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ACS 600 MultiDrive Service manual

Checking and replacing a


Power Plate
Checking and replacing a Power Plate

Service manual

Code: 3BFE 64158805 R0225

EFFECTIVE: 02.07.2001
SUPERSEDES: 22.3.1999

FIDRI\EIF200
PDM\00017219.DOC

 2001 ABB Industry Oy. All rights reserved.


Safety instructions

Overview The complete safety instructions stated in ACS 600 MultiDrive Safety
and Product Information (EN 63982229) must be followed when
installing, operating and servicing the frequency converters. Study the
complete safety instructions carefully.

General safety The general instructions are given below. These general instructions
include only the main parts of the complete safety instructions. The
instructions
general safety instructions are intended for all work on the ACA 600
MultiDrive frequency converters. In the text below, air-cooled ACN 600
MultiDrive and water-cooled ACW MultiDrive, are collectively referred
to as ACx 600. Neglecting these instructions can cause physical injury
and death.

WARNING! All electrical installation and maintenance work on the


ACx 600 should be carried out by qualified electricians.
Any installation and maintenance work must be done with the power
off and power is not to be reconnected unless the installation work is
complete. Dangerous residual voltages remain in capacitors when the
disconnecting device is opened. Wait five minutes after switching off
the supply before starting work. Always ensure that the measured
voltage between terminals UDC+ and UDC- and frame is close to 0 V
and that the supply has been switched off before performing any work
on the equipment or making main circuit connections.

If the main circuit of the inverter unit is live, the motor terminals are
also live even if the motor is not running!

Open the fuse switches of all parallel connected inverters before


installation or maintenance work in any of them.

Check the cable connections at the shipping split joints before


switching on the supply voltage.

If the auxiliary voltage circuit of the ACx 600 is powered from an


external power supply, opening the disconnecting device does not
remove all voltages. Control voltages of 115/230 VAC may be present
on the digital inputs or outputs even though the inverter unit is not
powered. Before starting work, check which circuits remain live after
opening of the disconnecting device by referring to the circuit diagrams
for you particular delivery. Ensure by measuring that the part of the
cabinet you are working on is not live.

Service manual v
Safety instructions

In ACx 600 frequency converters, control boards of the converter unit


may be at the main circuit potential. Dangerous voltages may be
present between the control boards and the frame of the converter
unit, when the main circuit voltage is on. It is critical that the use of
measuring instruments, such as an oscilloscope, and their connection
to the ACx 600 frequency converters is done with caution and safety
always a priority. The fault tracing instructions give a special mention
of cases in which measurements may be performed on the control
boards, also indicating the measuring method to be used.

Live parts on the inside of doors are protected against direct contact.
Special attention shall be paid to safety when handling shrouds made
of sheet metal.

Do not make any voltage withstand tests on any part of the unit while
the unit is connected. Disconnect the motor cables before making any
measurements on the motors or motor cables.

If an ACx 600 with the EMC Line Filter is installed to unearthed mains,
the mains will be connected to earth potential through the EMC filter of
the ACx 600. This may cause danger or damage the unit. Disconnect
the EMC filter capacitors before connecting the ACx 600 to unearthed
mains. For detailed instructions on how to do this, please contact your
local ABB distributor.

WARNING! Close fuse switches of all parallel connected inverters


before starting the frequency converter.

Do not open the drive section switch fuses when the inverter is
running.

Do not use Prevention of Unexpected Start for stopping the drive


when the inverter is running. Give a Stop command instead.

WARNING! Fans may continue to rotate for a while after the


disconnection of the electrical supply.

WARNING! Some parts, like heat sinks of power semiconductors


inside of cabinet remain hot for a while after the disconnection of the
electrical supply.

vi Service manual
Safety instructions

Power Plate
handling WARNING!
DO NOT ATTEMPT ANY WORK ON A POWERED ACx 600!

