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

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

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

Purpose and Scope

This document describes the procedure for replacing the Battery Control Module (BCM)
IGBT on the Capstone Model C200 MicroTurbine®/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) or
C1000 Series 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.

440250 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 Work Instructions: BCM IGBT Replacement

Material Information
The part being replaced is BCM IGBT C6X (518300-XXX).

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 nuts)
 12 mm socket wrench (for IGBT bus bar)
 13 mm socket wrench (for C200 panels, Flexibar nuts)
 5/16 inch Allen wrench (for bay doors)
 #2 Phillips-head screwdriver (for module covers)
 #3 Phillips-head screwdriver (for power board screws)
 Flat-head screwdriver (for opening C1000 Controller, battery (–) power board contact)
 Anti-static bags, large (for storing control board tray, storing power board assembly)
 Torque screwdriver, 0-90 in-lbs.
 Torque wrench, 0-90 in-lbs.
 PC running CRMS-APS
 Anti-static wrist strap
 Digital multimeter (DMM)
 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
 400008 Capstone Model C200 User’s Manual
 400024 Capstone C1000 Series User’s Manual
 512298 Field Service Report

440250 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 Work Instructions: BCM 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 or packs are installed, turn OFF and lock out main battery pack circuit or
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.
440250 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 Work Instructions: BCM IGBT Replacement

2. Remove BCM IGBT as follows.

a. Remove enclosure panel(s) as needed to access BCM.
CAUTION: Handle Electrostatic Discharge (ESD) sensitive devices properly. Failure to
observe this caution can result in equipment damage.
b. Remove BCM cover and locate control board. See Figure 1.

Control
board

Figure 1 - Battery Control Module

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

c. Disconnect all cables from BCM control board. See Figure 2.

NOTE: IGBT cable must be disconnected BELOW control board tray before
completely removing tray.
d. Remove screws (2 on BCM enclosure, 1 on IGBT) securing control board tray and
remove control board tray.

Screw
(1 of 3)

Cables

Cables

Screw
(1 of 3) and
plastic
washer (1
per screw)
Figure 2 - Control Board
440250 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 Work Instructions: BCM IGBT Replacement

e. Disconnect all cables from power board. See Figure 3.

f. Remove screws (3), nuts (3), washers (1 per screw) securing power board to IGBT.

Cable

Screw
(1 of 3) and Cables
washer (1
per screw)

Nut (1 of 3)
Figure 3 - Power Board

CAUTION: Do not tear Nomex beneath power board assembly. Failure to observe this
caution can result in equipment damage.
g. Remove screws (2) securing channel bracket and remove power board assembly.
See Figure 4.

Channel
Channel
bracket
bracket
screw
screw
(1 of 2)
(1 of 2)

Figure 4 - Channel Bracket Screws

h. Disconnect Flexibars from IGBT. See Figure 5.

i. Remove IGBT bus bar.

Flexibars IGBT bus

bar

Figure 5 - Flexibars and Bus Bar

440250 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 Work Instructions: BCM IGBT Replacement

j. Remove threaded studs from IGBT. See Figure 6.

Threaded
stud
(1 of 3)

Figure 6 - Threaded Studs

k. Remove mounting screws (6) from IGBT. See Figure 7.

l. Remove bracket mounting screws from interior bracket and remove bracket.
m. Slide IGBT toward BCM interior and remove IGBT.
Bracket
mounting
screw
(1 of 2) and
plastic
washer
(1 per
screw)

IGBT IGBT
mounting mounting
screws screws

Bracket
mounting
screw
(covered
by bracket)
Figure 7 - Mounting Screws

n. 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.

440250 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 Work Instructions: BCM IGBT Replacement

3. Install new BCM IGBT C6X (518300-XXX) as follows.

CAUTION: Do not over-tighten. Failure to observe this caution can result in equipment
damage.
a. Slide new IGBT into bracket and secure with screws (3) tightened to 45 in-lbs. See
Figure 8.
b. Reinstall second bracket with screws (2) and plastic washers (1 per screw) tightened
to 45 in-lbs.
c. Secure IGBT with screws (3) tightened to 45 in-lbs.
Bracket
mounting
screw
(1 of 2) and
plastic
washer
(1 per
screw)

IGBT IGBT
mounting mounting
screws screws

Bracket
mounting
screw
(covered
by bracket)
Figure 8 – Install New IGBT

d. Reinstall threaded studs to IGBT tightened to hand tightness. See Figure 9.

Threaded
stud
(1 of 3)

Figure 9 - Re-install Threaded Studs

440250 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 Work Instructions: BCM IGBT Replacement

e. Reinstall IGBT bus bar. See Figure 10.

f. Reinstall Flexibars (3) and tighten to 90 in-lbs.

Flexibars IGBT bus

bar

Figure 10 - Re-Install Flexibars and Bus Bar

g. Reinstall power board assembly and secure channel bracket with screws (2)
tightened to 45 in-lbs. See Figure 11.

Channel
Channel
bracket
bracket
screw
screw
(1 of 2)
(1 of 2)

Figure 11 - Re-Install Power Board Assembly

440250 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 Work Instructions: BCM IGBT Replacement

h. Reconnect cables to power board. Tighten Batt + cable (E3) to 5 in-lbs. Tighten Bus
(+/-) cables (E1, E2) to 45 in-lbs. See Figure 12.
i. Secure power board to IGBT using screws (3), washers (2 per screw), nuts (3)
tightened to 45 in-lbs.
Bus - (E2)
Fan Inv (J2)

Bus + (E1)

Batt - (E7)
Nut (1 of 3)

Voltage
Screw sense (J1)
(1 of 3)

Batt + (E3)

Figure 12 - Re-Connect Power Board Cables

j. Reconnect control board tray IGBT cable to IGBT. See Figure 13.

Figure 13 - Re-Connect IGBT Ribbon Cable

440250 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 Work Instructions: BCM IGBT Replacement

k. Reinstall control board tray and secure with screws (3) and plastic washer (1 on
interior screw) tightened to 5 in-lbs. See Figure 14.
l. Reconnect cables to control board.
Fan inv (J5)

BCM prechg.
Inter LCM / contactor (J7)
Intra BCM
(J6)
Voltage sense
(J3)

Battery PM Main IGBT

(J4) (J1)

Figure 14 - Control Board Cables

m. Reinstall BCM cover.

5. Return system to operation as follows.
a. For C200 microturbine(s):
(1) If applicable, reconnect battery cables and turn main battery pack circuit breakers
ON.
(2) Re-install panels.
(3) Reconnect microturbine to power sources.
(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.

440250 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 Work Instructions: BCM IGBT Replacement

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

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.

440250 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.