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ABB Drives MAINTENANCE INSTRUCTION 3AFE 6479 3675
Technical Description 00262693_E.DOC

Dept. Project Status Date Author Status Revision Page
APPROVED/KARVINEN RAUNO
STRAW 16.Nov 2011 LAHTINEN JUHANI E 1 / 66
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Safety Issues and ESD .........................................................................................................................2

Voltage Measurement......................................................................................................................3
High Center of Gravity ....................................................................................................................3
ESD..................................................................................................................................................3
Cabinet and Module Serial Numbers...................................................................................................4
Serial Number Hierarchy.................................................................................................................4
ACS800-X7 Cabinet....................................................................................................................4
ACS800 MD Line-up ..................................................................................................................5
Practical Examples ..........................................................................................................................5
Filling Out the Warranty Report..........................................................................................................9
General Description of the ACS800-104 Module .............................................................................12
Option Codes .................................................................................................................................12
Parts List ........................................................................................................................................13
Mechanical Parts for module with option code +V991.............................................................13
Mechanical Parts for old R8i module (without +V991) ............................................................17
Electrical Parts...........................................................................................................................20
About Maintenance Procedures.........................................................................................................23
Testing the Module after Maintenance ..........................................................................................23
ACS800-104 On-Site Tester......................................................................................................23
Maintenance of the Fan .....................................................................................................................23
Maintenance Tips: Left Hand Side of the Module ............................................................................24
Replacing the Controlled Fan Option (+C126) Circuit Boards .....................................................24
Replacing an AFPS-01C board with and AFPS-11C board ......................................................25
Replacing the Control Unit Circuit Boards ...................................................................................29
Replacing the AGBB board (Module with 2 x IGBT)...................................................................30
Replacing the IGBT/AGDR modules............................................................................................32
Replacing the Module Heating Set (+C123) .....................................................................................34
Maintenance Tips: Right Hand Side of the Module ..........................................................................35
Replacing the AOFC-0XC Filter Capacitor Board (+E205) .........................................................35
Replacing the ATMB-01C Temperature Measurement Board......................................................36
Replacing the Current Transducers ...............................................................................................37
Maintenance Tips: Replacing the AOFI-XX du/dt output filter (+E205) .........................................42
Maintenance Tips: Replacing the DC Capacitor Bank......................................................................47
Electrolyte Capacitor. ....................................................................................................................47
Film Capacitor (+E212).................................................................................................................55
Appendix I: Capacitor layouts for 300 - 500 V ElCo ........................................................................59
Appendix II: Capacitor layout for 690 V ElCo..................................................................................62
Appendix III: Module phase order.....................................................................................................65
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Safety Issues and ESD
WARNING! All electrical installation and maintenance work on the ACS 800
should be carried out by qualified electricians.
Do not attempt 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 and W1) and earth
must be measured with a multimeter (impedance at least 1MW) 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 attempted 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 appropriate 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 appropriate care when working on the unit to avoid permanent
damage to the circuits. Do not touch the boards unnecessarily.
WARNING! Only qualified electricians are allowed to carry out work

described in this instruction. Before working with the ACS 800 or handling
the IGBT modules, read carefully the S a fe ty Ins truction on the ACS800
Hardware Manual. Ignoring the safety instructions can cause injury or
death.
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Voltage Measurement
When repairing a module one must always to remember that there might be live voltages on some
components such as capacitors. Therefore, before disconnecting the module from the cabinet, it
is important to measure the dc voltage with a multimeter.
High Center of Gravity
The ACS800-104 module has an exceptionally high center of gravity. When performing
maintenance operations for the module, it is important to make sure that the module is pulled out
from the cabinet by using a service ramp (Figure 1) and that both support legs in the rear side of
the module are opened during the maintenance (Figure 2).
Figur e 1: Pulling the module out safely. Figur e 2: Suppor ting the module dur ing maintenance.
ESD
Always use ESD protection clothes, gloves, shoes and mat if possible. Avoid unnecessary
touching of the circuit boards.
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Cabinet and Module Serial Numbers

