ACS 1000 Service Manual

ABB
ACS 1000
Medium Voltage Drives
315 – 5000 kW
400 – 6200 hp
Service Manual
Document No.: 3BHS225931 ZAB E01 Rev. A

Issued: 17.11.2009
© ABB Switzerland Ltd. All Rights Reserved.

ABB
ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted. This
document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB. ABB
aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
2/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

ABB Chapter 1 - Introduction and Safety
Table of Contents
Chapter 1 - Introduction and Safety .................................................................................5
1.1. Introduction ....................................................................................................................... 5
1.2. Safety................................................................................................................................ 5
Chapter 2 - Inverter and Rectifier Failures.......................................................................7

2.1. Safety................................................................................................................................ 7
2.2. Typical Inverter Failures ................................................................................................... 7
2.3. Typical Rectifier Failures ................................................................................................ 10
2.4. Last Switched Vectors .................................................................................................... 11
Chapter 3 - Checking IGCTs and Diodes .......................................................................14

3.1. Safety.............................................................................................................................. 14
3.2. General ........................................................................................................................... 14
3.3. Checking IGCTs ............................................................................................................. 15
3.3.1. Required Tools ............................................................................................................... 15
3.3.2. IGCT Test Procedure...................................................................................................... 15
3.3.3. Test Procedure in case of ‘IGCT Fault’ Message ........................................................... 17
3.4. Checking Diodes............................................................................................................. 20
3.4.1. Testing Neutral-Point and Anti-Parallel Diodes with a Multimeter in Diode Test Mode .. 20
3.4.2. Testing Rectifier Diodes with a Multimeter in Diode Test Mode ..................................... 20
3.4.3. Testing Clamping Diodes................................................................................................ 21
3.4.3.1. Air-cooled Converters ..................................................................................................... 21
3.4.3.2. Water-cooled Converters................................................................................................ 22
Chapter 4 - Checking Current Transducers...................................................................24
Chapter 5 - Replacing Diodes and IGCTs ......................................................................26

5.1. Safety.............................................................................................................................. 26
5.2. Replacing Diodes and IGCTs in Air-cooled Converters and Braking Chopper............... 26
5.2.1. Required Tools and Accessories .................................................................................... 26
5.2.2. Checking IGCTs and Diodes in the Converter................................................................ 27
5.2.3. Releasing the Pressure of the Stack .............................................................................. 27
5.2.4. Replacing IGCTs ............................................................................................................ 27
5.2.5. Replacing Protection and Braking Chopper IGCTs ........................................................ 29
5.2.6. Replacing Neutral-Point or Clamping Diodes ................................................................. 29
5.2.7. Replacing Rectifier and Braking Chopper Diodes .......................................................... 30
5.2.8. Tightening of the Phase Stack........................................................................................ 31
5.3. Replacing Diodes and IGCTs in Water-Cooled Converter ............................................. 31
5.3.1. Required Tools and Accessories .................................................................................... 31
5.3.2. Checking IGCTs and Diodes in the Converter................................................................ 31
5.3.3. Opening the Swing Frame .............................................................................................. 31
5.3.4. Releasing the Pressure of the Phase Stack ................................................................... 32
5.3.5. Replacing IGCTs ............................................................................................................ 33
5.3.6. Replacing Diodes............................................................................................................ 34
ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 3/67

ABB
5.3.7. Tightening the Phase Stack ............................................................................................35
5.4. Replacing Rectifier Diodes in ACS 1000i........................................................................36
Chapter 6 - Replacing Printed Circuit Boards................................................................. 7

6.1. Safety................................................................................................................................7
6.2. Replacing the AMC Board ................................................................................................8
6.3. Replacing the AMC Flash Memory .................................................................................10
6.4. Replacing the INT Board.................................................................................................13
6.5. Replacing the OVVP Board / ACS 1000i Rectifier Monitoring ........................................16
6.6. Replacing the ADCVI Board ...........................................................................................19
6.7. Replacing the GUSP and the GUSP Subprints ..............................................................22
Chapter 7 - Function of LEDs ......................................................................................... 24

7.1. AMC Board .....................................................................................................................24
7.2. INT Board........................................................................................................................26
7.3. GUSP..............................................................................................................................27
7.4. IOEC Board.....................................................................................................................29
7.5. EPS Board ......................................................................................................................31
Appendix A - Measurement Tables ................................................................................. 32

ABB Chapter 1 - Introduction and Safety
Chapter 1 - Introduction and Safety
1.1. Introduction
The manual must be thoroughly read and understood before service work
on the converter is started.
The manual is addressed to qualified persons who are responsible for
maintaining and servicing the converter. Hence all general and safety
instructions given in the ACS 1000 User's Manual must be complied with.
1.2. Safety
DANGER!
Hazardous voltage!
High voltage can cause physical injury and death.
Maintenance, parts replacement and other work on the converter must
only be carried out by qualified personnel in compliance with local
regulations.
DANGER!
Do not try to gain access to the converter transformer, the medium
voltage units of the converter nor the motor as long as the drive system
is energized and not grounded.
DANGER!
The driven machine can cause the motor to rotate! Always disconnect,
short-circuit or block the motor before work is started.
NOTICE!
Before power is applied to the converter, check that:
• Mains and motor connections are ok.
• Auxiliary power and control cable connections are ok.
• No tools or other foreign objects are left in the cabinet.
• All doors of the power units are properly closed.

Chapter 1 - Introduction and Safety ABB

ABB Chapter 2 - Inverter and Rectifier Failures
Chapter 2 - Inverter and Rectifier Failures
2.1. Safety
IGCTs and diodes can only be tested after the DC link of the converter
has been deenergized and grounded.
DANGER!
Hazardous voltage!
Make sure that the converter has been completely deenergized and that
power cannot be applied by accident. Failure to do so may result in
injury or death.
NOTICE!
Do not turn the grounding switch to position "grounded", before the light
GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will be
damaged.
2.2. Typical Inverter Failures
Two typical semiconductor failures can occur in the inverter:

• 1 IGCT and 1 diode damaged (root cause: diode)
• 3 IGCTs and 1 diode damaged (root cause: one IGCT)
When a failure occurs, a short-circuit current will flow through the other
components in the short-circuit path and damage them.
NOTICE!
Always replace all components in the short circuit path even if some
components do not seem to be damaged.
NOTICE!
The clamping diode can fail as an effect of any of the two typical
semiconductor failures. The failed clamping diode should be on the
same side as the other damaged components.
ShortCir Plus Æ VCL1 / V4037.
ShortCir Minus Æ VCL2 / V4038.