There is a dangerous voltage inside the cabinet. After the mains


voltage is disconnected by means of the main switch, a high voltage
remains in the capacitor bank of ACx 600, which is discharged through
discharge resistors. WAIT AT LEAST FIVE MINUTES BEFORE
ATTEMPTING ANY WORK ON OR WITH THE UNIT! Always ensure
by voltage measurement that the DC voltage has dropped down to
close to zero and the mains voltage is disconnected (zero) before
performing any service or main circuit connections. Measure the DC
voltage between terminals UDC+ and UDC- and the mains voltage
between terminals U1, V1 and W1 (L1, L2 and L3). The meter must
withstand 1000 VDC and 750 VAC (Note, with 690 VAC supply the DC
voltage can exceed 1000 VDC!).

WARNING!
ONLY A QUALIFIED ELECTRICIAN SHOULD CARRY OUT THE
ELECTRICAL INSTALLATION!

Electrostatic Discharge (ESD) can damage electronic circuits. Do not


handle any components without following ESD precautions. For more
details, see ABB Industry Oy ESD Directive, codes 59240803 and
59240790. If not available, contact ABB Industry Oy, Helsinki.

Power Plate Caution must be observed in both transport and handling of


handling semiconductors. Power Plate can be destroyed by static electricity.
Therefore, the following precautions should be observed during
precautions
handling.

• When handling a Power Plate, hold the package and avoid touching
the terminals, especially the gate terminal.
• Always use an earthed wristband when handling a Power Plate.

Service manual vii


Safety instructions

viii Service manual


Table of contents

Safety instructions ..............................................................................................................................................v


Overview .....................................................................................................................................................v
General safety instructions ..........................................................................................................................v
Power Plate handling ................................................................................................................................ vii
Power Plate handling precautions................................................................................................... vii

Table of contents................................................................................................................................................ix

Chapter 1 - Inverter module frame sizes ....................................................................................................... 1-1


General.................................................................................................................................................... 1-1
Single R2i - R5i units ............................................................................................................................... 1-1
Single R6i - R12i units ............................................................................................................................. 1-2
Parallel units ............................................................................................................................................ 1-2

Chapter 2 - Power Plate .................................................................................................................................. 2-1


General.................................................................................................................................................... 2-1
Product structure........................................................................................................................... 2-1
Phase module ............................................................................................................................... 2-2
Measuring of a Power Plate .................................................................................................................... 2-2
General ......................................................................................................................................... 2-2
Measuring the collector-emitter resistance of the IGBT ................................................................ 2-5
Measuring the gate of the IGBT (checking of IGBTs) ................................................................... 2-6
Conclusions about measuring of IGBT and C-E ........................................................................... 2-6
Measuring the temperature of the Power Plate............................................................................. 2-6
Measurements against the frame.................................................................................................. 2-7
Measuring the emitter terminals.................................................................................................... 2-7
Checking of measuring terminals (+) and (-)................................................................................. 2-7
Faulty Power Plate detected ................................................................................................................... 2-8

Chapter 3 - Power Plate connections ............................................................................................................ 3-1


Power Plate, basic construction .............................................................................................................. 3-1
Power Plate connections, single inverters............................................................................................... 3-1
Power Plate connections, parallel inverters............................................................................................. 3-3
Power Plate classes (letter pairs and spare parts) .................................................................................. 3-4
Special requirements for the selection of the Power Plate ...................................................................... 3-6
Frames R4i- R7i ............................................................................................................................ 3-6
Spare parts....................................................................................................................... 3-6
Frames R8i, R9i ............................................................................................................................ 3-6
Spare parts....................................................................................................................... 3-6
Frames R10i.................................................................................................................................. 3-6
Spare parts....................................................................................................................... 3-6
Frames R11i, R12i, n x R11i, n x R12i.......................................................................................... 3-6
Spare parts....................................................................................................................... 3-7
Power stages of the inverter module....................................................................................................... 3-7

Service manual ix
Table of contents

Chapter 4 - Replacement of the Power Plate ................................................................................................ 4-1


General.................................................................................................................................................... 4-1
Accessing the Power Plate...................................................................................................................... 4-1
Thermal compound ................................................................................................................................. 4-1
Power Plate assembly ............................................................................................................................. 4-1
4-screw-type Power Plate ............................................................................................................. 4-2
6-screw-type Power Plate ............................................................................................................. 4-3
Check after the assembly.............................................................................................................. 4-4

x Service manual
Chapter 1 - Inverter module frame sizes

General Inverter modules are installed into cubicles depending upon the
physical size of the module. The frame size of inverter modules
determines the power rating: R2i, R3i, R4i, R5i, R6i, R7i, R8i, R9i,
R10i, R11i or R12i. Higher power ratings are implemented by
connecting inverter modules in parallel (R11i or R12i), see
Figure 1 - 1.

