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ABB inverter repair case
Recently, a customer reached out regarding an ACS800/110KW inverter installed on their site. After some operational time, the device began displaying an ACS800 TEMP fault, and the issue persisted even after multiple attempts to reset it. Recognizing the urgency, the engineer quickly headed to the location to address the problem.
Upon arrival, the inspection process began. The inverter was disassembled to inspect both the rectifier and inverter modules. Diode characteristics were also tested. With the inverter powered on, everything appeared normal at first glance. The three-phase output voltage was balanced. However, once loaded, the inverter again displayed the ACS800 TEMP fault. The following steps were taken to diagnose the issue:
1. Checked the external ambient temperature.
2. Inspected the inverter's cooling fan.
3. Examined the internal heat dissipation channels.
4. Verified compatibility between the motor and inverter.
5. Investigated potential faults in the temperature check circuit.
After analyzing these possibilities, it became clear that there could be several underlying causes:
1. The external environment might be excessively hot.
2. The cooling fan could have stopped functioning.
3. The heat dissipation channels inside the inverter could be obstructed.
4. The inverter and motor might not be properly matched.
5. There could be a malfunction in the temperature detection circuit.
First, we measured the external ambient temperature, which was around 40 degrees Celsius. While this is on the higher end of acceptable operating temperatures for the inverter, it wasn't excessively high given the equipment’s typical operational limits. The inverter was housed in an electrical room with multiple other inverters of similar power ratings.
Next, the inverter’s cooling fan was inspected. It was confirmed that the fan operated correctly whenever the inverter was running. Additionally, when the fan was detached and tested separately, it performed as expected.
Considering the fourth possibility, there was no evidence suggesting the motor and inverter were mismatched. This particular inverter had been in use for several years without any previous issues, such as overcurrent or overload faults, until the TEMP fault occurred. Thus, this hypothesis was deemed unlikely.
The fifth possibility involved a potential fault in the temperature detection circuit. While this couldn’t be entirely ruled out, further testing would be required to confirm or dismiss this theory.
Finally, upon thoroughly dismantling the inverter, it became evident that the heat dissipation channels were indeed blocked. This obstruction prevented proper cooling of the inverter, leading to the TEMP fault. This was identified as the root cause of the problem.
The repair process began by cleaning the heat dissipation channels. Once cleaned, the inverter’s board and capacitor box were reinstalled in sequence. The unit was then tested under power-on conditions. The inverter functioned normally, with balanced output voltages and no overheating issues. The TEMP fault was resolved, confirming that the blockage in the heat dissipation channels was the primary cause. No damage to the temperature detection circuit was detected.
In conclusion, based on extensive experience in maintaining ABB inverters, it is evident that most faults stem from clogged heat sinks within the inverter itself. Regular maintenance checks to ensure unobstructed airflow can prevent such issues from arising.