Acs 600 Multidrive Checking and Replacing A Power Plate: Service Manual
Acs 600 Multidrive Checking and Replacing A Power Plate: Service Manual
Service manual
EFFECTIVE: 02.07.2001
SUPERSEDES: 22.3.1999
FIDRI\EIF200
PDM\00017219.DOC
Overview The complete safety instructions stated in ACS 600 MultiDrive Safety
and Product Information (EN 63982229) must be followed when
installing, operating and servicing the frequency converters. Study the
complete safety instructions carefully.
General safety The general instructions are given below. These general instructions
include only the main parts of the complete safety instructions. The
instructions
general safety instructions are intended for all work on the ACA 600
MultiDrive frequency converters. In the text below, air-cooled ACN 600
MultiDrive and water-cooled ACW MultiDrive, are collectively referred
to as ACx 600. Neglecting these instructions can cause physical injury
and death.
If the main circuit of the inverter unit is live, the motor terminals are
also live even if the motor is not running!
Service manual v
Safety instructions
Live parts on the inside of doors are protected against direct contact.
Special attention shall be paid to safety when handling shrouds made
of sheet metal.
Do not make any voltage withstand tests on any part of the unit while
the unit is connected. Disconnect the motor cables before making any
measurements on the motors or motor cables.
If an ACx 600 with the EMC Line Filter is installed to unearthed mains,
the mains will be connected to earth potential through the EMC filter of
the ACx 600. This may cause danger or damage the unit. Disconnect
the EMC filter capacitors before connecting the ACx 600 to unearthed
mains. For detailed instructions on how to do this, please contact your
local ABB distributor.
Do not open the drive section switch fuses when the inverter is
running.
vi Service manual
Safety instructions
Power Plate
handling WARNING!
DO NOT ATTEMPT ANY WORK ON A POWERED ACx 600!
WARNING!
ONLY A QUALIFIED ELECTRICIAN SHOULD CARRY OUT THE
ELECTRICAL INSTALLATION!
• When handling a Power Plate, hold the package and avoid touching
the terminals, especially the gate terminal.
• Always use an earthed wristband when handling a Power Plate.
Table of contents................................................................................................................................................ix
Service manual ix
Table of contents
x Service manual
Chapter 1 - Inverter module frame sizes
General Inverter modules are installed into cubicles depending upon the
physical size of the module. The frame size of inverter modules
determines the power rating: R2i, R3i, R4i, R5i, R6i, R7i, R8i, R9i,
R10i, R11i or R12i. Higher power ratings are implemented by
connecting inverter modules in parallel (R11i or R12i), see
Figure 1 - 1.
• Increased reliability
- Controllability due to high driving-point impedance
- Short circuit safe due to internal connection
Product The ACx 600 Product Family utilises IGBT power semiconductors
structure exclusively. The state-of-the-art integrated IGBT technology (Power
Plate, see Figure 2 - 1) provides reliable drive units.
Phase module If more than one Power Plates are used together for forming a phase
voltage, the construction is called "phase module" (see Figure 3 - 3).
Phase modules are used in frames R10i - R12i and their parallel
connected configurations. A spare part phase module kit is delivered
as a V-phase module, but it can be changed to a U/ W-phase module
by replacing the interface board NINT-xx with an NXPP-xx board
included.
Measuring of a
Power Plate
The following actions should be done and results verified before the
measurement of the Power Plate is started:
Note also that in case the component measures good, but is visually
found to be defective, it must be replaced.
5 3 1
G13 G12 G11 UPPER
6 4 2
G23 G22 G21 LOWER
T1
T
T2
P3 P2 P1
∗
T1 +
G23 E23 G22 E22 G21 E21
P3 P2 P1
5 3 1
G 13 G 12 G 11 UPPER
E 13 E 12 E 11
6 4 2
G 23 G 22 G 21 LOW ER
E 23 E 22 E 21
T1
T
T2
P3 P2 P1
∗
T1
G 23 E 23 G 22 E 22 E21
+
G 21
E 13 G 13 E 12 G 12 E11 G 11
T2 -
P3 P2 P1
Measuring the The measurement is done with the multimeter in the diode position.
collector-emitter • The measurement is done between C-E of all six IGBTs (between
resistance of the + and Px terminals or Px and - terminals, see Figure 2 - 2 and
IGBT Figure 2 - 3.
