Working Instructions

4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 1 (38)

Index
1. General information .................................................................................................................................. 2
1.1 Safety ................................................................................................................................................. 2
1.2 Preparation work................................................................................................................................. 3
1.3 Parts list of the IGBT upgrade kit 42000548 ........................................................................................ 4
1.4 Needed tools ...................................................................................................................................... 4
1.5 ESD.................................................................................................................................................... 8
2. Removing the old hardware ...................................................................................................................... 9
2.1 Removing the assembly plate ............................................................................................................. 9
2.2 Disconnecting output busbars and clamping capacitors..................................................................... 10
2.3 Removing assembly plate of NPOW- and NGPS. .............................................................................. 11
2.4 Removing DC busbars ...................................................................................................................... 12
2.5 Removing IGBT modules .................................................................................................................. 13
2.6 Cleaning heat sink elements ............................................................................................................. 14
3. Installing the new hardware..................................................................................................................... 15
3.1 Preparing and installing of adapter plates.......................................................................................... 15
3.2 Preparing the NTC-thermistor ........................................................................................................... 17
3.3 Preparing the new IGBT module FF1400R12IP4............................................................................... 18
3.4 Mounting of the IGBTs and NTC-thermistor....................................................................................... 19
3.5 Tightening sequence of the IGBT ...................................................................................................... 20
3.6 Mounting of the NGDR-07C board .................................................................................................... 21
3.7 IGBTs and NGDR boards mounted ................................................................................................... 22
3.8. Mounting of the DC-busbars and measurement wires. ..................................................................... 23
3.9 Mounting of the output busbars. ........................................................................................................ 24
3.10 Installing of clamping capacitors...................................................................................................... 25
3.11 Mounting of flat cables and NPOW board assembly plate................................................................ 26
3.12 Mounting of stand-offs .................................................................................................................... 29
3.13 Installing upper assembly plate ....................................................................................................... 30
3.14 Assembling of the NINT- and NXPP-06C boards ............................................................................. 31
3.15 Mounting of ferrite wire and connecting of wires .............................................................................. 33
4 Finishing the upgrade work ...................................................................................................................... 34
4.1 Testing the drive ............................................................................................................................... 34
4.2 Finishing the work area ..................................................................................................................... 35
5 Working Instruction for thermal compound Grey Ice 4100 LV ................................................................... 36
Appendix 1, R9i 400-500V Inverter module main circuit diagram ................................................................. 37
Appendix 2, R9i 400-500V Inverter module main circuit diagram, power stage ............................................ 38

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 2 (38)

1. General information

These instructions are meant to be followed when carrying out the IGBT upgrade of the
ACN634 R9i 400V and 500V frequency converter.

If other required repair or maintenance tasks occur before or during the upgrade, ones that
have not been presented in this instruction, should the service personnel be familiar with the
working methods which are needed to get the required actions done safely without harming
the employee himself or the surroundings. Before starting the upgrade the whole work must
be planned so that the required actions are done according to the safety regulations.

1.1 Safety

WARNING! All electrical installation and maintenance work on the ACx600 should be carried
out by qualified electricians. Do not attempt any work on a powered ACx600. 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, W1) and earth must be measured with a multimeter (impedance at
least 1 M ) to ensure that the frequency converter is discharged before beginning work.

All insulation tests must be carried out with the ACx600 disconnected from the cabling.

The ACx600 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 attempted with
mains power applied.

The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC
voltage (over 500 V).

There can be dangerous voltages inside the ACx600 from external control circuits when the
ACx600 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
appropriate care when working with the unit.

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 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
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1.2 Preparation work

Clean the area before starting upgrade work, remove all unnecessary items nearby
the work area.
Arrange a clean table close to the work area so that ESD mat and all removed
components can be laid down onto it and ready to install components can be laid
down to be easily available during the work.
Check the delivery of the upgrade kit that all items are undamaged.
Check that items listed on the parts list are included, see chapter 1.3.
Read through this document in advance and organize all parts and tools before
starting upgrade work.
Assemble boxes for returnable items, assembly instructions provided with the upgrade
kit.
This document describes upgrade work when phase module is out from the cabinet.

