1 15 Powerblock Repair PDF

Power block / power circuit, interface boards and repair
Training objectives:
• You are familiar with the circuit diagrams of
the cabinet SINAMICS S150
• You are familiar with the circuit diagrams of

power blocks
• You are familiar with the replacement of the

spare part components of the power block
SINAMICS Date: 06.03.2007 SITRAIN Training for

Automation and Drives
Siemens AG 2007. All rights reserved. File: ABU DHABI: Page 15 - 1
Power block / Design, diagnosis and repair

Content Page
S150 / FS G [sheet 1 of 11]............................................................................................................. 4
S150 / FS G [sheet 2 of 11]............................................................................................................. 5
S150 / FS G [sheet 3 of 11]............................................................................................................. 6
S150 / FS G [sheet 4 of 11]............................................................................................................. 7
S150 / FS G [sheet 5 of 11]............................................................................................................. 8
S150 / FS G [sheet 6 of 11]............................................................................................................. 9
S150 / FS G [sheet 7 of 11]............................................................................................................. 10
S150 / FS G [sheet 8 of 11]............................................................................................................. 11
S150 / FS G [sheet 9 of 11]............................................................................................................. 12
S150 / FS G [sheet 10 of 11]........................................................................................................... 13
S150 / FS G [sheet 11 of 11]........................................................................................................... 14
Design of a power block................................................................................................................... 15
Connections of the power block (FS F)............................................................................................ 16
Thyristor Rectifier / TDB (FS F) ...................................................................................................... 17
IGBT Inverter / IGD (FS F) .............................................................................................................. 18
CTs and Interface Board / AIBO (FS F) .......................................................................................... 19
Power Supply Board / PSB................................................................................................................ 20
continued on page 3

Power block / Design, diagnosis and repair
Content Page
Thyristor Rectifier / TDB (FS H)...................................................................................................... 21
IGBT Inverter / IGD (FS H).............................................................................................................. 22
IGBT Inverter / IGD (FS H) ............................................................................................................. 23
Current transformers and Interface board AIBO (FS H).................................................................... 24
Power Supply Board / PSB (FS H).................................................................................................. 25
DRIVE CLiQ connection of CIBs (FS H).......................................................................................... 26
Repair work on the power block........................................................................................................ 27
Replacement of an IGBT assembly / Example FS F (1)................................................................. 28
Replacement of an IGBT assembly / Example FS G (1)................................................................. 31
Replacement of an IGBT assembly / Example FS G (2)................................................................. 32
Re-installation of an IGBT assembly................................................................................................. 33
Heat sink compound / Sequence to tighten the screws..................................................................... 34
Table of torque to tighten screws...................................................................................................... 35
Replacement of a power block / Example FS J (1)......................................................................... 36
Replacement of a power block / Example FS J (2)......................................................................... 37
Disassembly of the DC-link capacitor connections............................................................................ 38
Replacement of the IGBTs............................................................................................................... 39

S150 / FS G [sheet 1 of 11]
main circuit breaker
230VAC
UES (PSB)
fan contactor

pre charging contactor
pre charging
resistors line reactor
UES (PSB)
line clean
noise power
VL (PSB) filter filter
230VAC
voltage sensing module

power block: active line module

230V
to precharging contactor
to undervoltage coil and fan contactor

power block: motor module

circuit breaker
auxiliary
supply
transformer

230VAC main contactor

auxiliary voltage
24 V power supply
emerg.-off
relais
24V to PSB

control unit CU320
DRIVE
CLiQ
emerg.-off
relais
operating panel AOP30

terminal board TM31
DRIVE
CLiQ

emergency off key

230VAC
CU: DO
CU: DI
230 V emergency off circuit
main contactor
phases 1, 2, 3 230VAC
HS (PSB)
main contactor

S150 / FS G [sheet 10 of 11]
cabinet illumination with socket

S150 / FS G [sheet 11 of 11]
anti condensation heating

Design of a power block
Pre-charging
• B6-diode-precharging
• thyristor firing pulses
• basic interferance
RECT + 1 INV
RECT + 3 INV
suppression
2 INV
Rectifier
• B6-thyristor-bridge,
fully controlled
size F, G size H
DC-link
• capacitors
• braking chopper
RECT
INV
INV
INV
Inverter
• IGBT+ FW-diodes
• IGD: controls IGBTs
• heat sink
• balancing size J
• current transformers
High efficiency IGBTs / DC-link bus bar with low inductance / very compact design

Connections of the power block (FS F) G150
(1)
PSB CIB
(1) the transformer tapping has to be selected to match the local line voltage:
- for the supply of the fan of the motor module (active line module)
- for the internal 230VAC supply of the line connection module