ACx refers to ACN (air-cooled MultiDrive module) and ACW (water-


cooled MultiDrive module).

Figure 1 - 1 Inverter module configurations

Mechanical packaging is optimised for inverter applications, servicing


and reliability.

Single Power ratings:


R2i - R5i units 5 - 50 kVA, 400 VAC range
6 - 60 kVA, 500 VAC range
9 - 50 kVA, 690 VAC range
24 VDC cooling fans are used to transfer the heat losses out of the
inverter modules. The fans are located inside the module. The power
rating is defined in the ACS 600 MultiDrive type code as CAN 634-
0050-3 (kVA value underlined). The "3" stands for 400 VAC voltage
class ("5" stands for 500 VAC and “6” for 690 VAC voltage class).

Service manual 1-1


Chapter 1 –Inverter Module frame sizes

Single Power ratings:

R6i - R12i units 60 - 1120 kVA, 400 VAC range


70 - 1380 kVA, 500 VAC range
60 - 1380 kVA, 690 VAC range
AC cooling fans are used to transfer the heat losses out of the
inverter modules. AC fans are used for maximum cooling efficiency
with fast replacement times (separate fan modules).

Parallel units Power ratings:


1440 - 2820 kVA, 400 VAC range
1760 - 3450 kVA, 500 VAC range
1710 - 5140 kVA, 690 VAC range
The R11i or R12i inverter units (two or four and in water-cooled
ACW 600 also three in parallel) can be connected in parallel to
extend the power range. The motor outputs of the parallel inverter
units are connected together by an AC busbar or connected together
at the motor end.

1-2 Service manual


Chapter 2 - Power Plate

General Power Plate Technology

Insulated Gate Bipolar Transistor (IGBT) is a semiconductor type


widely used in the power stages of inverter units.

IGBT technology enables easy controllability and a high switching


frequency.

• Increased reliability
- Controllability due to high driving-point impedance
- Short circuit safe due to internal connection

• Reduced audible noise


- High switching frequency (resonances reduced)
- Depends on the control method - excellent results with DTC
(Direct Torque Control) that creates only white noise

• Integrated components which make a compact module


- Six IGBTs and free-wheeling diodes form a Power Plate (PP)
- Integrated temperature monitoring with a thermistor
- DC voltage measurement

Product The ACx 600 Product Family utilises IGBT power semiconductors
structure exclusively. The state-of-the-art integrated IGBT technology (Power
Plate, see Figure 2 - 1) provides reliable drive units.

Figure 2 - 1 In Power Plate technology six conventional IGBT


modules (left) are integrated into a single compact Power
Plate (right)

Service manual 2-1


Chapter 2 -Power Plate

Phase module If more than one Power Plates are used together for forming a phase
voltage, the construction is called "phase module" (see Figure 3 - 3).
Phase modules are used in frames R10i - R12i and their parallel
connected configurations. A spare part phase module kit is delivered
as a V-phase module, but it can be changed to a U/ W-phase module
by replacing the interface board NINT-xx with an NXPP-xx board
included.

Measuring of a
Power Plate

How to measure the condition of the Power Plate:


General
WARNING! THE POWER SUPPLY HAS TO BE DISCONNECTED
BEFORE ANY MEASUREMENTS ARE PERFORMED ON THE ACx
600. WAIT AT LEAST FIVE MINUTES FOR INTERMEDIATE
CIRCUIT CAPACITORS TO DISCHARGE.

The following actions should be done and results verified before the
measurement of the Power Plate is started:

• Before starting any individual Power Plate measurement described


below you can locate the broken component by measuring
between the (+) busbar and the motor outputs and similarly
between the (-) busbar and the motor outputs if an output phase is
short-circuited.
• Check the Power Plates also visually. Sometimes the case of the
Power Plate may be broken by for example an arc caused by a
short circuit inside the Power Plate.
• The Power Plate can be measured when it is still mounted on the
heat sink, if you remove the electronic boards on top of it.

