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ABB frequency converter maintenance

For the ACS300 inverter, a common fault is damage to the switching power supply. The ACS300 inverter switching power supply uses a waveform generator integrated block called LT1244 with similar functions to the UC3844. It is affected by sudden changes in the working voltage and the effects of the switching power supply. Damage to the load often causes damage to the integrated block. Due to long years of use, the electrolytic capacitor has also reached its service life, and the capacitor used for filtering has become the direct cause of damage to the switching power supply.
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    ABB inverter fault repair and response

    1. Common faults of ACS300 inverter

    For the ACS300 inverter, a common fault is damage to the switching power supply. The ACS300 inverter switching power supply uses a waveform generator integrated block called LT1244 with similar functions to the UC3844. It is affected by sudden changes in the working voltage and the switching Damage to the load carried by the power supply often causes damage to the integrated block. Due to long years of use, the electrolytic capacitor has also reached its service life, and the capacitor used for filtering has become the direct cause of damage to the switching power supply. . During maintenance, the author encountered frequent damage to the rectifier bridge of the ACS300 inverter. Perhaps from an economic perspective, they chose the most compact three-phase full-bridge rectifier from International Rectifier Company, which has a small size and load current and is difficult to dissipate heat. It is also poor, so damage will occur after a period of use. The probability of failure of the ACS300 main control board is also quite high. Communication failures between the control panel and the main board, and mainboard CPU failures occur from time to time. Usually, such failures are difficult to eliminate. ACS300 uses Mitsubishi's IPM module, which has a relatively low probability of failure. If the module is damaged, it can only be replaced, but the drive circuit must be completely normal before replacement.

     

    2. Common faults of ACS500 inverter

    For the ACS500 inverter, the most common fault is damage to the driving thick film. This driving thick film not only includes the driving circuit, but also includes short circuit detection, IGBT module detection, overcurrent detection, etc. Due to the good protection function, The high power modules of the ACS500 are rarely damaged. If the driver thick film is damaged during maintenance, we can only repair the thick film without accessories. Since thick film components are welded to ceramic sheets, heat dissipates very quickly. Be especially careful not to leave the soldering iron on for a long time. Heating on components may cause damage to the components. Due to the limitation of usage time, the cooling fan of ACS500 will also malfunction. A common phenomenon is that after powering on, only a "buzzing" sound is heard, but the fan does not rotate. Since it is an axial fan, the fan coil and bearings are often damaged. It was normal. After inspection, it was found that the deflection capacitor was faulty. After replacement, it returned to normal.

     

    3. Common faults of ACS600 inverter

    For the ACS600 frequency converter, it should be said that the performance and quality are quite reliable. However, due to the influence of the surrounding environment, improper parameter settings, and improper operation, it is possible to cause damage to the frequency converter. Of course, natural damage is also common. An inevitable factor for a brand of inverter. Different from previous ABB inverters, the ACS600 inverter uses optical fiber communication, which greatly improves the communication time between the CPU board and the I/O board, but it may also cause "LINK OR HWC" and "PPCC LINK" problems. Failure occurs, and the occurrence of this failure is not absolutely related to the damage of the optical fiber. "PPCC LINK" fault is a common fault of ACS600 inverter. Damage to the CPU board and I/O board may cause this fault. Damage to the switching power supply is also encountered in the ACS600 inverter. The fault mainly occurs on the switching tube. Due to the short circuit of the switching tube, a power resistor used for current limiting is often burned out. "SHORT CIRCUIT" Output short circuit fault is the most common type of fault we encounter. ACS600 uses an intelligent module. Load failure and some problems during use can cause damage to the module, and damage to the module will also cause damage to the module. It is often accompanied by damage to the driver board. Since spare parts are relatively expensive, the cost of repairing the inverter is also relatively high, so higher requirements are put forward for maintenance personnel to perform board-level maintenance.

     

    4. Common faults of ACS800 inverter

    DC UNDERVOLT (DC bus undervoltage fault)

    Cause of fault: The DC voltage of the DC circuit is insufficient, which may be caused by a phase loss in the power grid, a blown fuse or an internal fault in the rectifier bridge. Solution: (1) Check whether the main power supply is normal. If the incoming line of the frequency converter passes through the contactor, check whether the control circuit of the contactor malfunctions. If the control circuit malfunctions, it may cause the contactor to malfunction within a short period of time. Frequent starts and stops cause under-voltage faults in the frequency converter, which can be solved by resetting them. Therefore, for under-voltage faults that can be reset, the main contactor control circuit of the frequency converter must be carefully checked. (2) If an undervoltage fault occurs and cannot be reset, check whether the DC capacitor is leaking. (3) If the inverter has just lost power and is powered on quickly, this fault will also occur. Therefore, if the inverter is powered off, wait until the capacitor is discharged (about 5 minutes) before restarting the inverter.

    0VERCURRENT (output current is too large)

    Cause of fault: The output current exceeds the overcurrent trip limit of the software. Solution: (1) Check whether the motor load is short-circuited. (2) Check whether the mechanical transmission device is stuck. (3) Check whether the parameter settings are appropriate, including whether the acceleration and deceleration times are set too short and whether the starting torque is too small. (4). If an encoder is used, check whether the data transmitted by the encoder is accurate (you can remove the encoder from the parameters first, and then run it to check whether the current is normal).

     

    5. Regular maintenance
    Clean the air filter cooling duct and internal dust. Check whether the screws, bolts, plug-ins, etc. are loose, and whether there is a short circuit in the input and output reactor's resistance to ground and between phases. Normally it should be greater than tens of megohms. Check whether the conductors and insulators are corroded. If so, wipe them clean with alcohol in time.

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