ACS 5000A

Medium Voltage AC Drives

3.5 MVA / 7 MVA

ACS 5000A
Direct LSU Snubber Upgrade Instruction for power cell

Document No.: 3BHS798907E01 Rev.-

Issued 31.07.2014

ABB Switzerland Ltd. All Rights Reserved.



ABB reserves all rights to this document. Duplication and forwarding to

third parties is not permitted.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.

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Table of contents
1.1 Safety precautions ......................................................................................................... 4
1.2 Introduction .................................................................................................................... 5
1.3 Drawing, Overview ......................................................................................................... 5
1.4 Material .......................................................................................................................... 7
1.5 Labeling wires ................................................................................................................ 7
1.6 Labeling components ..................................................................................................... 7
1.7 Assembly Notes ............................................................................................................. 7
1.8 Cable List ....................................................................................................................... 8
1.9 Installation, Photos ......................................................................................................... 8
1.9.1 Disassembly screws ....................................................................................................... 8
1.9.2 Disassembly bus bars .................................................................................................... 9
1.9.3 Assembly modified bus bars .........................................................................................10
1.9.4 Assembly new (additional) bus bars ..............................................................................11
1.9.5 Install bus bar screws ....................................................................................................12
1.9.6 Install capacitors ...........................................................................................................13
1.9.7 Install capacitor screws (right side) ...............................................................................14
1.9.8 Install capacitor screws (left side) ..................................................................................15
1.9.9 Final installation ............................................................................................................16
1.10 Check............................................................................................................................17

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1.1 Safety precautions

For all manipulations of the system, for safety reasons grounding

switches must be closed!

Caution: Before starting the assembly / disassembly, make sure that

the ACS 5000A is completely de-energized. Disconnect auxiliary
! voltage and check that no voltage is present in the drive and
transformer.
Open the motor protection switch -Q1002 for the charging
transformer!

Note: Pay attention not to drop any tools and material inside the
converter!

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1.2 Introduction

This document is intended to describe the installation (upgrade) of additional

snubber capacitors C7223 and C7224 in the power cells. To solve the
several rectifier diode failures in the field, this upgrade have to be installed.
The capacitors are shown in the drawings below, according to page 016 and
722 in the ACS5000A HWR2 standard wiring diagram (power cell). Their tag
numbers are C7223 and C7224.
The materials needed to perform the installation are listed under 1.4.

1.3 Drawing, Overview

Snubber Upgrade

DC (+)
D01 D05 D09

21L1
21L2
21L3

D02 D06 D10

EAF DC (NP)

D03 D07 D11

22L1
22L2
22L3

D04 D08 D12

DC (-)

Diode Rectifier LSU

Direct Snubber snubber

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-C7223 and C7224 are installed as a direct snubber capacitor, right side of the rectifier:

Physically the capacitors are installed at the stack at the following position:

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1.4 Material

Material needed for upgrade / converter complete (3 power cells):

6x Capacitor 3BHB040288R0001
6x Bus bar 3BHB017735R0001
6x Bus bar 3BHB040889R0001
12x Rip-Lock-washer M6 9ABA450078P0004
6x Screw M6x8 HAQN400678P2255
6x Screw M6x10 HAQN400678P2256
30x Screw M8x20 9ABA450093R0310
3x THT1- label, -C7223 for component labeling
3x THT1- label, -C7224 for component labeling

1.5 Labeling wires

No labels are needed due to bus bar installation.

1.6 Labeling components

Following labels should be ordered in the size: THT-1:

-C7223, -C7224. The labels (THT1) can be fixed in the middle of the capacitor, front side.

1.7 Assembly Notes

IMPORTANT:

Use the new screws in the upgrade kid and throw the old screws from the disassembly away.
The bus bars in the upgrade kid are all AL and have to be used! Copper bus bars are not
allowed, otherwise a contact corrosion will happen!
Pay attention to use the right screws length at the capacitor! If the screw is too long, the electrical
contact at the capacitor is not really given, because the cap. is not tighten enough!

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1.8 Cable List

No Cable list upgrade is needed, because the upgrade is only done in the power part with AL bus bars.

1.9 Installation, Photos

1.9.1 Disassembly screws

Remove the screws, marked with the green circle (10 pieces in every power cell)

At the right side at the bottom, the screws will not be loosened. (3. Bus bar)

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1.9.2 Disassembly bus bars

Remove the 2 left Al busbars. The 3. busbar stays in position.

The screws will not be used anymore. In the upgrade kid are 10 combi screws per cell to fix the AL
busbars afterwards.

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1.9.3 Assembly modified bus bars

Install the new, modified busbars with the holes in the correct position according to the picture
above.
For the upgrade, only this 2 busbars will be replaced. In the future, there will be only one type of
busbar available (all with holes), which will be used at every position. It is already shown in the
next picture on the right side. For the upgrade, all other original busbars without holes can be
kept!

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1.9.4 Assembly new (additional) bus bars

Install the 2 additional busbars like in the picture above and fix the combi screws only by hand, to
adjust later the whole unit with the capacitor.

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1.9.5 Install bus bar screws

Now all combi screws can be installed and fixed by hand. (Totally only 10!, green circles)
The right bus bar must not be removed, thats why the original screws can be kept at the bottom.
New screws have to be used, that the detent edged washer have the full function.

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1.9.6 Install capacitors

After all screws are temporary fixed by hand, the capacitors can be put in place and adjusted.

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1.9.7 Install capacitor screws (right side)

With the shown screws and the washers, the capictors can be fixed on the right side by hand, too.

ATTENTION: Use the shorter screws (8mm) for the right fixing point!
(Screw M6x8 HAQN400678P2255)

Rem.: Another solution would be, to use a headless screw with a nut to avoid the length problem,
like at the clamp capacitor in the power cell!

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1.9.8 Install capacitor screws (left side)

With the shown screws and the washers, the capictors can be fixed on the left side by hand, too.
Here the longer screws (10mm) should be used. (M6x10 HAQN400678P2256)
After all screws are installed and the capictors are adjusted, all screws can be fixed and tightened
fully.
Mark the capacitors with the correct name like in the drawing and the picture above. Use the 2
component labels in the upgrade kid.
Repeat all the steps for the other 2 power cells in the converter.
After the upgrade, all 3 power cells have to have the same assembly status.

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1.9.9 Final installation

Complete overview of the Direct LSU Snubber Capacitor installation in one power cell after the
upgrade.

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1.10 Check

Check if the electrical connection is exactly at the right heat sinks (diodes) by reading the diode
name at the heat sinks and using the standard drawing from the power cell.
Physically the diodes are installed at the same position like in the standard power cell drawing:

Make a final check, that all is really fixed and correct to this instruction and the drawing.
Make sure that no tools, dust and other things are in the converter.
After a succesful upgrade and dopple check, the AUX power can be switched on to close the doors
and put the GND - Switch in ungrounded position. If everything on customer side is prepared
and the ACS5000A is in READY ON status, the drive can be charged.

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REVISION
Rev. Page (P) Description Date
ind. Chapt.(C) Dept./Init.
- all Initial version 2014-07-31
DMDR / QR
W. Schlachter

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