ABB 22KW AC Drive Repaired

By on May 6, 2017
ac drive repair

 

 

 

 

 

 

 

 

 

 

Now, I would like to share with you my repairing task to bring into life one 22KW ABB drive, having experience in repairing electronics in industrial field, I am glad to share with you all I have and  face of electronic failures and troubleshooting strategy.




Let us start with a brief of the problem as the customer brought it :

A big short in the input 400V, Probably due to high spike in the mains network, this lead to distraction of 3 phase bridge type : SKD 53/16 MADE BY SEMIKRON. and IGBT type FS75R12KE3 MADE BY Infineon.

shorted IGBT SEMIKRON

SKD 53/16 MADE BY SEMIKRON

These parts were ordered and installed with no problem, off course after cleaning of the Carbon and the remaining of the old parts. Everything seems to be ok ,.. I start testing the drive but to no sign of life at all .

AC DRIVE CIRCUIT BOARD

now I have to start digging for the cause of death of the power side. I made the usual check on the SMD high speed diode and the high frequency transformer, but nothing seems faulty.

SHORTED IC IN AC DRIVE

CHECK AC DRIVE COMPONENTS

HOW TO REPAIR AC DRIVE 22KW

HOW TO FIX 22KW AC DRIVE

With the help of the datasheet i checked the TL3844 CURRENT-MODE PWM controller, i could not find problem, still there is no output from the IC , which is the main part of SMPS.

I went again checking the output high frequency diode , and noted that there is some low resistance compared to the other diode with reference to ground. I made one cut in the board to isolate one line ,.. and after 2 hours of trouble shooting I come to the cause of the problem .. it is the AD34074. It is OP-AMP and there is a short in this IC causing the TL3844 to shut down. Below is the datasheet:

TL3844 DTASHEET

By replacing this IC, the inverter comes to life again and my customer saves a lot of money.

fix ac drive

how to fix ac drive

 

This article was prepared by Muftah H Shawish from Misrata -Libya. He is 49 years old and have more than 27 years experience in troubleshooting and repairing of  industrial systems, electronic control system, temperature controller, Motors drives, Automotive control unit. He was a BET graduate, currently work as a manager of electrical repair dept. in Libyan steel company , running his own electronics repair shop in the afternoon..




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Note: You may check out previous post about fixing active speaker in the below link:

http://jestineyong.com/modification-of-transistorresistors-in-ac-37kw-ls-inverter/

 

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11 Comments

  1. Albert van Bemmelen

    May 6, 2017 at 4:34 pm

    A unique repair on such a high power 22000 Watt UPS! Never had seen these large ones before. Thank you Mr.Muftah for the article and also for the PWM controller datasheet. Although the AD34074 Opamp was the defect component but not shown here. But the datasheet can be found here:
    http://www.alldatasheet.com/datasheet-pdf/pdf/172249/ONSEMI/MC34074.html
    Cheers!

    Likes(6)Dislikes(0)
    • Muftah

      May 7, 2017 at 6:01 pm

      Dear Albert,
      Thanks for your kind reply.
      regards
      Muftah

      Likes(4)Dislikes(0)
  2. Svend Saustrup

    May 6, 2017 at 10:05 pm

    --@Albert van Bimmelen :
    This is not a UPS, but an adjustable motor speed controller.

    Likes(2)Dislikes(0)
    • Albert van Bemmelen

      May 7, 2017 at 4:05 pm

      Understood Svend Thanks! I never have repaired or seen these kind of industrial devices.

      Likes(2)Dislikes(0)
  3. Owen

    May 6, 2017 at 11:46 pm

    I would love to hear more articles on Industrial VSD repairs.

    Likes(2)Dislikes(0)
    • Muftah

      May 7, 2017 at 6:03 pm

      Dear Owen,

      Thanks for you kind reply, i will try to post any good repairs in this topic.
      regards
      Muftah

      Likes(3)Dislikes(0)
  4. Parasuraman S

    May 7, 2017 at 11:20 pm

    VOW! Great! I learnt something new from this article! Many thanks! Please keep writing!

    Likes(3)Dislikes(0)
  5. Robert Calk

    May 8, 2017 at 4:56 pm

    Good job, Muftah. Thanks for the article.

    Likes(3)Dislikes(0)
  6. Lad

    May 11, 2017 at 2:30 am

    Muftah congratulation on the success!
    How did you find out that AD34074 was a cause to shut down TL3844 ?Thank you

    Likes(1)Dislikes(0)
  7. Humberto

    May 11, 2017 at 11:47 am

    Great repair Muftah, congrats.

    Likes(1)Dislikes(0)
  8. Yogesh Panchal

    May 18, 2017 at 5:57 pm

    Good Job! Sir,
    Please keep sharing your experience.

    Likes(0)Dislikes(0)

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