ACS800 R7 Instructions for replacing IGBT module 3AXD00000504740

Replacing IGBT
Instruction for module to

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ACS800 R7 unit
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© Copyright 2006 ABB.
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18.9.2020
Revision B
21/02/2006
3AXD00000504740
Content
 General info
 ACS800 R7 main circuit diagram
 Changing the ACS800 R7 unit IGBT
 Required tools
 Remove front and side plates of the drive
 Remove DC-capacitors
 Remove circuit board holder plastic
 Remove the corner post
 Remove fan transformer assembly plate
 Open supply busbar connections
 Remove AINP-board
 Remove air guide plexi
 Remove heatsinks
© Copyright 2006 ABB - 2 -
 Change IGBTs to heatsink

 Putting the drive back together
Vault ID: 00504740
 Inspecting your work

General info
 ALWAYS MAKE SURE THAT THE DRIVE IS POWERED OFF
BEFORE DOING ANY SERVICE OR MAINTENANCE WORK!
 DISCONNECT THE POWER FROM THE WHOLE DRIVE
 REMOVE THE SUPPLY FUSES
 IN CASE THE DRIVE IS CONNECTED TO PERMANENT MAGNET
MOTOR, MAKE SURE THAT THE MOTOR SHAFT CAN’T ROTATE
 MEASURE THAT THERE IS NO VOLTAGE IN THE INPUT
TERMINALS (BETWEEN PHASES AND BETWEEN PHASES AND
GROUND)
 MAKE SURE THAT NO-ONE ELSE CAN POWER UP THE UNIT
WHILE YOU ARE DOING THE SERVICE WORK
 WAIT AT LEAST 5 minutes after powering off the drive to make sure
that there is no voltage in the DC-capacitor bank
 Measure the DC-voltage from the DC-busbars after opening the unit
 Consider the DC-bus to be charged until you

have verified with measurement that there is no
Vault ID: 00504740
voltage
 One location to measure DC+ and DC- busbar
voltage is shown on the picture
General info
 There are several different types of IGBT/AGDR packages
are used in different size ACS800 R7 drives
 Make sure that you use the correct type of spare part for
the drive
 See more info from ABB Drives IHMM
ACS800 Product Notice 13
ACS800 Product Notice 14
 AGDR-7xC boards are used in R7 units built after May 2005
(manufacturing year & week can be seen from the module serial number
(digits 2-3 indicate manufacturing year and digits 4-5 indicate
manufacturing week)
 ACS800 R7 drive can be built with FUJI or EUPEC IGBT module
Vault ID: 00504740
General info
 AGDR-6x series boards can be replaced with AGDR-7x

series boards as follow:
 AGDR-61C or AGDR-61  AGDR-71C
 AGDR-7x series boards should be always used

with ACS800 R7 drives, even if the drive was originally
shipped with AGDR-6x series driver boards!
Vault ID: 00504740
General info
 Take your time when changing the IGBTs

 The following pictures are from ACS800-04 230 V / 400 V / 500 V
with brake chopper (+D150 on the type code)
 In 690 V drives the capacitor bank has one extra wire!
 Process for 02 and U2 drives is almost similar. On those drives input
busbars must also be removed
 Take breaks to inspect your work
 Know what you are doing. Do not try to guess.
 All connectors are labelled (e.g A43:X2)
 From the next slide you can check that A43 is the APOW-01 board;
from that board you can find connector X2
 In following slides, mechanical connections are marked GREEN
and electrical connections in RED

Vault ID: 00504740
General info
 WARNING! The printed circuit boards contain

components sensitive to electrostatic discharge.
 Wear a grounding wristband when handling the boards.
 Do not touch the boards unnecessarily.
Vault ID: 00504740
Vault ID: 00504740
ACS800 R7 main circuit diagram 1/2
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ACS800 R7 main circuit diagram 2/2
Changing IGBTs, required tools
 Tools needed after module has been removed from cabinet

 PZ2 screw driver (Crosshead) (only needed for front and side cover
plates)
 T15 screw driver (Torx)
 10 mm wrench
 Torque wrench (1 Nm and 5 Nm, needed only for tightening the IGBT)
 Socket set with reversible ratchet wrench, 10 mm is needed
 Short and long extension (about 30 cm) for the ratchet wrench
 Rubbing alcohol & piece of cloth
 Additional tools are usually needed in order to remove the module

from cabinet
Vault ID: 00504740
Removing front and side plates
 Use PZ2 screw driver to remove the ACS800

