Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA

Telephone: (818) 734-5300 • Fax: (818) 734-5320 • Website: www.capstoneturbine.com

Work Instructions
GCM IGBT Replacement
Capstone Model C200 MicroTurbine®/C1000 Series

Purpose and Scope

This document describes the procedure for replacing the Generator Control Module (GCM)
IGBT (Phase A, B, C, Brake Resistor) on the Capstone C200 MicroTurbine® and C1000
Series.
This procedure must be conducted by an Authorized Service Provider (ASP).

Guidelines
Review entire procedure prior to performing. Ensure you have all material, tools/equipment,
and reference documents on hand.
Conduct maintenance in a clean, well-lighted area using normal shop tooling to avoid
damage to delicate components.
Retain all parts removed for use in re-assembly, unless otherwise specified.

Safety Procedures
Become familiar with general safety precautions in the C200 User’s Manual (400008) and/or
C1000 User’s Manual (400024). Follow all warnings and cautions in this work instruction.

Symbols
The following symbols are used throughout Capstone documents to alert you to potential
hazards to people or equipment and tips for proper operation of the equipment.
ELECTRICAL WARNING: Identifies an electrical hazard that can result in personal
injury or death.

WARNING: Identifies a hazard that can result in personal injury or death.

CAUTION: Alerts you to a hazard that can result in equipment damage.

NOTE: Clarifies instructions or highlights important information.

440185 Rev A (November 2011) Page 1 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

Material Information
The part(s) being replaced is one or more of the following

Part # Description IGBT Phase

511641-XXX IGBT, SKIIP2, 2 pack, 600A, 1200V SMTH HTSK A or B

511642-XXX IGBT, SKIIP2, 2 pack, 600A, 1200V SRTD HTSK C

518299-XXX LCM NEUTRAL IGBT C6X Neutral

Required Tools and Equipment

Tools/materials required for this procedure are listed below. Refer to Capstone
Recommended Tools (400003) for more detailed requirements and recommendations.
 10 mm socket wrench (for power board assembly, IGBT brackets, small DC cables)
 12 mm socket wrench (for Flexibar)
 13 mm socket wrench (for C200 panels, large DC cables)
 Torque wrench, 0-90 in-lbs.
 5/16 inch Allen wrench (for bay doors)
 #2 Phillips-head screwdriver (for module covers)
 #3 Phillips-head screwdriver (for power board assembly, brackets)
 Flat-head screwdriver (for opening C1000 Controller)
 Anti-static bags (for control board and power board assembly storage)
 Zip ties (for binding cables, attaching cable bundles to control board tray)
 Digital multimeter (DMM)
 Anti-static wrist strap
 Personal Protective Equipment
• Mechanic’s gloves with lining

Reference Documents
The following Capstone documents are referenced in these Work Instructions:
 400003 Recommended Tools, Capstone MicroTurbine
 440000 Microturbine Standard Maintenance Schedule
 400008 Model C200 User’s Manual
 400024 C1000 Series User’s Manual
 512298 Field Service Report

440185 Rev A (November 2011) Page 2 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

Procedures
1. Prepare for procedure as follows.

ELECTRICAL WARNING: High voltage! Follow Step 1 sub-steps to avoid electrical

hazard. Failure to observe this warning can result in personal injury or death.

WARNING: Fuel hazard! Shut off fuel supply. Failure to observe this warning can
result in personal injury, death, and/or equipment damage.
a. For C200 microturbine(s):
(1) Issue Stop command for affected microturbine.
(2) Shut off fuel inlet supply.
(3) Ensure that microturbine chassis remains properly grounded throughout
procedure.
(4) If microturbine is connected to grid, disconnect and lock out from utility in
accordance with local electrical regulations.
(5) If battery packs are installed, turn OFF and lock out main battery pack circuit
breakers, and disconnect battery cables.
(6) Fully isolate microturbine from any other power sources (for example, solid state
relays on user communications board).
(7) Wait at least ten minutes to fully discharge power from the system.
(8) Use DMM to verify that there is no voltage on DC bus and no voltage on high
voltage AC terminal block.
b. For C1000 Series:
(1) If system is configured in MultiPac mode, perform the following steps.
i. Set Override Start to FORCED OFF via CRMS-APS.
ii. Once system is in Stand by mode, disable MultiPac via CRMS.
(2) Continue with the following for all systems.
i. Open C1000 Series Enclosure electrical panel door to access circuit
breakers.
ii. Turn OFF and lock out main circuit breaker for affected bay(s).
iii. Turn OFF and lock out auxiliary circuit breaker for affected bay(s).
iv. Open engine-side door on affected bay(s) and prop open.
v. Shut off fuel inlet supply to bay at ball valve located inside bay door.
vi. Ensure that C1000 enclosure remains properly grounded throughout
procedure.
vii. If battery packs are installed in affected bay, lock main battery pack circuit
breakers in OFF position and disconnect battery cables.
viii. Fully isolate microturbine from any other power sources (for example, solid
state relays on user communications board).
ix. Wait at least ten minutes to fully discharge power from the system.
x. Use DMM to verify that there is no voltage on DC bus and no voltage on
LCM AC output.
440185 Rev A (November 2011) Page 3 of 11
This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