Each cabinet, module and circuit board is equipped with a serial number. In this context, the
essential serial number information is collected from cabinet and module, which in this case refers
to an ACS800-104-XXXX-Y –inverter module.
The serial number is needed in order to maintain the field quality statistics as well as the event
history of a single cabinet and module. This has a significant strategic importance in ABB Drives
products and should be considered as an imperative each case a warranty repair is performed.
The following three chapters include important information about serial number hierarchies of
different cabinets and modules as well as practical examples on how to find the right serial
number for each case and how to fill the warranty report
Serial Number Hierarchy
ACS800-X7 Cabinet
Single drive serial numbers can be divided into two levels: cabinet level and module level (Figure
3). If for example the module has faulted, both cabinet and module level serial number is needed.
On the other hand, if f. ex. one of the control boards has a defect in it, only the cabinet level serial
number is needed for the control board cannot be traced to a module. The module serial number
is always in the same spot.
Figur e 3:Ser ial number hier ar chy of an ACS800 single dr ive cabinet. The type codes and ser ial number of the
units enclosed by a r ed r ectangle ar e impor tant.
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ACS800 MD Line-up
The multidrive serial number hierarchy is more complicated than the one for single drives (Figure
4). The first level is the device level witch is the MDs serial number. However this has little
significance for the statistics. That is why the first and second levels (device level and TL level)
are not needed for warranty reports. The serial number information needed in warranty report is
the unit level serial number and the module level serial number. If for example the module is
defected, both unit level serial number and module level serial number is needed. In Figure 4 this
means f. ex. the serial numbers from drive unit (ACS800-107-0400-7) and the module it contains
(ACS800-104-0400-7).
Sometimes the equipments are not in the same cabinet as the unit type code. Situation like this is
encountered with control boards. When again referring to Fig. 2 this could mean that the control
board RDCU-12C for unit ACS800-107-0400-7 is mounted to another locker. It must be bared in
mind that no matter where the control board is mounted, the important fact is that it controls the
mentioned unit. In this case only the unit level serial number is needed. The module serial number
is always in the same spot.
Figur e 4: Ser ial number hier ar chy of an ACS800 multi dr ive cabinet. The type codes and ser ial number of the
units enclosed by a r ed r ectangle ar e impor tant.
Practical Examples
There are some differences between the placing of the serial number stickers in different
cabinets, such as ACS800-X7 and ACS800MD. In general the serial number and type of the
ACS800-X7 cabinet can be found on the lower right side of the first cabinet door, that is, right
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above the lower air ventilation grill. In multidrive cabinets the unit serial number and type can be
found from the upper third of the door above the upper door bracket. Some examples are listed
below.
ACS800-X7-Y Single drive cabinet
The ACS800-X7 serial number label can usually be found on outer surface of the door above the
door grill (Figures 5). When filling the warranty report the serial number and the type code of the
cabinet (Figure 5) is needed. If the module is defective, the module serial number and type code
is needed as well (Figure 6).
Figur e 5: Ser ial number sticker position in the ACS800-X7 cabinet door .
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Figur e 6: Module type code and ser ial number .
ACS800MD cabinet
The ACS800MD serial number label is usually mounted on the inner surface of the door, above
the upper door bracket (Figure 7). The unit type code (f. ex. ACS800-107-XXXX-Y) is printed next
to the serial number and is needed for the warranty report as well (Figure 8). Module serial can be
found from the module as shown in Figure 6.
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Figur e 7: ACS800 Multidr ive unit type code and ser ial number .
Figur e 8: ACS800-107-1740-7 dr ive unit's type code and ser ial number .
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Filling Out the Warranty Report
When visiting the site, it is very important to fill out the warranty report form carefully. All serial
numbers and type codes must be correct and the fault description has to be detailed enough. The
customer information is also important. It is very important to know what happened at the site.
Also any considerations about the possible abnormalities before the defect are to be reported. Try
to estimate the time how long the drive has been running. Remember to evaluate the conditions in
the electrical room as well. With the serial number information the manufacturer is able to access
detailed data about the drive.
We strongly recommend that InfoPaht warranty report template, available in Installed Base, would
be used for warranty reporting. Reports should be also uploaded to Installed Base after field
service to gather history data of individual drive service history.
If installed base and infopath is not used, then a report template, which is presented in following
pages, that is available in IHMM can be used instead.
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General Description of the ACS800-104 Module

ACS800-104 (frame R8i) inverter module is used in various different frequency converters. They
might be installed in a customized OEM customer built cabinet or in an ABB Drives built cabinet.
Two different ACS800-104 modules are represented in Figure 9. NOTE: Module phase order is
showed in Appendix III.
Figur e 9: ACS800-104-XXXX-Y modules. Left module is equipped with elector ylitc DC capacitor bank while
the r ight one has a DC film capacitor .
Option Codes
The ACS800-104 R8i –modules come in various configurations. The module can be ordered with
electrolytic or film capacitor (option E212) and with or without an internal du/dt filter (option E205).
Also inverter fan can be controlled with option C126, the drive can be protected with an
unexpected start-up function (option Q950 or Q967 when replaced with STO-function), equipped
with card space heater (C123) and/or with an air filter (C124). Different options are presented in
Table 1.
Table 1: Option codes for ACS800-104 R8i modules.

Op tio n c o d e Fu nc tio n
C123 Card Space Heater (3 heating resistors and an AHCB-01C
board)
C124 Compact Filter
C126 Controlled Fan
E212 Film Capacitor
E205 du/dt-filter + Output filter board (AOFC-0X)
Q950 Prevention of Unexpected Start-Up (AGPS-21C board)
Q967 ASTO Safety Function (ASTO-21)
V991 New Type AGDR-7X and an Air Cored Choke
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Parts List
Mechanical Parts for module with option code +V991
Part codes fof the ACS800-104 R8i modules with option code +V991 are presented in following
images. Please not that there are two pages which have wind turbine specific mechanics.
Figur e 10 +V991 R8i module mechanics 1/5

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Figur e 13 +V991 R8i module mechanics 3 (wind)/5

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Figur e 15 +V991 R8i module mechanics 4 (wind)/5

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Mechanical Parts for old R8i module (without +V991)

Please note that on this document page 18 there is figure 18 which presents the old module
mechanics wind specific variant. Different components for wind module are listed in that figure
(items 1-10).
Figur e 17 Old R8i module mechanics 1/3

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Figur e 19 Old R8i module mechanics 2 (wind)/3

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Table 2 Old R8i module mechanics

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Electrical Parts
ACS800-104 (R8i) electrical parts are listed in Table 3. The information where most of the
common parts are used is listed in Table 4.
Table 3: R8i Electr ical and Option Par ts.

