ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 1 / 66 Safety Issues and ESD .........................................................................................................................2 Voltage Measurement......................................................................................................................3 High Center of Gravity ....................................................................................................................3 ESD..................................................................................................................................................3 Cabinet and Module Serial Numbers...................................................................................................4 Serial Number Hierarchy.................................................................................................................4 ACS800-X7 Cabinet....................................................................................................................4 ACS800 MD Line-up ..................................................................................................................5 Practical Examples ..........................................................................................................................5 Filling Out the Warranty Report..........................................................................................................9 General Description of the ACS800-104 Module .............................................................................12 Option Codes .................................................................................................................................12 Parts List ........................................................................................................................................13 Mechanical Parts for module with option code +V991 .............................................................13 Mechanical Parts for old R8i module (without +V991) ............................................................17 Electrical Parts...........................................................................................................................20 About Maintenance Procedures.........................................................................................................23 Testing the Module after Maintenance ..........................................................................................23 ACS800-104 On-Site Tester......................................................................................................23 Maintenance of the Fan .....................................................................................................................23 Maintenance Tips: Left Hand Side of the Module ............................................................................24 Replacing the Controlled Fan Option (+C126) Circuit Boards .....................................................24 Replacing an AFPS-01C board with and AFPS-11C board ......................................................25 Replacing the Control Unit Circuit Boards ...................................................................................29 Replacing the AGBB board (Module with 2 x IGBT)...................................................................30 Replacing the IGBT/AGDR modules ............................................................................................32 Replacing the Module Heating Set (+C123) .....................................................................................34 Maintenance Tips: Right Hand Side of the Module ..........................................................................35 Replacing the AOFC-0XC Filter Capacitor Board (+E205) .........................................................35 Replacing the ATMB-01C Temperature Measurement Board......................................................36 Replacing the Current Transducers ...............................................................................................37 Maintenance Tips: Replacing the AOFI-XX du/dt output filter (+E205) .........................................42 Maintenance Tips: Replacing the DC Capacitor Bank......................................................................47 Electrolyte Capacitor. ....................................................................................................................47 Film Capacitor (+E212).................................................................................................................55 Appendix I: Capacitor layouts for 300 - 500 V ElCo ........................................................................59 Appendix II: Capacitor layout for 690 V ElCo..................................................................................62 Appendix III: Module phase order.....................................................................................................65 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 2 / 66 Safety Issues and ESD WARNING! All electrical installation and maintenance work on the ACS 800 should be carried out by qualified electricians. Do not attempt 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 and W1) and earth must be measured with a multimeter (impedance at least 1MΩ) 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 attempted 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 appropriate 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 appropriate care when working on the unit to avoid permanent damage to the circuits. Do not touch the boards unnecessarily. WARNING! Only qualified electricians 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. