3axd10000388969 01

Field Rework Instructions for
ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx

frame R6 (powex)
Project Status Date Author Status Revision Version Page
ACS800 12.Nov 2014 JORMANAINEN JONI A 1 1 / 23
1. FIELD REWORK INSTRUCTION FOR ACx550, ACS800, ACS850

and ACQ810 frame R6 (powex)
This document instructs how to replace the old UDC- bus bar type MPR 68407416-C, with the current UDC-
bus bar type MPR 64707361-D in ACS800 sizes 135/165/205-3, 165/205/255-5, ACx550 sizes 246/290A-4,
ACS850 sizes 225/260/290A-5 and ACQ810 sizes 203/240/286A-4
The mechanical changes to the converters described in this rework will increase the clearance and creepage
distance between the UDC- and UDC+ bus bars providing increased electrical insulation.
This instruction applies to converter units manufactured before week 48 2014. Starting from week 49 2014 the
converter units manufactured at the factory are implemented with a new bus bar design and improved electrical
insulation between the bus bars.
2. PRECAUTIONS
Only qualified electricians are allowed to install and maintain the drive. Never work on the drive, motor
cable or motor when main power is applied. After switching off the input power, always wait at least of
5 min to allow for the intermediate circuit capacitors to discharge before staring working on the drive,
motor cable or motor. See Safety Instructions from ACS800 Hardware Manual.
The printed circuit boards contain components sensitive to electrostatic discharge. Ware a grounding
wristband when handling the boards. Do not touch to board unnecessarily.
3. PARTS REQUIRED
Rework kit 42003600 is required to apply the change and include all necessary parts. The content of the kit is:
- 1 x UDC- bus bar, code 68407419

- 1 x insulation bushing, code 3AUA0000172739
- 1 x instruction
Additional tools needed are:

- 1 x common blade screwdriver: small, (0,5x3 for example).
- 1 x Phillips style screwdriver: Tip size PH1 (tip extension is useful).
- 1 x Torx screwdriver: Tip size T20 (tip extension is useful)
- 1 x Torx screwdriver: Tip size T25
- 1 x torque screwdriver
- 1 x Needle-nose plier
- 1 x Side cutting plier
- 1 x Cable tie
ABB reserves all rights in this document and in the information contained therein. Reproduction use or disclosure to third parties without express authority is strictly forbidden.
frame R6 (powex)
4. STEP-BY-STEP INSTRUCTION FOR APPLYING THE

CHANGE
*WARNING* Make sure that the power is cut to the drive before starting working on it. See 2. PRECAUTIONS
above.
Please read through the step-by-step instructions before applying the change. Depending on the drive type and
drive features, indicated to by + codes (See Hardware manual), different steps apply.
STEP 1* For IP 55 drives, remove the bottom part of the

protective cover of the drive.
(DRIVES
WITH 1. Unlock the lock screws starting from the bottom.
PLUS 2. Unlock the front facing lock screw last.
CODE
+B056) NOTE: Be careful when unlocking the front lock screw,
too much force may damage the housing inside.
TOOLS:
Phillips style screwdriver: Tip size PH1 (tip extension is
useful).
frame R6 (powex)
STEP 2* For IP 55 drives, remove the top part of the

protective cover of the drive.
(DRIVES
WITH 1. Unlock the lock screws starting from the bottom.
PLUS
CODE
+B056) TOOLS:
useful).
STEP 3 Remove fieldbus adapters.
1. Remove the fieldbus adapter grounding screws.
NOTE: Be careful not to lose the screws.
frame R6 (powex)
Remove fieldbus adapters.
2. Carefully pull out the fieldbus adapters by

gripping the top and bottom sides.
Remove fieldbus adapters.
3. Pull the fieldbus adapters straight out of the

slots.
NOTE: Be careful not to damage the connection pins of

the fieldbus adapters.
STEP 4 Detachment of drive cover, bottom side.
1. Remove the 3 plastic screws from the fieldbus