P a rt n a m e MRP Qty P a rt Num be r Op tio
Co d e n
Co d e
IGBT FS450R17KE3/AGDR-71C 68444217 3 A21/V21 +V991
A22/V22
A23/V23
A22/V22
A23/V23
A22/V22
A23/V23
A22/V22
A23/V23
IGBT FS450R17KE3/AGDR-61C 68336970 3 A21/V21

A22/V22
A23/V23
A22/V22
A23/V23
A22/V22
A23/V23
A22/V22
A23/V23
CURRENT TRANSDUCER LF 64572881 3 U31 – U33
1005-S/SP16
CURRENT TRANSDUCE LF 64572814 3 U31 – U33
505-S/SP13
CAPACITOR 64435001 9 C211 – C213

C4BSTBX3470ZAFJ C221 – C223
C231 – C233
CAPACITOR MKP 64423746 9 C211 – C213
C4BSNBX4120ZAJJ C221 – C223
C231 – C233
POWER RESISTOR VHP-6 64522787 3 R21 – R23

3X8K
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POWER RESISTOR VHP-5 64522736 3 R21 – R23

2X4K7
FILTER CAPACITOR 58985066 3 C31 – C33
FAN D2D160-BE02-11 64650424 1 Y41

CONTACTOR B 6-30-10 64693051 1 K1
440V4KW. CO
THICK-FILM HYBRID NRED-61 58926451 1 A28

MAIN CIRC. INTERF AINT-14C 68685826 1 A42
POWER SUPPLY APOW-01C 64605666 1 A43
GATE DRIVER BRANC AGBB- 68242843 1 A46
01C
FAN INVERTER 1 KW AFIN- 64693808 1 +C126
01C
POWER SUPPLY BOAR AFPS- 68969972 1 +C126
11C
POWER SUPPLY BOAR AFPS- 68969972 1 (Old) +C126
01C
COMPACT FILTER ELSU-W- 68228409 +C124
F6-400X65-94
HEATING CONTROL B AHCB- 64815555 1 +C123
01C (C126)
HEATING FOIL 68228727 2 R411 / R412 +C123
(C126)
GDR POWER SUPPLY AGPS- 64668064 1 +Q950
21C
PROTECTION BOARD ASTO- 3AUA0000 1 +Q967
21C 061832
EL. CAPACITOR B43586- 64410539 N C251 – C256

S3468-Q1 …
C271 – C276
EL. CAPACITOR B43586- 64410512 N C251 – C256
S9418-Q1 …
C271 – C276
CAPACITOR UL9-20833K 64793012 1 C200 +E212
OUTPUT FILTER IND AOFI-69 68634377 1 Z1 +E205

OUTPUT FILTER RES UXP 600 64650149 3 R321 – E323 +E205
OUTPUT FILTER BOA AOFC-02 68295459 1 A311 +E205
OUTPUT FILTER IND AOFI-51 64650441 1 Z1

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Table 4: Common Par ts vs. Type List.

