ACS 2000 ServiceMan 3BHS344169 E01 Rev

Service manual
Medium voltage AC drive

ACS 2000, 400 - 1000 kVA, 6,0 - 6,9 kV
ABB
ABB
ACS 2000 Service manual 3BHS344169 ZAB E01 Rev. - 1 (4)
Table of contents
General information on manual and equipment 1
Copyright notice 1
Document identification 1
Equipment covered by the manual 1
Contact information 1
Target groups and required qualifications 1
Writing conventions 2
Meaning of icons 2
Text conventions 2
Trademarks 3
Meaning of terms and abbreviations 3
Related documentation 4
Tools and personal equipment 4
Personal safety 4
Module tray 4
Personal computer 5
Hand tools 5
Measuring equipment 5
Cleaning equipment 6
Chapter 1 - Safety 1-1
1.1 Classification of safety signs used in this manual 1-1
1.2 Stopping the drive 1-2
1.3 Deenergizing the drive 1-3
Chapter 2 - Grounding switch and door safety switch 2-1
2.1 Malfunctioning grounding switch 2-1
2.2 Doors and door locks 2-2
2.2.1 Door safety switch 2-3
Chapter 3 - Replacing phase modules 3-1
3.1 Overview 3-1
3.2 Dimensions and weight 3-2
3.3 Required tools and accessories 3-2
3.3.1 Procedure 3-2
Table of contents ABB
2 (4) 3BHS344169 ZAB E01 Rev. - ACS 2000 Service manual
Chapter 4 - Checking phase modules 4-1
4.1 Checking a phase module for short-circuit 4-1
4.1.1 Visual check of the phase module 4-1
4.1.2 Measuring the voltage across the phase module terminals 4-2
4.2 Measuring phase capacitors 4-4
4.2.1 Required tools and accessories 4-4
4.2.2 Procedure 4-4
4.3 Dismantling the phase module 4-5
4.3.2 Overview 4-5
4.3.3 Procedure 4-6
4.4 Checking IGBT modules 4-9
4.4.2 Procedure 4-9
4.4.3 Checking the free-wheeling diodes 4-11
4.4.4 Checking the gate unit 4-11
4.5 Replacing the IGBT heatsink assembly 4-12
4.5.2 Procedure 4-12
4.6 Replacing phase capacitors 4-14
4.6.2 Procedure 4-14
Chapter 5 - Removing the NP frame 5-1
5.2 Procedure 5-1
Chapter 6 - Converter insulation test 6-1
6.2 Procedure 6-1
Chapter 7 - Replacing circuit boards (PCBs) 7-1
7.1 Location of circuit boards 7-1
7.2 Handling instructions for PCBs and fiber-optic cables 7-2
7.2.1 PCBs 7-2
7.2.2 Fiber-optic cables 7-2
7.3 Replacing an AMC circuit board 7-2
7.3.1 Changing the AMC software flash memory 7-4
7.4 Replacing the main INT circuit board 7-6
7.5 Replacing ASE and SYN circuit boards 7-7
ABB Table of contents
7.5.1 ASE circuit board 7-8
7.5.2 SYN circuit board 7-9
7.6 Replacing the VLSCD circuit boards 7-9
7.6.1 Rear access 7-10
7.6.2 Front access 7-10
Chapter 8 - Function of LEDs 8-1
8.1 Safety 8-1
8.2 Main INT circuit board 8-2
8.3 Phase Int INT circuit board 8-3
Chapter 9 - Uploading data from the black box 9-1
Table of contents ABB
ABB
List of figures
Figure 1-1 Connecting a grounding set 1-5
Figure 2-1 Door locks 2-2
Figure 2-2 Location of door safety switch 2-3
Figure 3-1 AFE and INU compartment 3-1
Figure 3-2 Phase module 3-2
Figure 4-1 Measuring point locations 4-1
Figure 4-2 Measuring points 4-3
Figure 4-3 Top view of a phase module 4-5
Figure 4-4 Dismantling the phase module 4-10
Figure 4-5 IGBT module 4-11
Figure 7-1 Location of circuit boards 7-1
Figure 7-2 AMC circuit board 7-2
Figure 7-3 AMC flash memory 7-4
Figure 7-4 Main INT circuit board 7-6
Figure 7-5 Location of SYN and ASE circuit board 7-7
Figure 7-6 ASE circuit board 7-8
Figure 7-7 Location of VLSCD circuit board 7-9
Figure 8-1 AMC circuit board 8-1
Figure 8-2 Main INT circuit board 8-2
Figure 8-3 Phase INT circuit board 8-3
Figure 9-1 Black box 9-1
ABB
ABB
List of tables
Table 4-1 Readings of a healthy phase module in diode mode 4-2
Table 4-2 Readings of a healthy phase module in diode mode 4-2
Table 4-3 Readings of a healthy IGBT module in diode mode 4-11
Table 4-4 Readings of a healthy IGBT module in resistance mode 4-11
Table 8-1 Function of LEDs on the AMC circuit board 8-1
Table 8-2 LEDs on the main INT circuit board 8-2
Table 8-3 LEDs on the phase INT circuit board 8-3
ABB
ABB
General information on manual and equipment
Copyright notice
The information in this manual is subject to change without notice.
This manual and parts thereof must not be reproduced or copied, or
disclosed to third parties, nor used for any unauthorized purpose without
written permission from ABB Switzerland Ltd, Medium Voltage Drives.
Document identification
Ownership ABB Switzerland Ltd
Medium Voltage Drives
Document number 3BHS344169 ZAB E01
Revision index -
Issue date 13.10.2010
Equipment covered by the manual
The manual does not claim to cover all variations and details of the
equipment, nor to consider all eventualities that may arise during service
of the equipment.
If information is required beyond the instructions in this manual refer the
matter to ABB. See section Contact information.
Contact information
Address ABB Switzerland Ltd
CH-5300 Turgi, Switzerland
Phone +41 844 845 845
Fax +41 58 589 29 84
Email mvdrives@ch.abb.com
Target groups and required qualifications
The equipment presented in this manual is part of an industrial
environment where voltages are present that contain a potential hazard of
electric shock and / or burn.
For this reason, only personnel who have a thorough knowledge of the
equipment and the industrial environment and have obtained the required
General information on manual and equipment ABB
qualification may service the equipment. Personnel must know the safe
shutdown and grounding procedures for the equipment.
Writing conventions
The following icons and text conventions are used in the manual.
Meaning of icons