Chapter 2 - Inverter and Rectifier Failures ABB
IMPORTANT!
In case of any other combination of broken components contact local
ABB (or MV AC Supportline for further consulting).
Figure 2-1 Example of a Failure on the Positive Inverter Side

Shown is an inverter failure with 1 IGCT and 1 diode on the positive side
of the inverter (short-circuit plus). The short-circuit can occur in all
phases.
Figure 2-2 Example of Failure on the Negative Inverter Side

Shown is an inverter failure with 1 IGCT and 1 diode on the negative side
of the inverter (short-circuit minus). The short-circuit can occur in all
phases.

LS1/ L4001
VCL1 / V4037
V1U / V4021 V1V / V4031 V1W / V4041
RS1 / 40xx
C1 / C30xx CCL1 / C4011
V2U / V4022 V2V / V4032 V2W / V4042
VN1U / VN1V / VN1W /

V4025 V4035 V4045
NP NP
V3U / V4023 V3V / V4033 V3W / V4043

V4026 V4036 V4046
C2 / C30xx CCL3 / C4012
V4U / V4024 V4V / V4034 V4W / V4044

RS2 / R40xx
VCL2 / V4038
LS2 / L4001
Figure 2-3 Example of a Failure on the Positive Inverter Side

Shown is an inverter failure with 3 IGCTs and 1 diode on the positive side
of the inverter (short-circuit plus). The short-circuit can occur in all
phases.
LS1/ L4001
VCL1 / V4037
V1U / V4021 V1V / V4031 V1W / V4041
RS1 / 40xx
C1 / C30xx CCL1 / C4011
V2U / V4022 V2V / V4032 V2W / V4042

V4025 V4035 V4045
NP NP
V3U / V4023 V3V / V4033 V3W / V4043

V4026 V4036 V4046
C2 / C30xx CCL3 / C4012
V4U / V4024 V4V / V4034 V4W / V4044

RS2 / R40xx
VCL2 / V4038
LS2 / L4001
Figure 2-4 Example of a Failure on the Negative Inverter Side

Shown is an inverter failure with 3 IGCTs and 1 diode on the negative
side of the inverter (short-circuit minus). The short-circuit can occur in all
phases.

2.3. Typical Rectifier Failures
There are two root causes for rectifier damages:

• Ground fault in the transformer secondary winding or in the cable
between the supply transformer and the converter.
• Overvoltage from the supply network (lightning, clearing of a short-
circuit etc.).
After the first diode is damaged, the short-circuit current can damage two
more diodes, the failed components should always be in one row (see
Figure 2-5).
The amount of broken diodes depends mainly on the setting (fast /slow
reaction) of the overcurrent protection of the transformer secondary side.
NOTICE!
When a failure in the rectifier occurs, always check if the root cause for
the failure can be determined, i.e. megger the transfomer and the
transformer secondary cables prior to start up to ensure that there are
no ground faults in the drive system.
Figure 2-5 Example of Rectifier Failure

2.4. Last Switched Vectors
The converter constantly monitors the switching of the inverter. When a

fault “Short Circ Pl” or “Short Circ Min” occurs, the last switchings are
automatically saved in the parameters 190.30 Switched Vector 0, 190.31
Switched Vector -1 and 190.32 Switched Vector -2. The values of the
parameters 190.30, 190.31 and 190.32 are automatically saved in the
flash memory and saved also after switching off the auxiliary power.
The last 6 bits in the parameters 190.30, 190,31 and 190.32 describe the
last switchings:
• Last two bits indicate the switching state of phase W,

• Middel two bits indicate the switching state of phase V,
• First two bits (from left) indicate the switching state of phase U.
Figure 2-6 Example of swithced vectors
Table 2-1 Explanation of Parameter Value of Switched Vector
Switched Vector Switched Potential
11 Plus potential is switched (+)
01 Zero potential is switched
00 Minus potential is switched (-)
10 All IGCTs are turned off
Table 2-2 Example of Switching Vectors
Parameter Parameter Value U V W
190.30 switched vector 0 01 11 11 zero + +
190.31 switched vector -1 01 11 01 zero + zero
190.32 switched vector -2 01 11 11 zero + +

Drives without any short circuit history or after downlanding new software
indicate the following:
190.30 Switched Vector 0 0000 0000 0000 0000 0000 0000 0100 0000
Figure 2-7 Example of swithced vectors after software download


Chapter 3 - Checking IGCTs and Diodes ABB
Chapter 3 - Checking IGCTs and Diodes
3.1. Safety
IGCTs and diodes can only be tested after the DC link of the converter
has been deenergized and grounded.
DANGER!
Hazardous voltage!
power cannot be applied by accident. Failure to do so may result in injury
or death.
NOTICE!
damaged.
NOTICE!
Semiconductors must only be tested with a multimeter. Testing semi-
conductors with a megger can damage them.
3.2. General
In case of any “inverter related fault” (for example: inverter short circuit,
overcurrent, overvoltage, MCB Disturb) before resetting or turning off the
auxiliary power, the following information should be downloaded from the
converter with DriveDebug version 2.91 or higher or with DriveWindows
version 2.12 or higher.
• Fault logger
• TrendLogWin (can only be downloaded with DriveDebug)
• DataLogger 1 and DataLogger 2
• Parameter File (with group 190)
If the fault is reset or the auxiliary power is turned off, the information in
the dataloggers will be lost.
If DriveWindow or DriveDebug is not available, read the fault buffer and
parameters 190.30, 190.31 and 190.32 (switched Vector 0, -1 and -2) and
write down the information before turning off the auxiliary power.
Write down which of the LEDs on the GUSP subprints are blinking.

ABB Chapter 3 - Checking IGCTs and Diodes
Measure all power semiconductors before and after repairing the

converter and write down the measured values in the tables in Appendix
A of this manual.
3.3. Checking IGCTs
3.3.1. Required Tools
The following tools are needed to test IGCTs:

• Multimeter
• Ratchet with 400 mm extension and 19 mm socket (for water-cooled
converters)
• Screw drivers, PZ3 bit and 3 mm and 5 mm hex sockets
3.3.2. IGCT Test Procedure
Proceed as follows:
1 Deenergize and ground the converter but leave the auxiliary power on.
2 Check the IGCTs for burned components.
If any component is burned, the whole IGCT must be replaced.
3 Check that the green and the yellow LEDs on all GUSP subprints are
on (see Figure 3-1).
If a LED on a GUSP subprint blinks, the output of the board may be
short-circuited (the gate unit of the IGCT is short-circuited).
LEDs on GUSP subprint
Figure 3-1 GUSP Unit
NOTICE!
To prevent an undefined control state when checking, be careful not to
disconnect the fiber optic cable while the IGCT is energized.

