ABB Drives Service

Field Service Report

Field Ser vice Report

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

2 Installed Base Information

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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)

SAMAC MMA/PMMA PROJECT.

CTCI

City Road 184, Jubail Industrial Area,Al- Jubail, 31951,

Kingdom of Saudi Arabia.
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Country
Site Type

2.2 Product and Service History

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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

ABB Drives Service Field Service Report Page 2 of 7

 Industry Petrochemical
Process
Nominal Inverter power [kVA] 1864.000

3 Report On-Site Activities

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Field Service Type

Date service visit started 26.03.2017

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Yes No Comments
Commissioning X
Repair X
Preventive Maintenance X
Upgrade
IN X

3.1 Faults and Repair

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3.1.1 Fault 1

Yes No Comments
Fault 1 X
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Fault 1

Fault Category Voltage (over, under, NP voltage)

Date of Fault 26.03.2017
Warranty Order No.
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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,

ABB Drives Service Field Service Report Page 3 of 7

after some time aux incoming control supply(480V) feeder got tripped. Drive stopped, MCB got
trip command and it got opened. During dc voltage discharge, together with motor coasting there was a
sound from sine capacitor, (sound was not noticeable due to fan sound) and with serious of faults to-
gether noticed in fault history. In drive window its captured that DC over voltage, over current, short
circuit ,self excitation etc., and noticed that flux generated during motor coast and motor rms current was
still present in the system. which is abnormal.

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.

as a preliminary suspect, we have noticed graphs after trip is abnormal, either

this issue is with self excitation phenomena which is resulting RMS current to be
present in the system, and when motor stator frequency match with sine filter ex-
citation frequency, resonance is taking place between motor and sine filter, result-
ing failure of components.
In normal coast stop, drive will bring motor speed to less than 1343 rpm which is
calculated has self excited frequency and release coast stop.

ABB Drives Service Field Service Report Page 4 of 7

 But if in case when motor is running above exc.speed and drive got tripped and opened MCB, drive
will make current zero. so that it wont be taking care about motor safe stopping after self exc.speed.

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.

Refer previous page signal description

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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

ABB Drives Service Field Service Report Page 5 of 7

 Diode 3BHL000396P000 INU1-V4026
1
Diode 3BHL000396P000 INU1-V4046
1
IGCT / IGBT / 3BHL000392P010 INU1-V4024
phase module 1
IGCT / IGBT / 3BHL000392P010 INU1-V4044
phase module 1
Diode 3BHL000396P000 INU1-V4038

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1

3.2 Performed Recommended Services

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3.2.1 Preventive Maintenance and Upgrades

Preventive Maintenance and Upgrade

Kit Name Description Due Date Closed Date

ACS1000 PM 1y Preventive replacement 11.12.2016
of air filters.
ACS1000 PM 2y Preventive replacement
IN 11.12.2017
of filter cartridge and
deionizer. NOTE:
Select appropriate
deionizer dependent on
pump type (CM or CHI
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type).
ACS1000 PM 4y Preventive replacement 11.12.2019
of fans and pumps in
case of no redundancy.
NOTE: Rebuild kit for
pumps available in
order to update
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redundant and non-

redundant water-cooled
drive types to latest
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.

ABB Drives Service Field Service Report Page 6 of 7

 ACS1000 PM 8y Preventive replacement 11.12.2023
of fans and pumps in
case of redundancy.
NOTE: Rebuild kit for
pumps available in
order to update
redundant and non-
redundant water-cooled
drive types to latest

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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.

3.3 Service Summary

Summary of Performed Services IN

Date service visit ended 26.03.2017
Drive Status under commissioning
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Yes No Comments
Commissioning completed? X
Drive tested and running in normal operation after
X
repair?
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Summary of Performed Actions

Drive meggering and startup completed

successfully, during motor trails over voltage
followed by over current fault occured in drive.
Summary of performed actions
drive components failed warranty has been
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claimed for defective materials, root cause for

probelm yet to be analysed.

ABB Drives Service Field Service Report Page 7 of 7