adapter plate.
2. Remove any wiring holders’.
3. Remove the drive cover holding screw.
4. Loosen the panel cable.
5. If the drive is equipped with a prevention of
unexpected start (+Q950/+Q967) disconnect the
cable.
TOOLS:
Phillips style screwdriver: Tip size PH1.
Torx screwdriver: Tip size T20.
Detachment of drive cover, bottom side.
6. Use a needle-nose plier for removal of the plug-

in connectors.
TOOLS:
Needle-nose plier.
frame R6 (powex)
Detachment of drive cover, bottom side.
7. Carefully, pull the plug-in connectors straight

out.
TOOLS:
Needle-nose plier.
STEP 5 Detachment of drive cover, top side.
1. The internal fan needs to be disconnected in

order to remove the drive’s cover.
2. Loosen the fan cable from the plastic holder.
Detachment of drive cover, top side.
3. Use a small common blade screwdriver to hold

down the X36 fan connector (white part) and a
needle-nose plier to disconnect the fan.
frame R6 (powex)
Detachment of drive cover, top side.
4. Carefully, disconnect the fan by pulling the fan

cable connector (black) straight out from the fan
connector X36 while holding down the fan
connector X36 (white).
NOTE: Be extra careful when disconnecting the fan.

Misuse of force may result in detachment of fan
connector X36 from the main circuit board resulting in
improper cooling of the drive.
STEP 6 Remove the cover of the drive.
CHECK!
1. Check that the bottom part of the drive is

completely detached (See STEP 4).
Remove the cover of the drive.
2. Gently, lift the bottom part of the cover.
frame R6 (powex)
Remove the cover of the drive.
3. Gently, push the cover up and out of the holding

clips located on the top side of the drive.
4. The drive cover can now be removed.
STEP 7 Disconnect RMIO board cables.
1. Disconnect the RMIO 24V power supply cable

from the RINT connector X34 and disconnect the
RMIO signal cable from the connector on the
RASI board.
STEP 8* Loosen choke cables from RMIO grounding plate.

(DRIVE
TYPE 1. Depending on the drive type the choke cables
DEPEN- may be fastened to the RMIO grounding plate. If
DENT) so, cut the cable tie holding them.
NOTE: Do not cut the choke cables
frame R6 (powex)
STEP 9* Disconnect the prevention of unexpected start /

ASTO cable (plus code +Q950/+Q967).
(DRIVES
WITH 1. If the drive is equipped with a prevention of
PLUS unexpected start function, disconnect the cable
CODE from connector X40 on the RINT board.
+Q950 /
+Q967)
STEP Disconnect the cables from the RRFCU board (plus

10* code +E202).
(DRIVES 1. If the drive is equipped with an EMC function it

WITH has a RRFCU board attached underneath the
PLUS RMIO grounding plate.
CODE 2. Mark the cables from the RRFCU board and
+E202) disconnect them from the RRFCU terminal block.
NOTE: Remember to mark the cables. They later need to

be attached in the correct order.
TOOLS:
Common blade screwdriver: small, (0,5x3 for example).
Disconnect the cables from the RRFCU board (plus
code +E202).
3. Mark the cables from the RRFCU board and

disconnect them from the input terminals by
removing the three M4x8 screws.
4. Remove the M4x20 grounding screw.
NOTE: Remember to mark the cables. They later need to

be attached to the same phases they were removed
from.
TOOLS:
Torx screwdriver: Tip size T20 (tip extension is useful).
frame R6 (powex)
STEP 11 Remove the RMIO grounding plate.
1. There are six M4x8 screws holding the RMIO

grounding plate to the frame of the drive.
Remove the RMIO grounding plate.
2. Remove the two M4x8 screws on the right hand

side of the RMIO grounding plate.
TOOLS:
frame R6 (powex)
3. Remove one M4x8 screw on the left hand side of

the RMIO grounding plate.
TOOLS:
4. Remove the two M4x8 screws on the bottom

side of the RMIO grounding plate.
TOOLS:
frame R6 (powex)
5. Remove the last M4x8 screw on the top side of