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 3 / 66 Voltage Measurement When repairing a module one must always to remember that there might be live voltages on some components such as capacitors. Therefore, before disconnecting the module from the cabinet, it is important to measure the dc voltage with a multimeter. High Center of Gravity The ACS800-104 module has an exceptionally high center of gravity. When performing maintenance operations for the module, it is important to make sure that the module is pulled out from the cabinet by using a service ramp (Figure 1) and that both support legs in the rear side of the module are opened during the maintenance (Figure 2). Figure 1: Pulling the module out safely. Figure 2: Supporting the module during maintenance. ESD Always use ESD protection clothes, gloves, shoes and mat if possible. Avoid unnecessary touching of the circuit boards. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 4 / 66 Cabinet and Module Serial Numbers Each cabinet, module and circuit board is equipped with a serial number. In this context, the essential serial number information is collected from cabinet and module, which in this case refers to an ACS800-104-XXXX-Y –inverter module. The serial number is needed in order to maintain the field quality statistics as well as the event history of a single cabinet and module. This has a significant strategic importance in ABB Drives’ products and should be considered as an imperative each case a warranty repair is performed. The following three chapters include important information about serial number hierarchies of different cabinets and modules as well as practical examples on how to find the right serial number for each case and how to fill the warranty report Serial Number Hierarchy ACS800-X7 Cabinet Single drive serial numbers can be divided into two levels: cabinet level and module level (Figure 3). If for example the module has faulted, both cabinet and module level serial number is needed. On the other hand, if f. ex. one of the control boards has a defect in it, only the cabinet level serial number is needed for the control board cannot be traced to a module. The module serial number is always in the same spot. Figure 3:Serial number hierarchy of an ACS800 single drive cabinet. The type codes and serial number of the units enclosed by a red rectangle are important. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 5 / 66 ACS800 MD Line-up The multidrive serial number hierarchy is more complicated than the one for single drives (Figure 4). The first level is the device level witch is the MDs serial number. However this has little significance for the statistics. That is why the first and second levels (device level and TL level) are not needed for warranty reports. The serial number information needed in warranty report is the unit level serial number and the module level serial number. If for example the module is defected, both unit level serial number and module level serial number is needed. In Figure 4 this means f. ex. the serial numbers from drive unit (ACS800-107-0400-7) and the module it contains (ACS800-104-0400-7). Sometimes the equipments are not in the same cabinet as the unit type code. Situation like this is encountered with control boards. When again referring to Fig. 2 this could mean that the control board RDCU-12C for unit ACS800-107-0400-7 is mounted to another locker. It must be bared in mind that no matter where the control board is mounted, the important fact is that it controls the mentioned unit. In this case only the unit level serial number is needed. The module serial number is always in the same spot. Figure 4: Serial number hierarchy of an ACS800 multi drive cabinet. The type codes and serial number of the units enclosed by a red rectangle are important. Practical Examples There are some differences between the placing of the serial number stickers in different cabinets, such as ACS800-X7 and ACS800MD. In general the serial number and type of the ACS800-X7 cabinet can be found on the lower right side of the first cabinet door, that is, right ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 6 / 66 above the lower air ventilation grill. In multidrive cabinets the unit serial number and type can be found from the upper third of the door above the upper door bracket. Some examples are listed below. ACS800-X7-Y Single drive cabinet The ACS800-X7 serial number label can usually be found on outer surface of the door above the door grill (Figures 5). When filling the warranty report the serial number and the type code of the cabinet (Figure 5) is needed. If the module is defective, the module serial number and type code is needed as well (Figure 6). Figure 5: Serial number sticker position in the ACS800-X7 cabinet door. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 7 / 66 Figure 6: Module type code and serial number. ACS800MD cabinet The ACS800MD serial number label is usually mounted on the inner surface of the door, above the upper door bracket (Figure 7). The unit type code (f. ex. ACS800-107-XXXX-Y) is printed next to the serial number and is needed for the warranty report as well (Figure 8). Module serial can be found from the module as shown in Figure 6. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 7: ACS800 Multidrive unit type code and serial number. Figure 8: ACS800-107-1740-7 drive unit's type code and serial number. 3AFE 6479 3675 00262693_E.DOC Revision Page E 8 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 9 / 66 Filling Out the Warranty Report When visiting the site, it is very important to fill out the warranty report form carefully. All serial numbers and type codes must be correct and the fault description has to be detailed enough. The customer information is also important. It is very important to know what happened at the site. Also any considerations about the possible abnormalities before the defect are to be reported. Try to estimate the time how long the drive has been running. Remember to evaluate the conditions in the electrical room as well. With the serial number information the manufacturer is able to access detailed data about the drive. We strongly recommend that InfoPaht warranty report template, available in Installed Base, would be used for warranty reporting. Reports should be also uploaded to Installed Base after field service to gather history data of individual drive service history. If installed base and infopath is not used, then a report template, which is presented in following pages, that is available in IHMM can be used instead. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 10 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 11 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 12 / 66 General Description of the ACS800-104 Module ACS800-104 (frame R8i) inverter module is used in various different frequency converters. They might be installed in a customized OEM customer built cabinet or in an ABB Drives built cabinet. Two different ACS800-104 modules are represented in Figure 9. NOTE: Module phase order is showed in Appendix III. Figure 9: ACS800-104-XXXX-Y modules. Left module is equipped with electorylitc DC capacitor bank while the right one has a DC film capacitor. Option Codes The ACS800-104 R8i –modules come in various configurations. The module can be ordered with electrolytic or film capacitor (option E212) and with or without an internal du/dt filter (option E205). Also inverter fan can be controlled with option C126, the drive can be protected with an unexpected start-up function (option Q950 or Q967 when replaced with STO-function), equipped with card space heater (C123) and/or with an air filter (C124). Different options are presented in Table 1. Table 1: Option codes for ACS800-104 R8i modules. Option code C123 C124 C126 E212 E205 Q950 Q967 V991 Function Card Space Heater (3 heating resistors and an AHCB-01C board) Compact Filter Controlled Fan Film Capacitor du/dt-filter + Output filter board (AOFC-0X) Prevention of Unexpected Start-Up (AGPS-21C board) ASTO Safety Function (ASTO-21) New Type AGDR-7X and an Air Cored Choke ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 13 / 66 Parts List Mechanical Parts for module with option code +V991 Part codes fof the ACS800-104 R8i modules with option code +V991 are presented in following images. Please not that there are two pages which have wind turbine specific mechanics. Figure 10 +V991 R8i module mechanics 1/5 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 11 +V991 R8i module mechanics 2/5 Figure 12 +V991 R8i module mechanics 3/5 3AFE 6479 3675 00262693_E.DOC Revision Page E 14 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 13 +V991 R8i module mechanics 3 (wind)/5 Figure 14 +V991 R8i module mechanics 4/5 3AFE 6479 3675 00262693_E.DOC Revision Page E 15 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 15 +V991 R8i module mechanics 4 (wind)/5 Figure 16 +V991 R8i module mechanics 5/5 3AFE 6479 3675 00262693_E.DOC Revision Page E 16 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 17 / 66 Mechanical Parts for old R8i module (without +V991) Please note that on this document page 18 there is figure 18 which presents the old module mechanics wind specific variant. Different components for wind module are listed in that figure (items 1-10). Figure 17 Old R8i module mechanics 1/3 Figure 18 Old R8i module mechanics 2/3 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 19 Old R8i module mechanics 2 (wind)/3 Figure 20 Old R8i module mechanics 3/3 3AFE 6479 3675 00262693_E.DOC Revision Page E 18 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Table 2 Old R8i module mechanics Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 19 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY 3AFE 6479 3675 00262693_E.DOC Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Revision Page E 20 / 66 Electrical Parts ACS800-104 (R8i) electrical parts are listed in Table 3. The information where most of the common parts are used is listed in Table 4. Table 3: R8i Electrical and Option Parts. Part name MRP Code Qty Part Number IGBT FS450R17KE3/AGDR-71C 68444217 3 IGBT FS450R12KE3/AGDR-71C 68444161 3 IGBT FS300R12KE3/AGDR-72C 68444152 