VARIABLE FREQUENCY DRIVE

VFD System
TRAINNING COURSE

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 TRAINNING COURSE
TABLE OF CONTENTS

CHAPTER 1
 Principles of
VFD Drives

CHAPTER 2

 D S U UNIT

CHAPTER 3

 INVERTER UNIT

CHAPTER 4

 OPTIONAL MODULE

CHAPTER 5

 CAPACITOR RFORMING

CHAPTER 6

 UNIQUE DEVICES

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

CHAPTER 1
Principles Of VFD Drive

Prepared By : TAREK HUSSIEN MOHAMED ALI VFD DRIVE SYSTEM

 Principles of VFD
Drives

In this section the AC drive is introduced and explained. It is

important to have certain knowledge of drives before
thinking about the testing methods.
AC drive or variable frequency drive is an electronic device
for controlling e.g. electric motor. AC drive has many
advantages compared to use of an AC motor when the mo-
tor needs to be controlled. Operating speed is fast and
because the process can be controlled precisely, AC drive is
more energy efficient. AC drive also enables soft start which
reduces mechanical stress.

Structure

This part explains the structure of an AC drive. The single

drive consists of two converter modules: the first one is
called rectifier which converts AC voltage to DC, and the
second one is inverter which then converts DC voltage to AC
with different frequency and amplitude.
Between the inverter and the rectifier are the DC voltage
intermediate circuits and control electronics. The next image
illustrates the AC drive structure (Fig. 1).

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Rectifier DC link Inverter

U1 U2
V1 C V2
W1 W2

Control electronics

Fig. 1 AC drive with diode rectifier and IGBT inverter

The mains are connected to terminals U1, V1 and W1 and

the motor to terminals U2, V2 and W2. This particular drive
has diode rectifier and IGBT inverter.

The voltage waveforms in different parts of an AC drive are

shown in the next image
(Fig. 2).

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Fig. 2 Voltage wave forms of the AC drive

After the rectifier, the three phase sine wave (yellow, green
and red waveforms) has turned into a pulsating DC voltage
(purple) which is filtered in the DC voltage intermediate
circuit before it is fed to an inverter unit. When using
PWM, the inverter chops the filtered DC voltage (orange)
and creates a series of voltage pulses (blue) with de- sired
frequency. The amplitude of the pulses is kept as constant
as possible but the width of the pulses is changed.
Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM
 The sinusoidal component (black) represents the cur- rent
in the motor. The impedance of the motor creates current
and also filters it to a sine wave. If demanded, it is also
possible to filter the voltage of the inverter output into a
sinusoidal form using sine filters.

The AC drives can be either single drives or multi-drives.

Single drives contain the Rectifier and one inverter module
while the multi-drives contain more than one inverter

Single drive

U1
V1 ~= = M
W1
~
Multidrive

U1
V1 ~= =
~
M
W1

=
~
M

=
~
M

Fig. 3 Difference between a single drive and a multidrive

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Multi-drives need only one common DC link for number of
inverters and motors. This simplifies the connections and
maximizes the floor space when the process requires more
than one controlled motor. It is also possible to add more
rectifiers to the multi- drive if there are a lot of inverters and
more needed power.

Rectifier

The rectifier converts AC voltage into DC voltage. The

rectifier can be made using different kinds of components,
such as diodes, thy or IGBTs. Diode rectifier (Fig. 4) is the
most common and simplest solution. It typically consists of
six or twelve diodes and it only allows the energy (E) to flow
from network to DC voltage intermediate circuit.

E
+

U1
V1
W1

Fig. 4 6-pulse diode bridge rectifier

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 A thy and IGBT rectifiers allow the energy to flow in both
directions so that the braking energy can be fed back into the
network. When using thy, two bridges are needed because
the first one is working as motoring and the second one as
regenerative bridge (Fig. 5)

U1
V1
W1

-
Fig. 5 Regenerative thyristor rectifier

When feeding energy back to the network, the current has to

be limited so that the energy in the DC link does not drop too
low. This is why the thy are needed both, in motoring and
regenerative bridges

The IGBT rectifier (Fig. 6) consists of six IGBTs and six

freewheeling diodes which protect the IGBTs and allow the
energy to flow in two directions

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 E

U1
V1
W1

Fig. 6 IGBT rectifier

A rectifier creates a pulsating DC voltage which must be

filtered before feeding it to the inverter unit. The number of
the pulses is dependent on the number of power semi-
conductors in the rectifier. A rectifier with six power
semiconductor components creates a DC wave with six
pulses per period, and a rectifier with 12 components creates
12-pulse DC voltage. The pulsating DC voltage is then filtered
and clean DC comes as a result.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 DC Voltage Intermediate
Circuit

The main purpose of the DC voltage intermediate circuit or

DC link is to operate as energy storage and to filter the
pulsating DC voltage from the rectifier. Usually the energy is
stored into a capacitor and a choke levels the pulsating DC
voltage of the rectifier. It also includes a charging circuit for
the capacitor and may include a braking chopper and a
resistor (Fig. 7).

R
Fig. 7 DC voltage intermediate circuit with braking chopper and resistor

It is important that the capacitance of the storage capacitor is

high enough so that the voltage of the intermediate circuit is kept
as constant as possible. This allows the inverter unit to operate
precisely

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Inverter

The inverter is the last module of the AC drive. The next

image illustrates the construction of the IGBT inverter (Fig.
8).

U2
V2
W2

Fig. 8 Three phase 6-pulse IGBT inverter

The IGBT inverter converts DC voltage from DC voltage

intermediate circuit into AC voltage with variable frequency and
amplitude. It can also be made of thy or other semi-conductors
but IGBTs are the most common nowadays

Inverter chops DC voltage of the intermediate circuit and creates

a series of voltage pulses which are fed to a motor

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 Control
The electric motors are controlled by using various control
methods, which must be comprehended to understand the actual
operation of the AC drives. Also different control methods are
used in different parts of the test. The next image illustrates why
and how the drives are controlled (Fig. 10).

This graph could be about the control of e.g. an elevator.

These three lines represent the speed (red), position (blue)
and torque (purple) of the elevator and time is in the X-axis.
First, the elevator must start softly and then its speed is
accelerated to a full using maximum torque all the time.
When the elevator has reached its full speed the torque can
be lowered. At the deceleration part, the torque turns
negative which slows down the elevator. As this example
shows the key measures in the drive control are torque and
speed. [10, p. 8]

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Scalar and vector controls are based on PWM, unlike the
Direct Torque Control which allows controlling the torque and
the speed directly. These methods are explained in the
following chapters. It is important to understand the
difference of various control methods because different kinds
of controls are used in different testing practices
3-1 Scalar
Control

In the scalar control or open-loop control, neither the position

nor the direction of the speed is considered. The scalar
control is used in applications such as pumps and ventilators
where exact precision is not needed. Motion sensors are not
used and the control is done by changing the voltage
amplitude and frequency. The V/f ratio is kept constant when
not exceeding the nominal speed. The image below explains
the principle of scalar control (Fig. 11).

Speed is controlled by changing the frequency reference.

Voltage and frequency reference values are fed to a
modulator. The inverter uses PWM, and based on the
modulator values it creates a series of voltage pulses. The
pulses are then fed to a motor. The impedance of the motor
creates a current and also filters it into the sinusoidal form.
The scalar control does not take motor values into account.
Only the currents of the motor are measured and considered.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Rectifier

fRef VRef Inverter

V/f
Modulator

I ia

ib

Fig. 11 Scalar control

This practice is cheap to implement since the position sensors

tend to be expensive, but the control is not precise because
the actual speed of the motor is unknown. This means that
the slip cannot be compensated and that the motor speed is
dependent on the load. The other downside is that the
modulator is needed. Use of the modulator slows down the
control.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

3-2 Vector
Control

Unlike in the scalar control, in the flux vector control also the
actual position and the speed of the motor are taken into
account. The purpose of the vector control is to control the
motor correctly at all situations. This is why the actual speed
and position of the motor are measured by using motion
sensors, so that the torque can be controlled indirectly
.

Rectifier

Ramp Flux control

Inverter
Modulator
Torque
control

PI

Motor
model
M
Identification

Fig. 12 Vector control

Flux and speed are controlled separately. The actual speed is

measured using speed sensor.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Measures such as voltage, current and frequency are produced in a
microprocessor, which also contains the mathematical model of the
motor. The microprocessor calculates the magnetic flux of the motor;
the flux and the torque are controlled separately. The measures
created by the microprocessor’s flux and torque control, are fed to
the modulator which gives commands to the inverter. The inverter
then generates the voltage pulses using PWM. The impedance of the
motor creates and filters the current.

The actual speed and motor currents are measured. The actual
speed of the motor is fed to PI controller that determines the speed
reference so that the slip is compensated.