Illustrates an illuminated lamp or pushbutton.
Illustrates a button or key to be pressed.
Arrows indicate an alternating display message.
Refers to further information in a separate document.
Text conventions
Bulleted list
Used to list items or steps in a procedure, where the sequence does
not matter.
Bulleted list of a subsection following a main paragraph
Used to list items for procedures, where the sequence does not
matter.
1 Steps of a procedure, to be followed in the specified order (e.g. 1, 2,
3.....)
1 Figure legend, numbers identify the items referred to in the illustration
above (e.g. 1, 2, 3.....)
Arial Bold is used to highlight switches to be operated, status messages
shown in a display and special terms.
UPPERCASE letters refer to a parameter.
Italic is used for references to illustrations, chapters and supplementary
documentation.
ABB General information on manual and equipment
Trademarks
Names that are believed to be trademarks of other companies and
organizations are designated as such. The absence or presence of such
a designation should however not be regarded as an offence of the legal
status of any trademark. The following registrations and trademarks are
used in this manual:
Fluke Registered trademark of Fluke Corporation
Meaning of terms and abbreviations
Abbreviation Meaning
AFE Active Front End
The AFE, also referred to as ARU (Active Rectifier Unit), is the
line-side rectifier of the drive that enables four-quadrant operation
and reactive power compensation.
AMC Application and Motor Controller
The digital signal processor is the heart of the control system of
the drive. A separate AMC circuit board is assigned to the line-
side rectifer (AFE) and the motor inverter (INU) of the drive.
DC Direct current
Drive Short form for ACS 2000 frequency converter
EMC Electromagnetic compatibility
All measures to suppress electromagnetic disturbances caused
by different electrical equipment in the same electromagnetic
environment, and to strengthen the immunity of the equipment to
such disturbances.
Equipment Frequency converter and related equipment
Ground Earth
To ground The conducting path (e.g. conductor) between the electric
equipment (e.g. frequency converter) and the earth. The electric
equipment is connected to the earth, e.g. by a grounding set or a
grounding switch.
Drive Short form for ACS 2000 frequency converter
HVD High voltage divider
INT Interface
INU Inverter unit of the drive. The INU converts the DC voltage to the
required AC motor voltage and frequency.
IPS Isolated power supply
LED Light emitting diode
NP Neutral point
OEI Optical electrical interface
PCB Printed circuit board
Related documentation
The following documents are available for supplementary information:
Tools and personal equipment
Personal safety
Safety goggles or spectacles
Dust mask
Hearing protection earmuffs
Safety helmet
Soft leather mechanics gloves
Module tray
The module tray is delivered with each drive. The tray is used if a phase
module of the drive has to be removed from the cabinet.
SW Software
VLSCD Voltage level short circuit detection
Abbreviation Meaning
Title Document number
ACS 2000 Users manual 3BHS297030 ZAB E01
Warranty directives 3BHS404420 ZAB E01
Wiring diagrams 3BHS319007 ZAB E01
ABB General information on manual and equipment
Personal computer
Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical
transmitter / receiver, optical cables and DriveWindow or DriveDebug
Hand tools
Drive socket set with ratchets and extension bars
Spanner set
Screwdriver set
Side cutter
Hex key set
Measuring equipment
Multimeter (e.g. Fluke 87)
Test leads of sufficient length
Test probes
The test probes should have sufficient length and short uninsulated
tips (see circles).
5 kV Megger, for example AVO BM11D
Fiber-optic cable tester, e.g:
Tempo 253B Led source (set to 660nm, no modulation), 10ZP
Adapter
Tempo 557B power meter (set to 660nm, dBm), 10ZP Adapter
Photom 205A - optical power meter, Haktronics Co., Ltd
LEONI optical power meter
LEONI optical sender ZXXX-TS0
Fiber optic GmbH, 96524 Neuhaus-Schierschnitz, ZXXX-TM0
~30 cm
Cleaning equipment
Antistatic vacuum cleaner (for example SV-497 ABF - VACUUM 3M
220V from 3M) for cleaning of sensitve electronic components (e.g.
printed circuit boards)
Antistatic brush for cleaning of printed circuit boards
Cloths and brushes for general cleaning
ABB
ACS 2000 Service manual 3BHS344169 ZAB E01 Rev. - 1-1 (6)
Chapter 1 - Safety
1.1 Classification of safety signs used in this manual
Safety instructions are used to highlight a potential hazard when working
on the equipment. Safety instructions must be strictly followed! Non-
compliance can jeopardise the safety of personnel, the equipment and the
environment.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
The safety instructions are derived from the following standards:
ISO 3864-2:2004 (E)
Graphical symbols Safety colours and safety signs Part 2: Design
principles for product safety labels
ANSI Z535.6
American National Standard for Product Safety Information in
Product Manuals, Instructions, and Other Collateral Materials
Chapter 1 - Safety ABB
1-2 (6) 3BHS344169 ZAB E01 Rev. - ACS 2000 Service manual
1.2 Stopping the drive
Press the stop key on the CDP control panel.
The motor stops according to the preset stop function and the drive stops
modulating. While the motor stops, the status line of the display shows
ReadyRef. The run status indication blinks during the stop sequence.

