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DEPT PREPARED
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EJQ
Ilkka Ikonen
08.03.2005
K. Ingman
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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.
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Ilkka Ikonen
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K. Ingman
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Thermal Compound The recommended thermal compound type is WPS II. The power module spare parts kit includes a tube of thermal compound.
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Ilkka Ikonen
08.03.2005
K. Ingman
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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 .
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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 2-6-3-7-4-81-5 according to Figure 3 .
64549910
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EJQ
Ilkka Ikonen
08.03.2005
K. Ingman
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Figure 3. Upper view of the power module Tighten the screws to the final torque according to table 1 in sequence 2-6-37-4-8-1-5 according to Figure 3.
64549910
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Ilkka Ikonen
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K. Ingman
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64549910
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Ilkka Ikonen
08.03.2005
K. Ingman
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Spare part code Module Code R7-R8 frames 64571214 (IGBT) 68313198 64606221 (AGDR) 64571231 (IGBT) 64635867 64606221 (AGDR) 64571249 (IGBT) 64635875 64606221 (AGDR) Replaced with 64571265 (IGBT) 64717839 64649183 (AGDR) 64571273 (IGBT) 64717839 64649183 (AGDR) 64571281 (IGBT) 64781812 64606239 (AGDR)
Module Type FS225R12KE3+ AGDR-61C FS300R12KE3+ AGDR-61C FS450R12KE3+ AGDR-61C FS225R17KE3+ AGDR-66C FS300R17KE3+ AGDR-66C FS450R17KE3+ AGDR-62C
Screws 8pcs M5x20 * 8pcs M5x20 * 8pcs M5x20 * 8pcs M5x25 ** 8pcs M5x20 * 8pcs M5x20 * 8pcs M5x20 * 8pcs M5x25 **
* The needed screw type for aluminium heatsink, screws not included in the spare part kit ** The needed screw type for Copper baseplate heatsink (high power type) , screws not included in the spare part kit
Maximum final torque for Fuji and Mitsubishi IGBT modules is 4,0 Nm (applies to Fuji and Mitsubishi 2nd source components if 1st source component has higher final torque). Table 2. IGBT connection torques to busbars and cables
Spare part code Module code Module type DC-busbars Output phase cables 3,0 Nm, M5x35 3,0 Nm, M5x35 3,0 Nm, M5x35 3,0 Nm, M5x35 3,0 Nm, M5x35 3,0 Nm, M5x35 5,0Nm M6x16 5,0Nm M6x16 5,0Nm M6x16 5,0Nm M6x16 5,0Nm M6x16 5,0Nm M6x16 5,0Nm M6x16 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 Output phase busbars R5-R6 frames 68443067 64439677 68443075 Replaced with 68443202 68443202 68443172 68443181 68443199 64439693 64666002 64666070 64624768 64624857 64624873
CM100DY-24A SKM145GB124DN CMY150DY-24A SKM195GB124DN SKM100GB173D SKM145GB174DN FF150R12KE3G SKM200GB128D FF200R12KE3 SKM300GB128D FF300R12KE3 SKM400GB128D SKM200GB174D FS225R12KE3+ AGDR-61C FS300R12KE3+ AGDR-61C FS450R12KE3+ AGDR-61C FS225R17KE3+ AGDR-66C FS300R17KE3+ AGDR-66C FS450R17KE3+ AGDR-62C
3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12 5,0 Nm, M6x12
68443229 64666282 R7-R8 frames 64571214 (IGBT) 68313198 64606221 (AGDR) 64571231 (IGBT) 64635867 64606221 (AGDR) 64571249 (IGBT) 64635875 64606221 (AGDR) Replaced with 64571265 (IGBT) 64717839 64649183 (AGDR) 64571273 (IGBT) 64717839 64649183 (AGDR) 64571281 (IGBT) 64781812 64606239 (AGDR)
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Ilkka Ikonen
08.03.2005 Module type VUO121-16N01 SKD116/18-L75 SKD146/18-L75 SKKH42/16E SKKH57/16E SKKH72/16E SKKH42/18E TD162N16KOF TD140N18KOF TD140N18KOF TD162N16KOF TD180N16KOF SKKH250/16E MCD255-16IO1 TD250N16KOF SKKH250/18E MCD255-18IO1 TD250N18KOF SKKH330/16E MCD312-16IO1 TD330N16KOF SKKH330/18E MCD312-18IO1 SKKH500/16E TD570N16KOF SKKH500/18E TD425N18KOF
K. Ingman Screws 2pcs M5x16 2pcs M5x16 2pcs M5x16 2pcs M6x20 2pcs M6x20 2pcs M6x20 2pcs M6x20 2pcs M6x16 2pcs M6x16 2pcs M5x25 2pcs M5x25 2pcs M5x25 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4pcs M5x20 4 pcs M5x25 4 pcs M5x25 4 pcs M5x25 4 pcs M5x25
C Pre-torque 1,2 Nm 1,2 Nm 1,2 Nm 1,2 Nm 1,2 Nm 1,2 Nm 1,2 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm 0,5 Nm
