Hello everyone, I encountered an unusual problem while attempting to autotune a motor using a PF525 drive. The setup includes an enclosure housing two PF525 drives controlling two motors with identical specifications: 575V, 60Hz, 3HP, 3.44A, 1720RPM. When we tried to run a Static Tune on Motor A through Drive A, we received fault F080 - Autotune failure. Despite ensuring that our start input was uninterrupted and attempting the autotune multiple times, the fault persisted. However, when we ran the Static Tune on Motor B through Drive B, it completed successfully without any issues. After conducting resistance tests and meggering on both motors, we switched the motor leads between the drives and found that Motor A successfully completed the autotune when connected to Drive B. Meanwhile, Motor B connected to Drive A still triggered the F080 fault. We confirmed that all parameters, including motor nameplate data, were the same on both drives. We are planning to swap out the power section of the problematic drive and potentially the control module as well. If the issue persists, we may consider that the drive itself is faulty from the start. The only other possible explanation could be a wiring issue causing induced voltage in a conductor. Does anyone have insights on why one drive is failing to autotune multiple motors while the other drive is successful?
If both motors are functioning properly in drive B but not in drive A, it is likely that there is an issue with drive A. This could be related to either the power or control module. It would be advisable to replace drive A to resolve the issue. - Alan.
After successfully swapping out the power module and completing a successful autotune, I am still unsure of the root cause of the initial issue. I plan to reach out to my local AB drive representative to see if they have encountered this issue in the past.
Have you discovered the root cause of this problem?
jpanelle11 asked if the issue's root cause was ever discovered. It seems that we were unable to pinpoint the cause, leading us to ultimately replace the faulty power module.
Today, I encountered a problem with an f80 while attempting an auto tune, which was unsuccessful. I plan to follow the suggested solutions and see if they yield better results tomorrow.
It sounds like you've done some thorough troubleshooting! One aspect you could examine might be software related. Make sure both drives are running on the same firmware version. Differing software versions can sometimes cause unexplained issues like the one you've reported. Also, I suggest checking the drive parameters settings once more, even if you've already entered the same values on both. Any small variance could lead to autotune failure. Lastly, check for any voltage instability that might interrupt the autotune process on Drive A. Your plan to swap the power section and control module is worth trying, and if there’s still no progress, the drive itself may need to be replaced.
It sounds like you've done some thorough testing there. From your description, it's apparent that the problem is more likely related to Drive 'A' rather than Motor 'A'. Swapping out the power section and, potentially, the control module is indeed a good step. However, also make sure to test or replace the wiring associated with Drive 'A', as well. Any voltage spikes or drops could cause problems in the autotune process that aren't immediately apparent. Keep in mind, just because wiring worked fine for Drive 'B' doesn't necessarily mean it will work for Drive 'A'. Environmental factors such as positioning, heat dispersion, or neighboring equipment could be affecting circuits of Drive 'A'. I've experienced situations where this type of intermittent fault was traced back to a ground loop problem or a faulty cable shield. So, look into all those aspects too.
Given your explanation, it sounds like you've covered most of the obvious troubleshooting steps. It's often hard to pinpoint the exact issue with complex systems like these, but your decision to swap out the power section and potentially the control module could indeed rectify the problem. It's worth noting however, that a faulty encoder could produce similar symptoms, particularly if it's not correctly sending back position information. It might be worth checking the encoder and its wiring before replacing the modules, especially as a misaligned or malfunctioning encoder could lead to further problems down the line. Equally, the issue could lie with the drive unit's software, so perhaps it's worth considering a firmware update as well.
Your troubleshooting efforts seem quite thorough and the possibility of a faulty drive seems plausible given the pattern of the problem. However, it might also be instructive to check the firmware version of both drives. It's possible that Drive A might be running on an older firmware version with potential bugs affecting the autotune function, while Drive B, with a newer or different version, does not express the same issue. Sometimes, such issues can be resolved by updating or rolling back the firmware. Also, pay close attention to the cabling, connectors and terminations between both the drives and motors to rule out any external source of noise.
It sounds like you've done some thorough troubleshooting already! Given that Motor A works fine with Drive B and completes autotuning without issues, it really does point to a potential fault within Drive A itself, especially since you've ruled out motor and wiring problems. Before swapping out parts, it might be worth checking if there are any unusual settings or hidden parameters specific to Drive A that could be causing the autotune to fail—it could be something simple like an incorrect filter setting. Additionally, checking for any error logs or history on the drive could provide more clues. Good luck, and hope you get it sorted out soon!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: - The issue could be related to the specific drive or motor causing the failure, potential wiring issues, or induced voltage in a conductor.
Answer: - Autotune failures can be caused by issues such as interrupted start input, incorrect motor parameters, faulty drive components, or wiring problems.
Answer: - Steps may include verifying motor specifications, checking for wiring issues, conducting resistance tests and meggering on the motors, swapping motor leads between drives, and potentially replacing faulty components like the power section or control module.
Answer: - If the problem persists after component swaps, it may indicate a faulty drive unit. Further investigation into potential wiring issues causing induced voltage may also be necessary to address the autotune failure.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.