The vector control is very precise but difficult to implement because

the motion sensors are needed. As in the scalar control, in the vector
control the modulator is needed which limits the dynamic
performance

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 3-3 Direct Torque
Control

By using Direct Torque Control or DTC instead of PWM, it is possible

to directly control the torque and speed without using motion sensors
(Fig. 13). Torque is calculated precisely in the microprocessor which
also holds the mathematical model of the motor. Since there is no
need of modulator, the DTC is much faster than scalar or vector
control methods.

The motor currents and DC voltage are measured and fed to the
motor model. The microprocessor calculates the optimal switching of
the IGBTs so that there is no un- necessary switching.

Quick torque response keeps the speed of the motor constant

despite the change in the load. DTC also provides full torque at
minimum speed.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 CHAPTER 2
DSU UNIT

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 GENERAL
This document describes how to replace the Thyristor modules, DC-fuses, boards and the fan of the
ACS800-304/704 supply unit.

ACS800-304/704 MAINTENANCE INSTRUCTION

WARNING! All electrical installation and maintenance work on the ACS 800 should
be carried out by qualified electricians.

Do not attempt any work on a powered ACS 800. After switching off the mains,
always allow the intermediate circuit capacitors 5 minutes to discharge before
working on the frequency converter, the motor or the motor cable. The voltage
between each input terminal (U1, V1, W 1) and earth must be measured with a
multimeter (impedance at least 1MΩ) to ensure that the frequency converter is
discharged before beginning work.

All insulation tests must be carried out with the ACS 800 disconnected from the
cabling.

The ACS 800 motor cable terminals are at a dangerously high voltage when input
power is applied, regardless of motor operation. No work on the motor cable should
be attemped with mains power applied.

There can be dangerous voltage inside the ACS 800 from external control circuits
when the ACS 800 input power is shut off. No work on the control cables should be
attempted when power is applied to the frequency converter or to the external
control circuits. Exercise appropiate care when working with the unit.

ESD (Electro Static Discharge) The printed circuit boards contain integrated
circuits that are extremely sensitive to electrostatic discharge. Exercise appropiate
care when working on the unit to avoid permanent damage to the circuits. Do not
touch the boards unnecessarily.

WARNING! Only qualified electrians are allowed to carry out work described in this
instruction. Before working with the ACS 800 or handling the IGBT modules, read
carefully the Safety Instruction on the ACS800 Hardware Manual. Ignoring the
safety instructions can cause injury or death.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Maintenance without opening the module
Supply module fan replacement

Changing the fan

• Read and repeat the steps in Safety Instructions.

• Open the cabinet doors.
• Loosen the screw tightening the fan frame against the module. (1)
• Disconnect the fan power cable plug. (2)
• Pull the fan out. (3)
• Install a new fan in reverce order.

Figure 1-1 Replacing DSU module cooling fan.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Opening the module

Remove the module from cabinet

WARNING! DSU modules are heavy and the centre of gravity is high. Be
careful when removing or replacing the module.

• Turn the switch-disconnector handle to open position. (1)

• Release the door handle and open the doors. (2)
• Loosen the module fastening screws and the quick connector locking screw (5 mm
hexagonal head). (3)
• Place the module pull-out ramp firmly against the cabinet base. (4)
• Pull the module carefully out of the cabinet. (5)

Figure 2-1 Opening the cabinet and removing DSU module.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Put module into horizontal position
Before opening the module it must be put into horizontal position. Be careful - the weight
of module is about 180kg. Note that modules left side must be against floor or table.

NOTE: Use a crane or other applicable lifting tool to assure personal safety.

Remove right side plate and top plate.

• Open 2pcs M6 nut for wheels. (1)

• Open 8pcs screws for handle. (2)
• Open ab. 16pcs screws for side plater and top plate. (3)
• Lift the side plate up. (4)
• Remove the top plate. (5)
1

2
3 4
5

Figure 2-2 Opening DSU module cover.

Replace the faulty components.

Figure 2-3 Opened DSU module.

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 Component locations

V11…V13 3 pcs 3AFE64607701 THY RISTOR/DIODE MODULE SKKH 210/20 E

V21…V23 3 pcs 3AFE64607701 THY RISTOR/DIODE MODULE SKKH 210/20 E
Q1 1 pcs 3AFE64607201 DISCONNECTOR OETL400KML33-2
1 pcs 3AFE10000432 AUXILIA RY CONTACT OZXK 1
K1, K2 2 pcs 3AFE64607821 CONTACTOR A300-30-11-80
L1, L2 1 pcs 3AFE64610813 AC CHOKE DCHO-7D-400
A12 1 pcs 3AFE64630199 ACCESSORY BOA RD DSAB-01C
A13 1 pcs 3AFE64637029 PLUG CONNECTOR BOA RD DSCB-01C
A43 1 pcs 3AFE64691929 POWER SUPPLY BOARD DSMB-01C
A45 1 pcs 3AFE64666606 CONTROL BOARD DSMB-02C
C11…C23 1 pcs 3AFE64705563 SNUBBER BOA RD DSSC-01C
R2 1 pcs 3AFE64674617 THERMA L SWITCH
F1, F3 2 pcs 3AFE64720066 SCREWFUSE 170M4467
2 pcs 3AFE58063690 ALARM CONTACT 170H0069
F2, F4 2 pcs 3AFE64607383 SCREWFUSE 170M4417
M1 1 pcs 3AFE64650114 COOLING FAN D2D146-AA02-22
T31…T33 1 pcs 3AFE64697811 CURRENT TRANSFORMER VM5000K DIA 0.14CU, SET 3PCS
T34…T36 1 pcs 3AFE64697811 CURRENT TRANSFORMER VM5000K DIA 0.14CU, SET 3PCS

Figure 3-1 DSU module component locations.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Replacing boards

DSAB-01C

NOTE! When updating DSAB-01C board from revision D (or older) to F (or
newer), read document 3AFE 6825 5601 “Updating Instruction”. Board
support and cable set are needed to be updated by the replace of old revision
of DSAB board.

• Undo connectors, 9 pcs.

• Open fixing screws, 13 pcs M4.
• Open fixing clips, 3pcs.
• Replace DSAB-01C board.
• Fasten M4 fixing screws to 1.5 Nm torque.
• Fasten connectors.

Figure 4-1 DSAB-01C board, cables and fixing screws.

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 DSMB-01C and/or DSMB-02C
• Undo connectors
• Remove cable ties and the screws (2 pcs M4, fastened to DC bus bar) holding the ferrite
ring.
• Remove metallic support for lower plastic board support (3 pcs screws).
• Replace DSMB-01C and/or DSMB-02C board.
• Fasten Connectors.
• Fasten ferrite ring.
• Use the orginal number of cable ties.

Figure 4-2 DSMB-01C and -02C boards, cables and board supports.

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 Replacing DC fuses

• Remove Auxiliary contacts. (1)

1
1

Figure 5-1 Auxiliary contacts of the DC fuses.

• Remove flat DC busbars. (2)

• Note! Also ferrite support screws (2 pcs) must be removed from DC minus bar.

Figure 5-2 DSU module open, removing DC busbars.

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 • Open M8 screws for DC busbars. (3)

3 3

Figure 5-3 DC busbar assembly screws.

• Remove DC busbars together with fuses

Figure 5-4 DC busbars with fuses.

• Replace fuses. Note! Ensure correct fuse orientation (see figure 5-4 above). Fixing torque
is 10 Nm.
• Reassemble module. Torque for M8 electrical contacts is 10 Nm

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 Replacing Thyristor/diode modules
NOTE! When replacing Thyristor/Diode modules to DSU modules
manufactured before week 05 year 2005, read document 3AFE 6859 0671
“Instruction of Thyristor/diode maintenance”. Thyristor/Diode module type has
changed and extra components are needed for the changing.

Accessing the Thyristor/Diode module

• Remove the DC busbars and the thermostat plate to gain access to the Thyristor/Diode
modules.
• Remove wiring.
• Remove the faulty Thyristor/Diode modules.
• Clean the contact surface of the heatsink with an appropriate solvent and a soft cloth from
excessive thermal compound and particles.

Thyristor/Diode module assembly

• Clean the contact surface and terminals of the Thyristor/Diode module. Check that the
contact surface is not damaged.
• Apply a thin and uniform layer of thermal grease (typ. thickness 50 –100 µm) to whole
contact area of the Thyristor/Diode modules with a roller or a rubber spatula. The Amount
of grease is sufficient when bright contact surface of Thyristor/Diode module is not visible
through the grease. Check visually that there are no foreign particles among the spread
grease.
• Place the module to heatsink by hand and press it about 5 sec. Repeat phases above to
every Thyristor/Diode module before the next phase.
• Place the thermostat plate according to Figure 6-1.

Figure 6-1 Assembly of thyristors and the thermostat plate.

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 • Tighten the M5 screws to a pre-torque according to Table 6-1 and in sequence 1-2-3-4
according to Figure 6-2.

2 3

4 1

Figure 6-2 Screw numbers for Thyristor/Diode module.

