ABB Drives

Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

3AFE 6479 3675

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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) 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.

ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

Figure 1. ACS800-104 module

Table 1. Parts list

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ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

Table 2. Designations
DESIGNATION

NAME

TYPE

Y41

Fan

D2D160-BE02-11

Puhallin

C211 - 233

Capacitor 500V

MKP C4BSPBx4120ZA0J

Kondensaattori 500V

Capacitor 690V

MKP C4BSWBx3470ZA0J

Kondensaattori 690V

Gatedriver Board 500V

AGDR-62C

Hilapiirikortti 500V

Gatedriver Board 690V

AGDR-61C

Hilapiirikortti 690

IGBT-module 500V

FS450R17KE3

IGBT-moduuli 500V

IGBT-module 690V

FS300R12KE3

IGBT-moduuli 690V

A42

Main Circuit Interface Board

AINT-01C

Ppiiriliitynt

A43

Power Supply Card

APOW-01C

A431

Gatedriver Power Supply Board AGPS-21C

A21 - A23
V21 - V23

R21 - R23

FINNISH NAME

Teholhdekortti
Hilaohj. Tehol. 24V

Power Resistor 500V

VHP-5 2x4K7

Tehovastus 500V

Power Resistor 690V

VHP-6 3x8K

Tehovastus 690V

C251 - C267

Electrolytic Capacitor 500V

B43586-S9418-Q1

El. Kondens. 500V

C251 - C276

Electrolytic Capacitor 690V

B43586-S3468-Q1

El. Kondens. 690V

Filmi Kondes. 500V

C200

Film Capacitor 500V

UL9-20832K

Film Capacitor 690V

UL9-20833K

Filmi Kondes. 690V

R321 - R323

Output Filtering Resistor

UXP 600

Lhtosuotovastus

Z1

Output Filtering Inductor 500V

AOFI-51

Lhts.kuristin 500V

Output Filtering Inductor 690V

AOFI-61

Lhts.kuristin 500V

Figure 2.

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ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Figure 3.

Figure 4.

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

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ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

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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ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

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2. ASSEMBLING OF THE ACS800104 MODULE (STEP BY

STEP PROCEDURE)
On the left side of the module, open eight screws to remove cover. The Cover is fastened with 48 screws
and tightening torque is 2,4Nm. Under the cover is mounting plate for the APOW and AINT.

Picture 1. Mounting plate for Power Supply Card and Main Circuit Interface Board. Below the
mounting plate is INU for fan. Mounting plate is fastened with four 4x16 Torx screws and Serpress M4 nut.

ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

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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ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

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Picture 4. Release cables from their holders under the mounting plate.

Picture 5. After disconnecting mounting plate, cables from AGDR boards are hanging loose.

ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

3AFE 6479 3675

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Picture 6. Remove the capacitors and busbars connected to faulty IGBT module. They are fastened to
modules with 612 Combi-Torx screws.
If necessary, remove incoming cables from busbars. Cables are fastened with 825 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 M520
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.

ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

3AFE 6479 3675

00262693.DOC
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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 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.

ABB Drives
Dept.

Project

MAINTENANCE INSTRUCTION
Technical Description
Status Date

STRAW 18.Aug 2004

BERRY

Author

Status

FORSBERG TUOMO

APPROVED/TALJA MARKKU

3AFE 6479 3675

00262693.DOC
Revision

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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

Name

Connection of the module

pre- / final torque (Nm)

Connection of the
power terminal (Nm)

64571214
64571231
64571249
64571265
64571273
64571281

FS225R12KE3
FS300R12KE3
FS450R12KE3
FS225R17KE3
FS300R17KE3
FS450R17KE3

0,5 / 3 6
0,5 / 3 6
0,5 / 3 6
0,5 / 3 6
0,5 / 3 6
0,5 / 3 6

3
3
3
3
3
3