Type 0170- 0210-3 0210-5 0210-7 0260-3 0260-5 0260-7 0320-3 0320-5
3
IGBT 300/1 300/12/ 300/12/ 300/17/ 300/12/ 300/12/ 300/17/ 450/12/ 300/12/
2/62 62 62 66 62 62 66 61 62
V991 300/1 300/12/ 300/12/ 300/17/ 300/12/ 300/12/ 300/17/ 450/12/ 300/12/
2/72 72 72 76 72 72 76 71 72
QTY 2 2 2 2 2 2 2 2 2
DC B435 B43586 B43586 B43586 B43586 B43586 B43586 B43586 B43586
Capa 86- -S9418- -S9418- -S3468- -S9418- -S9418- -S3468- -S9418- -S9418-
citor S9418 Q1 (4.1 Q1 (4.1 Q1 (4.6 Q1 (4.1 Q1 (4.1 Q1 (4.6 Q1 (4.1 Q1 (4.1
type -Q1 mF) mF) mF) mF) mF) mF) mF) mF)
(4.1
mF)
QTY 8 8 8 9 8 8 9 10 8
VHP 5 5 5 6 5 5 6 5 5
NRE No No No Yes No No Yes No No
D
AOFI- 52 52 52 62 52 52 62 52 52
XX
V991 56 56 56 66 56 56 66 56 56
Clam C4BS C4BSN C4BSN C4BST C4BSN C4BSN C4BST C4BSN C4BSN
p NBX4 BX4120 BX4120 BX3470 BX4120 BX4120 BX3470 BX4120 BX4120
Capa 120Z ZAJJ ZAJJ ZAFJ ZAJJ ZAJJ ZAFJ ZAJJ ZAJJ
citors AJJ (1.2 uF) (1.2 uF) (0.47 (1.2 uF) (1.2 uF) (0.47 (1.2 uF) (1.2 uF)
(1.2 uF) uF)
uF)
CTs SP13 SP13 SP13 SP13 SP13 SP13 SP13 SP16 SP13
Type 0320- 0390-3 0400-5 0400-7 0440-7 0460-5 0510-3 0580-7 0610-5
7
IGBT 450/1 300/12/ 450/12/ 450/17/ 450/17/ 300/12/ 450/12/ 450/17/ 450/12/
2/61 62 61 61 61 62 61 61 61
V991 450/1 300/12/ 450/12/ 450/17/ 450/17/ 300/12/ 300/12/ 450/17/ 450/12/
2/71 72 71 71 71 72 71 71 71
QTY 3 3 3 3 3 3 3 3 3
DC B435 B43586 B43586 B43586 B43586 B43586 B43586 B43586 B43586
Caps 86- -S9418- -S9418- -S3468- -S3468- -S9418- -S9418- -S3468- -S9418-
S3468 Q1 (4.1 Q1 (4.1 Q1 (4.6 Q1 (4.6 Q1 (4.1 Q1 (4.1 Q1 (4.6 Q1 (4.1
-Q1 mF) mF) mF) mF) mF) mF) mF) mF)
(4.6
mF)
QTY 12 12 10 12 15 12 14 18 14
VHP 6 5 5 6 6 5 5 6 5
NRE Yes No No Yes Yes No No Yes No
D
AOFI- 62 51 52 62 61 51 51 61 51
XX
V991 66 59 56 66 69 59 59 69 59
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Clam C4BS C4BSN C4BSN C4BST C4BST C4BSN C4BSN C4BST C4BSN
p TBX3 BX4120 BX4120 BX3470 BX3470 BX4120 BX4120 BX3470 BX4120
Capa 470Z ZAJJ ZAJJ ZAFJ ZAFJ ZAJJ ZAJJ ZAFJ ZAJJ
citors AFJ (1.2 uF) (1.2 uF) (0.47 (0.47 (1.2 uF) (1.2 uF) (0.47 (1.2 uF)
(0.47 uF) uF) uF)
uF)
CTs SP13 SP16 SP16 SP13 SP16 SP16 SP16 SP16 SP16
About Maintenance Procedures
Testing the Module after Maintenance
ACS800-104 On-Site Tester
It is best to test the module after maintenance. The most convenient way of doing this is to use
the ACS800-104 On-Site Tester manual (IHMM Document 3AFE 68806470).
Maintenance of the Fan

∑ 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.
Figur e 21: Replacing the Fan.

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Maintenance Tips: Left Hand Side of the Module
Replacing the Controlled Fan Option (+C126) Circuit Boards
Depending on the used option set, there are two possible configurations for the controlled fan.
The basic configuration consists only of AFPS and AFIN boards. However, if the module is
equipped with a card space heater (+C123) the configuration is a bit different because the
controlled fan boards are also equipped with a heating set.
1. Measure the DC voltage.
2. Remove the side plate as shown in Figure 14.
3. Remove the broken board from the frame by unscrewing the 6 pcs M4 x 8 screws (torque
0.7 Nm) if the board is an AFPS board. If the board is an AFIN board, remove the 4 pcs
M4x8 combi torx screws (0.7 Nm).
a. If the module is equipped with a card space heating set (+C123) there will be four
support pillars in AFPS board and two in AFIN board.
b. If the board is AFPS-01C revision D or F, the board has an EMC shielding. When
replacing the older board (AFPS-01C rev. A F) with newer one (AFPS-11C) the
EMC shielding must be removed. Instructions for removing the shielding are shown
in chapter 7.1.1. When remounting the board, be sure that the fixing torque of the
screws (and support pillars) is the correct one (0.7 Nm).
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Figur e 22: Replacing AFPS or AFIN boar ds.
Replacing an AFPS-01C board with and AFPS-11C board
The old AFPS-01C (code: 64711245) board and the AFPS shield kit must be removed before new
AFPS-11C (code: 68969972) can be installed. In the below Figure 15 you can see the parts of
AFPS shield kit that should be removed.
Figur e 23: AFPS shield kit.
1. Remove the left module cover plate by loosing eight (8) torx screws.
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2. Remove old AFPS-01C board from the inverter module by disconnecting board cable
connectors and loosing six (6) M4 torx combi screws.
In the picture 16 red arrows are pointing out the six (6) fixing screws that should be removed.
Figur e 24: Fixing scr ews of AFPS boar d.
Be careful when removing the card. Small parts may fall down to the fan. Using some kind of
cover above the fan grill is advised.
3. Remove four (4) O-rings. In the picture 17 red arrows are pointing out four (4) rubber O-
rings on the static shield.
Figur e 25: The O-r ings of AFPS shield kit.

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4. Remove the static shield and the four (4) round insulating sheets. In the picture 18 the
static shield is marked with green lines and the round insulation sheets with red arrows.
Figur e 26: Static shield plate and r ound insulation sheets.
5. Do not unscrew the mounting pillars.
6. Install the AFPS-11C (Figure 19) to the mounting pillars. Mount the board with M4 combi
screws (0.7 Nm).
Figur e 27: AFPS-11C boar d.
7. Connect the board cable connectors to X1 and X2. In the Figure 20, the red arrow is
pointing out the connector.
Figur e 28: AFPS-11C mains connector .

