ABB ACS800 Repair
Expert ABB ACS800 Direct Torque Control drive repair — 0.55kW to 5600kW, all cabinet configurations. AINT/RMIO/D2D board repair, IGBT module replacement. 48-hour turnaround. Pan India.
India's most experienced ABB ACS800 repair centre. With ACS800 DTC architecture expertise, BSM-series IGBT modules in stock, and 48-hour turnaround on most repair scopes, we return your high-performance drive to full operation — at a fraction of the cost of OEM replacement.
The ABB ACS800 is ABB's flagship high-performance drive, built around ABB's proprietary Direct Torque Control (DTC) algorithm — delivering precise torque and speed control without encoder feedback. Deployed extensively in Indian paper mills, steel plants, cement factories, mining operations, and crane systems, the ACS800 range spans from compact single drives (0.55kW) to multi-megawatt drive systems (5600kW). Common failure modes include IGBT module (BSM series) failure, AINT inverter board faults, RMIO control board degradation, D2D fiber optic adapter failure, and DC bus capacitor ageing. Synchronics has repaired over 3,800 ACS800 units and holds detailed knowledge of both the single-drive and multi-drive (RDCU + AINT) architectures.
Diagnosis Guide
Common ABB ACS800 Problems We Fix
Experiencing any of these symptoms? Our engineers have diagnosed and repaired thousands of these faults.
Fault 2310 — Overcurrent
Drive trips immediately at start or during acceleration, no motor output, possible blown pre-fuse
IGBT shoot-through failure, motor winding insulation breakdown, output cable short, load jam causing instantaneous current spike
Fault 7121 — Drive Overtemperature
Drive trips after running for a period, temperature warning precedes trip, cooling fan audible or absent
Cooling fan failure, heat sink contamination, thermal compound dried, high ambient temperature, sustained overload operation
Fault 2320 — DC Overvoltage
DC bus overvoltage trip during deceleration or coasting, possible on regenerative loads
Braking chopper or resistor fault, deceleration ramp too aggressive, drive mains voltage above rated limit
Fault 3211 — Input Phase Loss
Drive trips, DC bus voltage low, input rectifier output unbalanced
Input fuse blown (one phase), supply contactor fault, input choke connection loose, supply transformer issue
Fault 7010 — Panel Communication Loss
CDP/CDP312R panel shows communication error, drive parameters inaccessible, panel display blank
CDP panel cable damaged, RMIO communication port fault, panel connector corrosion, firmware mismatch
Fault 4110 — Control Board Overtemperature
RMIO or AINT board internal temperature alarm, drive derate or trip at high load
Cooling fan air not reaching control boards, internal duct blockage, high ambient, fan speed feedback fault
How It Works
Our ACS800 Repair Process
A systematic, schematic-driven repair process — from receipt to dispatch.
Receipt & Configuration Recording
ACS800 drive type, option codes, and firmware version recorded. CDP panel parameters downloaded where possible. Visual inspection for arc damage, contamination, burnt components on AINT and RMIO boards.
IGBT and Power Stage Test
IGBT modules tested in-circuit — gate-emitter threshold, collector saturation voltage, and reverse diode characteristics measured. AINT board gate signals verified with oscilloscope on isolated supply.
Board-Level Fault Isolation
RMIO and AINT boards separated and tested independently. Fiber optic D2D link signal levels measured. Fault is isolated to specific board and component before any replacement is made.
Component Replacement
Failed IGBTs (BSM series), gate driver ICs, optocouplers, electrolytic capacitors, and passive components replaced from 2M+ inventory. AINT fiber optic transceivers replaced if D2D link is degraded.
DTC Configuration & Motor ID
RMIO firmware verified, motor nameplate data entered (Group 99), and Motor ID Run performed to calibrate DTC torque model. DDCS communication and I/O tested.
Load Test & Dispatch
Full load bank test at rated current with torque step response measured. Thermal imaging of IGBT modules and heatsink. 6-month warranty certificate and detailed repair report issued.
Thorough Inspection
ACS800 Component Inspection Checklist
Every unit goes through a comprehensive inspection checklist before and after repair.
IGBT Power Module (BSM Series)
AINT Inverter Board (A5E00124754)
RMIO Control Board
D2D Fiber Optic Adapter
DC Bus Capacitor Bank
Cooling Fan Assembly
The Synchronics Advantage
Why Choose Us for ABB ACS800 Repair
DTC Architecture Expertise
We understand the ACS800 DTC motor model calibration process — Motor ID Run, flux reference tuning, and torque ripple verification. Repaired drives are not just electrically restored, they are re-calibrated for correct DTC operation.
