ti vsd- abb acs800 trouble shooting 2946 0703 01

Atlas Copco Airpower n.v Oil -free Air division Service department

Registration code Collection: Technical Information

Z90 VSD Z>=160 VSD ` VSD Page: 1/17

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-ABB ACS800- TROUBLE SHOOTING INSTRUCTION

APPLICABLE FOR: ACS800-02 ACS800-04M

TOOLS NEEDED: True RMS digital voltmeter True RMS digital clamp ampere meter Drive window light + communication cable Hardware manual Firmware manual

CONTENTS 1 ABB ACS800 OVERVIEW TROUBLESHOOTING .............................................................2 2 ABB ACS800 HARDWARE TROUBLE SHOOTING ..........................................................3

2.1 Test input rectifier......................................................................................................3 2.1.1 Static test by multimeter ...................................................................................5 2.1.2 Semi-Dynamically test by clamp ampere meter...............................................6

2.2 Test of pre-pre charging circuit R11/V17 ..................................................................7

2.3 Test input capacitors .................................................................................................8 2.3.1 Static test........................................................................................................10 2.3.2 Dynamic test...................................................................................................10

2.4 Test IGBTs ..............................................................................................................11 2.4.1 Static test........................................................................................................13

2.5 Test of APOW .........................................................................................................15

2.6 Control panel dark: flow chart .................................................................................16

2.7 LEDs........................................................................................................................17

2.8 Current transformers ...............................................................................................17




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1 ABB ACS800 OVERVIEW TROUBLESHOOTING

No

Check hardware troubleshooting (see on page 3)Read carefully Fault tracing ACS800

Check FAULT list Check WARNING list

Drive ok

Drive is not working properly

Yes

Yes

No

No

Converter death or

short-circuited

FAULT or

WARNING

VSD Will not start

Yes (Check status word) (Check fault word) (Check limit word) Check parameters Check wiring




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2 ABB ACS800 HARDWARE TROUBLE SHOOTING

2.1 TEST INPUT RECTIFIER

Figure 1: Input rectifier; drawing




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Figure 2: Input rectifier; picture

Figure 3: Input thyristor

Gate cathode

Bus bar

Cathode 1m

Gate

A/K 1 Cathode 1 Anode 2




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2.1.1 Static test by multimeter 1. Switch of the power supply, wait for 5 minutes.

2. Double-check the input power supply and DC voltage by voltmeter.

WARNING: Do not start with following measurements when AC or DC voltage is present!!

3. Disconnect gate-cathode connectors from all three input thyristors (see Figure 2)

4. Remove all three bus bars (see Figure 2).

5. Input thyristors must not be removed.

Measurements to be carried out for ALL THREE input thyristors Connect + Lead to :

Connect - Lead to :

Measure by Ohm meter

Measure by diode test

Where to measure: see Figure 3 Limits are: Limits are:

Gate Cathode 1m 15 25 N/a

Cathode 1m Cathode 1 0 0.5 N/a

A/K 1 Cathode 1 N/a

Anode 2 A/K 1 N/a 0.2V 0,4V

A/K 1 Anode 2 V

CAUTION: If one of the measured values is not within the specifications the thyristor is broken!!! If one thyristor is broken AINP has to be replaced




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2.1.2 Semi-Dynamically test by clamp ampere meter 1. Start the compressor with the service switch

NOTE: Measure at slow speed and at full speed

I_L1 I_L2 I_L3 Max diff

20Hz Full speed

CAUTION: Maximum difference in both cases is below 5% the input rectifier is working properly




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2.2 TEST OF PRE-PRE CHARGING CIRCUIT R11/V17

When connecting the power supply to the frequency converter, there is no initial DC-energy available to fire the input thyristors. In order to start firing the input thyristors, R11and V17 (see Figure 1) need to pre-pre charge the DC link.

CAUTION: If R11 or V17 fails the VSD will not start.

Figure 4: pre-pre charging circuit

To be tested by ohm meter: R11 To be tested by diode tester: V11 (value must be between 0.45V - 0.65V)

To be disconnected for testing Terminal 1/3D

V11

R11




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2.3 TEST INPUT CAPACITORS

CAUTION: Be careful; there is a lot of energy stored in the capacitors!!

CAUTION: Always replace the COMPLETE capacitor bank! Always buy original ABB capacitors!

REMARK: If capacitors are broken, the ripple on the DC link will be too high. Fault Supply phase (3130) will be generated.

