DCS800 Service Manual

DCS800 Service Manual

DCS800

Service Manual

DCS800 Drives (20 A to 5200 A)



DCS800 Manuals

DCS800 Quick Guide

DCS800 Tools & Documentation CD

DCS800 Converter module

Flyer DCS800

Technical Catalog DCS800

Hardware Manual DCS800

Hardware Manual DCS800 update DCF503B/DCF504B

Firmware Manual DCS800

Installation according to EMC

Technical Guide

Service Manual DCS800

12-Pulse Manual

CMA-2 Board

Flyer Hard - Parallel

Drive Tools

DriveWindow 2.x - User's Manual

Public. number

3ADW000191

3ADW000211

3ADW000190

3ADW000192 x x

3ADW000194 x

3ADW000194Z0301 x

3ADW000193

3ADW000032

3ADW000163 x x x

3ADW000195

3ADW000196

3ADW000136

3ADW000213

3BFE64560981 x x x x x

DriveOPC 2.x - User's Manual

Optical DDCS Communication Link

DDCS Branching Units - User’s Manual

DCS800 Applications

3BFE00073846

3AFE63988235

3BFE64285513

PLC Programming with CoDeSys CoDeSys_V23

61131 DCS800 target +tool description - Application Program 3ADW000199

DCS800 Crane Drive

DCS800 Crane Drive Manual suppl.

DCS800 Crane Drive Product note

DCS800 Winder ITC

DCS800 Winder Product note

3AST004143

PDC5 EN

PDC2 EN

Language

E x x

D x x x x x x x x x x x x x x x

DCS800 Winder description ITC

Winder Questionnaire

DCS800-E Panel Solution

Flyer DCS800-E Panel solution

Hardware Manual DCS800-E

DCS800-A Enclosed Converters

Flyer DCS800-A

Technical Catalogue DCS800-A

Installation of DCS800-A

DCS800-R Rebuild System

Flyer DCS800-R

DCS800-R Rebuild Kits

DCS800-R Optical Rebuild Kits

DCS800-R DCS500/DCS600 Upgrade Kits

Extension Modules

RAIO-01 Analogue IO Extension

RDIO-01 Digital IO Extension

RRIA-01 Resolver Interface Module

RTAC-01 Pulse Encoder Interface

RTAC-03 TTL Pulse Encoder Interface

AIMA R-slot extension

Door mounting kits

Door mounting DCS Control Panel (IP54, click in)

Door mounting DCS Control Panel (fix mounting)

Door mounting DCS Control Panel (IP66, fix mounting)

Serial Communication

Drive specific serial communication

NETA Remote diagnostic interface

Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)

Fieldbus Adapter with DC Drives RCAN-02 (CANopen)

Fieldbus Adapter with DC Drives RCNA-01 (ControlNet)

Fieldbus Adapter with DC Drives RDNA- (DeviceNet)

Fieldbus Adapter with DC Drives RMBA (MODBUS)

3ADW000308

3ADW000253z

3ADW000210

3ADW000224

3ADW000213

3ADW000198

3ADW000091

3ADW000007

3ADW000197

3ADW000415

3ADW000256

3AFE64484567

3AFE64485733

3AFE68570760

3AFE64486853

3AFE68650500

3AFE64661442

3AUA0000076085

3AFE68294673

3AFE68829593

3AFE64605062

3AFE64504215

3AFE64506005

3AFE64504223

3AFE64498851

3AFE64539736 x x x x x x x x x x x x x x x x x x x x x x x x x x x x

Fieldbus Adapter with DC Drives RETA (Ethernet) x -> existing p -> planned

Status 06.2012

DCS800 Drive Manuals-List_l.doc

I x

ES F x x x x p x x x x x x x x x

CN RU PL PT SE x x x x x x x x x x x x x

DCS800 Drives

20 to 5200 A

Service Manual

Code: 3ADW000195R0601 Rev F

DCS800 Service Manual e f.doc

Effective: 09.2012

Supersedes: Rev E 03.2011

2012 ABB Automation Products GmbH. All rights reserved.

3ADW000195R0601 DCS800 Service Manual e f

5

Safety instructions

Chapter overview

This chapter contains the safety instructions you must follow when installing, operating and servicing the drive.

If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

To which products this chapter applies

The information is valid for the whole range of the product DCS800, the converter modules DCS800-S0x size

D1 to D7, field exciter units DCF80x, etc. like the Rebuild Kit DCS800-R00-9xxx.

Usage of warnings and notes

There are two types of safety instructions throughout this manual: warnings and notes. Warnings caution you about conditions, which can result in serious injury or death and/or damage to the equipment, and advice on how to avoid the danger. Notes draw attention to a particular condition or fact, or give information on a subject.

The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage, which can cause physical injury or death and/or damage to the equipment.

General danger warning warns about conditions, other than those caused by electricity, which can result in physical injury or death and/or damage to the equipment.

Electrostatic sensitive devices warning warn of electrostatic discharge, which can damage the equipment.

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

WARNING!

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. Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

1. Voltage between drive input phases U1, V1 and W1 and the frame is close to 0 V.

2. Voltage between terminals C+ and D- and the frame is close to 0 V.

 Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.

 Do not make any insulation resistance or voltage withstand tests on the drive or drive modules.

Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor.

When reconnecting the motor cable, always check that the C+ and D- cables are connected with the proper terminal.

Note:

The motor cable terminals on the drive are at a dangerously high voltage when the main power is on, regardless of whether the motor is running or not.

 Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO).

 DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply.

Safety instructions

3ADW000195R0601 DCS800 Service Manual e f

6

Grounding

These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic interference.

WARNING!

Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and pick-up.

 Make sure that grounding conductors are adequately sized and marked as required by safety regulations.

 In a multiple-drive installation, connect each drive separately to protective earth (PE ).

 Minimize EMC emission and make a 360° high frequency grounding (e.g. conductive sleeves) of screened cable entries at the cabinet lead-through plate.

 Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

 Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations.

 As the normal leakage current of the drive is higher than 3.5 mA

AC

50178, 5.2.11.1), a fixed protective earth connection is required.

Printed circuit boards and fiber optic cables

or 10 mA

DC

(stated by EN

These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

WARNING!

The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wristband when handling the boards. Do not touch the boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING!

Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands, as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions

3ADW000195R0601 DCS800 Service Manual e f

7

Mechanical installation

These notes are intended for all who install the drive. Handle the unit carefully to avoid damage and injury.

WARNING!

DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back.

 DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

 Make sure that dust from drilling does not enter the drive when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

 Ensure sufficient cooling.

 Do not fasten the drive by riveting or welding.

Operation

These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

WARNING!

Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

 Do not control the motor with the disconnecting device (disconnecting mains); instead, use the control panel keys and

 Mains connection

, or commands via the I/O board of the drive.

You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuitbreaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main contacts to open. The mains disconnect must be locked in its "OPEN" position during any installation and maintenance work.

EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals "RUN", "drive OFF" or "Emergency Stop" respectively "control panel" or "PC tool".

 Intended use

The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in industrial installations.

If in special cases the electrical machines and devices are intended for use in non-industrial installations - which may require stricter safety regulations (e.g. protection against contact by children or similar) - these additional safety measures for the installation must be provided by the customer during assembly.

Note:

 When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key .

Safety instructions

3ADW000195R0601 DCS800 Service Manual e f

8

Table of contents

DCS800 Manuals 2

Safety instructions 5

Chapter overview ........................................................................................................................... 5

To which products this chapter applies .......................................................................................... 5

Usage of warnings and notes ........................................................................................................ 5

Installation and maintenance work................................................................................................. 5

Mechanical installation ................................................................................................................... 7

Operation ....................................................................................................................................... 7

Table of contents 8

Introduction 11

Chapter overview ......................................................................................................................... 11

Before You Start .......................................................................................................................... 11

What this manual contains........................................................................................................... 11

Target group ................................................................................................................................ 11

Associated publications ............................................................................................................... 11

Storage and transport .................................................................................................................. 11

Name plate ............................................................................................................................................... 12

Type code ................................................................................................................................................. 13

Voltage ratings .......................................................................................................................................... 14

Current ratings .......................................................................................................................................... 15

Fault Tracing Thyristors 16

Tools ......................................................................................................................................................... 16

For commissioning and fault tracing ............................................................................................ 16

Additionally for service and preventive maintenance ................................................................... 17

How to detect a faulty thyristor .................................................................................................................. 17

A fuse is blown ............................................................................................................................. 17

DC-current pulses measured using an oscilloscope.................................................................... 17

Thyristor diagnosis ....................................................................................................................... 18

Ripple monitor .............................................................................................................................. 18

How to find a faulty thyristor ...................................................................................................................... 18

Converters size D1 to D4 (20 ... 1000 A) ..................................................................................... 18

Blown fuses .................................................................................................................................. 18

Converters size D5, D6 and D7 (900 ... 5200 A) ......................................................................... 19

Blown fuses .................................................................................................................................. 19

Ripple monitor .............................................................................................................................. 20

Handling the Semiconductors 21

General Instruction how to handle semiconductors .................................................................................. 21

Exchange thyristors sizes D1 to D4 22

Installation of OnBoard bridge (V1) and thyristor modules in converters size D1 to D4 (20 ... 1000 A) ... 22

Required tools .............................................................................................................................. 22

Find faulty thyristor modules ........................................................................................................ 22

Remove faulty thyristor modules .................................................................................................. 23

Install new thyristor modules ........................................................................................................ 26

Remove faulty OnBoard bridge (V1) ............................................................................................ 28

Install new OnBoard bridge (V1) .................................................................................................. 28

OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units ......................... 28

OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units ......................... 29

OnBoard bridge and thyristor module terminals .......................................................................... 30

Table of contents

3ADW000195R0601 DCS800 Service Manual e f

9

Exchange thyristors size D5 32

Installation of disc type thyristors in converters size D5 (900 ... 2000 A) ................................................. 32

Required Tools ............................................................................................................................ 32

Disk type thyristors ...................................................................................................................... 33

Original thyristor type (900 A) ...................................................................................................... 34

Second thyristor type (900 A) ...................................................................................................... 34

Original thyristor type (1200 A) .................................................................................................... 35

Second thyristor type (1200 A) .................................................................................................... 35

Find faulty thyristor modules ........................................................................................................ 36

Remove faulty thyristor ................................................................................................................ 37

Install new thyristor ...................................................................................................................... 38

Location of thyristors in frame D5 (4-Q bridge) ........................................................................... 39

Location of thyristors in frame D5 (2-Q bridge) ........................................................................... 39

Location of branch fuses frame D5 ............................................................................................. 40

Exchange thyristors size D6 41

Installation of disc type thyristors in converters size D6 (1900 ... 3000 A) ............................................... 41

Required Tools ............................................................................................................................ 41

Disk type thyristors ...................................................................................................................... 42

Original thyristor type ................................................................................................................... 43

Second thyristor type ................................................................................................................... 43

Bidirectional-Controlled-Thyristors (BCTs) .................................................................................. 44

Find faulty thyristor modules ........................................................................................................ 45

Remove faulty thyristor ................................................................................................................ 46

Install new thyristor ...................................................................................................................... 49

Location of thyristors in frame D6 (4-Q bridge with single thyristors) .......................................... 51

Location of thyristors in frame D6 (4-Q bridge with BCTs) .......................................................... 52

Location of thyristors in frame D6 (2-Q bridge with single thyristors) .......................................... 53

Location of branch fuses frame D6 ............................................................................................. 54

Exchange thyristors size D7 55

Installation of disc type thyristors in converters size D7 (2500 ... 5200 A) ............................................... 55

Required Tools ............................................................................................................................ 55

Find faulty thyristor modules ........................................................................................................ 56

Remove faulty thyristor ................................................................................................................ 58

Install new thyristor ...................................................................................................................... 60

Location of thyristors in frame D7 (4-Q bridge) ........................................................................... 62

Location of thyristors in frame D7 (2-Q bridge) ........................................................................... 62

Location of branch fuses frame D7 (busbars on the right) .......................................................... 63

Location of branch fuses frame D7 (busbars on the left) ............................................................ 64

Exchange SDCS-CON-4 65

General ..................................................................................................................................................... 65

Required Tools ............................................................................................................................ 65

Overview SDCS-CON-4 exchange .............................................................................................. 65

Service 73

Exchange converter fans sizes D1 to D3 (two fans) ................................................................................ 73

Exchange converter fans size D3 (four fans) ........................................................................................... 76

Exchange converter fan size D6 .............................................................................................................. 80

Exchange converter fan size D7 .............................................................................................................. 81

Exchange current transformers sizes D5 to D7 ....................................................................................... 82

Current transformers for sizes D5 and D6 ................................................................................... 83

Current transformers for size D7 ................................................................................................. 84

Exchange current transformers size D5 ...................................................................................... 85

Exchange current transformers size D6 ...................................................................................... 86

Exchange current transformers size D7 ...................................................................................... 87

Table of contents

3ADW000195R0601 DCS800 Service Manual e f

10

DCS800 firmware download ..................................................................................................................... 88

General ........................................................................................................................................ 88

Download SDCS-CON-4 firmware ............................................................................................... 88

Add firmware or text files ............................................................................................................. 98

Create a workspace ................................................................................................................... 102

Download SDCS-COM-8 firmware ............................................................................................ 111

Set type code .......................................................................................................................................... 113

Type code table ......................................................................................................................... 115

DC-Motor neutral zone adjustment ......................................................................................................... 116

Types concerned ....................................................................................................................... 116

Summary .................................................................................................................................... 116

General ...................................................................................................................................... 116

Preventive Maintenance 117

Recommended regular maintenance ..................................................................................................... 118

Maintenance schedule ............................................................................................................................ 118

Annual preventive maintenance ............................................................................................................. 119

3 years preventive maintenance ............................................................................................................. 122

6 years preventive maintenance ............................................................................................................. 123

9 years preventive maintenance ............................................................................................................. 124

Preventive maintenance Checklist DCS800 ........................................................................................... 125

Appendix A: Spare Parts List 127

Table of contents

3ADW000195R0601 DCS800 Service Manual e f

Introduction

Chapter overview

This chapter describes the purpose, contents and the intended use of this manual.

Before You Start

The purpose of this service manual is to provide detailed information on how to service DCS800 power

converters. The

Safety instructions

at the beginning of this manual needs to by studied before attempting any

work on or with the drive. Read this manual before servicing the drive.

What this manual contains

The

Safety instructions

are at the beginning of this manual.

Introduction

, the chapter you are currently reading, introduces you to this manual and the thyristor power

converter rating plate.

Fault Tracing Thyristors

, this chapter describes how to detect and select a faulty thyristor.

Handling the Semiconductors

, this chapter describes the handling of thyristors and thyristor modules.

Exchange of Thyristors for sizes D1 to D4

, this chapter describes the exchange of thyristors in converters

sizes D1 to D4.

Exchange of Thyristors for size D5

, this chapter describes the exchange of thyristors in converters sizes D5.

Exchange of Thyristors for size D6

, this chapter describes the exchange of thyristors in converters sizes D6.

Exchange of Thyristors for size D7

, this chapter describes the exchange of thyristors in converters sizes D7.

Exchange of SDCS-CON-4

, this chapter describes the exchange of a SDCS-CON-4.

Service

, this chapter contains hardware change information, firmware download and technical hints.

Preventive Maintenance

, this chapter describes preventive maintenance of thyristor converters.

Appendix A: Spare Parts list

, Appendix A contains the spare parts list.

Target group

This manual is designed to help those responsible for planning, installing, starting up and servicing thyristor power converters.

These people should possess:

− basic knowledge of physics, electrical engineering, electrical wiring principles, components as well as symbols used in electrical engineering and

− basic experience with DC drives and DC products.

Associated publications

A list of associated publications is published on the inner page of this manual’s cover, see

DCS800 Manuals

.

The above listed documentation can be found on the CD-ROM being attached to the

DCS800 Quick Guide

(3ADW000191) .

Storage and transport

If the unit has been in storage prior to installation or is transported to another location, care must be taken to

ensure that the environmental conditions are complied with (see

DCS800 Hardware Manual

).

11

Introduction

3ADW000195R0601 DCS800 Service Manual e f

12

Name plate

For purposes of identification, each thyristor power converter is fitted with name plates, stating the type code and the serial number, which serve for each unit's individual identification.

The type code contains information about the characteristics and the configuration of the unit.

