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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
-