8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 1 / 11 GENERAL This document shows christmas tree for the ACS800-104 and describes how to replace the IGBT modules and the fan of the ACS800-104 drive. ACS800-104 MAINTENANCE INSTRUCTION WARNING! All electrical installation and maintenance work on the ACS 800 should be 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 before working on the frequency converter, the motor or the motor cable. The voltage between each input terminal (U1, V1, W1) and earth must be measured with a multimeter (impedance at least 1M Ω ) to ensure that the frequency converter is discharged before beginning work. All insulation tests must be carried out with the ACS 800 disconnected from the cabling. The ACS 800 motor cable terminals are at a dangerously high voltage when input power is applied, regardless of motor operation. No work on the motor cable should be attemped with mains power applied. There can be dangerous voltage inside the ACS 800 from external control circuits when the ACS 800 input power is shut off. No work on the control cables should be attempted when power is applied to the frequency converter or to the external control circuits. Exercise appropiate care when working with the unit. ESD (Electro Static Discharge) The printed circuit boards contain integrated circuits that are extremely sensitive to electrostatic discharge. Exercise appropiate care when working on the unit to avoid permanent damage to the circuits. Do not touch the boards unnecessarily. WARNING! Only qualified electrians are allowed to carry out work described in this instruction. Before working with the ACS 800 or handling the IGBT modules, read carefully the Safety Instruction on the ACS800 Hardware Manual. Ignoring the safety instructions can cause injury or death. http://slidepdf.com/reader/full/r8imaintinstr00262693 1/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 2 / 11 Figure 1. ACS800-104 module Table 1. Parts list http://slidepdf.com/reader/full/r8imaintinstr00262693 2/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW BERRY Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 18.Aug 2004 3AFE 6479 3675 00262693.DOC Revision Page A 3 / 11 Table 2. Designations DESIGNATION Y41 C211 - 233 NAME Fan Capacitor 500V Capacitor 690V A21 - A23 Gatedriver Board 500V Gatedriver Board 690V V21 - V23 IGBT-module 500V IGBT-module 690V TYPE FINNISH NAME D2D160-BE02-11 Puhallin MKP C4BSPBx4120ZA0J Kondensaattori 500V MKP C4BSWBx3470ZA0J AGDR-62C AGDR-61C FS450R17KE3 FS300R12KE3 Kondensaattori 690V Hilapiirikortti 500V Hilapiirikortti 690 IGBT-moduuli 500V IGBT-moduuli 690V A42 Main Circuit Interface Board AINT-01C Pääpiiriliityntä A43 Power Supply Card APOW-01C Teholähdekortti A431 Gatedriver Power Supply Board AGPS-21C Hilaohj. Tehol. 24V R21 - R23 Power Resistor 500V VHP-5 2x4K7 C251 - C267 Power Resistor 690V Electrolytic Capacitor 500V VHP-6 3x8K B43586-S9418-Q1 Tehovastus 690V El. Kondens. 500V C251 - C276 Electrolytic Capacitor 690V B43586-S3468-Q1 El. Kondens. 690V C200 Film Capacitor 500V Film Capacitor 690V R321 - R323 Z1 Output Filtering Resistor UL9-20832K UL9-20833K UXP 600 Tehovastus 500V Filmi Kondes. 500V Filmi Kondes. 690V Lähtosuotovastus Output Filtering Inductor 500V AOFI-51 Lähtös.kuristin 500V Output Filtering Inductor 690V AOFI-61 Lähtös.kuristin 500V Figure 2. http://slidepdf.com/reader/full/r8imaintinstr00262693 3/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 4 / 11 Figure 3. Figure 4. http://slidepdf.com/reader/full/r8imaintinstr00262693 4/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 5 / 11 1. INVERTER MODULE FAN REPLACEMENT 1. 2. 3. 4. 