3

∼ 525 V

Made in Germany

N713

ABB Automation Products GmbH

Type: DCS800-S02-0025-05

Ser No: 0025421A06294264

U1

I1 f1

SCCR

20 A

50/60 Hz

65 kA

U2 610 V

I2 25 A

I f

Fan

6 A

----

+K454

+J409

Production year

2006 and week 29

Rated input voltage

Rated input current

Rated output current

Rated internal field exciter current

Rated fan voltage

Plus code

Introduction

3ADW000195R0601 DCS800 Service Manual e f

13

Type code

The type code contains information on the specification and configuration of the drive. The first digits from left show the basic configuration (e.g. DCS800-S01-2000). The optional selections are given thereafter on the name plate by plus code. The main selections are described below. Not all selections are available for all types.

The drive’s basic type code: DCS800-AAX-YYYY-ZZB + plus code

Product family

Type:

Bridge type:

Module type:

Rated AC voltage

Power connection:

Field exciter configuration:

Fan voltage:

DCS800

AA = S0

= R0

= E0

= A0

X

YYYY

ZZ

= 1

= 2

=

= 04

= 05

= 06

= 07

= 08

= 10

= 12

B = -

= a

= L

= R

+0S163

+S164

Standard converter module

Rebuild system

Panel solution

Enclosed converter

Single bridge (2-Q)

2 anti parallel bridges (4-Q)

Rated DC current

230 V

230 V

270 V

AC

AC

AC

315 V

AC

- 400 V

- 525 V

- 600 V

AC

AC

AC

- 690 V

AC

360 V

AC

- 800 V

AC

450 V

AC

- 990 V

AC

540 V

AC

- 1200 V

AC

Standard D1 - D6

Second thyristor type D5, D6

Left side D7

Right side D7

Without OnBoard field exciter (D1 - D4)

With internal field exciter, supply external (D5: 25 A, Rebuild kit: 16 A / 25 A)

Current measurement:

Voltage measurement:

SDCS-DSL-4:

DCS Control Panel:

Fieldbus:

Standard

+S171

Standard

Standard

+S172

+S175

+S186

+S185

+S180

+S181

+S182

+S183

+S189

+P905

+P906

+S199

+0S199

0J400

J409

K454

K451

K466

K458

Size D4

Fan voltage:

Fan voltage:

Size D6

230 V / 1-ph

115 V / 1-ph

400 V / 525 V / 800 V units: 400 V - 500 V / 3-ph

600 V / 690 V units:

600 V / 690 V units:

SDCS-CMA-2 (D5 - D7)

525 V - 690 V / 3-ph

400 V - 500 V / 3-ph

120 V SDCS-SUB-4 (D1 - D4)

SDCS-PIN-51 configured to 120 V (D5 - D7)

SDCS-PIN-51 configured to 600 V (D5 - D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 690 V (D5 - D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 800 V (D6, D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 990 V (D6, D7), 12-pulse serial / serial sequential

Galvanic isolation (D6, D7)

Electronic boards are located in the D7 module

Electronic boards are in a separate electronic housing (outside the D7 module)

With SDCS-DSL-4

Without SDCS-DSL-4

Without DCS Control Panel

Door mounting kit, including 3 m cable

Profibus RPBA-01

DeviceNet RDNA-01

Ethernet/IP, Modbus/TCP RETA-01

Modbus (RTU) RMBA-01

I/O and DDCS:

L500

L501

L508

L509

Analog Extension RAIO-01

Digital Extension RDIO-01

DDCS communication board (10 Mbaud CH0) SDCS-COM-81

DDCS communication board (5 Mbaud CH0) SDCS-COM-82

The technical data and specifications are valid as of going to press. ABB reserves the right to make subsequent alterations.

If you have any questions concerning your drive system, please contact your local ABB agent.

Introduction

3ADW000195R0601 DCS800 Service Manual e f

14

Voltage ratings

The maximum available armature voltages have been calculated using the following assumptions:

− U

VN

= rated mains voltage, 3-phase,

− Voltage tolerance ±10 %,

− Internal voltage drop approximately 1 %:

If a deviation or a voltage drop has to be taken into account in compliance with IEC and VDE standards, the output voltage and / or the output current must be reduced.

Mains voltage

U

VN

[V

230

380

AC

]

400

415

440

460

480

500

525

575

U

Maximum DC voltage d max 2-Q

[V

DC

] U d max 4-Q

[V

610

670

700

765

800

915

1160

1380

265

440

465

480

510

530

555

580

545

600

625

685

720

820

1040

1235

240

395

415

430

455

480

500

520

DC

]

Ideal DC voltage DC voltage class

U d0

[V

310

510

DC

]

540

560

590

620

640

670

700

770

600

660

690

800

810

890

930

1060

990

1200

1350

1590

The maximum available field voltage can be calculated using following formula:

07

08

10

12

05

06

06

07

05

05

05

05

04

04

04

04

U

F

≤ 1 .

35 ∗

U

VN



100 %

100

TOL

%



, with:

U

F

= field voltage,

U

VN

= mains voltage and

TOL = tolerance of the mains voltage in %.

Introduction

3ADW000195R0601 DCS800 Service Manual e f

Current ratings

1

Unit size 2-Q rated current

DCS800-01 [A

DC

]

D1

D2

D3

D4

D5

D6

D7

2000

1900

2050

2500

3000

2050

2600

3300

4000

4800

5200

only available as 2-Q drive

405

470

610

740

900

900

1200

1500

20

45

65

90

125

180

230

315

4-Q rated current

DCS800-02 [A

DC

]

2000

1900

2050

2500

3000

2050

2600

3300

4000

4800

5200

450

520

680

820

1000

900

1200

1500

25

50

75

100

140

200

260

350

Supply voltage [V

AC

]

400 525 600 690 800 990 1200

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

15

3ADW000195R0601 DCS800 Service Manual e f

Introduction

16

Fault Tracing Thyristors

Tools

For commissioning and fault tracing

Following software tools are mandatory:

− DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program

and

− DriveWindow for fast drive monitoring using SDCS-COM-8.

Following tools are mandatory in addition to standard tools:

− An oscilloscope including memory function with either galvanically isolating transformer or isolating amplifier (probe) for safe measurements. It can also be a hand held (portable) oscilloscope.

− A clamp on current probe. In case the scaling of the DC load current needs to be checked it must be a DC clamp on current probe.

− A voltmeter (at least CAT III 1000 V)

− 1000 V probes and test leads

− An ESD-field service kit (ABB Service Finland code 0001ESD / MS-Antistatic)

Make sure that all equipment in use is suitable for the voltage level applied to the power part!

Fault Tracing Thyristors

3ADW000195R0601 DCS800 Service Manual e f

Additionally for service and preventive maintenance

Following additional tools are mandatory for cleaning:

− An ESD safe blower / ESD vacuum cleaner

(ABB Service Finland code 0006ESD /

MUNTZ 555-ESD-S-E)

How to detect a faulty thyristor

Thyristor problems can be noticed differently:

A fuse is blown

This is an indication that a strong overcurrent has happened due to one of the following reasons:

− An internal short circuit between the phases (line side / AC-side) because of a defective thyristor (short circuit inside a thyristor from anode to cathode).

− An internal short circuit between the phases (line side / AC-side) because of circulating current in a 4-Q converter (malfunction of the control electronics, no thyristor defective).

− An external short circuit at the DC terminals of the converter without sufficient impedance.

− A commutation fault during generating (active braking with high current, high EMF and with low AC voltage) of a 4-Q converter.

Note:

− In case of parallel fuses: If one of the parallel fuses is blown, all parallel fuses have to be changed. The

‘undamaged’ fuses might be ‘half-blown’ and will blow with the next high current.

− In case of serial fuses (e.g. DC-fuses): If one of the serial fuses is blown, all serial fuses have to be changed. The ‘undamaged’ fuses might be ‘half-blown’ and will blow with the next high current.

DC-current pulses measured using an oscilloscope

Connect an oscilloscope to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3) and check for the proper amount of current pulses:

17

3ADW000195R0601 DCS800 Service Manual e f

Fault Tracing Thyristors

18

There should be six current pulses in positive direction.

In case of a 4-Q converter also the six current pulses for the negative current direction or other speed direction have to be checked.

Thyristor diagnosis

Also the thyristor diagnosis provided by the firmware can be used:

− Switch the drive to local mode (DriveWindow, DriveWindow Light, DCS Control Panel or local I/O).

− Start the thyristor diagnosis by means of ServiceMode (99.06) = ThyDiagnosis and set On and Run within 20 s.

− During the thyristor diagnosis the main contactor will be closed and the thyristors are checked. The field current is not released while the thyristor diagnosis is active and thus the motor should not turn.

− When the thyristor diagnosis is finished check Diagnosis (9.11) for details.

− For more information consult the

DCS800 Firmware Manual

.

Ripple monitor

The ripple monitor indicates that the ripple of the DC current is much higher than normal. In such a case, most often one thyristor does not work. Its missing current contribution causes a deep dip in the direct current.

The structure of the current loop (current controller) will force the other thyristors to compensate the dip by a certain overcurrent in order to keep the average current constant. Such a compensation results in a ripple monitoring fault during motoring mode operation with

α ≤ 90°.

The reason for a current less thyristor may be:

− A blown line fuse. This is possible only for converters with 20 ... 1000 A.

− A fuse has disconnected one of the six thyristors. This is possible only for converters with 900 ... 5200 A

(six internal branch fuses).

− A loose gate / cathode connector.

− A thyristor does not get firing pulses or does not react to firing pulses.

− The current controller may be totally mismatched to the DC load.

− The AC mains network is causing that fault message. In this case, asymmetrical phase shift, uneven phase voltage or critical designed power factor correction equipment or harmonic reduction equipment can be the reason.

How to find a faulty thyristor

If a blown fuse is suspected, the problem is caused most often by a faulty thyristor. To make sure, that a thyristor is the reason and needs to be exchanged fault tracing must be done in two different ways, depending on the size of the converter.

In general, make sure, that all safety instructions, given within this manual or within

the

Safety instructions

, related to the machine or the application itself, are obeyed.

Converters size D1 to D4 (20 ... 1000 A)

These converters require semiconductor fuses in the 3 AC lines.

− The converter must be disconnected from the mains.

− One motor armature cable should be disconnected from the converter.

Blown fuses

− Make sure, that the connection to the motor is open (e.g. disconnect motor cables).

− Using the OHM function of a normal multimeter, measurements must be made from each AC terminal to each DC terminal (U1 to C1, V1 to C1, W1 to C1, U1 to D1, V1 to D1 and W1 to D1:

Fault Tracing Thyristors

3ADW000195R0601 DCS800 Service Manual e f

19

Bridge configuration D1 to D4

− Normally, every measurement should show high resistance (> 1 kΩ).

− Target: find a short circuit, indicated by low resistance (< 1 Ω) (destroyed thyristor).

− If the converter is designed with thyristor modules, then a module consists of two thyristors. In this case it is sufficient to know which thyristor module has a defective thyristor because the complete module must be replaced.

− After a thyristor module is replaced, the above mentioned measurement should be done another time to make sure that all faulty thyristors have been detected!

Note:

The RC / snubber circuit could also cause 0

Ω results for a short time.

The measurement, showing less resistance than 1

Ω should be made a second time with test leads applied to the terminals with opposite polarity; if this measurement shows the same result, one or two thyristors located in that path are faulty; they need to be replaced.

Converters size D5, D6 and D7 (900 ... 5200 A)

These converters are equipped with fuses in the branches of the power part.

− The converter must be disconnected from the mains.

Blown fuses

− Make sure, that the connection to the motor is open (e.g. disconnect motor cables).

− In case of a blown fuse, the faulty thyristor or the faulty pair of thyristors are already isolated at one side from the others and therefore the faulty branch is known:

Fault Tracing Thyristors

3ADW000195R0601 DCS800 Service Manual e f

20

Bridge configuration D5 to D7

− The OHM test should be performed, when the thyristor is still clamped. Outside the converter a special thyristor clamping device is needed.

− For 4-Q converters with anti-parallel thyristors or BCT’s: o The selection of a forward or reverse thyristor or BCT (Bidirectional-Controlled-Thyristor) is done

during the disassembly. Continue with related part Exchange of Thyristors for Size

D5 ,

D6

or D7

section Find faulty thyristor.

− After a thyristor was replaced, the OHM test should be done another time to make sure that all faulty thyristors have been detected! If the motor is still connected to the converter the result of the measurement may be wrong.

Ripple monitor

If the ripple monitor fault occurred, a fault tracing as described above must be carried out:

− Check the fuses and the thyristors, according to the statements before.

− If the power section seems to be ok, but still one or more thyristors don’t take current, something went wrong in between the firing pulse generation and the thyristor’s gate; in this case check: o Is a firing pulse present on the primary side of the firing pulse transformer? o Is a firing pulse present on the secondary side of the firing pulse transformer? o Is the firing pulse transferred to the gate of the thyristor (loose gate connector)? Are all electrical connections still healthy? o Can the thyristor be fired with the applied firing pulse? Is the pulse form of the firing pulse identical at all measuring positions?

− Check the settings of the current controller.

− Check the AC mains network by taking recordings of the line voltage and current at all 3 phases at the same time.

Fault Tracing Thyristors

3ADW000195R0601 DCS800 Service Manual e f

21

Handling the Semiconductors

General Instruction how to handle semiconductors

Thyristor modules, busbars and fuses have to be mounted with the correct torque using a torque screw driver or torque wrench.

In converters sizes D5 (900 ... 2000 A), D6 (1900 ... 3000 A) and D7 (2050 ... 5200 A) the mounting force is indicated by an indicating spring welded to the mounting clamp, which is inside the unit.

Always mark suspected damaged components clearly after removing them from the circuit, to avoid confusion with "good" components.

When removing a damaged semiconductor, write down how and where it was installed (direction, location, connected gate leads and with BCT’s the position of the gate connectors).

Check that the new and old components have the same type designation or that the new component can replace the old one. A semiconductor can be replaced by different compatible semiconductor according to the codes in the manufacturers' table.

Semiconductor components are high-precision products. All unnecessary used tools and objects might damage the easily dented and scratched surfaces of the semiconductors.

1. Keep new semiconductors as long as possible in their original packages.

2. Use protective gloves if possible.

3. Clean work area and hands frequently.

4. Use good illumination.

3ADW000399R0101 DCS550 Service Manual e a

Handling the Semiconductors

22

Exchange thyristors sizes D1 to D4

Installation of OnBoard bridge (V1) and thyristor modules in converters size D1 to D4 (20 ... 1000 A)

All DCS800 size D1 to D4 are equipped with an OnBoard bridge (excitation) and thyristor modules. In order to keep the operating temperature of the semiconductor module low, the joint between the heat sink and the module should have a good heat conducting ability. The electrical conductivity of the connectors must also be good. For this reason the following instructions must be observed with particular care.

Required tools

Special tools or material needed in addition to standard tools for the exchange of thyristor modules:

− Torx screwdrivers

− Torque spanner

TX10, TX20, TX25 mounting torques for the OnBoard bridge and the thyristor modules

to heat sink and electrical connections see table

Nominal mounting torque for OnBoard bridge and thyristor modules

.

− Torque spanner for electrical connections

13 Nm (M8)

25 Nm (M10)

50 Nm (M12)

− Screws are metric type; use appropriate nuts

− Tissue paper

− Solvent (e.g. ethanol)

− Thermal joint compound (grease) type Berulub FZ1 E3

Manufacturer: Carl Bechem GmbH, 58089 Hagen or

− thermal joint compound

ABB Service: GHSN 390 011 P 0051 type WLPF 20 (10 ml)

ABB Service: GHSN 390 011 P 10

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

Find faulty thyristor modules

See

Fault Tracing Thyristors

of this publication.

Exchange thyristors sizes D1 to D4

3ADW000195R0601 DCS800 Service Manual e f

23

Remove faulty thyristor modules

1. Remove DCS Control Panel and design cover

2. Remove all plug in options on the intermediate cover e.g.:

− serial communication modules (Rtype),

− extension I/O modules (RAIO, RDIO),

− extension modules for second encoder (RTAC) or resolver (RRIA),

− communication board (SDCS-COM-8),

− isolated I/O (SDCS-IOB-2x, SDCS-

IOB-3) and

− SDCS-MEM-8 (Memory Card).

