Working Instructions DOC29 ACS600MD R11i PP30012 Revc

Working instruction
4FPS10000075073
ACS600MD R11i IGBT upgrade
Drives Service PP30012 DOCWIACS60029
Department Date Author Approved Revision Page
ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 1 (46)
Index
1. General information .................................................................................................................................. 2
1.1 Safety ................................................................................................................................................. 2
1.2 Preparation work................................................................................................................................. 3
1.3 Parts list of IGBT upgrade kit 42000552. ............................................................................................. 4
1.4 Needed tools ...................................................................................................................................... 5
1.5 ESD.................................................................................................................................................... 8
1.5 The rule of parallel connected IGBTs in nxR11i ACS600 MultiDrive.................................................... 9
2. Removing the old hardware .................................................................................................................... 11
2.1 Hardware construction R11i .............................................................................................................. 11
2.2 Phase module preparation ................................................................................................................ 12
2.3 Removing the NINT- or NXPP-board assembly plate ........................................................................ 13
2.4 Disconnecting NINT- or NXPP-boards and NGDR-boards ................................................................. 14
2.5 Removing NPOW-board and current transducer assembly plate ....................................................... 15
2.6 Removing Clamping capacitors and output bars................................................................................ 16
2.7 Removing IGBTs .............................................................................................................................. 17
2.8 Cleaning the heat sink elements ....................................................................................................... 18
3. Installing the new hardware..................................................................................................................... 19
3.1 Preparing and installing of adapter plates.......................................................................................... 19
3.2 Preparing the NTC-thermistor ........................................................................................................... 21
3.3 Preparing the new IGBT FF1400 module .......................................................................................... 22
3.4 Mounting of the IGBTs ...................................................................................................................... 23
3.5 Mounting of the NTC-thermistor ........................................................................................................ 24
3.6 Tightening sequence of the IGBT ...................................................................................................... 25
3.7 Mounting of the NGDR-07C board .................................................................................................... 26
3.8 Mounting of the thermistor connector to NGDR-07C.......................................................................... 27
3.9 Mounting of the DC-busbars and output busbars............................................................................... 28
3.10 Mounting of clamp capacitors.......................................................................................................... 29
3.11 Mounting of assembly plate and flat cables ..................................................................................... 30
3.12 Mounting of stand-off pillars ............................................................................................................ 33
3.13 Mounting of lower assembly plate ................................................................................................... 34
3.14 Preparing the NINT-72C / NXPP-02C and NXPP-05C board ........................................................... 35
3.15 Mounting of the NINT/ NXPP-board assembly ................................................................................. 36
3.16 Mounting of ferrite wire, connecting of additional DC-measurement wire ......................................... 37
3.17 Connecting of rest of the wires ........................................................................................................ 38
4 Finishing the upgrade work ...................................................................................................................... 41
4.1 Testing the drive ............................................................................................................................... 41
4.2 Finishing the work area ..................................................................................................................... 42
5 Working Instruction for thermal compound Grey Ice 4100 LV ................................................................... 43
Appendix 1, Inverter module circuit diagram R11i ........................................................................................ 44
Appendix 2, Inverter module circuit diagram R11i, power stage, phase V .................................................... 45
Appendix 3, Inverter module circuit diagram R11i, power stage, phases U and W ....................................... 46
© Copyright 2012 ABB Oy. All rights reserved.

Working instruction
4FPS10000075073
1. General information
These instructions are meant to be followed when carrying out the IGBT upgrade of the
ACN6x4 R10i or R11i phase module.
If other required repair or maintenance tasks occur before or during the upgrade, ones that
have not been presented in this instruction, should the service personnel be familiar with the
working methods which are needed to get the required actions done safely without harming
the employee himself or the surroundings. Before starting the upgrade the whole work must
be planned so that the required actions are done according to the safety regulations.
1.1 Safety
WARNING! All electrical installation and maintenance work on the ACx600 should be carried
out by qualified electricians. Do not attempt any work on a powered ACx600. 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 1 M ) to ensure that the frequency converter is discharged before beginning work.
All insulation tests must be carried out with the ACx600 disconnected from the cabling.
The ACx600 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.
The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC
voltage (over 500 V).
There can be dangerous voltages inside the ACx600 from external control circuits when the
ACx600 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.