R7 front and side covers
 Using PH (Philips) screw driver will damage
the screws
 Remove the front plate (with air ventilation
holes)
 Remove side plate
 It is possible that you have to remove the
module from the cabinet
 Trolley 68553491 is handy, if the module must be
pulled out of the cabinet
 Trolley can be found from standard

price list
Vault ID: 00504740
 Also available from PartsOnline in

case rapid delivery is needed
Removing DC-capacitors
 MEASURE THAT THE DC-VOLTAGE IS 0 V
BEFORE TOUCHING ANYTHING ELSE
 DC capacitor bank must be removed
after removing the covers
 All 10 mm screws and nuts has to be
opened to remove the DC-capacitor bank
 Mechanical connections
 Three screws
 Electrical connections
 Five nuts
 Two nuts in top of the capacitor bank
 One nut in middle (connects grey
wire to the capacitor bank)
 Two nuts in bottom of the capacitor

bank (connects DC-bus voltage to
the pedestal DC+ & DC- terminals)
Vault ID: 00504740
 Be careful not to damage DC-capacitor

bank when handling it!
Removing the AINT card holder
 Remove insulator plexi in front of
AINT-board (two T20 screws)
 Remove optical fibres from the
AINT-board (first release the fibre
from the clip and then pull from
connectors, DO NOT pull from
the fibres)
 Remove IGBT control flat
ribbon cables (connectors X1-X3)
 Remove current transducers
cable (connector X7)
 Remove power supply cable (connector X8)
 Remove input bridge control board +12V power cable (connector X6)
 In case the drive has internal brake chopper (+D150 in the type code),
remove Brake IGBT control flat ribbon cable (connector X4)
 To remove the card holder: Push the two clips on top of the plastic card
Vault ID: 00504740
holder gently downwards with a screw driver 

Pull the top part of the card holder slightly towards you 
Pull the card holder upwards and then the bottom clips are
also released  Pull the card holder out
Removing the corner post
 To remove the corner post

 Open the nut in top of the unit
 Open the two bolts in bottom of the
unit
 Pull the corner post out
Vault ID: 00504740
Removing the fan transformer assembly plate (1/2)
 Open the RMIO power supply connector
and grounding wire from top of the drive
 Open two bolts from the top of the unit
 Pull the optical fibre out through the hole

 Open AC fan supply from W & V supply phases
 Remove wires coming from

charging resistor and diode
(on the AIBP-51 board on
the rear side of the

assembly plate)
Vault ID: 00504740
Removing the fan transformer assembly plate (2/2)
 Open three nuts that fasten the support plate to the
unit L-plate
 Open fan connector
 Remove optical fibre from
the assembly plate
 Open the last
screw that keeps
the plate on its place
 Remove the assembly plate,
be careful not to damage Fan
Transformer
 There is still one more cable
that you must open when

pulling the plate out, remove
Vault ID: 00504740
wiring from AIBP-51 board

connector X1
Opening supply busbars from input bridge
 Remove three topmost 10 mm bolts from the input
bridge power modules
 Notice the order of the wires (White – Grey – Black)
 If the unit has a braking chopper

(+D150), remove the brake chopper
IGBT-module output busbar and the

Vault ID: 00504740
connected wire by opening the

10 mm bolt
Remove AINP-board (and ABRC if chopper +D150)
 Remove wiring from AINP
connectors X3 (thyristor control
pulse wires) and X1 (+12V
supply voltage)
 Remove AINP board by pushing
from the clips on the left edge
and pulling the board out from
the left edge at the same time
 If the unit has a braking chopper (+D150), remove the

brake chopper control board (ABRC-board)
 Remove temperature measurement wire from connector X42