3. Remove the intermediate cover by depressing the two locks on the upper right and left hand side of the cover

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors sizes D1 to D4

24

4. Disconnect all I/O plugs (X3 to X7) at the

SDCS-CON-4 and the plugs at the SDCS-

DSL-4 board, if used (X51 to X54)

5. Remove the grounding plug and the holding screw at the electronic tray

Remove the grounding plug and the holding screw

Exchange thyristors sizes D1 to D4

3ADW000195R0601 DCS800 Service Manual e f

6. To unhinge the electronic tray including the

SDCS-CON-4 pull it up and then out

7. Before removing the tray completely unplug the flat cables (X12, X13, X37)

Electronic tray with SDCS-CON-4

25

Remove flat cables

8. Remove all cables and plugs at the SDCS-

PIN-4

Keep the winding direction and amount of windings through T100 in mind.

For X8 use a screw driver:

Attention:

Write down the winding direction of the field current cable through T100!

D1: thread the wire 4 times through the hole in T100 (that equals 3 loops)

D2 - D4: thread the wire 1 time through the hole in T100 (that equals no loops)

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors sizes D1 to D4

26

9. Remove the SDCS-PIN-4 board

OnBoard field exciter bridge module

Thyristor modules

Snubber resistor

Current transformer Temperature sensor

10. Remove the gate leads from the faulty thyristor module and mark the connectors clearly.

11. Remove the busbars necessary to get full access to the faulty thyristor module.

12. If a current transformer must be removed, mark its position, direction and the connections clearly.

Note:

Remove only as many parts as needed around the faulty thyristor module.

13. Remove the faulty thyristor module and mark it clearly as defective.

Install new thyristor modules

1. Ensure that the new thyristor module is of the correct type (see

Appendix A

of this manual).

2. Remove old heat conducting compound (grease) from the heat sink. Clean the mounting surfaces (heat sink and thyristor module) with an appropriate solvent (e.g. ethanol) by means of tissue paper. When the heat sink is clean, spread out the heat conducting compound with a rubber spatula or by hand.

3. Apply a thin layer of heat conducting compound to the new thyristor module

Exchange thyristors sizes D1 to D4

3ADW000195R0601 DCS800 Service Manual e f

27

4. Spread the heat conducting compound evenly by moving the thyristor module forward and backward on the heat sink.

5. Tighten all clamping screws by hand until the screw heads touch the bottom of the thyristor module. Then tighten the screws to 2.0 Nm torque.

Note:

If the thyristor module is mounted by means of four screws, tighten the screws crosswise.

6. Tighten the screws to nominal torque according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

.

Thyristor modules and SDCS-BAB-F Nominal mounting torque

Size Type Electrical connections

Thyristor module to heat sink

29 mm bridge block VVZF 70-16

20 mm block

20 mm block

34 mm block

SKKT 27, 42, 57, 106

MCC 26, 44, 56, 95

MCC 162

-

3 Nm

2.5 ... 4 Nm

4.45 … 5.5 Nm

5 Nm

5 Nm

2.5 ... 4 Nm

2.25 … 2.75 Nm

34 mm block

34 mm block

50 mm block

SKKT 162

TT 162

MCC 255

5 Nm

6 Nm

11 … 13 Nm

5 Nm

6 Nm

4.5 … 7 Nm

50 mm block TT 250, 330 12 Nm 6 Nm

60 mm block TT 425, 570 12 Nm 6 Nm

7. Reinstall the current transformer. Make sure, its position and direction is correct.

8. Reinstall the busbars. Make sure, the correct torque is applied according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

.

9. Reconnect all gate leads to the thyristor module.

10. Perform an OHM test to make sure the thyristor is ok.

11. Reinstall the SDCS-PIN-4 board.

12. Reconnect all cables and plugs at the SDCS-PIN-4:

1. snubber resistor (X30, X31),

2. temperature sensor (X22),

3. current transformers (X3, X4, X5),

4. OnBoard excitation (X8, X9, X11), use proper winding direction and amount of windings for T100

5. gate leads (first X16, X18 then X15, X17),

6. OnBoard excitation line voltage (X1, X2, X7),

7. all plugs (X10, X96, X99) and

8. all flat cables (X12, X13, X37), use the lock connectors at the SDCS-PIN-4

13. Reconnect the flat cables at the SDCS-CON-4 (X12, X13, X37) and re-hinge the electronic tray.

14. Reconnect the grounding plug and the holding screw at the electronic tray.

15. Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7) and the plugs at the SDCS-DSL-4 (X51 to X54).

16. Reinstall the intermediate cover, all plug in options (do not forget the screws), the design cover and the

DCS Control Panel.

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors sizes D1 to D4

28

Remove faulty OnBoard bridge (V1)

1. Follow the instructions

Remove faulty thyristor modules

until step 9 is done.

2. Remove all connectors from the faulty OnBoard bridge and mark the connectors clearly.

3. Remove the faulty OnBoard bridge and mark it clearly as defective.

Install new OnBoard bridge (V1)

1. Ensure that the new OnBoard bridge is of the correct type (see

Appendix A

of this manual).

2. Remove old heat conducting compound (grease) from the heat sink. Clean the mounting surfaces (heat sink and OnBoard bridge) with an appropriate solvent (e.g. ethanol) by means of tissue paper. When the heat sink is clean, spread out the heat conducting compound with a rubber spatula or by hand.

3. Apply a thin layer of heat conducting compound to the new OnBoard bridge.

4. Spread the heat conducting compound evenly by moving the OnBoard forward and backward on the heat sink.

5. Tighten all clamping screws by hand until the screw heads touch the bottom of the thyristor module. Then tighten the screws to 2.0 Nm torque.

6. Tighten the screws to nominal torque according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

.

7. Reconnect all connectors or cables to the OnBoard bridge.

8. Follow the instructions

Install new thyristor modules

beginning with step 11.

OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units

DCS800-S01-0020 ... 0180 DCS800-S01-0230

V1 V1

V14/V11

4 2 3 1

V16/V13

4 2 3 1

V12/V15

4 2 3 1

V14/V11

V16/V13 V12/V15

V1

V14/V11

G2 G1 K1

DCS800-S01-0315 ... 0470

V16/V13

G2 G1 K1

V12/V15

G2 G1 K1

V1

V14/V11

DCS800-S01-0610 ... 0900

V16/V13 V12/V15

DCS800 loc of mod 1Q.dsf

Note:

This drawing is only showing the location of the OnBoard bridge and thyristor modules, the actual converter module size is different!

Exchange thyristors sizes D1 to D4

3ADW000195R0601 DCS800 Service Manual e f

OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units

DCS800-S02-0025 ... 0200 DCS800-S02-0260

V1 V1

V14/V21 V16/V23 V12/V25

V14/V21

4 2 3 1

V16/V23

4 2 3 1

V12/V25

4 2 3 1

29

1 3 2 4

V11/V24

1 3 2 4

V13/V26

1 3 2 4

V15/V22

V11

V24

G1

G2

K1

K2

A

V1

K

DCS800-S02-0350 ... 0520

AK

AK K A

K2

G2

G1

K1

V14

V21

V15

V22

G1

G2

K1

K2

A K AK

AK K A

K2

G2

G1

K1

V12

V25

V13

V26

G1

G2

K1

K2

A K AK

AK K A

K2

G2

G1

K1

V16

V23

V11/V24

V1

V13/V26

V15/V22

DCS800-S01-0680 ... 1000

V26/V13 V22/V15

V24/V11

V21/V14

V23/V16

V25/V12

DCS800 loc of mod 4Q.dsf

Note:

This drawing is only showing the location of the OnBoard bridge and thyristor modules, the actual converter module size is different!

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors sizes D1 to D4

30

OnBoard bridge and thyristor module terminals

The next figures show the terminals of the OnBoard bridge and all used thyristor modules. The terminal description is also stamped or marked by a sticker on the OnBoard bridge and all thyristor modules.

For all firing pulse cables is valid:

Yellow is gate lead.

Red is cathode lead.

(AK) (K)

1 2

5

4

VVZF 70-16

6 7

(A)

3

1

2 3

7 G

6 K

5 K

4 G

SKKT 27, 42, 57, 106

6 7

MCC162

5 4

(AK) (K)

1 2

4

5 7

6

(A)

3

1

2 3

6 G

7 K

4 K

5 G

MCC26, 44, 56, 95

(AK)

1

(K)

2

5

4 7 6

(A)

3

1 2 3

SKTT 162

6 7

4 5

Exchange thyristors sizes D1 to D4

3ADW000195R0601 DCS800 Service Manual e f

A

K

K

K1 G1 K2 G2

A

A K

K

A

A

K K

K1 G1

TT 162

K2 G2

A

K 2 G 2

K 1 G 1

AK

K

A

K2

G2

G1

K1

TT 250, 330

(A)

3

MCC255

6G 7K 5G 4K

(K)

2

(AK)

1

3 2

TT 425, 570

1

5G

4K

6G

7K

31

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors sizes D1 to D4

32

Exchange thyristors size D5

Installation of disc type thyristors in converters size D5 (900 ... 2000 A)

All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the disc type semiconductor component is such that it requires a certain compression force to operate. The prevention of overheating of the component essentially depends on good heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.

Required Tools

Special tools or material needed in addition to standard tools for the exchange of thyristor modules:

− Torx screwdrivers

− Torque spanner for electrical connections

TX10, TX20, TX25

13 Nm (M8)

25 Nm (M10)

50 Nm (M12)

− Screws are metric type; use appropriate nuts

− 17 mm ring spanner for fuse and busbar connections

− 17 mm ring spanner for press clamp

− Tissue paper

− Solvent (e.g. ethanol)

− Thermal joint compound (grease) type BECHEM-RHUS SU 2

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 001 P 0001

3ADT 621 023 P1 − Disassembly tool

Note:

For more detailed information about the wiring of the power part, see

Hardware Manual

.

Therefore strict observance of the build in instructions given below is of utmost importance. Make sure that the new component can replace the old one in accordance with the spare part list (see

Appendix A

of this manual).

Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage. Avoid touching the contact surfaces. Do not lift the semiconductor with the gate wire. Do not lift the semiconductor by touching the current contact surfaces. Do not damage the welding flange or the contact surface.

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

Exchange thyristors size D5

3ADW000399R0101 DCS550 Service Manual e a

Disk type thyristors

Some converter modules size D5 are equipped with different disc type thyristors. For easy identification the name plate of the converter module is marked with “ a ” after the voltage identification:

Converter with original thyristor type T459Nxxx

Id code: DCA0012007P0001

U

1

Converter with second thyristor type T460Nxxx

Id code: 3ADC340105P0001

DCS800-S01-0900-06

DCS800-S02-0900-06

DCS800-S01-0900-07

DCS800-S02-0900-07

Converter with original thyristor type T589Nxxx

Id code: DCA0012015P0001

3 ~ 600 VAC

3 ~ 600 VAC

3 ~ 690 VAC

3 ~ 690 VAC

U

1

DCS800-S01-0900-06

a

DCS800-S02-0900-06

a

DCS800-S01-0900-07

a

DCS800-S02-0900-07

a

Converter with second thyristor type T590Nxxx

Id code: 3ADC340106P0001

DCS800-S01-1200-04

DCS800-S02-1200-04

DCS800-S01-1200-05

DCS800-S02-1200-05

3 ~ 400 VAC

3 ~ 400 VAC

3 ~ 525 VAC

3 ~ 525 VAC

DCS800-S01-1200-04

DCS800-S01-1200-05

a

DCS800-S02-1200-04

a a

DCS800-S02-1200-05

a

The current and voltage ratings of original and second thyristor type are the same, but the sizes of gate and cathode terminals are different. Thus it is not possible to interchange both thyristor types as spares.

Attention:

Use always the correct spare thyristor!

33

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors size D5

34

Original thyristor type (900 A)

Converter with original thyristor type T459Nxxx Id code: DCA0012007P0001

Gate (G):

Cathode (HK):

Conductive plate:

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm

Diameter 36 mm

Second thyristor type (900 A)

Converter with second thyristor type T460Nxxx Id code: 3ADC340105P0001

Gate (4):

Cathode (5):

Conductive plate:

Round terminal D = 1.5 mm

Faston 4.8 x 0.5 mm

Diameter 36 mm

Exchange thyristors size D5

3ADW000399R0101 DCS550 Service Manual e a

Original thyristor type (1200 A)

Converter with original thyristor type T589Nxxx Id code: DCA0012015P0001

35

Gate (G):

Cathode (HK):

Conductive plate:

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm

Diameter 36 mm

Second thyristor type (1200 A)

Converter with second thyristor type T590Nxxx Id code: 3ADC340106P0001

Gate (4):

Cathode (5):

Conductive plate:

Round terminal D = 1.5 mm

Faston 4.8 x 0.5 mm

Diameter 36 mm

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors size D5

36

Find faulty thyristor modules

1. Find the defective branches by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1

Bridge configuration D5 to D7

2. Disconnect the branching fuses of the defective branches.

3. Find the defective thyristors by performing an OHM test (both polarities) over their heat sinks.

4. In a 4-quadrant converter change both thyristors clamped between the same heatsinks at once.

Note:

Because “Disc Type” semiconductors need a certain compression force to operate properly, a measurement outside the clamped heat sinks might be wrong. To be sure which thyristor is broken change only one thyristor, clamp the heat sinks again and repeat step three.

Exchange thyristors size D5

3ADW000399R0101 DCS550 Service Manual e a

Remove faulty thyristor

1. Remove the screws of the DC-busbars and branch fuses preventing the stack to be prized open.

Note:

It depends on the location of the defective thyristor which DC-busbar and fuses have to be disconnected.

2. Write down the direction and location of the thyristors to be removed and mark their gate leads.

3. Remove the gate leads if possible.

4. Loosen the mounting clamp at the top of the thyristor stack.

Loose condition

TORQUE INDICATING SPRING

37

Insulating plate

Heatsink

Attention:

While loosen the mounting clamp the indicating spring must be pulled out a little, otherwise the spring will be damaged!

5. Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks.

Mounting clamp

View from the left

Disassembly tool

View from the right

Front view mountcl_b.dsf

6. Remove the thyristors.

Attention:

To centre the thyristors spring pins are used. The pins are inlayed into all lower heat sinks. Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor!

Exchange thyristors size D5

3ADW000195R0601 DCS800 Service Manual e f

38

Install new thyristor

1. Ensure that the new thyristor is of the correct type (see

Appendix A

of this manual). Keep the

semiconductor and its surroundings clean.

Note:

Do not touch the polished surfaces of the thyristor.

2. Clean all parts with tissue paper moistened with solvent, which have had or will have contact with the thyristor or each other (lower / upper heat sink). Do not clean the surfaces of grease too thoroughly, because the aluminum surfaces will oxidize in a few seconds. Dry all surfaces.

3. Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent. Dry all surfaces. Spread a thin layer of conducting paste on both sides of the thyristor, if necessary use a rubber spatula.

4. Connect the gate leads if possible.

5. Centre the thyristors by means of the spring pins.

Note:

Be sure that the thyristor is installed in the right direction. Do not pinch or cut the gate leads or any other cable.

6. Turn the thyristor so that the gate leads point in the right direction.

7. Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks.

Note:

The indicating spring is a very sensitive instrument and must be handled with care.

8. Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further.

Correct torque

Note:

The correct torque is indicated by means of the welded indicating spring.

9. Perform an OHM test to make sure the thyristor is ok.

10. Reconnect the DC-busbars, branch fuses and all other dismantled parts.

11. Perform an OHM test between U1, V1, W1 and C1, D1 to make sure the power part is ok.

Exchange thyristors size D5

3ADW000399R0101 DCS550 Service Manual e a

39

Location of thyristors in frame D5 (4-Q bridge)

U1 V1 W1

rear

left stack

front

right stack

front rear

V24 V11

V13 V26

V22 V15

V14 V21

V23 V16

V12 V25

V11

V13

V15

View from the left Front view View from the right

Location of thyristors in frame D5 (2-Q bridge)

U1 V1 W1

rear

left stack

front

right stack

front rear

V14

V16

V12

View from the left Front view View from the right

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40

Location of branch fuses frame D5

W1

V1

U1

D1 (-)

Exchange thyristors size D5

C1 (+)

3ADW000399R0101 DCS550 Service Manual e a

41

Exchange thyristors size D6

Installation of disc type thyristors in converters size D6 (1900 ... 3000 A)

All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the disc type semiconductor component is such that it requires a certain compression force to operate. The prevention of overheating of the component essentially depends on good heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.