• Tighten the M5 screws to the final torque according to Table 6-1 in sequence 1-2-3-4
according to Figure 6-2.
• After the tightening a small rim (1 – 4 mm) of grease must be seen around the mounted
module. This shows that the amount of grease is sufficient. Wipe off the excess grease.
• Connect the DC busbars to the thyristor modules by M8 screws to 10Nm torque.

Figure 6-3 Connecting DC busbars.

• Connect gate control cables from DSMB-02C to Thyristor/Diode modules.

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 Check after the assembly

• It is important to check that the cables (6 pcs) from DSMB-02C board connectors -X111 to
-X161 are properly connected to Thyristor/Diode modules pins 4 and 5. By these wires are
the gates of the Thyristor/Diode modules controlled by DSMB-02C board.
• Ensure that the thermistor switch cable is connected to DSMB-01C connector -X173.

Table 6-1 Torque for the installation and the connection screws.

Terminal Torque
Pre-Torque Final torque
Module assembling screws
M5 (Ø 5 mm) 2.5 Nm 5.0 Nm
Main circuit terminals
M8 (Ø 8 mm) 10 Nm

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 FAULT TRACING
This chapter instructs how to interpret the fault indications of the Diode Supply Unit. The
information is valid for cabinet-installed DSU types ACS800-307 and -507, and for modules
ACS800-304 and -704 when equipped with similar auxiliary devices.

Fault diagnostics by DSSB-01C fault LEDs

LED Cause What to do

LEDs on the control board DSSB-01
FAN FAILURE The module cooling fan has over Check fan operation. The fan is rotating
heated and the thermistor switch of freely. Broken fan bearing causes noise
the fan motor has opened. This may and sticky bearing may be noticed by
be caused by jammed fan bearing or rotating the fan rotor by hand. See the
the fan has been running by full fan production week from the fan label.
speed too long. Problems have been with bearing of the
fans produced before week 42/04.
Damaged cooling fan supply cabel. Check cooling fan supply cable from
DSMB-01 board to fan motor or change
the fan.
Thermistor switch of the cooling fan Change cooling fan.
motor is defective.

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 LED Cause What to do
OVER TEMP DSU module has exceeded Check ambient temperature. Check
FAILURE temperature fault limit and thermistor cooling air flows freely and cooling fan
switch of the DSU module has operation. Check inlet and outlet
opened by module over heating. airfilters. Check heatsink for dust pick-up.
Thermistor switch of the DSMB-01C See instructions above.
board (DSU module auxiliary power
supply board) has opened by over
heating.
OVER TEMP DSU module or DSMB-01C boards Change the module thermistor or change
FAILURE thermistor switches are defective DSMB-01C board.
There is some failure in the cabeling Check the DSU module internal wiring
of the above mentioned thermistor for loose connectors or wiring failures.
switches. Measure wiring by multimeter.
EXTERNAL FAULT External swiches or auxiliary Check wiring and external switches
contacts wired to digital input (DI) 4 connected to DI4 of DSSB board.
of the DSSB-01C board are
activating the External Fault.
EARTH FAULT Earth fault supervision is active even Switch off the earth fault supervision
the supply net type is floating. from DSSB board. Earth fault supervision
works properly only in earthed supply
net.
Load unbalance due to earth Check supply cables.
(ground) fault leakage current inside Ensure the function is not set too
the DSU module or supply cable. sensitive.
Control board DSSB-01C is distorted Check earth fault settings on the board.
on some reason, but the earth fault is Change the DSSB-01C board.
not actual.
Heavy unbalance of the supply net. Measure mains.
SUPPLY MISSING LED blinks and Phase L_._ Missing LED on module cover blinks:
Main circuit AC fuse has blown. Check the DSU modules which ones are
indicating Supply Missing failure by
binking leds. Change main circuit AC
fuse. Measure also thyristor diode
modules and circuit boards of the DSU
module. Blown AC fuses are signal from
major failure.
3A cardridge fuse on DSAB-01C Check DSAB board fuses and change
board has blown. blown fuse. Measure DSMB-01C board.
Short-circuit on DSMB-01C will blow
DSAB board fuses.

Note! If fuse blown on revision J or K

DSAB board, change the whole board.
Charging resistors may be blown.
Input power terminal is loose. Check and tighten input power terminals.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 LED Cause What to do
SUPPLY MISSING LED blinks but no Phase L_._ Missing LED on module cover blinks:
Auxiliary circuit AC fuse of Diode Change blown auxiliary circuit AC fuse.
supply Unit has blown.
Main circuit AC fuse of brances L1.1, Change blown main circuit AC fuse.
L2.1 or L3.1 of the first DSU module
has blown.
Input power terminal is loose. Check and tighten input power terminals.

LED on:
DSU overload. Constantly lighted Check load. Are all palallel-connected
LED is indicating that overload supply modules in place? Is the
supervision of the DSU has tripped. aircirculation cover plate (code:
(New function on revision K and 68395721) used if DSU module
newer DSSB boards). removed? Decrease load or replace
missing module.
Faulty DSSB board. Change faulty DSSB board.
DC FUSE DC Fuse(s) blown. Change DSU module DC fuses. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown DC
fuses are signal from major failure.
DC fuse auxiliary contact wiring is Check DC fuse auxiliary contacts and
faulty. DC fuse auxiliary contact is wiring between DSAB board and
faulty or loose. auxiliary contacts.
Connector -X411 or -X412 loose or Check DSAB board connectors.
uncoupled on DSAB board.
EMERGENCY STOP / Appears immediately after connecting supply:
OTHER FAULT
Emergency stop circuit is open, or Release emergency stop button. Check
nor connected correctly. connections of emergency stop circuit.
Loose connectors -X4 or -X8 on Check connectors -X4 and -X8 are
DSSB board. properly fastened.
4A fuse blown on DSSB board and + Measure +/-24VDC from DSSB board
or -24VDC is missing from connectors -X4 and -X8. Change the 4A
emergency stop circuit. circuit board fuses F1 and F2 of DSSB
board.
Short-circuit on DSSB board If the fuses are blown again after
emergency stop circuit (rev. F and changing for new ones, change the
older boards). DSSB board. Rev. F DSSB (and older)
boards diodes may be blown to short-
circuit.
DSMB-01 board is defective and is Change DSMB-01C board.
not supplying -24V auxiliary voltage.
Defective flat ribbon cable between Check flat ribbon cable X500
DSSB board and DSU modules.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 LED Cause What to do
EMERGENCY STOP / Appears after trying to charge the DC voltage
OTHER FAULT (START command given for DSU and after 5 seconds DSU trips):
2A fuse blown on DSMB-02 board. Change 2A fuses to DSMB-02 board.
DC voltage supply connector -X104 Check connector -X104 is properly
loose on DSMB-02 board. fasten to DSMB-02C board.
+16V auxiliary supply voltage cable Check connector -X192 from DSMB-01C
loose between DSMB-01C and -02C and -X102 from DSMB-02C board.
boards.
Charging control signal cable is not Check connector -X193 from DSMB-01C
connected between DSMB-01C and and -X103 from DSMB-02C board.
-02C boards.
Loose or defective flat ribbon cable Check flat ribbon cable between DSMB-
between DSMB-01C and DSCB-01C 01C and DSCB-01C boards. Also check
boards. the flat ribbon cable connectors -X302
from DSCB and -X100 from DSMB-01C
boards. Change flat ribbon cable if
needed.
DSAB-01C board do not close the Check DSAB board connectors -X402
main contactors K1 and K2. and -X404 for main contactor supply.
Replace DSAB board if main contactors
cannot be closed.
Auxiliary contact of the main Check the auxiliary contacts of the main
contactor K1 or K2 is not working or contactors K1 & K2. The function of the
loose. auxiliary contacts may be tested by
manually pressing the main contactors
closed and the auxiliary contacts should
be short-circuited (ohmic measured).
Defective DSCB-01 connector board. Change DSCB-01C board.
Supply net is too weak for charging If the operation of the DSU unit is tested
the DC voltage. DSU takes and the supply net is too weak to give
remarkable charging current for the charging current for DSU, must the
charging the intermediate circuit INU modules be removed or
capacitors of INU modules. Supply disconnected.
net must be rated for the DSU unit.
OVER TEMP Cooling fan rotates at maximum Check ambient temperature.
WARNING speed and the DSU module has Check cooling air flows freely.
exceeded temperature warning limit.
Check cooling fan operation.
Check inlet and outlet airfilters.
Check heatsink for dust pick-up.
Check load. Are all palallel-connected
supply modules in place? Is the air
circulation blocking plate used if supply
module is removed? Reduce load or
replace missing module.
NTC resistor resistace of the cooling Replace the DSU module NTC-resistor
fan is too low ohmic and this drives that is connected to connector X173 of
the cooling fan to full speed (even the DSMB-01 board.
the DSU module is cold).

