10 strokes to deal with ABB inverter common faults

ABB inverters are widely used and it is inevitable that various faults will occur during use. There are two methods for dealing with ABB inverter faults (other inverter faults are similar): Fault code analysis method and main circuit analysis method.

1, fault code analysis

If there is a fault in the ABB inverter, there is a corresponding fault code on the operation panel. When dealing with faults in the inverter, the fault code must be found on the operation panel, and a deep level analysis should be performed according to the fault code. According to the experience of the individual in the inverter maintenance process and some common fault codes, some common troubleshooting methods are discussed below.

1.1 Failure Code: BRAKE FLT

Cause of the problem: The brake is faulty, the brake is open or the brake is not turned on.

Treatment method: Open the cover of the brake at the scene, and forcefully open the brake coil in the program to observe the open state of the brake. If the brake cannot be opened or the mechanism is stuck, replace the brake.

If the limit switch is far away from the distance limit sensor, adjust the distance of the sensor and ensure its tightness. According to the author's years of equipment management experience, the failure rate of the electronic inductive proximity switch is much lower than the mechanical switch. Most of the departments are important. Limits are improved from pre-installation mechanical switches to electronic inductive proximity switches);

If the brake opens, there are two ways to do this: 1) If the brake is opened slightly, then the brake opening delay time is extended; 2) The brake is opened very slowly, and the new brake hydraulic rod must be replaced.

1.2 Failure Code: MF COMM ERR

Fault reason: The master and slave bus communication are invalid.

Processing method: Check the fiber connections between the master and slave bus connections and the master CH: to the slave CH:. See if the connection is tight. If it is loose, reinsert it and make sure the connection is reliable. In addition, it is necessary to check whether the optical fiber communication is normal and whether the optical fiber head is clean. If the requirements are not met, the optical fiber must be cleaned or replaced with a precision electronic instrument cleaning agent.

If the above conditions are normal or the fault cannot be eliminated, the inverter's output coil of the contactor must be forced to operate for approximately 5 minutes in the program, and the fault can be eliminated.

1.3 Failure Code: SHORT CIRCUIT

Fault cause: The externally connected motor cable is faulty or the inverter's own hardware is faulty.

Disposal method: Disconnect the output line of the inverter, measure the three relative ground insulation conditions and three-phase power group with a megohmmeter. If there is a problem with the motor or cable, replace the motor and cable; if the output is normal, check the inverter's master. Circuit, mainly check IGBT, inverter block and rectifier bridge. How to determine whether IGBT, inverter block and rectifier bridge are normal, here I have tested the above good electric device with multimeter diode file, and the test results are as follows:

1 For IGBTs, the black meter of the multimeter measures C, and when the red meter measures E, the resistance is about 0.34MΩ, and vice versa. The other four conditions are all infinite.

2 For the inverting block, the black meter of the multimeter measures the positive polarity, and when the red meter measures the negative pole, the resistance value is about 0.67 MΩ, otherwise it is infinite. The multimeter's black meter pen measures the grounding electrode. When the red meter pen measures the negative electrode, the resistance is about 0.34MΩ. Otherwise, the resistance is infinite. The black meter of the multimeter measures the positive pole, and when the red meter measures the grounding pole, the resistance is about 0.34MΩ, and vice versa.

3 For the rectifier bridge, the black meter of the multimeter is measured 1 and when the red meter is 3, the resistance is about 0.37 MΩ, and vice versa. The other four conditions are all infinite.

If the test result deviates too much from the above result, it is recommended to replace it. If it is considered to reduce the impact of maintenance on production time, I suggest that it is preferable to replace the inverter directly because replacing one inverter

The device needs time to be controlled, about 2h, and because of the SHORT CIR-CUlT fault code maintenance, the time is much longer than 2h, and the time is not controllable.

1.4 Failure Code: AMBINET TEMP

Fault reason: The operating environment temperature of the inverter is too low.

Treatment method: Air conditioning in the electrical room is considered to increase air conditioning and increase the working environment temperature of the inverter. If emergency recovery is desired, you can use a hair dryer and other heating tools to increase the ambient temperature.

2, the main circuit analysis

The main circuit analysis method starts from the main circuit of the frequency converter and analyzes the causes and solutions of the faults. According to experience, when the main circuit fault of ABB inverter is met, the following aspects can be started.

2.1 Filter Capacitor Caused Failure

Cause of failure: The grid voltage is unstable, and the internal temperature is too high, and the component performance is not good.

Solution:

1 The main equipment is unstable and susceptible to electromagnetic interference;

2 Replace high-quality components to improve ventilation.

2.2 Frequency Converter Over Temperature

Cause of failure: The fan does not turn and the air duct is blocked.

Solution:

1 Check if the fan coil is damaged;

2 Clean up cold air duct dust, such as oil shortage, should be added light oil, add some solid grease;

3 When replacing the new cold air fan, pay attention to some fans with automatic rotation signal, and some without the fan rotation signal, change the original model fan.

2.3 The output current is too large

Cause: The output current exceeds the set limit and trips.

Solution:

1 Check whether the motor load is short-circuited;

2 Check that the motor brake is fully open;

3 Check whether the mechanical rotation device is flexible;

4 Judging whether there is temperature rise, odor, or abnormal noise during the operation of the asynchronous motor;

5 After confirming the fault of the motor and winding coil, pay attention to the original model and parameters when changing.

2.4 brake failure

Cause of the fault: The brake is not running properly, the signal limit of the in-position signal does not work, and the brake is mechanically faulty.

Solution:

1 Check whether the brake power supply is normal;

2 Check whether the brake mechanical transmission is normal;

3 check brake coil failure;

4 Check brake limit and return signal;

5 Check if the contactor is normal.

6 The contactor's main power failure is caused by a bad contact or loose contact screws. The repair and replacement of new components are to be adopted. Brake damage should be taken from the new offline and replaced, and pay attention to the original model and parameters when replacing.

2.5 encoder failure

Cause of fault: The inverter has detected an error in the data signal fed back by the encoder or interrupted communication.

Solution:

1 Check if the encoder is connected to the motor or equipment.

2 Check if the encoder signal cable is in good condition;

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

4 Check if the encoder is disturbed by surrounding equipment;

5 Correct the encoder position to exclude other interference.

2.6 Interference failure

Cause of failure: mainly conducted and electromagnetic induction.

Solution:

1 It is mainly to check whether each grounding line is good;

2 Check if each shielded cable is connected properly.

The above are the typical faults and solutions that have appeared during the use of ABB inverters in recent years. In order to effectively reduce the failure rate of the inverter, it is essential for daily inspection and maintenance.

Periodically remove dust, regularly check whether the bolts are loose, check whether the cooling fan is running normally, check the cables and signal lines for looseness, overheating, and deformation. Check whether the heat-dissipating silicone on the rectifier modules and inverter modules is dry and check the wiring of the control system. Whether the electronic components are abnormal or not is the main starting point for inspection and maintenance.