1. Fault code analysis method

If the ABB frequency converter has a fault, there are corresponding fault codes on the operation panel. Generally, when dealing with frequency converter faults, it is necessary to find its fault code on the operation panel and conduct a deeper analysis based on the fault code. Based on my personal experience in frequency converter maintenance and some common fault codes, I will briefly discuss some common fault handling methods.

1.1 Fault code: BRAKEFLT

Reason for malfunction: Brake failure, brake opening timeout or brake not opening properly.

Solution: Open the cover of the brake on site, forcefully open the brake coils in the program, observe the limit opening status of the brake, and if the brake cannot be opened or the mechanism is stuck, replace the brake;

If the distance between the limit opening and the limit sensing piece is far, adjust the distance of the sensing piece and ensure its fastening (based on the author's years of equipment management experience, the failure rate of electronic induction proximity switches is much lower than that of mechanical switches, and most important limit switches in our department have been improved from mechanical switches before installation to electronic induction proximity switches);

If the brake opens out of time, two methods can be used: ① If the brake opens slightly slowly, extend the delay time for opening the brake; ② The brake opens very slowly, and a new brake hydraulic push rod must be replaced at this time.

1.2 Fault code: MFCOMMERR

Reason for malfunction: Invalid communication between the master and slave buses.

Solution: Check the fiber optic connections between the master and slave bus connections, as well as between the host CH: and the slave CH:. Check if the connection is tight. If it is loose, it needs to be reinserted and the connection confirmed to be reliable. In addition, it is necessary to check whether the fiber optic communication is normal and whether the fiber optic head is clean. If it does not meet the requirements, it must be cleaned with precision electronic instrument cleaning agents or replaced with high-quality fibers.

If all the above situations are normal and the fault cannot be eliminated, force the output coil of the inverter contactor to move for about 5 minutes in the program, and the fault can be eliminated.

1.3 Fault code: SHORTCIRCUIT

Reason for malfunction: External motor cable malfunction or hardware malfunction of the frequency converter itself.

Solution: Disconnect the output line of the frequency converter, use a megohmmeter to measure the insulation condition of the three phases to ground and the three-phase electrical group. If there is a problem with the motor or cable, replace the motor and cable; If the output is normal, check the main circuit of the frequency converter, mainly the IGBT Inverter block and rectifier bridge, etc. How to determine if IGBT>inverter block and rectifier bridge are normal? Here, I tested the above intact electrical components with a multimeter diode setting, and the test results are as follows:

① For IGBT, when measuring C with the black probe and £ with the red probe of the multimeter, the resistance value is around 0.34MQ, otherwise it is infinite. The other four cases are all infinitely large.

② For the inverter block, when the black probe of the multimeter is used to measure the positive pole and the red probe is used to measure the negative pole, the resistance value is around 0.67 M Ω, otherwise it is infinite. When the black probe of the multimeter is used to measure the grounding electrode and the red probe is used to measure the negative electrode, the resistance value is about 0.34M Ω, otherwise it is infinite; When measuring the positive pole with the black probe and the grounding pole with the red probe of a multimeter, the resistance value is around 0.34M Ω, and vice versa, it is infinite.

③ For the rectifier bridge, when the black probe of the multimeter measures 1 and the red probe measures 3, the resistance value is around 0.37MC, otherwise it is infinite. The other four cases are all infinitely large.

If the test results deviate too much from the above results, it is recommended to replace them. If considering reducing the impact of maintenance on production time, the author suggests that it is more advisable to directly replace the frequency converter, because replacing a frequency converter requires controllable time, about 2 hours, while repairing due to the occurrence of the SHORTCIR-CULT fault code takes much more than 2 hours, and the time is uncontrollable.

1.4 Fault code: Ambinettemp

Reason for malfunction: The working environment temperature of the frequency converter is too low.

Solution: Consider adding air conditioning to the electrical room and increasing the working environment temperature of the frequency converter; If you want to resume work quickly in emergency situations, you can use heating tools such as hair dryers to increase the ambient temperature.

Ink smudge segmentation line

2. Main Circuit Analysis Method

The main circuit analysis method starts from the main circuit of the frequency converter, analyzing the causes and solutions of faults. Based on experience, when encountering faults in the main circuit of ABB frequency converters, the following aspects can be taken into consideration.

2.1 Faults caused by filtering capacitors

Reason for malfunction: Unstable voltage in the power grid, high internal temperature, and poor component performance.

resolvent:

① Mainly due to unstable equipment and susceptibility to electromagnetic interference;

② Replace high-quality components and improve ventilation conditions.