the RMIO grounding plate and carefully remove
the frame.
NOTE: Hold the RMIO grounding plate while removing

the last screw in order to make sure that the RMIO
grounding plate does not fall down, damaging the frame
or the RMIO board.
TOOLS:
STEP 12 Removal of UDC- bus bar.
1. The part of the UDC- bus bar that needs to be

changed is circled in the picture to the left.
NOTE: If the drive is equipped with a brake chopper,

continue from STEP 14.
frame R6 (powex)
Removal of UDC- bus bar.
2. Location of UDC- bus bar and UDC+ bus bar are

marked in the picture to the left. The support
pillar for the brake chopper bus bar is circled.
Removal of UDC- bus bar.
3. Carefully, remove the M6x12 screw (blue) and

the M6x16 screw (green) and remove the bus
bar.
TOOLS:
STEP 13 Installation of new UDC- bus bar.
1. Place the insulating bush around the support

pillar of the brake chopper bus bar. Make sure
that the base of the insulating bush is faced
towards the UDC+ bus bar.
2. See picture below.
Installation of new UDC- bus bar.
CHECK!
3. Correct placing of insulating bush with base of

insulating bush faced towards the UDC+ bus bar.
frame R6 (powex)
4. Place the new UDC- bus bar on top of the base

of the insulating bush.
NOTE: Make sure that the UDC- bus bar lies on top of
the base of the insulating bush.
5. Carefully, fasten the M6x12 screw (blue) and the

M6x16 screw (green) and remove the bus bar.
Do not tighten the screws yet, just make sure
they are on the right threads.
NOTE: Make sure that the bus bar screws are on the
right thread. Screws tighten on the wrong thread or
otherwise tighten improperly will cause damage to
the drive.
TOOLS:
Torx screwdriver: Tip size T25
6. Tighten the screws with a torque screwdriver

to a torque of 3 Nm.
otherwise tighten improperly, will cause damage to
the drive.
TOOLS:
Use a torque screwdriver for tightening the screws.
frame R6 (powex)
CHECK!
7. Correct placement UDC- bus bar. The base of

the insulating bush is faced towards the UDC+
bus bar and the UDC- bus bar is placed on top of
STEP Removal of UDC- bus bar for drives equipped with

14* brake chopper (plus code +D150).
(DRIVES 1. The part of the UDC- bus bar that needs to be

WITH changed is circled in the picture to the left.
PLUS
CODE
+D150)
Removal of UDC- bus bar for drives equipped with

brake chopper (plus code +D150).
2. Carefully, remove the M6x12 screw (blue) and

the M6x16 screw (green) and remove the bus
bar.
TOOLS:
STEP Installation of new UDC- bus bar for drives equipped

15* with brake chopper (plus code +D150).
(DRIVES 3. Remove the two 4x12 pt screws (blue) and the

WITH K50x16 pt screw (green) in order to loosen the
PLUS brake chopper bus bar.
CODE
+D150)
TOOLS:
frame R6 (powex)
Installation of new UDC- bus bar for drives equipped

with brake chopper (plus code +D150).
8. Gently lift up the brake chopper bus bar from the

terminal in order to make it loose.
NOTE: Do not use excessive force. The bus bar needs

only to be raised for about 1 cm.

9. Hold up the brake chopper bus bar and insert the

insulating bush around the support pillar.
10. Make sure that the base of the insulating bush is
faced towards the UDC+ bus bar.
NOTE: Only raise the bus bar enough so that the

insulating bush can be placed underneath it and around
the support pillar. Make sure not to bend or raise the bus
bar more than it needs to.
frame R6 (powex)

CHECK!
11. Correct placement of insulating bush with base

of insulating bush faced towards the UDC+ bus
bar.