Multi-Drive System Support
We repair ACS800 multi-drive systems including RDCU + AINT configurations, APBU splitter boards, and D2D fiber links — the complete high-power parallel inverter architecture.
48-Hour Turnaround
Most ACS800 single-drive repairs are completed within 48 hours. Large cabinet and multi-drive systems are assessed individually — we provide a realistic turnaround estimate with the repair quotation.
Troubleshooting
ABB ACS800 Fault Codes We Fix
Seeing one of these error codes? We diagnose and repair the root cause.
Overcurrent — motor current exceeds 3.5× drive rated current
IGBT failure, motor winding short, cable insulation breakdown, load jam
DC overvoltage — DC bus exceeds maximum safe level
Braking chopper fault, deceleration too fast, regenerative load energy, mains overvoltage
DC undervoltage — DC bus below minimum threshold
Mains phase loss, input fuse blown, capacitor bank degradation, charging circuit fault
Short circuit — output short circuit detected
IGBT shoot-through, motor cable phase-to-phase fault, output terminal short
Input phase loss — one input phase missing
Input fuse blown, contactor fault, supply cable loose connection
Control board overtemperature — AINT/RMIO temperature limit
Cooling fan fault, internal air duct blockage, high ambient temperature
Panel communication loss — CDP panel not responding
CDP cable fault, RMIO communication port damage, panel connector corrosion
Drive overtemperature — heatsink temperature above limit
Fan failure, blocked heatsink, IGBT thermal resistance increased, overload operation
ACS800 faults are logged in the fault history register (Group 06) with time stamps. When sending your drive for repair, note the fault codes and operating conditions — this significantly speeds up our diagnosis.
Industries Served
Where ABB ACS800s Are Used
Paper & Pulp Mills
Winder drives, headbox pumps, press section, coater drives — demanding dynamic torque control
Steel & Metal Processing
Rolling mill drives, coiler/uncoiler, tension stands, run-out tables requiring precise DTC
Mining & Minerals
Conveyor belt drives, crusher feeders, hoist drives, ball mill, SAG mill — high-inertia loads
Cement Plants
Kiln fan drives, raw mill, cement mill, bucket elevator, belt feeder applications
Cranes & Material Handling
Bridge cranes, overhead cranes, port equipment, hoist drives requiring four-quadrant operation
Marine & Offshore
Thruster drives, pump drives, HVAC fans on marine and offshore platforms
Trusted Brands
Brands We Service
Component-level repair for all major manufacturers
FAQ
Frequently Asked Questions
Yes. We repair the complete ACS800 multi-drive architecture — RDCU rectifier control unit, AINT inverter boards, APBU fiber splitter, and D2D adapter. Each board is tested independently and as a system before dispatch.
Fault 2310 at startup is a strong indicator of IGBT module failure, but it can also be caused by a fault on the AINT gate driver board (which may have been damaged by the IGBT failure). We test both the IGBT module and AINT board gate circuits before replacing either component.
Yes. If motor nameplate data is provided, we perform the Motor ID Run in our facility using a test motor of appropriate rating to calibrate the DTC torque model. For large drives above 200kW, we set motor data parameters manually per ABB procedure and recommend a site Motor ID Run on the actual motor.
Yes. We stock common BSM series modules (BSM75GB120DN2, BSM100GB120DN2, BSM150GB120DN2, BSM200GB120DN2) for fast turnaround. For less common high-power modules, we source from verified suppliers — we will include expected lead time in the repair quotation.
All repaired ACS800 drives carry a written 6-month warranty. If the same fault recurs within the warranty period, repair is free of charge. The warranty covers the repaired components and workmanship — not damage from external causes such as input power surges or motor faults.
ABB ACS800 Drive Repair Services Across India
Synchronics provides specialist ABB ACS800 Direct Torque Control drive repair for industrial customers across India — from our facility in Vadodara, Gujarat, with pan-India pickup and delivery. We repair ACS800 drives for paper mills in Vapi, steel plants in Surat, cement factories in Rajasthan, mines in Jharkhand and Odisha, and crane operators in Mumbai and JNPT — covering every major industrial region.
The ABB ACS800 family spans a remarkable power range from 0.55kW single-phase drives to 5600kW multi-drive cabinet systems. Our engineers are trained on the DTC motor model architecture, AINT/RMIO board circuitry, and D2D fiber optic communication system that make ACS800 unique. With a 2M+ component inventory that includes BSM IGBT modules, AINT board components, and fiber optic adapters, we deliver the fastest ACS800 repair turnaround available in India.
Get Your Equipment
Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service