Working instruction
4FPS10000075073
1.2 Preparation work
Clean the area before starting upgrade work, remove all unnecessary items nearby
the work area.
Arrange a clean table close to the work area so that ESD mat and all removed
components can be laid down onto it and ready to install components can be laid
down to be easily available during the work.
Check the delivery of the upgrade kit that all items are undamaged.
Check that all items are included in the upgrade kit, see chapter 1.3.
Read through this document in advance and organize all parts and tools before
starting upgrade work.
Assemble boxes for returnable items, assembly instructions provided with the upgrade
kit.
This document describes upgrade work when phase module is out from the cabinet.

Working instruction
4FPS10000075073
1.3 Parts list of IGBT upgrade kit 42000552.
42000480 IGBT MODULE KIT FF1400R12 R11I R9 XT 1 PC

68814201 ADAPTER PLATE FF1000 2 PC
68908914 CAPACITOR KPF-183 4 PC
68827850 ADAPTER BOARD NXPP-05 1 PC
68887402 ACN634-644 R10I, R11I (wire set) 1 PC
DOCWIACS60029 WORKING INSTRUCT ACS600MD R11I PP300 IGBT UPGR 1 PC
3AFE68962463 INST INSTRUCTION ACN/ACW644+V991 MODULE 1 PC
DOCTNACS60017 TECHNICAL NOTE ACS600 IGBT NGPS-13... 1 PC
42000370 V991 CODE STICKER 42000370 2 PC
42000403 MECHANICS KIT R10I R11I IGBT UPGRAD 1 PC
68872057 BUS BAR ACS600 1 PC
68846153 BUS BAR ACS600 1 PC
68986192 DC BUS BARS 1 PC
68922682 ASSEMBLY PLATE ACS600 1 PC
10024030 STANDOFF M4 L=20 MS/NI 5 PC
68343097 COMBISCREW M4X8 TORX T20 7 PC
68447933 STANDOFF M4 L=38 MS/NI 1 PC
57938005 INSULATING PILLAR TPI/9,5/38/M4 RM 3 PC
68688531 STANDOFF M4 L=25 FE/ZN 1 PC
68922658 BASE ACS600 1 PC
3AUA0000026569 BRACKET CABLE CLAMP 27MM 1 PC
68893861 MACHINE SCREW M6X16 TORX 20 PC
42000407 ACCESSORIES KIT R11I PHASE MODULE 1 PC
68922623 PLATE ACS600 1 PC
68922658 BASE ACS600 1 PC
3AUA0000042489 OPTIONS KIT POWER SUPPLY NGPS-13C 1 PC
3AUA0000033361 POW. SUPP. BOARD NGPS-13C 1 PC
61381996 WIRE HARNESS FOR R10-11I FOR NGPS-12 1 PC
64375831 WIRING HARNESS R NINT-72 / R10-/R11i(V) 1 PC
10027969 STANDOFF M4 L=12 6 PC
3AUA0000074768 THERMAL COMPOUND HEAT TRANSFER COMPOUND 4 PC
42001623 PP3 STENCIL KIT 1 PC

Working instruction
4FPS10000075073
1.4 Needed tools
True RMS multimeter, at least CAT III 1000V, e.g. FLUKE 87 III as shown in the
picture 1.
Test leads + probes, at least CAT III 1000V
Pic 1.
Screw drivers set for electrical work, 1.

Side cutting pliers, 2.
Pointed pliers, 3.
3.
1.
2.
Pic 2.

Working instruction
4FPS10000075073
(Cordless Screwdriver)
Set wrench kit (8-21 mm), 4.
Torx-kit +bit set, 5.
5.
4.
Pic 3.
Torque spanner 2-10Nm for torx- and crosshead screws, 6.

Torque spanner 10-110Nm for busbar bolts, 7.
7. 6.
Pic 4.

