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The mechanical changes to the converters described in this rework will increase the clearance and creepage
distance between the UDC- and UDC+ bus bars providing increased electrical insulation.
This instruction applies to converter units manufactured before week 48 2014. Starting from week 49 2014 the
converter units manufactured at the factory are implemented with a new bus bar design and improved electrical
insulation between the bus bars.
2. PRECAUTIONS
Only qualified electricians are allowed to install and maintain the drive. Never work on the drive, motor
cable or motor when main power is applied. After switching off the input power, always wait at least of
5 min to allow for the intermediate circuit capacitors to discharge before staring working on the drive,
motor cable or motor. See Safety Instructions from ACS800 Hardware Manual.
The printed circuit boards contain components sensitive to electrostatic discharge. Ware a grounding
wristband when handling the boards. Do not touch to board unnecessarily.
3. PARTS REQUIRED
Rework kit 42003600 is required to apply the change and include all necessary parts. The content of the kit is:
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
Please read through the step-by-step instructions before applying the change. Depending on the drive type and
drive features, indicated to by + codes (See Hardware manual), different steps apply.
TOOLS:
Phillips style screwdriver: Tip size PH1 (tip extension is
useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Phillips style screwdriver: Tip size PH1.
Torx screwdriver: Tip size T20.
Detachment of drive cover, bottom side.
TOOLS:
Needle-nose plier.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Needle-nose plier.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
CHECK!
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Common blade screwdriver: small, (0,5x3 for example).
Disconnect the cables from the RRFCU board (plus
code +E202).
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T25.
CHECK!
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
NOTE: Make sure that the UDC- bus bar lies on top of
the base of the insulating bush.
NOTE: Make sure that the bus bar screws are on the
right thread. Screws tighten on the wrong thread or
otherwise tighten improperly will cause damage to
the drive.
TOOLS:
Torx screwdriver: Tip size T25
Installation of new UDC- bus bar.
NOTE: Make sure that the bus bar screws are on the
right thread. Screws tighten on the wrong thread or
otherwise tighten improperly, will cause damage to
the drive.
TOOLS:
Torx screwdriver: Tip size T25.
Use a torque screwdriver for tightening the screws.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
CHECK!
TOOLS:
Torx screwdriver: Tip size T25.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
CHECK!
TOOLS:
Torx screwdriver: Tip size T20.
Use a torque screwdriver for tightening the screws.
Installation of new UDC- bus bar for drives equipped
with brake chopper (plus code +D150).
15. Slip the new bus bar into place from the side.
NOTE: Make sure that the UDC- bus bar lies on top of
the base of the insulating bush.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
CHECK!
NOTE: Make sure that the bus bar screws are on the
right thread. Screws tighten on the wrong thread or
otherwise tighten improperly will cause damage to
the drive.
TOOLS:
Torx screwdriver: Tip size T25.
Use a torque screwdriver for tightening the screws.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
Use a torque screwdriver for tightening the screws.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
CHECK!
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Common blade screwdriver: small, (0,5x3 for example).
Re-connect the cables to the RRFCU board (plus
code +E202).
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
STEP 20 Re-connect RMIO board cables.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Torx screwdriver: Tip size T20.
Use a torque screwdriver for tightening the screws.
TOOLS:
Phillips style screwdriver: Tip size PH1.
STEP 23 Re-attach plug-in connectors, wire holders and
fieldbus adapters
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Phillips style screwdriver: Tip size PH1.
Use a torque screwdriver for tightening the screws.
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx
frame R6 (powex)
Project Status Date Author Status Revision Version Page
TOOLS:
Phillips style screwdriver: Tip size PH1 (tip extension is
useful).
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.