3 IGBT FS300R17KE3/AGDR-76C 68444195 3 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 IGBT FS450R17KE3/AGDR-61C 68336970 3 IGBT FS450R12KE3/AGDR-61C 68350301 3 IGBT FS300R12KE3/AGDR-62C 68350204 3 IGBT FS300R17KE3/AGDR-66C 68336988 3 CURRENT TRANSDUCER LF 1005-S/SP16 CURRENT TRANSDUCE LF 505-S/SP13 64572881 3 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 A21/V21 A22/V22 A23/V23 U31 – U33 64572814 3 U31 – U33 CAPACITOR C4BSTBX3470ZAFJ 64435001 9 MKP 64423746 9 C211 – C213 C221 – C223 C231 – C233 C211 – C213 C221 – C223 C231 – C233 VHP-6 64522787 3 CAPACITOR C4BSNBX4120ZAJJ POWER RESISTOR 3X8K R21 – R23 Optio n Code +V991 +V991 +V991 +V991 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY POWER RESISTOR 2X4K7 VHP-5 3AFE 6479 3675 00262693_E.DOC Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 64522736 3 R21 – R23 FILTER CAPACITOR 58985066 3 C31 – C33 FAN 64650424 1 Y41 B 6-30-10 64693051 1 K1 THICK-FILM HYBRID NRED-61 MAIN CIRC. INTERF AINT-14C POWER SUPPLY APOW-01C GATE DRIVER BRANC AGBB01C FAN INVERTER 1 KW AFIN01C POWER SUPPLY BOAR AFPS11C POWER SUPPLY BOAR AFPS01C COMPACT FILTER ELSU-WF6-400X65-94 HEATING CONTROL B AHCB01C HEATING FOIL 58926451 68685826 64605666 68242843 1 1 1 1 A28 A42 A43 A46 64693808 1 +C126 68969972 1 +C126 68969972 1 D2D160-BE02-11 CONTACTOR 440V4KW. CO (Old) 68228409 +C126 +C124 64815555 1 68228727 2 GDR POWER SUPPLY AGPS21C PROTECTION BOARD ASTO21C 64668064 1 +C123 (C126) +C123 (C126) +Q950 3AUA0000 061832 1 +Q967 EL. CAPACITOR S3468-Q1 B43586- 64410539 N EL. CAPACITOR S9418-Q1 B43586- 64410512 N CAPACITOR UL9-20833K 64793012 OUTPUT FILTER IND AOFI-69 OUTPUT FILTER IND AOFI-59 OUTPUT FILTER IND AOFI-66 OUTPUT FILTER IND AOFI-56 OUTPUT FILTER RES UXP 600 OUTPUT FILTER BOA AOFC-02 OUTPUT FILTER IND AOFI-51 OUTPUT FILTER IND AOFI-52 OUTPUT FILTER IND AOFI-61 OUTPUT FILTER IND AOFI-62 R411 / R412 1 C251 – C256 … C271 – C276 C251 – C256 … C271 – C276 C200 +E212 68634377 68634351 68634369 68634342 64650149 68295459 1 1 1 1 3 1 Z1 Z1 Z1 Z1 R321 – E323 A311 +E205 +E205 +E205 +E205 +E205 +E205 64650441 68265690 64710109 68265703 1 1 1 1 Z1 Z1 Z1 Z1 Revision Page E 21 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY 3AFE 6479 3675 00262693_E.DOC Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Revision Page E 22 / 66 Table 4: Common Parts vs. Type List. Type 01703 0210-3 0210-5 0210-7 0260-3 0260-5 0260-7 0320-3 0320-5 IGBT 300/1 2/62 300/1 2/72 2 B435 86S9418 -Q1 (4.1 mF) 8 5 No 300/12/ 62 300/12/ 72 2 B43586 -S9418Q1 (4.1 mF) 300/12/ 62 300/12/ 72 2 B43586 -S9418Q1 (4.1 mF) 300/17/ 66 300/17/ 76 2 B43586 -S3468Q1 (4.6 mF) 300/12/ 62 300/12/ 72 2 B43586 -S9418Q1 (4.1 mF) 300/12/ 62 300/12/ 72 2 B43586 -S9418Q1 (4.1 mF) 300/17/ 66 300/17/ 76 2 B43586 -S3468Q1 (4.6 mF) 450/12/ 61 450/12/ 71 2 B43586 -S9418Q1 (4.1 mF) 300/12/ 62 300/12/ 72 2 B43586 -S9418Q1 (4.1 mF) 8 5 No 8 5 No 9 6 Yes 8 5 No 8 5 No 9 6 Yes 10 5 No 8 5 No 52 52 52 62 52 52 62 52 52 56 C4BS NBX4 120Z AJJ (1.2 uF) SP13 56 C4BSN BX4120 ZAJJ (1.2 uF) 56 C4BSN BX4120 ZAJJ (1.2 uF) 66 C4BST BX3470 ZAFJ (0.47 uF) 56 C4BSN BX4120 ZAJJ (1.2 uF) 56 C4BSN BX4120 ZAJJ (1.2 uF) 66 C4BST BX3470 ZAFJ (0.47 uF) 56 C4BSN BX4120 ZAJJ (1.2 uF) 56 C4BSN BX4120 ZAJJ (1.2 uF) SP13 SP13 SP13 SP13 SP13 SP13 SP16 SP13 03207 450/1 2/61 450/1 2/71 3 B435 86S3468 -Q1 (4.6 mF) 12 0390-3 0400-5 0400-7 0440-7 0460-5 0510-3 0580-7 0610-5 300/12/ 62 300/12/ 72 3 B43586 -S9418Q1 (4.1 mF) 450/12/ 61 450/12/ 71 3 B43586 -S9418Q1 (4.1 mF) 450/17/ 61 450/17/ 71 3 B43586 -S3468Q1 (4.6 mF) 450/17/ 61 450/17/ 71 3 B43586 -S3468Q1 (4.6 mF) 300/12/ 62 300/12/ 72 3 B43586 -S9418Q1 (4.1 mF) 450/12/ 61 300/12/ 71 3 B43586 -S9418Q1 (4.1 mF) 450/17/ 61 450/17/ 71 3 B43586 -S3468Q1 (4.6 mF) 450/12/ 61 450/12/ 71 3 B43586 -S9418Q1 (4.1 mF) 12 10 12 15 12 14 18 14 6 Yes 5 No 5 No 6 Yes 6 Yes 5 No 5 No 6 Yes 5 No 62 51 52 62 61 51 51 61 51 66 59 56 66 69 59 59 69 59 V991 QTY DC Capa citor type QTY VHP NRE D AOFIXX V991 Clam p Capa citors CTs Type IGBT V991 QTY DC Caps QTY VHP NRE D AOFIXX V991 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Clam p Capa citors CTs C4BS TBX3 470Z AFJ (0.47 uF) SP13 3AFE 6479 3675 00262693_E.DOC Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Revision Page E 23 / 66 C4BSN BX4120 ZAJJ (1.2 uF) C4BSN BX4120 ZAJJ (1.2 uF) C4BST BX3470 ZAFJ (0.47 uF) C4BST BX3470 ZAFJ (0.47 uF) C4BSN BX4120 ZAJJ (1.2 uF) C4BSN BX4120 ZAJJ (1.2 uF) C4BST BX3470 ZAFJ (0.47 uF) C4BSN BX4120 ZAJJ (1.2 uF) SP16 SP16 SP13 SP16 SP16 SP16 SP16 SP16 About Maintenance Procedures Testing the Module after Maintenance ACS800-104 On-Site Tester It is best to test the module after maintenance. The most convenient way of doing this is to use the ACS800-104 On-Site Tester manual (IHMM Document 3AFE 68806470). Maintenance of the Fan • • • • • 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 21: Replacing the Fan. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 24 / 66 Maintenance Tips: Left Hand Side of the Module Replacing the Controlled Fan Option (+C126) Circuit Boards Depending on the used option set, there are two possible configurations for the controlled fan. The basic configuration consists only of AFPS and AFIN boards. However, if the module is equipped with a card space heater (+C123) the configuration is a bit different because the controlled fan boards are also equipped with a heating set. 1. Measure the DC voltage. 