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
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1.3 Parts list of the IGBT upgrade kit 42000548

42000484 IGBT MODULE KIT FF1400R12 R9I R9 SD 3 PC

68908914 CAPACITOR KPF-183 6 PC
68827884 ADAPTER BOARD NXPP-06 1 PC
68814201 ADAPTER PLATE FF1000 3 PC
42000408 MECHANICS KIT R8I R9I R12I IGBT UPGR 1 PC
68846161 BUS BAR ACS600 (AC) 3 PC
68986231 DC BUSBARS 1 PC
61262407 BUSBAR ACN634 R8I/R9I 2 PC
68922691 ASSEMBLY PLATE ACS600 1 PC
68922640 BASE ACS600 1 PC
10024030 STANDOFF M4 L=20 MS/NI 8 PC
68343097 COMBISCREW M4X8 TORX T20 4 PC
68447933 STANDOFF M4 L=38 MS/NI 1 PC
68688531 STANDOFF M4 L=25 FE/ZN 1 PC
57938005 INSULATING PILLAR TPI/9,5/38/M4 RM 3 PC
57199644 INSULATING PILLAR TPI/9,5/25/M4 RM 3 PC
3AUA0000026569 BRACKET CABLE CLAMP 27MM 1 PC
36623110 COMBISCREW M6X16 TORX T25 1 PC
68893861 MACHINE SCREW M6X16 TORX 30 PC
3AUA0000042489 OPTIONS KIT POWER SUPPLY NGPS-13C 1 PC
3AUA0000033361 POW. SUPP. BOARD NGPS-13C 1 PC
61381996 WIRE HARNESS FOR R10-11I FOR NGPS-12 1 PC
64375831 WIRING HARNESS R NINT-72 / R10-/R11i(V) 1 PC
10027969 STANDOFF M4 L=12 6 PC
68343097 COMBISCREW M4X8 TORX T20 6 PC
DOCTNACS60017 TECHNICAL NOTE ACS600 IGBT NGPS-13 1 PC
DOCWIACS60026 WORKING INSTRUCT ACN634 R9I IGBT UPGRAD 1 PC
42000370 V991 CODE STICKER 42000370 2 PC
3AUA0000074768 THERMAL COMPOUND HEAT TRANSFER COMPOUND 6 PC
42001623 PP3 STENCIL KIT 1 PC

1.4 Needed tools

True RMS multimeter, at least CAT III 1000V, e.g. FLUKE 87 III as shown in the
picture 1.
Test leads + probes, at least CAT III 1000V

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 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
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Pic 1.

Screw drivers set for electrical work, 1.

Side cutting pliers, 2.
Pointed pliers, 3.

3.
1.
2.

Pic 2.

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 Working Instructions
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ACN634 R9i IGBT upgrade
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(Cordless Screwdriver)
Set wrench kit (8-21 mm), 4.
Torx-kit +bit set, 5.

5.

4.

Pic 3.

Torque spanner 2-10Nm for torx- and crosshead screws, 6.

Torque spanner 10-110Nm for busbar bolts, 7.

7. 6.

Pic 4.

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 Working Instructions
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ACN634 R9i IGBT upgrade
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Rubber spatula or small paint roll for thermal compound

Soft cloth wipers, lint free
Industrial alcohol or equivalent oil-free cleaning solvent. Petrol or diesel (gas-oil) fuel
not allowed.
Padlock
"Do not switch-men at work" signs as shown in the picture 5.

Pic 5.

ESD field service kit

Pic 6.

Laptop with DriveWindows SW + DDCS communication accessories

Compressed air or compressed air cans for cleaning
Note that compressed air must be dry and absolutely oil-free!
ESD vacuum cleaner for cleaning

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 Working Instructions
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1.5 ESD

WARNING!
Ensure ESD protection when handling the components.
Circuit boards contain components sensitive to electrostatic discharge (ESD). Wear
an earthing wrist band and use ESD field service mat when handling the components.
Do not touch the boards and components unnecessarily.
Assemble the ESD field service kit as shown in the picture.

Wrist band

Components
in box

Earth Card

Working mat

Pic 7.

Keep new boards and semiconductors for as long as possible in their original
packages.

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 Working Instructions
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ACN634 R9i IGBT upgrade
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2. Removing the old hardware

2.1 Removing the assembly plate

Pic 8.

