FaulttracingofACS800variablespeeddrivesInstructionfor

ABBServiceNetworkAuthor:TomiV?is?l?

ABBOyDrives

Helsinki19.9.2005

ContentSafetyissuesGeneralfaulttracinginfoACS800R7&R8maincircuitdiagramFaulttracingMeasuringkeyelectricalcomponentsSafetyissuesRemembersafetyatalltimes!Therecanbealmost1000VDCinsidethedriveALWAYSMAKESURETHATTHEDRIVEISPOWEREDOFFBEFOREDOINGANYSERVICEORMAINTENANCEWORK!DISCONNECTTHEPOWERFROMTHEWHOLECOMPRESSORMEASURETHATTHEREISNOVOLTAGEINTHEINPUTTERMINALS(BETWEENPHASESANDBETWEENPHASESANDGROUND)MAKESURETHATNO-ONEELSECANPOWERUPTHEUNITWHILEYOUAREDOINGTHESERVICEWORKWAITATLEAST6minutesafterpoweringoffthedrivetomakesurethatthereisnovoltageintheDC-capacitorbankMeasuretheDC-voltagefromtheDC-busbarsafteropeningtheunitConsidertheDC-bustobechargeduntilyou

haveverifiedwithmeasurementthatthereisno

voltageOnelocationtomeasureDC+andDC-busbar

voltageisshownonthepictureAVOIDBEINGINFRONTOFTHEUNITWHENIT

ISPOWEREDSafetyissuesIfyouwanttomeasuresomevoltageswhentheunitispoweredupFIRSTPOWERDOWNTHEDRIVEANDMAKESURETHATNO-ONEELSECANPOWERUPTHEUNITWHILEYOUWORKONITWAIT6MINUTESOPENTHEUNITMEASUREDCBUSVOLTAGETOMAKESURETHATTHEDCBUSVOLTAGEIS0VCONNECTTHEEXTERNALMEASUREMENTDEVICELEADSTOTHELOCATIONYOUWANTTOMEASURECLOSETHEUNITPOWERUPTHEDRIVEANDSEETHEMEASUREMENTOUTCOMEDONOTTRYTOMEASUREANYTHINGUNLESSYOUHAVEPROPERELECTRICALTRAININGPleasereferACS800-04andACS800-04M

Hardwaremanualformoredetails(3AFE64671006)Document3AFE64671006availableatFaulttracingofACS800drives/GeneralIngeneralafaultindriveiscausedbyHardwareprobleminthedrive(e.g.brokencomponent)Wrongparametersetting(e.g.customerhasmodifiedparametersettings)Processproblem(e.g.MotorStallfaultasresultoffailedbearingintheloadmachine)Operatingenvironment(e.g.toohotambienttemperature)Electricalnetwork(e.g.missingsupplyphase,overvoltagefromthenetwork,etc.)Trytounderstand,whichoneoftheabovementionedreasonsiscausingthefaultIfthefaultisactiveallthetime,thenthereasonfortheproblemisfairlyeasytofindSporadicfaults(forexample1faultafterevery2weeks)arethemostdifficultonesFaulttracingofACS800drives/GeneralFaultsarealwaysbasedonmeasurementresults,thisyieldsthatfaultreasoniseitherMeasuredvalueexceedsthetriplevelIncorrectmeasurement(duetohardwareorsoftwareproblem)ACS800DrivemeasuresDCbusvoltageOutputcurrent(fromallthreephases)DCchoketemperature(ONLYINFRAMESR2&R3)IGBTtemperatureMotorcontrolboard(RMIO)temperatureVoltageovereachIGBT(usedforshortcircuitprotection)PPCClinkcommunicationerrors(opticallinkbetweenRMIOandAINT)StatusofI/OsignalsFaulttracingofACS800drives/GeneralWhenanalyzingaproblemCheckfaultlogIfthefaultisactiveallthetime,thentheproblemisusuallyfairlyeasytoremoveMonitorlimitwordandstatusword(seeFirmwaremanualFieldbussectionhowtointerpretthemeaningofeachbit)MonitoringthelimitwordcangiveideawheretheproblemiscomingMonitorStatuswordindicatesthestatusofthedrivewhentheproblemoccursUseRMIOloggersandDriveWindowtrendingtools(seeDriveWindowmanualfordetails)Monitoringmeasurementsfromparametergroup160isoftenthebestplacetoseewhatthedriveismeasuringCheckambientTemperatureHumidityCheckprocessIstheproblemrelatedtoachangeintheprocess/loadKeepitsimpleSolutiontoaproblemisoftensimpleafteryoufinditoutFaulttracingofACS800drives/ToolsFollowingequipmentisusefulwhenrepairing/faulttracingadriveTrue-RMSMultimeterLaptopPCDriveWindow2.1xsoftwarePossibilitytoloadsoftwaretoRMIOLocalcopyofIHMMforActiveandClassicdrives68553491Trolley(forR7orR8drives)PortableDC-powersupply(incasethemodule

