ACS800 Maintenance preventive

ABB Drives
MAINTENANCE INSTRUCTION
Technical Description
3AFE 6479 3675
00262693_E.DOC
Dept. Project
STRAW
BERRY
Status Date
16.Nov 2011
Author
LAHTINEN JUHANI
Status
APPROVED/KARVINEN RAUNO
Revision
E
Page
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
MAINTENANCE INSTRUCTION
Technical Description
3AFE 6479 3675
00262693_E.DOC
Dept. Project
STRAW
BERRY
Status Date
16.Nov 2011
Author
LAHTINEN JUHANI
Status
APPROVED/KARVINEN RAUNO
Revision
E
Page
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
MAINTENANCE INSTRUCTION
Technical Description
3AFE 6479 3675
00262693_E.DOC
Dept. Project
STRAW
BERRY
Status Date
16.Nov 2011
Author
LAHTINEN JUHANI
Status
APPROVED/KARVINEN RAUNO
Revision
E
Page
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
MAINTENANCE INSTRUCTION
Technical Description
3AFE 6479 3675
00262693_E.DOC
Dept. Project
STRAW
BERRY
Status Date
16.Nov 2011
Author
LAHTINEN JUHANI
Status
APPROVED/KARVINEN RAUNO
Revision
E
Page
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
MAINTENANCE INSTRUCTION
Technical Description
3AFE 6479 3675
00262693_E.DOC
Dept. Project
STRAW
BERRY
Status Date
16.Nov 2011
Author
LAHTINEN JUHANI
Status
APPROVED/KARVINEN RAUNO
Revision
E
Page
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