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 LED Cause What to do
READY Off: Input terminals are not live and Close switch-disconnectors and check
module switch-disconnectors are that the cooling fan starts to rotate. If the
switched off. Or DSMB-01C board is cooling fan is not rotating even the
not supplying the auxiliary voltage. supply voltage is switched is the DSMB-
01C board damaged or input fuses
blown.
Blinking: DSU module contactor is Contactors off: Close contactors by
off or DSU is charging intermediate giving start command for DSU.
circuit (charging mode). Input Contactors on: Wait until DSU has
terminals are live and module switch- charged intermediate circuit (i.e LED
disconnectors are switched on. illuminates steadily) and start to load the
unit.
Fast blinking: DSU has changed -
from diode mode to charging mode
because intermediate circuit voltage
has dropped more than 30% from the
actual voltage level. If the
intermediate voltage drops below
400VDC turns the DSU to off/ride
through function.
On: DSU is in operation (diode Load/control DSU.
mode) and can be loaded; Input
terminals are live, module switch-
disconnectors and contactors are on,
intermediate circuit capacitors have
been charged.

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Fault diagnostics by DSU module fault LEDs

LED Cause What to do

LEDs on the DSU module (on DSAB board)
DC FUSE FAILURE DC Fuse(s) blown. Change DSU module DC fuses. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown DC
fuses are signal from major failure.
DC fuse auxiliary contact wiring is Check DC fuse auxiliary contacts and
faulty. DC fuse auxiliary contact is wiring between DSAB board and
faulty or loose. auxiliary contacts.
Connector -X411 or -X412 loose or Check DSAB board connectors.
uncoupled on DSAB board.
FAN FAILURE The module cooling fan has over Check fan operation. The fan is rotating
heated and the thermistor switch of freely. Broken fan bearing causes noise
the fan motor has opened. This may and sticky bearing may be noticed by
be caused by jammed fan bearing or rotating the fan rotor by hand. See the
the fan has been running by full fan production week from the fan label.
speed too long. Problems have been with bearing of the
fans produced before week 42/04.
Damaged cooling fan supply cabel. Check cooling fan supply cable from
DSMB-01 board to fan motor or change
the fan.
Thermistor switch of the cooling fan Change cooling fan.
motor is defective.
OVER TEMP DSU module has exceeded Check ambient temperature. Check
FAILURE temperature fault limit. Thermistor cooling air flows freely. Check cooling
switch of the DSU module has fan operation. Check inlet and outlet
opened by module over heating. airfilters. Check heatsink for dust pick-up.
Thermistor switch of the DSMB-01C See instructions above.
board (DSU module auxiliary power
supply board) has opened by over
heating.
DSU module or DSMB-01C boards Change the DSU module thermistor or
thermistor switches are defective change DSMB-01C board.
Damaged wiring of the DSU module Check the DSU module internal wiring
or DSMB-01C boards thermistor for loose connectors or wiring failures.
switches. Measure wiring by multimeter. When the
thermistor switch is cold should the
short-circuit be measured from the switch
pins.

Prepared By Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 LED Cause What to do
PHASE L_._ MISSING Main circuit AC fuse has blown. Change main circuit AC fuse. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown AC
fuses are signal from major failure.
3A cardridge fuse on DSAB-01C Check DSAB board fuses and change
board has blown. blown fuse. Measure DSMB-01C board.
Short-circuit on DSMB-01C will blow
DSAB board fuses.

Note! If fuse blown on revision J or K

DSAB board, change the whole board.
Charging resistors may be blown.
Input power terminal is loose. Check and tighten input power terminals.
FAN FULL SPEED By the switch on of mains Fan Full This is not a fault. Revision K and newer
Speed LED is lighted and cooling fan DSSB boards are forcing the cooling fan
rotates at maximum speed for about to maximum speed when the supply
5 seconds. voltage is switched on. After 5 seconds
the fan returns to normal speed.
Cooling fan rotates constantly at See Over Temp Warning below.
maximum speed and the DSU
module is overheating.
NTC resistor (that controls cooling Check NTC-resistor wires and coupling.
fan rotating speed) resistace is too Change the NTC-resistor.
low ohmic and this forces the cooling
fan to full speed (even the DSU
module is cold).
OVER TEMP Cooling fan rotates at maximum Check ambient temperature.
WARNING speed and the DSU module has Check cooling air flows freely.
exceeded temperature warning limit.
Check cooling fan operation.
Check inlet and outlet airfilters.
Check heatsink for dust pick-up.
Check load. Are all palallel-connected
supply modules in place? Is the air
circulation blocking plate used if supply
module is removed? Reduce load or
replace missing module.
NTC resistor resistace of the cooling Replace the DSU module NTC-resistor
fan is too low ohmic and this drives that is connected to connector X173 of
the cooling fan to full speed (even the DSMB-01 board.
the DSU module is cold).

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 LED Cause What to do
POWER Off: Input terminals are not live and Close switch-disconnectors and check
module switch-disconnectors are that the cooling fan starts to rotate. If the
switched off. Or DSMB-01C board is cooling fan is not rotating even the
not supplying the auxiliary voltage. supply voltage is switched is the DSMB-
01C board damaged or input fuses
blown.
Blinking: DSU module contactor is Contactors off: Close contactors by
off or DSU is charging intermediate giving start command for DSU.
circuit (charging mode). Input Contactors on: Wait until DSU has
terminals are live and module switch- charged intermediate circuit (i.e LED
disconnectors are switched on. illuminates steadily) and start to load the
unit.
On: DSU is in operation (diode Load/control DSU.
mode) and can be loaded; Input
terminals are live, module switch-
disconnectors and contactors are on,
intermediate circuit capacitors have
been charged.

Other indication of fault

Indication Cause What to do
DSSB panel display +/- 24VDC auxiliary voltage is Ckeck that flat ribbon cable connector
and LEDs are dark missing. X500 is properly fastened.
Check DSU modules, are the cooling
fans rotating and power LEDs lighted?
Auxiliary power supply board DSMB-01C
is most propably broken if the fan is not
rotating and power LED not lighted.
Change DSMB-01C board.

If DSMB-01C board has short-circuited

check also DSAB-01C board 3A fuses
and charging resistors.
DSSB board software has jammed. Switch supply voltage off for about 5
minutes and restart the DSU unit. If this
do not help, change the DSSB board.
DSSB boards processor is not Change DSSB board.
working or some other fault on board.
DSSB panel display DSSB board software has jammed or Change DSSB board.
and / or all LEDs are processor has broken.
continuosly lighted
Displayed AC DSSB displays much higher phase Ckeck and measure that DSU module
currents are not currents than the actual currents are. current transformers are properly wired.
correct on DSSB Current transformer(s) is faulty on Change faulty current transformer (code
panel DSU module. 64697811).

If DSU unit contains more than one DSU

module, test the modules assembling
one by one to DSU unit. Charge
intermediate voltage and load the DSU
module. Faulty module will be detected

Prepared By: Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 by displayed phase currents of DSSB.

DSU module cooling Broken DSMB-01C board. Change DSMB-01C board.

fan is not rotating Jammed fan bearing. Change cooling fan.
Fan inverter of DSMB-01C in failure Try to restart DSU by switching mains
state (only revision G and older supply OFF and after few seconds ON.
DSMB-01C boards).
Change DSMB-01C board.

Table 7-2 Measurements in the reverse direction of the rectifier diodes of DSMB-02C board

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Measuring the rectifier diodes of DSMB-02C board
The measurement is done with millimeter in the diode position.

• The measurement is done between diodes anode(+) and cathode(-) and

measured from circuit board connector pins, see Figure 7-1 on next page.
• Diodes are coupled in series on the circuit board and because the measurement is
done via connector pins are two or three diodes measured simultaneously, as
Figure 7-1 shows.
• When the measurement with the millimeter displays infinite (OL Over Limit) in one
direction and the forward voltage of diode (e.g. 500 mV) in the opposite direction the
junction is OK. Note that the values shown by the millimeter depends on its brand
and type. Different millimeters with different output voltages show different forward
voltages when measuring semiconductor components.
• If the millimeter indicates a short-circuit, the diode in question is faulty and the
board must be replaced.
• If the forward voltage of some of the diodes is different from the others, the diode is
most probably broken.
• Tolerance of the measurements is about 0.2V.

Note: If 2A cardridge fuses of DSMB-02C board are blown, must the measurement
done from fuse holders.