Required Tools

Special tools or material needed in addition to standard tools for the exchange of thyristor modules:

− Torx screwdrivers

− Torque spanner for electrical connections

TX10, TX20, TX25

13 Nm (M8)

25 Nm (M10)

50 Nm (M12)

− Screws are metric type; use appropriate nuts

− 17 mm ring spanner for fuse and busbar connections

− 24 mm ring spanner for press clamp

− Tissue paper

− Solvent (e.g. ethanol)

− Thermal joint compound (grease) type BECHEM-RHUS SU 2

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 001 P 0001

DCF 1066721 P1 − Disassembly tool

Note:

For more detailed information about the wiring of the power part, see

Hardware Manual

.

Therefore strict observance of the build in instructions given below is of utmost importance. Make sure that the new component can replace the old one in accordance with the spare part list (see

Appendix A

of this manual).

Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage. Avoid touching the contact surfaces. Do not lift the semiconductor with the gate wire. Do not lift the semiconductor by touching the current contact surfaces. Do not damage the welding flange or the contact surface.

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

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42

Disk type thyristors

Some converter modules size D6 are equipped with different disc type thyristors. For easy identification the name plate of the converter module is marked with “ a ” after the voltage identification:

Converter with original thyristor type T 1329Nxxx

Id code: 3ADC340081P0001

U

1

Converter with second thyristor type T 1xxx-24

Id code: 3ADC340098P0001

DCS800-S01-1900-08

DCS800-S02-1900-08

DCS800-S01-2050-05

DCS800-S02-2050-05

3 ~ 800 VAC

3 ~ 800 VAC

3 ~ 525 VAC

3 ~ 525 VAC

DCS800-S01-1900-08

a

DCS800-S02-1900-08

a

DCS800-S01-2050-05

a

DCS800-S02-2050-05

a

DCS800-S01-2050-06

a

DCS800-S01-2050-06

DCS800-S02-2050-06

DCS800-S01-2050-07

DCS800-S02-2050-07

3 ~ 600 VAC

3 ~ 600 VAC

3 ~ 690 VAC

3 ~ 690 VAC

DCS800-S02-2050-06

a

DCS800-S01-2050-07

a

DCS800-S02-2050-07

a

The current and voltage ratings of original and second thyristor type are the same, but the sizes of gate and cathode terminals are different. Thus it is not possible to interchange both thyristor types as spares.

Attention:

Use always the correct spare thyristor!

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

43

Original thyristor type

Thyristor T 1329Nxxx with Id code 3ADC340081P0001

Gate (4):

Cathode (5):

Conductive plate:

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm

Diameter 48 mm

Second thyristor type

Thyristor T 1xxx-24 with Id code 3ADC340098P0001

Gate (y):

Cathode (K1):

Conductive plate:

Round terminal D = 1.5 mm

Faston 4.8 x 0.5 mm

Diameter 50 mm

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44

Bidirectional-Controlled-Thyristors (BCTs)

In some converter modules size D6 so called BCTs (Bidirectional-Controlled-Thyristors) are used. BCTs are a pair of anti-parallel thyristors in one disk type housing. They can easily identified by the second pair of gate leads. The second gate is marked with Gate B on the thyristor.

Gate A

Gate B

BCT.dsf

Note:

The Faston connectors of the gates are of different size.

Gate A should always be in front of the clamped heat sinks due to cooling reasons. Location of BCTs gate A when built in.

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

45

Find faulty thyristor modules

1. Find the defective branches by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1

Bridge configuration D5 to D7

2. Disconnect the branching fuses of the defective branches.

3. Find the defective thyristors by performing an OHM test (both polarities) over their heat sinks.

4. In a 4-quadrant converter with BCTs change the BCT.

5. In a 4-quadrant converter with 2 single thyristors change both thyristors clamped between the same heatsinks at once.

Note:

Because “Disc Type” semiconductors need a certain compression force to operate properly, a measurement outside the clamped heat sinks might be wrong. To be sure which thyristor is broken change only one thyristor, clamp the heat sinks again and repeat step three.

3ADW000195R0601 DCS800 Service Manual e f

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46

Remove faulty thyristor

1. Replace all blown fuses and reconnect all fuses taken out during search for the faulty thyristor.

2. Remove the screws of the DC-busbar plates adjacent to the defective thyristors.

Note:

It depends on the location of the defective thyristor which DC-busbar plates have to be disconnected.

3. Write down the direction and location of the thyristors to be removed and mark their gate leads. In case of

BCTs add the position of the gates.

4. Remove the gate leads if possible.

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

5. Loosen the mounting clamp at the top of the thyristor stack.

47

Attention:

While loosen the mounting clamp the indicating spring must be pulled out a little, otherwise the spring will be damaged!

Do not remove the nuts totally, otherwise the treaded rods will fall down!

6. Pull out both DC-busbar plates.

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48

7. Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks.

8. Remove the thyristors with e.g. a pair of pliers.

Attention:

To centre the thyristors spring pins are used. The pins are inlayed into all lower heat sinks. Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor!

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

49

Install new thyristor

1. Ensure that the new thyristor is of the correct type (see

Appendix A

of this manual). Keep the

semiconductor and its surroundings clean.

Note:

Do not touch the polished surfaces of the thyristor.

2. Clean all parts with tissue paper moistened with solvent, which have had or will have contact with the thyristor or each other (lower / upper heat sink). Do not clean the surfaces of grease too thoroughly, because the aluminum surfaces will oxidize in a few seconds. Dry all surfaces.

3. Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent. Dry all surfaces. Spread a thin layer of conducting paste on both sides of the thyristor, if necessary use a rubber spatula.

4. Centre the thyristors by means of the spring pins.

Note:

Be sure that the thyristor is installed in the right direction. Do not pinch or cut the gate leads or any other cable.

5. Turn the thyristor so that the gate leads point in the right direction. When changing BCTs make sure, that

gate A is in front (see

Bidirectional-Controlled-Thyristors

).

6. Connect the gate leads if possible.

7. Insert first the top DC-busbar plate and then the bottom one.

Note:

The DC-busbar plates should line up with the adjacent heat sinks.

8. Reconnect the DC-busbars.

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50

9. Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks.

Note:

The indicating spring is a very sensitive instrument and must be handled with care.

10. Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further.

Note:

The correct torque is indicated by means of the welded indicating spring.

11. Perform an OHM test to make sure the thyristor is ok.

12. Reconnect all other dismantled parts.

13. Perform an OHM test between U1, V1, W1 and C1, D1 to make sure the power part is ok.

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

Location of thyristors in frame D6 (4-Q bridge with single thyristors)

51

C1(+)

front

Stack

rear

V11

V24

U1

D1(-)

V21

V14

V16

V23

V1

C1(+)

V26

V13

V15

V22

W1

D1(-)

V25

V12

View from the right

A6_thyr_locat.dsf

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52

Location of thyristors in frame D6 (4-Q bridge with BCTs)

C1(+)

front

stack

rear

V11 / V24

U1

D1(-)

V14 / V21

V16 / V23

V1

C1(+)

V13 / V26

V15 / V22

W1

D1(-)

V12 / V25

View from the right

A6_thyr_locat.dsf

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

Location of thyristors in frame D6 (2-Q bridge with single thyristors)

53

C1(+)

front

stack

rear

V11

U1

D1(-)

V14

V16

V1

C1(+)

V13

V15

W1

D1(-)

V12

View from the right

A6_thyr_locat.dsf

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54

Location of branch fuses frame D6

C1(+)

D1(-)

U1

V1

W1

F11

F14

F16

F13

F15

F12

C1(+)

F11

U1

F14

D1(-)

F16

V1

F13

C1(+)

F15

W1

F12

D1(-)

A6_branch_fuse_locat.dsf

Exchange thyristors size D6

3ADW000195R0601 DCS800 Service Manual e f

55

Exchange thyristors size D7

Installation of disc type thyristors in converters size D7 (2500 ... 5200 A)

All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the disc type semiconductor component is such that it requires a certain compression force to operate. The prevention of overheating of the component essentially depends on good heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.

Required Tools

Special tools or material needed in addition to standard tools for the exchange of thyristor modules:

− Torx screwdrivers

− Torque spanner for electrical connections

TX10, TX20, TX25

13 Nm (M8)

25 Nm (M10)

50 Nm (M12)

− Screws are metric type; use appropriate nuts

− 17 mm ring spanner for fuse and busbar connections

− 24 mm ring spanner for press clamp

− Tissue paper

− Solvent (e.g. ethanol)

− Thermal joint compound (grease) type BECHEM-RHUS SU 2

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 001 P 0001

DCF 1066721 P1 − Disassembly tool

Note:

For more detailed information about the wiring of the power part, see

Hardware Manual

.

Therefore strict observance of the build in instructions given below is of utmost importance. Make sure that the new component can replace the old one in accordance with the spare part list (see

Appendix A

of this manual).

All thyristors are always mounted in the same direction, independent of current, voltage, number of quadrants

(2-Q or 4-Q), left or right side connection.

Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage. Avoid touching the contact surfaces. Do not lift the semiconductor with the gate wire. Do not lift the semiconductor by touching the current contact surfaces. Do not damage the welding flange or the contact surface.

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

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56

Find faulty thyristor modules

3. Find the defective branches by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1

Bridge configuration D5 to D7

Exchange thyristors size D7

3ADW000195R0601 DCS800 Service Manual e f

3. Remove the AC busbars, of the defective branches.

4-quadrant converter:

3. Remove all screws of the DC - busbars either above or below the fuses of the defective branches.

Note:

The connection is made with a screw socket, which may fall down, when all screws are removed.

57

3. Put a small piece of isolator (e.g. paper) between the DC-busbar and the heat sink to insulate the antiparallel thyristors from each other.

3. Find the defective thyristors by performing an OHM test (both polarities) over their heat sinks.

2-quadrant converter:

3. Find the defective thyristors by performing an OHM test (both polarities) over their heat sinks.

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58

Remove faulty thyristor

1. Remove the screws of all DC / AC - busbars preventing the stack to be prized open. Remove the branch fuses, if the defective thyristors are covered by them.

Note:

It depends on the location of the defective thyristors, which DC / AC - busbars have to be disconnected.

2. Loosen the screws holding the backplate and make sure the backplate can move up.

3. Write down the direction and location of the defective thyristors to be removed and mark their gate leads.

4. Remove the gate leads if possible.

5. Loosen the mounting clamp at the top of the thyristor stack.

Attention:

While loosen the mounting clamp the indicating spring must be pulled out a little, otherwise the spring will be damaged!

Do not remove the nuts totally, otherwise the treaded rods will fall down!

Exchange thyristors size D7

3ADW000195R0601 DCS800 Service Manual e f

6. Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks.

59

7. Remove the thyristors with e.g. a pair of pliers.

Attention:

To centre the thyristors spring pins are used. The pins are inlayed into all lower heat sinks. Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor!

3ADW000195R0601 DCS800 Service Manual e f

Exchange thyristors size D7

60

Install new thyristor

1. Ensure that the new thyristor is of the correct type (see

Appendix A

of this manual). Keep the

semiconductor and its surroundings clean.

Note:

Do not touch the polished surfaces of the thyristor.

2. Clean all parts with tissue paper moistened with solvent, which have had or will have contact with the thyristor or each other (lower / upper heat sink). Do not clean the surfaces of grease too thoroughly, because the aluminum surfaces will oxidize in a few seconds. Dry all surfaces.

3. Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent. Dry all surfaces. Spread a thin layer of conducting paste on both sides of the thyristor, if necessary use a rubber spatula.

4. Centre the thyristors by means of the spring pins.

Note:

Be sure that the thyristor is installed in the right direction. Do not pinch or cut the gate leads or any other cable.

5. Turn the thyristor so that the gate leads point in the right direction.

6. Connect the gate leads if possible.

7. Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks.

Note:

The indicating spring is a very sensitive instrument and must be handled with care.

Exchange thyristors size D7

3ADW000195R0601 DCS800 Service Manual e f

8. Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further.

61

Note:

The correct torque is indicated by means of the welded indicating spring.

9. Perform an OHM test to make sure the thyristor is ok.

10. Reconnect the backplate, branch fuses, DC- / AC-busbars and all other dismantled parts.

11. Perform an OHM test between U1, V1, W1 and C1, D1 to make sure the power part is ok.

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Exchange thyristors size D7

V11

V24

V13

V26

V15

V22

62

Location of thyristors in frame D7 (4-Q bridge)

V21 V21

V14 V14

V23 V23

V16

V16

V25 V25

V12

V12

V15

V22

V11

V24

V13

V26

Assembly D7

Busbars on the right; view from the front

D7_ass.dsf

Assembly D7

Busbars on the left; view from the front

Location of thyristors in frame D7 (2-Q bridge)

V11 V11

V14 V14

V13

V13

V16

V16

V15 V15

V12 V12

Assembly D7

Busbars on the right; view from the front

Exchange thyristors size D7

D7_ass.dsf

Assembly D7

Busbars on the left; view from the front

3ADW000195R0601 DCS800 Service Manual e f

Location of branch fuses frame D7 (busbars on the right)

63

F14

U1

AC-busbar

F11

F16

V1

AC-busbar

F13

F12

W1

AC-busbar

F15

D1(-)

DC-busbar

C1(+)

DC-busbar

A7_branch_fuse_lopcat.dsf

Exchange thyristors size D7

3ADW000195R0601 DCS800 Service Manual e f

64

Location of branch fuses frame D7 (busbars on the left)

F11

F14

U1

AC-busbar

F13

F16

V1

AC-busbar

F12

F15

W1

AC-busbar

C1(+)

DC-busbar

A7_branch_fuse_lopcat.dsf

D1(-)

DC-busbar

Exchange thyristors size D7

3ADW000195R0601 DCS800 Service Manual e f

65

Exchange SDCS-CON-4

General

All DCS550 size D1 to D7 are equipped with the same controller board SDCS-CON-4, thus the exchange of the board is similar for all module sizes.

Required Tools

Special tools or material needed in addition to standard tools for the exchange of the SDCS-CON-4:

− Torx screwdrivers

TX10, TX20, TX25

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

Before the work is started, make sure the firmware versions of the old SDCS-CON-4 and the new SDCS-CON-4 match - see FirmwareVer (4.01) - when using DCSLink communication - see parameters (94.12) to (94.35).

The peer-to -peer (P2P) identifier for the DCSLink (group 94) has been changed from firmware versions 3.6 to 3.7. Thus it is not possible to mix firmware versions 3.6 and lower with firmware versions 3.7 and higher when using mailbox communication!

Overview SDCS-CON-4 exchange

1. Save parameters,

2. Write down type code of the drive,

3. Set jumpers on the new SDCS-CON-4 according to the old SDCS-CON-4,

4. Exchange the SDCS-CON-4,

5. Set type code of the drive,

6. Enable application program and

7. Download and compare parameters.

1. Save parameters

Parameters can be saved by various means:

DCS Control Panel:

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66

− Press Soft key 1 until the main menu is shown (see figure above),

− Press LOC/REM button, display will show LOC on the upper left side,

− Press Soft key 2 (MENU),

− Scroll with UP / DOWN buttons to menu item PAR BACKUP,

− Confirm with Soft key 2 (ENTER),

− Select UPLOAD TO PANEL and confirm with Soft key 2 (SEL), the upload progress bar will be shown on the display,

− Successful upload will be shown by message,

− Confirm with Soft key 1 (OK),

− Press Soft key 1 until back to the main menu (see figure above),

− The actual parameter set is now stored in the DCS Control Panel.

DriveWindow Light

− Click File then Save As…

− Click Save

DriveWindow

− Click File then Parameters and Save As…

Exchange SDCS-CON-4

3ADW000195R0601 DCS800 Service Manual e f

67

− Click Save

2. Write down type code of the drive

Write down the contents of TypeCode (97.01). This information must be set in the new SDCS-CON-4 manually.

3. Set jumpers on the new SDCS-CON-4 according to the old SDCS-CON-4

Copy the jumper settings (S1 to S4) of the old SDCS-CON-4 onto the new SDCS-CON-4 accordingly.

4. Exchange the SDCS-CON-4

Remove the old SDCS-CON-4

1. Remove design cover and DCS Control

Panel

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68

2. Remove all plug in options on the intermediate cover e.g.:

− serial communication modules (Rtype),

− extension I/O modules (RAIO, RDIO),

− extension modules for second encoder (RTAC) or resolver (RRIA),

− communication board (SDCS-COM-8),

− isolated I/O (SDCS-IOB-2x, SDCS-

IOB-3) and

− SDCS-MEM-8 (Memory Card).

