Cause : Motor 1 calculated overload comes when the motor is drawing more current than its rated capacity, which can lead to overheating, reduced efficiency, and premature failure.

F507 fault in ABB DCS800 drive indicate Motor 1 calculated overload. This means the drive has determined the motor is drawing more current than its rated capacity.

Here’s how to troubleshoot and resolve this fault:

1. Check Motor Load:

• Assess the mechanical load connected to the motor. Ensure it is not overloaded beyond the motor’s rated capacity.
• Look for any obstructions or excessive friction in the driven equipment (like pumps, fans, or conveyors) that could cause increased load.

2. Inspect Electrical Connections:

• Ensure all electrical connections between the drive and the motor are secure and free of corrosion. Loose or poor connections can lead to increased resistance and higher current draw.
• Check the motor windings for short circuits or insulation failures, as these can cause excessive current draw.

3. Verify Drive Settings:

• Check the motor settings in the drive’s configuration. Ensure that the motor rated current, voltage, and frequency are correctly entered.
• Review any overload settings in the drive’s configuration. If the settings are too sensitive or incorrectly configured, they may trigger an overload fault prematurely.

4. Monitor for Thermal Issues:

• Overheating can cause the motor to draw more current. Ensure the motor is properly cooled and that cooling fans (if applicable) are functioning correctly.
• Inspect the motor for signs of overheating, such as discoloration or burnt smell.

5. Check for Inrush Current:

• If the motor is starting under heavy load, it may experience high inrush current. Consider adding a soft starter or adjusting the acceleration ramp settings in the drive to mitigate this.

6. Inspect for Faulty Components:

• Check the motor itself for any mechanical issues, such as bearing failures, misalignment, or excessive loading, which could lead to increased current draw.
• Ensure that other components in the system (like gearboxes or pulleys) are functioning correctly and are not causing additional load.