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ABB Drives MAINTENANCE INSTRUCTIONTechnical Description

3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status

APPROVED/TALJA MARKKU

Revision

A

Page

1 / 11

GENERALThis document shows christmas tree for the ACS800-104 and describes how to replace the IGBTmodules and the fan of the ACS800-104 drive.

ACS800-104 MAINTENANCE INSTRUCTION

WARNING! All electrical installation and maintenance work on the ACS 800 shouldbe carried out by qualified electricians.

Do not attemp any work on a powered ACS 800. After switching off the mains,always allow the intermediate circuit capacitors 5 minutes to discharge beforeworking on the frequency converter, the motor or the motor cable. The voltagebetween each input terminal (U1, V1, W1) and earth must be measured with amultimeter (impedance at least 1M ) to ensure that the frequency converter isdischarged before beginning work.

All insulation tests must be carried out with the ACS 800 disconnected from thecabling.

The ACS 800 motor cable terminals are at a dangerously high voltage when inputpower is applied, regardless of motor operation. No work on the motor cable shouldbe attemped with mains power applied.

There can be dangerous voltage inside the ACS 800 from external control circuitswhen the ACS 800 input power is shut off. No work on the control cables should beattempted when power is applied to the frequency converter or to the externalcontrol circuits. Exercise appropiate care when working with the unit.

ESD (Electro Static Discharge) The printed circuit boards contain integratedcircuits that are extremely sensitive to electrostatic discharge. Exercise appropiatecare when working on the unit to avoid permanent damage to the circuits. Do nottouch the boards unnecessarily.

WARNING! Only qualified electrians are allowed to carry out work described in thisinstruction. Before working with the ACS 800 or handling the IGBT modules, readcarefully the Safety Instruction on the ACS800 Hardware Manual. Ignoring the safetyinstructions can cause injury or death.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

2 / 11

Figure 1. ACS800-104 module

Table 1. Parts list

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

3 / 11

Table 2. DesignationsDESIGNATION NAME TYPE FINNISH NAME

Y41 Fan D2D160-BE02-11 Puhallin

C211 - 233 Capacitor 500V MKP C4BSPBx4120ZA0J Kondensaattori 500VCapacitor 690V MKP C4BSWBx3470ZA0J Kondensaattori 690V

A21 - A23 Gatedriver Board 500V AGDR-62C Hilapiirikortti 500V

Gatedriver Board 690V AGDR-61C Hilapiirikortti 690

V21 - V23 IGBT-module 500V FS450R17KE3 IGBT-moduuli 500V

IGBT-module 690V FS300R12KE3 IGBT-moduuli 690V

A42 Main Circuit Interface Board AINT-01C Ppiiriliitynt

A43 Power Supply Card APOW-01C Teholhdekortti

A431 Gatedriver Power Supply Board AGPS-21C Hilaohj. Tehol. 24V

R21 - R23 Power Resistor 500V VHP-5 2x4K7 Tehovastus 500V

Power Resistor 690V VHP-6 3x8K Tehovastus 690VC251 - C267 Electrolytic Capacitor 500V B43586-S9418-Q1 El. Kondens. 500V

C251 - C276 Electrolytic Capacitor 690V B43586-S3468-Q1 El. Kondens. 690V

C200 Film Capacitor 500V UL9-20832K Filmi Kondes. 500VFilm Capacitor 690V UL9-20833K Filmi Kondes. 690V

R321 - R323 Output Filtering Resistor UXP 600 Lhtosuotovastus

Z1 Output Filtering Inductor 500V AOFI-51 Lhts.kuristin 500V

Output Filtering Inductor 690V AOFI-61 Lhts.kuristin 500V

Figure 2.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

4 / 11

Figure 3.

Figure 4.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

5 / 11

1. INVERTER MODULE FAN REPLACEMENT1. Open the inverter cubicle doors.2. Disconnect the fan wiring plug (1).3. Remove the locking screws (2).4. Pull the fan out along its sliding trails (3).5. Install a new fan in reverse order.