Note also that in case the component measures good, but is visually
found to be defective, it must be replaced.

The names of the terminals of the Power Plate are presented in


Figure 2 - 2 (large Power Plate) and in Figure 2 - 3 (medium-size
Power Plate), where

2-2 Service manual


Chapter 2 - Power Plate

Terminal Name Character


G11, G12, G13, Gate G
G21, G22, G23
E11, E12, E13, Emitter E
E21, E22, E23
T1, T2 Terminals for
measuring temperature
P1, P2, P3 Collector for IGBTs C
6, 4 and 2
+ Collector for IGBT C
5, 3 and 1

∗ Auxiliary (+) and (-)

5 3 1
G13 G12 G11 UPPER

E13 E12 E11

6 4 2
G23 G22 G21 LOWER

E23 E22 E21

T1
T
T2

P3 P2 P1

T1 +
G23 E23 G22 E22 G21 E21

E13 G13 E12 G12 E11 G11


T2 -

P3 P2 P1

Figure 2 - 2 Terminals of a large Power Plate

Service manual 2-3


Chapter 2 -Power Plate

5 3 1
G 13 G 12 G 11 UPPER

E 13 E 12 E 11

6 4 2
G 23 G 22 G 21 LOW ER

E 23 E 22 E 21

T1
T
T2

P3 P2 P1


T1
G 23 E 23 G 22 E 22 E21
+
G 21

E 13 G 13 E 12 G 12 E11 G 11
T2 -

P3 P2 P1

Figure 2 - 3 Terminals of a medium-size Power Plate

2-4 Service manual


Chapter 2 - Power Plate

Measuring the The measurement is done with the multimeter in the diode position.
collector-emitter • The measurement is done between C-E of all six IGBTs (between
resistance of the + and Px terminals or Px and - terminals, see Figure 2 - 2 and
IGBT Figure 2 - 3.
• When the measurement with the multimeter displays infinite (OL
Over Limit) in one direction and the forward voltage of diode (e.g.
350 mV) in the opposite direction, the C-E junction is OK.
Note that the values shown by the multimeter depends on its
brand and type. Different multimeters with different output voltages
show different forward voltages when measuring semiconductor
components.
• If the multimeter indicates a short circuit, the C-E junction or the
diode in question is faulty and the Power Plate must be replaced.
• If the forward voltage of some of the diodes is different from the
others, the diode is most probably broken and the Power Plate
must be replaced. See the replacement information in the
subsection Faulty Power Plate detected.

Table 2 - 1 Measurements in the C-E Direction (see Figure 2 - 2 and


Figure 2 - 3)
+ probe - probe Display
+ P1 OL
+ P2 OL
+ P3 OL
P1 - OL
P2 - OL
P3 - OL

Table 2 - 2 Measurements in the E-C Direction (see Figure 2 - 3and


Figure 2 - 3 )
+ probe - probe Display
P1 + ≈ 0.35V
P2 + ≈ 0.35V
P3 + ≈ 0.35V
- P1 ≈ 0.35V
- P2 ≈ 0.35V
- P3 ≈ 0.35V

The display (OL) of the multimeter means Over Limit (infinite).


Note that the above-mentioned values were measured on one
randomly chosen Power Plate and a Fluke 87 Multimeter. The values

Service manual 2-5


Chapter 2 -Power Plate

may vary slightly with different multimeters and different Power


Plates.

Measuring the The measurement is done with the multimeter in the resistance
gate of the IGBT position.
(checking of • The resistance is measured between G-E on all six IGBTs (G11-
IGBTs) E11, G21-E21, and so on) (see Figure 2 - 3 and Figure 2 - 3).
• The IGBT is OK, if the display of the multimeter shows infinite (OL)
between G-E.
Note that OL is shown only after a while (after the capacitance is
loaded).
• If there is a short circuit between G-E or only some ohms, the
IGBT is faulty.