12. Fasten the brake copper bus bar once the

insulating bush is placed around the support
pillar.
13. Fasten the two 4x12 pt screws (blue) and the
K50x16 pt screw (green)
14. Use a torque screwdriver and tighten the two
4x12 pt screws (blue) to a torque of 2 Nm, and
the tighten the K50x16 pt screw (green) to a
torque of 3 Nm.
TOOLS:
15. Slip the new bus bar into place from the side.
NOTE: Make sure that the UDC- bus bar lies on top of
frame R6 (powex)

CHECK!
16. Correct placement UDC- bus bar. The base of

the insulating bush is faced towards the UDC+
bus bar and the UDC- bus bar is placed on top of

17. Carefully, fasten the M6x12 screw (blue) and the

M6x16 screw (green). Do not tighten the
screws yet, just make sure they are on the right
threads.
18. Now, tighten the screws with a torque
screwdriver to a torque of 3 Nm.
otherwise tighten improperly will cause damage to
the drive.
TOOLS:
frame R6 (powex)
STEP 16 Re-attach the RMIO grounding plate.
1. Start with the top side M4x8 screw. Hold the

frame in place and make sure that all sides align.
Do not tighten the screw yet, just make sure
that it is fastened.
NOTE: Make sure that the frame is aligned properly.
TOOLS:
Re-attach the RMIO grounding plate.
2. Fasten the rest of the RMIO grounding plate

screws (M4x8). Do not tighten the screws yet,
just make sure that they are fastened and that
the grounding plate is properly aligned.
3. Now tighten all 6 screws with a torque of 2
Nm.
TOOLS:
frame R6 (powex)
Re-attach the RMIO grounding plate.
CHECK!
1. Make sure that the discharge resistor cables

(indicated to by arrows) do not get stuck between
the capacitor frame and the legs of the RMIO
grounding plate (area indicated to by ellipses).
STEP Re-attach choke cables on the front of the RMIO

17* grounding plate.
(DRIVE 1. Depending on the drive type the choke cables

TYPE may have been fastened to the RMIO grounding
DEPEN- plate. If they were loosen at STEP 8*, re-attach
DENT) them with a cable tie.
STEP Re-connect the prevention of unexpected start /
18* ASTO cable (plus code +Q950/+Q967).
(DRIVES 1. If the drive is equipped with a prevention of

WITH unexpected start function, re-connect the cable
PLUS to connector X40 on the RINT board.
CODE
+Q950 /
+Q967)
frame R6 (powex)
STEP Re-connect the cables to the RRFCU board (plus

19* code +E202).
(DRIVES 1. If the drive is equipped with an EMC function it

WITH has a RRFCU board attached underneath the
PLUS RMIO grounding plate.
CODE 2. Attach the cables to the RRFCU terminal block
+E202) according to the markings.
NOTE: Ensure that the order of the cables is correct.
TOOLS:
Common blade screwdriver: small, (0,5x3 for example).
Re-connect the cables to the RRFCU board (plus
code +E202).
1. Attach the cables from the RRFCU board to the

input terminals according to the markings.
2. Tighten the three M4x8 screws to a torque of 1,2
Nm
3. Re-attach the RRFCU grounding cable with the
M4x20 grounding screw to a torque of 2 Nm.
NOTE: Ensure that the order of the cables from the

RRFCU board to the terminals is correct.
TOOLS:
STEP 20 Re-connect RMIO board cables.
1. Re-connect the RMIO 24V power supply cable to

the RINT connector X34 and re-connect the
RMIO signal cable to the connector on the RASI
board.
frame R6 (powex)
STEP 21 Re-attach the drive cover.
1. Start by gently, pushing the top of the cover

down and in to the holding clips located on the
top side of the drive.
2. Once the top side is in place, gently push the
bottom side of the cover into place.
Re-attach the drive cover.
3. Secure the cover with the cover holding screw