• When the measurement with the multimeter displays infinite (OL
Over Limit) in one direction and the forward voltage of diode (e.g.
350 mV) in the opposite direction, the C-E junction is OK.
Note that the values shown by the multimeter depends on its
brand and type. Different multimeters with different output voltages
show different forward voltages when measuring semiconductor
components.
• If the multimeter indicates a short circuit, the C-E junction or the
diode in question is faulty and the Power Plate must be replaced.
• If the forward voltage of some of the diodes is different from the
others, the diode is most probably broken and the Power Plate
must be replaced. See the replacement information in the
subsection Faulty Power Plate detected.
Measuring the The measurement is done with the multimeter in the resistance
gate of the IGBT position.
(checking of • The resistance is measured between G-E on all six IGBTs (G11-
IGBTs) E11, G21-E21, and so on) (see Figure 2 - 3 and Figure 2 - 3).
• The IGBT is OK, if the display of the multimeter shows infinite (OL)
between G-E.
Note that OL is shown only after a while (after the capacitance is
loaded).
• If there is a short circuit between G-E or only some ohms, the
IGBT is faulty.
Conclusions • If the junction C-E is short circuited and the junction G-E displays
OL (loading capacitance)(=OK), only the diode is faulty
about measuring
of IGBT and C-E • If the G-E junction is short circuited and the junction C-E displays
infinite (=OK), only the IGBT is faulty
• If both the C-E junction and the G-E junction displays short
circuited, only the IGBT or both the IGBT and the diode are faulty.
Measuring the The measurement is done with the multimeter in the resistance
thermistor of the position.
Power Plate • If the resistance of the Thermistor is OK (measured at connectors
T1 and T2, see Figure 2 - 2 and Figure 2 - 3), the multimeter
displays about 11 kΩ.
Measuring the The measurement is done with the multimeter in the resistance
emitter terminals position.
detected • For small frame sizes (R2i), change the whole unit (because
control boards are soldered to the IGBT module)
• For larger frame sizes (>R3i), it is possible to change the Power
Plate (in frame size R3i the IGBT module)
• Replace also the NINT-xx (or NXPP-xx) and NGDR-xx (used with
R4i and upwards) board if the Power Plate is damaged.
• For the spare part Power Plates follow the instructions in Chapter
3 - Power Plate connections
• For phase module inverters (frame sizes R10i and upwards) the
fault word (FW1; bits B12, B13, B14, B15) indicates which phase
is faulty (a short circuit in the parallel connected inverters). The
fault words can be found in the Application Program Template for
ACS 600, Firmware manual (EN 63700185).
• In case of a fault it is recommended to change the whole phase
module.
Power Plate, basic Figure 3 - 1 shows the basic construction of a Power Plate, consisting
of six IGBTs, six free-wheeling diodes, one NTC Thermistor Resistor
construction
and six Gate Resistors. The outputs of the Power Plate are phase
voltages P1 (U), P2 (V) and P3 (W).
Note: The small size inverters (R2i-R3i) use standard IGBTs, not
Power Plates. The R2i IGBT module has a similar construction to the
basic construction in Figure 3 - 1. The R3i IGBT module has only one
third of the components of the basic construction in Figure 3 - 1. The
basic construction is used for frames R4i - R7i (power range 20 to 140
kVA).
P1 P2 P3
Power Plate Frames R4i to R9i use Power Plates and frames R10i to R12i use
phase modules.
connections,
single inverters In frames R8i and R9i (see Figure 3 - 2), one phase is made by
connecting together terminals P1 - P3 of the Power Plate. The number
of Power Plates is three. The power range is 180 to 490 kVA.
U V W U V W
Figure 3 - 2 Symbol of a Power Plate (left). In frame sizes R8i and R9i
each phase has an individual Power Plate (right).
R10i, R11i
Phase module Phase module Phase module
P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3
U V W
Figure 3 - 3 The phase modules. Frames R10i, R11i.
R12i
Phase module Phase module Phase module
P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3
U V W
Power Plate Extended power range is achieved by connecting two or four frame
R11i or R12i inverters in parallel (see Figure 3 - 5). The power range
connections, reaches 5140 kVA. The number of Power Plates when four R12i
parallel inverters inverters are in parallel totals 4 x 9 = 36.