Table 7-1 Measurements in the forward direction of the rectifier diodes of DSMB-02C board

+ probe - probe Display

-X104: 3 (DC+) -X101: 1 (AUX+) ≈ 1.1 V
-X101: 5 (AUX-) -X104: 1 (DC-) ≈ 1.1 V
DSMB-02C connector

-X101: 5 (AUX-) -X150: 1 (Phase U1 ) ≈ 1.1 V

-X101: 5 (AUX-) -X150: 3 (Phase V1) ≈ 1.1 V
-X101: 5 (AUX-) -X130: 1 (Phase W1 ) ≈ 1.1 V
-X101: 5 (AUX-) -X130: 3 (Phase U2) ≈ 1.1 V
-X101: 5 (AUX-) -X110: 1 (Phase V2 ) ≈ 1.1 V
-X101: 5 (AUX-) -X110: 3 (Phase W2) ≈ 1.1 V

-X150: 1 (Phase U1 ) -X101: 1 (AUX+) ≈ 1.6 V

-X150: 3 (Phase V1) -X101: 1 (AUX+) ≈ 1.6 V
-X130: 1 (Phase W1 ) -X101: 1 (AUX+) ≈ 1.6 V
-X130: 3 (Phase U2) -X101: 1 (AUX+) ≈ 1.6 V
-X110: 1 (Phase V2 ) -X101: 1 (AUX+) ≈ 1.6 V
-X110: 3 (Phase W2) -X101: 1 (AUX+) ≈ 1.6 V

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 + probe - probe Display
-X101: 1 (AUX+) -X104: 3 (DC+) OL
-X104: 1 (DC-) -X101: 5 (AUX-) OL

DSMB-02C connector
-X150: 1 (Phase U1 ) -X101: 5 (AUX-) OL
-X150: 3 (Phase V1) -X101: 5 (AUX-) OL
-X130: 1 (Phase W1 ) -X101: 5 (AUX-) OL
-X130: 3 (Phase U2) -X101: 5 (AUX-) OL
-X110: 1 (Phase V2 ) -X101: 5 (AUX-) OL
-X110: 3 (Phase W2) -X101: 5 (AUX-) OL

-X101: 1 (AUX+) -X150: 1 (Phase U1 ) OL

-X101: 1 (AUX+) -X150: 3 (Phase V1) OL
-X101: 1 (AUX+) -X130: 1 (Phase W1 ) OL
-X101: 1 (AUX+) -X130: 3 (Phase U2) OL
-X101: 1 (AUX+) -X110: 1 (Phase V2 ) OL
-X101: 1 (AUX+) -X110: 3 (Phase W2) OL

Figure 7-1 Simplified circuit diagram of the rectifier diodes of DSMB-02C board

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Measuring of a Thy/Diode module
The following action should be done and results verified before the measurement of the
Thy/Diode module is started:

• Before starting any individual Thy/Diode module measurement described below the broken
component can be located by measuring between the (+) bus bar and input phases and
similarly (-) bus bar and input phases if an input phase is short-circuited.
• Check Thyristor/Diode modules also visually. Sometimes the case of the Thyristor/Diode
module may be broken or burned by for example an arc caused by a short-circuit inside the
Thy/Diode module.
• The Thy/Diode modules can be measured when they are still mounted on the heat sink,
if the DC busbars are removed on top of them.
• Undo also Thyristor cate control cables (between Thyristors and DSMB-02C board).
• When the measurement with the multimeter displays infinite (OL Over Limit) in one
direction and the forvard voltage of diode (e.g. 380 mV) in the opposite direction the
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 forfard voltages
when measuring semiconductor components.
• If the multimeter indicates a short-circuit, the Thyristor or Diode in question is faulty and the
Thyristor/Diode module must be replaced.
• If the forward voltage of some of the diodes is different from the others, the diode is most
propably broken.

The names of the terminals of the Thyristor/Diode module are presented in Table 7-3.

The measurement is done with multimeter in the diode position.

Table 7-3 Terminal names of the Thyristor/Diode module

Terminal Name
1 Thyristor anode / Diode catode
2, 4 Thyristor catode
3 Diode anode
5 Thyristor gate

Figure 7-2 Terminals of the Thyristor/Diode module

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

 Figure 7-3 Circuit diagram of the Thyristor/Diode module

Table 7-4 Measurements in the A-C direction

+ probe - probe Display

1 2 OL
Thyristor/Diode
1 5 OL
module terminal
3 1 ≈ 0.38 V

Table 7-5 Measurements in the C-A direction

+ probe - probe Display

1 3 OL
Thyristor/Diode 2 1 OL
module terminal 5 1 OL
2 5 OL

Measure also the gate resistance of each Thysristor. Measurement is done in the resistance
mode between Thyristor gate and catode.

Table 7-6 Thyristor gate resistance measurement

+ probe - probe Display

Thyristor/Diode
module terminal 5 2 ≈ 20 Ohm

Prepared By : Eng. Mohamed Shoeib VFD DRIVE SYSTEM

Measuring of the charging resistors of DSAB-01C board
The measurement is done with multimeter in the resistance position.

• Revision F and newer DSAB boards have charging resistors. The charging resistors have to be
measured in auxiliary power supply board DSMB-01C failure or short-circuit.
• The charging resistors of the DSAB-01C board can be measured when the board is still
mounted on the DSU module.
• Undo DSAB cable connectors X401A and X401B.
• Measure the 3A cardridge fuses of DSAB board. If the fuses are ok, measure the charging
resistors according the Table 7-7. If the fuse(s) is blown, measure the resistace through the upper
fuse holder (not from connectors X404A…F).
• Correct resistance measured between board connector pins is 7 ± 0.5 ohm.
• If the multimeter indicates OL or higher resistance than 8 ohm, the charging resistor(s) in
question is faulty and the DSAB board must be replaced.

The names of the DSAB-01C board terminals are presented in Table 7-7 and in Figure 7-4.

Table 7-7 DSAB-01C board charging resistor measurements

+ probe - probe Display

X401A: 1 X404A 7
X401A: 3 X404B 7
DSAB-01C board X401A: 5 X404C 7
connector X401B: 1 X404D 7
X401B: 3 X404E 7
X401B: 5 X404F 7

Figure 7-4 DSAB-01C charging resistor circuit.

CHAPTER 3
INVERTER UNIT
GENERAL
This document shows christmas tree for the ACS800-104 and describes how to replace the IGBT
modules and the fan of the ACS800-104 drive.

ACS800-104 MAINTENANCE INSTRUCTION

WARNING! All electrical installation and maintenance work on the ACS 800 should
be carried out by qualified electricians.

Do not attemp any work on a powered ACS 800. After switching off the mains,
always allow the intermediate circuit capacitors 5 minutes to discharge before
working on the frequency converter, the motor or the motor cable. The voltage
between each input terminal (U1, V1, W 1) and earth must be measured with a
millimeter (impedance at least 1M) to ensure that the frequency converter is
discharged before beginning work.

All insulation tests must be carried out with the ACS 800 disconnected from the
cabling.

The ACS 800 motor cable terminals are at a dangerously high voltage when input
power is applied, regardless of motor operation. No work on the motor cable should
be attemped with mains power applied.

There can be dangerous voltage inside the ACS 800 from external control circuits
when the ACS 800 input power is shut off. No work on the control cables should be
attempted when power is applied to the frequency converter or to the external
control circuits. Exercise appropiate care when working with the unit.

ESD (Electro Static Discharge) The printed circuit boards contain integrated
circuits that are extremely sensitive to electrostatic discharge. Exercise appropiate
care when working on the unit to avoid permanent damage to the circuits. Do not
touch the boards unnecessarily.

WARNING! Only qualified electrians are allowed to carry out work described in this
instruction. Before working with the ACS 800 or handling the IGBT modules, read
carefully the Safety Instruction on the ACS800 Hardware Manual. Ignoring the safety
instructions can cause injury or death.
 Figure 1. ACS800-104 module

Table 1. Parts list

Table 2. Designations
DESIGNATION NAME TYPE FINNISH NAME
Y41 Fan D2D160-BE02-11 Puhallin
C211 - 233 Capacitor 500V MKP C4BSPBx4120ZA0J Kondensaattori 500V
Capacitor 690V MKP C4BSW Bx3470ZA0J Kondensaattori 690V
A21 - A23 Gatedriver Board 500V AGDR-62C Hilapiirikortti 500V
Gatedriver Board 690V AGDR-61C Hilapiirikortti 690
V21 - V23 IGBT-module 500V FS450R17KE3 IGBT-moduuli 500V
IGBT-module 690V FS300R12KE3 IGBT-moduuli 690V
A42 Main Circuit Interface Board AINT-01C Pääpiiriliityntä
A43 Power Supply Card APOW -01C Teholähdekortti
A431 Gatedriver Power Supply Board AGPS-21C Hilaohj. Tehol. 24V
R21 - R23 Power Resistor 500V VHP-5 2x4K7 Tehovastus 500V
Power Resistor 690V VHP-6 3x8K Tehovastus 690V
C251 - C267 Electrolytic Capacitor 500V B43586-S9418-Q1 El. Kondens. 500V
C251 - C276 Electrolytic Capacitor 690V B43586-S3468-Q1 El. Kondens. 690V
C200 Film Capacitor 500V UL9-20832K Filmi Kondes. 500V
Film Capacitor 690V UL9-20833K Filmi Kondes. 690V
R321 - R323 Output Filtering Resistor UXP 600 Lähtosuotovastus
Z1 Output Filtering Inductor 500V AOFI-51 Lähtös.kuristin 500V
Output Filtering Inductor 690V AOFI-61 Lähtös.kuristin 500V

Figure 2.
Figure 3.