Figure 5: R21 (see Figure 1)

R21 = 2 * resistor in parallel




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Figure 6: 1/2 of R21

REMARK: The most accurate test is carried out with an RLC-measurement tool. All capacitors have to be disconnected and each capacitor has to be tested separated. If this measurement tool is not available, then the capacity can be estimated by a multi meter with F function. The static and dynamic test mentioned below is a good indicator.




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2.3.1 Static test

REMARK: Important: The voltage has to be equally divided between C201 and C202 (see Figure 1).

Note: U_C201 = voltage across C201.

2.3.2 Dynamic test 1. Be sure the input rectifier is working properly. 2. Be sure a 3 phase power supply is available. 3. Start the VSD at full speed, if not possible reduce frequency. 4. Ensure that correct power supply has been applied. 5. Measure the AC-voltage on the DC-link. 6. An excessive high ripple above 25% means the capacitors are broken.

U_C201 == U_C202

Dynamic test needed Switch of power supply

wait 5 minutes

R21 == ok?

Yes

No

Capacitors are broken Replace capacitors

Yes

No

Replace R21

Switch on the power supply Do not start the VSD 0Hz!




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2.4 TEST IGBTS

The IGBTs can only be tested static; ABB has not agreed to measure the gate firing pulse by an oscilloscope. The AGDR (see Figure 8) is soldered directly to the IGBTs, this means that gate capacity can not be measured. So only a short circuit can be measured. The static test can only ensure that IGBTs are broken, but not that the IGBTs are 100% good. Basically the static test says exactly the same as the INT fault word see actual signal 3.12. The only difference is that the static test has to be carried out when the power is switched off. Sometimes the input fuses will blow when an IGBT is short-circuited. In this situation the actual signals cannot be monitored because no DC voltage is present.

Figure 7: One phase IGBT consists of 3 single IGBTs

IGBT 1

IGBT 2

IGBT 3

1: out

2: DC+

3: DC-




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Figure 8: IGBT

IGBT 1

IGBT 2

IGBT 3

AGDR directly soldered to IGBT

Three IGBTs in one casing

1: out 2: DC+

3: DC-




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2.4.1 Static test 1. Switch off power supply and wait 5 minutes

2. Disconnect the motor

3. Measure the resistance between DC+ and DC- .

4. If a short circuit is found, the DC bus bar has to be removed from all IGBTs, before continuing further measurements.

REMARK: If a short circuit is found, the DC bus bar has to be removed from all IGBTs, before continuing further measurements.

Figure 9: DC link between IGBTs

2: DC+ bus

3: DC-bus bar already removed




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Figure 10: DC link between IGBTs removed

Measurements to be carried out for ALL THREE phases Connect + Lead to :

Connect - Lead to :

Measure by Ohm meter

Measure by diode test

Where to measure: see Figure 10 Limits are: Limits are:

Out DC+ N/a 0.25V-0.4V

DC- Out N/a 0.25V-0.4V

CAUTION: If one of the measured values is not within the specifications the IGBT is broken!!!

DC +

DC -OUT




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2.5 TEST OF APOW

Figure 11: APOW block diagram 1. Connect supply to the frequency converter

2. Do not start the motor

Measurements to be carried out for ALL THREE phases To be measured with DC voltmeter Connect + Lead to :

Connect - Lead to :

Normal voltage +/- 2V

Where to measure: see Figure 11

X2 : 8 GND1 +24V

X2 : 6 GND1 -24V

X2 : 2 GND2 +12V

X3 : 1 GND +24V

DC input High voltage!!

Output X2 To RMIO

Output X4 To AINP




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2.6 CONTROL PANEL DARK: FLOW CHART

The flow chart below can be followed when the CDP312R control panel is dark.

Figure 12: Flow chart to be followed when control panel dark

3 times AC input Voltage present at input rectifier?

no

yes

Pre-pre charging R11/V17 ok?

24V available at RMAO

Replace control panel CDP312R

Control panel Still dark?

Replace RMIO Replace control panel

Replace APOW Replace RMIO if APOW is overloaded by RMIO

Repair R11/V17 yes

yes

yes

no

no

Too much input current Input fuses blow all the time

To be tested static: Input rectifier IGBTs

yes

Problem at customers, no power supply

no




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2.7 LEDS

2.8 CURRENT TRANSFORMERS

Active current transformers are used in ACS800-02/04, see block diagram below: Figure 13 1. Switch off power supply, wait 5 minutes.

2. Disconnect all three current transformers.

3. Measure three times the resistance according to figure above with respect of polarity.

4. Compare with other 2 transformers.

+24V

out

-24V

+

M

-

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ti vsd- abb acs800 trouble shooting 2946 0703 01

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