Case studies 05 September 2023

Emergency repair on a 120KW ABB ACS800 drive

Client expectation

Our client, a leader in the manufacturing of polyethylene films, called us following two breakdowns encountered on two 120 KVA ABB ACS800 drives. Indeed, when the first one broke down at 8.00 pm, our client had immediately installed the drive they had in stock, but at 10.00 pm, that also broke down.

DV GROUP Solution

Our Technical Assistance team immediately sent an expert on site. The diagnosis revealed the failure of an IGBT module characterised by a short circuit between an output phase and the DC bus. The breakdown was identical on both drives. In order to allow our client to restart as quickly as possible, we dismantled the drive on site and brought both defective products back to the workshop in order to carry out an emergency repair.

Work carried out

  • Full disassembly of the drive
  • Replacement of the IGBT module from DV GROUP stock
  • Repair of the IGD card
  • Preventive maintenance of the product (upgrading of the electronic cards, replacement of the turbine bearings, cleaning)
  • Load test

Our experts worked all night in order to refurbish one of the drives, so our client was able to restart his production line at 8.00 am that morning.

The drive taken from stock was also repaired over the next two days.

Clients gains and benefits


  • Speed: emergency diagnosis and repair in order to be able to restart within a few hours
  • Savings: low cost compared to replacing with new
  • Expertise: efficiency of our Technical Assistance team and intervention by a DV GROUP electronics expert in the middle of the night


We provide you with engineering, maintenance and control solutions based on our knowledge of your processes.

Case studies

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