Figure 4.
1. INVERTER MODULE FAN REPLACEMENT
1. Open the inverter cubicle doors.
2. Disconnect the fan wiring plug (1).
3. Remove the locking screws (2).
4. Pull the fan out along its sliding trails (3).
5. Install a new fan in reverse order.

Figure 5. Replacing the fan

2. ASSEMBLING OF THE ACS800–104 MODULE (STEP BY
STEP PROCEDURE)
On the left side of the module, open eight screws to remove cover. The Cover is fastened with 4×8 screws
and tightening torque is 2,4Nm. Under the cover is mounting plate for the APOW and AINT.

Picture 1. Mounting plate for Power Supply Card and Main Circuit Interface Board. Below the
mounting plate is INU for fan. Mounting plate is fastened with four 4x16 Torx screws and Serpress M4 nut.
Picture 2. Disconnect the wire from AINT-12C connector X7 and pull it away from
under the board. Also disconnect cables coming from the AGPS boards.

Picture 3. Disconnect the DC wires from the NRED-61 thick-film hybrid

Picture 4. Release cables from their holders under the mounting plate.

Picture 5. After disconnecting mounting plate, cables from AGDR boards are hanging loose.
Picture 6. Remove the capacitors and busbars connected to faulty IGBT module. They are fastened to
modules with 6×12 Combi-Torx screws.

If necessary, remove incoming cables from busbars. Cables are fastened with 8×25 screws and M8 nut.
Under the nut are two washers. Tightening torque is 16Nm.

Remove the faulty IGBT module and clean the heat sink surface with an appropriate solvent (e.g. Grafol) and
a soft cloth from excess thermal compound and particles. IGBT module is fastened to heatsink with M5×20
Combi-Torx screws. Also check inside of the inverter module for foreign objects.

W hen placing a new IGBT module, follow the instructions written in chapter three (Installation of Econopack+
in ACS800 inverters) of this maintenance instruction.

Install the rest of the components in reverse order to the above.

3. INSTALLATION OF ECONOPACK+ IN
ACS800 INVERTERS
1. Clean the contact surface of heatsink.

2. Clean the contact surface and the terminals of IGBT-module.

Check that the contact surface is not damaged.

3. Apply a thin and uniform layer of thermal grease (typ. thickness 50 –

100 m) to whole contact area of IGBT-module with a roller or a rubber
spatula. Amount of grease is sufficient when bright contact surface of
IGBT-module is not visible through the grease. Check visually that
there are no foreign particles among the spread grease.

4. Place a module to heatsink by hand and press it about 5 sec.

Repeat phases 1 - 4 to every IGBT-module before the next phase.

5. All the M5 screws must be tightened uniformly to specified

mounting torque. For a good thermal contact to the heatsink we
recommend the following procedure of tightening the 8 screws:

 Tighten module to heatsink with M5 screws to a pretightening torque

(0,5 Nm) in the following sequence:
screw no. 2 – 6 – 3 – 7 – 4 – 8 – 1 – 5. (Figure 1)

 Tighten screws to final tightening torque (3 - 6 Nm) in the same

sequence:
2 – 6 – 3 – 7 – 4 – 8 – 1 – 5.

Figure 6. The screwing sequence and sizes.

After the tightening a small rim (1 – 4 mm) of grease must be seen around the mounted module. This shows that amount of grease is sufficient.
Extra grease is wiped away.

1 - 4 mm

Figure 7. A rim of grease around the module.

8. Busbars are connected to power terminals of IGBT-module with M6 screws. Tightening torque is 3 Nm.

Table 3. Codes and tightening torques of the modules

MRP- Name Connection of the module Connection of the

code pre- / final torque (Nm) power terminal (Nm)
64571214 FS225R12KE3 0,5 / 3 – 6 3
64571231 FS300R12KE3 0,5 / 3 – 6 3
64571249 FS450R12KE3 0,5 / 3 – 6 3
64571265 FS225R17KE3 0,5 / 3 – 6 3
64571273 FS300R17KE3 0,5 / 3 – 6 3
64571281 FS450R17KE3 0,5 / 3 – 6 3
CHAPTER 4
HARDWARE OPTION
„ Braking choppers and „ EMC solutions
resistors „ 1st Environment,
„ Motor thermal protection restricted

„ Pt100 or thermistor „ 2nd environment,

relay unrestricted

„ Control panel CDP312R „ Filtering solutions

and its mounting „ dU/dt filters & limitation
platform „ Common mode filters
„ Different mounting „ Prevention of unexpected
variants and output start-up
busbar variants
(ACS800-04 & -04M)

ABB
ACS800-04 controller connections

„ The R7 & R8 ACS800-04(M)

uses the RDCU controller
„ Contains an ACS800 RMIO-02
control PCB

„ Keypad connector for

CDP312R, X39
„ 24V power in (twisted pair), X34
„ Fieldbus and I/O, Option
module slots
„ DDCS option fitted (RDCO)
„ Optical connections to
Inverter, V57 (Tx), V68 (Rx)

„ Standard I/O
ABB
ACS800-04 – RDCU-02 Option connections

„ Slot 1
„ RDIO, RAIO, RTAC, Fieldbus.
Slot 1 „ Slot 2
„ RDIO, RAIO, RTAC
Slot 2
„ Slot 3, RDCO (DDCS ports).
Slot 3 „ CH0 - Fieldbus modules
3 2 1 0 „ Nxxx modules
„ CH1 - add motherboard AIMA,
and use RDIO, RAIO, RTAC
OR* - use NDIO, NAIO, NTAC
„ CH2 - Master follower, NTAC

„ CH3 - PC connection for

DriveAP and Drive Windows.
* Remember to use the correct RDCO version (-01, -02, -03)
ABB
ABB industrial drive, ACS800 Control part (RDCU)
„ In ACS800-01
not in use as
functionality is
integrated to the
module
„ In others
external - can be
located in the
optimal place in the
cabinet
„ I/O terminals
I/O extensions, Field Bus Optic links (standard and optional)
pulse encoder Adapters (DDCS) „
& Modbus (SLOT1) DDCS adapter with 4 Slot for
(either for SLOT1 channels
or SLOT2 ) •PC connection
fieldbus
- •Master/Follower modules
•„Old‟ options
„ Mounted
to DIN-rail
 Connectivity
Control Panel External power supply
CDP312R
modbus 24VDC
19,2 kbit/s

Slot 1
• Digital I/O Extension (RDIO)
• Analogue I/O Extension (RAIO)
Reference voltage
(±10V max 10mA) • Pulse Encoder Interface (RTAC)
2 Analog inputs • Fieldbus Interface
2 Analog outputs
Slot 2
• Digital I/O Extension (RDIO)
7 Digital inputs • Analogue I/O Extension (RAIO)
• Pulse Encoder Interface (RTAC)

Slot 3
• DDCS Link (RDCO-0x)
3 Digital outputs

PPCS Connection to drive module

8 Mbit/s
when n x R8i true APBU44

DDCS Connection to Application

DDCS 4 Mbit/s
PC-Tool 1 Mbit/s Controller
DriveWindow eg. AC80 or AC800M
DDCS
4 Mbit/s
 800-07 with ACS 800-04
ACS 800-07 T ACS 800-04 ~230
T 1.
CDP +24V FAN
ADPI 312R 2.

RMIO AIMA Option

APOW AIBP 3.

+24V
Option Option
AINP 4.
modules modules

Option
AINT
Option
modules modules 5.

RDCO option
Option
modules AGDR 6.
Ch 1

Ch 0
Ch 2
Ch 3

7.

V
1. Fan transformer W
U + -
2. Chokes
3. Filtering & Protection devices
4. Rectifier M
Pulse encoder,
External 5. DC Capacitors
Fieldbus,
option 6. Inverter
Extended I/O 7. Current transducers
modules
ACS 800 Boards ACS 800-07 with DSU
ACS 800-07
DSSB DSU T
CDP MMI 2.
ADPI 312R
3~
3. Drive unit
T FAN
RMIO +24V
AIMA Option 4.

Option Option
modules modules DSAB

Option Option APOW

modules modules DSCB 5.

RDCO option DSMB-02

Option AINT
modules DSMB-01 AGDR 6.
Ch 3

Ch 2

Ch 1

Ch 0

FAN 7.