2. Remove the side plate as shown in Figure 14. 3. Remove the broken board from the frame by unscrewing the 6 pcs M4 x 8 screws (torque 0.7 Nm) if the board is an AFPS board. If the board is an AFIN board, remove the 4 pcs M4x8 combi torx screws (0.7 Nm). a. If the module is equipped with a card space heating set (+C123) there will be four support pillars in AFPS board and two in AFIN board. b. If the board is AFPS-01C revision D or F, the board has an EMC shielding. When replacing the older board (AFPS-01C rev. A F) with newer one (AFPS-11C) the EMC shielding must be removed. Instructions for removing the shielding are shown in chapter 7.1.1. When remounting the board, be sure that the fixing torque of the screws (and support pillars) is the correct one (0.7 Nm). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 25 / 66 Figure 22: Replacing AFPS or AFIN boards. Replacing an AFPS-01C board with and AFPS-11C board The old AFPS-01C (code: 64711245) board and the AFPS shield kit must be removed before new AFPS-11C (code: 68969972) can be installed. In the below Figure 15 you can see the parts of AFPS shield kit that should be removed. Figure 23: AFPS shield kit. 1. Remove the left module cover plate by loosing eight (8) torx screws. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 26 / 66 2. Remove old AFPS-01C board from the inverter module by disconnecting board cable connectors and loosing six (6) M4 torx combi screws. In the picture 16 red arrows are pointing out the six (6) fixing screws that should be removed. Figure 24: Fixing screws of AFPS board. Be careful when removing the card. Small parts may fall down to the fan. Using some kind of cover above the fan grill is advised. 3. Remove four (4) O-rings. In the picture 17 red arrows are pointing out four (4) rubber Orings on the static shield. Figure 25: The O-rings of AFPS shield kit. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 27 / 66 4. Remove the static shield and the four (4) round insulating sheets. In the picture 18 the static shield is marked with green lines and the round insulation sheets with red arrows. Figure 26: Static shield plate and round insulation sheets. 5. Do not unscrew the mounting pillars. 6. Install the AFPS-11C (Figure 19) to the mounting pillars. Mount the board with M4 combi screws (0.7 Nm). Figure 27: AFPS-11C board. 7. Connect the board cable connectors to X1 and X2. In the Figure 20, the red arrow is pointing out the connector. Figure 28: AFPS-11C mains connector. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 8. The AFPS-11C board is now installed (Figure 21). Figure 29: The installed board. 3AFE 6479 3675 00262693_E.DOC Revision Page E 28 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 29 / 66 Replacing the Control Unit Circuit Boards The ACS800-104 (R8i) module’s control unit is shown in Figure 22. Since the EMC performance has been improved during the lifetime of the module, there exists some variance in the modules. These improvements have affected the wiring of the control unit and it is important to know which wire sets compatible with a certain layout. Some wire sets are listed in Table 5. Table 5: Different wire sets for ACS800-104 control unit. Wire Set PCB 300 - 500 V PCB 300 - 500 V + AGPS PCB 690 V PCB 300 - 500 V (2 x IGBT) MRP Code 68692148 68692756 DC cap to APOW 68692148 68692756 DC cap to APOW 68692148 68692156 NRED 68692164 NRED 68692148 68692156 68692164 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 30 / 66 Figure 30: ACS800-104 Control Unit. When replacing control unit boards, the correct torques for each board are listed in Table 6. In addition, when replacing NRED-61C it is important to clean the old heat conduction paste well and sterilize the area with industrial alcohol before replacing the new heat conduction paste. Table 6: Correct torques for each control unit board. Board AINT-12C or AINT-14C (serpress M4 4 pcs) NRED-61C (4 pcs M4x8) APOW-01C (4 pcs M4x8) AGPS-21C (6 pcs M4x8) AGBB-01C (4 pcs M4x9) Torque 1.5 Nm 1.2 Nm 1.2 Nm 1.2 Nm 1.2 Nm Replacing the AGBB board (Module with 2 x IGBT) The AGBB board is used when the module has only two IGBTs. The configuration is showed in Figure 23. Pay extra attention when replacing the AGBB board flat cable connector: Do not force the board into its place. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 31: An ACS800/104 R8i module with an AGBB board. 3AFE 6479 3675 00262693_E.DOC Revision Page E 31 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 32 / 66 Replacing the IGBT/AGDR modules 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 µm) 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 (1 Nm) in the following sequence: screw no. 2 – 6 – 3 – 7 – 4 – 8 – 1 – 5. (Figure 24) • Tighten screws to final tightening torque (5 Nm) in the same sequence: 2 – 6 – 3 – 7 – 4 – 8 – 1 – 5. Figure 32: The Screwing sequence and screw sizes. 6. 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. NOTE: The grease brand must be the same for all IGBT-modules in the drive. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 33 / 66 Figure 33: A rim of grease around the module 7. Busbars are connected to power terminals of IGBT-module with M6 screws. Tightening torque is 5 Nm. Table 3. Codes and tightening torques of the modules Table 7: Codes and tightening torques of the modules. MRPcode 64571214 64571231 64571249 64571265 64571273 64571281 Name FS225R12KE3 FS300R12KE3 FS450R12KE3 FS225R17KE3 FS300R17KE3 FS450R17KE3 Connection of the module pre- / final torque (Nm) 1/5 1/5 1/5 1/5 1/5 1/5 Connection of the power terminal (Nm) 5 5 5 5 5 5 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 34 / 66 Replacing the Module Heating Set (+C123) Modules equipped with option +C123 have a card space heating set. The heating set includes a heating resistor set. The heating resistor set consists of 3 heating resistors: two for the controlled fan option (+C126) and one for the IGBT modules and control unit boards and AHCB-01C Heating Control Board. The module with a +C123 option is showed in Figure 26. When replacing the heating set, all insulating sheets and resistors as well as the control unit plate must be replaced. The parts online code for the heating set is 68232171. Figure 34: Replacing the card space heating set. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 35 / 66 Maintenance Tips: Right Hand Side of the Module The right hand side of the module is shown in Figure 27. Figure 35: The right hand side of the module. Replacing the AOFC-0XC Filter Capacitor Board (+E205) Remove the lower right cover plate as shown in Figure 27. Remove the AOFC-board by removing the 4 pcs M4x8 (1.2 Nm) (Figure 28). Figure 36: Replacing the AOFC-0X board. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 36 / 66 Replacing the ATMB-01C Temperature Measurement Board Open the lower right cover plate as shown in Figure 27. Unscrew the 2 pcs M4x8 (1.2 Nm) combi torx screws. Figure 37: Replacing the ATMB-01C board. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 37 / 66 Replacing the Current Transducers Warning! Always read the whole instruction before starting the maintenance procedure. Warning! When operating the module in standing position, bare in mind that the module has a high center of gravity. Always use the module’s support legs. Warning! When rebuilding the module, pay extra attention to correct torques. 1. Spread the module’s support legs by pushing the string and turning the leg (Figure 30). 2. Disconnect and remove the fan (Figure 30). By removing the fan, one can ensure that no loose parts such as washers, bolts or nuts are dropped in the fan. 3. Loosen the 3 pcs of M4x8 torx screws (3 Nm) from both sides of the lower side plate of the module. NOTE: You don’t have to unscrew them completely. Pull off the lower side plate. (Figure 30). 4. Figure 38: Phase 1: removing the 3 M4x8 torx screws from the lower side plate and disconnecting and removing the fan (chapter 6). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 38 / 66 5. Remove the AOFC-0X board and the plastic protection sheet by unscrewing the 4 pcs M4x8 torx screws (3 Nm) (Figure 31). Also disconnect the AOFI-XX output cables. Figure 39: Remove the AOFC-0X board. 6. Pull out the current transducers’ metal cover plates. It is more convenient to tilt the covers upwards while pulling them out (Figure 32). Figure 40: Pull out the current transducers’ covers. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 39 / 66 7. 1. Loosen the current transducer packages by unscrewing the M4x8 torx screws. This will help the procedure of removing the current transducer bus bars (Figure 35). 2. Unscrew the blue capacitors from the current transducer bus bars. There is one attached to each current transducer bus bars (1 pc M4x8 combi torx screw). Tightening torque for the capacitors is 1.5 Nm (Figure 33). Figure 41: 1. Loosen the CT packages and 2. unscrew the capacitors from the bus bar ends. 8. Detach the current transducer bus bar from the isolation pillars by unscrewing the M5x12 combi torx screws (3 Nm) (Figure 34). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 40 / 66 Figure 42: Remove the M5x12 combi (3 Nm) from the current transducer bus bar isolation pillars. 9. Loosen the M12x35 (70 Nm) bolts attaching the current transducer bus bars and module output bus bars. You can move the current transducer packages in order to make more room for the tools (Figure 35). Figure 43: Loosen the connecting bolts between the current transducer bus bar and the moduel output bus bar. 10. Unscrew the M8x16 combi bolt in order to be able to push the W-phase bus bar outwards. This way it is possible to pull out the M12 bolt (Figure 36). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 41 / 66 Figure 44: Unscrew the M8x16 bolt in order to be able to move the W-phase bus bar. 11. Pull out the current transducer package and the bus bar (Figure 37). Figure 45: Current transducer + bus bar. 12. Slide out the metal casket surrounding the current transducer. Tilt the current transducer bus bar and pull it out without using excess force. Replace the current transducer and repeat the procedure backwards (Figure 38). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 42 / 66 Figure 46: Current transducer. Maintenance Tips: Replacing the AOFI-XX du/dt output filter (+E205) Warning! Always read the whole instruction before starting the maintenance procedure. Warning! When operating the module in standing position, bare in mind that the module has a high center of gravity. Always use the module’s support legs. Warning! When rebuilding the module, pay extra attention to correct torques. 