8/13 Final torque 3,0 Nm 3,0 Nm 3,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 5,0 Nm 6,0 Nm 5,0 Nm 6,0 Nm
Spare part code Module Code R4-R6 frames 64605542 64062093 64703421 64666576 Replaced with 64666584 64703421 68296773 10016525 68296871 10003270 68442982 64553186 68296919 10034655 68443032 64642456 64677004 64522400 R7 and R8 frames 64677004 64522400 64635255 64642456 64635255 64522264 64783807 10003326
64783807
10034698
64783807
64407384
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3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 3,0 Nm, M5x12 5,0 Nm, M6x12/M6x20 5,0 Nm, M6x12/M6x20 5,0 Nm M6x16 5,0 Nm M6x16 5,0 Nm M6x16 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M10x20 12,0 Nm M10x20 12,0 Nm M10x20 12,0 Nm M10x20
R7 and R8 frames 64677004 64522400 64635255 64642456 64635255 64522264 64783807 10003326
64783807
10034698
64783807
64407384
TD140N18KOF TD162N16KOF TD180N16KOF SKKH250/16E MCD255-16IO1 TD250N16KOF SKKH250/18E MCD255-18IO1 TD250N18KOF SKKH330/16E MCD312-16IO1 TD330N16KOF SKKH330/18E MCD312-18IO1 SKKH500/16E TD570N16KOF SKKH500/18E TD425N18KOF
5,0 Nm M6x16 5,0 Nm M6x16 5,0 Nm M6x16 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M8x20 8,0 Nm M8x20 12,0 Nm M8x20 12,0 Nm M10x20 12,0 Nm M10x20 12,0 Nm M10x20 12,0 Nm M10x20
Maximum final torque for Fuji and Mitsubishi IGBT modules is 4,0 Nm (applies to Fuji and Mitsubishi 2nd source components if 1st source component has higher final torque).
64549910
00154838_C.DOC
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EJQ
Ilkka Ikonen
08.03.2005
K. Ingman
10/13
64549910
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Ilkka Ikonen
08.03.2005
K. Ingman
11/13
7MBR10SA-120 7MBR15SA-120 7MBR25SA-120 7MBR35SB-120 7MBR50SB-120 6MBI75S-120 BSM50GD170DL CM100DY-24A CM150DY-24A SKM145GB174DN FF150R12KE3G FF200R12KE3 FF300R12KE3 SKM200GB174D FS225R12KE3 FS300R12KE3 FS450R12KE3 FS225R17KE3 FS300R17KE3 FS450R17KE3
* * * * * *
When changing the IGBT modules of R5-R6 units always all three modules must be replaced at once during the warranty period.
64549910
00154838_C.DOC
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EJQ
Ilkka Ikonen
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K. Ingman
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SKKH500/18E
For R7 and R8 frame sizes the number of the spare part articles is reduced by combing current and voltage classes, because of this never use as a spare part the second source component of the spare component mentioned in the table. For example although TD425N18KOF is second source for SKKH500/18 it doesnt cover the current ratings which SKKH500/18 is capable when used instead of SKKH500/16 as spare part. When changing the input bridge modules it is recommended to replace all three modules at once. Table 13. Brake IGBT module 2nd source list
Module Code 2nd source supplier type 2nd source supplier Eupec Eupec 1st source supplier type 1st source supplier Fuji Semikron Semikron Semikron Eupec Semikron Semikron Semikron Eupec R4-R6 frames 64439731 BSM35GD120DLCE3224 Replaced with BSM100GAL120DLCK 64439758 64439758 64667416 64624873 SKM400GB128D 64666282 R7 and R8 frames 64408917 SKM400GB128D 64408925 BSM200GB170DLC 64780620 SKM400GB176D
Semikron
When changing the brake-IGBT modules of R8 units always all three modules must be replaced at once during the warranty period.
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00154838_C.DOC
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EJQ
Ilkka Ikonen
08.03.2005
K. Ingman
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Short circuiting unnecessary gate-emitter terminals in R7 and R8 brake choppers In R7 and R8 frame size converters the used/replacement Brake IGBT module might in some cases have another pair of gate-emitter connectors (depending the module type and supplier, in type code either FF or GB) which must be shorted, otherwise the module turns on by itself . Use the delivered short circuit wire(s) to short the connectors 4 and 5 (gate and emitter of the upper leg IGBT) of each module.
Figure 4 terminals to be shorted if present Table 14. Discharging resistor 2nd source list
Module Code 10028493 10028507 64522736 64522787 2nd source supplier type 2nd source supplier 1st source supplier type NXBU 3x4,7K 50W NXBU 3x6,8K 65W VHP-5 2x4K7 66W VHP-6 3X8K 51W 1st source supplier Aspocomp Aspocomp EBG EBG
1st source supplier type CAH 150 27R VHPR 80 HX 3R3 VHPR 80 HX 6R8