The faults ´Ground Fault´ , ´Short Circuit´ , ´Short Cir Pl´ or ´Short Cir
Min´ and ´BchopShort´ will activate trip reaction 3. Trip reaction 3
turns on the six middle IGCTs.
4 The fault must be reset to turn off the middle IGCTs. To reset the
fault, switch the auxiliary power off and on again.
5 Measure the voltage between gate and anode of the IGCT (see
Figure 3-2 and Figure 3-3) and record the measured values in the
measurement table in Appendix A.
When the IGCT is not short-circuited and switched off, the measured
value should be –20 VDC +/- 0.5 VDC.
NOTICE!
When measuring be careful not to short-circuit gate and cathode / anode
of the IGCT.
Use short tipped probes.
Hold one probe against the cooler on the anode side and the other
probe against a screw head on the gate side.
Anode
Gate
Cathode
ACS1xxx-A1
Anode
Gate
Cathode
ACS1xxx-A2
Anode
Gate
Cathode ACS1xxx-A3
Figure 3-2 Testing IGCTs in Air-Cooled Converters

Cathode
Gate
Anode
ACS1xxx-W1
Cathode
Gate
Anode
ACS1xxx-W2 or
ACS1xxx-W3
Figure 3-3 Testing IGCTs in Water-Cooled Converters
6 Turn off the auxiliary power and measure the voltage between
anode-cathode and cathode-anode of the IGCT with the multimeter in
diode mode and write down the measured values in the
measurement table in Appendix A.
3.3.3. Test Procedure in case of ‘IGCT Fault’ Message
The message ‘IGCT fault’ means that one or several IGCTs do not switch
on.
During the first part of the start, the ACS 1000 checks that all IGCTs
switch on and off properly. If it is detected, that at least one IGCT does
not switch, a trip is initiated.
The switching of IGCTs can be tested with parameter 112.31
IGCTTestOnTime (only available in software version MSOH4100 or
higher). Parameter 112.31 switches the IGCTs on in a predefined
sequence (see Figure 3-4).
When parameter 112.31 is set to zero, the function is disabled. When the
parameter is not set to zero, two IGCTs are switched on together for the
selected time, first the 2 upper then the 2 lower IGCTs of phase U, then
the same IGCTs of phase V and W. After one sequence, parameter
112.31 is automatically set back to 0.

Figure 3-4 IGCT Test Sequence
To check the switching of an IGCT, measure the gate-cathode voltage in

both switched on and switched off state. The measured value should be
approximately +0.5 - 0.7 VDC when the IGCT is switched on and -20
VDC when the IGCT is switched off.

Preparation:
1 Close the grounding switch (check that the LED of digital input 11 on
IOEC1 is on).
2 Reset all faults.
Test procedure:
1 Change the value of parameter 112.31 IGCTTestOnTime from 0 s to
15 s.
2 Measure the voltage between gate and anode of the following IGCTs:
• V1U / V4021, V1V / V4031 and V1W / V4041
Wait until the first IGCT switches on / off, then measure the next
IGCT and after that the last IGCT and record the value.
15 s.
• V2U / V4022, V2V / V4032 and V2W / V4042
15 s.
• V3U / V4023, V3V / V4033 and V3W / V4043
15 s.
• V4U / 4024, V4V / V4034 and V4W / V4044

3.4. Checking Diodes
Diodes in the inverter of the ACS 1000 can be checked in two ways:
• Using a multimeter in diode test mode.
• (Using a multimeter in resistance test mode).
3.4.1. Testing Neutral-Point and Anti-Parallel Diodes with a Multimeter in Diode

Test Mode
Proceed as follows:
1 Deenergize and ground the converter.
2 Switch off the auxiliary power supply.
3 Measure the anode/cathode voltage using a multimeter in diode test
mode with suitable probes and compare the measured values with
the expected measurement results (see Table 3-1).
4 Measure the cathode/anode voltage using a multimeter in diode test
NOTICE!
When the motor is connected, the multimeter will charge the clamping
capacitors through the motor, this causes the cathode/anode voltage to
rise.
Table 3-1 Expected Measurement Results
Free wheeling and Voltage between Voltage between

Anti-parallel Diodes Anode/Cathode Cathode/Anode
Out of range (diode is
~ 0.25.....0.35 V
blocking)
3.4.2. Testing Rectifier Diodes with a Multimeter in Diode Test Mode
Proceed as follows:
3 Measure the anode/cathode voltage using a multimeter in diode test
4 Measure the cathode/anode voltage using a multimeter in diode test

Table 3-2 Expected Measurement Results
Voltage between Voltage between

Rectifier Diodes
Anode/Cathode Cathode/Anode
V1A / V2151…V4C / V2166 ~ 0.25.....0.35 V ~ 0.8....1 V
V5A / V2101…V8C / V2116 ~ 0.25.....0.35 V ~ 0.8....1 V
3.4.3. Testing Clamping Diodes
3.4.3.1. Air-cooled Converters
IMPORTANT!
In air-cooled converters, it is not possible to use a multimeter in diode
mode for testing the clamping diodes because the clamping choke and
the clamping resistor are connected in parallel with the clamping diodes.
Proceed as follows:
3 Measure the resistance across the diode using a multimeter in
resistance test mode with suitable probes and compare the
measured value with the expected measurement result (see Table
3-3).
Table 3-3 Expected Measurement Results in Air-Cooled Converters
Clamping Diodes Resistance between

VCL1 / V4037 and VCL2 / V4038 Anode/Cathode
ACS1xx2-A2 and ACS1X42-A2 ~ 0.9 Ω

ACS1xx2-A3 and ACS1x42-A3 ~ 0.9 Ω
ACS1xx3-A1 ~ 4.2 Ω
ACS1xx3-A2 ~ 1.2 Ω
ACS1xx3-A3 ~ 0.9 Ω

4 If the results of the measurement are not clear or there is reason to
assume that the clamping diode is damaged, remove the diode from
the stack and measure it separately. See section 5.2.6 Replacing
Neutral-Point or Clamping Diodes.
3.4.3.2. Water-cooled Converters
Proceed as follows:
3 Open the swing frame.
4 Measure the voltage across the diode using a multimeter in diode
test mode with suitable probes and compare the measured value with
the expected measurement result (see Table 3-4).
Table 3-4 Expected Measurement Results in Water-Cooled Converters
Clamping Diodes Voltage between Voltage between

Anode/Cathode Cathode/Anode
Out of range
VCL1 / V4037…VCL2 / V4038 ~ 0.25.....0.35 V
(diode is blocking)
5 Close the swing frame.