Vault ID: 00504740
 Remove gate control wires from X41

 Remove the board by pushing the clips on the left
edge and pulling the board out
Removing air guide and opening output busbars
 Remove the air
guide plexi by
pulling it out
 Bend the right
edge slightly
upwards and then
pull the plexi out
 Make sure that the charging resistor
wires are out of their groove
 Open the three 10 mm nuts from

the output busbars
Vault ID: 00504740
Removing the heatsink
 Open the six 10 mm bolts from the heatsink
 A long (~ 30 cm) extension is needed to reach two of

the nuts on the right hand side of the heat sink
 Nuts on the left hand side and in front can be opened
with normal set wrench
 After opening the nuts, you can pull the heat sink out
 Look out for the supply phase busbars when
pulling the heat sink out, they need to be helped
with a hand in order not to bend them
 Output busbars needs also to be helped with
hand
 In older units the plate must be bent in order to
pull the heatsink out
Vault ID: 00504740
Changing the IGBT module (1/2)
 Be careful not to hit the circuit board with any tool
 Remove all the IGBT fastening screws (8 screws to mount the IGBT to
the heatsink and 12 screws to remove the busbars from terminals)
 Clean the thermal compound from the heat sink before installing a new
IGBT on it (use rubbing alcohol)
 Clean the bottom plate of the replacement IGBT with rubbing alcohol
 Spread about one tube thermal compound to the bottom of the IGBT
 The layer of thermal compound must be thin and it must cover the whole
bottom of the IGBT module
Vault ID: 00504740
Changing the IGBT module (2/2)
 Tighten the IGBT to the heat-sink with a torque wrench
 See more info from IHMM
Replacement of the Power Modules
 First tighten all screws to 1 Nm (total 8 pcs, T20 torx is used)
 After that tighten all the screws to the final torque of 5 Nm
 Remember to place the insulators and air guides carefully
 5 Nm is used to tighten the busbars to the IGBT module terminals
(T25 torx)
 Install the ribbon cables to the AGDR

board (check correct order from cable
and connector markings)
 PRESS THE CONNECTOR WITH
YOUR THUMB FIRMLY TO THE
BOTTOM AND SECURE THE

CONNECTION BY CLOSING
Vault ID: 00504740
THE LATCHES AFTER THAT

 DOUBLE CHECK THAT
EVERYTHING IS TIGHT
AND OK
Putting the drive back together / Heatsinks
 Check once more that the IGBT is properly installed to the heatsink
(everything is tight, insulators are in place, flat ribbon cable firmly in
place)
 Insert the heatsink back to the unit
 Be careful with the input busbars (especially the U phase busbar with
the charging diode requires attention)
 Four 10 mm nuts needed to mechanically fasten the heatsink to the unit
frame L-plate
 Fasten the two 10 mm nuts above the charging resistor
 Fasten the output busbars with three 10 mm nuts
 Fasten the input bridge busbars and the wires (order, white – grey – black,
torque 5 Nm)
 If the unit has braking chopper (+D150), fasten the chopper output
busbar and the emitter wire (torque 5 Nm)
Vault ID: 00504740
Putting the drive back together / Air guide plexi
 Install the air guide plexi back to the drive

 A bit force is needed
 If the unit is built after week 36-2005, make sure that the
additional AGDR air guide goes to the small groove on the air
guide plexi
 Make sure that the charging
resistor wires go into their groove
Vault ID: 00504740
Putting the drive back together / AINP + ABRC
 Put AINP board back to its place

 Connect the thyristor control wires to connector to X3
 Connect the supply voltage wires from AINT to connector X1
 If the unit has a braking chopper (+D150), put the brake
chopper control board (ABRC-board) back
 Put the temperature measurement wire back to connector X42
 Put the gate control wires back to X41
Vault ID: 00504740
Putting the drive back together / Inspecting
 Inspect everything once more

 Check that ALL input bridge screws are tight
 If +D150, check that ALL brake IGBT screws are tight
 Check that all wires on discharging resistors are tight and in
place
 Check that all wires are in correct order
 Check that AINP (and ABRC) wires are connected properly
Vault ID: 00504740
Putting the drive back together / Assembly plate
 Install the fan transformer assembly plate back to the drive

 Be careful not to damage the transformer windings
 Remember to connect the supply phase wires back to AIBP-51
connector X1
 Reconnect the charging resistor and diode to AIBP-51
 Reconnect fan supply to phases W & V busbars
 Fasten the assembly plate to the unit frame (L-plate) with three 10 mm
nuts and one T20 torx screw
 Fasten the assembly plate to unit roof with two 10 mm bolts
 Reconnect the RMIO power cord and grounding wire (T20 screw)
 Fasten the optical fibre to the assembly plate
Vault ID: 00504740
Putting the drive back together / Corner post
 Put the corner post back