Figure 5. Replacing the fan

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

6 / 11

2. ASSEMBLING OF THE ACS800104 MODULE (STEP BYSTEP PROCEDURE)

On the left side of the module, open eight screws to remove cover. The Cover is fastened with 48 screwsand tightening torque is 2,4Nm. Under the cover is mounting plate for the APOW and AINT.

Picture 1. Mounting plate for Power Supply Card and Main Circuit Interface Board. Below themounting plate is INU for fan. Mounting plate is fastened with four 4x16 Torx screws and Serpress M4 nut.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

7 / 11

Picture 2. Disconnect the wire from AINT-12C connector X7 and pull it away fromunder the board. Also disconnect cables coming from the AGPS boards.

Picture 3. Disconnect the DC wires from the NRED-61 thick-film hybrid

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

8 / 11

Picture 4. Release cables from their holders under the mounting plate.

Picture 5. After disconnecting mounting plate, cables from AGDR boards are hanging loose.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

9 / 11

Picture 6. Remove the capacitors and busbars connected to faulty IGBT module. They are fastened to

modules with 612 Combi-Torx screws.

If necessary, remove incoming cables from busbars. Cables are fastened with 825 screws and M8 nut.Under the nut are two washers. Tightening torque is 16Nm.

Remove the faulty IGBT module and clean the heat sink surface with an appropriate solvent (e.g. Grafol) anda soft cloth from excess thermal compound and particles. IGBT module is fastened to heatsink with M520Combi-Torx screws. Also check inside of the inverter module for foreign objects.

When placing a new IGBT module, follow the instructions written in chapter three (Installation of Econopack+in ACS800 inverters) of this maintenance instruction.

Install the rest of the components in reverse order to the above.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

10 / 11

3. INSTALLATION OF ECONOPACK+ IN ACS800 INVERTERS

1. Clean the contact surface of heatsink.

2. Clean the contact surface and the terminals of IGBT-module. Check that the contact surface is notdamaged.

3. Apply a thin and uniform layer of thermal grease (typ. thickness 50 100 m) to whole contact area ofIGBT-module with a roller or a rubber spatula. Amount of grease is sufficient when bright contact surface ofIGBT-module is not visible through the grease. Check visually that there are no foreign particles among thespread grease.

4. Place a module to heatsink by hand and press it about 5 sec. Repeat phases 1 - 4 to every IGBT-modulebefore the next phase.

5. All the M5 screws must be tightened uniformly to specified mounting torque. For a good thermal contactto the heatsink we recommend the following procedure of tightening the 8 screws:

Tighten module to heatsink with M5 screws to a pretightening torque (0,5 Nm) in the following sequence:screw no. 2 6 3 7 4 8 1 5. (Figure 1)

Tighten screws to final tightening torque (3 - 6 Nm) in the same sequence:2 6 3 7 4 8 1 5.

Figure 6. The screwing sequence and sizes.

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3AFE 6479 367500262693.DOC

Dept. Project

STRAWBERRY

Status Date

18.Aug 2004

Author

FORSBERG TUOMO

Status


Revision

A

Page

11 / 11

After the tightening a small rim (1 4 mm) of grease must be seen around the mounted module. This showsthat amount of grease is sufficient. Extra grease is wiped away.

Figure 7. A rim of grease around the module.

8. Busbars are connected to power terminals of IGBT-module with M6 screws. Tightening torque is 3 Nm.

Table 3. Codes and tightening torques of the modules

MRP-code

Name Connection of the modulepre- / final torque (Nm)

Connection of thepower terminal (Nm)

64571214 FS225R12KE3 0,5 / 3 6 364571231 FS300R12KE3 0,5 / 3 6 364571249 FS450R12KE3 0,5 / 3 6 364571265 FS225R17KE3 0,5 / 3 6 364571273 FS300R17KE3 0,5 / 3 6 364571281 FS450R17KE3 0,5 / 3 6 3

1 - 4 mm

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