6 Measure the resistance across the diode using the multimeter in
resistance test mode and suitable probes and compare the measured
value with the expected measurement result (see Table 3-5).
Table 3-5 Expected Measurement Results in Water-Cooled Converters
Clamping Diodes Resistance between

VCL1 / V4037 and VCL2 / V4038 Anode/Cathode
ACS1xx2-W1 ~ 1.25 Ω
ACS1xx2-W2 ~ 0.63 Ω
ACS1xx3-W1 ~ 1.25 Ω
ACS1xx3-W2 ~ 0.63 Ω
ACS1xx3-W3 ~ 0.63 Ω
ACS1xx4-W1 ~ 1.25 Ω
ACS1xx4-W2 ~ 0.63 Ω
ACS1xx4-W3 ~ 0.63 Ω


ABB Chapter 4 - Checking Current Transducers
Chapter 4 - Checking Current Transducers

If there is a reason to doubt the current measurement, the functionality of
the current transducers must be checked. This is done by leading a
current through the current transducer and monitoring the currents with
the actual values in parameters:
• 2.10 InvCurrent IU
• 2.11 InvCurrent IW
• 2.12 InvEarthCurrent
• 2.13 FiltCurrent IU
• 2.14 FiltCurrent IW
IMPORTANT!
When the auxiliary power is turned on and the grounding switch is closed
(DI11 on IOEC1 on) an offset calibration of the current measurement is
carried out automatically.
Do not let a current flow through a current transducer until the offset
calibration is finished. Wait a few minutes after the auxiliary power is
turned on to prevent wrong offset calibration.
Using a current source (needed also for protection relay testing) a current
is fed through the current transducer via a separate wire. The current of
the current source is then compared with the actual value shown in the
corresponding parameter.
If a current source is not available, the measurement can be done by
winding several rounds of wire around the current transducer and then
supplying a current by using a power supply and a resistor.
Example:
Use for example the 27 VDC internal power supply and a 4 Ω resistor and
wind 10 turns of wire around the current transducer. With this
configuration the current should be about 27/4 * 10 = 67.5 A.
When using a DC supply, measure the current in both directions.
Resistor
Fuse
Voltage source
Figure 4-1 Testing of Current Transducers

ABB Chapter 4 - Checking Current Transducers

ABB Chapter 5 - Replacing Diodes and IGCTs
Chapter 5 - Replacing Diodes and IGCTs
5.1. Safety
IGCTs and diodes of phase modules can only be tested after the
converter has been deenergized and grounded.
DANGER!
Hazardous voltage!
injury or death.
NOTICE!
damaged.
5.2. Replacing Diodes and IGCTs in Air-cooled Converters and

Braking Chopper
5.2.1. Required Tools and Accessories
• Lifting tools (code: HL000181R1KIT)

• 10 mm spanner
• 24 mm ring spanner
NOTICE!
Printed circuit boards are sensitive to electrostatic discharge (ESD).
When handling printed circuit boards, ground yourself properly with a
wrist strap or other appropriate means.
NOTICE!
Before replacing any components in the middle section of the ACS
1000i, cover the main transformer to prevent objects from dropping into
the transformer.

5.2.2. Checking IGCTs and Diodes in the Converter
Measure the diodes and IGCTs in the converter according to the

instructions in Chapter 3 of this manual.
5.2.3. Releasing the Pressure of the Stack
Release the pressure of the phase stack with the damaged components
by opening the 21 mm nuts. Loosen each nut half a turn a time until the
pressure plate can be moved easily.
Tightening nuts
Alignment disks
Lifting tools
Figure 5-1 Phase Stack in Air-Cooled Converter and Lifting Tools
5.2.4. Replacing IGCTs
Proceed as follows:
1 Unplug the fiber optic cable and the power supply connector.
2 Open the stack according to the instructions in section 5.2.3
Releasing the Pressure of the Stack.
3 Place the lifting tools on both sides of the heat sink above the faulty
IGCTs (see Figure 5-1).
4 Fix each tool by tightening the lower bolt with a 10 mm wrench.
5 Lift the heat sink by tightening the upper bolt. Lift up both sides
equally.

Chapter 5 - Replacing Diodes and IGCTs ABB
Figure 5-2 Extracting an IGCT
6 Withdraw the IGCT by holding it at the plastic clips.

7 Check that the surfaces of the heat sinks are clean and that there are
no burnmarks on them.
8 Clean the heat sinks with a cloth and a solvent (industrial ethanol).
NOTICE!
Do not use any grease on the surface of the heat sinks.
9 Push the new IGCT into its place.
NOTICE!
The holding clips snap into the heat sink, when the IGCT is in the
correct position.
10 Lower the heat sink by loosening the upper bolts of the lifting tools,
release the tools by loosening the lower bolts.
11 Reconnect the fiber optic cable and the power supply connector.

5.2.5. Replacing Protection and Braking Chopper IGCTs
NOTICE!
When removing diodes, apply pressure to the stack by hand to prevent
diodes from dropping.
After the replacement, check the alignment of all diodes in the stack.
Proceed as follows:
2 Open the stack according to the instructions in section 5.2.3
3 Pull the heat sink towards the front to release the IGCT.
Do not let the diode drop when pulling out the heat sink. Manually,
apply pressure to the heatsinks of the other diodes.
4 Withdraw the IGCT by holding it at the plastic clips.
NOTICE!
7 Push the IGCT into its place. The holding clips snap into the heat
sink, when the IGCT is in the correct position.
8 Reconnect the fiber optic cable and the power supply connector.
5.2.6. Replacing Neutral-Point or Clamping Diodes
NOTICE!
Check the polarity of the diodes (the polarity can also be checked by
means of the circuit diagram).
Proceed as follows:
1 Open the stack according to the instructions in chapter 5.2.3
2 Place the lifting tools on both sides of the heat sink above the faulty
diode.
3 Fix each tool by tightening the lower bolt with a 10 mm wrench.
4 Lift the heat sink by tightening the upper bolt. Lift up both sides
equally.

5 Pull out the diode.
6 Check the surfaces of the heat sinks are clean and that there are no
burnmarks on them.
7 Clean the heat sinks with cloth and solvent (industrial ethanol).
NOTICE!
8 Place the diode between the center points of the heat sinks.
9 Lower the heat sink by loosening the upper bolts of the lifting tools,
release the tools by loosing the lower bolts.
5.2.7. Replacing Rectifier and Braking Chopper Diodes
NOTICE!
NOTICE!
When removing diodes, apply pressure to the stack by hand to prevent
diodes from dropping.
After the replacement, check the alignment of all diodes in the stack.
Proceed as follows:
1 Open the stack according to the instructions in chapter 5.2.3
2 Pull the heat sink carefully towards the front to release the diode from
the centering pin.
Do not let the diode drop when pulling the heat sink. Manually, apply
pressure to the heatsinks of the other diodes.
3 Pull out the diode.
NOTICE!
6 Place the diode between the center points of the heat sinks.