1. Spread the module’s support legs by pushing the string and turning the leg (Figure 39). 2. Remove the left hand side plate. To do this, loosen 4 pcs M4x8 torx screws (3 Nm) on each side of the module. Pull out the cover plate (Figure 39). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 43 / 66 Figure 47: Loosen the 4 + 4 pcs M4x8 screws and pull out the cover plate. 3. Disconnect the 9 pcs M8x25 bolts, washers, pressure washers and nuts (22 Nm) from the IGBT output terminals (Figure 40). This is needed in order to release the AOFI-XX input cables (terminals A1 – A9) (Figure 40). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 44 / 66 Figure 48: Disconnect the AOFI-XX input cables (A1 – A9) by removing the M8x25 bolts from the IGBT output terminals. 4. Remove the right hand side cover plate (Figure 41). Figure 49: Remove the right hand side lower cover plate by loosening the 3 + 3 pcs M4x8 (3 Nm) torx screws. 5. Unscrew the 13 pcs M4x8 torx screws (3 Nm) and pull out lower cover plate (Figure 42). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 45 / 66 Figure 50: Unscrew 13 pcs M4x8 torx screws and pull lower cover plate. 6. Pull out the upper cover plate. Disconnect the AOFI-XX output cables (9 pcs M8x25 bolts, 18 pcs of M8 washers, 9 pcs of M8 pressure washers and 9 pcs M8 nuts; torque is 25 Nm) (Figure 43). Figure 51: Pull out the upper cover plate. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 46 / 66 7. The AOFI-XX filter is extremely heavy. It is recommended that one first unscrews two M4x8 torx screws (3 Nm) and loosens the remaining two a few turns (as shown in Figure 44). Figure 52: Unscrew 2 pcs M4x8 screws attaching the AOFI filter from front and rear plates. Loosen the remaining two M4x8 screws (marked by a red arrow). 8. Unscrew the 2 pcs remaining M4x8 torx screws (3 Nm). While unscrewing the screws, weigh the filter with your other hand. Finally, carefully pull out the AOFI-XX du/dt filter (Figure 45). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 47 / 66 Figure 53: Unscrew the remaining 2 pcs M4x8 torx screws. Wigh the AOFI-XX filter with other hand and pull out the filter. Maintenance Tips: Replacing the DC Capacitor Bank Warning! Always read the whole instruction before starting the maintenance procedure. Warning! When operating the module in standing position, bare in mind that the module has a high center of gravity. Always use the module’s support legs. Warning! When rebuilding the module, pay extra attention to correct torques. Electrolyte Capacitor. 1. Spread the module’s support legs by pushing the string and turning the leg (Figure 39). 2. Remove the left hand side plate. To do this, loosen 4 pcs M4x8 torx screws (3 Nm) on each side of the module. Pull out the cover plate (Figure 46). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 48 / 66 Figure 54: Loosen the 4 + 4 pcs M4x8 screws and pull out the cover plate. 3. Disconnect the 9 pcs M8x25 bolts, washers, pressure washers and nuts (22 Nm) from the IGBT output terminals (Figure 40). This is needed in order to release the AOFI-XX input cables (terminals A1 – A9) (Figure 47). Figure 55: Disconnect the AOFI-XX input cables (A1 – A9) by removing the M8x25 bolts from the IGBT output terminals. 4. Disconnect all circuit boards in the control unit, pull out the control unit by loosening 4 pcs M4 serpress nuts (3 Nm), disconnect the flat cables from the AGDR boards, remove the ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 49 / 66 18 pcs M6x12 combi torx screws (3 Nm) and unscrew the 3 pcs M4x8 combi torx screws from the DC bus bar (Figure 48). Figure 56: Disconnect all electrical boards. Remove the control unit (4 pcs M4 serpress nuts), clamp capacitors and the DC bus bar connection screws (3 pcs M4x8 combi torx screws). 5. Remove the right hand side cover plate (Figure 41). Figure 57: Remove the right hand side lower cover plate by loosening the 3 + 3 pcs M4x8 (3 Nm) torx screws. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 50 / 66 6. Unscrew the 13 pcs M4x8 torx screws (3 Nm) and pull out lower cover plate (Figure 42). Figure 58: Unscrew 13 pcs M4x8 torx screws and pull lower cover plate. 7. Pull out the upper cover plate. Disconnect the AOFI-XX output cables (9 pcs M8x25 bolts, 18 pcs of M8 washers, 9 pcs of M8 pressure washers and 9 pcs M8 nuts; torque is 25 Nm) (Figure 43). Figure 59: Pull out the upper cover plate. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 51 / 66 8. The AOFI-XX filter is extremely heavy. It is recommended that one first unscrews two M4x8 torx screws (3 Nm) and loosens the remaining two a few turns (as shown in Figure 44). Figure 60: Unscrew 2 pcs M4x8 screws attaching the AOFI filter from front and rear plates. Loosen the remaining two M4x8 screws (marked by a red arrow). 9. Unscrew the 2 pcs remaining M4x8 torx screws (3 Nm). While unscrewing the screws, weigh the filter with your other hand. Finally, carefully pull out the AOFI-XX du/dt filter (Figure 45). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 52 / 66 Figure 61: Unscrew the remaining 2 pcs M4x8 torx screws. Wigh the AOFI-XX filter with other hand and pull out the filter. 