As long as the stop sequence is in progress, the drive can always be
restarted by pressing the start key on the CDP control panel.
Just before the motor will come to a standstill, the CDP control panel
displays shortly the message Stopping.
When the drive has stopped modulating, the CDP control panel displays
ReadyRun:
1 L -> 600.0 rpm
StateINU ReadyRef
MOTOR SP 300.00 rpm
POWER 20.0 kW
1 L -> 600.0 rpm 0
StateINU Stopping
MOTOR SP 0.00 rpm
POWER 0.0 kW
1 L -> 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
ABB Chapter 1 - Safety
As long as the MCB has not been opened, the motor can be started
again.
1.3 Deenergizing the drive
DANGER
Hazardous voltage!
Do not try to gain access to the input transformer, the medium voltage
compartments of the drive, nor the motor, as long as the drive system is
energized and not grounded.
To disconnect the drive from the main power supply, proceed as follows:
1 Stop the motor as described in 1.2 Stopping the drive.
When the motor has reached zero speed, the display shows
ReadyRun:
2 Press the SUPPLY OFF pushbutton to disconnect the drive from the
main power supply. The following takes place:
The MCB opens.
The DC link discharges.
While the DC link discharges, the display shows OffSeqOn:
The SUPPLY OFF pushbutton flashes and changes to a perma-
nent light when the DC link is discharged completely.
1 L -> 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
1 L -> 600.0 rpm
StateINU OffSeqOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
When the DC link is discharged, the display shows ReadyOn:
3 Rack-out, lock-out, ground and tag-out the MCB.
4 Turn the grounding switch to the grounded position when the lamp
GROUNDING SWITCH UNLOCKED is on.
NOTICE
Do not turn the grounding switch to the grounded position before the
light GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will
be damaged.
The lamp is only turned on after the fan has stopped. The fan contin-
uous running for a preset time after the main power supply has been
switched off to dissipate the heat from the resistor assembly in the
back of the cabinet.
If the lamp does not light up and there is reason to believe that the
grounding circuit is malfunctioning, refer to Chapter 2 - Grounding
switch and door safety switch, 2.1 Malfunctioning grounding switch
for further information.
When the grounding switch is in the grounded position, the status
line of the display alternates between DCGnd NOpen, NotReadyOn,
AFE NotRdy:
1 L -> 600.0 rpm
StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
1 L -> 600.0 rpm
StateINU DCGnd NOpen
MOTOR SP 0.00 rpm
POWER 0.0 kW
DCGnd Nopen
NotReadyOn
AFE NotRdy
ABB Chapter 1 - Safety
DANGER
The grounding switch connects the DC link of the drive to the PE ground
bus.
If it is planned to perform maintenance on the drive that includes the
removal of phase modules, the connection of grounding equipment at the
appropriate locations is a must. This is to ensure that hazardous voltages
cannot be fed into the drive neither from the main power supply nor the
motor.
Figure 1-1 shows an example how the terminals of the feeder cables
(1) are grounded at the PE ground bus (2) using a 4-way grounding
set (3).
Figure 1-1 Connecting a grounding set
5 Switch off all auxiliary voltages from external sources.
The drive is now dead, and safe access is possible.
3
1
2
ABB
Chapter 2 - Grounding switch and door safety switch
2.1 Malfunctioning grounding switch
When the DC link of the drive has been deenergized, the lamp
GROUNDING SWITCH UNLOCKED lights up to indicate that the
grounding switch is released and can be turned to the grounded position.
If the lamp does not light up and there is reason to assume that the
grounding circuit is malfunctioning, proceed as follows:
1 Do not try with force to turn the grounding switch in any direction.
The handle and / or the switch could be damaged if tried.
2 Verify that the MCB is in the open position.
3 Check the drive status on the CDP control panel.
The message ReadyOn is displayed when the DC link of the drive
has been discharged.
4 Verify that the DC link has been discharged.
The discharging level can be viewed in parameter 2.01 DC
VOLTAGE. The value should be below 50 V.
5 Check if there are any alarm and fault messages on the display.
If there are any, look up the messages in the Troubleshooting guide
and follow the instructions.
6 Try to rectifiy the reason for the alarms and faults, and then press the
reset key on the CDP control panel.
1 L -> 0.0 rpm
StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
Chapter 2 - Grounding switch and door safety switch ABB
2.2 Doors and door locks
To ensure safety and to prevent the doors being opened unintentionally,
all doors are lockable, and the doors of compartments where medium
voltages are present during operation are bolted or electromechanically
secured. Additionally, the doors of the medium voltage compartments
have locks with different inserts than the control compartment door. The
different lock inserts ensure that these doors can only be opened by
personnel authorized to do so.
Figure 2-1 Door locks
1 Door of terminal compartment: bolted and lockable
2 Door of control compartment: lockable
3 Door of AFE / INU compartment: electromechanically locked
Door cannot be opened when the main power has been applied.
The louvered panels can be removed during operation to replace the
filter mat.
4 Cover of input filter compartment: bolted
The louvered panel can be removed during operation to replace the
filter mat.
1 2 3
4
ABB Chapter 2 - Grounding switch and door safety switch
2.2.1 Door safety switch
2.2.1.1 Function
The safety switch of the AFE / INU compartment door is tied into an
interlocking mechanism that operates in conjunction with the grounding
switch and the interlocks from the main circuit breaker in the main power
supply circuit of the drive:
The interlocking system ensures that the main power cannot be
initialized to the drive unless the door is securely closed and the
