TI VSD - ABB ACS800 Trouble Shooting 2946 0703 01

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Registration code Collection: Technical Information Z90 VSD – Z>=160 VSD ` VSD Page: 1/17

-ABB ACS800TROUBLE 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

PM: replaces: 2946 0703 00

2946 0703 01 09/09/2005

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Registration code Collection: Technical Information Z90 VSD – Z>=160 VSD ` VSD Page: 2/17

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1 ABB ACS800 OVERVIEW TROUBLESHOOTING Drive is not working properly

Converter death or short-circuited

No

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

FAULT or WARNING

No

Yes Check FAULT list Check WARNING list

VSD Will not start

No

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

Drive ok PM: replaces: 2946 0703 00

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Registration code Collection: Technical Information Z90 VSD – Z>=160 VSD ` VSD Page: 3/17

2 ABB ACS800 HARDWARE TROUBLE SHOOTING 2.1 TEST INPUT RECTIFIER

Figure 1: Input rectifier; drawing

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Registration code Collection: Technical Information Z90 VSD – Z>=160 VSD ` VSD Page: 4/17

Bus bar

Gate cathode

Figure 2: Input rectifier; picture

Gate

Cathode 1m A/K 1

Cathode 1

Anode 2

Figure 3: Input thyristor PM: replaces: 2946 0703 00

2946 0703 01 09/09/2005

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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. ¾ Measurements to be carried out for ALL THREE input thyristors Connect + Lead to :

Connect - Lead to :

Where to measure: see Figure 3

Measure by Ohm Measure by diode meter test Limits are:

Limits are:

Gate

Cathode 1m

15 – 25 Ω

N/a

Cathode 1m

Cathode 1

0 – 0.5 Ω

N/a

A/K 1

Cathode 1

∝Ω

N/a

Anode 2

A/K 1

N/a

0.2V – 0,4V

A/K 1

Anode 2

∝Ω

∝V

CAUTION:

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

PM: replaces: 2946 0703 00

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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% Î 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 DCenergy 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.

To be testing

disconnected

for

Terminal 1/3D R11

V11 Figure 4: pre-pre charging circuit ¾ To be tested by ohm meter: R11 ¾ To be tested by diode tester: V11 (value must be between 0.45V - 0.65V) PM: replaces: 2946 0703 00

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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.

R21 = 2 * resistor in parallel

Figure 5: R21 (see Figure 1)

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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 µF function. The static and dynamic test mentioned below is a good indicator.

PM: replaces: 2946 0703 00

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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.

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

No U_C201 == U_C202

Yes Switch of power supply wait 5 minutes

Dynamic test needed

No

R21 == ok?

Yes Replace R21

Capacitors are broken Replace capacitors

2.3.2 Dynamic test 1. 2. 3. 4. 5. 6.

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

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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.

2: DC+

IGBT 1

3: DCIGBT 2

IGBT 3

1: out

Figure 7: One phase IGBT consists of 3 single IGBTs

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1: out

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2: DC+ IGBT 1

3: DCIGBT 2

IGBT 3

Figure 8: IGBT AGDR directly soldered to IGBT

Three IGBTs in one casing

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

REMARK:

2: DC+ bus

3: DC-bus bar already removed

Figure 9: DC link between IGBTs

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DC +

DC -

Figure 10: DC link between IGBTs removed OUT

¾ Measurements to be carried out for ALL THREE phases Connect + Lead to :

Connect - Lead to :

Where to measure: see Figure 10

Measure by Ohm Measure by diode meter test 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 Î the IGBT is broken!!!

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2.5 TEST OF APOW

DC input High voltage!!

Output X2 To RMIO Output X4 To AINP

Figure 11: APOW block diagram 1. Connect supply to the frequency converter 2. Do not start the motor ¾ 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

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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.

no

Problem at customer’s, no power supply

no

3 times AC input Voltage present at input rectifier?

yes

Too much input current Input fuses blow all the time yes no

To be tested static: Input rectifier IGBT’s

Pre-pre charging R11/V17 ok? yes

Repair R11/V17 no

24V available at RMAO yes

Replace APOW Replace RMIO if APOW is overloaded by RMIO

Replace control panel CDP312R

Control panel Still dark? yes Replace RMIO Replace control panel

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

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2.7 LEDS

2.8 CURRENT TRANSFORMERS Active current transformers are used in ACS800-02/04, see block diagram below:

+24V out -24V

+ M

-

Ω

Ω

Ω

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. PM: replaces: 2946 0703 00

2946 0703 01 09/09/2005