Working instruction
4FPS10000075073
Rubber spatula or small paint roll for thermal compound

Soft cloth wipers, lint free
Industrial alcohol or equivalent oil-free cleaning solvent. Petrol or diesel (gas-oil) fuel
not allowed.
Padlock
"Do not switch-men at work" signs as shown in the picture 5.
Pic 5.
ESD field service kit
Pic 6.
Laptop with DriveWindows SW + DDCS communication accessories

Compressed air or compressed air cans for cleaning
Note that compressed air must be dry and absolutely oil-free!
ESD vacuum cleaner for cleaning

Working instruction
4FPS10000075073
1.5 ESD
WARNING!
Ensure ESD protection when handling the components.
Circuit boards contain components sensitive to electrostatic discharge (ESD). Wear
an earthing wrist band and use ESD field service mat when handling the components.
Do not touch the boards and components unnecessarily.
Assemble the ESD field service kit as shown in the picture.
Wrist band
Components
in box
Earth Card
Working mat
Pic 7.
Keep new boards and semiconductors for as long as possible in their original
packages.

Working instruction
4FPS10000075073
1.5 The rule of parallel connected IGBTs in nxR11i ACS600 MultiDrive
NOTE!! Due to the parallel connected IGBTs in each phase module, all
phase modules of the same phase must be upgraded in the case of one
defective phase module! It is extremely forbidden to run the drive with
one upgraded module only if more than one phase modules in parallel.
There is a very high probability of serious IGBT failure if this rule is
ignored!
Minimum upgrade or new type of module if one phase module

defective:
In R11i drive, one phase module is minimum upgrade
In 2xR11i drive, two phase modules is minimum upgrade
In 4xR11i drive, four phase modules is minimum upgrade
An example of minimum upgrade marked with red [X] in pictures 8 and 9.
U V W
Pic.8. A principle drawing of parallel connected IGBTs in R11i drive.
X X X X
U V W
Pic.9. A principle drawing of parallel connected IGBTs in 4x R11i drive.

Working instruction
4FPS10000075073
One upgrade kit includes 2pcs of selected IGBTs.
Before starting upgrade work, mark clearly all IGBT modules of the kit with
same phase indicators, i.e. as shown in the pictures below. Then it is easier to
follow that all IGBTs of the one kit are mounted to the same phase module.
U1.1 U2.1 U3.1 U4.1
U1.2 U2.2 U3.2 U4.2
Pic.10. Example of markings when upgrading phase U in 4xR11i drive. 4pcs of IGBT module kit 42000480.

Working instruction
4FPS10000075073
2. Removing the old hardware

2.1 Hardware construction R11i
Pic.11 Pic.12
In R11i 400-500V units type PP30012 PowerPlates used.

PP30012 IGBT module kit in the picture 12.
Quantity of the DC-capacitors may vary between different power and
voltage ratings of the R11i phase module.

Working instruction
4FPS10000075073
2.2 Phase module preparation
NGPS
U/W V
Pic 13.
Remove the covers of the phase modules.

Disconnect output busbar bolts of all phase modules to be upgraded.
Disconnect DC busbar connections of the phase modules to be upgraded.
Note that boards between different phase modules vary. Only V-phase (in the
middle) module has NPOW board and optional NGPS board, picture 11. U- and W-
phase modules are without NPOW boards, left side module.
These instructions are meant for all phase modules.

Working instruction
4FPS10000075073
2.3 Removing the NINT- or NXPP-board assembly plate
U/W V
Pic.14
Disconnect flat cables between NINT and NXPP boards, marked in green (picture
14).
Disconnect current transducers wires and APOW wire to NINT, marked in red.
Disconnect wires from output bars to NINT, marked in orange.
Open fixing screws (M4) of the NINT or NXPP assembling plate, marked in blue.

Working instruction
4FPS10000075073
2.4 Disconnecting NINT- or NXPP-boards and NGDR-boards
Pic 15.
Take NINT- or NXPP- board assembly plate away and keep it in a safe place
(picture 15).
Later remove NINT or NXPP board away from old assembly plate.