5.2.8. Tightening of the Phase Stack
Proceed as follows:
1 Tighten both nuts equally by hand and then with a wrench, half a turn
at a time until the alignment disks are on the same level.
2 Check the alignment with a ruler, the small disks should be at same
level as the large disk.
3 Tighten all fixing parts of the phase stack.
4 Check the IGCTs and diodes of the frame once more according to
the instruction in Chapter 3 of this manual.
5.3. Replacing Diodes and IGCTs in Water-Cooled Converter
Replacing instruction is based on the type of stack. Two different types of

stack exist. The Old stack is requering 60 mm spanner for stack service
and the new stack is requering a hex sockets.
5.3.1. Required Tools and Accessories
• 60 mm spanner (supplied with the converter – OLD Stacks)

• 12 mm hex socket (for NEW stacks)
• Ratchet with 400 mm extension and 19 mm socket
• Screw drivers, PZ3 bit and 3mm and 5mm hex sockets
NOTICE!
Printed circuit boards are sensitive to electrostatic discharge (ESD).
When handling printed circuit boards, ground yourself properly with a
wrist strap or other appropriate means.
5.3.2. Checking IGCTs and Diodes in the Converter
Measure all diodes and IGCTs in the converter according to the

instructions in Chapter 3 of this manual.
5.3.3. Opening the Swing Frame
Proceed as follows:
1 Remove the door center post.
2 Remove the upper and lower 19 mm fixing bolt of the swing frame.
3 Pull the swing frame open.

Upper fixing screws of door
center post
Upper fixing bolt
Lower fixing bolt
Lower fixing screws of

door center post
Figure 5-3 Swing Frame Fixings
5.3.4. Releasing the Pressure of the Phase Stack
Proceed as follows (for OLD Stacks):

1 Release the pressure of the phase stack by opening the 60 mm nuts
(see Figure 5-4).
2 Loosen each nut half a turn a time until you can loosen and pull out
the pressure plate.
3 Remove the plastic holder of the IGCTs.
The plastc holders must be used again because the new IGCTs are
supplied without plastic holders (see Figure 5-4).

Upper plastic holder of

V4V / V4034
Tightening nuts
Alignment disks
Tightening nuts
Lower plastic holder of
V4V / V4034
Figure 5-4 Phase Stack of Water-Cooled Converter (OLD Stacks)
Proceed as follows (for NEW Stacks):

1 Slide the clamp pressure loading gauge under the clamp ring of the
pressure adjusting bolt and loosen the bolt using 12 mm hex socket
to release the clamp pressure of the stack (see Figure 5-5).
2 Remove the plastic holders of the IGCTs.
The plastic holders must be used again because the new IGCTs are
supplied without plastic holders (see above Figure 5-4).
Figure 5-5 Phase Stack of Water-Cooled Converter (NEW Stacks)
5.3.5. Replacing IGCTs
Proceed as follows:
2 Open the stack according to sections 5.3.3 Opening the Swing
Frame and 5.3.4 Releasing the Pressure of the Phase Stack.
3 Remove both plastic holders from the IGCT.

Figure 5-6 Extracting an IGCT
4 Pull out the IGCT by holding it at the plastic clips.

NOTICE!
7 Push the IGCT into its place.

8 Attach both retaining clamps to the IGCT.
9 Reconnect the fiber optic cable and the power connector.
5.3.6. Replacing Diodes
NOTICE!
Proceed as follows:
1 Open the stack according to the instructions in chapters 5.3.3
Opening the Swing Frame and 5.3.4 Releasing the Pressure of the
Phase Stack.
2 Lift out the diode together with the retaining and positioning hanger.

NOTICE!
5 Make sure that the polarity of the diode is correct and place it in the
hanger.
6 Insert the diode together with the hanger into its place.
7 Check that hanger and diode are placed correctly and that the diode
is centered.
5.3.7. Tightening the Phase Stack
Proceed as follows (for OLD Stacks):

1 Hand tighten both nuts equally.
Using a wrench turn the nuts half a turn a time until the alignment
disks are level with each other (see Figure 5-4).
2 Check the alignment with a ruler. The smaller disks should be level
with the larger disk.
3 Tighten all fixing parts of the phase stack (see Figure 5-4).
4 Check the IGCTs and diodes according to the instructions in Chapter
3 of this manual.
Proceed as follows (for NEW Stacks):

1 Tighten the pressure adjusting bolt until the clamp pressure loading
gauge is released (see Figure 5-5).
2 Refit the clamp pressure loading gauge in its storage place on the
side of the stack.
3 Tighten all fixing parts of the phase stack (see Figure 5-5).
4 Check the IGCTs and diodes according to the instructions in Chapter
3 of this manual.

NOTICE!
After the service is completed, it must be checked that the center posts
are installed and the fixing screws are properly tightened. The center
posts are important to lock the doors securely.
To secure proper connection of the electric contacts of the swing frame
with the connectors at the back, the fixing bolts of the swing frame must
be properly tightened..
5.4. Replacing Rectifier Diodes in ACS 1000i
Minimum distance
between cables and
busbars: 15 mm
Figure 5-7 Rectifier Diodes in ACS 1000i
NOTICE!
Check the polarity of the diodes (can also be checked by means of the
circuit diagram).
Proceed as follows:
1 Remove the busbars and the electric connections on top of the diode.
2 Open the bolts on the cooling element and remove the diode.
NOTICE!

5 Make sure that the polarity of the diode is correct and tighten it
crosswise applying 6 Nm tightening torque.
6 Install the busbars and the electric connection and tighten them
applying 12 Nm tightening torque.

ABB Chapter 5 - Replacing Diodes and IGCTs

Chapter 6 - Replacing Printed Circuit Boards
6.1. Safety
DANGER!
Hazardous voltage!
injury or death.
NOTICE!
damaged.
NOTICE!
Do not touch printed circuit boards or other sensitive components
without applying static-sensitive handling precautions!
Static electricity can damage boards and components!
Do not touch the components without wearing a properly grounded wrist
strap.
Put the board or component on a grounded working surface protected
against electrostatic discharges.
Hold a board only at the edges.
Handle a faulty board as carefully as a new one.
NOTICE!
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.
NOTICE!
When a board has been replaced, check that a rubber plug is inserted
into each non- used optical receiver.

Chapter 6 - Replacing Printed Circuit Boards ABB
6.2. Replacing the AMC Board
Figure 6-1 AMC33 Board (3BHE010751R0101)
Figure 6-2 AMC34 Board (3BHE024577R0101)
The AMC board is mounted inside the control cabinet on the swing frame
or on the inside of the converter door in case of an ACS 1000i (see Figure
6-3).

ACS 1000 Air/Water AMC board
ACS 1000i
AMC board
Figure 6-3 Fitting Position of AMC Board

3 Before touching the AMC board, ground yourself at the converter
frame with a wrist strap.
4 Unplug the fiber optic cables, the power supply connector and the
control panel connector.