Table 2 - 3 G = Gate and E = Emitter


+ probe - probe Display
G11 E11 OL (loading capacitance)
G21 E21 OL (loading capacitance)
G12 E12 OL (loading capacitance)
G22 E22 OL (loading capacitance)
G13 E13 OL (loading capacitance)
G23 E23 OL (loading capacitance)

Conclusions • If the junction C-E is short circuited and the junction G-E displays
OL (loading capacitance)(=OK), only the diode is faulty
about measuring
of IGBT and C-E • If the G-E junction is short circuited and the junction C-E displays
infinite (=OK), only the IGBT is faulty
• If both the C-E junction and the G-E junction displays short
circuited, only the IGBT or both the IGBT and the diode are faulty.

Measuring the The measurement is done with the multimeter in the resistance
thermistor of the position.
Power Plate • If the resistance of the Thermistor is OK (measured at connectors
T1 and T2, see Figure 2 - 2 and Figure 2 - 3), the multimeter
displays about 11 kΩ.

Table 2 - 4 T = terminal for measuring the thermistor


+ probe - probe Display
T1 T2 11 kΩ (+/-10%) at 25 °C

2-6 Service manual


Chapter 2 - Power Plate

Measurements The measurement is done with the multimeter in the resistance


position. This measurement determines the insulation resistance of
against the frame Power Plate.

See Figure 2 - 3 or Figure 2 - 3 for terminal markings.

Table 2 - 5 Measurements against the frame


+ probe - probe Display
T1 frame OL
T2 frame OL
auxiliary + frame OL
auxiliary - frame OL
P1 frame OL
P2 frame OL
P3 frame OL
Auxiliary (+) and (-) are marked with (*) in Figure 2 - 2 and
Figure 2 - 3

For a sufficient insulation the resistance should be over 50 MΩ.

Measuring the The measurement is done with the multimeter in the resistance
emitter terminals position.

Table 2 - 6 Measuring the Emitter terminals


+ probe - probe Display
E11 P1 ≈0Ω
E12 P2 ≈0Ω
E13 P3 ≈0Ω
E21 - ≈0Ω
E22 - ≈0Ω
E23 - ≈0Ω
For terminal markings see Figure 2 - 2 or Figure 2 - 3.

Checking of The measurement is done with the multimeter in the resistance


measuring position.
terminals (+) and • Measure between the plus (+) terminals (one is situated at the
(-) edge of module and the other is the plus terminal of the main
circuit).
• Similarly measure between the minus (-) terminals.
• When the multimeter displays a short circuit in both cases, the
connections between the (+) terminals and between the (-)
terminals are OK.

Service manual 2-7


Chapter 2 -Power Plate

Faulty Power Plate When a Power Plate is found to be faulty:

detected • For small frame sizes (R2i), change the whole unit (because
control boards are soldered to the IGBT module)
• For larger frame sizes (>R3i), it is possible to change the Power
Plate (in frame size R3i the IGBT module)
• Replace also the NINT-xx (or NXPP-xx) and NGDR-xx (used with
R4i and upwards) board if the Power Plate is damaged.
• For the spare part Power Plates follow the instructions in Chapter
3 - Power Plate connections
• For phase module inverters (frame sizes R10i and upwards) the
fault word (FW1; bits B12, B13, B14, B15) indicates which phase
is faulty (a short circuit in the parallel connected inverters). The
fault words can be found in the Application Program Template for
ACS 600, Firmware manual (EN 63700185).
• In case of a fault it is recommended to change the whole phase
module.

2-8 Service manual


Chapter 3 - Power Plate connections

Power Plate, basic Figure 3 - 1 shows the basic construction of a Power Plate, consisting
of six IGBTs, six free-wheeling diodes, one NTC Thermistor Resistor
construction
and six Gate Resistors. The outputs of the Power Plate are phase
voltages P1 (U), P2 (V) and P3 (W).

Note: The small size inverters (R2i-R3i) use standard IGBTs, not
Power Plates. The R2i IGBT module has a similar construction to the
basic construction in Figure 3 - 1. The R3i IGBT module has only one
third of the components of the basic construction in Figure 3 - 1. The
basic construction is used for frames R4i - R7i (power range 20 to 140
kVA).

P1 P2 P3

Figure 3 - 1 Basic construction of Power Plate

Power Plate Frames R4i to R9i use Power Plates and frames R10i to R12i use
phase modules.
connections,
single inverters In frames R8i and R9i (see Figure 3 - 2), one phase is made by
connecting together terminals P1 - P3 of the Power Plate. The number
of Power Plates is three. The power range is 180 to 490 kVA.

