ACS800 TEMP (4210) fault.

I have ACS800-01-0120-3 drive which is tripping with 4210 fault when ever powered up.
Till now I have changed RINT,RVAR, RMIO & temperature sensor. But still fault is present in the drive.

Can you suggest any other options which I could try. Even ABB engineer is unable to solve this issue.

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rajeevvapl Rank: 3142

Asked 1 year ago

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Hi
the fault indicated regard the IGBT module of your drive. Probably, if you should try to change one parts of the drive, you need to change the power unit - IGBT modules - of your drive and test particularly the temperature probe inside the IGBT modules.

Hope this help you

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by rajeevvapl Rank: 3142 on 2/11/2019 11:36:52 PM | Like (0) | Report

I have bypassed all 3 IGBT's one by one by physically disconnecting IGBT to RINT cable and powered up the drive even though fault remains same.

by rajeevvapl Rank: 3142 on 2/11/2019 11:45:14 PM | Like (0) | Report

Can you share any circuit diagram or manual explaining how RINT card is sensing temp from IGBT module connecting pins(4,5/6,7).
As temp sensor connected to X33 of RINT card gives PP temp value but how does IGBT temp is sensed in ACS800 TEMP parameter.

by Flavio Mussolin AKS expert

Rank: 4 on 2/12/2019 12:07:53 AM | Like (0) | Report

The internal connection diagrams are exclusively for the ABB service technicians.
Have you tried to contact the ABB service in your area?

by rajeevvapl Rank: 3142 on 2/12/2019 12:10:01 AM | Like (0) | Report

Yes, they have visited our site but they failed to analyse the root cause of this issue.

by Flavio Mussolin AKS expert

Rank: 4 on 2/12/2019 12:20:17 AM | Like (0) | Report

So in this case, if the service technician could not solve the issue, you need to consider to substitute the drive, because the repair of the unit it may not be convenient. Please also note that you have to reconstruct the cause of the failure, that is, what it originated from

by rajeevvapl Rank: 3142 on 2/12/2019 12:23:45 AM | Like (0) | Report

OK... But is there any way to check the temp sensor of IGBT module

by Flavio Mussolin AKS expert

Rank: 4 on 2/12/2019 12:32:59 AM | Like (0) | Report

Probably yes, I think it's possible. Having the correct documentation and the necessary skills, I think it can be done. But do you really need it? If a fundamental control such as temperature control is compromised, I would not try to bypass this control in your place, perhaps jeopardizing a large production plant. ACS800 is a product that came out of production, I not know how many years of work has your drive but a thought in the replacement, perhaps it is useful to do it

by rajeevvapl Rank: 3142 on 2/12/2019 12:40:14 AM | Like (0) | Report

We 587 No.s of ABB drive with AcS800 ACS550 & ACS880 drives installed at different units of our plant. We are in process of upgrading all AcS800 drives with 880 but the installed quantity of ACS800 is more which will take time to get fully upgraded.
So, being an responsible person for maintain the drives I need to know how to identify the faulty temp sensor of an IGBT module.
Also, I worked 3yrs previously in ABB as well but didn't performed in depth analysis before for this ACS800 Temp fault.

by Flavio Mussolin AKS expert

Rank: 4 on 2/12/2019 1:05:51 AM | Like (0) | Report

My congratulations for your experience and for the large number of drives you have installed. Obviously, I can not know each other's experiences and I have to make suggestions inspired by general concepts and prudence.
When I write about the necessary experience and the appropriate documentation, I refer to those diagrams of the internal parts of the drives that are not made available to users but only to ABB's assistance centers.
You could try, since you have the necessary experience, to replace the entire block of IGBT and the interface of temperature acquisition. Again, without schemes, I understand that it is not easy to do.

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Flavio Mussolin AKS expert

Rank: 4

Answered 1 year ago

As per the Fault code reference,

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Deepak.S Rank: 24

Answered 1 year ago

Source: 3AUA0000085967

Hi,

In case you replaced the main boards and think the HW parts are OK, the possible solution could be re-loading of the firmware of the drive.
But you need a correct software and firmware files, which usually belongs to authorised ABB Service technicians.
Unfortunately that could not be a reason, if you replaced RMIO board.
You have to know, that the power of the unit is loaded in FW / RMIO. In case you replace the RMIO it could be "programmed" for smaller power unit, e.g. ACS800-01-0025 and not for ACS800-01-0120 as your drive.
That parameter is hidden and should be set in the factory, when you order the spare RMIO board, or changed later during installation, from ABB service
Another option is to try disconnect the encoder board - one time it creates a problems to me, but not with that fault message

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by rajeevvapl Rank: 3142 on 2/12/2019 2:05:14 AM | Like (0) | Report

For the same reason I have already replaced old RMIO card with new RMIO card with crane firmware but fault is still there.

by rajeevvapl Rank: 3142 on 2/12/2019 2:07:15 AM | Like (0) | Report

Yes, I have encoder board installed in the drive.

kstoilov

Rank: 6 on 2/12/2019 2:13:14 AM | Like (0) | Report

look again my answer, I modified it. Check RMIO's firmware version and for what type code it is programmed

kstoilov

Rank: 6 on 2/12/2019 2:17:31 AM | Like (0) | Report

That is a last possible reason for the fault, described in FW manual:
"Check motor power against unit power."

by rajeevvapl Rank: 3142 on 2/12/2019 2:21:13 AM | Like (0) | Report

As of now I am powering up the drive without motor connected to it.
And I have also changed the firmware rating to 120KVA byusing pass code 564.

As of now I am arranging IGBT module to replace it. That's the only last activity that is left to do. I will update once I finish it.

kstoilov

Rank: 6 on 2/12/2019 2:23:49 AM | Like (0) | Report

:-)
Hopefully not so much modules in ACS800-01

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kstoilov

Rank: 6

Answered 1 year ago

Hello

Did you resolved the issue, Im also facing same issue of trip with 4210 after just power on the drive.
Please let me know the exact cause and solution.

Thnaks

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kannan07c Rank: 1729

Answered 6 months ago

I have the same problem with the same ABB drive model, did you find the solution?

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eduardo_3575 Rank: 2193

Answered 1 month ago

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ACS800 TEMP (4210) fault.

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