AF90 Autotuning Fault in ABB DCS880 Drive
AF90 Autotuning in the ABB DCS880 Drive indicates that the selected autotuning procedure or commissioning assistant did not complete successfully. The DCS880 uses several automatic tuning functions to optimize motor control, including field current, armature current, speed feedback, speed controller, EMF controller, and flux linearization tuning. If the selected procedure is interrupted, times out, or encounters an error, the drive generates Warning AF90.
This warning generally indicates an interrupted autotuning process, incorrect motor configuration, wiring problem, parameter mismatch, or commissioning issue, rather than a hardware fault.
Possible Causes
- Autotuning interrupted before completion.
- Run or ON command removed during autotuning.
- Autotuning timeout.
- Motor rotating before autotuning started.
- No speed zero indication.
- Armature current not zero.
- Incorrect field exciter selection.
- No field exciter configured.
- Open or interrupted field circuit.
- Field current unable to reach reference.
- Field inductance detection failed.
- Invalid nominal armature current.
- Armature circuit wiring incorrect.
- Armature voltage measurement wiring incorrect.
- No load connected to the armature circuit.
- Speed limitation preventing tuning.
- Voltage limitation preventing tuning.
- Motor unable to reach base speed.
- Tacho adjustment failure.
- Incorrect operation mode.
- Firmware fault.
Solutions
- Complete the autotuning procedure successfully.
- If the warning remains, keep the Reset signal (for example, via a Digital Input) active for more than 3 seconds.
- Check the Auxiliary Code (XXXXYYYY) to identify the failed autotuning procedure and the specific reason.
- Correct the identified problem.
- Repeat the autotuning until it completes successfully.
Autotuning Procedure Identification (XXXX)
| XXXX | Autotuning Procedure |
|---|---|
| 0001 | Field Current Autotuning |
| 0002 | Armature Current Autotuning |
| 0003 | Speed Feedback Assistant |
| 0004 | Speed Controller Autotuning |
| 0005 | EMF Controller Autotuning |
| 0006 | Flux Linearization Autotuning |
| 0007 | Thyristor Test |
| 0008 | Tacho Fine Tuning |
For Drive Sizes H5 to H8, during 0007 Thyristor Test, ensure:
- 99.11 – M1 Nominal Current ≥ 50 A
Common Auxiliary Code Meanings (YYYY)
Field Current Autotuning (0001xxxx)
| Auxiliary Code | Meaning | Corrective Action |
|---|---|---|
| 00010001 | Autotuning interrupted | Repeat autotuning |
| 00010002 | Motor rotating | Ensure motor is stopped |
| 00010003 | Armature current not zero | Remove armature current |
| 00010004 | Wrong autotuning selected | Use Field Exciter autotuning |
| 00010005 | No field exciter selected | Check 99.07 M1 Used Field Exciter Type |
| 00010006 | ON command timeout | Apply ON command in time |
| 00010007–0001000A | Field current cannot reach reference / Field circuit open | Check field wiring and field resistance |
| 0001000B | Field inductance not detected | Check field circuit |
| 0001000C | Firmware fault | Update or repair firmware |
Armature Current Autotuning (0002xxxx)
| Auxiliary Code | Meaning | Corrective Action |
|---|---|---|
| 00020002 | Autotuning interrupted | Repeat autotuning |
| 00020003 | Run command timeout | Apply RUN command correctly |
| 00020004 | Invalid nominal armature current | Check 99.11 M1 Nominal Current |
| 00020005 | Motor rotating | Stop motor |
| 00020006 | Armature wiring incorrect | Check C1/D1 and SDCS-PIN-H51 wiring |
| 00020007 | No armature load | Connect motor/load |
| 00020008 | Armature voltage measurement open | Inspect voltage measurement circuit |
| 00020009 | Firmware fault | Update firmware |
Speed Feedback Assistant (0003xxxx)
| Auxiliary Code | Meaning | Corrective Action |
|---|---|---|
| 00030001 | Autotuning interrupted | Repeat autotuning |
| 00030002 | Speed limitation | Check 30.11 and 30.12 |
| 00030003 | Voltage limitation | Verify 99.10, 99.12, 99.14 |
| 00030004 | Run timeout | Apply RUN command |
| 00030005 | Motor cannot reach base speed | Reduce 23.12 Acceleration Time 1 |
| 00030006 | Tacho adjustment fault | Check tacho wiring and voltage |
Speed Controller Autotuning (0004xxxx)
| Auxiliary Code | Meaning | Corrective Action |
|---|---|---|
| 00040001 | Autotuning interrupted | Repeat autotuning |
| 00040002 | Run timeout | Apply RUN command |
| 00040003 | Speed limitation | Check 30.11 and 30.12 |
| 00040004–00040006 | Motor rotating | Stop motor |
| 00040007 | Motor cannot decelerate | Check braking capability |
| 00040008 | Armature current not zero | Remove current |
| 00040009 | Voltage limitation | Verify 99.10, 99.12, 99.14 |
| 0004000A | Torque reference not achieved | Increase available torque |
| 0004000B | Wrong operating mode | Check 19.01 Actual Operation Mode |
| 0004000C | Motor cannot reach base speed | Reduce 23.12 Acceleration Time 1 |
| 0004000D | Cannot write controller parameters | Check parameter write protection |
| 0004000E | Firmware fault | Update firmware |
Additional Information
The ABB DCS880 includes several commissioning assistants and autotuning routines designed to optimize:
- Field current control.