M4x8 to a torque of 1,2 Nm.
TOOLS:
STEP 22 Re-attach fieldbus adapter plate and panel cable.
1. Carefully, re-attach the fieldbus adapter plate

with the 3 M3x6 plastic screws. Use hand force
only.
2. Re-attach the panel cable. Make sure the pins
align.
NOTE: Be careful not to damage the panel connector

pins when re-connecting the panel cable to the RMIO
board.
TOOLS:
STEP 23 Re-attach plug-in connectors, wire holders and
fieldbus adapters
1. Re-attach any plug-in connectors and wire

holders.
2. If the drive is equipped with a prevention of
unexpected start (+Q950/Q967) re-connect the
cable.
3. Be extra careful when re-attaching the fieldbus
adapters into the slots. Gently push the adapter
straight in. Make sure that the adapter pins do
not get bent or damaged.
frame R6 (powex)
Re-attach plug-in connectors, wire holders and

fieldbus adapters
4. Attach the fieldbus adapter grounding screws

M3x10 to a torque of 0,5 Nm.
TOOLS:
STEP For IP 55 drives, re-attach the protective cover

24*
1. Attach the top part of the protective cover. Start
(DRIVES by locking the lock screws from the top going
WITH down.
PLUS
CODE
+B056) TOOLS:
useful).
frame R6 (powex)
For IP 55 drives, re-attach the protective cover
2. Attach the bottom part of the protective cover.

Start by locking the lock screws on the sides
from the top going down.
3. Lastly lock the front facing lock screw.
NOTE: Be extra careful when locking the front lock

screw, too much force may damage the housing inside.
TOOLS:
useful).

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Field Rework Instructions for

ACx550, ACS800, ACS850 and ACQ810 3AXD10000388969.docx

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 1 / 23

1. FIELD REWORK INSTRUCTION FOR ACx550, ACS800, ACS850

- 1 x UDC- bus bar, code 68407419

Additional tools needed are:

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 2 / 23

4. STEP-BY-STEP INSTRUCTION FOR APPLYING THE

STEP 1* For IP 55 drives, remove the bottom part of the

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 3 / 23

STEP 2* For IP 55 drives, remove the top part of the

STEP 3 Remove fieldbus adapters.

1. Remove the fieldbus adapter grounding screws.

NOTE: Be careful not to lose the screws.

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 4 / 23

Remove fieldbus adapters.

2. Carefully pull out the fieldbus adapters by

Remove fieldbus adapters.

3. Pull the fieldbus adapters straight out of the

NOTE: Be careful not to damage the connection pins of

STEP 4 Detachment of drive cover, bottom side.

1. Remove the 3 plastic screws from the fieldbus

6. Use a needle-nose plier for removal of the plug-

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 5 / 23

Detachment of drive cover, bottom side.

7. Carefully, pull the plug-in connectors straight

STEP 5 Detachment of drive cover, top side.

1. The internal fan needs to be disconnected in

Detachment of drive cover, top side.

3. Use a small common blade screwdriver to hold

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 6 / 23

Detachment of drive cover, top side.

4. Carefully, disconnect the fan by pulling the fan

NOTE: Be extra careful when disconnecting the fan.

STEP 6 Remove the cover of the drive.

1. Check that the bottom part of the drive is

Remove the cover of the drive.

2. Gently, lift the bottom part of the cover.

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 7 / 23

Remove the cover of the drive.

3. Gently, push the cover up and out of the holding

STEP 7 Disconnect RMIO board cables.

1. Disconnect the RMIO 24V power supply cable

STEP 8* Loosen choke cables from RMIO grounding plate.

NOTE: Do not cut the choke cables

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 8 / 23

STEP 9* Disconnect the prevention of unexpected start /

STEP Disconnect the cables from the RRFCU board (plus

(DRIVES 1. If the drive is equipped with an EMC function it

NOTE: Remember to mark the cables. They later need to

3. Mark the cables from the RRFCU board and

NOTE: Remember to mark the cables. They later need to

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 9 / 23

STEP 11 Remove the RMIO grounding plate.

1. There are six M4x8 screws holding the RMIO

Remove the RMIO grounding plate.

2. Remove the two M4x8 screws on the right hand

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 10 / 23

Remove the RMIO grounding plate.

3. Remove one M4x8 screw on the left hand side of

Remove the RMIO grounding plate.

4. Remove the two M4x8 screws on the bottom

ACS800 12.Nov 2014 JORMANAINEN JONI A 1 11 / 23