Service manual 3-1


Chapter 3 – Power Plate connections

R4i - R7i R8i, R9i


P1 P2 P3 P1 P2 P3 P1 P2 P3
P1 P2 P3

U V W U V W

Figure 3 - 2 Symbol of a Power Plate (left). In frame sizes R8i and R9i
each phase has an individual Power Plate (right).

In frames R10i and R11i (see Figure 3 - 3) two Power Plates


connected in parallel are used for making one phase. The number of
the Power Plates is 3 x 2 = 6. The power range is 500 to 930 kVA.

R10i, R11i
Phase module Phase module Phase module

P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3

U V W
Figure 3 - 3 The phase modules. Frames R10i, R11i.

3-2 Service manual


Chapter 3 – Power Plate connections

In frame R12i (see Figure 3 - 4) three Power Plates are connected


parallel for each phase. The number of Power Plates totals 3 x 3 = 9.
The power range is 1040 to 1380 kVA.

R12i
Phase module Phase module Phase module
P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3
U V W

Figure 3 - 4 The phase modules. Frame R12i.

Power Plate Extended power range is achieved by connecting two or four frame
R11i or R12i inverters in parallel (see Figure 3 - 5). The power range
connections, reaches 5140 kVA. The number of Power Plates when four R12i
parallel inverters inverters are in parallel totals 4 x 9 = 36.

4 x R12i
R12i R12i R12i R12i

P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3 P1P2P3P1P2P3 P1P2P3

U V W
Figure 3 - 5 The parallel connected phase modules. Frame 4 x R12i.

Service manual 3-3


Chapter 3 – Power Plate connections

Power Plate Every Power Plate that can be used for parallel connection of the
phase modules is marked (classified) with a letter pair AA, AB, AC,
classes (letter AD, to, IJ. The smallest Power Plates may have only one letter per
pairs and spare IGBT.
parts) In (Figure 3 - 7) VCEsat (= collector - emitter saturation voltage
(IGBT)) corresponds to the 1st letter in the letter pair and VF = forward
voltage (diode) corresponds to the 2nd letter in the letter pair.

Starting from December 2000 inverters that use Power Plate type
PP18017 (180A, 1700 V) have an extra “L” letter in front of the letter
pair. These Power Plates are manufactured by using low injection
process and they cannot be connected in parallel with older PP18017
types.

The voltage VCEsat varies from 2.0 V (= letter A), 2.2 V (= B), to 3.7 V
(= I) on the X-axis. Similarly, the VF diode varies from 2.0 V (= letter
A), 2.2 V (= B), to, 3.9 V (= J) on the Y-axis.

The possible spare part classes are SP1, SP2, SP3, SP4, SP5, SP6,
SPL5 and SPL6.

Figure 3 - 6 Different kinds of Power Plate labels.

3-4 Service manual


Chapter 3 – Power Plate connections

NOTE 1: The Power Plates used in frames R8i - R12i are classified
based on the nominal on-state voltages of the IGBTs (VCE) and the
diodes (VF).

NOTE 2: The class is marked by a letter pair.

NOTE 3: Spare parts are selected from four groups and marked by
the letter pair and SPx, for example. “DC SP4” can replace an original
Power Plate from classes DC, DB, EC or EB.

NOTE 4: Low injection PP18017 types have an extra “L” letter in front
of the actual categorisation letter pair and also in front of the SP class
number, for example. “LFE SPL6”.

VCEsat 2 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3 3,1 3,2 3,3 3,4 3,5 3,6 3,7
A B C D E F G H I
VF
2 A AA BA CA DA EA FA GA HA IA
2,1 SP3
2,2 B AB BB CB DB EB FB GB HB IB
2,3 SP4
2,4 C AC BC CC DC EC FC GC HC IC
2,5
2,6 D AD BD CD DD ED FD GD HD ID
2,7 SP5
2,8 E AE BE CE DE EE FE GE HE IE
2,9 SP6
3 F AF BF CF DF EF FF GF HF IF
3,1 SP1
3,2 G AG BG CG DG EG FG GG HG IG
3,3 SP2
3,4 H AH BH CH DH EH FH GH HH IH
3,5
3,6 I AI BI CI DI EI FI GI HI II
3,7
3,8 J AJ BJ CJ DJ EJ FJ GJ HJ IJ
3,9

PP30012 Multidrive
PP18017 Multidrive
PP18017 Multidrive old classes

Figure 3 - 7 The selection table of the spare parts of 300 A and 180 A
Power Plates as a function of VCE (IGBT) and VF (diode).