5. Open the inverter cubicle doors. Disconnect the fan wiring plug (1). Remove the locking screws (2). Pull the fan out along its sliding trails (3). Install a new fan in reverse order. Figure 5. Replacing the fan http://slidepdf.com/reader/full/r8imaintinstr00262693 5/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 6 / 11 2. ASSEMBLING OF THE ACS800–104 MODULE (STEP BY STEP PROCEDURE) On the left side of the module, open eight screws to remove cover. The Cover is fastened with 4×8 screws and tightening torque is 2,4Nm. Under the cover is mounting plate for the APOW and AINT. Picture 1. plate Mounting plate Power Supply Card and Main Interface Board.and Below the M4 nut. mounting is INU for fan.for Mounting plate is fastened with Circuit four 4x16 Torx screws Serpress http://slidepdf.com/reader/full/r8imaintinstr00262693 6/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 7 / 11 Picture 2. Disconnect the wire from AINT-12C connector X7 and pull it away from under the board. Also disconnect cables coming from the AGPS boards. Picture 3. Disconnect the DC wires from the NRED-61 thick-film hybrid http://slidepdf.com/reader/full/r8imaintinstr00262693 7/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU Picture 4. Release cables from their holders under the mounting plate. Picture 5. After disconnecting mounting plate, cables from AGDR boards are hanging loose. http://slidepdf.com/reader/full/r8imaintinstr00262693 3AFE 6479 3675 00262693.DOC Revision Page A 8 / 11 8/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY Picture 6. MAINTENANCE INSTRUCTION Technical Description Status Date Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 18.Aug 2004 3AFE 6479 3675 00262693.DOC Revision Page A 9 / 11 Remove the capacitors and busbars connected to faulty IGBT module. They are fastened to modules with 6×12 Combi-Torx screws. If necessary, remove incoming cables from busbars. Cables are fastened with 8×25 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) and a soft cloth from excess thermal compound and particles. IGBT module is fastened to heatsink with M5×20 Combi-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. http://slidepdf.com/reader/full/r8imaintinstr00262693 9/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. Project STRAW BERRY MAINTENANCE INSTRUCTION Technical Description Status Date 18.Aug 2004 Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU 3AFE 6479 3675 00262693.DOC Revision Page A 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 not damaged. 3. Apply a thin and uniform layer of thermal grease (typ. thickness 50 –100 µ m) to whole contact area of IGBT-module with a roller or a rubber spatula. Amount of grease is sufficient when bright contact surface of IGBT-module is not visible through the grease. Check visually that there are no foreign particles among the spread grease. 4. Place a module to heatsink by hand and press it about 5 sec. Repeat phases 1 - 4 to every IGBT-module before the next phase. 5. All the M5 screws must be tightened uniformly to specified mounting torque. For a good thermal contact to 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. http://slidepdf.com/reader/full/r8imaintinstr00262693 10/11 8/9/2019 R8iMaintinstr_00262693 ABB Drives Dept. MAINTENANCE INSTRUCTION Technical Description Project Status Date STRAW BERRY 18.Aug 2004 3AFE 6479 3675 00262693.DOC Author Status FORSBERG TUOMO APPROVED/TALJA MARKKU Revision Page A 11 / 11 After the tightening a small rim (1 – 4 mm) of grease must be seen around the mounted module. This shows that amount of grease is sufficient. Extra grease is wiped away. 1 - 4 mm 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 MRPcode 64571214 64571231 64571249 64571265 64571273 64571281 Name FS225R12KE3 FS300R12KE3 FS450R12KE3 FS225R17KE3 FS300R17KE3 FS450R17KE3 http://slidepdf.com/reader/full/r8imaintinstr00262693 Connection of the module pre- / final torque (Nm) 0,5 / 3 – 6 0,5 / 3 – 6 0,5 / 3 – 6 0,5 / 3 – 6 0,5 / 3 – 6 0,5 / 3 – 6 Connection of the power terminal (Nm) 3 3 3 3 3 3 11/11
