ABB ACS800 Problem

No, but I believe a telephone call to ABB is in order to solve the problem.

You are screwing with an ABB drive? Do you know what these cost? Let ABB help you.

Programming and wiring them are one thing, but to go onto the circuit boards and dabble around - nuts!

Firstly did the new drive have the same issue? I cant remember if line voltage is measured and displayed on the CDP (motor voltage is), but if so, did it measure the incoming voltage correctly, if displayed? Its 10 years since I dealt with ACS800's, dont remember everything now.

Did the circuit boards or plugs that you seen when disassembling have any sign of corrosion, dirt, moisture, carbon etc etc? Are they conformally coated? From memory, the DC bus voltage is fed to the gate drive board and typically stepped down by voltage dropping resistor network. BUT I do remember something about a scaling pcb (whether Im thinking ABB or other), so maybe this was the pcb DC bus voltage might be fed to first - which could be the voltage dropper network/scaling pcb (as ABB/European drives do pass signals through multiple pcbs for various reasons).

I had ~13 year old 315KW ACS600 with complex intermittent error - traced the hardware error message source through the various cards via schematic drawings (I still have in a folder at work) to an intermediate gate drive splitter pcb between individual IGBT gate driver pcbs and the main gate driver pcb, and found slight corrosion on the pcb itself at the plug that carried the signal that the error was detected on. Simply cleaned plug/socket and pcb corrosion with CRC2-26, error never returned after that.

How old was the old drive and was it in a reasonably hostile environment? - ie; quite dusty, in or within 10km of industrial plant(s), reasonably humid (although humidity and 'fine corrosive elements' (eg; fine acid rain) 'in the air' are near impossible to detect by human eye and is only detected over long period of time on electrical/electronic equipment).

One other problem I came across on a 400KW ACS800 about 12 years ago was the max drive power rating displayed on the drive was 30KW when it was a 400KW unit. I got into the engineering menu (hidden completely) and had to set the power rating back to 400KW. I did find root cause of that issue, but cannot remember that now. So maybe the mains voltage level is set wrong in that menu (due to software glitch, etc) and now displays the DC voltage of a unit of the next voltage up, eg; instead of 415V mains rated now, it shows voltage of a 480V mains unit, (realising though the DC bus voltage is measured and not calculated from mains voltage, still may affect DC V).