grounding switch is in position not grounded.
The interlocking system also ensures that the door cannot be opened
until the main power is disconnected, the DC link capacitors are
discharged and the grounding switch is in position grounded.
The door of the control compartment is not integrated into the interlocking
mechanism and can always be opened.
The safety switch is located under the roof plate behind the door of the
AFE / INU compartment (see arrow).
Figure 2-2 Location of door safety switch
2.2.1.2 Manual release
Before the drive leaves the factory, the safety switch is put to position
unlocked. If the safety switch is in postion locked by mistake and the
auxiliary voltage is turned off, the door cannot be opened. To open the
door, the safety switch must then be unlocked manually.
The safety switch is equipped with a mechanical release (1) that has two
adjustable positions:
Unlocked (2)
The mechanical release is put into this
position in the factory.
The auxiliary voltage can either be
switched on or off.
Locked (3)
This is the normal operating position.
To open the door, the DC link must be
discharged and the auxiliary voltage
must be switched on.
If the auxiliary voltage is switched off
and the door is locked, the safety
switch must be unlocked manually as
described in the following section.
Procedure 1 Open the control compartment door to access the release dial of the
safety switch (see arrow).
2 3 1
ABB Chapter 2 - Grounding switch and door safety switch
2 Using a slotted or Philips screwdriver, screw out the locking screw (1)
until the release dial (2) can be turned.
3 Using a slotted screwdriver (tip width 5 mm), turn the release dial from
the locked to the unlocked position.
4 After the door has been opened, turn the release dial to the locked
position and screw in the locking screw.
Note: After the mechanical and electrical installation has been finished, it
is the task of the commissioning personnel to check that the manual
release of the safety switch is in the locked position. Otherwise, the drive
cannot be started up.
1
2
ABB
Chapter 3 - Replacing phase modules
3.1 Overview
Figure 3-1 AFE and INU compartment
1 Phase module 1 of INU
4 Phase module 1 of AFE
1
2
3
4
5
6
Chapter 3 - Replacing phase modules ABB
3.2 Dimensions and weight
Figure 3-2 Phase module
Dimensions (L x W x H) 650 x 490 x 25 (mm)
Weight Approximately 30 kg
3.3 Required tools and accessories
Module tray
Reversible ratchet with extension
5 mm hex-head drive socket
6 mm hex-head drive socket
3.3.1 Procedure
1 Switch off the main power supply and ground the equipment.
See Chapter 1 - Safety, 1.3 Deenergizing the drive if information on
deenergizing is required.
2 Switch off the auxiliary power supply.
Depending on the auxiliary power supply configuration of the drive,
switch off the following miniature circuit breakers:
Drives with common auxiliary power supply (no safeline):
Miniature circuit breaker -Q1302 disconnects the complete
single-phase auxiliary voltage from the drive.
Drives with separate auxiliary power supplies (safeline):
ABB Chapter 3 - Replacing phase modules
Miniature circuit breaker -Q1354 disconnects the auxiliary
voltage from the phase modules.
Miniature circuit breaker -Q1352 disconnects the auxiliary
voltage from the control compartment.
See the Wiring diagrams to identifiy the miniature circuit breakers and
the electric circuits.
CAUTION
After the miniature circuit breakers have been switched off, the charging
transformer and the fan unit are still connected to their power supplies.
3 Remove the acrylic panel (1).
Screw type: M10 socket-head screw
Required tool: 6 mm hex-head drive socket
When working on the AFE, first pull out the air pressure tube at the
bottom of the panel.
l
4 Remove the screws on each side of the phase module.
Screw type: M10 socket-head screw
Required tool: 6 mm hex-head drive socket
1
5 Attach the module tray to the cabinet.
The tray is attached to two brackets, one on each side (see arrows).
.
Hold the tray at an angle (1) to slide the hook-shaped ends of the tray
behind the brackets. Lower it down (2) to engage the hooks with the
brackets.
.
CAUTION
Make sure the module tray is securely attached to the cabinet (see arrows)
to prevent dropping the phase module when placed on the tray.
1
2
6 Holding the phase module at the handles, pull it out until it is flush with
the leading edge of the tray.
7 Disconnect all cables going into the cabinet from the phase INT circuit
board (1):
Auxiliary power supply cable (2)
Two fiber-optic cables (3)
The cables are partly concealed by the grounding strap.
Current transformer cable (4)
Note: This cable is only present in phase modules of the AFE.
.
8 Detach the cable chain on the side of the phase module (1, 2). Pull
down the end of the chain a little (3) and pull it into the direction of the
arrow (4) to disengage the chain from the mounting bracket.
.
1 2 3 4
1 2
9 Lift the phase module off the module tray.
Owing to the weight (approximately 35 kg [77 lb]), it is recommended
that two persons, one on each side, lift the phase module off the tray.
Hold the phase module at the positions indicated by the arrows.
.
10 After the phase module has been replaced, proceed in reverse order
of removal.
3 4
11 When reconnecting the fiber-optic cables, pay attention to connect
them to their corresponding receptacles (see arrows).
.
12 When all cables have been reconnected, check that the drive control
system and the phase module communicate with each other.
Depending on the auxiliary power supply configuration of the drive,
switch on the following miniature circuit breakers:
Drives with common auxiliary power supply (no safeline):
Switch on miniature circuit breaker -Q1302.
Drives with separate auxiliary power supplies (safeline):
Switch on miniature circuit breaker -Q1354.
Wait a few seconds.
Check that the LEDs onthe phase INT circuit board of the phase
module are on (see rectangle).