V
T. Transformer W
U
2. Chokes
3. Filtering & Protection devices
4. Rectifier (1 or 2 pc.) M
Pulse encoder,
External 5. DC Capacitors
Fieldbus,
option 6. Inverter
Extended I/O 7. Current transducers
modules
 ACS 800 Control and I/O board RMIO

ACS 800

ACS600 - 6, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Control and I/O board RMIO

ACS600 - 6, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Control and I/O board RMIO

+24V

STOP
GND

GND1
GND2

+24V
+24V

+VREF

-VREF
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1

GND
AO2-
AO2+
AO1-
AO1+
AI3-
AI3+
AI2-
AI2+
AI1-
AI1+
GND
X 27 X 26 X 25
3 2 1 3 2 1 3 2 1
2 1 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 2 1

X 22
X23

X20
X21
Digital Inputs AD / DA Interface

Relays

Fault
LED Red
Power OK
LED Green
AD & DA
RAM & FLASH
Conversion

Connector(X29)
Panel Board
CH0TD
DDCS-Option Board (X33)

T R AN S
CH0LC + 5 V

Ad-On-Cards Interface
38-pin Connectors X31 and X32
GND
CH0RD G N D
B-
+ 5 V
CH1TD A+G
G N D
CH1LC N D
A 0 -A 9
CH1RD
Motor Control
ASIC
DSP56303 +24V
D 0 -D 7
/B u sy
CH2TD /IR Q
CH2LC /R D
CH2RD /W R
CH3TD /C S
CH3LC Power /R E S E T

CH3RD 15/5/AGND/-15 + 2 4 V
+5V 24/GNDDI2 G N D
GND 5/3,3/DGND
Motor Control Signal Power Connector
Connector (X30) (X24)

PPCC TD +5 V + 24V
PPCC RD GND
GND
CHGND

ACS600 - 6, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Main Circuit Board RINT 5211
Power Supply

DC-capacitors
Clamping capacitor

RASI-board
Diode bridge snubber - A/D
capacitor - PPCC-asic
- earth fault
detection

Capacitors to
minimise
radiated Current measurement
emissions scaling by converter type
(soldered slots)
Optical isolators for
DC-link gate drivers
Output phases
(Braking resistor output)
Gate driver
transformers
Current transducers

ACS600 - 7, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Main Circuit Board RINT 5211

R- Gate Gate G ate IG BT tem p.

Bu sbars on PCB Driver Driver D rive r m easurem ent
UD C+ / R+
DC-
BR
UDC + IGBT MODULE U2 Current
UDC+ Power modul es (IGBT, in put, Brake)
m easurem ent U2
soldered during manufactu ring
Cha rging R-
D C-choke circuit Prev ent at ion of
E M C-filter +15V Gate
conn ection +5V unex pected +15V (Integrated
Power Drive rs Curre nt
Input UDC - start up to GDR Powerin g braking ch opper V2 V2
supply -1 5V IGBT) measurem ent
bridge
Inpu t
bridg e
DC +24V
GND
protection bank W2
Current W2
UDC- measurem ent
DC-vo ltage DC-vo ltage Fan
control
+24V
Fan
G ND
Gate Brak ing Chopper Voltag e
Charging drivers FAN Fan / IP54 Gate Gate Gate
Gate Driver & Divisions Current Measurem ent
E arth Faulth control disablin g control Drive r D rive r Driver Scalin g
Gate con trol (Brakin g) Protectio n
RA SI-x1 G ate con tro l
PPCC2 Asic G ate con tr ol
G ate con tro l
32 MHz oscillato r
T o / From G ate con tr ol
A/D con verter
control board G ate con tro l
E art Faulth Level Settin g Gate con tr ol

IGBT saturatio n logic UDC

Power supply su per vising UU1
UV1
220V & 500V: V oltage level sh iftin g for ADC UW1
Flat cable with 4
220V/500V : UBra ke
signal lines an d
+5V in heat sink Optoco uplers,
IGBT Tem p.
p otential conn ector TEM P
IU2
690V: 690V: IV2
Optical cable pair O ptical
IW 2
tranmitter& recei ver
Saf e Isola tion

ACS600 - 8, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Control and I/O board RMIO

+24V

STOP
GND

GND1
GND2

+24V
+24V

+VREF

-VREF
DI 6
DI 5
DI 4
DI 3
DI 2
DI 1

GND
AO2-
AO2+
AO1-
AO1+
AI3-
AI3+
AI2-
AI2+
AI1-
AI1+
GND
X 27 X 26 X 25
3 2 1 3 2 1 3 2 1
2 1 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 2 1

X23

X 22

X20
X21
Digital Inputs AD / DA Interface

Relays

Fault
LED Red
Power OK
LED Green
AD & DA
RAM & FLASH
Conversion

Connector(X29)
Panel Board
CH0TD
DDCS-Option Board (X33)

T R AN S
CH0LC + 5 V

Ad-On-Cards Interface
38-pin Connectors X31 and X32
GND
G N D
CH0RD B-
+ 5 V
CH1TD A+G
G N D
CH1LC N D
A 0 -A 9
CH1RD
Motor Control
ASIC
DSP56303 +24V
D 0 -D 7
/B u sy
CH2TD /IR Q
CH2LC /R D
CH2RD /W R
CH3TD /C S
CH3LC Power /R E S E T

CH3RD 15/5/AGND/-15 + 2 4 V
+5V 24/GNDDI2 G N D
GND 5/3,3/DGND
Motor Control Signal Power Connector
Connector (X30) (X24)

PPCC TD +5 V + 24V
PPCC RD GND
GND
RDCO-Board CHGND

ACS600 - 9, rev. 1 Copyright © ABB Industry Oy

 ACS 800 RFI-filter board RRFC-5211

Overvoltage protection
Input terminals
ground

Overvoltage protection

Filter ground

Common mode
chokes

Filter capacitors

ACS600 - 10, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Control and I/O board RMIO

DDCS adapter with 4 channels

DDCS adapter connector

ACS600 - 11, rev. 1 Copyright © ABB Industry Oy

 ACS 800 RFI-filter board RRFC-5211

Chokes

Input Terminals

Input Capacitors

Filter resistors and Overvoltage Varistors

Capacitors

Screws for filter ground connection have to Screw for varistor

be removed when board used with floated ground
network connection

ACS600 - 12, rev. 1 Copyright © ABB Industry Oy

 ACS 800 Panel CDP-312R

Oscillator

Chip-on-glass LCD display

RS-485 Connector

Heat seal

Keyboard connector

ACS600 - 13, rev. 1 Copyright © ABB Industry Oy

 ACS 800 RVAR

ACS600 - 14, rev. 1 Copyright © ABB Industry Oy

 ACS 800 AINT

ACS600 - 15, rev. 1 Copyright © ABB Industry Oy

 ACS 800 AGDR

ACS600 - 16, rev. 1 Copyright © ABB Industry Oy

 ACS 800 APOW

ACS600 - 17, rev. 1 Copyright © ABB Industry Oy

 ACS 800 AINP

ACS600 - 18, rev. 1 Copyright © ABB Industry Oy

 ACS 800 AINPB

ACS600 - 19, rev. 1 Copyright © ABB Industry Oy

 ACS 800 ARFC

ACS600 - 20, rev. 1 Copyright © ABB Industry Oy

 ACS 800 DSMB-02 and DSMB-01

DSMB-02 DSMB-01

ACS600 - 21, rev. 1 Copyright © ABB Industry Oy

 ACS 800 DSAB

ACS600 - 22, rev. 1 Copyright © ABB Industry Oy

 ACS 800

ACS600 - 23, rev. 1 Copyright © ABB Industry Oy

 ACS 800 R8i right-side open

ACS600 - 24, rev. 1 Copyright © ABB Industry Oy

 ACS 800 R8i left-side open

ACS600 Copyright © ABB Industry Oy

CHAPTER-5
CAPACITOR
PEFORMING
CONVERTER INTERMEDIATE CIRCUIT CAPACITOR
REFORMING (RE-AGEING) AFTER STORAGE

Introduction
This guide applies to ACS 600 SingleDrive frequency converters and ACS 600
MultiDrive ACN 634 drive units.

Converter DC link capacitors need to be reformed (re-aged) if the converter has been non-
operational for more than one year. Without reforming capacitors may be damaged when
the converter starts to operate. The reforming methods introduced in this guide require, that
the converter has been stocked clean and dry. It is recommended to reform the capacitors
once a year.

How to check the converter age

Converter serial number defines the week, when the converter has been built:
7 digit: e.g. 7260034, 7 denotes manufacturing year (1997), 26 manufacturing week and 0034
running manufacturing number.
8 digit: e.g. 18250125, 1 denotes manufacturing country (1= Finland), 8 manufacturing year
(1998), 25 manufacturing week and 0125 running manufacturing number.
10 digit: e.g. 1983200725, 1 denotes manufacturing country, 98 manufacturing year, 32
manufacturing week and 00725 running manufacturing number.

Reforming time
The intermediate circuit of the converter is kept in its nominal voltage for the reforming time
to “wake up”the capacitors. The reforming time required depends on how long the converter
has been stocked (non-operational).

Capacitor reforming time

6

5
Forming time in hours

0
0 1 2 3 4 5 6
Method 1 Method 2

Non-operational time in years

Figure 1. Capacitor reforming time for Method 1 and Method 2

Document includes 4 pages

Converters stocked (non-operational) less than 2 years
Switch the power on to the converter for a time given in Figure 1 (Method 1). The converter
“wakes up”its capacitors by itself. Power the ACS 600 MultiDrive ACN 634 drive units and
the ACx 604/607 units 0400-3, 0490-5 and 0490-6 and up once a year to keep the
capacitors in operational condition.