Thyristor Rectifier / TDB (FS F) G150
AIBO line
The firing angle as

calculated by CU320
TDB
is signalled to module
PSA via DRIVE-CLiQ;
from module PSA to operating
module AIBO and on rectifier
to module TDB and to
the thyristors.
TDB
pre charging
rectifier
CIB
MIVI
CLiQ
PSA
LWL to CT
AIBO to INV

IGBT Inverter / IGD (FS F) G150

PSB
S150
upper switch
upper
AIBO switch
lower
switch lower switch
AIBO
U.CE
IGD

IGD CTs and Interface G150
Board / AIBO (FS F) S150
AIBO (2)
connection to PSB
PSA (1)
TDB
(1) The values of f.set and v.set as calculated by the

CU320 are signalled to the PSA via DRIVE-CLiQ;
module PSA generates the pulse sequence.
(2) Optical cables are controlled via AIBO; from

there on to module IGD and to the transistors.

Power Supply Board / PSB G150

S150
24V ext.
PSB
IGD
V.DC / RECT
AIBO

Thyristor Rectifier / TDB (FS H) G150

IGBT Inverter / IGD (FS H) G150

S150
phase 1

IGBT Inverter / IGD (FS H) G150
S150
phase 2
phase 3

Current transformers and Interface board AIBO (FS H) G150

S150
wiring
see
next
page

Power Supply Board / PSB (FS H) G150
S150
IGD INV 1 IGD INV 2 IGD INV 3

DRIVE CLiQ connection of CIBs (FS H) G150

S150
PSB 1 / CIB for power block 1
Additional DRIVE CLiQ connection

if two power blocks are paralleled
PSB 2 / CIB for power block 2

Repair work on the power block
On the power block following parts

may be replaced:
• IGBT/IGD-assembly
• Thyristors
(only G150)
• Pre-charging resistors
(only G150)
• Thyristor control board

(only G150)
• Current transformers

Replacement of an IGBT assembly / Example FS F (1)
Disconnect the plugs with the optical cable

(numbered from bottom up; verify!)
Disconnect the auxiliary supply

(press the release catch)
Undo the top IGBT-connections (Torx 30) Remove the 6 screws of the bus bars (screws are self
tapping in the plastic support; be careful in re-assembling)

Remove the fixing screws Lift the copper bus bars free of the IGBTs; Current transformers
of the PCB (Torx 10) slacken the four screws of the transformer are held in place by a
assembly to gain clearance between the large clip.
copper bus bars and the IGBTs
To replace one of the

current transformers it
is suggested to remove
Undo the bottom IGBT the entire transformer
connections (Torx 30) assembly prior to ex-
changing an individual
current transformer.

Undo the eight IGBT fixing screws
Note the PCB support spacers of the IGBT-module!
Lift the IGBT assembly clear

Replacement of an IGBT assembly / Example FS G (1)
Disconnect the plugs with the optical cable

(numbered from left to right; verify!)
Disconnect the auxiliary supply

(press the release catch)
Undo the 6 self tapping bus bar fixing screws Undo 24 IGBT connections (Torx 25)

Replacement of an IGBT assembly / Example FS G (2)
The bus bars are now loose. In order to

lift them, slacken, but do not remove the
CT assembly (seven screws) to create
space between the copper bus bars and
the IGBTs.
Now lift each bus bar

individually and temporarily
hang it onto the plastic
assembly using a spare screw.
Bus bars are now clear of

the IGBTs;
the IGBT assembly can
now be removed.

Re-installation of an IGBT assembly
Install the new IGBT assembly noting the following

(as discussed in detail on previous occasions):
• Clean the heat sink
• Apply new compound in thin layers
• Put the IGBT module in place directly after applying the compound
• Note the sequence of tightening the screws
• Apply jointing compound between IGBT and copper bus bars
• Following the right sequence, tighten all screws using the advised
torque

Heat sink compound / Sequence to tighten the screws
Application of the heat sink compound

• Clean the heat sink with alcohol and a cloth free of lint
• Apply new compound with a rubber roller in thin layers inter-
secting at 90 degrees covering the entire base-plate of the
module (thickness of compound 0.1 – 0.2 mm; transparent)
• Put the the thyristor module in place
immediately after applying the compound.
• Be careful to place the module in its
correct position right away; it must not
be relocated after it has been placed
in position.
Fixing semiconductor modules

• Semiconductor modules and resistors on support plates are
extremely sensitive to mechanical stress Æ risk of breaking
the ceramic insulation
• Place the module onto the heat sink in correct position
• Note the sequence of tightening the screws according to
the type of module; initially use 0.8 Nm to fix the module
• Again observing the sequence of tightening the screws
tighten them using the advised torque (refer to the table
next page)