2. Remove GCM IGBT as follows.

a. Remove enclosure panel(s) as needed to access GCM.
CAUTION: Handle Electrostatic Discharge (ESD) sensitive devices properly. Failure to
observe this caution can result in equipment damage.
b. Remove screws from GCM cover and remove cover.

NOTE: If wires/cables are not labeled, label or color-code them before disconnecting.

c. Disconnect ribbon cables from IGBTs. See Figure 1.

d. Disconnect all cables except ribbon cables from control board.
e. Carefully pull ICB P11, PDM #1, PDM #2 cables through hole in tray.
f. Remove PDM-PDB cables by cutting zip ties (not shown) around connector and
removing connector.
g. Disconnect CHS wires from both sides of control board tray.
h. Cut zip ties binding PDM-PBD cables to tray.
i. Remove screws (2 on GCM exterior side, 1 on GCM interior side) from control board
tray.
j. Remove control board tray and store in anti-static bag.

Ribbon cable Zip tie (1 of 2

(1 of 4) on tray)

CHS Wire
(1 of 2) PDM #1
Temp/J20
PDM-PDB Cable ICB P11 cable
(zip tie, cable not
shown)
Hole in right
Dump Valve Cable side of tray
(cable not shown)

CapComm A Right tray

(cable not shown) screw (1)
CapComm B
(cable not shown) PDM #2
Temp/J19

Left tray screw

(1 of 2) Ribbon cable
(1 of 4)
PDM-PDB Cable
(zip tie not shown)
Figure 1 – Remove Control Board Tray
440185 Rev A (November 2011) Page 4 of 11
This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

k. Remove screws, nuts, and washers from top and bottom of power board assembly.
See Figure 2.
NOTE: Nuts securing power board assembly include one washer on either side of
board. Use caution when removing assembly so as not to lose washers in GCM.
l. Disconnect IGBT and GND cables from top and bottom of power board assembly.

IGBT cable

GND cable

Nut (1 of 8) and
Washer (2 per
nut)

Screw (1 of 8)

Screw (1 of 8)

Nut (1 of 8) and
washer (2 per
nut)

GND cable

IGBT cable

Figure 2 – Disconnect Power Board Assembly

440185 Rev A (November 2011) Page 5 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

m. Disconnect remaining cables, except control board cable, from power board
assembly. See Figure 3.

Large DC (4)

Small DC (1)

SPS Power/J5,
J4

Voltage
sense/J3

Control board
cable (not
shown)/J1

Figure 3 - Disconnect Cables from Power Board Assembly

n. Remove bracket screws from both ends of power board assembly. See Figure 4.

CAUTION: Do not damage Nomex paper beneath power board assembly.

o. Remove power board assembly and store in anti-static bag.

Bracket screw
(1 of 4)

Nomex paper

Figure 4 - Remove Power Board Assembly

440185 Rev A (November 2011) Page 6 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

p. Remove Flexibar on affected IGBT. See Figure 5.

q. Remove side bracket screws of affected IGBT.
CAUTION: Do not damage plastic washers beneath bracket nuts, rubber on edge of
brackets against enclosure, or Nomex beneath IGBTs.
r. Remove bracket nuts (2 per bracket) and remove bracket(s) on affected IGBT.
s. Remove IGBT.