2.2 Inverter overheating

Reason for malfunction: The fan does not rotate and the air duct is blocked.

resolvent:

① Check if the fan coil is damaged;

② Clean up the dust accumulation in the cold air duct. If it is stuck due to lack of oil, add light oil first and then add some solid lubricating grease;

③ When replacing a new cold air fan, it is important to note that some fans come with an automatic rotation signal, while others do not. Replace the fan with the original model.

2.3 Excessive output current

Fault cause: Output current exceeds the set limit and trips.

resolvent:

① Check if the motor load is short circuited;

② Check if the motor brake is fully open;

③ Check whether the mechanical rotating device operates flexibly;

④ Determine whether there is temperature rise, odor, abnormal noise and other phenomena during the operation of asynchronous motors;

⑤ After determining the motor and winding coil faults, pay attention to the original model and parameters when replacing them.

2.4 Brake malfunction

Reason for malfunction: The brake does not operate properly, the limit signal does not work, and the brake is mechanically faulty. resolvent:

① Check if the power supply to the brake is normal;

② Check if the mechanical transmission of the brake is normal;

③ Check for brake coil malfunction;

④ Check the brake limit and return signal;

⑤ Check if the contactor is functioning properly;

⑥ The main electrical fault of the contactor is caused by poor contact of a certain contact or loose screws of the contact terminal. Repair and replacement of new components should be carried out. If the brake is damaged, it should be rewired and replaced. When replacing, pay attention to the original model and parameters.

2.5 Encoder malfunction

Reason for malfunction: The frequency converter detected an error in the data signal feedback from the encoder or a communication interruption.

resolvent:

① Check if the encoder is properly connected to the motor or equipment;

② Check if the encoder signal cable is intact;

③ Check the connection between the encoder and the control board;

④ Check if the encoder is disturbed by surrounding devices;

⑤ Correct the encoder position and eliminate other interferences.

2.6 Interference Fault

Reason for malfunction: Mainly caused by conducted interference and electromagnetic induction interference.

resolvent:

① Mainly check whether each grounding wire is in good condition;

② Check if all shielded wires are connected properly.

Common faults and maintenance strategies

Due to the large sales volume of ABB frequency converters in the Chinese market, including some early used ACS2OO, ACS3OO, ACS50O, which have entered a period of frequent failures, many problems will inevitably be encountered during use. Below, we will discuss some common faults of ABB frequency converters with users:

For ACS300O frequency converters, a common fault we encounter is damage to the switching power supply. The ACS300O frequency converter switching power supply uses a waveform generator integrated block called EF1244, which has a similar function to UC3844. Due to sudden changes in operating voltage and damage to the load carried by the switching power supply, damage to this integrated block often occurs. As the electrolytic capacitor has reached its service life after a long period of use, the capacitor used for filtering has become the direct cause of damage to the switching power supply. We often encounter damage to the rectifier bridge of ACS3OO frequency converters during maintenance. Perhaps from an economic perspective, we have chosen the most compact three-phase full bridge rectifier from an international rectifier company, which has a small volume and load current, and poor heat dissipation. Therefore, damage may occur after a period of use. The probability of ACS300O main control board failure is also quite high. Communication failures between the control board and the motherboard, as well as CPU failures on the motherboard, occur from time to time, and these types of failures are usually difficult to troubleshoot. ACS300O uses Mitsubishi's IPM module, which has a relatively low probability of failure. If the module is damaged, it can only be replaced, but before replacement, it is necessary to ensure that the drive circuit is completely normal.

For ACS500O frequency converters, a common fault is damage to the drive thick film, which not only includes the drive circuit, but also short-circuit detection, IGBT module detection, overcurrent detection, etc. Due to its good protection function, the high-power module of ACS500O is rarely damaged. If the driver thick film is damaged during maintenance and there are no accessories available, we can only repair the thick film. Due to the fact that thick film components are soldered onto ceramic plates, heat dissipation is quite fast. Special attention should be paid not to damage the components by heating the soldering iron on them for a long time. Due to the limitation of usage time, the cooling fan of ACS500O may also malfunction. The common phenomenon is that only a "buzzing" sound is heard after power on, but the fan does not rotate. As it is an axial fan, the fan coil and bearings are often normal. After inspection, it was found that the deflection capacitor had malfunctioned. After replacement, it was restored to normal.

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