4 x R12i
R12i R12i R12i R12i
P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3
U V W
Figure 3 - 5 The parallel connected phase modules. Frame 4 x R12i.
Power Plate Every Power Plate that can be used for parallel connection of the
phase modules is marked (classified) with a letter pair AA, AB, AC,
classes (letter AD, to, IJ. The smallest Power Plates may have only one letter per
pairs and spare IGBT.
parts) In (Figure 3 - 7) VCEsat (= collector - emitter saturation voltage
(IGBT)) corresponds to the 1st letter in the letter pair and VF = forward
voltage (diode) corresponds to the 2nd letter in the letter pair.
Starting from December 2000 inverters that use Power Plate type
PP18017 (180A, 1700 V) have an extra “L” letter in front of the letter
pair. These Power Plates are manufactured by using low injection
process and they cannot be connected in parallel with older PP18017
types.
The voltage VCEsat varies from 2.0 V (= letter A), 2.2 V (= B), to 3.7 V
(= I) on the X-axis. Similarly, the VF diode varies from 2.0 V (= letter
A), 2.2 V (= B), to, 3.9 V (= J) on the Y-axis.
The possible spare part classes are SP1, SP2, SP3, SP4, SP5, SP6,
SPL5 and SPL6.
NOTE 1: The Power Plates used in frames R8i - R12i are classified
based on the nominal on-state voltages of the IGBTs (VCE) and the
diodes (VF).
NOTE 3: Spare parts are selected from four groups and marked by
the letter pair and SPx, for example. “DC SP4” can replace an original
Power Plate from classes DC, DB, EC or EB.
NOTE 4: Low injection PP18017 types have an extra “L” letter in front
of the actual categorisation letter pair and also in front of the SP class
number, for example. “LFE SPL6”.
VCEsat 2 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3 3,1 3,2 3,3 3,4 3,5 3,6 3,7
A B C D E F G H I
VF
2 A AA BA CA DA EA FA GA HA IA
2,1 SP3
2,2 B AB BB CB DB EB FB GB HB IB
2,3 SP4
2,4 C AC BC CC DC EC FC GC HC IC
2,5
2,6 D AD BD CD DD ED FD GD HD ID
2,7 SP5
2,8 E AE BE CE DE EE FE GE HE IE
2,9 SP6
3 F AF BF CF DF EF FF GF HF IF
3,1 SP1
3,2 G AG BG CG DG EG FG GG HG IG
3,3 SP2
3,4 H AH BH CH DH EH FH GH HH IH
3,5
3,6 I AI BI CI DI EI FI GI HI II
3,7
3,8 J AJ BJ CJ DJ EJ FJ GJ HJ IJ
3,9
PP30012 Multidrive
PP18017 Multidrive
PP18017 Multidrive old classes
Figure 3 - 7 The selection table of the spare parts of 300 A and 180 A
Power Plates as a function of VCE (IGBT) and VF (diode).
Note that the spare part class used in parallel modules is marked on
the module.
Special The phase modules are used in the frames R10i - R12i and in their
parallel configurations.
requirements for
the selection of the A phase module kit is delivered as a V-phase module, but it can be
changed to a U/W -phase module by replacing the interface board
Power Plate NINT-xx with an NXPP-xx included. The spare part’s power supply
boards NPOW-62 and NGPS-xx have to be disconnected from the
main circuit (or completely removed).
When replacing a Power Plate with a new one, certain rules have to
be followed in the selection of a spare part Power Plate. In the
following rules, the different types of Power Plates are:
2P = a Power Plate used to make one motor phase output (R8i - R10i)
(see Figure 3 - 2)
PAR = a Power Plate suitable for paralleling to make one motor output
(see Figure 3 - 3), using specified classes (see Figure 3 - 7) (R11i and
R12I)
Frames R4i- R7i No special requirement, any Power Plate with whichever letter pair (2P
or PAR) or no letter pair (=6P) can be used.
Spare parts No requirement for the letter pair (6P, 2P, PAR or SP).
Frames R8i, R9i Any letter pair (2P), different phases can have different letter pairs.
Spare parts No requirement for the letter pairs (2P, PAR or SP).
Frames R10i The phase modules of the same phase have an identical letter pair
(2P).