3. Remove the intermediate cover by depressing the two locks on the upper right and left hand side of the cover

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

4. Disconnect all I/O plugs (X3 to X7) at the

SDCS-CON-4 and the plugs at the SDCS-

DSL-4 board, if used (X51 to X54):

Exchange SDCS-CON-4

3ADW000195R0601 DCS800 Service Manual e f

69

5. Remove screws and studs

6. Unplug the flat cables (X12, X13, X37)

7. Remove the SDCS-CON-4

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70

Install the new SDCS-CON-4

1. Reconnect the flat cables at the SDCS-CON-4 (X12, X13, X37),

2. Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7), the plugs at the SDCS-DSL-4 (X51 to X54) and

3. Reinstall the intermediate cover, all plug in options, the design cover and the DCS Control Panel.

5. Set type code of the drive

Follow the instructions in chapter

Set type code

.

6. Enable application program

If a SDCS-MEM-8 (Memory Card) is used the application program must be enabled before the parameters are downloaded. Set:

ParApplSave (16.06) = EnableAppl

7. Download and compare parameters

Parameters can be downloaded and compared by various means:

DCS Control Panel

− Press Soft key 1 until the main menu is shown,

− Press LOC/REM button, display will show LOC on the upper left side,

− Press Soft key 2 (MENU),

− Scroll with UP / DOWN buttons to menu item PAR BACKUP,

− Confirm with Soft key 2 (ENTER),

− Select DOWNLOAD FULL SET and confirm with Soft key 2 (SEL), the download progress bar will be shown on the display,

− Successful download will be shown by message,

− Confirm with Soft key 1 (OK),

− Press LOC/REM button, display will show REM on the upper left side,

− Press Soft key 1 until back to the main menu and

− The actual parameter set is now downloaded into the new SDCS-CON-4.

DriveWindow Light

− Click File then Open…

− Choose correct parameter file and click

Open

Exchange SDCS-CON-4

3ADW000195R0601 DCS800 Service Manual e f

71

− Click Drive then Parameters & Signals and

Download All Parameters

− To check, if the parameter download was successful, connect the drive with

DriveWindow Light and compare the drive memory with the downloaded parameter set. Click Drive then Parameters & Signals and Compare…

DriveWindow

− Click File then Parameters and

Download…

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Exchange SDCS-CON-4

72

− Click Open and follow the instructions

− To check, if the parameter download was successful, connect the drive with

DriveWindow and compare the drive memory with the downloaded parameter set. Click File then Parameters and

Compare…

Exchange SDCS-CON-4

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Service

Exchange converter fans sizes D1 to D3 (two fans)

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

Converters types DCS800-S01-0045-0x to

DCS800-S02-0350-0x using two 115 V either connected in series, for 230 V parallel, for 115 V

AC

AC

AC

fans.

Depending on the supply voltage they are

. or in

In case a fan fails there are different approaches due to the incoming voltage.

230 V

AC

:

With a supply voltage of 230 V fans have to be changed.

AC

fans M55 and M56 are connected in series. Consequently both fans have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. In this case both

115 V

AC

:

With a supply voltage of 115 V

AC broken fan.

all fans are connected in parallel. Thus it is possible to change only the

Removing the converter fan

1. Remove the DCS Control Panel, the design cover and the fan connection plug

X2 on the top of the converter housing

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74

2. Remove the two fan arrangement screws

3. Move the fan arrangement forward

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75

4. Remove the fan holding screws:

5. Remove Faston plugs and fans

6. Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module

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Exchange converter fans size D3 (four fans)

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

Converters types DCS800-S01-0405-0x to

DCS800-S02-0520-0x using four 115 V either connected in series, for 230 V parallel, for 115 V

AC

AC

AC

Depending on the supply voltage they are

fans.

. or in

In case a fan fails there are different approaches due to the incoming voltage.

230 V

AC

:

With a supply voltage of 230 V

AC

fans M55 and M56 are connected in series as well as fans M57 and M58.

Consequently fans connected in series have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. Always change the two fans connected in series.

115 V

AC

:

With a supply voltage of 115 V

AC

all fans are connected in parallel. Thus it is possible to change only the broken fan.

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Removing the converter fans

1. Remove the DCS Control Panel, the design cover and the fan connection plug

X2 on the top of the converter housing

2. Remove the two fan arrangement screws

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3. Move the fan arrangement forward

4. Remove the fan holding screws:

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5. Remove Faston plugs and fans

79

6. Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module

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Exchange converter fan size D6

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

1. Remove the three screws at the top of the fan.

2. Disconnect the cables.

3. Lift the fan up and pull it out.

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Exchange converter fan size D7

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

1. Remove the three screws at the bottom of the fan.

2. Disconnect the cables.

3. Lift the fan up and pull it out.

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Exchange current transformers sizes D5 to D7

Measuring the actual current

The control electronic of the converters is designed to use either 2 or 3 standard current transformers. They are located on the AC side of the bridge to measure the armature current.

Wiring

The wiring of the current transformers is basically identical for all converters. The figure below shows the most common configurations.

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Current transformers for sizes D5 and D6

Type

Ordering number

Rated primary current

Rated secondary current

Ratio

Magnetic overload capacity for a short time

Maximum rated voltage

Maximum test voltage

Dimensions

Weight

Maximum ambient (e.g. cooling air) temperature at rated current

Maximum conductor (wire / busbar) temperature at rated current

LT 2032

3 ADT 751 010 P 0001

3000 A

1.2 A

AC

AC

2500 : 1

3 times rated primary current

1500 V

5000 V

AC

In mm, see figure below

1.7 kg

55°C

AC

for less than 3 seconds

90°C

83

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84

Current transformers for size D7

Ordering number

Rated primary current

Rated secondary current

Ratio

Magnetic overload capacity for a short time

Maximum rated voltage

Maximum test voltage

Dimensions

Weight

Maximum ambient (e.g. cooling air) temperature at rated current

Maximum conductor (wire / busbar) temperature at rated current

3 ADT 751 007 P 0001

5000 A

AC

1.25 A

AC

4000 : 1

3 times rated primary current

1200 V

AC

4000 V

AC

for less than 60 seconds

In mm, see figure below

1.7 kg

55°C

90°C

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Exchange current transformers size D5

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

If current transformers fail or need to be repaired, the following has to be considered:

− It is important, that all current transformers are orientated and mounted in the same way on the busbars.

− Check the wiring of the old current transformers according the figure in subchapter

Wiring

. It is important,

that all current transformers are wired in the same way. Take additional care in case the connection is not done by coded twisted pair cables.

Current transformer type

− The current transformers are located in the D5 module.

− AC busbars are routed through the current transformers. The current transformers are kept in place by design and need no further mounting.

− The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends.

Exchange

− Disconnect the AC wires / busbars at the top of the drive.

− To get access to the current transformers remove the top panel of the converter’s body.

− Now the old current transformers can be removed.

− Install the new current transformers with proper orientation. No extra mechanical mounting is necessary.

− Take care of proper electrical connections.

− Remount the top panel.

− Reconnect the AC wires / bus bars.

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Exchange current transformers size D6

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

If current transformers fail or need to be repaired, the following has to be considered:

− It is important, that all current transformers are orientated and mounted in the same way on the busbars.

− Check the wiring of the old current transformers according the figure in subchapter

Wiring

. It is important,

that all current transformers are wired in the same way. Take additional care in case the connection is not done by coded twisted pair cables.

Current transformer type

− The current transformers are located in the D6 module.

− Bolts with sleeves are routed through the current transformers. The current transformers are kept in place by design and need no further mounting.

− The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends.

Exchange

− Remove the fuses connected to the busbars leading to the current transformers.

− To get access to the current transformers remove the bolts with sleeves from the AC busbars outside the converter.

− Make sure the current transformers are not falling down when removing the bolts and sleeves.

− Install the new current transformers with proper orientation. No extra mechanical mounting is necessary.

− Fasten the bolts including sleeves.

− Take care of proper electrical connections.

− Remount the fuses.

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Exchange current transformers size D7

Before the work is started, disconnect the converter completely from the power supply, then check the voltage free condition and make sure, everything is located in an electrical and mechanical safe condition!

If current transformers fail or need to be repaired, the following has to be considered:

− It is important, that all current transformers are orientated and mounted in the same way on the busbars.

− Check the wiring of the old current transformers according the figure in subchapter

Wiring

. It is important,

that all current transformers are wired in the same way. Take additional care in case the connection is not done by coded twisted pair cables.

Current transformer type

− The current transformers are located outside the D7 module.

− AC busbars are routed through the current transformers. The current transformers are mounted on the busbars by means of screws.

− The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends.

Exchange

− Disconnect the AC wires / busbars at the side of the drive.

− Remove the mounting screws.

− Remove the old current transformers.

− Install the new current transformers with proper orientation.

− Fix the current transformers by means of the mounting screws.

− Take care of proper electrical connections.

Note:

Some of the older converters require to drill a hole for the mounting screw. When drilling the hole make sure no copper shavings are left in and at the drive.

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DCS800 firmware download

General

This chapter describes how to download firmware into the SDCS-CON-4 and SDCS-COM-8.

Download SDCS-CON-4 firmware

Installation

− From the DCS800 Tools CD select the tasks Firmware Download Tool 2.2 (FDT) and SDCS-CON-4 Firmware x.xx

Service

This installs the Hitachi Flash Development Toolkit 2.2 including workspace, firmware, text and needed file structure.

Workspaces

ABB provides workspaces called DCS800.fdt. New workspaces have to be saved in:

C:\ABB\DCS800\Firmware\CON-4\Ver x.x

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Firmware / text file

The firmware consists of two parts. The firmware file itself and the text file. New firmware files (*.rec) have to be saved in:

C:\ABB\DCS800\Firmware\CON-4\Ver x.x\Firmware

89

New text files (*.cde) have to be saved in:

C:\ABB\DCS800\Firmware\CON-4\Ver x.x\Text

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Download firmware file

The firmware download is done via a PC COM Port.

Attention:

If there is no COM Port available an adapter PCMCIA / ExpressCard to COM Port has to be used. Adapters

USB to COM Port are not reliable.

The download of the firmware is done in two steps:

1. Firmware file (*.rec)

2. Text file (*.cde)

Attention:

A firmware download does not influence the parameter settings! The previous parameter settings are kept.

− De-energize the DCS8000 electronics

− Set jumper S5 on SCDS-CON-4 from position 3-4 to position 1-2

− Connect a RS232 cable between a PC

COM Port and DCS8000 X34

− Energize the DCS800 electronics, the 7segment display shows a

-

Start download tool

− Start the Hitachi Flash Development Toolkit 2.2 by means of Start/Programs/Hitachi/Flash Development

Toolkit 2.2/Flash Development Toolkit 2.2

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Choose workspace

− Mark Open an existing Workspace,

− Confirm with OK

− Select the workspace in directory:

C:\ABB\DCS800\Firmware\CON-4\Ver x.x

− Confirm with Open

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Activate firmware download

− Select Firmware with a right mouse click and choose Set as Active Project from the pop up menu

Choose COM Port and communication speed

− Select Firmware with a right mouse click and choose Properties from the pop up menu

− Select the Communications tab, choose the desired COM Port, un-tick the box Use

default baud from the pop up menu and set the Target Baud Rate to 38400

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Download firmware file to device

− Select desired firmware with a right mouse click and choose Download File to Device from the pop up menu

Disconnect tool

− After the completed download the FDT2.2 has to be disconnected. Select Firmware with a right mouse click and choose

Disconnect from the pop up menu

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Download text file

− De-energize the DCS800 electronics

− Set jumper S5 on SCDS-CON-4 from position 1-2 to position 3-4

− Energize the DCS800 electronics. In case the 7-segment display shows a

d

the firmware’s corresponding text file has to be downloaded from the workspace.

Note:

If the 7-segment display shows something else, it is not necessary to download the text file and the download is complete.

Activate text download

− Select Text with a right mouse click and choose Set as Active Project from the pop up menu

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Choose COM Port and communication speed

− Select Text with a right mouse click and choose Properties from the pop up menu

95

− Select the Communications tab, choose the desired COM Port, un-tick the box Use

default baud from the pop up menu and set the Target Baud Rate to 38400

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Download text file to device

− Select desired text file with a right mouse click and choose Download File to Device from the pop up menu

− After the completed download the 7segment display shows a

u

Attention:

Do not de-energize the drive or disconnect the tool while the seven segment display shows the

u

− Wait until the 7-segment display shows an

8.

and after the boot a

.

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Disconnect tool

− Now FDT2.2 has to be disconnected.

Select Text with a right mouse click and choose Disconnect from the pop up menu

Close download tool

− When closing FDT2.2, save the workspace only, if firmware files or text files have been added

The firmware / text download is complete now.

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Add firmware or text files

Start download tool

− Start the Hitachi Flash Development Toolkit 2.2 by means of Start/Programs/Hitachi/Flash Development

Toolkit 2.2/Flash Development Toolkit 2.2

Choose workspace

− Mark Open an existing Workspace,

− Confirm with OK

− Select the workspace in directory:

C:\ABB\DCS800\Firmware\CON-4\Ver x.x

− Confirm with Open

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Add firmware files

− If the firmware file to be downloaded is not shown under Target files the firmware file has to be added

− Select Firmware with a right mouse click and choose Add Files to Project… from the pop up menu

− Go to the directory containing the desired firmware file e.g.

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99

100

− Choose the desired firmware file and press Open

Add text files

If the text file to be downloaded is not shown under Target files the text file has to be added

− Select Text with a right mouse click and choose Add Files to Project… from the pop up menu

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− Go to the directory containing the desired text file e.g.

− To display the desired text file write *.* in

File name and press Open:

− Choose the desired text file and press

Open:

Close download tool

− When closing FDT2.2, save the workspace only, if firmware files or text files have been added

Adding of files is complete now.

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Create a workspace

General

In case the Hitachi Flash Development Toolkit 2.2 is not installed at its default location (e.g. using Windows in a different language than English):

C:\Program Files\Hitachi\FDT2.2 it is not possible to use the standard ABB workspace called DCS800.fdt. Thus the user has to create a new workspace.

Start download tool

− Start the Hitachi Flash Development Toolkit 2.2 by means of Start/Programs/Hitachi/Flash Development

Toolkit 2.2/Flash Development Toolkit 2.2

Create new workspace

− Choose FileNew Workspace…

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Name new workspace

− Name the new workspace,

− choose its location and

− confirm with OK

− Choose Yes

Create the project for the firmware file

− Name the new project and

− confirm with Next

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Choose Device And Kernel

− Select Device: H8S/2633F and

− confirm with Next

Communication port

− Select the proper COM port,

Select Baud Rate: 38400,

− un-tick Use Default Baud Rate and

− confirm with Next

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Device Settings

Enter the CPU crystal frequency for the

selected device: 6.25 MHz,

Select the multiplier for the main clock

frequency (CKM): 4 and

− confirm with Next

Connection Type

Select connection: BOOT Mode,

Select Interface: Direct Connection,

− un-tick Kernel already resident and

− confirm with Next

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Programming Options

Protection: Automatic and

Messaging: Advanced,

− confirm with Finish

− Now the project for the firmware file is finished

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Create the project for the text file

− Select Workspace with a right mouse click and choose New Project…

− Name the new project and

− confirm with Next

Choose Device And Kernel

− Select Device: H8S/2633F and

− confirm with Next

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Communication port

− Select the proper COM port,

Select Baud Rate: 38400,

− un-tick Use Default Baud Rate and

− confirm with Next

Device Settings

Enter the CPU crystal frequency for the

selected device: 6.25 MHz,

Select the multiplier for the main clock

frequency (CKM): 4 and

− confirm with Next

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Connection Type

Select connection: BOOT Mode,

Select Interface: Direct Connection,

− un-tick Kernel already resident and

− confirm with Next

Programming Options

Protection: Automatic and

Messaging: Advanced,

− confirm with Finish

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− Now the project for the text file is finished

Close download tool

− When closing the FDT2.2 confirm with Yes

Creating of projects is complete now.

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Download SDCS-COM-8 firmware

Requirements

− In case the USB adapter RUSB-02 is used together with DriveWindow 2.22 (and higher) and firmware package COM-8 88x160.zip (and higher) no additional actions have to be taken.

− In case the PCMCIA adapter NDPA-02 with NDPC-12 is used the NtNisa drivers have to be installed (see

NtNisa5x.zip or NtNisa5x.exe) before downloading the firmware.

Firmware download

− Close all applications especially DriveWindow and DriveWindow Light!