Disconnect connectors and fibre optic cable marked in blue from NINT board.
First open M4 fixing screws of the NINT marked in red from the assembly plate.
Pull carefully the assembly plate out together with the NINT board and keep it in a safe
place.

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2.2 Disconnecting output busbars and clamping capacitors

Pic 9.

Remove NGDR boards from the IGBT modules if they are not coming along the NINT-
board.
Disconnect output busbars from the IGBT modules marked in red.
Disconnect clamp capacitors from the IGBT modules marked in blue.

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2.3 Removing assembly plate of NPOW- and NGPS.

Pic 9.

Disconnect wire from DC capacitors to NPOW board.

Open M6 screws of the assembly plate of NPOW and NGPS, marked in red. Note that
NGPS board is optional.
Note that if the module is in the cabinet it must be pulled out so that M6 screws can be
reached outside of the module frames.

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2.4 Removing DC busbars

NPOW
wires

Pic 10.

Open the screws of the current transducers, marked in blue.

Remove current transducer assembly and insulation part behind it.
Open M6 screws of the DC-busbars from the DC-capacitor bank, marked in green.
Disconnect DC-wires of the NPOW board.

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2.5 Removing IGBT modules

Pic 11.

Remove old IGBT components by opening 6 pc M6 screws, marked in red, from the
heat sink of each IGBT.

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2.6 Cleaning heat sink elements

Pic 12.

Clean surfaces of the heat sink elements with soft cloth and industrial alcohol or
equivalent cleaning solvent. Crease or oil-based solvent is not allowed.
Clean the rest of the module if needed.

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3. Installing the new hardware

3.1 Preparing and installing of adapter plates

10. 7.

6. 3.

Pic 13a. Example of how result looks 2. 1.

when spreading is done with a stencil

4. 5.

8. 9.

Pic 13b. spreading done with a rubber Pic 14.

spatula or a small paint roller.

Clean the surfaces of the adapter plates by using soft cloth and industrial alcohol.
Spread thermal compound to the other side with rubber spatula or small paint roller
(picture 13b). Note that the compound must be spread to the opposite side of the
counter-bored holes.
! Follow separate instruction (4FPS10000048908) for spreading the thermal
compound with stencil (picture 13a).
Fix adapters loosely, first with two diagonal counter-bored screws e.g. screws # 7 – 8.
Press slightly with the hand on the adapter plate, if Grey Ice and stencil has not been,
distribute the paste by a slight rotary motion.
Install other adapter plates and fixing screws same way.
Tight the screws crosswise in two phases in the sequence shown in the picture 14.
First phase with 1Nm and finally with 3Nm.

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Pic 15.

When all three adapters are mounted and tightened at final torque, clean the
excessive thermal compound and surfaces of the adapter plates by using soft cloth
and industrial alcohol.

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3.2 Preparing the NTC-thermistor

Pic.16.Old revision NTC-thermistor

Pic.17.New revision NTC-thermistor

Note that there are two revisions of NTC-thermistor, an older type, which needs to be
bend, and newer type, which is already bent, so that one does not need any actions
before mounting.
If the NTC is old type, picture 16, bend carefully with pointed pliers the tail of the
thermistor to the 90 degrees angle. Note that the bent must be on the back side of the
thermistor, as it is with the new one in the picture 17.

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3.3 Preparing the new IGBT module FF1400R12IP4

Pic 18a. Pic 18b.

Pic 19a. Example of how result looks Pic 19b.

when spreading is done with a stencil

NOTE ESD!
IGBT module kit includes the NGDR-07C board and mounting screws also. Keep the
board in a safe place in the meantime when preparing IGBTs.
Do not mix NGDR boards! Keep the content of the one packing, IGBT and the
NGDR-07C, as a pair! Pairs are marked with stickers containing serial number
(Picture 18b).
Clean the base plate of the IGBT´s by using soft cloth and industrial alcohol.
Spread thermal compound evenly with rubber spatula or small paint roller (picture
19a).
! Follow separate instruction (4FPS10000048908) for spreading the thermal
compound with stencil (Picture 19a).

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3.4 Mounting of the IGBTs and NTC-thermistor

Pic 20.

Pic 21.