Working instruction
4FPS10000075073
2.5 Removing NPOW-board and current transducer assembly plate
Pic.16
Remove NGDR-boards from the IGBT modules if they are not coming along the
NINT and NXPPs.
Disconnect wire from DC-bus to the NPOW / NRED and dismount the lead-in
rubber grommet, marked in blue. (NRED not presented in the picture 16)
Open the fixing screws (M6) of NPOW and the current transducer assembling
plate, marked with red.
Take the assembling plate away and keep it in a safe place.
Note that in R10i frame the IGBT module is smaller.
Working instruction
4FPS10000075073
2.6 Removing Clamping capacitors and output bars
Pic.17 Pic.18
Open the output busbars and the clamping capacitors screws (M6) marked in red.
(Picture 17)
Remove the output busbars and the clamping capacitors.
Open the screws (M6) marked in blue of the DC-busbars from the capacitor bank.
(Picture 18)
Remove the DC busbars and NPOW wires from the DC busbars.
Note that in R10i frame has smaller IGBT modules (PP20012) and less clamping
capacitors.
Working instruction
4FPS10000075073
2.7 Removing IGBTs
Pic.19 Pic.20
Open the screws (M6) of the IGBT´s, marked in red. (Picture 19)
Remove IGBTs from the heat sink. (Picture 20)

Working instruction
4FPS10000075073
2.8 Cleaning the heat sink elements
Pic.21 Before cleaning Pic.22 After cleaning
Clean surfaces of the heat sinks carefully by using soft cloth and industrial alcohol.
Clean the rest of the module if needed.

Working instruction
4FPS10000075073
3. Installing the new hardware

3.1 Preparing and installing of adapter plates
Pic.23
Clean the surfaces of the adapter plates by using soft cloth and industrial alcohol
(picture 23).
Pic.24a. Example of how result looks Pic.24b. spreading done with a rubber spatula
when spreading is done with a stencil or a small paint roller.
Spread thermal compound to the other side with rubber spatula or small paint roller
(picture 24b). Note that the compound must be spread to the opposite side of the
counter-bored holes.
! Follow separate instruction (4FPS10000048908) for spreading the thermal
compound with stencil (picture 24a).

Working instruction
4FPS10000075073
10. 7.
6. 3.
2. 1.
4. 5.
8. 9.
Pic.25 Pic.26
Fix adapters loosely, first with two diagonal counter-bored machine screws (M6) e.g.
screws # 7 – 8. Press slightly with hand on the adapter plate, if Grey Ice and stencil
has not been, distribute the paste by a slight rotary motion.
Tight the screws crosswise in two phases in the sequence shown in the picture 25.
First phase with 1Nm and finally with 3Nm.
Clean the other side of the adapter plates by using soft cloth and industrial alcohol.

Working instruction
4FPS10000075073
3.2 Preparing the NTC-thermistor
Pic.27.Old revision NTC-thermistor
Pic.28.New revision NTC-thermistor
Note that there are two revisions of NTC-thermistor, older type, which needs to be
bend, and newer type, which is already bent, so that one does not need any actions
before mounting.
If the NTC is old type, picture 27, bend carefully with pointed pliers the tail of the
thermistor to the 90 degrees angle. Note that the bent must be on the back side of the
thermistor, as it is with the new one in the picture 28.

Working instruction
4FPS10000075073
3.3 Preparing the new IGBT FF1400 module
Pic.29a Pic.29b
Pic.30a. Example of how result looks Pic 30b.

when spreading is done with a stencil
NOTE ESD!
Keep the NGDR board in the box and safe place while mounting IGBT and keep IGBT
modules and NGDR boards together.
Do not mix NGDR boards, keep the content of the one IGBT packing, IGBT and
NGDR, as a pair! Pairs are marked with stickers containing serial number
(Picture 29b).
Clean the base plate of the IGBT´s by using soft cloth and industrial alcohol.
Spread thermal compound evenly with rubber spatula or small paint roller (picture
30b).
! Follow separate instruction (4FPS10000048908) for spreading the thermal
compound with stencil (Picture 30a).

Working instruction
4FPS10000075073
3.4 Mounting of the IGBTs
14. 11.
10. 7.
6. 3.
2. 1.
4. 5.
8. 9.
12. 13.
Pic.31
Fix modules loosely with two diagonal screws e.g. screws (M5) # 11 – 12. Press
slightly with hand on the module, if rey Ice and stencil has not been,distribute the
paste by a slight rotary motion.
Ensure that modules are mounted gate terminals upwards.