Table of torque to tighten screws
Component Torque Note
IGBT-module on heat sink 3.0 Nm (+15% / -15%) pre-tighten with 0.8 Nm
IGD-board on IGBT 2.0 Nm (+5% / -10%) pre-tighten with 0.8 Nm
Resistors on heat sink 1.8 Nm pre-tighten with 0.8 Nm
Thermosensors on heat sink 3.0 Nm
PCB-support bolts on heat sink 6.0 Nm
Nuts on PCB-support bolts 6.0 Nm
Power connections on bus bars 13 Nm

Replacement of a power block / Example FS J (1)
Remove connection to Disconnect the

the DC-link (8 screws) signal connectors
After taking out 2x4 screws (at the top

and on the bottom) remove the motor
side copper bus bars
(the power block in the center has been Remove the upper fixing bolt
removed already) (set back)

Replacement of a power block / Example FS J (2)
Disconnect the screen

of the CT-wiring and
remove the plug
Remove the lower mechanical fixing on the right

hand side of the unit and lift out the complete
power block. Please be careful: HEAVY!

Disassembly of the DC-link capacitor connections
Remove the plastic cover

Unplug the connections to the
symmetrising resistors
Remove the assembly of
copper and insulating
plates.
Note: the plates are not
fixed together; take care
the spacers and plates do
not come loose!
Remove all fixing screws and

connections (on the side as well)

Replacement of the IGBTs
6 fixing screws to be removed
2 temperature sensors to unplug
3 plastic spacers to watch out for
Remove the IGBT drive board
Replace any damaged IGBTs
Note the following when putting in new IGBTs:

• Wipe off old compound and clean the heat sink
• Apply new compound in thin layers
• Apply jointing compound between IGBT and bus bar
• Observe sequence and advised torque when fixing
the screws


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Power block / power circuit, interface boards and repair

• You are familiar with the circuit diagrams of

• You are familiar with the replacement of the

SINAMICS Date: 06.03.2007 SITRAIN Training for

Power block / Design, diagnosis and repair

SINAMICS Date: 06.03.2007 SITRAIN Training for

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 1 of 11]

main circuit breaker

SINAMICS Date: 06.03.2007 SITRAIN Training for

pre charging contactor

voltage sensing module

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 3 of 11]

power block: active line module

SINAMICS Date: 06.03.2007 SITRAIN Training for

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 5 of 11]

SINAMICS Date: 06.03.2007 SITRAIN Training for

230VAC main contactor

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 7 of 11]

control unit CU320

operating panel AOP30

SINAMICS Date: 06.03.2007 SITRAIN Training for

terminal board TM31

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 9 of 11]

emergency off key

SINAMICS Date: 06.03.2007 SITRAIN Training for

cabinet illumination with socket

SINAMICS Date: 06.03.2007 SITRAIN Training for

S150 / FS G [sheet 11 of 11]

anti condensation heating

SINAMICS Date: 06.03.2007 SITRAIN Training for

SINAMICS Date: 06.03.2007 SITRAIN Training for

Connections of the power block (FS F) G150

SINAMICS Date: 06.03.2007 SITRAIN Training for

The firing angle as

SINAMICS Date: 06.03.2007 SITRAIN Training for

IGBT Inverter / IGD (FS F) G150

SINAMICS Date: 06.03.2007 SITRAIN Training for

(1) The values of f.set and v.set as calculated by the

(2) Optical cables are controlled via AIBO; from

SINAMICS Date: 06.03.2007 SITRAIN Training for

Power Supply Board / PSB G150

SINAMICS Date: 06.03.2007 SITRAIN Training for

SINAMICS Date: 06.03.2007 SITRAIN Training for

IGBT Inverter / IGD (FS H) G150

SINAMICS Date: 06.03.2007 SITRAIN Training for

SINAMICS Date: 06.03.2007 SITRAIN Training for

Current transformers and Interface board AIBO (FS H) G150

SINAMICS Date: 06.03.2007 SITRAIN Training for

IGD INV 1 IGD INV 2 IGD INV 3

SINAMICS Date: 06.03.2007 SITRAIN Training for

DRIVE CLiQ connection of CIBs (FS H) G150

Additional DRIVE CLiQ connection

PSB 2 / CIB for power block 2

SINAMICS Date: 06.03.2007 SITRAIN Training for

On the power block following parts

• Thyristor control board

SINAMICS Date: 06.03.2007 SITRAIN Training for

Replacement of an IGBT assembly / Example FS F (1)