Ensure that IGBT modules are mounted that M4 gate terminals are upwards.
Install the IGBTs to the adapter plate first with 2 pcs of combiscrew M5x10, e.g. like
marked in red.
Install the thermistor under the mounting screw, right side of the IGBT, third screw
from the top.
With every IGBT must be a thermistor.
Press slightly with the hand on the module, if Grey Ice and stencil has not been,
distribute the paste by a slight rotary motion.
Then install all other M5 screws.

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3.5 Tightening sequence of the IGBT

Pic 22.

Tight the screws crosswise in two phases in the sequence shown in the picture 22.
First phase with 2Nm+/-15% and finally with 3Nm.

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3.6 Mounting of the NGDR-07C board

4. 2.
1. 3.

Pic 23a. Pic 23b.

Pic 24. Pairs are marked with stickers containing serial number.

Put the insulation part on to the IGBT module like shown in the picture 23a and mount
NGDR-07C board with 4pc M4x8 screws to the gate terminals.
Do not mix NGDR boards! Keep the content of the one packing, IGBT and the
NGDR-board as a pair! Pairs are marked with stickers containing serial number
(Picture 24).
The M4 fixing screws of NGDR-06C board must be tightened in following way:
1. First the screws are tightened with LIGHT FINGER TIGHTNESS in sequence 1-
2-3-4, shown in the picture 23b.
2. Then screws are tightened with 0.5 Nm torque in sequence 1-2-3-4.
3. Finally screws are tightened with 2 Nm (final torque) in sequence 1-2-3-4.

Note, due to that gate control signals are transmitted through the mounting screws,
correct mounting is very important!
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3.7 IGBTs and NGDR boards mounted

Pic 25a. Pic 25b.

Connect the wires of the NTC-thermistors to the white connector of NDGR boards,
marked with red arrow.
When IGBTs and NGDR boards are at their positions and tightened, the module is
ready for DC-busbars.

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3.8. Mounting of the DC-busbars and measurement wires.

Pic 26.

Install the new DC-busbar assembly as shown with M6 bolts for the DC-capacitors,
marked in red. Tightening torque 3Nm.
Install the additional DC-measurement wire to the upper left corner marked with blue
arrow.
Install DC-voltage wire to NPOW, marked in green, and wires of the discharging
resistors
Mount back the original insulation part of the mounting rail of the current transducers,
marked with yellow arrow.

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3.9 Mounting of the output busbars.

Pic 27.

Install mounting rail of the current transducers marked in yellow.

Install new output busbars as shown with M8 bolts for the IGBT modules, marked in
red.

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3.10 Installing of clamping capacitors

Pic 28.

Install new 2uF clamping capacitors, KPF-183, to DC-terminals as show with M8 bolts.
Two pieces is needed for each phase.
Fasten M8 phase output- and DC-terminal screws at 8Nm tightness, marked in red.

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3.11 Mounting of flat cables and NPOW board assembly plate

Pic 29.

Mount back assembly plate of the NPOW / NGPS board; connect wires from DC
capacitors to NINT. (Note, NRED board does not exist in 400V and 500V units)
Ensure that the new DC-measurement wire comes out behind the plate as shown
(marked with blue arrow).
Connect flat cables (3 pc) to the NGDR-07C boards, marked in yellow. Markings
A51.1: X1, A51.2: X1 and A51.3: X1 at flat cables are to be connected to the NGDR
boards. Pay attention for proper connection.

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It is really important to double-check that all flat cable connectors are connected
properly as shown. Otherwise several faults or warnings might be indicated.

Pic 30. Press the plug properly with your thumb into its socket to ensure a good connection.

Ensure that the plug is plugged properly into its socket.

Pictures 31 and 32 are showing improper connections.

Pic 31. Improper connection

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Pic 32. Incorrect closing

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3.12 Mounting of stand-offs

Pic 33.

Mount 3pcs of 25mm plastic insulation pillars marked in red to the DC busbar threads.
Install 1pc of 25mm metal grounding pillar marked in yellow.

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3.13 Installing upper assembly plate

Pic 34.

Connect AC voltage measurement wire for NINT.