Working instruction
4FPS10000075073
3.5 Mounting of the NTC-thermistor
Pic.32
Install the IGBTs to the adapter plate with 14 pcs of combi screw M5x10.
Install the thermistor under the mounting screw, right side of the IGBT, third screw
from the top. (Mounting screw number 3 in picture 31.)
With every IGBT must be a thermistor.

Working instruction
4FPS10000075073
3.6 Tightening sequence of the IGBT
14. 11.
10. 7.
6. 3.
2. 1.
4. 5.
8. 9.
12. 13.
Pic.33
Tight the screws crosswise in two phases in the sequence shown in the picture 33.
First phase with 2Nm+/-15% and finally with 3Nm.

Working instruction
4FPS10000075073
3.7 Mounting of the NGDR-07C board
4. 2.
1. 3.
Pic.34a Pic.34b
Pic 34c. Pairs are marked with stickers containing serial number.
Put the insulation part on to the IGBT module like shown in the picture 34a and install
NGDR-07C board with 4pc M4x8 screws to the gate terminals like shown in the picture
34b.
Do not mix NGDR boards! Keep the content of the one packing, IGBT and the
NGDR-07C, as a pair! Pairs are marked with stickers containing serial number
(Picture 34c).
The M4 fixing screws of NGDR-07C board must be tightened in following way:
1. First the screws are tightened with LIGHT FINGER TIGHTNESS in sequence 1-
2-3-4, shown in the picture 34b.
2. Then screws are tightened with 0.5 Nm torque in sequence 1-2-3-4.
3. Finally screws are tightened with 2 Nm (final torque) in sequence 1-2-3-4.
Note, due to that gate control signals are transmitted through the mounting screws,
correct mounting is very important!

Working instruction
4FPS10000075073
3.8 Mounting of the thermistor connector to NGDR-07C
Pic.35
Connect the thermistor wire to terminal in NGDR-07C. Be sure that the thermistor wire
connector is connected properly to terminal.

Working instruction
4FPS10000075073
3.9 Mounting of the DC-busbars and output busbars
Pic.36
Mount DC-busbar as shown and fasten it first loosely to capacitor bank power
connection screws (M6) marked in blue.
Remember to connect wires of discharging resistors.
Mount the output busbars with M8 bolts marked in red.
Connect a new additional DC measurement wire to DC plus busbar and tighten wire
connector screw (M4), marked in green, at 2Nm torque.

Working instruction
4FPS10000075073
3.10 Mounting of clamp capacitors
Pic.37 Pic.38
Mount 2 pcs of 2uF clamp capacitors to DC-terminals of each IGBT with M8 bolts,
marked in red, as shown in the picture. Fasten all M8 bolts at 8Nm tightness.
Check that additional DC+ wire (with white sleeve) is connected with old DC+ wire of
NPOW, as shown in picture 38. Note that connection method may vary, flat tab
terminal or ring type, bolt connection terminal.
Tighten DC+ wire screw (M6) at 3Nm.
Tighten DC capacitor pole screws, marked in blue, at 3Nm.

Working instruction
4FPS10000075073
3.11 Mounting of assembly plate and flat cables
Pic.39 Pic.40
Mount back the assembly plate of NPOW-board and current transducer.

Connect wires from DC-capacitors to the NPOW, marked in green, and fix lead-in
rubber grommet.
Note! NRED-61 component presented in the picture 39 does not belong to 400V and
500V R11i units.
Tighten assembling plate fastening screws (M6), marked in red.
Connect output voltage measurement wire to the output busbar, marked in yellow.
Note that module of the phase of U the wire must be connected to the busbar on the
right side.
Connect flat cables (2 pc) to the NGDR-07C boards, marked in blue. Markings
A51.1:X1 and A51.2:X1 at flat cables are to be connected to the NGDR boards. Pay
attention for proper connection.

Working instruction
4FPS10000075073
NOTE! If module is equipped with NGPS-11 or -12 board, it must be replaced

with enclosed NGPS-13 board! Refer to the enclosed document
DOCTNACS60017.
It is really important to double-check that all flat cable connectors are connected
properly as shown. Otherwise several faults or warnings might be indicated.
Pic.41. Press the plug properly with your thumb into its socket to ensure a good connection.
Ensure that the plug is plugged properly into its socket.

