189762498-Reemplazo-de-IGBTs

ABB Oy Replacing the POWER 64549910
BU Drives, Helsinki 00154838_C.DOC
Module
DEPT PREPARED DATE APPROVED Revision PAGE
EJQ Ilkka Ikonen 08.03.2005 K. Ingman C 1/13
REPLACEMENT OF THE POWER MODULE
WARNING!
Warning!
DO NOT ATTEMPT ANY WORK ON A POWERED ACS800!
There is a dangerous voltage inside the cabinet. After the mains voltage is
disconnected by means of the main switch, a high voltage remains in the
capacitor bank of ACS800, which is discharged through discharge resistors. WAIT
AT LEAST FIVE MINUTES BEFORE ATTEMPTING ANY WORK ON OR
WITH THE UNIT! Always ensure by voltage measurement that the DC voltage has
dropped to zero and the mains voltage is disconnected (zero) before performing any
service or main circuit connections. Measure the DC voltage between terminals
UDC+ and UDC- and the mains voltage between terminals U1, V1 and W1 (L1, L2
and L3). The meter must withstand 1000 VDC and 750 VAC.
For more details, see Safety Instructions in the ACS800 Hardware manual.
CAUTION! ONLY A QUALIFIED ELECTRICIAN SHOULD CARRY OUT THE
ELECTRICAL INSTALLATION!
Electrostatic Discharge (ESD) can damage electronic circuits. Do not handle any
components without following ESD precautions. For more details, see ABB Oy ESD
Directive.

ABB Oy Replacing the POWER 64549910
BU Drives, Helsinki 00154838_C.DOC
Module
DEPT PREPARED DATE APPROVED Revision PAGE
EJQ Ilkka Ikonen 08.03.2005 K. Ingman C 2/13
Power Module Handling Precautions
Caution must be observed in both transport and handling of semiconductors. IGBT
and other modules can be destroyed by static electricity. Therefore, the following
precautions should be observed during handling.
- When handling a power module, hold the package and avoid touching
the terminals, especially the gate terminal.
- Always use an earthed wrist band when handling a power module.
Accessing the POWER Module
- Clear a suitable space outside of immediate work area for removed screws,
bolts, components and subassemblies to avoid mislaying or damaging them.
- Study Safety Instructions in the ACS800 Hardware manual.
- Disconnect the mains supply.
- Wait at least five minutes.
- Remove the front cover of the ACS 800 Unit.
- Measure the DC voltage and the mains voltage. The voltages must be zero
before you continue working on the unit.
- Install the wrist band and the earthing mat according to ABB Oy ESD
Directive.
- Put the wrist band on your wrist.
- Remove the boards and busbars to access to the power module.
- Remove the wiring.
- Remove the faulty power module.
- Clean the heat sink surface with an appropriate solvent (e.g. Grafol) and a
soft cloth from excess thermal compound and particles.
Thermal Compound
The recommended thermal compound type is WPS II.
The power module spare parts kit includes a tube of thermal compound.

ABB Oy Replacing the POWER 64549910
BU Drives, Helsinki 00154838_C.DOC
Module
DEPT PREPARED DATE APPROVED Revision PAGE
EJQ Ilkka Ikonen 08.03.2005 K. Ingman C 3/13
POWER Module Assembly
When installing a power module on a heat sink, the following instructions should be
applied to maximise the effect of the heat sink and to minimise the stress
concentrated on the power module.
4-screw-type power modules
- Clean the base of the module with an appropriate solvent (e.g. Grafol) and a
soft cloth from particles.
- Apply a thin layer of thermal compound with a rubber spatula or with the
roller on the base of the module. The thermal compound layer should be as
thin as possible but metal should not be visible through the compound (figure
1).
Figure 1. Thermal compound applied to power module
- Put the power module on the heat sink and press by hands to extend the
thermal compound. Press at least 5 seconds.
- Tighten the screws to a pre-torque according to tables 1, 3 and 5 in sequence
1-4-3-2 according to Figure 2 .

ABB Oy Replacing the POWER 64549910
BU Drives, Helsinki 00154838_C.DOC
Module
DEPT PREPARED DATE APPROVED Revision PAGE
EJQ Ilkka Ikonen 08.03.2005 K. Ingman C 4/13
Figure 2. Upper view of the power module
- Tighten the screws to the final torque according to tables 1, 3 and 5 in
sequence 2-3-4-1 according to Figure 2.
- After the tightening a small rim (1 – 4 mm) of thermal compound must be
seen around the mounted module. This shows that amount of thermal
compound is sufficient.
- Wipe off the excess of thermal compound.
- Use the torques according to tables 2, 4 and 6 to connect busbars and cables
to power modules.
2-screw-type power modules
In case of two screw type power modules follow the steps of 4 screw type modules
applied to 2 screw type modules. Assembling and connection torques can be found
in tables 1-10.
8-screw-type power modules
In case of eight screw type power modules follow the steps of 4 screw type modules
applied to 8 screw type modules except tightening instruction wich is presented
below. Assembling and connection torques can be found in tables 1-10.
Tighten the screws to a pre-torque according to table 1 and in sequence 2-6-3-7-4-8-
1-5 according to Figure 3 .

ABB Oy Replacing the POWER 64549910
BU Drives, Helsinki 00154838_C.DOC
Module
DEPT PREPARED DATE APPROVED Revision PAGE
EJQ Ilkka Ikonen 08.03.2005 K. Ingman C 5/13
Figure 3. Upper view of the power module
- Tighten the screws to the final torque according to table 1 in sequence 2-6-3-
7-4-8-1-5 according to Figure 3.
PLEASE REPORT THE FAILED POWER MODULE ACCORDING TO WARRANTY
DIRECTIVE.