Note that the spare part class used in parallel modules is marked on
the module.

Service manual 3-5


Chapter 3 – Power Plate connections

Special The phase modules are used in the frames R10i - R12i and in their
parallel configurations.
requirements for
the selection of the A phase module kit is delivered as a V-phase module, but it can be
changed to a U/W -phase module by replacing the interface board
Power Plate NINT-xx with an NXPP-xx included. The spare part’s power supply
boards NPOW-62 and NGPS-xx have to be disconnected from the
main circuit (or completely removed).

When replacing a Power Plate with a new one, certain rules have to
be followed in the selection of a spare part Power Plate. In the
following rules, the different types of Power Plates are:

6P = a Power Plate used to make one motor output (R4i – R7i)(see


Figure 3 - 2)

2P = a Power Plate used to make one motor phase output (R8i - R10i)
(see Figure 3 - 2)

PAR = a Power Plate suitable for paralleling to make one motor output
(see Figure 3 - 3), using specified classes (see Figure 3 - 7) (R11i and
R12I)

SP = a spare part Power Plate suitable for parallel connection to make


one motor output (see Figure 3 - 3), using specified classes (see
Figure 3 - 7) (R11i and R12I)

Frames R4i- R7i No special requirement, any Power Plate with whichever letter pair (2P
or PAR) or no letter pair (=6P) can be used.

Spare parts No requirement for the letter pair (6P, 2P, PAR or SP).

Frames R8i, R9i Any letter pair (2P), different phases can have different letter pairs.

Spare parts No requirement for the letter pairs (2P, PAR or SP).

Frames R10i The phase modules of the same phase have an identical letter pair
(2P).

Spare parts The Power Plates in the same phase must have an identical letter pair
(2P or PAR). Therefore both Power Plates in the same phase must be
replaced in a case one of them is damaged.

Frames R11i, All Power Plates of the same motor output must have the same letter
R12i, n x R11i, pair (PAR):
n x R12i • DA, DB, DC, EA, EB or EC of PP30012 Power Plate type and
• FD,FE, FF, GD, GE, GF, LFD, LFE, LFF, LGD, LGE or LGF of
PP18017 type (in the old classes FF, FG, FH, GF, GG or GH)

3-6 Service manual


Chapter 3 – Power Plate connections

Spare parts All Power Plates in the damaged phase module must be changed. The
spare part Power Plate kit must have a correct SP marking, currently:

• SP3 or SP4 for the PP30012 Power Plate type and


• SP5, SP6, SPL5 or SPL6 for the PP18017 type (in the old classes
SP1 and SP2)

Power stages of Figure 3 - 8 shows an inverter module ACN 634 (frame R6i) made
using one Power Plate.
the inverter module
In Figure 3 - 9 the inverter module ACN 634 (frame R8i) uses one
Power Plate for each phase.

In Figure 3 - 10 there is a phase module A2 ACN 634 (frame R10i)


that is constructed using two Power Plates for each phase. The
module is used for the V phase.

Service manual 3-7


Chapter 3 – Power Plate connections

Figure 3 - 8 The circuit diagram of an inverter module ACN 634 (R6i) (00012264.dwg)

3-8 Service manual


Chapter 3 – Power Plate connections

Figure 3 - 9 The circuit diagram of an inverter module ACN 634 (R8i) (00012267.dwg)

Service manual 3-9


Chapter 3 – Power Plate connections

Figure 3 - 10 The circuit diagram of phase module A2 ACN 644, Phase V (R10i), (00005542.dwg)

3-10 Service manual


Chapter 4 - Replacement of the Power Plate

General Before working with ACx 600 or handling the Power Plate, read
carefully Safety instructions - section Power Plate handling which
includes warnings, cautions and precautions for working on a powered
ACx 600 and for handling a Power Plate.