Pictures 42 and 43 are showing improper connections.
Pic.42 Improper connection

Working instruction
4FPS10000075073
Pic.43 Incorrect closing.

Working instruction
4FPS10000075073
3.12 Mounting of stand-off pillars
Note! 25mm
pillars!
Pic.44
When upgrading module of phase V, mount 25mm stand-off pillars to the DC-busbar
as shown, pillars marked in red must be 25mm plastic insulating pillars and 25mm
metallic marked in yellow.
IMPORTANT! When upgrading U or W-phase modules, all stand-offs at the DC-
busbar must be plastic ones!

Working instruction
4FPS10000075073
3.13 Mounting of lower assembly plate
Note! 38mm
pillars!
Pic.45
Mount lower assembly plate as shown, pillars marked in red must be 38mm plastic
insulating pillars and 38mm metallic marked in yellow.
Note that at this state pillars must be installed like this regardless the phase of
the module.
Note! NRED-61 component presented in the picture 45 does not belong to 400V and
500V R11i units.
NOTE! If module is equipped with NGPS-11 or -12 board, it must be replaced
with NGPS-13 board included in the upgrade kit! Refer to the enclosed
document DOCTNACS60017.

Working instruction
4FPS10000075073
3.14 Preparing the NINT-72C / NXPP-02C and NXPP-05C board
Pic.46
Take NINT- (in phase V) or NXPP-board (in phases U or W) and new adapter board,
NXPP-05C (picture 46).
When new NINT board, remember correct setting of the jumpers. Jumper settings as
originally, according to the old PowerPlate type.
Mount NINT / NXPP-02C to the assembly plate with M4 metal pillars as shown.
Pic.47
Assemble adapter board with NINT- or NXPP-board like shown in picture 47.
Be very careful with the pins of NXPP-05 so that they do not bend when pushing
boards together.
Fasten adapter board with M4x8 screws.

Working instruction
4FPS10000075073
3.15 Mounting of the NINT/ NXPP-board assembly
Pic.48
Mount assembly of NINT / NXPP-board with 4 pc of M4 combi screws as shown in

picture 48.
In the phase V, remove NPOW board and remove middle left side M6 mounting screw
of the assembly plate, marked in yellow.

Working instruction
4FPS10000075073
3.16 Mounting of ferrite wire, connecting of additional DC-measurement wire
Pic.49 Pic.50 ferrite wire
Pic.51 bracket
Connect additional DC+ wire to NXPP-05C connector, marked with red arrow. (Picture
49).
Mount bracket with the ferrite wire to the left side, under the middle M6 mounting
screw of the assembly plate, check that connector X42 reaches the NINT before
fastening the screw.
Mount back the NPOW board.
Connect ferrite wire between NPOW connector X32 to NINT board connector X42.

Working instruction
4FPS10000075073
3.17 Connecting of rest of the wires
Pic.52
Connect voltage measurement wires, wires from NGPS and current transducers,
marked in blue, to NINT board as they were originally.

Working instruction
4FPS10000075073
Pic 53.
Connect the flat cables to NINT- or NXPP-board connectors (picture 53). Pay attention
for proper connection as mentioned in the chapter 3.11.
Ignore black and red test leads shown in the picture.

Working instruction
4FPS10000075073
3.15 Connecting of busbar joints
Connect flat cables between phase modules.

Check that terminals of optic fiber are clean and connect fiber to NINT board.
Double check that all of the connectors are correctly and properly connected.
Use cable ties where necessary.
Connect output busbar bolts (M10) and tighten those at 30Nm torque.
Connect DC-busbar terminals with M8 bolts at 15-22Nm tightness.
If phase module were pulled out from the cabinet, mount fixing screws of the module
to original positions.
Assemble phase modules covers back.
Depending the phase of the upgraded module an additional grounding plate is needed
between the phase modules. Refer to the document 3AFE 6896 2463 for instructions.
Remember to upgrade all phase modules of the same phase!