Bracket nut Bracket nut

(2 per bracket) (2 per bracket)

Side bracket
screw
(6 per IGBT) Flexibar

Figure 5 - Remove Affected IGBT (Phase C shown)

t. Contact Capstone Call Center to determine if removed part should be returned to

factory. If yes, Capstone Call Center will issue Return Material Authorization (RMA)
instructions. If no, dispose of part(s) according to local recycling and/or environmental
regulations.
3. Install new GCM IGBT (511641-XXX, 511642-XXX, or 518299-XXX) as follows.
a. Install new IGBT in place of removed IGBT. See Figure 5.
b. Re-install side bracket(s) using nuts (2 per bracket) and plastic washers (1 per nut)
tightened to 45 in-lbs.
c. Secure IGBT with side bracket screws (6) tightened to 45 in-lbs.
d. Secure Flexibar and tighten to 90 in-lbs.
e. Re-install power board assembly. See Figure 4.
CAUTION: Nomex beneath power board assembly MUST prevent contact between
power board assembly and enclosure. Failure to do so will result in malfunction or
equipment damage.
f. Secure power board assembly with channel bracket screws (4) tightened to 45 in-lbs.
g. Re-connect cables to power board assembly. See Figure 3. Tighten DC cables to 90
in-lbs.

440185 Rev A (November 2011) Page 7 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

h. Secure power board assembly using screws (8), nuts (8), and washers (2 per nut, 1
either side of power board) tightened to 45 in-lbs. See Figure 6.
i. Re-connect IGBT and GND cables to power board assembly.
IGBT cable

GND cable

Screw (1 of 8)

Nut (1 of 8) and
washer (2 per nut) Nut (1 of 8) and
Washer (2 per
nut)

GND cable
Screw (1 of 8)

IGBT cable

Figure 6 - Secure Power Board Assembly

440185 Rev A (November 2011) Page 8 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

j. Re-install control board tray and secure with screws (3). See Figure 7.
k. Re-install PDM-PDB cables and secure connectors to control board tray with zip ties.
l. Bind PDM-PDB cables to sides of control board tray using zip ties and plastic anchors
on tray.
m. Re-connect CHS cable (1 per side) to each side of control board tray.
n. Carefully thread ICB P11 cable through hole on control board tray and connect to
control board.
o. Re-connect cables to control board and IGBTs.
Ribbon cable
(1 of 4)

Zip tie (1 of 2
CHS Wire on tray)
(1 of 2)

PDM-PDB Cable PDM #1

(zip tie not shown) Temp/J20

ICB P11 cable

Left tray screw
(1 of 2)
Hole in right
CapComm A side of tray
(cable not shown)

CapComm B Right tray

(cable not shown) screw (1)

PDM #2
Left tray screw Temp/J19
(1 of 2)

PDM-PDB Cable
(zip tie not shown) Ribbon cable
(1 of 4)

Figure 7 – Re-Install Control Board Tray

p. Re-install GCM cover.

4. Return system to operation as follows.
a. For C200 microturbines:
(1) Re-install panels.
(2) Reconnect microturbine to power sources.

440185 Rev A (November 2011) Page 9 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

(3) If applicable, reconnect battery cables and turn main battery pack circuit breakers
ON.
(4) Open system fuel supply.
(5) Issue Start command.
(6) Test system for proper operation.
a. For C1000 Series:
(1) If battery packs are installed in affected bay(s), reconnect battery cables and turn
main battery pack circuit breakers ON.
(2) At electrical panel, turn main circuit breaker and auxiliary circuit breaker ON for
affected bay(s).
(3) Open fuel inlet supply to bay(s).
(4) Close bay door(s).
(5) If system is configured in MultiPac mode, perform the following steps.
i. Enable MultiPac via CRMS.
ii. Set Override Start to AVAILABLE via CRMS-APS.
(6) Continue with the following for all systems.
i. Test system for proper operation.

Responsibility
It is the responsibility of Capstone to:
• Make these procedures available to Authorized Service Providers so they can
successfully complete this task.
It is the responsibility of the Authorized Service Provider to:
• Read this document, understand its contents, and effectively complete procedures.
• Explain service benefits provided to end user.
• Upon completion of service, submit a Field Service Report (512298) to
service@capstoneturbine.com.

Capstone Technical Support

If you have questions or need assistance, please contact the Capstone Call Center:
E-mail: service@capstoneturbine.com
Toll Free Telephone: (866) 4-CAPSTONE or (866) 422-7786
Direct Telephone: (818) 407-3600 • Fax: (818) 734-5382

440185 Rev A (November 2011) Page 10 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
 Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
C200/C1000 Series Work Instructions: GCM IGBT Replacement

Capstone Document Library

The latest revisions of all Capstone product documents are available on our website,
www.capstoneturbine.com . Select Document Library link under Quick Links box on lower left
side of home page.
Capstone values your feedback. Please email comments or suggestions for improving
documentation to service@capstoneturbine.com and enter "Documentation" in the subject
line.

© 2011 Capstone Turbine Corporation. All rights reserved.

440185 Rev A (November 2011) Page 11 of 11

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.