Accessing the • Clear a suitable space outside of the immediate work area for
removed screws, bolts, components and subassemblies to avoid
Power Plate mislaying or damaging them.
• Study the safety instructions in Safety instructions-chapter.
• Disconnect the mains supply.
• Wait at least five minutes.
• Remove the front cover of the ACx 600 unit.
• Measure the DC voltage and the mains voltage. The voltages must
be zero before you continue working with the unit.
• Install the wristband and the earthing mat according to ABB
Industry Oy ESD Directive.
• Put the wristband on your wrist.
• Remove the boards and the busbars to gain access to the Power
Plate.
• Remove the wiring.
• Remove the faulty Power Plate.
• Clean the heat sink surface with an appropriate solvent (e.g. Grafol)
and a soft cloth from excessive thermal compound and particles.

Thermal compound The recommended thermal compound type is WPS II. The Power
Plate spare parts kit includes a tube of a thermal compound.

Power Plate When installing the Power Plate on the heat sink, the following
instructions should be applied to maximise the effect of the heat sink
assembly
and to minimise the stress concentrated on the Power Plate.

Service manual 4-1


Chapter 4 -Replacement of the Power Plate

4-screw-type • Clean the base plate surface with an appropriate solvent (e.g.
Grafol) and a soft cloth from particles.
Power Plate
• Apply a thin layer of thermal compound with a rubber spatula or
with hand on the surface of the base plate. The thermal compound
layer should be as thin as possible. Thermal compound should fill
the areas (holes) on the base plate and heat sink, so that no air is
left between (see Figure 4 - 1).

Figure 4 - 1 Side view of a Power plate

• Put the Power Plate on the heat sink and press by hands to extend
the thermal compound. Press at least five seconds.
• Tighten the screws to a pre-torque according to Table 4 - 1 and in
sequence 1-2-3-4 according to Figure 4 - 2.

Figure 4 - 2 Screw numbers for a 4-screw-type Power Plate

• Tighten the screws to the final torque according to Table 4 - 1 in


sequence 1-2-3-4 according to Figure 4 - 2.
• Wipe off the excess of thermal compound (see Figure 4 - 3).

4-2 Service manual


Chapter 4- Replacement of the Power Plate

Figure 4 - 3 Top view of a Power Plate

6-screw-type • Clean the base plate surface with an appropriate solvent (e.g.
Grafol) and a soft cloth from particles.
Power Plate
• Apply thin layer of thermal compound with a rubber spatula or with
hand on the surface of the base plate. The thermal compound layer
should be as thin as possible. Thermal compound should fill the
areas (holes) on the base plate and heat sink, so that no air is left
between (see Figure 4 - 1).
• Put the Power Plate on the heat sink and press by hands to extend
the thermal compound. Press at least five seconds.
• Tighten the screws to a pre-torque according to Table 4 - 1 in
sequence 1-2-3-4-5-6 according to Figure 4 - 4.

Figure 4 - 4 Screw numbers for a 6-screw-type Power Plate

• Tighten the screws to the final torque according to Table 4 - 1 in


sequence 1-2-3-4-5-6 according to Figure 4 - 4.
• Wipe off the excess of thermal compound (see Figure 4 - 3).

Service manual 4-3


Chapter 4 -Replacement of the Power Plate

• Connect and tighten the wiring according to Table 4 - 1.


Please, report the failed Power Plate type and manufacturing date
code to ABB Industry, Drives, Helsinki, Finland.

Check after the • When assembling the NGDR (Gate Driver Board) it is necessary to
check that the connection pins of the Power Plate go into the
assembly connectors of the NGDR board.
• Ensure that the flat cables of the phase modules are properly
fastened (locked).

Table 4 - 1 Torque for the installation and the connection screws.

Assembling screw type Torque


Pre-torque Final torque
Module assembling screws
M6 (∅ 6 mm) 1.0 Nm 3.0 Nm
Main circuit terminals
M6 (∅ 6 mm) 3,0 Nm

4-4 Service manual


EFFECTIVE: 02.07.2001
3BFE 64158805 R0225

ABB Industry Oy
Drives
P.O.Box 184
FIN-00381 HELSINKI
FINLAND
Telephone + 358 10 22 2000
Telefax + 358 10 22 22681