13 Push the phase module back into the rack as far as it goes and
tighten the fastening bolt on each side.
14 Remove the module tray and reinstall the acrylic panel.
15 Switch on all miniature circuit breakers in the control compartment.
16 Start the drive.
See the Users manual, 8.5 Starting the drive system locally if infor-
mation on the start-up procedure is required.
ABB
Chapter 4 - Checking phase modules
4.1 Checking a phase module for short-circuit
A faulty phase module can be detected by one of the two methods:
Visually checking the phase module
Measuring the voltage across the phase module terminals
4.1.1 Visual check of the phase module
Note: For the visual check, the phase module needs to be pulled half way
out of the cabinet. To do this, follow the instructions up to step 7 in Chapter
3 - Replacing phase modules, 3.3.1 Procedure.
Each phase module contains one phase INT circuit board (2) which
interfaces with the six gate drives (1). Each gate drive controls two IGBTs.
Figure 4-1 Measuring point locations
Visually check the six gate drives of the phase module. Possible findings:
All LEDs on the gate drives are on.
R4011
Measuring point E
PH DC- NP DC+
Measuring point C
1 1 2
Chapter 4 - Checking phase modules ABB
This means that the phase module could be healthy or faulty. For
further investigation, proceed with section 4.1.2 Measuring the
voltage across the phase module terminals.
The LEDs on one or several gate drives are off.
This means that these gate drives are short-circuited at the output.
Either the gate drive or one the associated IGBTs cause the problem.
In this case, the phase module has to be replaced to get the drive
running again. Check the faulty phase module according to section
4.1.2 Measuring the voltage across the phase module terminals.
4.1.2 Measuring the voltage across the phase module terminals
Note: The phase module needs to be completely pulled out of the cabinet.
To do this, follow the instructions up to step 7 in Chapter 3 - Replacing
phase modules, 3.3.1 Procedure.
With the multimeter in diode test mode, measure the voltages at the
measuring points shown in Figure 4-2. The reading should be as stated
inTable 4-1 below. If the measured values are different, contact the MV
drives supportline for further advice.
Note: The threshold voltage for each IGBT is ~0.35 V; the measurement
includes two IGBTs.
Table 4-1 Readings of a healthy phase module in diode mode
Plus probe Minus probe Reading
PH C ~0.7 V
C DC+ ~0.7 V
NP C ~0.7 V
DC- E ~0.7 V
E PH ~0.7 V
E NP ~0.7 V
Table 4-2 Readings of a healthy phase module in diode mode
Minus probe Plus probe Display reading
PH C OL
C DC+ OL
NP C OL
DC- E OL
E PH OL
E NP OL
ABB Chapter 4 - Checking phase modules
Figure 4-2 Measuring points
4.2 Measuring phase capacitors
4.2.1 Required tools and accessories
LCR meter or multimeter with high capacitance range, e.g. Fluke 179
5 mm hex key
Module tray
4.2.2 Procedure
Note: This test does not require the complete removal of the phase
module.
1 Switch off the main and the auxiliary power supply and ground the
equipment.
2 Attach the module tray and place the phase module on the tray.
See Chapter 3 - Replacing phase modules, 3.3.1 Procedure. Follow
the instructions up to step 7.
3 Considering the polarity, measure directly on the terminals of the
phase capacitor.
The measurement should show the value in F as printed on the
capacitor rating plate, plus or minus the stated tolerance.
4.3 Dismantling the phase module
IMPORTANT
The phase module must only be dismantled or repaired on site after
checking this with the MV drives supportline.
Small slotted screwdriver
5 mm hex key
Side cutter
4.3.2 Overview
Figure 4-3 Top view of a phase module
1 Phase capacitor
2 Phase INT circuit board
3 Cover plate
1 2 3
6 NP DC- DC+ 4 4 5 PH 7
4 Gate drives
5 DC busbars
6 HVD circuit board
7 IGBT heatsink assembly
4.3.3 Procedure
1 Cut the cable ties which connect the ferrite rings (1) to the phase
module frame and put them aside.
2 Carefully unplug the six gate drive plugs (2) which connect the gate
units to the phase INT circuit board.
3 Unplug the DE-9 connector (3) from the phase INT circuit board . The
cable connects the HVD circuit board to the phase INT circuit board.
1 1 3 2 2
4 Disconnect the cable between the HVD circuit board and the neutral
point plug (see arrow).
5 Remove the screw of the cable which connects the phase-input-
output bus end (see arrow) to the IGBTs (V4012 and V4013) and
push the cable out of the current transducer (1).
6 Remove the six screws (see arrows) connecting the internal DC
busbars to the cover plate.
1
7 Remove the four socket-head fastening screws of the cover plate
(see arrows in Figure 4-3).
8 Carefully remove the cover plate.
The circuit board can break easily. Therefore, pay attention not to
touch any part of the gate drive circuit boards with the sharp edges of
the cover plate.
DC bus screws (wo)
4.4 Checking IGBT modules
Multimeter, e.g. Fluke-87
5 mm hex key
10 mm spanner
4.4.2 Procedure
equipment.
2 Remove the phase module from the cabient as described in Chapter
3 - Replacing phase modules.
3 Place the phase module on a clean and stable working surface suit-
able for the weight of the phase module (approximately 35 kg [77 lb]).
4 Remove the phase module cover as described in section 4.3 Disman-
tling the phase module.
5 Unplug cables 1 and 2 at the position indicated in Figure 4-4.
6 Unscrew cable 3 at the position indicated in Figure 4-4.
7 Remove the link (see squares in Figure 4-4).
8 Remove the fastening screws (see circles in Figure 4-4) of the DC
busbars.
Figure 4-4 Dismantling the phase module
9 Proceed with section
4.4.3 if the free wheeling diodes have to be checked,
4.4.4 if the gate unit has to be checked.
3
1 2
4.4.3 Checking the free-wheeling diodes
Check the free-wheeling diode with the multimeter in diode test mode.
Figure 4-5 IGBT module
4.4.4 Checking the gate unit
Check the gate units with a multimeter in resistance mode.