Spare parts The Power Plates in the same phase must have an identical letter pair
(2P or PAR). Therefore both Power Plates in the same phase must be
replaced in a case one of them is damaged.
Frames R11i, All Power Plates of the same motor output must have the same letter
R12i, n x R11i, pair (PAR):
n x R12i • DA, DB, DC, EA, EB or EC of PP30012 Power Plate type and
• FD,FE, FF, GD, GE, GF, LFD, LFE, LFF, LGD, LGE or LGF of
PP18017 type (in the old classes FF, FG, FH, GF, GG or GH)
Spare parts All Power Plates in the damaged phase module must be changed. The
spare part Power Plate kit must have a correct SP marking, currently:
Power stages of Figure 3 - 8 shows an inverter module ACN 634 (frame R6i) made
using one Power Plate.
the inverter module
In Figure 3 - 9 the inverter module ACN 634 (frame R8i) uses one
Power Plate for each phase.
Figure 3 - 8 The circuit diagram of an inverter module ACN 634 (R6i) (00012264.dwg)
Figure 3 - 9 The circuit diagram of an inverter module ACN 634 (R8i) (00012267.dwg)
Figure 3 - 10 The circuit diagram of phase module A2 ACN 644, Phase V (R10i), (00005542.dwg)
General Before working with ACx 600 or handling the Power Plate, read
carefully Safety instructions - section Power Plate handling which
includes warnings, cautions and precautions for working on a powered
ACx 600 and for handling a Power Plate.
Accessing the • Clear a suitable space outside of the immediate work area for
removed screws, bolts, components and subassemblies to avoid
Power Plate mislaying or damaging them.
• Study the safety instructions in Safety instructions-chapter.
• Disconnect the mains supply.
• Wait at least five minutes.
• Remove the front cover of the ACx 600 unit.
• Measure the DC voltage and the mains voltage. The voltages must
be zero before you continue working with the unit.
• Install the wristband and the earthing mat according to ABB
Industry Oy ESD Directive.
• Put the wristband on your wrist.
• Remove the boards and the busbars to gain access to the Power
Plate.
• Remove the wiring.
• Remove the faulty Power Plate.
• Clean the heat sink surface with an appropriate solvent (e.g. Grafol)
and a soft cloth from excessive thermal compound and particles.
Thermal compound The recommended thermal compound type is WPS II. The Power
Plate spare parts kit includes a tube of a thermal compound.
Power Plate When installing the Power Plate on the heat sink, the following
instructions should be applied to maximise the effect of the heat sink
assembly
and to minimise the stress concentrated on the Power Plate.
4-screw-type • Clean the base plate surface with an appropriate solvent (e.g.
Grafol) and a soft cloth from particles.
Power Plate
• Apply a thin layer of thermal compound with a rubber spatula or
with hand on the surface of the base plate. The thermal compound
layer should be as thin as possible. Thermal compound should fill
the areas (holes) on the base plate and heat sink, so that no air is
left between (see Figure 4 - 1).
• Put the Power Plate on the heat sink and press by hands to extend
the thermal compound. Press at least five seconds.
• Tighten the screws to a pre-torque according to Table 4 - 1 and in
sequence 1-2-3-4 according to Figure 4 - 2.
6-screw-type • Clean the base plate surface with an appropriate solvent (e.g.
Grafol) and a soft cloth from particles.
Power Plate
• Apply thin layer of thermal compound with a rubber spatula or with
hand on the surface of the base plate. The thermal compound layer
should be as thin as possible. Thermal compound should fill the
areas (holes) on the base plate and heat sink, so that no air is left
between (see Figure 4 - 1).
• Put the Power Plate on the heat sink and press by hands to extend
the thermal compound. Press at least five seconds.
• Tighten the screws to a pre-torque according to Table 4 - 1 in
sequence 1-2-3-4-5-6 according to Figure 4 - 4.
Check after the • When assembling the NGDR (Gate Driver Board) it is necessary to
check that the connection pins of the Power Plate go into the
assembly connectors of the NGDR board.
• Ensure that the flat cables of the phase modules are properly
fastened (locked).
ABB Industry Oy
Drives
P.O.Box 184
FIN-00381 HELSINKI
FINLAND
Telephone + 358 10 22 2000
Telefax + 358 10 22 22681