ABB · AC Drives & VFDs
ABB ACS800 repair
ABB ACS800 drives repaired at component level, from single drives on pumps and fans to cabinet-built multidrives, by engineers on MachineryFix.
Cost confirmed before any work starts · Warranty of 30 days to 6 months
About this model
The ABB ACS800
The ACS800 is ABB's long-running industrial AC drive, found across Indian cement, steel, paper, water and chemical plants on pumps, fans, conveyors, extruders and winders. It comes as wall-mounted single drives, free-standing cabinet drives and multidrive line-ups sharing a common DC bus, and many units in service today have been running for well over a decade.
ABB has moved new projects to the ACS880, so ACS800 spares are getting harder to find. Component-level repair keeps these drives running without re-engineering the panel or the process: the failed stage, whether an IGBT module, DC capacitors, a fan, a gate-drive board or the control unit, is found and replaced, and the drive is tested on its own motor and load.
Engineers on MachineryFix work on the full ACS800 range. An engineer can come to the plant from our Hyderabad base, or the drive or the failed module can be sent to MachineryFix from anywhere in India and routed to an engineer who works on ACS800s.
Common faults
What goes wrong on the ACS800
Overcurrent and short-circuit trips
An ACS800 that trips on overcurrent at start, or reports a short circuit, usually has a failed IGBT, a damaged motor cable or a motor insulation fault. The motor and cable are tested with the drive disconnected before the power stage is opened.
DC overvoltage on deceleration
Fast deceleration of high-inertia loads such as fans and centrifuges pushes energy back into the DC link. A failed braking chopper or resistor, or a deceleration ramp set too short, causes the trip.
Overtemperature
Blocked air paths, failed cooling fans and hot electrical rooms. ACS800 cooling fans have a finite life and are a routine replacement on older drives; a drive that overheats in summer often just needs its fans and filters attended to.
Earth faults
Insulation breakdown in the motor or cable, moisture in a terminal box during the monsoon, or a failing current measurement circuit inside the drive. Insulation is measured with the motor isolated from the drive.
Supply and charging faults
Supply phase loss, a failing input stage or ageing DC capacitors show up as supply or undervoltage faults, often after a power disturbance.
Fault codes
ACS800 fault codes
Codes and names as ABB lists them; the explanations are ours. Check the manual for your firmware version before acting on a code.
| Code | Name | What it usually means |
|---|---|---|
| 2310 | OVERCURRENT | Output current exceeded the trip limit. Check the load and acceleration ramp first; if it trips at start with no load, suspect the power stage or motor cable. |
| 2330 | EARTH FAULT | Current is leaking to earth. Test motor and cable insulation with the drive disconnected before resetting. |
| 2340 | SHORT CIRC | A short circuit in the motor, cable or output stage. Do not reset repeatedly; this often means a failed IGBT or a cable fault. |
| 3130 | SUPPLY PHASE | The intermediate circuit voltage is oscillating, usually from a missing supply phase or a blown input fuse. |
| 3210 | DC OVERVOLT | The DC link voltage is too high, typically during deceleration. Check the braking chopper and resistor and the deceleration time. |
| 3220 | DC UNDERVOLT | The DC link voltage is too low: a supply dip, a missing phase or a failing input stage. |
| 4210 | ACS800 TEMP | The drive's power stage is too hot. Check cooling fans, filters, heatsink cleanliness and the room temperature. |
| 4310 | MOTOR TEMP | The motor temperature model or sensor reports overheating: overload, poor motor cooling or wrong motor data. |
| 5300 | PANEL LOSS | The control panel selected as the control location has stopped communicating: a loose panel, cable or connector. |
| 7121 | MOTOR STALL | The motor is running in the stall region: a jammed load, a brake not releasing or limits set too low. |
2310
OVERCURRENT
Output current exceeded the trip limit. Check the load and acceleration ramp first; if it trips at start with no load, suspect the power stage or motor cable.
2330
EARTH FAULT
Current is leaking to earth. Test motor and cable insulation with the drive disconnected before resetting.
2340
SHORT CIRC
A short circuit in the motor, cable or output stage. Do not reset repeatedly; this often means a failed IGBT or a cable fault.
3130
SUPPLY PHASE
The intermediate circuit voltage is oscillating, usually from a missing supply phase or a blown input fuse.
3210
DC OVERVOLT
The DC link voltage is too high, typically during deceleration. Check the braking chopper and resistor and the deceleration time.
3220
DC UNDERVOLT
The DC link voltage is too low: a supply dip, a missing phase or a failing input stage.
4210
ACS800 TEMP
The drive's power stage is too hot. Check cooling fans, filters, heatsink cleanliness and the room temperature.
4310
MOTOR TEMP
The motor temperature model or sensor reports overheating: overload, poor motor cooling or wrong motor data.
5300
PANEL LOSS
The control panel selected as the control location has stopped communicating: a loose panel, cable or connector.
7121
MOTOR STALL
The motor is running in the stall region: a jammed load, a brake not releasing or limits set too low.
First checks
What to check before calling an engineer
Safe for plant staff
- Read the fault code and fault history from the control panel, and note what the drive was doing when it tripped.
- Check that the cooling fans run and that filters and heatsinks are not blocked with dust.
- Check whether other drives on the same supply tripped at the same time, which points to the supply.
- Disconnect the motor and test its insulation with a suitable tester before restarting after an earth or short-circuit fault.
Leave to a specialist
- Any work inside the drive: ACS800 DC links hold a dangerous charge after isolation and need the waiting time in the manual.
- Replacing IGBT modules, capacitors, gate-drive or control boards.
- Changing motor data, control mode or protection parameters on a drive running a critical process.
- Work on multidrive line-ups that share a DC bus with other drives.
Getting it fixed
How to get a ACS800 repaired
Technicians work onsite from our Hyderabad base and travel to plants across India; anything that can be removed can also be sent to MachineryFix from anywhere in the country. The diagnosis and repair cost are confirmed before any work starts.
Warranty. Repairs carry a warranty of 30 days to 6 months, depending on the item and the repair; the exact term is confirmed before work starts.
FAQ
ACS800 repair questions
Is the ACS800 still worth repairing now that ABB sells the ACS880?+
Usually, yes, for drives that are otherwise healthy. Repair keeps the panel, cabling and settings unchanged and avoids an engineering project. Where a drive keeps failing or spares can't be found, the engineer will say so and outline a migration to a current drive.
Can an ACS800 be repaired onsite?+
Fan, capacitor and many board replacements can be done onsite. Power-stage repairs on larger drives are often done on a bench and the drive or module refitted. Either way, it is tested on the motor and load before handover.
How do I send an ACS800 for repair?+
Send the drive or the failed module to MachineryFix with the model, rating and fault code. It is routed to an engineer who works on ACS800s, and the diagnosis and repair cost are confirmed before any work starts.
Will our parameters be kept?+
Parameters are read and saved before work where the drive allows it, and restored afterwards. If the control unit has failed, settings are rebuilt from your records or the motor and process data.
Is there a warranty on the repair?+
Yes. Repairs carry a warranty of 30 days to 6 months, depending on the item and the repair; the exact term is confirmed before work starts.
Same manufacturer
Other ABB AC Drives & VFDs
ABB and ACS800 are named only to identify the equipment. MachineryFix is not affiliated with or endorsed by ABB.
ACS800 down?
Send the fault code and what the machine was doing. We'll match an engineer who works on it.