 Fasten the corner post with one 10 mm nut from the top
 Fasten the corner post with two 10 mm bolts from the bottom
Vault ID: 00504740
Putting the drive back together / DC capacitors
 Put the DC-capacitor bank back to the
drive
 Mechanically fasten the capacitor bank with
three 10 mm bolts
 Fasten the capacitor bank with
four electrical connections
(four 10 mm nuts, two nuts to
on top and two on the bottom
of the capacitor bank)
 Connect the discharge
resistors to the capacitor bank
middle point potential with one
10 mm bolt
Vault ID: 00504740
Putting the drive back together / AINT holder
 Put the AINT holder plastic back to the drive
 First make sure that the bottom clips of the board holder go into their holes
 Then push the top into its place
 Make sure that the board holder is firmly in place by trying to pull it out
 Connect the AINT wires
 Reconnect optical fibres to the AINT-board
 Reconnect IGBT control flat ribbon cables (connectors X1, X2 & X3)
 Double check that the wires are in right connectors, each ribbon cable has a
connector name written into it
 PRESS THE CONNECTOR WITH YOUR THUMB FIRMLY TO THE BOTTOM
AND SECURE THE CONNECTION BY CLOSING THE LATCHES AFTER THAT
 Reconnect current transducers cable (connector X7)
 Reconnect power supply cable (connector X8)

Vault ID: 00504740
 Reconnect input bridge control board +12V power cable

(connector X6)
 In case the drive has internal brake chopper (+D150 in the type
code), reconnect the brake IGBT control flat ribbon cable
Putting the drive back together / Inspecting
 Inspect everything once more
 Check ALL output busbar nuts
 Check ALL DC capacitor screws
 Check ALL wiring once more
 Fan circuit
 APOW
 AINT
 AINP
 ABRC (if +D150)
 DC capacitor middle point potential wire
 Fan transformer is tapped according to the supply network
 In case the supply net frequency is 60 Hz, put the transformer

Vault ID: 00504740
secondary side connector to the 220 V terminal
 After inspecting that everything is OK, put back

the insulator plexi in front of AINT board (two T20 screws)
Putting the drive back together / Cover plates
 Install the cover plates

 (Put the module back to the cabinet)
 Check that the RMIO supply cable is connected to the
drive and that the fibre is in place also in RMIO board
 Before starting the motor make sure that the main fan is
running (you can easily hear the fan when the supply
voltage is on)
 Make test run for the drive if possible
Vault ID: 00504740

ACS800 R7 Instructions for replacing IGBT module 3AXD00000504740

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ACS800 R7 Instructions for replacing IGBT module 3AXD00000504740

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Replacing IGBT

Instruction for module to

 Change IGBTs to heatsink

 Inspecting your work

 Consider the DC-bus to be charged until you

 AGDR-6x series boards can be replaced with AGDR-7x

 AGDR-7x series boards should be always used

 Take your time when changing the IGBTs

and electrical connections in RED

 WARNING! The printed circuit boards contain

 Tools needed after module has been removed from cabinet

 Additional tools are usually needed in order to remove the module

 Use PZ2 screw driver to remove the ACS800

 Trolley can be found from standard

 Also available from PartsOnline in

 Two nuts in bottom of the capacitor

 Be careful not to damage DC-capacitor

holder gently downwards with a screw driver 

 To remove the corner post

 Open two bolts from the top of the unit

 Pull the optical fibre out through the hole

 Remove wires coming from

the rear side of the

that you must open when

wiring from AIBP-51 board

 If the unit has a braking chopper

IGBT-module output busbar and the

connected wire by opening the

 If the unit has a braking chopper (+D150), remove the

 Remove temperature measurement wire from connector X42

 Remove gate control wires from X41

 Open the three 10 mm nuts from

 Open the six 10 mm bolts from the heatsink

 A long (~ 30 cm) extension is needed to reach two of

 Install the ribbon cables to the AGDR

BOTTOM AND SECURE THE

THE LATCHES AFTER THAT

 Install the air guide plexi back to the drive

 Put AINP board back to its place

 Inspect everything once more

 Install the fan transformer assembly plate back to the drive

 Put the corner post back

 Reconnect power supply cable (connector X8)

 Reconnect input bridge control board +12V power cable

 In case the supply net frequency is 60 Hz, put the transformer

secondary side connector to the 220 V terminal

 After inspecting that everything is OK, put back

 Install the cover plates

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