10. Unscrew the 4 pcs M6x12 torx screws from the dc bus bars (Figure 54). Remove any electrical connections i. e. the discharge resistor chain wires (M6x12; 3 Nm). Figure 62: Unscrew the 4 pcs M6x12 torx scerws from the DC (+) and DC (-) bus bars. 11. Unscrew the M5 serpress nuts from the DC-busbar insulation pillars so that the insulator pillars are still attached to the module top plate (Figure 55). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 53 / 66 Figure 63: Unscrew 4 pcs serpress M5 nuts from the insulator pillars (5 Nm). 12. Remove the DC bus bar support plates (Figure 56). Figure 64: Remove the DC bus bar support plates by unscrewing the 4 pcs M5 serpress nuts. 13. Unscrew the 3 + 3 pcs M4x8 torx screws (3 Nm) (top plate of the module) from both the front and back plates of the module (Figure 57). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 54 / 66 Figure 65: Unscrew the 3 + 3 pcs M4x8 torx screws from the top plate. 14. Remove the top plate and insulator sheet by unscrewing the remaining 5 pcs of M4x8 torx screws (3 Nm). Figure 66: Removing the module top plate. 15. Unscrew the lower 2 + 2 M4x8 torx screws ( front and back plate, as shown in Figure 59) that fix the DC capacitor bank’s bottom plate. Loosen the 1 pcs upper M4x8 torx screws a few turns. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 55 / 66 Figure 67: Unscrew the 2 + 2 pcs of M4x8 torx screws (3 Nm). Loosen the uppest M4x8 torx screws a few turns. 16. Tilt the DC capacitor bank and unscrew the remaining 1 + 1 pcs M4x8 torx screws. Figure 68: Tilt the DC capacitor bank and unscrew the remaining M4x8 torx screws. 17. When reassembling the capacitor bank, see instructions for different layouts in Appendix I (300 - 500 V) and Appendix II (690 V). Film Capacitor (+E212) Warning! Always read the whole instruction before starting the maintenance procedure. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 56 / 66 Warning! When operating the module in standing position, bare in mind that the module has a high center of gravity. Always use the module’s support legs. Warning! When rebuilding the module, pay extra attention to correct torques. 1. Remove the control unit, IGBT clamp capacitors and the AOFI-XX filter. The most convenient way of doing this is to remove the left hand side cover plate, disconnect all the wires, pull out the control unit (loosen 4 M4 serpress nuts (1.2 Nm)) and the IGBT clamp capacitors (9 pcs; 18 x M6x12 combi torx screws (3 Nm)). It is also necessary to remove the du/dt filter AOFI-XX input cables (9 x M8x25 bolt, M8 pressure washer, M8 washer and M8 nut; 25 Nm) from the IGBT output terminals (Figure 61). Figure 69: Remove the left side plate, control unit, AOFI du/dt filter's input cables and IGBT clamp capacitors. 2. Remove the AOFI-XX output filter from the right hand side of the module. To do this, follow instructions shown in Figure A3. Both covers must be removed for also the AOFI-XX output cables must be removed from the current transducer bus bar input terminals (9 x M8x25 bolt, M8 pressure washer, M8 washer and M8 nut; 25 Nm). Remove the du/dt filter AOFI-XX (Figure 62). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 57 / 66 Figure 70: Remove the right side plates AOFI cables and the AOFI du/dt filter. 3. Unscrew the M4x8 torx screws (3 Nm) from the module skeleton as shown in Figure 63. Note that only the screws in front plate and back plate are removed. The ones on the top are not unscrew (5 screws on both sides; three on the top plate and two in the middle of the front / back plate). ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 58 / 66 Figure 71: Remove the 5 + 5 M4x8 torx screws that fix the film capacitor bank. 4. Carefully tilt the film capacitor bank and remove it from the module (Figure 64). Figure 72: Remove the film capacitor bank. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 59 / 66 Appendix I: Capacitor layouts for 300 - 500 V ElCo Figure 73: 500 V ELCO structure. NOTE: The upper edge is the one with M4x8 torx screw holes. Figure 74: 500 V ElCo layout 1. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 60 / 66 Figure 75: 500 V ElCo layout 2. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. Figure 76: 500 V layout 3. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 61 / 66 Figure 77: 500 V ElCo layout 4. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 62 / 66 Appendix II: Capacitor layout for 690 V ElCo Figure 78: 690 V ElCo structure. NOTE: The upper edge is the one with M4x8 torx screw holes. Figure 79: 690 V ElCo layout 1. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 63 / 66 Figure 80: 690 V ElCo layout 2. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. Figure 81: 690 V ElCo layout 3. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO 3AFE 6479 3675 00262693_E.DOC Revision Page E 64 / 66 Figure 82: 690 V ElCo layout 4. The capacitor layout in this picture is the same for each listed power rating. The colours in the picture are not essential. ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Appendix III: Module phase order Figure 83: Module phase order (left hand side) 3AFE 6479 3675 00262693_E.DOC Revision Page E 65 / 66 ABB Drives Dept. Project MAINTENANCE INSTRUCTION Technical Description Status Date STRAW 16.Nov 2011 BERRY Author Status LAHTINEN JUHANI APPROVED/KARVINEN RAUNO Figure 84: Module phase order (right hand side). 3AFE 6479 3675 00262693_E.DOC Revision Page E 66 / 66