Converters stocked (non-operational) for 2 years and over

Use method 2 A or method 2 B (below) for capacitor reforming if the converters have been
stocked (non-operational) for two or more years.

WARNING! The inverter module of ACS 600 MultiDrive units and

ACX 604/607 units 0400-3, 0490-5 and 0490-6 and up must be reformed outside the
cabinet.
Method 2 A:
Capacitor reforming is realised by switching-in a rectifier and a resistor circuit, which is
connected to the converter DC link. The reforming circuit is given below. Circuit component
values for different voltages are given in the table below. See the reforming time from
Figure 1.

WARNING! The converter supply must be disconnected, while reforming

circuit is connected.

Ux

Disconnect
UDC- UDC+

W1 W2

Ux
V1 CONVERTER V2

U1 U2

Figure 2: Reforming circuit for method 2 A.

Recommended components
A R C
380 V < Ux < 415 V SKD 82/16 220 Ohm / 700 W 22 nF / 2000 V
380 V < Ux < 500 V SKD 82/16 470 Ohm / 1200 W 22 nF / 2000 V
525 V < Ux < 690 V SKD 82/16 680 Ohm / 1700 W 22 nF / 2000 V
Table 1: Component values for reforming above.
CHAPTER 6
MAINTENANCE GUIDE
 101

Maintenance

What this chapter contains

This chapter contains preventive maintenance instructions.

Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work inside the cabinet,
• isolate the drive from the supply (note that the switch-disconnector on the door
does not switch off the voltage from the input terminals)
• wait for 5 minutes to let the intermediate circuit capacitors discharge
• open the cabinet doors
• ensure there is no dangerous voltage present by measuring the voltage of the
input terminals and the intermediate circuit terminals.

Maintenance
 102

Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.

Interval Maintenance action Instructions

See document ACS 600/800 Capacitor Reforming

Every year of storage Capacitor reforming Guide (Code: 3BFE 64059629 [English]) and
Capacitors.

Every 6 to 12 months (depending Heatsink temperature

See Heatsinks.
on dustiness of environment) check and cleaning

Air filter check;

Every year (IP22 and IP42 units)
replacement if necessary See Checking and replacing the air filters.
Every year (IP54 units) Air filter replacement

Cooling fan check;

Every 3 years See Cooling fans.
replacement if necessary

Power connections check

Every 3 years See Power connections.
and cleaning

Every 6 years Cooling fan change See Cooling fans.

PPCS branching unit Locate the APBU unit. Switch off the power to the
Every 6 years (APBU-xx) – Memory unit. Remove cover. Replace battery with a new
backup battery renewal CR 2032 battery.

Every 10 years (if drive subjected

Capacitor change See Capacitors.
to high ambient temperature)

Every 12 years Capacitor change See Capacitors.

Maintenance
 103

Redundancy (Reduced run capability)

If one of the parallel-connected supply or inverter modules must be taken out of the
cabinet for service, it is possible to continue operation using the remaining modules
at reduced power.

Supply modules
1. Read and repeat the steps in the safety instructions above.
2. Extract the module to be serviced from the cabinet. Follow the directions given on
page 75.
3. Fasten the air baffle provided with the unit to the top module guide to block airflow
through the empty module bay.
4. On the DSSB control panel, modify the number of supply modules present as
required. (This will only affect external metering instruments connected to
terminal X9 on the DSSB board.) See page 29 for instructions.
5. Reconnect the module after service in reverse order.

Note: W hen running the drive at reduced power, avoid overloading the supply unit
since it is only protected through its temperature measurement.

Inverter modules

Note: This function is only available if the drive is equipped with a PPCS branching
unit of type APBU-xx. (Redundancy is not supported by type NPBU branching units.)

1. Read and repeat the steps in the safety instructions above.

2. Extract the module to be serviced from the cabinet. Follow the directions given on
page 82.
3. Fasten the air baffle provided with the unit to the top module guide to block airflow
through the empty module bay.
4. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware Manual.
5. Reconnect the module after service in reverse order.

Maintenance
 104

Checking and replacing the air filters

1. Read and repeat the steps in Safety instructions above.
2. Open the cabinet doors.
3. Check the air filters and replace if necessary (see Technical data for the correct
filter types). The inlet (door) filters can be accessed by removing the fastener(s) at
the top of the grille, then lifting the grille and pulling it away from the door. The
outlet (roof) filter in IP54 units has a similar mechanism.
4. Check the cleanliness of the cabinet. Clean the interior of the cabinet if necessary
using a soft brush and a vacuum cleaner.
5. Close the cabinet doors.

Power connections
1. Read and repeat the steps in section Safety instructions above.
2. Open the cabinet doors.
3. Extract one supply or inverter module from the cabinet as described in the
connection procedures in the chapter Electrical installation.
4. Check the tightness of the cable connections at the quick connector. Use the
tightening torque table in Technical data.
5. Clean all contact surfaces of the quick connector and apply a layer of suitable joint
compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
6. Re-insert the supply/inverter module.
7. Repeat steps 3 to 6 for all remaining supply and inverter modules.

Maintenance
 105

Cooling fans
Power module cooling fans
The lifespan of the cooling fans of the supply and inverter modules is about 50 000
hours. The actual lifespan depends on the running time of the fan, ambient
temperature and dust concentration. Each supply and inverter module has its own
cooling fan. Replacements are available from ABB. Do not use other than ABB
specified spare parts.
The application program keeps track of the running time of the cooling fan of the
inverter modules. See the Firmware Manual delivered with the drive for the actual
signal which indicates the running time.
Supply module fan replacement
1. Read and repeat the steps in section Safety instructions above.
2. Open the supply cubicle doors.
3. Loosen the locking screw (1).
4. Disconnect the fan wiring plug (2).
5. Pull out the fan (3).
6. Install a new fan in reverse order.

Maintenance
 106

Inverter module fan replacement

1. Read and repeat the steps in section Safety instructions above.
2. Open the inverter cubicle doors.
3. Disconnect the fan wiring plug (1).
4. Remove the locking screws (2).
5. Pull the fan out along its sliding rails (3).
6. Install a new fan in reverse order.

Maintenance
 107

Control and I/O cubicle cooling fans

The cooling fans inside the control and I/O cubicle can be replaced as follows:
1. Read and repeat the steps in section Safety instructions above.
2. Open the door of the control and I/O cubicle (or combined control, I/O and supply
cubicle).
3. Detach the wiring from each fan (AC plug and grounding wire).
4. Undo the four fastening screws of the fan assembly and pull the assembly
outwards to gain access to the fan fastening screws.
5. Undo the fastening screws of the fans (there are four for each fan) from below.
Remove the fans.
6. Install new fans in reverse order. Before fastening the fans, make sure the airflow
arrow on both fans is pointed up.

3 3

4
5

Maintenance
 108

IP54 (UL type 12) fan replacement

1. Remove the front and back gratings of the fan cubicle by lifting them upwards.
2. Remove the shrouds by undoing the fastening screws.
3. Undo the fastening screws of the side/top cover of the fan.
4. Lift the side/top cover of the fan off.
5. Disconnect the fan supply wire connector from the cabinet roof (on top and
inside the cabinet).
6. Undo the fastening screws of the fan cassette at each corner.
7. Lift the fan cassette off.
8. Undo the cable ties on the top of the fan cassette.
9. Disconnect the cables (detachable terminals).
10. Remove the fan capacitor by undoing the fastening screw of the clamp.
11. Undo the fastening screws of the fan.
12. Pull the fan out.
13. Install the new fan and fan capacitor in reverse order to the above. Ensure that
the fan is centered and rotates freely.

2 2 4

1
3
2
2
3

7
6
5
5

Maintenance
 109

10
9

8
8
9
8 8

12
11 11

Heatsinks
The heatsink fins of the power modules pick up dust from the cooling air. The module
runs into overtemperature warnings and faults if the heatsinks are not clean. In a
“normal” environment (not especially dusty nor clean) the heatsinks should be
checked annually, in a dusty environment more often.
Whenever necessary, clean the heatsinks as follows:
1. Remove the cooling fan (see section Cooling fans).
2. Blow dry clean compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
3. Refit the cooling fan.

Capacitors
The inverter modules employ several electrolytic capacitors. Their lifespan is at least
90 000 hours depending on the operating time of the drive, loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict capacitor failure. Capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if
capacitor failure is suspected.

Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629 [English], available through your local
ABB representative.

Capacitor replacement
Contact an ABB service representative.

Maintenance
 110
Other maintenance actions

Power module replacement

To replace power modules (i.e. supply and inverter modules), follow the
instructions
on module removal and refitting given in the chapter Electrical installation.

Maintenance
 111

Maintenance