start command (has start command been
cycled?).
 Is the NC stop contact wired correctly?
 Have you verified with a meter the polarity of your analog
signal and where it is landed?
 Are you on the right set of contacts? – Form C.

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Troubleshooting
Cooling Issues

 Possible causes:
 #1 - - Dirty Filters or VFD heatsink.
 VFD cooling fans not working.
 Enclosure stirring fans not working.
 Enclosure cooling fan filters are clogged.
 Ambient temperature is above the rating of the VFD.
 Top Vents.
 Do not used compressed air to blow out the VFD.
 Low Pressure air may be used to blow out some heat sinks
 Note that some VFD cooling fans:
 Only run when the VFD is running.
 A specific time or temperature after the VFD has stopped.

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Troubleshooting
VFD Faults: Input Phase Loss or Under-Voltage

 Verify phase-to-phase voltage.

 Verify input current in all 3 phases
 If permissible, look at voltage drop across each pole of the
breaker or fuse. You must follow company procedures!
 Look at the connection points for the breaker or fuse – are they
discolored?
 Compare your meter readings to the VFD display – do they
agree? (Know how to use your meter and verify, measure and re-
verify.)
 Be aware – some VFDs monitor ripple current on DC bus to
indicate input phase loss / undervoltage.
 Management of DC bus without mains?
 Where’s the squirrel?

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Troubleshooting
VFD Faults: Output Phase Loss

 Verify balanced phase-to-phase output with your meter.

 Know that the reading may not be what you expect as
your meter may “ring” on the drive waveform.
 Balance is important . Best to drop the motor leads
when practical.
 Is there a bypass? Have you validated the isolation
contactor and it’s control?
 VFD configured for bypass?
 Verify the motor lead connections.
 Is there a line of sight disconnect?
 Drive type and motor control algorithm will effect how a
VFD trips on OPL (ACS550 only trips in vector mode)

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Troubleshooting
VFD Faults: Instantaneous Overcurrent

 Start up problem or has VFD been running for some period?

 Balanced input and output voltage?
Check input current in each leg, as this verifies the rectifier.
Check output currents in each leg to verify the motor.
• Motor ramping up in speed or only when approaching full speed
 Motor cables together or smoking insulation? All 3 motor leads
must be run together.
 Mechanical problem
 Bypass? Isolation contactor chattering? or pilot relay?
 Conduit box: taping inspected? Have leads rubbed together?
 Motor : location – wet, hot, ultra high efficiency

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Troubleshooting
VFD: Overload

 Initial Start-Up – Verify Paramter sets

 Measure DC bus – do you have a solid bus
 Has it ever run? What changed?
 Balanced output voltage? Phase-to-phase – check for
balance – not level.
 Balanced output currents?
 Set up issue: Acceleration too short, gains to high, PID
 Multiple motors in a common conduit? Tray? – What is the
Mfg. recommendation?
 Scope Available? Look at incoming waveforms – especially
if tripping at a higher speed (may be IOC)

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Troubleshooting
VFD Faults: Ground Fault

 Motor leads up or down?

 Condition inside conduit?
 Most common is moisture in conduit or motor
 Corner Grounded Delta input?
 Subsidence?
 Multiple motor leads in conduit?
 Long motor leads – over 100’?
 How much ground current do you measure?
 What kind of conductor was used?
 Has it been ohmed out?
 Do you have a ground plane?

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Troubleshooting
VFD Faults: Unbalanced Currents

 Drop motor leads and verify output voltage phase-to-

phase.
 Roll motor leads (be particularly concerned about reversing
the motor). Does the issue follow the motor lead or stay in
the same phase?
 Conduit box: Taping, connections, and skinned
wires/connection.
 Grounding.
 Motor: If output voltages are balanced, then direct attention
to motor.
 Lugs discolored
 Motor integrity

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Troubleshooting
VFD Faults: DC Bus Overvoltage

 Mains Overvoltage
 Possible spike or change in the line voltage.
 PFCC (notice time of day).
 Lightening.
 Line strike (power pole strike).
 Line reactor.
 DB resistors.
 Regenerative Overvoltage
 Has application worked in past?
 Overhauling Loads.
 Deceleration ramp.
 DB resistor: Installed, OL tripped.
 Decel ramp adaptation: automatic extension of ramps.
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Troubleshooting
Fault History

 Many VFDs have a fault history.

 Review for multiple faults. If time stamped note time.
 More then one fault may have happened at the same time.
 Self test ?
 Reference the VFD manual.

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Troubleshooting
Fault Resetting

 SAFETY FIRST – if fuses have cleared – make sure to do a

through electrical and physical check of the product!
 After a fault issue has been resolved and it is okay to reset, there are
several ways to accomplish the reset:
 Digital input via an operator, if configured.

 Network communications.

 VFD keypad (for many VFDs).

 Power cycle.

 Automatic fault reset.

 Good for remote applications.
 But be cautious as to what and how you configure!
 Think of how the operation will function under this occurrence and
the people around it.

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System problems
Vibration

 Issue: Heavy vibration at one or more particular operating

speeds.
 Fix: Skip speeds / frequencies.
 Most all VFDs allow you to program a window of operating
speed that is not to be used.
 Vibration may also occur at the motor rated / nominal
speed.
 Physically check the motor and motor current.

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System problems
Water Hammer

 Maybe a simple fix.

 During acceleration: Increase the accel rate.
 During deceleration: Increase the decel rate.
 Soft pipe fill.

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Troubleshooting
Factory Default – “Danger Will Robinson”

 Possible Un-assignment of required I/O

 Why is the VFD / system not working as it use to?
 Everything mechanically is fine but the operation is not?
 How could the parameters in the VFD have changed?
 Factory default might be the answer ? CAUTION!
 Controls, communications, motor parameters, etc…
 Make sure that you have your original parameter list.
 Some VFDs allow you to store a parameter set in
memory.
 Most all VFDs have programming software, which is a
good way to backup.

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Other Helpful tips

 Make sure that the VFD has been programmed with the
correct motor nameplate information.
 Does the motor nameplate FLA exceed the VFD amperage
rating?
 Has the proper VFD been selected? Variable or Constant
Torque?
 Some VFDs have an auto diagnostics function.
 If you have access to the VFD keypad confirm that it is
showing the proper status (run and speed command).
 If the VFD system has bypass, there will be an overload
device for the bypass circuit, but if tripped, will also prevent
the VFD connect to the motor.
 Make sure if you have a bypass function that both the VFD
and bypass mode operate the motor in the same direction.
 Test the VFD without a motor to possibly isolate a problem
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Maintenance

 Clean equipment a must

 Keep your VFD clean.
 Heat sinks.
 Vacuum away dust (do NOT use compressed air!).
 Enclosure air filters
 For Type 12 enclosures with cooling fans, replace the
air filters, as necessary.
 Thermal Scan
 Especially connections.
 Megger
 Leads and motor but not the VFD.

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