- Armature current control.
- Speed feedback.
- Speed controller performance.
- EMF controller.
- Flux linearization.
- Thyristor operation.
- Tacho calibration.
Warning AF90 is generated whenever one of these procedures fails or is interrupted.
According to ABB:
- The warning can be cleared by successfully completing the autotuning procedure.
- Alternatively, hold the Reset command active for more than 3 seconds.
- The Auxiliary Code (XXXXYYYY) identifies both the autotuning procedure (XXXX) and the specific failure (YYYY), making troubleshooting much easier.
Unlike a hardware fault, AF90 is primarily a commissioning and parameterization warning.
Common Symptoms
- Drive displays AF90 Autotuning.
- Autotuning stops before completion.
- Commissioning assistant exits unexpectedly.
- Warning appears during motor commissioning.
- Motor does not reach base speed during tuning.
- Speed controller tuning fails.
- Field current tuning fails.
- EMF tuning cannot be completed.
- Warning clears after successful autotuning.
- Drive operates normally after tuning is completed.
Recommended Troubleshooting Sequence
- Record the complete Auxiliary Code (XXXXYYYY).
- Identify the autotuning procedure (XXXX).
- Identify the specific failure (YYYY).
- Verify the motor is stopped if required.
- Check field and armature wiring.
- Verify motor nameplate data.
- Check 99.07, 99.10, 99.11, 99.12, and 99.14.
- Verify 19.01 Actual Operation Mode.
- Check 30.11 and 30.12 speed limits.
- Verify 23.12 Acceleration Time 1 if the motor cannot reach base speed.
- Repeat the autotuning procedure.
- Hold Reset for more than 3 seconds if required.
- Confirm the warning has cleared.
- Verify normal drive operation.
- Contact ABB technical support if the warning persists.
AF90 Autotuning Check Table
| Check Point | Action |
|---|---|
| Auxiliary Code | Identify XXXX and YYYY values |
| Motor status | Ensure motor is stopped when required |
| Motor parameters | Verify nameplate data |
| Field circuit | Inspect wiring and current |
| Armature circuit | Verify wiring and measurements |
| Speed limits | Check 30.11 and 30.12 |
| Acceleration | Verify 23.12 Acceleration Time 1 |
| Nominal values | Verify 99.10, 99.11, 99.12, 99.14 |
| Operation mode | Check 19.01 Actual Operation Mode |
| Field exciter | Verify 99.07 M1 Used Field Exciter Type |
| Firmware | Update if firmware-related errors occur |
| ABB technical support | Contact if autotuning cannot be completed |
Preventive Maintenance Tips
- Perform autotuning only after completing all motor and field wiring.
- Verify motor nameplate data before starting commissioning.
- Ensure the motor is unloaded where required during autotuning.
- Check field and armature circuits for continuity before tuning.
- Confirm adequate mains voltage is available during commissioning.
- Avoid interrupting the Run or ON command during autotuning.
- Keep firmware up to date with ABB-approved versions.
- Save a backup of successful parameter settings after commissioning.
- Verify safety and operating mode settings before running autotuning.
- Record recurring AF90 Autotuning warnings and their auxiliary codes to assist long-term diagnostics.
Proper verification of the Auxiliary Code (XXXXYYYY), motor wiring, field and armature circuits, motor nameplate parameters, speed and voltage settings, and successful completion of the required autotuning procedure will help prevent recurring AF90 Autotuning warnings in ABB DCS880 drives, ensuring accurate motor commissioning, optimized control performance, reliable operation, and dependable long-term performance of the drive system.
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