− Unzip the SDCS-COM-8 firmware (file COM-8 88xxxx.zip) by right click on the zip file

− Following files and folders will be created

− Connect the DCS800 directly with the PC, fiber optic cable from SDCS-COM-8 channel 3 to:

1. USB adapter RUSB-02 or

2. PCMCIA adapter NDPA-02 with NDPC-12

− Switch on the DCS800

− Set Ch3 HW Config (70.21) = Ring

− Set Ch3 NodeAddr (70.22) = 1

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− Start firmware download by a double click on file L_AMC_DC.BAT:

− A DOS window will appear. Wait until the download is finished (the DOS window will close automatically)

Attention:

Do not touch the PC during the download of the firmware!

− Check Com8SWVersion (4.11) for proper firmware version

− Set Ch3 HW Config (70.21) back to its original setting

− Set Ch3 NodeAddr (70.22) back to its original setting

− Re-connect the drive to the DriveWindow network

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Set type code

The type code - TypeCode (97.01) - is preset in the factory and is write protected. It identifies the drives current-, voltage-, temperature measurement and its quadrant type. The type code can only be changed as whole or individually.

To change the type code as whole follow the instructions below:

− un-protect the type code by means of ServiceMode (99.06) = SetTypeCode

− set TypeCode (97.01) = S01-0020-04 to S02-5200-05 (details, see table below)

The drive’s basic type code: DCS800-AAX-YYYY-ZZB

Product family: DCS800

Type: AA = S0 Modules

= R0 Rebuild system

= E0 Panel solution

= A0 Enclosed converter

Bridge type:

Module type:

Rated AC Voltage:

X

YYYY

ZZ

= 1

= 2

= single bridge (2-Q)

2 anti parallel bridges (4-Q) converter type current

= 04 230 VAC - 400 VAC

= 05 230 VAC - 525 VAC

= 06 270 VAC - 600 VAC

= 07 315 VAC - 700 VAC

= 08 360 VAC - 800 VAC

Power connection: B

= 10 450 VAC - 990 VAC

= 12 540 VAC - 1200 VAC

= - Standard D1 - D6

= a

= L

Second thyristor type D5, D6

Left side D7

= R Right side D7

Attention:

When using D1, D2, D3 or D4 modules the current and voltage range of the type code setting is limited to maximum 1000 A

DC

and maximum 600 V

AC

.

− the change of the type code is immediately taken over and ServiceMode (99.06) is automatically set back to NormalMode

− the new values can be seen in group 4

ConvNomCur (4.05),

ConvNomVolt (4.04),

MaxBridgeTemp (4.17) and

QuadrantType (4.15).

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To change the type code individually follow the instructions below:

− un-protect the type code by means of ServiceMode (99.06) = SetTypeCode

− set the type code individually by means of

S ConvScaleCur (97.02),

S ConvScaleVolt (97.03),

S MaxBrdgTemp (97.04) and

S BlockBridge2 (97.07)

− the change of the type code is immediately taken over and ServiceMode (99.06) has to be set back to

NormalMode by the user

− the new values can be seen in group 4

ConvNomCur (4.05),

ConvNomVolt (4.04),

MaxBridgeTemp (4.17) and

QuadrantType (4.15)

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Type code table

0

1

None

S01-0020-04

2

3

S01-0020-05

S01-0045-04

4

5

S01-0045-05

S01-0065-04

6

7

S01-0065-05

S01-0090-04

8

9

S01-0090-05

S01-0125-04

10

S01-0125-05

11

S01-0180-04

12

S01-0180-05

13

S01-0230-04

14

S01-0230-05

15

S01-0315-04

16

S01-0315-05

17

S01-0290-06

18

S01-0405-04

19

S01-0405-05

20

S01-0470-04

21

S01-0470-05

22

S01-0590-06

23

S01-0610-04

24

S01-0610-05

25

S01-0740-04

26

S01-0740-05

27

S01-0900-04

28

S01-0900-05

29

S01-0900-06

30

S01-0900-07

31

S01-1200-04

32

S01-1200-05

33

S01-1500-04

34

S01-1500-05

35

S01-1500-06

36

S01-1500-07

37

S01-1900-08

38

S01-2000-04

39

S01-2000-05

40

S01-2000-06

41

S01-2000-07

42

S01-2050-05

43

S01-2050-06

44

S01-2050-07

45

S01-2500-04

46

S01-2500-05

47

S01-2500-06

48

S01-2500-07

49

S01-2500-08

50

S01-2050-10

51

S01-2600-10

52

S01-2600-12

53

S01-3000-04

54

S01-3000-05

55

S01-3000-06

56

S01-3000-07

57

S01-3000-08

58

S01-3300-04

59

S01-3300-05

60

S01-3300-06

61

S01-3300-07

62

S01-3300-08

63

S01-3300-12

64

S01-4000-04

65

S01-4000-05

66

S01-4000-06

67

S01-4000-07

68

S01-4000-08

69

S01-3300-10

70

S01-4000-10

71

S01-4800-06

72

S01-4800-07

73

S01-4800-08

74

S01-5200-04

75

S01-5200-05

76

S02-0025-04

77

S02-0025-05

78

S02-0050-04

79

S02-0050-05

80

S02-0075-04

81

S02-0075-05

82

S02-0100-04

83

S02-0100-05

84

S02-0140-04

85

S02-0140-05

86

S02-0200-04

87

S02-0200-05

88

S02-0260-04

89

S02-0260-05

90

S02-0350-04

91

S02-0350-05

92

S02-0320-06

93

S02-0450-04

94

S02-0450-05

95

S02-0520-04

96

S02-0520-05

97

S02-0650-06

98

S02-0680-04

99

S02-0680-05

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131

132

133

134

135

136

137

138

139

140

119

120

121

122

123

124

125

126

127

128

129

141

142

143

144

145

146

147

148

149

150

108

109

110

111

112

113

114

115

116

117

118

100

101

102

103

104

105

106

107

S02-0820-04

S02-0820-05

S02-1000-04

S02-1000-05

S02-0900-06

S02-0900-07

S02-1200-04

S02-1200-05

S02-1500-04

S02-1500-05

S02-1500-06

S02-1500-07

S02-1900-08

S02-2000-04

S02-2000-05

S02-2050-05

S02-2050-06

S02-2050-07

S02-2500-04

S02-2500-05

S02-2050-10

S02-2600-10

S02-2600-12

S02-3000-04

S02-3000-05

S02-2500-06

S02-2500-07

S02-3000-06

S02-3000-07

S02-2500-08

S02-3000-08

S02-3300-04

S02-3300-05

S02-3300-06

S02-3300-07

S02-3300-08

S02-3300-12

S02-4000-04

S02-4000-05

S02-4000-06

S02-4000-07

S02-4000-08

S02-3300-10

S02-4000-10

S02-4800-06

S02-4800-07

S02-4800-08

S02-5200-04

S02-5200-05

S01-4000-12

S02-4000-12

Service

116

DC-Motor neutral zone adjustment

Types concerned

DC-Motors

Summary

Procedure to adjust the neural zone of a DC-motor

General

− Loosen the bolts holding the brush bridge.

− Connect a scope or a voltmeter between two adjacent brush-holder assemblies (holders with different polarity).

− Set the scaling on the scope or voltmeter to mV AC.

− Disconnect the excitation cables and connect 110 to 240 V is sufficient).

AC

between F+ and F- (a normal extension cord

− Start moving the brush bridge slowly in one direction and watch the scope or voltmeter. If the voltage is increasing move the brush bridge in the other direction.

− Try to get the voltage down to less than 50 mV AC. The smaller the better.

− When this is achieved, start tightening the brush bridge bolts and watch the voltage. Sometimes you have to do a little offset to compensate for movements during tightening.

− Finally, mark the correct neutral zone position in case the motor will be taken apart in the future.

Service

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117

Preventive Maintenance

WARNING! Before performing any maintenance the chapter

Safety Instructions

at the

beginning of this manual must be followed. Negligence of these instructions can cause injury or death.

WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Use an

ESD-field service kit

when handling the boards. Do not touch the boards

unnecessarily.

Handling the boards:

When ESD sensitive boards are removed from the drive and transferred to a temporary work surface, they should be placed in a protective packaging.

Handle unprotected ESD sensitive boards only when connected to the system and always place them in a protective package that is sealed.

It is easiest to use the spare parts ESD package. Place the protective package on the ESD mat before opening.

Preventive Maintenance

3ADW000195R0601 DCS800 Service Manual e f

118

Recommended regular maintenance

The DCS requires very little maintenance if installed in an appropriate environment. Regular inspection according to the maintenance schedule is strongly recommended. Preventive maintenance prevents unexpected production stop and production loss. It also increases availability of the drive.

The environmental and operating conditions of the drive are also to be considered.

A harsh environment, such as high ambient temperature, humidity, dust and cyclic heavy load, not only shortens the components lifetime but also the preventive maintenance and replacement intervals.

Maintenance schedule

Preventive Maintainance

3ADW000195R0601 DCS800 Service Manual e f

119

Annual preventive maintenance

The following actions have to take place:

− Check the cooling fans of units D1 to D7.

The lifetime of the cooling fan is about 30,000 to 45,000 hours depending on the converter type. The actual lifetime depends on the usage of the DCS and the ambient temperature. Fan failure can be mentioned symptoms appear.

− Check the cooling air pressure switch of units D6 and D7. predicted by means of increasing noise from its bearings and a gradual rise of the heatsink temperature. If the DCS operates in a critical part of the process it is recommended to replace the fan once the above

Actions: o Make sure electrical safety is performed. o Open the module's door and hold it in position to prevent any movement. o Repeat it with the cabinet’s door. o Start the drive. o The air pressure switch is ok when the converter is switched off by F527 ConvFanAck - see

ConvFanAck (10.30). Crosscheck this result with the module’s door closed.

Attention:

Do not reach into the fan. Negligence to this warning can cause injury.

− Check for tightness of heatsink terminals of units D7.

The thyristors together with the heatsinks are stacked. Every single thyristor is connected to the DC+ and

DC- busbars via flexible copper busbars. These busbars consist of 10 layers of pre-shaped sheet copper.

This construction is able to compensate for small changes in length caused by temperature rise when current is flowing. The screw fixings between heatsink and flexible copper busbar have to withstand different types of mechanical stress.

Therefore each fixing needs to be checked for correct torque.

Actions: o Make sure all supply voltages are switched off, most important the supply for the power part

(armature), for the drive electronics (SDCS-POW-4), for the converter fan and for other auxiliaries! o Open the cabinet’s and module’s door; if needed secure them. o Set a latching torque spanner to 25 Nm (18 lb-ft). A 17 mm nut is needed too. o Check the torque of the screws marked within the next figure. o Apply the torque spanner to the screw and turn right until the right torque is indicated. o Don’t loosen the screws by a left hand turn! o Put on a new marking, if appropriate.

Preventive Maintenance

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Preventive Maintainance

3ADW000195R0601 DCS800 Service Manual e f

121

− Check the door air filters.

− Clocked up filters prevent proper cooling of the drive. Wash dirty filters with water

(60°C) and detergent.

− Check for dust, corrosion and temperature inside the module / cabinet. The DCS will run into overtemperature faults if the heatsinks are not clean.

− Use compressed air to remove the dust from the heatsinks (the air flow must be from bottom to top). Fan rotation caused by the compressed air must be stopped in order to prevent damage.

− Use an

ESD vacuum cleaner

to clean the dust from the air inlet, air outlet, the interior of the cabinet and the electronic boards.

− Any signs of corrosion, especially at ground components, must be removed.

− Check the quality of the supply voltage.

3ADW000195R0601 DCS800 Service Manual e f

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122

3 years preventive maintenance

Following additional actions have to take place:

− Replace the cooling fans of units D6 and

D7. o

Remove the cooling fan in a frame D6

o

Remove the cooling fan in a frame D7

− The manufacturers estimation for the operational time of the cooling fan is: o GR31M: o GR35C:

− The mayor problem is the failure of the bearings.

30,000 hours at 40°C

30,000 hours at 40°C

− Where used

DCS800-S0x-1900-y4/5/8…

DCS800-S0x-3000-y/5/8

DCS800-S0x-1900-y6/7

DCS800-S0x-3000-y6/7

D6

D6

GR31M

400 … 500 V

GR31M

500 … 690 V

DCS800-S0x-3300-y1…

DCS800-S0x-5200-y1

D7 GR35C

400 V / 690 V

− Aging of the components result in:

3. Increased vibration due to the imbalance of the cooling fan (can last for several months)

4. Increased temperature due to the stopped cooling fan (drive trips with overtemperature)

− Check the tightness of all terminals.

All connections should be inspected and checked for tightness.

− Check the condition of the contactors and relays.

Contactors and relays should be checked for proper function.

− Check the fiber optic cables and their connections.

Preventive Maintainance

3ADW000195R0601 DCS800 Service Manual e f

123

6 years preventive maintenance

Following additional actions have to take place:

− Replace the cooling fans of units D1 to D5.

o

Remove the cooling fans in frames D1 to D3

o

Remove the cooling fans in frame D3

− The manufacturers estimation for the operational time of the cooling fan is: o CN2B2: o W2E200: o W2E250: o D2E160: bearings.

40,000 hours at 60°C

45,000 hours at 60°C

40,000 hours

30,000 hours at 40°C

− The mayor problem is the failure of the

− Where used

DCS800-S0x-0045-y1…

DCS800-S0x-0140-y1

DCS800-S0x-0180-y1…

DCS800-S0x-0260-y1

DCS800-S0x-0315-y1…

DCS800-S0x-0350-y1

DCS800-S0x-0405-y1…

DCS800-S0x-0520-y1

DCS800-S0x-0610-y1…

DCS800-S0x-0820-y1

DCS800-S0x-0610-y1…

DCS800-S0x-0820-y1

DCS800-S0x-0900-y1…

DCS800-S0x-1000-y1

DCS800-S0x-0900-y1…

DCS800-S0x-1000-y1

D1

D2

D3

D3

D4

D4

D4

2x CN2B2

2x CN2B2

2x CN2B2

4x CN2B2

1x W2E200 (230 V)

1x W2E200 (115 V)

(plus code E171)

1x W2E250 (230 V)

DCS800-S0x-0900-y1…

DCS800-S0x-2000-y1

D4 1x W2E250 (115 V)

(plus code E171)

D5 D2E160

− Aging of the components result in:

1. Increased vibration due to the imbalance of the cooling fan (can last for several months)

2. Increased temperature due to the stopped cooling fan (drive trips with overtemperature)

− Check the flat cables and their connections.

3ADW000195R0601 DCS800 Service Manual e f

Preventive Maintenance

124

9 years preventive maintenance

Following additional actions have to take place:

− Replace the power interface board SDCS-

PIN-4 of units D1 to D4.

The SDCS-PIN-4 is located between the heat sink and the electronic tray. It operates continuously, because it supplies the drive electronics even when the armature current is switched-off. Therefore all its components are exposed to hot conditions.

Additionally the electrolytic capacitors on the SDCS-PIN-4 are aging. The SDCS-

PIN-4 also is equipped with several capacitors which are sensitive to high ambient temperature.

− Where used

− Aging of the electronic card result in:

1. Damage other devices

2. Trip the drive and cause break-down time

− Replace the power supply board SDCS-

POW-4 of units D5 to D7 and DCS800-R

(Rebuild- and Upgrade Kits).

The SDCS-POW-4 is located between the module door on the electronic tray. It operates continuously, because it supplies the drive electronics even when the armature current is switched-off. Therefore all its components are exposed to hot conditions.

Additionally the electrolytic capacitors on the SDCS-POW-4 are aging. The SDCS-

POW-4 also is equipped with several capacitors which are sensitive to high ambient temperature.

DCS800-S0x-0020, …, DCS800-S0x-1000 D1 to D4

− Where used

DCS800-S0x-1000, …,

DCS800-S0x-5200

D5 to D7 and DCS800-R

− Aging of the electronic card result in:

1. Damage other devices

2. Trip the drive and cause break-down time

− Replace the flat cables of all units D1 to D7.

Environmental conditions, especially temperature and humidity could cause corrosion on the contact surfaces and embitterment of the insulation.

