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Table of contents:
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1 Service Provider ............................................................................................................................... 2
2 Installed Base Information .............................................................................................................. 2
2.1 Customer Information .............................................................................................................. 2
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2.2 Product and Service History .................................................................................................... 2
3 Report On-Site Activities ................................................................................................................. 3
3.1 Faults and Repair .................................................................................................................... 3
3.1.1 Fault 1 ...................................................................................................................................... 3
3.2 Performed Recommended Services ........................................................................................ 6
3.2.1 Preventive Maintenance and Upgrades .................................................................................. 6
3.3 Service Summary .................................................................................................................... 7
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1 Service Provider
ABB Engineer
E-mail g.darshan@sa.abb.com
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2.1 Customer Information
Project Information
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Project Name CTCI Piller VSD 4201
End User
Site Information
Site name
Site Operator
Site Owner
IN Saudi Methacrylates Company's (SAMAC)
Product Info
Product ACS1000
Serial Number 3BHB901006083
Status under commissioning
Manufacturing Location Switzerland - Turgi
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ACS1144-A3-P0-00-SQ20-F0NM-3C10-055C-
Type Code
000A0-EN
ACS1144-A3-P0-00-SQ20-F0NM-3C10-055C-
Manufacturing Key
000A0-EN
Full Common TypeCode
Date of Delivery 11.12.2015
Date of Commissioning
Commissioning Engineer DARSHAN GIRISH*
End of Warranty 30.06.2018
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Field Service Type
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Yes No Comments
Commissioning X
Repair X
Preventive Maintenance X
Upgrade
IN X
Yes No Comments
Fault 1 X
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Fault 1
Fault Description
On 260317, trails with uncoupled motor was carried out, its observed that drive
tripped on series of faults. Explained below. 1. We ran motor up to 2500rpm, ini-
tially start took two min. to release ready reference because of magnetization and
fly start ,
Fault Description
once flux released to 100%, motor started running with given speed ref. in local
mode,
2. Second time we have started drive again after ensuring drive is OK after first incident, drive-started
normal with like first time. When we try to ran motor up to 3345 rpm drive tripped on motor over speed.
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And trip loop was opened by DCS following drive trip, after some 5sec during dc voltage discharge
same above phenomenon repeated, with some spark and sound near sine capacitor.
;Second trip I am explaining here: drive was running at 3000rpm parameter 20.02 speed limit was set
3600, over speed limit was set 3300, and I tried to give reference of 3345 which was max speed of motor
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as motor DS. Drive tripped on motor over speed fault. Please note that drive was running with
field weakening mode (base speed is 2988). This was requirement form customer during trials to in-
crease, motor speed more than base speed. we didn't change over speed limit, we did
increased speed limit and reference set point,
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Refer trend on next page.,
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Solution Description
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Solution Description
when coast stop method is selected and drive got tripped, depending upon
class of fault drive will choose whether to trip MCB or only switch OFF motor
with keeping dc bus energized, but here trip loop is looped via dcs , so any
sort of trip drive will receive MCB trip command from DCS.
Further action,before proceeding for next trails after faulty components replacement. after replacement
of components factory asked carryout below.
1. Insulation resistance test of drive installation.
2. Measurements of all values , semiconductors,filters.
3. Parameter changes to avoid components failure during drive trip above self excitation or resonance in
system.
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4. VSD 4201 cooling FAN designed for 50HZ, whereas supply voltage is 60HZ due to which motor is tak-
ing 20 amp instead 14 amp clarification from supplier
5. Trails with partial load, or full load. (Not confirmed), or no load trials with ramp stop method
6. 480V Aux Feeder supply MCCB got tripped during trails, and noticed that max setting is 20Amp
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whereas we need 23 Amp MCCB feeder
Note: with coupled condition resonance condition will not happening, and its valid only in decoupled con-
dition.
However final failure analysis is still been carried in ABB R&D department which will take some time.
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List of Replaced Parts
Part Type
IGCT / IGBT /
phase module
IGCT / IGBT /
phase module
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Part No.
3BHL000392P010
1
3BHL000392P010
1
Position
INU1-V4042
INU1-V4021
Old S/N New S/N
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IGCT / IGBT / 3BHL000392P010 INU1-V4041
phase module 1
Diode 3BHL000396P000 INU1-V4025
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1
Diode 3BHL000396P000 INU1-V4045
1
IGCT / IGBT / 3BHL000392P010 INU1-V4022
phase module 1
IGCT / IGBT / 3BHL000392P010 INU1-V4023
phase module 1
IGCT / IGBT / 3BHL000392P010 INU1-V4043
phase module 1
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1
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3.2.1 Preventive Maintenance and Upgrades
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HW release. Select
appropriate pump and
choose rebuild kit in
case of pump update.
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Pump rebuild kit may
not be suitable if drive
has been delivered
before 2003.