ABB ACS800 frequency converter common fault and maintenance skills

Part 1: Intruduce

ABB ACS800 series frequency converter is a high-performance, widely adaptable AC frequency converter with a wide range of applications, advanced technology, powerful starting torque, automatic start, flux optimization, reliability and stability, and humanization With its user interface and other advantages, it is widely used in various industrial fields, such as electric power, petrochemicals, metallurgy, building materials, etc. Can control various types of motors, including AC asynchronous motors, AC synchronous motors, DC brushless motors, etc.

In the power field, ACS800 series frequency converters can be used in power plants, substations, distribution stations and other places to control the operating speed and rotation speed of power equipment. In the petrochemical field, it can be used to control the operation of pumps, fans and other equipment to improve production efficiency and product quality. In the metallurgical field, it can be used to control the operation of rolling mills, continuous casting machines and other equipment to improve production efficiency and product quality. In the field of building materials, it can be used to control the operation of kilns, mixers and other equipment to improve production efficiency and product quality.

Part 2: Common faults analysis

However, during the use of ABB ACS800 series frequency converters, some problems often occur, which affect the normal operation of the equipment, such as:

1. Inverter module damage: This is usually caused by motor or cable damage and faults in the drive circuit. After repairing the drive circuit, the module should be replaced if the drive waveform is in good condition. After replacing the drive board on-site, it is necessary to check the motor and connecting cables. The inverter can only be operated when no faults are found.

2. No display after power-up: This is usually caused by damage to the switching power supply or damage to the soft charging circuit, resulting in no DC power in the DC circuit. This situation can also occur if the starting resistor is damaged or the operation panel is damaged.
3. Display overvoltage or undervoltage: usually caused by input phase loss, circuit aging and moisture on the circuit board.
4. Display of overcurrent or ground short circuit: usually due to damage to the current detection circuit. Such as Hall elements, op amp circuits, etc.
5. Power supply and drive board display overcurrent onstartup: This is usually caused by damage to the drive circuit or inverter module.
6. The no-load output voltage is normal, but overload or overcurrent is displayed after loading: This is usually caused by improper parameter settings or aging of the drive circuit or module damage.
7. Failures caused by the external environment, such as working environment temperature, vibration, moisture, electromagnetic induction interference, power supply abnormalities, lightning strikes, induced lightning, vibration and noise, etc.

These faults may affect the normal operation of the inverter and require timely investigation and repair. Different solutions should be adopted for different faults. If it cannot be repaired by yourself, it is recommended to contact professional technicians for repair

Part 3: Case sharing

Of these two inverters, model ACS800-01-0070-7, one frequently trips and stops during operation, and reports an over-temperature alarm.

Alt: ACS800-01-0070-7 frequency

Analysis and processing:

Since the inverter was running normally in the early stage, the over-temperature alarm trip is usually caused by the inverter operating at full load for a long time and unable to fully dissipate heat. The load condition of the motor was checked to be normal, but when the inverter was removed for inspection, it was found that there was a lot of dust on the heat sink. Thick, seriously hindering the heat dissipation performance of the inverter. After sufficient cleaning and maintenance of the accumulated dust, the inverter returns to normal operation.

It can be seen from the example that our maintenance of the frequency converter is not complicated. Some common minor problems are not the frequency converter itself, but that we do not pay attention to its operating environment. Usually, the reason why the frequency converter is burned out is because these environments are not guaranteed. , caused by the accelerated aging of its internal components. Therefore, we should especially check the working conditions of the inverter during daily maintenance, including keeping the surrounding environment dust-free, water-free, corrosion-free and constant temperature. If the environment cannot be changed, regular maintenance of the inverter is very necessary.

2. For another DCS-controlled inverter, after the operator set the operating frequency to 30Hz, he found that the actual motor speed was very slow or even stopped.

Alt: DCS-controlled inverter

Analysis and processing:

Since the original control is normal, it means that there should be no problem with the original external wiring and control method. Check that the inverter fault code is overcurrent and overload. The possible reason is that the load is too large. According to the feedback obtained on site, there is no problem with the motor. Due to the workmanship, The change has increased the load of the frequency converter. Check that the current limit of the frequency converter is normal. Check the operating parameters during the trial operation and find that the input switch value and analog data are also normal. However, when the input analog value is about 30Hz, the output frequency is inconsistent. It turns out that the inverter's starting load capacity is obviously poor. Adjust the U/F curve to increase the voltage setting at low frequency and then eliminate the fault.

Part 4: Tips

Routine maintenance methods and precautions for frequency converters include:

1. Check whether the ambient temperature and humidity meet the requirements, and whether there is dust and corrosive gas.
2. Check whether the appearance of the inverter is normal, including loose cables, heat sheets, filters and other components.
3. Check whether the power supply and grounding of the inverter are in good condition, and whether there are any abnormal sounds and vibrations during operation.
4. Check whether the control signals of the frequency converter are normal, including input signals and output signals.
5. Check whether the parameter settings of the inverter are correct, including motor parameters, control parameters, etc.
6. Perform regular maintenance on the inverter, including cleaning internal and external components, testing the performance of each component, and replacing aging and poorly performing components.
7. Be careful not to perform unnecessary operations while the inverter is running, such as touching the control panel, unplugging and plugging cables, etc.
8. When performing daily maintenance, you need to pay attention to safety, such as turning off the power, releasing residual power, etc.

Part 5: Conclusion

Routine maintenance is a key measure to ensure the normal operation of the inverter, extend its life, optimize performance, improve safety and reduce maintenance costs. It helps identify and resolve potential problems, keeping equipment running at its best and improving work efficiency and reliability.