#cementplant

Unexpected VFD trips are one of the most common causes of downtime in cement, power, and water plants. They can halt production, damage equipment, and lead to significant maintenance costs.

Most VFD failures are preventable if engineers understand the common causes and follow a structured preventive maintenance approach. Here are the 6 main causes of unexpected VFD trips:

Voltage fluctuations & phase loss – Unstable supply can trigger trips instantly.

Motor overload & mechanical jams – Excessive load or blocked motors cause VFD to protect itself.

Overheating & poor ventilation – Ensure proper airflow and ambient temperature control.

EMI / long cables / electrical noise – Interference from other equipment can corrupt signals.

Incorrect control settings or programming – Wrong parameters or logic can trip drives unexpectedly.

Dust, vibration & humidity – Harsh environmental conditions reduce reliability and trigger faults.

Pro tip: Following a preventive maintenance checklist ensures all these risks are minimized and your drives operate smoothly.

If you want to avoid costly production halts, check our full vfd preventive maintenance guide and keep your VFDs running safely and efficiently.

In the world of industrial drives, ABB ACS800 drives are the backbone of heavy-duty motors in cement plants — controlling crushers, conveyors, and fans. These drives work under extreme dust, heat, and continuous operation. Without proper care, unexpected trips or downtime can halt production and cost a lot.

At Najran Cement, our team carried out a comprehensive preventive maintenance program for ABB ACS800 drives to ensure reliability, reduce downtime, and extend their lifetime.

What We Did

Internal Cleaning: Removing cement dust affecting airflow and cooling

Cooling System Check: Fans, filters, and heat sinks inspected

Power Connections: Terminals tightened, DC bus checked

Module Inspection: IGBT modules and capacitors verified

Fault Review: Alarm history analyzed to prevent future trips

Functional Testing: Drives tested for smooth operation

Results

Reduced drive temperature and nuisance trips

Improved reliability for continuous operation

Extended drive lifetime

Lowered risk of unplanned downtime

Why Preventive Maintenance Matters

In cement plants, dust + heat + heavy loads = potential failures. Preventive maintenance is not just a cost — it’s a production protection strategy. Small interventions today prevent major shutdowns tomorrow.

In the world of industrial drives, ABB ACS800 drives are the backbone of heavy-duty motors in cement plants — controlling crushers, conveyors, and fans. These drives work under extreme dust, heat, and continuous operation. Without proper care, unexpected trips or downtime can halt production and cost a lot.

At Najran Cement, our team carried out a comprehensive preventive maintenance program for ABB ACS800 drives to ensure reliability, reduce downtime, and extend their lifetime.

What We Did

Internal Cleaning: Removing cement dust affecting airflow and cooling

Cooling System Check: Fans, filters, and heat sinks inspected

Power Connections: Terminals tightened, DC bus checked

Module Inspection: IGBT modules and capacitors verified

Fault Review: Alarm history analyzed to prevent future trips

Functional Testing: Drives tested for smooth operation

Results

Reduced drive temperature and nuisance trips

Improved reliability for continuous operation

Extended drive lifetime

Lowered risk of unplanned downtime

Why Preventive Maintenance Matters

In cement plants, dust + heat + heavy loads = potential failures. Preventive maintenance is not just a cost — it’s a production protection strategy. Small interventions today prevent major shutdowns tomorrow.

We replaced the main transformer of a SIEMENS ROBICON 4100 kW MV Drive powering the Raw Mill Fan (Line 5) — directly at the plant site.

✔️ Quick turnaround ✔️ No startup faults ✔️ Improved drive stability