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8. The AFPS-11C board is now installed (Figure 21).
Figur e 29: The installed boar d.

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Replacing the Control Unit Circuit Boards
The ACS800-104 (R8i) module control unit is shown in Figure 22. Since the EMC performance
has been improved during the lifetime of the module, there exists some variance in the modules.
These improvements have affected the wiring of the control unit and it is important to know which
wire sets compatible with a certain layout. Some wire sets are listed in Table 5.
Table 5: Differ ent wir e sets for ACS800-104 contr ol unit.

Wire Set MRP Code
PCB 300 - 500 V 68692148
68692756 DC cap to
APOW
PCB 300 - 500 V + AGPS 68692148
68692756 DC cap to
APOW
PCB 690 V 68692148
68692156 NRED
68692164 NRED
PCB 300 - 500 V (2 x 68692148
IGBT)
68692156
68692164
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Figur e 30: ACS800-104 Contr ol Unit.
When replacing control unit boards, the correct torques for each board are listed in Table 6. In
addition, when replacing NRED-61C it is important to clean the old heat conduction paste well and
sterilize the area with industrial alcohol before replacing the new heat conduction paste.
Table 6: Cor r ect tor ques for each contr ol unit boar d.
Boa rd Torque
AINT-12C or AINT-14C (serpress M4 4 pcs) 1.5 Nm
NRED-61C (4 pcs M4x8) 1.2 Nm
APOW-01C (4 pcs M4x8) 1.2 Nm
AGPS-21C (6 pcs M4x8) 1.2 Nm
AGBB-01C (4 pcs M4x9) 1.2 Nm
Replacing the AGBB board (Module with 2 x IGBT)
The AGBB board is used when the module has only two IGBTs. The configuration is showed in
Figure 23. Pay extra attention when replacing the AGBB board flat cable connector: Do not force
the board into its place.
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Figur e 31: An ACS800/104 R8i module with an AGBB boar d.

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Replacing the IGBT/AGDR modules
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 mm) 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 (1 Nm) in the

following sequence: screw no. 2 – 6 – 3 – 7 – 4 – 8 – 1 – 5. (Figure 24)
∑ Tighten screws to final tightening torque (5 Nm) in the same sequence:

2 – 6 – 3 – 7 – 4 – 8 – 1 – 5.
Figur e 32: The Scr ewing sequence and scr ew sizes.
6. 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.
NOTE: The grease brand must be the same for all IGBT-modules in the drive.
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Figur e 33: A r im of gr ease ar ound the module
7. Busbars are connected to power terminals of IGBT-module with M6 screws. Tightening

torque is 5 Nm.
Table 3. Codes and tightening torques of the modules
Table 7: Codes and tightening tor ques of the modules.

MRP- Name Connection of the module Connection of the
code pre- / final torque (Nm) power terminal (Nm)
64571214 FS225R12KE3 1/5 5
64571231 FS300R12KE3 1/5 5
64571249 FS450R12KE3 1/5 5
64571265 FS225R17KE3 1/5 5
64571273 FS300R17KE3 1/5 5
64571281 FS450R17KE3 1/5 5
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Replacing the Module Heating Set (+C123)
Modules equipped with option +C123 have a card space heating set. The heating set includes a
heating resistor set. The heating resistor set consists of 3 heating resistors: two for the controlled
fan option (+C126) and one for the IGBT modules and control unit boards and AHCB-01C Heating
Control Board. The module with a +C123 option is showed in Figure 26. When replacing the
heating set, all insulating sheets and resistors as well as the control unit plate must be replaced.
The parts online code for the heating set is 68232171.
Figur e 34: Replacing the car d space heating set.

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Maintenance Tips: Right Hand Side of the Module
The right hand side of the module is shown in Figure 27.
Figur e 35: The r ight hand side of the module.
Replacing the AOFC-0XC Filter Capacitor Board (+E205)
Remove the lower right cover plate as shown in Figure 27. Remove the AOFC-board by removing
the 4 pcs M4x8 (1.2 Nm) (Figure 28).
Figur e 36: Replacing the AOFC-0X boar d.

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Replacing the ATMB-01C Temperature Measurement Board
Open the lower right cover plate as shown in Figure 27. Unscrew the 2 pcs M4x8 (1.2 Nm) combi
torx screws.
Figur e 37: Replacing the ATMB-01C boar d.

