ABB 22KW AC Drive Repaired
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.
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 .
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.
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:
By replacing this IC, the inverter comes to life again and my customer saves a lot of money.
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:
https://jestineyong.com/modification-of-transistorresistors-in-ac-37kw-ls-inverter/
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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!
Muftah
May 7, 2017 at 6:01 pm
Dear Albert,
Thanks for your kind reply.
regards
Muftah
Svend Saustrup
May 6, 2017 at 10:05 pm
--@Albert van Bimmelen :
This is not a UPS, but an adjustable motor speed controller.
Albert van Bemmelen
May 7, 2017 at 4:05 pm
Understood Svend Thanks! I never have repaired or seen these kind of industrial devices.
Owen
May 6, 2017 at 11:46 pm
I would love to hear more articles on Industrial VSD repairs.
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
Parasuraman S
May 7, 2017 at 11:20 pm
VOW! Great! I learnt something new from this article! Many thanks! Please keep writing!
Robert Calk
May 8, 2017 at 4:56 pm
Good job, Muftah. Thanks for the article.
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
Humberto
May 11, 2017 at 11:47 am
Great repair Muftah, congrats.
Yogesh Panchal
May 18, 2017 at 5:57 pm
Good Job! Sir,
Please keep sharing your experience.
Tariq Mahmood
April 6, 2018 at 5:56 pm
i have an ABB ACS 510 11 kw inverter , it is going directly to set speed maximum with out any analog input.
when i check wiht ground referanc there are 9.7 VDC apperaing on ANAGLOG ONE TERMINAL
KINDLY TELL ME WHAT WILL BE PROBLEM
Ravikiran Dixit
May 16, 2018 at 4:36 pm
Very nice troubleshooting & repairing work on this Ac Drive.. It is very helpful in my AC Drive repairing work.. Thanks
please post more about vfd (ac Drive) repairing...