Table 4-3 Readings of a healthy IGBT module in diode mode
Plus probe Minus probe Display
1 2 OL
2 3 OL
2 1 ~0.35 V
3 2 ~0.35 V
Table 4-4 Readings of a healthy IGBT module in resistance mode
Plus probe Minus probe Display
5 6 OL
8 7 OL
6 2 0
7 3 0
4.5 Replacing the IGBT heatsink assembly
IMPORTANT
Any replacement work must only be carried out after checking this with the
MV drives supportline.
5 mm hex key
10 mm spanner
4.5.2 Procedure
equipment.
2 Remove the cover plate as described in section 4.3 Dismantling the
phase module.
3 Remove the DC busbars as described in section 4.4 Checking IGBT
modules.
4 Remove all connections between the gate drive and the IGBT
modules using long nose pliers.
5 Remove the link (see arrow) at the capacitor terminals .
6 Remove the four fastening screws of the IGBT heatsink assembly.
7 Lift the IGBT heatsink assembly carefully out of the phase module.
Best is to take out the heat sink with two people. Avoid touching any
connecting part of a busbar or IGBT. Otherwise the electric contacts
might be affected. Best is to wear thin leather gloves.
4.6 Replacing phase capacitors
5 mm hex key
10 mm spanner
4.6.2 Procedure
1 Remove the cover plate of the phase module as described in section
4.3 Dismantling the phase module.
2 Remove the DC busbars as described in section 4.4 Checking IGBT
modules.
3 Remove the link of the capacitor terminals and the cables connected
to the terminals of the phase capacitor as described in section 4.5
Replacing the IGBT heatsink assembly.
4 Remove the four screws fixing the capacitor using the hex key.
ABB
Chapter 5 - Removing the NP frame
Side cutter
Reversible ratchet
5 mm hex key
17 mm spanner
5.2 Procedure
equipment.
2 Remove all phase modules from the cabinet as described in Chapter
3 - Replacing phase modules.
3 Cut off all cable ties which fasten the cable chains to the side of the
NP frame (see arrows).
Chapter 5 - Removing the NP frame ABB
4 Remove the two fastening screws of all cable chains.
Secure the cable chains so they will not be damaged when the NP
frame is removed from the cabinet.
5 Use the hex key to remove all fastening screws (see arrows) on both
side walls of the NP frame.
ABB Chapter 5 - Removing the NP frame
6 Remove the four fastening screws on the bottom of the frame using
the 17 mm spanner.
7 Remove the cable (1) connected to the ground switch (2).
1
2
Chapter 5 - Removing the NP frame ABB
8 Place a metal plate in front of the NP frame.
Adjust the height of the metal plate so it is level with the bottom of the
NP frame (see arrows).
9 Hook the module tray to the NP frame. The module tray will serve as
a handle to remove the NP frame from the cabinet.
10 Pull out the NP frame and slide it on the metal plate
Note: When pulling out the NP frame, take care not to damage the
cables.
ABB
Chapter 6 - Converter insulation test
IMPORTANT
The insulation test must only be carried out if recommended by the MV
drives supportline. The test is not performed when the drive is commis-
sioned for the first time.
5 mm hex-head key
Multimeter
Test leads for short-circuiting the terminals
5 kV insulation tester (megger)
6.2 Procedure
Note: The terminals and components referred to in the following section
correspond to those in the Power electronics overview on page 6-3.
1 Switch off the main and auxiliary power supply and ground the equip-
ment.
Preparation 2 Short-circuit all medium voltage input and output terminals (U1, V1,
W1, U2, V2, W2).
3 Short-circuit all symmetrical resistors (R
su
, R
sv
, R
sw
, R
sr
, R
ss
, R
st
) of
the phase modules and connect them to the neutral point (NP).
4 Short-circuit the terminals of all phase capacitors (C
fu
, C
fv
, C
fw
, C
fr
,
C
fs
, C
ft
) and connect them to NP.
5 Short-circuit the IFU capacitors (C
r
, C
s
, C
t
) and connect them to NP.
6 Short-circuit the EMC capacitors (C
u
, C
v
, C
w
) and connect them to
NP.
7 Disconnect the NP-to-ground-capacitor (C1021) and short-circuit the
terminals of capacitor C1012.
8 Short-circuit the high voltage charging relay by short-circuiting the
secondary of the charging transformer with the low voltage side of the
relay.
9 Short-circuit the terminals of the grounding switch.
10 Put the grounding switch to the position not grounded.
Chapter 6 - Converter insulation test ABB
11 Connect the insulation tester between the main terminals (U1, V1,
W1, U2, V2, W2) and ground.
Test 12 Perform the insulation test between the main circuit and ground.
Test voltage: 5 kV for 60 seconds.
Duration: 60 seconds
The insulation test is passed if the measured insulation resistance is
100 Mohm or higher.
13 Remove the short-circuit leads.
NOTICE
A short-circuit in any part of the drive will lead to severe damage.
Therefore, check that all short-circuit leads have been removed before
energizing the drive.
ABB Chapter 6 - Converter insulation test
+
+
+
C
f
u
C
f
v
C
f
w
R
v
R
w
C
v
C
w U
2
V
2
W
2
V
W
D
C