hastoberemovedfromthecabinetandifthesupply

cablesmustberemovedforrepairandfaulttracing)TheDCpowersupplyinthepicture(for230VACsupply)capableofsupplying500VDCand~250mAEnoughtotestR8unitinscalarcontrolwithout

motorWeight<5kg,reasonablepricePortable24VDCpowersupply(totestRMIO)Insulationresistancemetertobeusedtomeasuremotor

andmotorcablePortableoscilloscope(onlyinspecialcases)FaulttracingofACS800drives/GeneralIncaseofShortCircuitfault,actualsignal4.02(INTSCINFO)canbeusedtoseewhichphaseIGBTisbrokenIncasetheunithasseveralAINT-boards,actualsignal4.01canbeusedtoseewhichmoduleiscausingthetripSeefirmwaremanualsection

FieldbuscontrolformoreinstructionshowtointerpretthevaluesFaulttracingofACS800drives/GeneralPasscodetoaccesshiddenparametergroupsis2303Gotogroup16.03Enterthepasscode2303AfterthathiddenparametergroupsarevisibleAllpasscodesarelistedinIHMMSeehint”PassCodesforACS600”in08Support/HintsandProductNotice,ACS600ServiceHintsforallpasscodesRemembertore-boottheRMIOafteropeningthehiddenparameters,sothatthecustomercan’tmodifythemafteryouleaveRiskthatthecustomerdamagestheunitFaulttracingofACS800drives/GeneralGoodsourcesofinformationManualsHints/productnoticesSoftwareReleasenotesCircuitboardrevisionreportsElectricalcomponentsofACS800R7/R8driveControlcomponentsRMIO-02CMotorControlandI/OboardTheRMIO-02Cboardispackedinsidecase,theRMIO+caseiscalledRDCU-02C(DriveControlUnit)OptionmodulesRDIO,RAIO,RTAC,fieldbusmodules,etc…CDP-312RControlPanelElectricalcomponentsofACS800R7/R8driveCircuitboardsinsideACS800R7/R8AINT-01(A41)MainCircuitInterfaceBoardAPOW-01(A43)PowerSupplyboardAINP-01(A45)InputBridgeControlBoardAIBP-51(A13)InputBridgeProtectionBoardAGDR-61C(A21,A22,A23)GateDriverBoard(toswitchIGBTsonandoff)ElectricalcomponentsofACS800R7/R8driveMaincircuitcomponentsAC-choke(L11)Chargingdiode(V17)Chargingresistor(R11)Thyristor/diodemodules(3pcs)(V11,V12,V13)DC-capacitors(C201–C214)Dischargeresistors(R21–R23)IGBTs(1pcsinR7units,3pcsinR8units)(V21,V22,V23)CurrentTransducers(CTs)(U31,U32,U33)ElectricalcomponentsofACS800R7/R8driveFancomponentsFanfuses(F41,F42)Fantransformer(T41)Fancapacitor(C41)OnephaseAC-fan(Y41)ACS800R8maincircuitdiagram1/2ACS800R8maincircuitdiagram2/2MeasuringsomeelectricalcomponentsChargingResistor(R11)Theresistanceofthechargingresistormustberoughly3–4Ohms(resistancemeasurementofamultimeter)ChargingDiode(V17)Thevoltagemustbe~0.5Vwhenmeasured

inconductingdirectionandOpenLoopin

reversedirection(diodemeasurement

ofamultimeter)CurrentTransducers(U31,U32,U33)(CTs)MeasureresistancebetweenallthreeterminalsoftheCTTherearetotalthreeCTsinonedrive,thevaluesfoundfromthethreeCTsshouldbealmostequalNOTE!MeasuringCTwithmultimeterdoesnotnecessarilyrevealifitisfaulty!NOTE!DifferentCTtypesareusedindifferentsize

units,themeasurementresultsofdifferentCTtypes

varysignificantlyCTswithinoneunitarealwayssametypeMeasuringkeyelectricalcomponentsFanfuses(F41,F42)Resistanceshouldbecloseto0OhmsFantransformer(T41)Primarysideresistance

(betweenN–500terminals)~3