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Replacing the Current Transducers
Warning! Always read the whole instruction before starting the

maintenance procedure.
Warning! When operating the module in standing position, bare in mind

that the module has a high center of gravity. Always use the module
support legs.
Warning! When rebuilding the module, pay extra attention to correct

torques.
1. Spread the module support legs by pushing the string and turning the leg (Figure 30).
2. Disconnect and remove the fan (Figure 30). By removing the fan, one can ensure that no
loose parts such as washers, bolts or nuts are dropped in the fan.
3. Loosen the 3 pcs of M4x8 torx screws (3 Nm) from both sides of the lower side plate of the
module. NOTE: You don t have to unscrew them completely. Pull off the lower side plate.
(Figure 30).
4.
Figur e 38: Phase 1: r emoving the 3 M4x8 tor x scr ews fr om the lower side plate and disconnecting and r emoving
the fan (chapter 6).
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5. Remove the AOFC-0X board and the plastic protection sheet by unscrewing the 4 pcs
M4x8 torx screws (3 Nm) (Figure 31). Also disconnect the AOFI-XX output cables.
Figur e 39: Remove the AOFC-0X boar d.
6. Pull out the current transducers metal cover plates. It is more convenient to tilt the covers
upwards while pulling them out (Figure 32).
Figur e 40: Pull out the cur r ent tr ansducer s’ cover s.

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7. 1. Loosen the current transducer packages by unscrewing the M4x8 torx screws. This will
help the procedure of removing the current transducer bus bars (Figure 35). 2. Unscrew
the blue capacitors from the current transducer bus bars. There is one attached to each
current transducer bus bars (1 pc M4x8 combi torx screw). Tightening torque for the
capacitors is 1.5 Nm (Figure 33).
Figur e 41: 1. Loosen the CT packages and 2. unscr ew the capacitor s fr om the bus bar ends.
8. Detach the current transducer bus bar from the isolation pillars by unscrewing the M5x12
combi torx screws (3 Nm) (Figure 34).
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Figur e 42: Remove the M5x12 combi (3 Nm) fr om the cur r ent tr ansducer bus bar isolation pillar s.
9. Loosen the M12x35 (70 Nm) bolts attaching the current transducer bus bars and module
output bus bars. You can move the current transducer packages in order to make more
room for the tools (Figure 35).
Figur e 43: Loosen the connecting bolts between the cur r ent tr ansducer bus bar and the moduel output bus bar .
10. Unscrew the M8x16 combi bolt in order to be able to push the W-phase bus bar outwards.
This way it is possible to pull out the M12 bolt (Figure 36).
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Figur e 44: Unscr ew the M8x16 bolt in or der to be able to move the W-phase bus bar .
11. Pull out the current transducer package and the bus bar (Figure 37).
Figur e 45: Cur r ent tr ansducer + bus bar .
12. Slide out the metal casket surrounding the current transducer. Tilt the current transducer
bus bar and pull it out without using excess force. Replace the current transducer and
repeat the procedure backwards (Figure 38).
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Figur e 46: Cur r ent tr ansducer .
Maintenance Tips: Replacing the AOFI-XX du/dt output filter

(+E205)


that the module has a high center of gravity. Always use the module s
support legs.

torques.
1. Spread the module support legs by pushing the string and turning the leg (Figure 39).
2. Remove the left hand side plate. To do this, loosen 4 pcs M4x8 torx screws (3 Nm) on
each side of the module. Pull out the cover plate (Figure 39).
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Figur e 47: Loosen the 4 + 4 pcs M4x8 scr ews and pull out the cover plate.
3. Disconnect the 9 pcs M8x25 bolts, washers, pressure washers and nuts (22 Nm) from the
IGBT output terminals (Figure 40). This is needed in order to release the AOFI-XX input
cables (terminals A1 – A9) (Figure 40).
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Figur e 48: Disconnect the AOFI-XX input cables (A1 – A9) by r emoving the M8x25 bolts fr om the IGBT output
ter minals.
4. Remove the right hand side cover plate (Figure 41).
Figur e 49: Remove the r ight hand side lower cover plate by loosening the 3 + 3 pcs M4x8 (3 Nm) tor x scr ews.
5. Unscrew the 13 pcs M4x8 torx screws (3 Nm) and pull out lower cover plate (Figure 42).
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Figur e 50: Unscr ew 13 pcs M4x8 tor x scr ews and pull lower cover plate.
6. Pull out the upper cover plate. Disconnect the AOFI-XX output cables (9 pcs M8x25 bolts,
18 pcs of M8 washers, 9 pcs of M8 pressure washers and 9 pcs M8 nuts; torque is 25 Nm)
(Figure 43).
Figur e 51: Pull out the upper cover plate.

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7. The AOFI-XX filter is extremely heavy. It is recommended that one first unscrews two
M4x8 torx screws (3 Nm) and loosens the remaining two a few turns (as shown in Figure
44).
Figur e 52: Unscr ew 2 pcs M4x8 scr ews attaching the AOFI filter fr om fr ont and r ear plates. Loosen the
r emaining two M4x8 scr ews (mar ked by a r ed ar r ow).
8. Unscrew the 2 pcs remaining M4x8 torx screws (3 Nm). While unscrewing the screws,
weigh the filter with your other hand. Finally, carefully pull out the AOFI-XX du/dt filter
(Figure 45).
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Figur e 53: Unscr ew the r emaining 2 pcs M4x8 tor x scr ews. Wigh the AOFI-XX filter with other hand and pull
out the filter .
Maintenance Tips: Replacing the DC Capacitor Bank


support legs.

