ACS880 Fault 2310 — Overcurrent

Overview

Fault 2310 (Overcurrent) on the ABB ACS880 variable frequency drive indicates that the drive's output current has exceeded its hardware trip limit. This protection threshold is configured internally to prevent catastrophic thermal or electrical destruction of the drive's insulated-gate bipolar transistors (IGBTs) and output power components. When this limit is crossed, the drive immediately terminates its output to safeguard both the internal processor, the inverter bridge, and the connected motor.

Symptoms

When a 2310 fault occurs, the drive and your industrial system will exhibit several clear signs:

• Control Panel Display: The ACS880 assistant control panel displays "Fault 2310" alongside a bright red LED indicator.
• Sudden Stop: The drive cuts power to the motor, triggering a coast-to-stop action of the load.
• Unresponsiveness: The drive refuses to run or immediately trips again upon accepting a start command.
• Frequent Intermittent Tripping: The drive runs for a few minutes or hours but trips under specific load transitions or acceleration phases.
• Auxiliary Code Warnings: In some cases, the overcurrent fault is accompanied by auxiliary codes that pinpoint the affected phase (e.g., indicating an unbalanced output phase output current spike).

Possible Causes

Identifying the underlying culprit requires looking beyond the drive itself. The most common causes of Fault 2310 include:

• Motor Cable Short Circuit: Damaged insulation on the motor cables leading to line-to-line or line-to-earth electrical shorts.
• Internal Motor Fault: Insulation breakdown within the motor windings, causing a phase-to-phase or phase-to-ground short circuit.
• Mechanical Load Seizure: A seized gearbox, jammed conveyor, or blocked pump impeller forcing the motor rotor to stall and draw excessive starting current.
• Incorrect Acceleration/Deceleration Ramps: Decelerating or accelerating too fast for a high-inertia load, causing the motor to draw extreme peak current.
• Incompatible Motor Parameters: Incorrectly programmed nominal motor data (current, voltage, power, speed) in Parameter Group 99.
• Damaged Drive IGBTs: A short circuit or damage inside the drive's internal inverter power modules.
• Current Sensing Failure: Degraded or faulty current transducers inside the ACS880 drive returning false high-current signals to the control board.

Step-by-Step Troubleshooting

Follow these troubleshooting steps in sequence to isolate and resolve the overcurrent condition. Ensure all appropriate lock-out, tag-out (LOTO) safety measures are implemented before embarking on physical diagnostics.

Step 1: Disconnect and Safely Power Down

Isolate the ACS880 drive from the main power supply. Wait at least 15 to 20 minutes for the internal DC bus capacitors to discharge fully. Use a digital multimeter to confirm that DC+ to DC- voltages, and phase-to-phase voltages at the input terminals (U1, V1, W1), are at 0 Volts before proceeding.

Step 2: Inspect Cables and Motor Connections

Uncouple the motor cables from the drive's output terminals (U2, V2, W2). Inspect the cable connections for loose connections, signs of arcing, heat damage, or moisture accumulation. Ensure that there is adequate physical clearance between the phase cables and the drive ground plate.

Step 3: Perform Insulation Resistance Testing (Megger)

With the motor cables completely disconnected from the drive (to prevent damaging the internal IGBTs), use an insulation tester (Megger):

1. Test the insulation resistance of the motor cables phase-to-phase and phase-to-ground.
2. Test the motor terminal windings phase-to-phase and phase-to-ground.
3. A healthy reading should typically be well above 100 Megohms. Any value under 5 Megohms indicates insulation breakdown, moisture infiltration, or a short circuit requiring motor or cable replacement.

Step 4: Perform a Drive Static Test (Diode Test)

With the motor still disconnected, test the drive's internal IGBT modules using your multimeter set to Diode test mode:

1. Place the positive probe on the negative DC bus terminal (UDC-) and touch the negative probe to each output phase terminal (U2, V2, W2). You should see a consistent diode drop reading of approximately 0.3V to 0.7V for each phase.
2. Place the negative probe on the positive DC bus terminal (UDC+) and touch the positive probe to each output phase terminal (U2, V2, W2). Again, verify a consistent diode drop reading.
3. An open circuit (OL) or short circuit (0.00V) in any phase indicates a destroyed IGBT module, meaning the drive needs immediate repair or replacement.

Step 5: Verify Motor Parameters and Ramps

Re-energize the drive (with the motor disconnected) and check the values within the ACS880 parameter settings:

• Group 99 (Motor data): Verify that the nominal motor current, voltage, speed, and power perfectly match the motor nameplate.
• Group 46 (Ramps): Increase the acceleration and deceleration times (Parameters 23.12 and 23.13) to see if the overcurrent trips occur during start-up or braking cycles. A longer ramp reduces the peak transient current demand on the VFD.

Step 6: Test the Drive Without a Load

Turn off the drive's scalar configuration if it is in vector control, or switch the drive temporarily to scalar control mode (Parameter 99.04). Attempt to run the drive with the motor completely disconnected. If the drive trips on Fault 2310 with absolutely no cable or motor attached, the internal current measurements or IGBTs are damaged, requiring a drive replacement.

Recommended Actions

To prevent the recurrence of an overcurrent trip, incorporate these long-term corrective actions:

• Conduct an ID Run: If the motor was recently replaced, perform a full Identification Run (ID Run) via Parameter 99.13 to ensure optimal vector motor control.
• Install Output Filters: For long output cable distances (>100 meters / 328 feet), install dv/dt filters or sine filters to suppress current spikes caused by cable capacitance.
• Verify Mechanical Seals and Bearings: Establish a preventive maintenance schedule for the driven load to check for mechanical wear that increases the startup torque and current.
• Implement Current Limits: Review the current limits configured in Parameter Group 30 (Limits) to ensure they are set appropriately for the application's physical boundaries.

Recommended Replacement Parts

If diagnostics point to internal hardware damage within your ABB ACS880 drive, consider stocking or replacing the following high-wear components:

• IGBT Power Modules: Crucial for rebuilding the output inverter stage of the drive after a severe short circuit.
• Current Transducers (CTs): Replace these if the drive returns false overcurrent alarms due to faulty feedback loop currents.
• Control Unit (ZCU / BCU): If the control board is no longer processing current measurements accurately or has sustained a control loop fault.
• ACS880 Control Panel (Assistant): Ensure your keypad configuration is updated; keep a spare on hand for diagnostic transfers.

Related Articles

• How to Perform a Safe IGBT Diode Test on ACS880 Drives
• Selecting the Appropriate Output Filters for ACS880 VFDs
• ZCU and BCU Control Board Replacement Guide for ACS880

FAQ

Q: Can a 2310 fault happen if the motor isn't actually overloaded or stalled?

Yes. An insulation breakdown in the motor cables or motor windings acts as an instantaneous path to ground, drawing extreme current which safety circuits detect immediately relative to your parameters.

Q: Why does the 2310 fault code trigger immediately upon hitting start?

This represents an active direct short-circuit on the load side or a blown internal IGBT. If this happens, do not keep attempting to reset and run the drive, as this will lead to further electrical damage. Perform diode testing and insulation testing immediately.

Q: How does a long motor cable run contribute to 2310 overcurrent faults?

Long cables act as capacitors to ground. Each time the IGBTs switch, high charging currents flow down the cable. For very long runs, this cumulative capacitive charging current can exceed the ACS880 drive’s overcurrent detection limit.

Q: What is the risk of resetting the 2310 fault repeatedly?

Resetting and restarting a drive with an active short-circuit can cause severe catastrophic failures, such as internal component explosions, carbon buildup on the circuit boards, or permanent damage to the motor casing.