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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.
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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
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A
2 / 11
Figure 1. ACS800-104 module
Table 1. Parts list
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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.
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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
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Figure 3.
Figure 4.
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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
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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
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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
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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
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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
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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
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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.
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R8iMaintinstr_00262693
ABB Drives
Dept.
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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
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A
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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.
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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
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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.
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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
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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
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