torques.
Electrolyte Capacitor.
1. Spread the module s support legs by pushing the string and turning the leg (Figure 39).
2. Remove the left hand side plate. To do this, loosen 4 pcs M4x8 torx screws (3 Nm) on
each side of the module. Pull out the cover plate (Figure 46).
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Figur e 54: Loosen the 4 + 4 pcs M4x8 scr ews and pull out the cover plate.
3. Disconnect the 9 pcs M8x25 bolts, washers, pressure washers and nuts (22 Nm) from the
IGBT output terminals (Figure 40). This is needed in order to release the AOFI-XX input
cables (terminals A1 – A9) (Figure 47).
Figur e 55: Disconnect the AOFI-XX input cables (A1 – A9) by r emoving the M8x25 bolts fr om the IGBT output
ter minals.
4. Disconnect all circuit boards in the control unit, pull out the control unit by loosening 4 pcs
M4 serpress nuts (3 Nm), disconnect the flat cables from the AGDR boards, remove the
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18 pcs M6x12 combi torx screws (3 Nm) and unscrew the 3 pcs M4x8 combi torx screws
from the DC bus bar (Figure 48).
Figur e 56: Disconnect all electr ical boar ds. Remove the contr ol unit (4 pcs M4 ser pr ess nuts), clamp capacitor s
and the DC bus bar connection scr ews (3 pcs M4x8 combi tor x scr ews).
5. Remove the right hand side cover plate (Figure 41).
Figur e 57: Remove the r ight hand side lower cover plate by loosening the 3 + 3 pcs M4x8 (3 Nm) tor x scr ews.
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6. Unscrew the 13 pcs M4x8 torx screws (3 Nm) and pull out lower cover plate (Figure 42).
Figur e 58: Unscr ew 13 pcs M4x8 tor x scr ews and pull lower cover plate.
7. Pull out the upper cover plate. Disconnect the AOFI-XX output cables (9 pcs M8x25 bolts,
18 pcs of M8 washers, 9 pcs of M8 pressure washers and 9 pcs M8 nuts; torque is 25 Nm)
(Figure 43).
Figur e 59: Pull out the upper cover plate.

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8. The AOFI-XX filter is extremely heavy. It is recommended that one first unscrews two
M4x8 torx screws (3 Nm) and loosens the remaining two a few turns (as shown in Figure
44).
Figur e 60: Unscr ew 2 pcs M4x8 scr ews attaching the AOFI filter fr om fr ont and r ear plates. Loosen the
r emaining two M4x8 scr ews (mar ked by a r ed ar r ow).
9. Unscrew the 2 pcs remaining M4x8 torx screws (3 Nm). While unscrewing the screws,
weigh the filter with your other hand. Finally, carefully pull out the AOFI-XX du/dt filter
(Figure 45).
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Figur e 61: Unscr ew the r emaining 2 pcs M4x8 tor x scr ews. Wigh the AOFI-XX filter with other hand and pull
out the filter .
10. Unscrew the 4 pcs M6x12 torx screws from the dc bus bars (Figure 54). Remove any
electrical connections i. e. the discharge resistor chain wires (M6x12; 3 Nm).
Figur e 62: Unscr ew the 4 pcs M6x12 tor x scer ws fr om the DC (+) and DC (-) bus bar s.
11. Unscrew the M5 serpress nuts from the DC-busbar insulation pillars so that the insulator
pillars are still attached to the module top plate (Figure 55).
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Figur e 63: Unscr ew 4 pcs ser pr ess M5 nuts fr om the insulator pillar s (5 Nm).
12. Remove the DC bus bar support plates (Figure 56).
Figur e 64: Remove the DC bus bar suppor t plates by unscr ewing the 4 pcs M5 ser pr ess nuts.
13. Unscrew the 3 + 3 pcs M4x8 torx screws (3 Nm) (top plate of the module) from both the
front and back plates of the module (Figure 57).
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Figur e 65: Unscr ew the 3 + 3 pcs M4x8 tor x scr ews fr om the top plate.
14. Remove the top plate and insulator sheet by unscrewing the remaining 5 pcs of M4x8 torx
screws (3 Nm).
Figur e 66: Removing the module top plate.
15. Unscrew the lower 2 + 2 M4x8 torx screws ( front and back plate, as shown in Figure 59)
that fix the DC capacitor bank bottom plate. Loosen the 1 pcs upper M4x8 torx screws a
few turns.
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Figur e 67: Unscr ew the 2 + 2 pcs of M4x8 tor x scr ews (3 Nm). Loosen the uppest M4x8 tor x scr ews a few tur ns.
16. Tilt the DC capacitor bank and unscrew the remaining 1 + 1 pcs M4x8 torx screws.
Figur e 68: Tilt the DC capacitor bank and unscr ew the r emaining M4x8 tor x scr ews.
17. When reassembling the capacitor bank, see instructions for different layouts in Appendix I
(300 - 500 V) and Appendix II (690 V).
Film Capacitor (+E212)

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support legs.