5 Remove the fastening screws (7 pcs.). Take all necessary
precautions to prevent screws and washers from falling onto other
components.
6 Verify that the SW version and the parameter settings of the new
board correspond to those of the converter.
7 Mount the new AMC board.
IMPORTANT!
It is important that all fastening screws are used to ensure proper
grounding of the board.
8 Reconnect the fiber optic cables, the power supply connector and the
control panel connector.
9 Verify the connections by comparing them with the corresponding
wiring diagram.
10 Put the defective board in an antistatic bag.
11 Power up the converter and confirm its proper functioning.
If the defective board has to be returned to ABB, particularly if the

component is still under warranty, follow the procedures as stated in the
Warranty Directives (this is recommended even if the warranty has
expired).
6.3. Replacing the AMC Flash Memory
The application control software and the parameter settings are saved in
the flash memory which is on a separate printed circuit board (PCB).
When the AMC board is replaced the old flash memory can still be used if
the software has not been upgraded.
The AMC3, 33 has one removable flash memory for storing the program
code, parameter and logger data.
On the AMC34 there are two removable flash memories. One is for
storing program code and parameters (PROG); the other one is working
as extra logger(LOG – Black box).

PROG LOG
Black Box
Figure 6-4 Program flash memory and extra logger flash
Proceed as follows:
1 Deenergize and ground the converter
If only the flash memory has to be replaced the AMC board can
remain in the cabinet. It is also not necessary to disconnect the fiber
optic cables.
2 Note the orientation of the white dot on the board for later reference
before removing the flash memory.
a b
Figure 6-5 AMC Board (a) and Flash Memory PCB (b)
3 Remove the flash memory PCB by holding it with both hands and
pulling it straight away from the AMC board.
Figure 6-6 Removing the Flash Memory PCB
4 When attaching the new PCB make sure that the white dot on the
PCB is on top of that on the AMC board (see Figure 6-7).

NOTICE!
Correct orientation of the flash memory is important. If attached wrongly,
the new flash memory will be damaged immediately when the auxiliary
power is switched on.
Figure 6-7 Attaching the Flash Memory PCB
5 Press the PCB firmly down to make sure that all pins are inserted
properly.
Figure 6-8 Inserting the New Flash Memory PCB


Warranty Directive (this is recommended even if the warranty period has
expired).

6.4. Replacing the INT Board
EPLD memory
Figure 6-9 INT Board
The INT board is mounted inside the control cabinet on the swing frame
behind the AMC board (see Figure 6-10).

INT board
behind AMC
board
Figure 6-10 Location of INT Board
Proceed as follows:
3 Before touching the INT board ground yourself at the converter frame
with a wrist strap.
4 Remove the AMC board (see section 6.2 Replacing the AMC Board).

5 Unplug the fiber optic cables and the power supply connector.
6 Remove the fastening screws (6 pcs.) take all necessary precautions
to prevent screws and washers from falling onto other components.
7 Remove the INT board and place it on a grounded working surface
protected against electrostatic discharges.
8 Remove the support legs for the AMC board (7 pcs.) from the old INT
board.
9 If the EPLD version on the spare part INT board is not compatible
with the old one, transfer the EPLD from the old INT board to the new
one.
Transferring the EPLD Chip

Proceed as follows:
1 Put the new INT board next to the board being replaced.
2 Extract the EPLD chip using an appropriate tool.
3 When inserting the EPLD chip into the new INT board, pay attention
to the orientation and the allocation of the chips. The notch on the
chip must be aligned with the notch on the socket (see Figure 6-9).
NOTICE!
Correct orientation of the EPLD chip is important. If attached wrongly it
will be damaged.
4 Install the support legs for the AMC board (7 pcs.) on the new INT
board.
5 Mount the new INT board using all fastening screws.
IMPORTANT!
Use all fastening screws to ensure proper grounding of the board.
6 Reconnect the fiber optic cables and the power supply connector.
7 Carry out a visual check and verify the connections by comparing
them with the corresponding wiring diagram.
8 Put the defective board into an antistatic bag.
9 Install the AMC board (see section 6.2 Replacing the AMC Board).
10 Confirm the proper functioning of the converter.


Warranty Directive (this is recommended even if the warranty period has
expired).
6.5. Replacing the OVVP Board / ACS 1000i Rectifier Monitoring
SVA board
Figure 6-11 OVVP and Rectifier Monitoring Board
The OVVP board in the standard ACS 1000 air or water cooled
converters is installed in the middle section of the cabinet inside an EMC
box (see arrows in Figure 6-12). In the same metal box is also the ADCVI
board.

ACS1xxx-W1 ACS1xxx-W2 and W3 ACS1xxx-Ax

Figure 6-12 Location of OVVP Board in standard ACS 1000 air or water
cooled converters
The OVVP board of the ACS 1000i is installed in the inverter section of
the converter (see arrow in Figure 6-13) and the Rectifier Monitoring
board is installed in the middle section next to the wall of the inverter
section (see square in Figure 6-13).

OVVP board Rectifier monitoring board

Figure 6-13 Location of OVVP Board and Rectifier Monitoring Board in
ACS 1000i
Proceed as follows:
3 Before touching the boards ground yourself at the converter frame
with a wrist strap.
4 The OVVP board is mounted in a EMC box. Remove the screws and
the cover, take all necessary precautions to prevent screws and
washers from falling onto other components.
5 Unplug the DC voltage measurement cables, the fiber optic cable
and the power supply connector.
6 Remove the fastening screws and release the plastic supports.
7 Remove the board and place it on a grounded working surface
protected against electrostatic discharges.
Transferring the SVA Board

Proceed as follows:
1 Put the new board next to the board being replaced.
2 Extract the SVA board from the old OVVP board and insert it into the
new board.
3 Mount the new board using all fastening screws.
4 Reconnect the DC voltage measurement cables, the fiber optic cable


wiring diagram.
Warranty Directive (this is recommended even if the warranty has
expired).
6.6. Replacing the ADCVI Board
SVA board
SCA board
Figure 6-14 ADCVI Board
The ADCVI board in the standard ACS 1000 air or water cooled
converters is installed in the middle section of the converter inside an
EMC box (see arrows in Figure 6-15). The OVVP board is in the same
box. The board is installed on top of the ADCVI board.

ACS 1xxx-W1 ACS 1xxx-W2 and W3 ACS 1xxx-Ax

Figure 6-15 Location of ADCVI Board in ACS 1000
The ADCVI-board of ACS 1000i converters is installed in the inverter

section (see arrow in Figure 6-16). The OVVP board is installed on top of
the ADCVI board.
Figure 6-16 Location of ADCVI Board in ACS 1000i
Proceed as follows:

3 Before touching the ADCVI board ground yourself at the converter

frame with a wrist strap.
4 Remove the OVVP board (see section 6.5 Replacing the OVVP
Board).
5 The ADCVI board is mounted in an EMC box under the OVVP board.
Loosen and remove the screws and remove the cover, take all
necessary precautions to prevent screws and washers from falling
onto other components.
6 Unplug the DC voltage measurement cables, the fiber optic cables
7 Remove the fastening screws, distance bolts and plastic supports.
8 Remove the ADCVI Board and place it on a grounded working
surface protected against electrostatic discharges.
Transferring the SVA Board

Proceed as follows:
1 Put the new ADCVI board next to the board being replaced.
2 Extract the SVA board from the old ADCVI board and insert it into
new ADCVI board.
3 Extract the SCA Board from the old ADCVI board and insert it into
new ADCVI Board.
4 Mount the new ADCVI board.
5 Reconnect the DC voltage measurement cables, the fiber optic
cables and the power supply connector.
wiring diagram.
8 Install the OVVP Board.
expired).