Mount upper assembly plate as shown with 3pcs of 38mm insulating pillars and one
38mm metal pillars.
(Note, NRED board does not exist in 400V and 500V units, wire from DC-capacitor
goes straight to the NPOW board.)

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3.14 Assembling of the NINT- and NXPP-06C boards

Pic 35.

Assemble NINT and new NXPP-06C board together with the assembly plate as
shown. Use metallic pillars between NINT and NXPP-06C boards provided with the
upgrade kit.
Pay attention with the pins of the NXPP-06C boards when mounting the boards
together.
Use M4 combi screws to fasten NXPP-06C board to the NINT.

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Pic 36.

Mount NINT / NXPP-06C board assembly as shown and fasten it to pillars with M4
combi screws, marked in red.
(Note, NRED board does not exist in 400V and 500V units.)
Note! Replace existing NGPS-11 or -12C board with NGPS-13C board included in
the upgrade kit!

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3.15 Mounting of ferrite wire and connecting of wires

Pic 37.

Mount ferrite wire and mounting bracket as shown to the plate underneath NINT /
NXPP assembly. Fasten the bracket with M6 combi screws. Connect wire with ferrites
to the NINT and NPOW, marked in red.
Connect wires from the NGPS, NPOW and current transducers to the NINT, marked in
blue.
Connect flat cables to the NXPP-06C board as shown, marked in yellow. Note that the
flat cable connector for the IGBT on the right is on the right side of the NXPP-06C,
behind the flat cable connector of the NINT.
Connect new additional DC measurement wire to the left side of the NXPP-06C,
marked in orange.

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Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 34 (38)

4 Finishing the upgrade work

4.1 Testing the drive

Testing without supply voltage

Measure with multimeter at resistance range that any of the DC or output busbars are
not short circuited against the frame.
Measure with multimeter at diode range from the DC-(+) and (-) terminals against the
output terminals (U, V and W). Any of these readings must not indicate 0V.

Testing with supply voltage

Connect the DriveWindow tool to the NAMC board of the drive

Connect multimeter to the DC-link terminals outside of the frame.
Put back the cover of the module and close cabinet doors!
Ensure that it is safe to connect the supply voltage!
Connect supply voltage for the drive.
Check that control panel does not show any fault or alarm messages, if yes disconnect
supply voltage, wait for 5 minutes and then locate the problem source.
Measure DC-voltage level and compare the value with value of the signal 01.07 DC
BUS VOLTAGE, if values are not the same, disconnect supply voltage, wait for 5
minutes and then check the connections again.
NOTE! Ensure that test run is safe to perform!
When the drive indicates normal status, perform a test run.
Monitor at least DC-voltage-, current- and speed signals with DriveWindow tool when
running the drive.
When everything is working fine prepare the drive ready for normal operation.

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 35 (38)

4.2 Finishing the work area

Clean the surroundings of the drive especially the area close to the cooling air input.
Stick a tag with text “+V991” to the drive unit, one close to the type code sticker and
the other to the cover so that it will indicate at the first sight that upgrade work is done.

Pic 50. Pic 51.

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 36 (38)

5 Working Instruction for thermal compound Grey Ice 4100 LV

Originally used thermal compound type is WPS II (10008000). Because of low viscosity it was
possible to spread without special tools.

The new thermal compound Grey Ice 4100 LV (3AUA0000074768) has been introduced for
ACS 600 IGBT upgrade solutions during 2012.

Pic 52.

The new Grey Ice 4100 LV thermal compound has better long term performance and higher
viscosity than WPS II. Because of high viscosity proper spreading of Grey Ice 4100 LV
requires a good stencil.

Pic 53.

Follow the separate working instruction ACS 600 IGBT upgrade Grey Ice 4100 LV
(4FPS10000048908).

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 37 (38)

Appendix 1, R9i 400-500V Inverter module main circuit diagram

© Copyright 2012 ABB Oy. All rights reserved.

 Working Instructions
4FPS10000075034
ACN634 R9i IGBT upgrade
Drives Service PP30012 DOCWIACS60026
Department Date Author Approved Revision Page

ESP300 01.11.2012 Ari Niskanen Mika Huuhtanen C 38 (38)

Appendix 2, R9i 400-500V Inverter module main circuit diagram, power stage

© Copyright 2012 ABB Oy. All rights reserved.