torques.
1. Remove the control unit, IGBT clamp capacitors and the AOFI-XX filter. The most
convenient way of doing this is to remove the left hand side cover plate, disconnect all the
wires, pull out the control unit (loosen 4 M4 serpress nuts (1.2 Nm)) and the IGBT clamp
capacitors (9 pcs; 18 x M6x12 combi torx screws (3 Nm)). It is also necessary to remove
the du/dt filter AOFI-XX input cables (9 x M8x25 bolt, M8 pressure washer, M8 washer and
M8 nut; 25 Nm) from the IGBT output terminals (Figure 61).
Figur e 69: Remove the left side plate, contr ol unit, AOFI du/dt filter 's input cables and IGBT clamp capacitor s.
2. Remove the AOFI-XX output filter from the right hand side of the module. To do this,
follow instructions shown in Figure A3. Both covers must be removed for also the AOFI-XX
output cables must be removed from the current transducer bus bar input terminals (9 x
M8x25 bolt, M8 pressure washer, M8 washer and M8 nut; 25 Nm). Remove the du/dt filter
AOFI-XX (Figure 62).
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Figur e 70: Remove the r ight side plates AOFI cables and the AOFI du/dt filter .
3. Unscrew the M4x8 torx screws (3 Nm) from the module skeleton as shown in Figure 63.
Note that only the screws in front plate and back plate are removed. The ones on the top
are not unscrew (5 screws on both sides; three on the top plate and two in the middle of
the front / back plate).
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Figur e 71: Remove the 5 + 5 M4x8 tor x scr ews that fix the film capacitor bank.
4. Carefully tilt the film capacitor bank and remove it from the module (Figure 64).
Figur e 72: Remove the film capacitor bank.

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Appendix I: Capacitor layouts for 300 - 500 V ElCo
Figur e 73: 500 V ELCO str uctur e.
NOTE: Th e u p p e r e d g e is th e o n e with M4x8 to rx s c re w h o le s .
Figur e 74: 500 V ElCo layout 1. The capacitor layout in this pictur e is the same for each listed power r ating. The
colour s in the pictur e ar e not essential.
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Figur e 76: 500 V layout 3. The capacitor layout in this pictur e is the same for each listed power r ating. The
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Appendix II: Capacitor layout for 690 V ElCo
Figur e 78: 690 V ElCo str uctur e.
NOTE: Th e u p p e r e d g e is th e o n e with M4x8 to rx s c re w h o le s .
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Appendix III: Module phase order
Figur e 83: Module phase or der (left hand side)

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Figur e 84: Module phase or der (r ight hand side).

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ABB Drives MAINTENANCE INSTRUCTION 3AFE 6479 3675

Technical Description 00262693_E.DOC

Safety Issues and ESD .........................................................................................................................2

Safety Issues and ESD

ESD (Electro Static Discharge)! The printed circuit boards contain

WARNING! Only qualified electricians are allowed to carry out work

High Center of Gravity

Cabinet and Module Serial Numbers

Serial Number Hierarchy

ACS800-X7-Y Single drive cabinet

Figur e 6: Module type code and ser ial number .

Filling Out the Warranty Report

General Description of the ACS800-104 Module

Table 1: Option codes for ACS800-104 R8i modules.

Mechanical Parts for module with option code +V991

Figur e 10 +V991 R8i module mechanics 1/5

Figur e 11 +V991 R8i module mechanics 2/5

Figur e 12 +V991 R8i module mechanics 3/5

Figur e 13 +V991 R8i module mechanics 3 (wind)/5

Figur e 14 +V991 R8i module mechanics 4/5

Figur e 15 +V991 R8i module mechanics 4 (wind)/5

Figur e 16 +V991 R8i module mechanics 5/5

Mechanical Parts for old R8i module (without +V991)

Figur e 17 Old R8i module mechanics 1/3

Figur e 18 Old R8i module mechanics 2/3

Figur e 19 Old R8i module mechanics 2 (wind)/3

Figur e 20 Old R8i module mechanics 3/3

Table 2 Old R8i module mechanics

Table 3: R8i Electr ical and Option Par ts.

IGBT FS450R17KE3/AGDR-61C 68336970 3 A21/V21

CAPACITOR 64435001 9 C211 – C213

POWER RESISTOR VHP-6 64522787 3 R21 – R23

POWER RESISTOR VHP-5 64522736 3 R21 – R23

FILTER CAPACITOR 58985066 3 C31 – C33

FAN D2D160-BE02-11 64650424 1 Y41

THICK-FILM HYBRID NRED-61 58926451 1 A28

EL. CAPACITOR B43586- 64410539 N C251 – C256

OUTPUT FILTER IND AOFI-69 68634377 1 Z1 +E205

OUTPUT FILTER IND AOFI-51 64650441 1 Z1

Table 4: Common Par ts vs. Type List.

About Maintenance Procedures

Testing the Module after Maintenance

ACS800-104 On-Site Tester

Maintenance of the Fan

Figur e 21: Replacing the Fan.

Maintenance Tips: Left Hand Side of the Module

Replacing the Controlled Fan Option (+C126) Circuit Boards

1. Measure the DC voltage.

2. Remove the side plate as shown in Figure 14.

Figur e 22: Replacing AFPS or AFIN boar ds.

Replacing an AFPS-01C board with and AFPS-11C board

Figur e 23: AFPS shield kit.

Figur e 24: Fixing scr ews of AFPS boar d.

Figur e 25: The O-r ings of AFPS shield kit.

Figur e 26: Static shield plate and r ound insulation sheets.