IPS FOLCROFT INDUSTRIAL ELECTRONICS

ABB Mining Inverter Repair

ACS800 & ACS880 Mining Drive Systems

Component-Level Repair • IGBT & Gate-Driver Repair • Testing • Critical Spares

ABB mining inverter module used in large modular mining drive systems

IPS Folcroft provides component-level repair and testing of ABB mining inverter and power-electronic assemblies. Our experience includes ABB drive equipment used in demanding mining applications, with particular focus on ACS800 and ACS880 platforms and ABB-equipped P&H mining systems.

ABB ACS800 & ACS880 Mining Inverter Repair

ABB has supplied ACS800 and ACS880 multidrive technology for heavy mining applications, including electric rope shovels. These systems use modular inverter and supply sections connected through a common DC bus. IPS Folcroft evaluates repairable inverter modules and associated power electronics to help customers return critical equipment to service and maintain dependable spares.

Component-Level Mining Drive Repair

IGBT power modules and inverter sections
Gate-driver and firing electronics
Control and interface boards
DC bus and power connections
Power supplies and auxiliary electronics
Cooling-related electrical failures
Insulation and high-current connection damage
Contamination and thermal deterioration

Common ABB Mining Inverter Failures We Find

The mining environment can expose drive electronics to contamination, vibration, thermal cycling and heavy electrical stress. The examples below are actual conditions found by IPS Folcroft during mining inverter inspection and repair.

Arc flash damage inside ABB mining inverter power section — **Arc-flash damage** — power-section damage found during incoming inspection.

Contaminated IGBTs and gate driver boards in ABB mining inverter — **Contamination** — conductive dust and debris around IGBTs and gate-driver electronics.

Damaged IGBT gate driver board in ABB mining inverter — **Gate-driver damage** — damaged IGBT gating electronics requiring component-level evaluation and repair.

Damaged power insulators in mining inverter assembly — **Insulation deterioration** — damaged power-section insulators and mounting components.

IGBT module showing gel leakage in mining inverter — **IGBT deterioration** — module condition including gel leakage and physical degradation.

ABB mining inverter IGBTs with dried heat sink compound — **Thermal-compound deterioration** — dried heat-sink compound can reduce effective heat transfer from the IGBT module.

From Damaged ACS800 to Rebuilt & Tested Inverter

The photos below show an actual ABB ACS800 mining inverter before and after component-level repair at IPS Folcroft. The damaged assembly was evaluated and rebuilt with new IGBTs, gate-driver boards, cables and capacitors.

Damaged ABB ACS800 mining inverter before repair at IPS Folcroft — **BEFORE — Damaged ABB ACS800 Mining Inverter**
Damaged IGBTs, gate-driver electronics and associated power-section components found during evaluation.

Rebuilt ABB ACS800 mining inverter with new IGBTs gate-driver boards cables and capacitors — **AFTER — Rebuilt ABB ACS800 Mining Inverter**
New IGBTs, gate-driver boards, cables and capacitors installed during the repair.

Dedicated ABB Inverter Testing Capability

Repair is only part of the process. IPS Folcroft uses dedicated test equipment and component-level checks to evaluate repaired mining inverter assemblies before return to the customer.

IPS Folcroft custom ABB inverter test cabinet — **Custom ABB Inverter Test Cabinet**
Dedicated IPS Folcroft test equipment used to support functional testing of ABB inverter assemblies.

IR testing of ABB mining inverter heaters and heater control boards at IPS Folcroft — **Heater & Heater-Control IR Testing**
IR testing of mining inverter heaters and heater control boards during evaluation.

Load & Functional Testing

Our ABB mining inverter repair capability includes resistive load testing up to 500 kW, inductive load testing up to 800 amps, and functional run-in testing of repaired inverter assemblies. These tests help verify repaired inverter operation under controlled conditions before the unit is returned to the customer.

Repair. Test. Return to Service.

A visibly failed IGBT or gate-driver board may be only part of the problem. Our evaluation looks for related electrical, thermal, contamination and insulation damage. Where practical, we perform component-level repair and test the repaired assembly before return to the customer.

ACS800 Legacy Support & Critical Spares

Installed ACS800 mining systems can remain productive long after replacement electronics become expensive or difficult to source. Repairable modules and rotating critical spares can help reduce exposure to extended downtime while an operation plans its longer-term equipment strategy.

ABB-Equipped P&H Mining Systems

IPS Folcroft also services ABB inverter and power-electronic assemblies associated with P&H mining equipment. For P&H-specific applications, see our Komatsu & P&H Mining Inverter Repair capability.

For the broader IPS Folcroft mining repair program, visit our Mining Inverter Repair page.

Start With the ABB Part Number

Have a failed ABB mining inverter or module? Send IPS Folcroft the ABB type code or part number, machine/application, fault description and photos of the unit. We can use that information to determine the next step for repair evaluation.

ABB ACS800 | ABB ACS880 | Mining Inverters | P&H Mining Applications