Working instruction
4FPS10000075073
4 Finishing the upgrade work

4.1 Testing the drive
Testing without supply voltage

Measure with multimeter at resistance range that any of the input or output busbars
are not short circuited against the frame.
Measure with multimeter at diode range from the DC-(+) and (-) terminals against the
output terminals (U, V and W). Any of these readings must not indicate 0V.
Testing with supply voltage

Connect multimeter to the DC-link terminals outside of the frame.
Connect the DriveWindow tool to the NAMC board of the drive
Put back the cover of the module.
Ensure that it is safe to connect the supply voltage!
Connect supply voltage for the drive.
Check that control panel does not show any fault or alarm messages, if yes disconnect
supply voltage, wait for 5 minutes and then locate the problem source.
Measure DC-voltage level and compare the value with value of the signal 01.07 DC
BUS VOLTAGE, if values are not the same, disconnect supply voltage, wait for 5
minutes and then check the connections again.
NOTE! Ensure that test run is safe to perform!
When the drive indicates normal status, perform a test run.
Monitor at least DC-voltage-, current- and speed signals with DriveWindow tool when
running the drive.
If everything is working fine prepare the drive ready for normal operation.

Working instruction
4FPS10000075073
4.2 Finishing the work area
Clean the surroundings of the drive especially the area close to the cooling air input.
Stick a tag with text “+V991” to the drive unit, one close to the type code sticker and
the other to the cover so that it will indicate at the first sight that upgrade work is done.
Pic.54 Pic.55

Working instruction
4FPS10000075073
5 Working Instruction for thermal compound Grey Ice 4100 LV
Originally used thermal compound type is WPS II (10008000). Because of low viscosity it was
possible to spread without special tools.
The new thermal compound Grey Ice 4100 LV (3AUA0000074768) has been introduced for
ACS 600 IGBT upgrade solutions during 2012.
Pic 56.
The new Grey Ice 4100 LV thermal compound has better long term performance and higher
viscosity than WPS II. Because of high viscosity proper spreading of Grey Ice 4100 LV
requires a good stencil.
Pic 57.
Follow the separate working instruction ACS 600 IGBT upgrade Grey Ice 4100 LV
(4FPS10000048908).

Working instruction
4FPS10000075073
Appendix 1, Inverter module circuit diagram R11i

Working instruction
4FPS10000075073
Appendix 2, Inverter module circuit diagram R11i, power stage, phase V

Working instruction
4FPS10000075073
Appendix 3, Inverter module circuit diagram R11i, power stage, phases U and W

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 1 (46)

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 2 (46)

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 3 (46)

1.2 Preparation work

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 4 (46)

1.3 Parts list of IGBT upgrade kit 42000552.

42000480 IGBT MODULE KIT FF1400R12 R11I R9 XT 1 PC

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 5 (46)

1.4 Needed tools

Screw drivers set for electrical work, 1.

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 6 (46)

Torque spanner 2-10Nm for torx- and crosshead screws, 6.

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 7 (46)

Rubber spatula or small paint roll for thermal compound

ESD field service kit

Laptop with DriveWindows SW + DDCS communication accessories

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 8 (46)

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 9 (46)

1.5 The rule of parallel connected IGBTs in nxR11i ACS600 MultiDrive

Minimum upgrade or new type of module if one phase module

Pic.8. A principle drawing of parallel connected IGBTs in R11i drive.

Pic.9. A principle drawing of parallel connected IGBTs in 4x R11i drive.

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 10 (46)

One upgrade kit includes 2pcs of selected IGBTs.

U1.1 U2.1 U3.1 U4.1

U1.2 U2.2 U3.2 U4.2

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 11 (46)

2. Removing the old hardware

In R11i 400-500V units type PP30012 PowerPlates used.

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 12 (46)

2.2 Phase module preparation

Remove the covers of the phase modules.

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 13 (46)

2.3 Removing the NINT- or NXPP-board assembly plate

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 14 (46)

2.4 Disconnecting NINT- or NXPP-boards and NGDR-boards

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 15 (46)

2.5 Removing NPOW-board and current transducer assembly plate

ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 16 (46)

2.6 Removing Clamping capacitors and output bars

ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 17 (46)

2.7 Removing IGBTs

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ESP300 15.11.2012 Ari Niskanen Mika Huuhtanen C 18 (46)