6.7. Replacing the GUSP and the GUSP Subprints
Female and male connector of GUSP

unit
Guiding pin
GUSP unit GUSP Subprint
Figure 6-17 GUSP Unit and GUSP Subprint
See arrows in Figure 6-18 to locate the GUSP units in the converters.
ACS 1xxx-W1 / W2 / W3 ACS 1xxx-Ax ACS 1000i

Figure 6-18 Location of GUSP Units

Proceed as follows:
2 Switch off auxiliary power supply.
3 Before touching the subprints ground yourself at the converter frame
with a wrist strap.
4 Unplug the power connector and if necessarry cut the cable tie which
secures the cable to the frame of the GUSP.
5 Remove the plastic support of the subprints.
6 Pull out the subprint.
NOTICE!
The subprint must be pushed in very carefully. If the pins of subprint are
not in the correct position they will bend and the board will be damaged.
7 Push in the new subprint.

8 Plug in the power connector and tighten it with a cable tie.
In case of replacing the complete GUSP Proceed as follows:

2 Switch off auxiliary power supply.
3 Before touching the GUSP ground yourself at the converter frame
with a wrist strap.
4 Unplug the power connector and if necessarry cut the cable tie which
secures the cable to the frame of the GUSP.
5 Unplug the power connector and the fiber cable from the GUSP main
board.
6 Unscrew the fixing bolts.
7 Mount the new GUSP and screw the bolts.
8 Plug in the power connector and the fiber cable to the GUSP main
board.
9 Plug in the power connector to every GUSP subprints and tighten it
with a cable tie.
expired).

Chapter 7 - Function of LEDs ABB
Chapter 7 - Function of LEDs
7.1. AMC Board
F R
M P
T1 T2
S3 S1
S2 S0
AMC3 / 33 Board AMC34 Board
Figure 7-1 AMC Board
Function of LEDs are described in table 7-1.

Table 7-1 LEDs on the AMC Board
LED LED Color Function
R green Always OFF

F red Not used (ON when booting)
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

7.2. INT Board
V641 V591 V561…V564 V103 V113
Figure 7-2 INT Board
Table 7-2 LEDs on the INT Board
LED LED Function

Color
V103 green internal +5 VDC supply is OK

V113 green redundant +5 VDC supply is OK
V591 red “CONFIG. FAULT“ EPLD is
booting
V641 red “Self excitation HW “
See: Note below
V561 yellow Supply from Batteries
V562 yellow Battery test ON
V563 yellow Not Used

IMPORTANT!
The red LED V641 “Self excitation HW “ indicates that a hardware trip
signal from the overvoltage detection board (OVVP board) is received.
The LED V641 can also be lit due to different power up times of the
boards. In that case, the trip must be reset manually by rebooting only
the INT board. To reboot, disconnect and then reconnect the auxiliary
power supply connector.
7.3. GUSP
LEDs of GUSP subprint
Figure 7-3 GUSP Unit

Table 7-3 LEDs on the GUSP Unit
Yellow LED Green LED State of Subprint
On On Output state OK, no overload

Dim light Blinking Output state operates correctly but overload / short-
circuit in output.
Output voltage < 10V
Subprint continuously tries to switch on.
Off On Yellow LED or its actuation is defective
Regulating board is functioning correctly
Off Off Supply voltage loss or control subprint defect.
CAUTION!
The GUSP subprints are at main circuit (medium voltage) potential.

7.4. IOEC Board
Dip switches for analog inputs
V726
Status LEDs of digital inputs
Soldering dot
Node address
V420
V740
Status LEDs of digital outputs
Figure 7-4 IOEC Board

Table 7-4 LEDs on the IOEC Board
LED LED Color Function (when lit)
V740 green + 5 VDC supply is OK

V726 green 24 VDC supply is OK
V420 red AMC communication fault
V107 – V237 yellow DI ON
V504 – V554 yellow DO ON
IMPORTANT!
To open the MCB fast in the event of a severe fault, the digital outputs
• DO1.6 (MCB trip command),
• DO2.5 (MCB open command),
• DO2.6 (MCB close command),
are controlled by the optical input MCB OFF from the INT board.
If there is light at the optical input MCB OFF, the digital outputs are
enabled, i.e. controlled by the software. If there is no light at the input,
the digital outputs outputs are forced to low and the MCB opens.
The optical control function can be deactivated on IOEC3, IOEC4,
IOEC5 and IOEC6 by removing the soldering joint.
Before exchanging an IOEC board, it is important to check the state of
the soldering joint.
IMPORTANT!
The node address of the IOEC boards is set with a rotary switch.
IOEC1 = address 2
IOEC2 = address 4
IOEC3 = address 6
IOEC4 = address 8
IOEC5 = address 10
IOEC6 = address 12

ABB Chapter 7 - Function of LEDs
7.5. EPS Board
V307
V171
V174
V177
V183
V186
V111
Figure 7-5 EPS Board
Table 7-5 LEDs on the EPS Board
LED LED Color Function
V111 green Battery test after replacement OK

V307 green +/- 20 VDC supply OK
V171 yellow Current of GUSP1 > 1,5A
V174 yellow Current of GUSP2 > 1,5A
V177 green 27 VDC supply OK
V183 green Battery connected
V186 yellow Battery test ON
IMPORTANT!
The power consumption of the GUSP units depends on the load of the
converter. During operation, the LEDs V171 and V174 may be on
permanently or may blink.

ABB Chapter 7 - Function of LEDs
Appendix A - Measurement Tables

The following components must always be measured in case of a short-circuit.
Table 7-6 Inverter (Multimeter in voltage and diode mode)
Gate-Anode Voltage Anode-Cathode Voltage Cathode-Anode Voltage

(in diode mode) (in diode mode)
Expected value OFF ON * VDC ~ 0.2…0.35 VDC out of range (diode is VDC
State State blocking)
-20 +/- 0.5
V1U / V4021 VDC VDC VDC
VN1U / V4025 NA VDC VDC
VN2U / V4026 NA VDC VDC
-20 +/- 0.5
V1V / V4031 VDC VDC VDC
VN1V / V4035 NA VDC VDC
VN2V / V4036 NA VDC VDC
-20 +/- 0.5
V1W / V4041 VDC VDC VDC
VN1W / V4045 NA VDC VDC
VN2W / V4046 NA VDC VDC

* Switching of the IGCT can be done by using switching Macro for old softwares or by using
parameter 112.31 for software MSOH4100 and newer.