-
N
P
R
u
C
u
I
N
U
R
s
u
R
s
v
R
s
w
E
M
C
L
u
L
v
L
w
D
C

+
+
+
+
U
1
V
1
W
1
S
T
C
f
r
C
f
s
C
f
t
C
t
C
s
C
r
L
r
L
s
L
t
A
F
E
C
1
0
1
2
C
1
0
2
1
L
1
0
2
1
R
1
0
2
1
R
1
0
1
4
/
1
5
R
s
r
R
s
s
R
s
t
I
F
U
R
U
+ +
R
C
M
?

=

R
1
0
1
4
/
1
5
C
C
M
?

=

C
1
0
1
2
R
P
G
N

=

R
1
0
2
1
L
P
G
N

=

L
1
0
2
1
C
P
G
N

=

C
1
0
2
1
P
o
w
e
r

e
l
e
c
t
r
o
n
i
c
s

o
v
e
r
v
i
e
w
2
N
u
m
b
e
r
s

c
o
r
r
e
s
p
o
n
d

t
o

t
h
e

s
t
e
p
s

i
n

s
e
c
t
i
o
n

6
.
2

P
r
o
c
e
d
u
r
e
3
3
3
3
3
3
4
4
4
4
4
4
2
9
9
1
0
6
7
7
5
Chapter 6 - Converter insulation test ABB
ABB
Chapter 7 - Replacing circuit boards (PCBs)
7.1 Location of circuit boards
Figure 7-1 Location of circuit boards
1 AMC and main INT circuit board of INU (AMC at the front)
2 AMC and main INT circuit board of AFE (AMC at the front)
3 OEI circuit board
4 CD circuit board
5 IPS (IGBT power supply)
6 SYN circuit board
7 ASE circuit board
8 VLSCD circuit board
1
2
4
6
3
7
5
8
Chapter 7 - Replacing circuit boards (PCBs) ABB
7.2 Handling instructions for PCBs and fiber-optic cables
7.2.1 PCBs
Do not touch circuit boards or other sensitive components without applying
static-sensitive handling precautions. Static electricity can damage circuit
boards and components.
Do not touch the components without wearing a properly grounded
wrist strap.
Put the circuit board or component on a grounded working surface
protected against electrostatic discharges.
Hold a circuit board only at the edge.
Handle a faulty circuit board as carefully as a new one.
7.2.2 Fiber-optic cables
Handle fiber-optic cables with care. Do not touch the ends of the fibers.
They are extremely sensitive to dirt. Always hold the connector when
unplugging a fiber-optic cable. Fiber-optic cables can be damaged if bent
sharply. Observe the minimum bend radius of 25 mm.
7.3 Replacing an AMC circuit board
Figure 7-2 AMC circuit board
ABB Chapter 7 - Replacing circuit boards (PCBs)
1 Before replacing the AMC circuit board, check that the installed soft-
ware version and the parameter settings of the new circuit board
correspond to those in the drive.
See Commissioning manual for information on loading software and
firmware to new AMC circuit board.
equipment.
2 Ground yourself at the converter frame with a wrist strap before
touching the AMC circuit board.
3 Unplug the fiber-optic cables, the power supply connector and the
control panel connector.
4 Remove the fastening screws (7 pcs.) and the AMC circuit board.
5 Attach the new AMC board.
Use all fastening screws to ensure proper grounding of the circuit
board.
6 Reconnect the fiber-optic cables, the power supply connector and the
control panel connector.
7 Verify the connections by comparing them with the corresponding
wirIng diagram.
8 Put the defective circuit board into an antistatic bag.
9 Power up the drive and check if it is functioning properly.
10 Follow the procedures as stated in the MV Warranty Directive if a
defective circuit board has to be returned to ABB, particularly if it is
still under warranty. This procedure is also recommended even if the
warranty period has already expired.
7.3.1 Changing the AMC software flash memory
The application control software and the parameter settings are saved in
the flash memory which is on a separate flash memory PCB (see
rectangle).
Figure 7-3 AMC flash memory
When the AMC circuit board is replaced, the old flash memory can still be
used if the software has not been upgraded in the meantime.
If only the flash memory has to be replaced, the AMC circuit board can
remain in the cabinet. It is also not necessary to disconnect the fiber-optic
cables.
equipment.
2 Ground yourself with a wrist strap before touching the circuit board.
3 Remove the flash memory PCB by holding it with both hands and
pulling it at a 90 angle away from the AMC circuit board.
.
4 Make sure that the white dot on the flash memory PCB is on top of
that on the AMC circuit board when attaching the new PCB.
NOTICE
The correct orientation of the new PCB is important. If attached wrongly,
the new PCB will be damaged immediately when the auxiliary power is
switched on.
5 Press the PCB down firmly making sure that all pins are inserted
properly.
.
6 Mount the AMC circuit board.
board.
7.4 Replacing the main INT circuit board
The main INT circuit board is located behind the AMC circuit board.
Figure 7-4 Main INT circuit board
equipment.
2 Remove the AMC circuit board as described in section 7.3 Replacing
an AMC circuit board.
Ground yourself at the drive frame with a wrist strap before touching
the main INT circuit board.
3 Unplug the fiber-optic cables and the power supply connector.
4 Remove the fastening screws (13 pcs.).
Take all necessary precautions to prevent screws and washers from
falling into other components.
AMC circuit board
Main INT circuit board
5 Remove the main INT circuit board and place it on a grounded
working surface.
6 Install the new main INT circuit board.
board.
7 Reconnect the fiber-optic cables and the power supply connector.
8 Carry out a visual check and verify the connections by comparing
them with the corresponding Wiring diagram.
7.5 Replacing ASE and SYN circuit boards
Figure 7-5 Location of SYN and ASE circuit board
1
2
1 ASE circuit board (behind the cover)
2 SYN circuit board
7.5.1 ASE circuit board
Figure 7-6 ASE circuit board
equipment.
2 Open the control section door and remove the cover of the IFU
compartment (screw type: Phillips).
3 Remove the cover of the ASE circuit board (screw type: Phillips).
4 Ground yourself at the drive frame with a wrist strap before touching