− Aging of the flat cables result in:

1. Contact problems

2. Flat cable breaks

Preventive Maintainance

3ADW000195R0601 DCS800 Service Manual e f

125

Preventive maintenance Checklist DCS800

Type of drive:

Serial number:

Last inspection:

Frame size:

Year of initial start up:

Inspection cycle

1. Environment

1.1 Checking the environment

1.2 Documentation checked and available

1.3 Checking the spare parts yearly yearly yearly

2. Maintenance with no voltage applied

2.1 Cleaning with ESD vacuum cleaner and / or soft brushes

Converter and cabinet yearly

Air inlet and outlet filters (replace / clean if IP54 or if needed) yearly

Fins of fan

Drive’s heat sinks

2.2 Relays & connections

Inspect relays / contacts for proper functionality

Inspect electrical connections for tightness

Inspect for proper grounding

Inspect for corrosion

Inspect tightness of heatsink terminals (25 Nm required)

Inspect connection of fiber optical cables

Inspect connection of flat cables

3. Maintenance with main supply voltage applied

yearly yearly

3 years

3 years yearly yearly yearly

3 years

6 years

Create parameter backup

Test cooling air pressure switch yearly yearly

Check level of all connected voltages

Check E-stop / coast stop function yearly yearly

Inspect condition of fans (check that all fans are operational) yearly

ABB Automation Products

3ADW000195R0601 DCS800 Service Manual e f



Preventive Maintenance

126

Inspection cycle

4. Preventive Replacements

4.1 Flat cables

SDCS-CON-4 - SDCS-PIN-4 (X12/X13, X37/X37)

SDCS-CON-4 - SDCS-PIN-51 (X12/X13)

4.2 Boards

SDCS-POW-4

SDCS-PIN-4

4.3 Fan

SDCS-CON-4 - SDCS-POW-4

SDCS-PIN-51 - SDCS-PIN-4x (X113/X213)

Cooling fan frame size D1 - D5

Cooling fan frame size D6, D7

Inspect = visual inspection, correction and replacement if needed

Remarks:

Date of inspection:

Name of field service engineer:

ABB Automation Products

Preventive Maintainance

3ADW000195R0601 DCS800 Service Manual e f

9 years

9 years

9 years

9 years

9 years

9 years

6 years

3 years



127

Appendix A: Spare Parts List

Item

8.03

8.04 - 8.05

8.06

8.07

8.08

8.09

10.00 - 29.00

30.00 - 36.00

40.00 - 49.00

50.00 - 65.00

Content

Control Panels and plug-in options D1 - D7

Field exciters FEX-425-Int, DCF803-0035 and DCF503/4B

Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A

Common parts for DCS800-A0 Enclosed Converters

Parts for DCS800-R0 Rebuild Kit

Parts for 12-pulse, supply voltage >= 800 VAC and hardparallel D7P

Modules D1 - D4, 20 A - 1000 A, 400 V, 525 V and 600 V

Modules D5, 900 A - 2000 A, 400 V, 525 V, 600 V and 690 V

Modules D6, 1900 A - 3000 A, 400 V, 500 V, 600 V, 690 V and 800 V

Modules D7, 2050 A - 5200 A, 400 V, 500 V, 600 V, 690 V, 800 V, 990 V and 1200 V

Item 8.03

Control Panels and plug-in options D1 - D7

8.03

Control Panels and plug-in options D1 - D7

DESCRIPTION QTY CODE

DCS Control Panel 1 3ADT220129R1001

DCSLink board

DDCS communication board

DDCS communication board

PROFIBUS-DP

DeviceNet

Modbus

CANopen

ControlNet

Ethernet Adapter Module

EtherCat Adapter Module

Analog I/O Extension

Digital I/O Extension

Pulse Encoder Interface (12 V)

Pulse Encoder Interface (TTL)

I/O Extension Adapter

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

3ADT200005R0001

3ADT220134R0001

3ADT220134R0002

3AFE64606859

3AFE64606891

3AFE64606778

3AFE64606905

3AFE64751701

3AFE64751727

3AUA0000045102

3AFE64606841

3AFE64606816

3AFE64610805

3AFE68654947

3AFE68286778

TYPE/DATA

DCS-CP-P

SDCS-DSL-4

SDCS-COM-81

SDCS-COM-82

RPBA-01

RDNA-01

RMBA-01

RCAN-01

RCNA-01

RETA-01

RECA-01

RAIO-01

RDIO-01

RTAC-01

RTAC-03

AIMA-01

NOTES

Control Panel for DCS800

(+S199)

(+L508), 10 Mbd (e.g. AC 800M)

(+L509), 5 Mbd (fieldbus)

(+K454)

(+K451)

(+K458)

(+K457)

(+K462)

(+K466)

(+K469)

(+L500)

(+L501)

(+L502)

(+L517)

-

Item 8.04 to 8.05

Field exciters FEX-425-Int, DCF803-0035, DCF503/4B

8.04

Field exciters 25 A, 16 A and 35 A, overvoltage protection included

DESCRIPTION QTY CODE TYPE/DATA

FEX-425-Int, 1-Q, 25 A

Fuses for FEX-425-Int

1

3

3ADT209022R0001

3ADC770032P0025

FEX-425-Int

KTK 25

NOTES

Internal field exciter for D5

25 A / 600 V

DCF803-0016, 1-Q, 16 A

DCF803-0035, 1-Q, 35 A

Semiconductor fuses field

Semiconductor fuses field

Semiconductor fuses field

Semiconductor fuses field

Semiconductor fuses field

3

3

3

1

1

3

3

3ADT209027R0001

3ADT209023R0001

3ADT730004R0001

3ADT730004R0002

3ADT730004R0003

3ADT730004R0004

3ADT730004R0006

DCF803-0016

DCF803-0035

UR 10A / 660V

UR 16A / 660V

UR 25A / 660V

UR 50A / 660V

UR 80A / 660V

Complete unit

Complete unit

For fieldcurrent <= 6 ADC

For fieldcurrent <= 12 ADC

For fieldcurrent <= 16 ADC

For fieldcurrent <= 35 ADC

For fieldcurrent <= 60 ADC

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

128

8.05

Field exciters 50 A and 60 A, overvoltage protection included

DESCRIPTION QTY CODE TYPE/DATA

DCF503B0050, 1-Q, 50 A

DCF504B0050, 4-Q, 50 A

1

1

3ADT209019R0201

3ADT209019R0202

DCF503B0050

DCF504B0050

DCF503B0060, 1-Q, 60 A

DCF504B0060, 4-Q, 60 A

Fan for DCF50xB0060

1

1

2

3ADT209019R0211

3ADT209019R0212

GHSN700002P0001

NOTES

Complete unit, replaced by DCF803-0050

Complete unit, replaced by DCF804-0050

DCF503B0060 Complete unit, replaced by DCF803-0060

DCF504B0060 Complete unit, replaced by DCF804-0060

AC220V 3115FS… Fan M55/M56 for DCF50xB0060

Item 8.06

Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A

8.06

Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A

DESCRIPTION QTY CODE TYPE/DATA NOTES

Control board DCF505/506

Overvoltage protection field

1

1

3ADT220090R0021

DCF1127101R0001

SDCS-FEP-1

DCF506-0140-51

(1400 V) for DCF505/506

Field exciter 25 A - 100 A

Overvoltage protection field 1 DCF1127119R0001 DCF506-0520-51 Field exciter 200 A - 520 A

Item 8.07

Common parts for DCS800-A Enclosed Converters

8.07

Common parts for DCS800-A Enclosed Converters

DESCRIPTION QTY CODE

DI/DO connection board 1 3ADT220090R0014

DI/DO connection board

DI/DO connection board

AI/AO connection board

1

1

1

3ADT220090R0013

3ADT220090R0023

3ADT220090R0020

TYPE/DATA

SDCS-IOB-21

SDCS-IOB-22

SDCS-IOB-23

SDCS-IOB-3

NOTES

24 VDC - 48 VDC, digital (A9)

115 VAC, digital (A9)

230 VAC, digital (A9)

Analog and encoder (A10)

Item 8.08

Parts for DCS800-R Rebuild Kit

8.08

DCR-Kit contains:

DESCRIPTION

2-Q 4-Q

Parts for DCS800-R Rebuild Kit

2-Q 4-Q

Pulse interface board

Pulse amplifier board

1

1

1

1

CODE

3ADT220090R0009

3ADT220090R0034

Pulse distribution board

Pow er supply for SDCS-REB-2

Puls transformer board

Pow er interface board

Current transformer 2500 / 1 A

Current transformer 4000 / 1 A

FEX-425-Int, 1-Q, 25 A

2

2

1

1

2

1

1

2

2

1

1

2

2

1

3ADT309300R0001

3ADT200003P0001

3BSE004939R1012

3ADT220090R0006

3ADT751010P0001

3ADT751007P0001

3ADT209022R0001

TYPE/DATA

SDCS-REB-1

SDCS-REB-2

SDCS-REB-3

QUINT-240/24/2A

SDCS-PIN-48-SD

SDCS-PIN-51

LT2032 2500/1A

4000/1A

FEX-425-Int

NOTES

115 - 240 VAC / 24 VDC

Replaces SDCS-PIN-41 / SDCS-PIN-48

For 400 VAC - 1000 VAC

T51 / T52 for D5 and D6

T51 / T52 for D7

Internal field exciter for Rebuild Kit

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

129

Item 8.09

Parts for 12-pulse, supply voltage >= 800 VAC, hardparallel D7P and galvanic isolation

8.09

Parts for 12-pulse, supply voltage >= 800 VAC, hardparallel D7P and galvanic isolation

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA NOTES

Current measurement aid

Insulation monitor

Insulation monitor

Voltage adaption for IRDH

Voltage adaption for IRDH

DC-DC transducer (Knick) A92

1

1

1

1

1

1

1

1

1

1

1

1

3ADT220090R0022

3AFE68335256

3ADV050058P0007

DCA0019711P0001

3ADV050058P0002

3ADN260008P0001

SDCS-CMA-2

IRDH 275

IRDH 375

AGH 204 S

AGH 150 W-4

P42000D3-0111

For D5 - D7 (12-pulse, hardparrallel)

Inside cabinet, 1 - 990 kOhm

Door mounted, 1 - 990 kOhm

For IRDH >= 690 VAC, 6-pulse

For IRDH >= 690 VAC, 12-pulse

For U >= 690 VAC, 12-pulse, replaches Knick

8680 A1/A92

High volt. transformer T90

High volt. fuses for U >= 750 VAC

High volt. fuses for U >= 750 VAC

Pow er Interface U>=750 VAC

Hardparrallel board 1

Hardparrallel board 2

2

1

1

1

1

3

2

1

1

1

1

3

3ADT745047P0001

3ADV050092P0015

T 90, 500 -1200 VAC For U >= 690 VAC, 12-pulse

CC 1051CP 10A/1000V 3 for T90 and capacitors

3ADV050092P0017 CC 1551CP 10A/1500V 2 for A92

3ADT780007R0002 SDCS-PIN-5x-1190 meas. Special test procedure & modified

3ADT220090R0031

3ADT220090R0032

SDCS-PAR-1

SDCS-PAR-2

Hardparallel master

Hardparallel slave

Item 10.00 to 29.00

Modules D1 - D4, 20 A - 1000 A, 400 V, 525 V and 600 V

10.00

Common parts for modules D1 - D4, 20 A - 1000 A

DESCRIPTION 2-Q 4-Q CODE

Control board 1 1 3ADT313900R1501

Interface board and field supply

Fuses on SDCS-PIN-4

Half controlled bridge block

Temperatur sensor (D1and D2)

Temperatur Sensor (D3 and D4)

1

1

1

1

3

1

1

1

1

3

3ADT314100R1001

3ADC770032P0025

3ADC340091R0001

3ADT710005P0001

3ADT710005P0002

TYPE/DATA

SDCS-CON-4

NOTES

Replaces 3ADT313900R1001

SDCS-PIN-4

KTK 25

OnBoard field up to 525 VAC

25 A / 600 V

VVZF 70-16xxx OnBoard field up to 525 VAC

KTY10-6-M4/250mm 20 A - 260 A, cable 250 mm

KTY10-6-M4/400mm 315 A - 1000 A, cable 400 mm

11.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0020-04/05 & DCS800-S02-0025-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

Semiconductor fuses (as field)

3

3

3

6

3

3

3ADC340063P0001

3ADT730004R0004

3ADV050169P0050

SKKT27B/xxx

UR 50 A / 660 V

UR 50 A / 600 V

NOTES

MCC 26 - 16 xxx

Blade- or knife fuse

When used as field in D6 or D7 cabinets

Module contains: 2-Q 4-Q

12.00

DCS800-S01-0045-04/05 & DCS800-S02-0050-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340063P0001 SKKT27B/xxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Semiconductor fuses (as field)

3

2

3

3

2

3

3ADT730004R0005

3ADT754014P0001

3ADV050169P0080

UR 63 A / 660 V

CN2B2

UR 80 A / 600 V

NOTES

MCC 26 -16 xxx

Blade- or knife fuse

4715 MS-12T-B5Axxx

When used as field in D6 or D7 cabinets

Module contains: 2-Q 4-Q

13.00

DCS800-S01-0065-04/05 & DCS800-S02-0075-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Semiconductor fuses (as field)

3

3

2

3

6

3

2

3

3ADC340067P0001

3ADT730004R0007

3ADT754014P0001

3ADV050169P0125

SKKT42B/xxx

NOTES

MCC 44 -16 xxx

Blade- or knife fuse UR 125 A / 660 V

4715 MS-12T-B5Axxx CN2B2

UR 125 A / 600 V When used as field in D6 or D7 cabinets

Appendix A: Spare Parts List

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130

Module contains:

14.00

DCS800-S01-0090-04/05 & DCS800-S02-0100-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

Cooling fan 115V, 50/60Hz

Semiconductor fuses (as field)

2-Q 4-Q

3

3

2

3

6

3

2

3

3ADC340068P0001

3ADT730004R0007

3ADT754014P0001

3ADV050092P0036

SKKT57B/xxx

NOTES

MCC 56 -16 xxx

Blade- or knife fuse UR 125 A / 660 V

4715 MS-12T-B5Axxx CN2B2

UR 200 A / 660 V When used as field in D6 or D7 cabinets

Module contains:

15.00

DCS800-S01-0125-04705 & DCS800-S02-0140-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

2-Q 4-Q

3

3

2

6

3

2

3ADC340064P0001

3ADT730004R0008

3ADT754014P0001

SKKT106B/xxx

UR 200 A / 660 V

4715 MS-12T-B5Axxx CN2B2

NOTES

MCC 95 -16 xxx

Blade- or knife fuse

16.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0180-04/05 & DCS800-S02-0200-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340064P0001

3ADT730004R0009

SKKT106B/xxx

UR 250 A / 660 V

Cooling fan 115 V, 50/60 Hz

Semiconductor fuses (as field)

2

3

2

3

3ADT754014P0001

3ADV050169P0250

NOTES

MCC 95 -16 xxx

Blade- or knife fuse

4715 MS-12T-B5Axxx CN2B2

UR 250 A / 660 V When used as field in D6 or D7 cabinets

17.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0230-04/05 & DCS800-S02-0260-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340094P0001

3ADT730004R0010

MCC162-16xxx

UR 315 A / 660 V

Cooling fan 115 V, 50/60 Hz 2 2 3ADT754014P0001 4715 MS-12T-B5Axxx CN2B2

NOTES

TT 162 Nxxx

Blade- or knife fuse

Module contains: 2-Q 4-Q

18.00

DCS800-S01-0290-06 & DCS800-S02-0320-06 (600 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor modules 3 6 3ADC340096P0001

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

3

2

3

2

3ADT730004R0012

3ADT754014P0001

TYPE/DATA

MCC 224-xxx

NOTES

UR 500 A / 660 V Blade- or knife fuse

4715 MS-12T-B5Axxx CN2B2

19.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0315-04/05 & DCS800-S02-0350-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340095P0001

3ADT730004R0013

MCC 255 - xxx

UR 700 A / 660 V

Cooling fan 115 V, 50/60 Hz

Semiconductor fuses (as field)

2

3

2

3

3ADT754014P0001

3ADV050092P0032

NOTES

TT250 Nxxx

Blade- or knife fuse

4715 MS-12T-B5Axxx CN2B2

UR 450 A / 660 V When used as field in D6 or D7 cabinets

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

131

Module contains:

20.00

DCS800-S01-0405-04/05 & DCS800-S02-0450-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

2-Q 4-Q

3

3

4

6

3

4

3ADC340095P0001

3ADT730004R0013

3ADT754014P0001

MCC 255 - xxx

UR 700 A / 660 V

4715 MS-12T-B5Axxx CN2B2

NOTES

TT250 Nxxx

Blade- or knife fuse

21.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0470-04/05 & DCS800-S02-0520-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340100P0001