Table 7-7 Clamping Diodes (Multimeter in diode mode)

Note: In water-cooled converters, the measurement should be made with the open swing frame.
Anode-Cathode Voltage Cathode-Anode Voltage

(diode mode) (diode mode)
Expected value ~ 0.2.....0.35 VDC out of range (diode is blocking) VDC
VCL1 / V4037 VDC VDC
VCL2 / V4038 VDC VDC
Table 7-8 Clamping Diodes (Multimeter in resistance mode)

Note: In water-cooled converters, the measurement should be made with the closed swing frame.
Anode-Cathode Resistance Cathode-Anode Resistance
Expected value Air-cooled converters: See Air-cooled converters: See
Table 3-3 Table 3-3

Water-cooled converters: See Water-cooled converters: See
Table 3-5 Table 3-5
VCL1 / V4037 Ω
VCL2 / V4038 Ω
Table 7-9 Rectifier Diodes (Multimeter in diode mode)

Expected value ~ 0.2.....0.35 VDC ~ 0.8….1 VDC
V1A/ V2151 VDC VDC
V2A/ V2154 VDC VDC
V3A/ V2161 VDC VDC
V4A/ V2164 VDC VDC
V1B/ V2152 VDC VDC
V2B/ V2155 VDC VDC
V3B/ V2162 VDC VDC
V4B/ V2165 VDC VDC
V1C/ V2153 VDC VDC
V2C/ V2156 VDC VDC
V3C/ V2163 VDC VDC
V4C/ V2166 VDC VDC

Measurement Tables ABB
Table 7-10 Rectifier Diodes in 24-pulse rectifier (Multimeter in diode mode)

Expected value ~ 0.2.....0.35 VDC ~ 0.8….1 VDC
V5A / V2101 VDC VDC
V6A / V2104 VDC VDC
V7A / V2111 VDC VDC
V8A / V2114 VDC VDC
V5B / V2102 VDC VDC
V6B / V2105 VDC VDC
V7B / V2112 VDC VDC
V8B / V2115 VDC VDC
V5C / V2103 VDC VDC
V6C / V2106 VDC VDC
V7C / V2113 VDC VDC
V8C/ V2116 VDC VDC
Table 7-11 Protection IGCTs (Multimeter in voltage and diode mode)
Gate-Anode Voltage Anode-Cathode Voltage Cathode-Anode Voltage

Expected value -20 VDC ~ 0.2.....0.35 VDC ~ 0.8….1 VDC

VS1 / FS1 VDC VDC VDC
VS2 / FS2 VDC VDC VDC
Table 7-12 Braking chopper IGCTs and Diodes (Multimeter in voltage and diode mode)
Gate-Anode Voltage Anode-Cathode Voltage Cathode-Anode Voltage (

Expected value -20 VDC ~ 0.2.....0.35 VDC ~ 0.8….1 VDC

VS1 VDC VDC VDC
VS1 VDC VDC VDC
VCS1 NA VDC VDC
VCS2 NA VDC VDC

Table 7-13 LEDs Status of GUSP1 (-U1 / -G4201)
Subprint of X3.1 X3.2 X3.3 X3.4 X.3.5 X3.6 X3.7

GUSP unit
Yellow- and
Green-LED light
Yellow LED Weak

light
Green LED blink
Table 7-14 LEDs Status of GUSP2 (-U2 / -G4202)
Subprint of X3.1 X3.2 X3.3 X3.4 X.3.5 X3.6 X3.7

GUSP unit
Yellow- and
Green-LED light
Yellow LED
Weak light
Green LED blink
Remarks

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ABB

Document No.: 3BHS225931 ZAB E01 Rev. A

© ABB Switzerland Ltd. All Rights Reserved.

2/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

Chapter 2 - Inverter and Rectifier Failures.......................................................................7

Chapter 3 - Checking IGCTs and Diodes .......................................................................14

Chapter 4 - Checking Current Transducers...................................................................24

Chapter 5 - Replacing Diodes and IGCTs ......................................................................26

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 3/67

Chapter 6 - Replacing Printed Circuit Boards................................................................. 7

Chapter 7 - Function of LEDs ......................................................................................... 24

Appendix A - Measurement Tables ................................................................................. 32

4/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

Chapter 1 - Introduction and Safety

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 5/67

6/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

Chapter 2 - Inverter and Rectifier Failures

2.2. Typical Inverter Failures

Two typical semiconductor failures can occur in the inverter:

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 7/67

Figure 2-1 Example of a Failure on the Positive Inverter Side

Figure 2-2 Example of Failure on the Negative Inverter Side

8/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

C1 / C30xx CCL1 / C4011

V2U / V4022 V2V / V4032 V2W / V4042

VN1U / VN1V / VN1W /

V3U / V4023 V3V / V4033 V3W / V4043

VN2U / VN2V / VN2W /

C2 / C30xx CCL3 / C4012

V4U / V4024 V4V / V4034 V4W / V4044

Figure 2-3 Example of a Failure on the Positive Inverter Side

C1 / C30xx CCL1 / C4011

V2U / V4022 V2V / V4032 V2W / V4042

VN1U / VN1V / VN1W /

V3U / V4023 V3V / V4033 V3W / V4043

VN2U / VN2V / VN2W /

C2 / C30xx CCL3 / C4012

V4U / V4024 V4V / V4034 V4W / V4044

Figure 2-4 Example of a Failure on the Negative Inverter Side

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 9/67

There are two root causes for rectifier damages:

Figure 2-5 Example of Rectifier Failure

10/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

2.4. Last Switched Vectors

The converter constantly monitors the switching of the inverter. When a

• Last two bits indicate the switching state of phase W,

Figure 2-6 Example of swithced vectors

Table 2-1 Explanation of Parameter Value of Switched Vector

Switched Vector Switched Potential

11 Plus potential is switched (+)

01 Zero potential is switched

00 Minus potential is switched (-)

10 All IGCTs are turned off

Table 2-2 Example of Switching Vectors

Parameter Parameter Value U V W

190.30 switched vector 0 01 11 11 zero + +

190.31 switched vector -1 01 11 01 zero + zero

190.32 switched vector -2 01 11 11 zero + +

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 11/67

Figure 2-7 Example of swithced vectors after software download

12/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual

ACS 1000 Service Manual 3BHS225931 ZAB E01 Rev. A 13/67

Chapter 3 - Checking IGCTs and Diodes

14/67 3BHS225931 ZAB E01 Rev. A ACS 1000 Service Manual