the ASE circuit board.
5 Unplug the auxiliary power, fiber-optics and DC connections.
6 Remove the fastening screws of the board (screw type: Phillips).
Take all necessary precautions to prevent screws and washers falling
into other components.
7 Remove the ASE circuit board and place it on a grounded working
surface.
8 Mount the new circuit board.
board.
9 Reconnect all cables.
10 Carry out a visual check and verify the connections by comparing
them with the corresponding Wiring diagram.
11 Reinstall the cover.
7.5.2 SYN circuit board
The replacement procedure for the SYN circuit board is the same as for
the ASE circuit board with the exception that no circuit board cover has to
be removed.
7.6 Replacing the VLSCD circuit boards
The AFE and the INU of the drive are each equipped with two VLSCD
circuit boards (device designation: F1031, F1032, F1061and F1062).
The circuit boards can be accessed in two ways:
Through the rear of the cabinet
Rear access requires the service cover in the rear of the cabinet to be
removed.
Through the front of the cabinet
Front access requires the NP frame to be removed.
Figure 7-7 Location of VLSCD circuit board
1 INU negative VLSCD
2 INU positive VLSCD
1
2
3
4
3 AFE positive VLSCD
4 AFE negative VLSCD
7.6.1 Rear access
DANGER
Hazardous voltage!
Do not remove the service cover before the drive has been deenergized
and grounded and the fan has stopped.
equipment.
2 Remove the service cover (screw type: Phillips).
3 Replace a circuit board following the instructions in section 7.5
Replacing ASE and SYN circuit boards, from step 9 onwards.
7.6.2 Front access
equipment.
2 Remove the NP frame as described in Chapter 5 - Removing the NP
frame.
3 Proceed as described in section 7.5 Replacing ASE and SYN circuit
boards when replacing the circuit boards.
ABB
Chapter 8 - Function of LEDs
8.1 Safety
Figure 8-1 AMC circuit board
Fault
M
T1
S3
S2
Run
P
T2
S1
S0
Table 8-1 Function of LEDs on the AMC circuit board
LED LED color Function
R green Run indication
F red Fault indication
P green supply OK
M green not used (ON when booting)
T1 yellow ON = receiving data on DDCS channel 0
T2 yellow ON = receiving data on DDCS channel 3
S0 yellow always OFF
Chapter 8 - Function of LEDs ABB
8.2 Main INT circuit board
Figure 8-2 Main INT circuit board
L
E
D
_
1
L
E
D
_
2
L
E
D
_
3
L
E
D
_
4
L
E
D
_
5
L
E
D
_
6
L
E
D
_
7
L
E
D
_
8
L
E
D
_
9
Table 8-2 LEDs on the main INT circuit board
1 yellow all configured PPCS phase INT links enabled
2 yellow any latched fault (fc1/fc2)
3 yellow supply OK
4 yellow reserved for future use
5 yellow internal use
6 yellow firing-through-link faulty
7 yellow PFF link to / from AFE faulty
8 yellow PFF link to / from INU faulty
9 yellow yellow, green, FPGA successfully configured
ABB Chapter 8 - Function of LEDs
8.3 Phase Int INT circuit board
Figure 8-3 Phase INT circuit board
Table 8-3 LEDs on the phase INT circuit board
Done green board ready
R_OK green reset released
GDerr red any gate driver link shut down (short circuit detected)
Alarm red alarm pending
Fault red fault pending
LED1 red not used
LED2 red not used
+ 5 V green power supply on
+ 3.3 V green power supply on
- 15 V green power supply on
Chapter 8 - Function of LEDs ABB
ABB
Chapter 9 - Uploading data from the black box
The AMC34 circuit board is equipped with an additional flash memory
PCB (see rectangle). The PCB serves as a black box which saves data
and fault loggers of the drive for a longer time even if the auxiliary power
has been switched off. When a fault occured in the drive, it is recom-
mended to send the black box data to the MV Drives Supportline of ABB
for assistance in analysing the fault.
Figure 9-1 Black box
The tools for uploading the content of the black box are part of the loading
package. The tools become only visible after the command l_acs has
been entered in a DOS window. Afterwards the folder BlackBox is created
in the loading package. The folder contains one file:
blackbox_upload.exe
1 To upload any data from the black box, open a DOS window and open
folder BlackBox. All files downloaded from the black box will be
saved in this folder.
2 After uploading move the files to another folder or rename them.
Otherwise they will be overwritten the next time a file is downloaded
from the black box.
The black box has two separate parts:
the data loggers and
the fault / parameter loggers.
Chapter 9 - Uploading data from the black box ABB
Uploading
the fault logger
To upload the fault logger, enter the command:
blackbox_upload 1 /bb_upload_data /mbaud=8
1 indicates the channel 3 node number of the circuit board.
To upload data from a circuit board with node number 2, the command
would be:
blackbox_upload 2 /bb_upload_data /mbaud=8
Uploading
the data logger
To upload the dataloggers, enter the command:
blackbox_upload 1 /dl_upload_data /mbaud=8
1 indicates the channel 3 node number of the circuit board.
Each data logger is uploaded to a new file. Empty data loggers are not
uploaded.
If the black box is full, uploading the data can take up to 15 minutes. Once
started, do not interrupt the upload. If the upload is interrupted (e.g. by
closing the DOS window), some communication services will not be
closed properly and it will not be possible to start the upload again. If this
happens, do the following:
Open DriveDebug set any bit of parameter 103.01 to 1.
Uploading of data should work again.
2
ABB Switzerland Ltd
CH-5300 Turgi
Phone: +41 58 589 27 95
Fax: +41 58 589 29 84
E-Mail: mvdrives@ch.abb.com
www.abb.com/drives

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