I am seeking assistance with a current issue I am facing concerning an ABB drive. The problem I am encountering is that the ABB drive supplying power to a large fan is unable to reach 100% speed without tripping due to supply loss, even though there is no fault indication. I have two drives operating the exact same spec fans, but I only experience issues with one drive when it has been inactive for extended periods. When ramping from 98-100% speed, the drive will trip. I have attempted various solutions such as code traps, reaching out to ABB service support, and changing hardware. Occasionally, the drive will inconsistently reach 100% speed, but once it does, it remains stable until the next maintenance outage. Currently, I am running the drive at 98% after the maintenance period. I am seeking expert assistance to address this persistent issue. Any help would be greatly appreciated.
After reaching optimal temperature, could you please restore it to its full capacity of 100%? This is quite unusual...
Unfortunately, the system did not function properly, running at 95% for 24 hours before attempting to ramp up to 100%, but encountering the same issue. It is indeed a peculiar situation, with no response from the ABB service team.
Can you provide additional information such as the VFD's nominal power, nominal input voltage, power supply type (direct to grid/transformer, etc), and acceleration ramp time? What is the motor's nominal power and nominal speed? In what scenarios does the VFD decrease output voltage without notification, particularly when attempting to exceed 95% of the nominal motor speed, maximum reference frequency set on the VFD, or another speed parameter?
If your centrifugal fan is experiencing power loss, it is likely due to a drop in its power supply. As fan speed increases by just 2%, the drive will require significantly more power. For a detailed explanation, refer to the Third Fan Law found in the link below: Understanding the Basic Fan Laws - Axair Fans. Gain insight into pressure, power, and air volume with our practical examples. Visit our website for more information. Remember to monitor supply voltage across the fan speed spectrum.
It certainly sounds like a frustrating issue you're facing. One possibility might be that this drive could have a slight misalignment or imbalance when it's starting. When idle for long periods, materials can settle or shift slightly, potentially causing imbalance only at highest operational levels like 98-100% speed. When you do manage to get to 100% speed, it could be due to all elements eventually syncing up or ‘running in’. You may consider a thorough examination of the physical installation and maybe a dynamic balancing test if you haven't done so already. Additionally, in parallel consider thoroughly examining the running data logs (VFD and system operational logs) to search for any abnormality that might be happening exclusively at those peak speeds. If you have an identical system running without faults, compare the data for any significant differences. Debugging this way might uncover a clue to help rectify the issue.
It sounds like you've certainly covered a lot of ground trying to troubleshoot this issue. In my experience, this kind of intermittent behaviour often hints towards a thermal problem or a weak component somewhere. If the drive heats up differently when it's been inactive for a while, that might explain the tripping when you push to 100%. It could also be tied to a voltage/rating issue. My suggestion would be to thoroughly check the power ratings and the environment in which the drives are operating. Try comparing temperatures between the problematic drive and the functioning one, both after inactivity and while under load. It might also be worth looking into power quality issues or any anomalies in your power supply chain.
From your description, it sounds like the issue could be related to a problem with the drive's ramp up speed or potentially a voltage imbalance. I'd suggest examining any differences in power supply quality between your two drives, as well as checking your PID loop settings. It's also possible that your drive is experiencing a thermal overload during the ramp-up stage. You might consider using a thermal imaging camera to identify any areas of heat build-up during this time. Finally, if none of these suggestions work, it could be worthwhile to have ABB service support examine the drive logs directly, as they might be able to spot something you're missing.
It sounds like you're dealing with a frustrating situation! Since you've already tried a number of troubleshooting steps and the issue seems tied to how long the drive has been idle, it might be worth investigating the parameters related to the motor start conditions or settings around the acceleration ramp. Sometimes, extending the ramp-up time or checking for any variances in the power supply during that critical range can help. Also, consider if there's any environmental factors or thermal conditions affecting the drive after it's been inactive for a while. Good luck, and hopefully, you'll find a solution soon!
It sounds like a frustrating situation, especially with the inconsistency when trying to get to 100% speed. Given that this only happens after periods of inactivity, it could be worth checking the drive’s settings for any parameters related to soft starting or overload protection, as these might be kicking in prematurely. Additionally, consider the possibility of a thermal issue that might not trigger a fault but affects performance when the drive is pushed to its limits. If you're not already doing so, running a full analysis on any logged events during the trips could provide more insight. Sometimes, a detailed look at the cooling or environment around the drive can reveal underlying issues contributing to these trips. Good luck!
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Answer: Answer: The issue could be related to supply loss during the ramp-up process, especially after extended periods of inactivity. It's recommended to investigate the power supply stability and potential voltage fluctuations.
Answer: Answer: Some suggested troubleshooting steps include checking the power supply quality, reviewing the drive's configuration and settings, ensuring proper ventilation and cooling for the drive, and examining the motor and fan system for any anomalies.
Answer: Answer: The intermittent success in reaching and maintaining 100% speed could be due to various factors, such as temporary improvements in power supply conditions or other external influences. It's important to investigate these instances further to identify the root cause.
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