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Repair of ABB ACS800 Drive – Case Study

Comprehensive ABB ACS800 repair services ensuring dependable performance, quick turnaround, and long-lasting results for your automation systems.

1. Background

  • Client: Wind farm operator using Gamesa G80/G90 turbines
  • Turbine Type: Gamesa (2.0 MW capacity)
  • Inverter Model: ABB ACS800-104-0580-7 regenerative drive
  • Location: Texas
  • Date: July 2023

2. Problem Statement

The wind turbine was experiencing intermittent faults leading to repeated shutdowns. Upon
inspection, the inverter (ABB ACS800-104-0580-7) was suspected to be the source of the issue.
The error codes indicated:

  • Overcurrent fault
  • DC overvoltage
  • Communication fault with the turbine controller

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3. Initial Diagnosis

  • Visual inspection revealed no external damage.
  • Fault logs indicated irregular DC bus voltages and overcurrent conditions.
  • IGBT status logs showed one phase experiencing intermittent switching failures.
  • Cooling fans were operating below spec, and thermal sensors were logging unusually high temperatures.

4. Repair Procedure

Step 1: Disassembly and Component Testing

  • Removed the inverter from the nacelle and transported to workshop.
  • Conducted full cleaning to remove dust and debris.
  • Inspected control board, power board, capacitors, and IGBT modules.
  • Found one IGBT module partially failed (thermal stress cracking).
  • DC bus capacitors showed signs of degradation (ESR out of tolerance).

Step 2: Component Replacement

  • Replaced faulty IGBT module.
  • Replaced aging electrolytic capacitors on DC link.
  • Replaced cooling fans and cleaned heatsinks.

Step 3: Testing

  • Bench tested the repaired inverter.
  • Ran ABB ACS800 inverter in the test stand for 8 hours.
  • Verified voltage regulation, current handling, and thermal performance.
  • Passed all diagnostic tests with 100% compliance.

5. Reinstallation and Commissioning

  • Reinstalled inverter in turbine nacelle.
  • Conducted cold start and full load test.
  • Verified grid synchronization, MPPT tracking, and response to variable wind input.

6. Results

MetricBefore RepairAfter Repair
Uptime78%99.5%
Fault Rate5 per week0 in 3 months
Output Power StabilityFluctuatingStable
Maintenance CallsFrequentNone (since repair)

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7. Lessons Learned

  • Regular preventive maintenance and thermal imaging could have identified the IGBT degradation earlier.
  • Cleaning inverter, upgrading fans and monitoring cooling system health is critical in high-altitude, high-heat, or high-dust environments.

8. Conclusion

The repair of the ABB ACS800 inverter restored full operational capacity to the Gamesa wind turbine. Through targeted diagnostics and component-level repair, the client avoided a costly full inverter replacement and minimized turbine downtime.