3ADT730004R0013

MCC 312 - xxx

UR 700 A / 660 V

Cooling fan 115 V, 50/60 Hz 4 4 3ADT754014P0001 4715 MS-12T-B5Axxx CN2B2

NOTES

TT330 Nxxx

Blade- or knife fuse

Module contains: 2-Q 4-Q

22.00

DCS800-S01-0590-06 & DCS800-S02-0650-06 (600 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor modules 3 6 3ADC340097P0001

TYPE/DATA

SKKT 430/20xxx

Semiconductor fuses

Cooling fan 230 V, 50/60 Hz

3

1

3

1

3ADT730004R0014

DCA0012171P0001

UR 900 A / 660 V

W2E 200-HH38-06

NOTES

TT430 Nxxx, MT3-430-xx

Blade- or knife fuse

Module contains: 2-Q 4-Q

23.00

DCS800-S01-0590-06 & DCS800-S02-0650-06 +S171 (600 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340097P0001 SKKT 430xxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

3

1

3

1

3ADT730004R0014

3ADT754012P0001

NOTES

TT430 Nxxx, MT3-430-xx

UR 900 A / 660 V Blade- or knife fuse

W2E 200-HH86-14 (+S171)

24.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0610-04/05 & DCS800-S02-0680-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340103P0001 MCC 501 - xxx

Semiconductor fuses

Cooling fan 230 V, 50/60 Hz

Fuses as Enclosed Converter

3

1

3

3

1

3

3ADT730004R0015

DCA0012171P0001

DCA0012724P0001

UR 900 A / 660 V

W2E 200-HH38-06

170M6813

TT 425 Nxxx

Screw type fuse

NOTES

Fuses as Enclosed Converter w ith OESA

25.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0740-04/05 & DCS800-S02-0820-04/05 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340099P0001 MT3-595-xxx

Semiconductor fuses

Cooling fan 230 V, 50/60 Hz

Fuses as Enclosed Converter

3

1

3

3

1

3

3ADT730004R0015

DCA0012171P0001

DCA0012724P0001

UR 900 A / 660 V

W2E 200-HH38-06

170M6813

3ADW000195R0601 DCS800 Service Manual e f

TT 570 Nxxx

Screw type fuse

NOTES

Fuses as Enclosed Converter w ith OESA

Appendix A: Spare Parts List

132

Module contains: 2-Q 4-Q

26.00

DCS800-S01-0900-04/05 & DCS800-S02-1000-04/05 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC3400099P0001

3ADT730004R0016

MT3-595-xxx TT 570 Nxxx

UR 1250 A / 660 V Screw type fuse

Cooling fan 230 V, 50/60 Hz

Fuses as Enclosed Converter

1

3

1

3

3ADT754017P0001

3ADV050092P0020

W2E250-HL06-10

170M6016

NOTES

Fuses as Enclosed Converter w ith OESA

Module contains: 2-Q 4-Q

27.00

DCS800-S01-0610-04/05 & DCS800-S02-0680-04/05 +S171 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340103P0001 MCC 501 - xxx TT 425 Nxxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Fuses as Enclosed Converter

3

1

3

3

1

3

3ADT730004R0015

3ADT754012P0001

DCA0012724P0001

NOTES

UR 900 A / 660 V Screw type fuse

W2E 200-HH86-14 (+S171)

170M6813 Fuses as Enclosed Converter w ith OESA

Module contains: 2-Q 4-Q

28.00

DCS800-S01-0740-04/05 & DCS800-S02-0820-04/05 +S171 (400 V - 525 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340099P0001 MT3-595-xxx TT 570 Nxxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Fuses as Enclosed Converter

3

1

3

3

1

3

3ADT730004R0015

3ADT754012P0001

DCA0012724P0001

NOTES

UR 900 A / 660 V Screw type fuse

W2E 200-HH86-14 (+S171)

170M6813 Fuses as Enclosed Converter w ith OESA

29.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-0900-04/05 & DCS800-S02-1000-04/05 +S171 (400 V - 525 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor modules 3 6 3ADC340099P0001 MT3-595-xxx TT 570 Nxxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Fuses as Enclosed Converter

3

1

3

3

1

3

3ADT730004R0016

3ADT754015P0001

3ADV050092P0020

NOTES

UR 1250 A / 660 V Screw type fuse

W2E250-HL08-09

170M6016

(+S171)

Fuses as Enclosed Converter w ith OESA

Item 30.00 to 36.00

Modules D5, 900 A - 2000 A, 400 V, 525 V, 600 V and 690 V

30.00

Common parts for modules D5, 900 A - 2000 A

DESCRIPTION 2-Q 4-Q CODE

Control board 1 1 3ADT313900R1501

Pow er supply board

Puls transformer board

Pow er interface board

Temperatur sensor (R57)

Current transformer 2500 / 1 A

Cooling fan

1

2

1

1

1

1

1

2

1

1

2

1

3ADT315100R1012

3BSE004939R1012

3ADT220090R0006

3ADT710003P0001

3ADT751010P0001

3ADT754018P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4-SD

SDCS-PIN-48-SD

SDCS-PIN-51

KTY 2K-M4-800

LT2032 2500/1A

D2E 160-AH02-15

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

NOTES

Replaces 3ADT313900R1001

Replaces SDCS-POW-4

Replaces SDCS-PIN-41 / SDCS-PIN-48

T51 / T52 for D5 and D6

133

Module contains:

31.00

DCS800-S01-0900-06/07 & DCS800-S02-0900-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor

Semiconductor fuses

2-Q 4-Q

6

6

12

6

DCA0012007P0001

3ADC770009P0007

T459Nxxx

NOTES

Original thyristor type

UR 630 A / 1250 V Screw type fuse

Module contains: 2-Q 4-Q

31.00a

DCS800-S01-0900-06a/07a & DCS800-S02-0900-06a/07a (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340105P0001 T460Nxxx

NOTES

Second thyristor type

Semiconductor fuses 6 6 3ADC770009P0007 UR 630 A / 1250 V Screw type fuse

Module contains: 2-Q 4-Q

32.00

DCS800-S01-1200-04/05 & DCS800-S02-1200-04/05 (400 V - 500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor

Semiconductor fuses

6

6

12

6

DCA0012015P0001

3ADC770010P0005

T589Nxxx

UR 800 A / 660 V

NOTES

Original thyristor type

Screw type fuse

Module contains: 2-Q 4-Q

32.00a

DCS800-S01-1200-04a/05a & DCS800-S02-1200-04a/05a (400 V - 500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340106P0001 T590Nxxx

NOTES

Second thyristor type

Semiconductor fuses 6 6 3ADC770010P0005 UR 800 A / 660 V Screw type fuse

Module contains: 2-Q 4-Q

33.00

DCS800-S01-1500-04/05 & DCS800-S02-1500-04/05 (400 V - 500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340102P0001 T2 XXX-18

Semiconductor fuses 6 6 3ADC770010P0009 UR 1250 A / 660 V Screw type fuse

NOTES

Module contains: 2-Q 4-Q

34.00

Thyristor

DCS800-S01-1500-06/07 & DCS800-S02-1500-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q

6 12

CODE

3ADC340098P0001

TYPE/DATA

T1 XXX-24

Semiconductor fuses 6 6 3ADC770009P0012 UR 1100 A / 1250 V Screw type fuse

NOTES

35.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-2000-04/05 & DCS800-S02-2000-04/05 (400 V - 500 V)

2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340102P0001

T2-XXX-18

Semiconductor fuses 6 6 3ADC770010P0012 UR 1600 A / 660 V Screw type fuse

NOTES

36.00

Module contains:

DESCRIPTION

2-Q n.a.

DCS800-S01-2000-06/07 (600 V - 690 V)

2-Q n.a.

CODE

Thyristor

Semiconductor fuses

6

6

---

---

3ADC340090P0001

3ADC770009P0013

TYPE/DATA

TV 989-2700-xxx

UR 1400 A / 1100 V Screw type fuse

NOTES

3ADW000195R0601 DCS800 Service Manual e f

Appendix A: Spare Parts List

134

Item 40.00 to 49.00

Modules D6, 1900 A - 3000 A, 400 V, 500 V, 600 V, 690 V and 800 V

40.00

Common parts for modules D6, 1900 A - 3000 A

DESCRIPTION 2-Q 4-Q CODE

Control board

Pow er supply board

1

1

1

1

3ADT313900R1501

3ADT315100R1012

Pow er interface board

Air Flow detector (P1)

Temperatur Sensor (R57)

Current transformer 2500 / 1 A

1

1

1

2

1

1

1

2

3ADT220090R0006

DCF1066659P0001

DCA0012139P0004

3ADT751010P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4-SD

SDCS-PIN-51

P 233A-4-AHC

KTY 10-6 M4

LT2032 2500/1A

NOTES

Replaces 3ADT313900R1001

Replaces SDCS-POW-4

Cable 1200 mm

T51 / T52 for D5 and D6

Module contains: 2-Q 4-Q

41.00

DCS800-S01-1900-08 & DCS800-S02-1900-08 (800 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor 6 12 3ADC340081P0001

Puls transformer board

Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3BSE004939R1012

3ADC770009P0007

3ADT754008P0001

TYPE/DATA

T 1329Nxxx

NOTES

Original thyristor type

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 630 A / 1250 V Screw type fuse (double fuses)

GR31M-..(500V) 400 V - 500 V / 50/60 Hz

Module contains: 2-Q 4-Q

41.00a

DCS800-S01-1900-08a & DCS800-S02-1900-08a (800 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340098P0001 T 1xxx-24

Puls transformer board

Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3BSE004939R1012

3ADC770009P0007

3ADT754008P0001

NOTES

Second thyristor type

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 630 A / 1250 V Screw type fuse (double fuses)

GR31M-..(500V) 400 V - 500 V / 50/60 Hz

Module contains: 2-Q 4-Q

42.00

DCS800-S01-2050-05 & DCS800-S02-2050-05 (500 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor 6 12 3ADC340081P0001

Puls transformer board

Semiconductor fuses

Cooling fan

1

6

1

2

6

1

3BSE004939R1012

3ADC770010P0011

3ADT754008P0001

TYPE/DATA

T 1329Nxxx

NOTES

Original thyristor type

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 1500 A / 660 V Screw type fuse

GR31M-..(500V) 400 V - 500 V / 50/60 Hz

Module contains: 2-Q 4-Q

42.00a

DCS800-S01-2050-05a & DCS800-S02-2050-05a (500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340098P0001 T 1xxx-24

Puls transformer board

Semiconductor fuses

Cooling fan

1

6

1

2

6

1

3BSE004939R1012

3ADC770010P0011

3ADT754008P0001

NOTES

Second thyristor type

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 1500 A / 660 V Screw type fuse

GR31M-..(500V) 400 V - 500 V / 50/60 Hz

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

Module contains: 2-Q 4-Q

43.00

DCS800-S01-2050-06/07 & DCS800-S02-2050-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340081P0001 T 1329Nxxx

Puls transformer board

Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3BSE004939R1012

3ADC770009P0008

3ADT754008P0002

NOTES

Original thyristor type

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 700 A / 1250 V Screw type fuse (double fuses)

GR31M-..(690V) 525 V - 690 V / 50/60 Hz

Module contains: 2-Q 4-Q

43.00a

DCS800-S01-2050-06a/07a & DCS800-S02-2050-06a/07a (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340098P0001 T 1xxx-24

NOTES

Second thyristor type

Puls transformer board

Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3BSE004939R1012

3ADC770009P0008

3ADT754008P0002

SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

UR 700 A / 1250 V Screw type fuse (double fuses)

GR31M-..(690V) 525 V - 690 V / 50/60 Hz

Module contains:

Thyristor for DCS800-S02, 4-Q

2-Q 4-Q

44.00

DCS800-S01-2500-04/05 & DCS800-S02-2500-04/05 (400 V - 500 V)

DESCRIPTION

Thyristor for DCS800-S01, 2-Q

2-Q 4-Q

6

-

CODE

3ADC340089P0001

TYPE/DATA

T 989-3030xxx

-

6 3ADC340079P0001 5 STB 24-Qxxx

Puls transformer board

Puls transformer board

1

-

-

2

3BSE004939R1012

3BSE004939R1003

SDCS-PIN-48-SD

SDCS-PIN-46

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770010P0006

3ADT754008P0001

UR 900 A / 660 V

GR31M-..(500V)

NOTES

DCR 3400V18 (3ADC340121P0001)

Bidirectional-Controlled-Thyristor (BCT)

Replaces SDCS-PIN-41 / SDCS-PIN-48

Only used for BCT's

Screw type fuse (double fuses)

400 V - 500 V / 50/60 Hz

45.00

Module contains:

DCS800-S01-2500-06/07 & DCS800-S02-2500-06/07 (600 V - 690 V)

DESCRIPTION

Thyristor for DCS800-S01, 2-Q

2-Q 4-Q

2-Q 4-Q

6

-

CODE

3ADC340090P0001

TYPE/DATA NOTES

TV 989-2700-2xxx DCR 2760V28 (3ADC340120P0001)

Thyristor for DCS800-S02, 4-Q

-

6 3ADC340079P0001 5 STB 24-Qxxx Bidirectional-Controlled-Thyristor (BCT)

Puls transformer board 1

-

3BSE004939R1012 SDCS-PIN-48-SD Replaces SDCS-PIN-41 / SDCS-PIN-48

Puls transformer board

-

2 3BSE004939R1003 SDCS-PIN-46 Only used for BCT's

Semiconductor fuses 12 12 3ADC770009P0011 UR 1000 A / 1250 V Screw type fuse (double fuses)

Cooling fan 1 1 3ADT754008P0002 GR31M-..(690V) 525 V - 690 V / 50/60 Hz

Module contains:

Thyristor for DCS800-S02, 4-Q

2-Q 4-Q

46.00

DCS800-S01-2500-08 & DCS800-S02-2500-08 (800 V)

DESCRIPTION

Thyristor for DCS800-S01, 2-Q

2-Q 4-Q

6

-

CODE

3ADC340087P0001

-

6 3ADC340079P0001

Puls transformer board

Puls transformer board

1

-

-

2

3BSE004939R1012

3BSE004939R1003

TYPE/DATA

TV 989-2770xxx

5 STB 24-Qxxx

SDCS-PIN-48-SD

SDCS-PIN-46

Semiconductor fuses 12 12 3ADC770009P0011

NOTES

DCR 3400V18 (3ADC340121P0001)

Bidirectional-Controlled-Thyristor (BCT)

Replaces SDCS-PIN-41 / SDCS-PIN-48

Only used for BCT's

UR 1000 A / 1250 V Screw type fuse (double fuses)

Cooling fan 1 1 3ADT754008P0001 GR31M-..(500V) 400 V - 500 V / 50/60 Hz

135

3ADW000195R0601 DCS800 Service Manual e f

Appendix A: Spare Parts List

136

Module contains:

Thyristor for DCS800-S02, 4-Q

2-Q 4-Q

47.00

DCS800-S01-3000-04/05 & DCS800-S02-3000-04/05 (400 V - 500 V)

DESCRIPTION

Thyristor for DCS800-S01, 2-Q

2-Q 4-Q

6

-

CODE

3ADC340088P0001

TYPE/DATA

T 989-3300xxx

-

6 3ADC340079P0001 5 STB 24-Qxxx

Puls transformer board

Puls transformer board

1

-

-

2

3BSE004939R1012

3BSE004939R1003

SDCS-PIN-48-SD

SDCS-PIN-46

Semiconductor fuses 12 12 3ADC770010P0009

NOTES

Bidirectional-Controlled-Thyristor (BCT)

Replaces SDCS-PIN-41 / SDCS-PIN-48

Only used for BCT's

UR 1250 A / 660 V Screw type fuse (double fuses)

Cooling fan 1 1 3ADT754008P0001 GR31M-..(500V) 400 V - 500 V / 50/60 Hz

48.00

Module contains:

Thyristor for DCS800-S01, 2-Q

Thyristor for DCS800-S02, 4-Q

2-Q 4-Q

DCS800-S01-3000-06/07 & DCS800-S02-3000-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q

6

-

-

6

CODE

3ADC340046P0002

3ADC340079P0001

TYPE/DATA

5STP 3328Lxxx

5 STB 24-Qxxx

Puls transformer board 1

-

3BSE004939R1012 SDCS-PIN-48-SD

Puls transformer board

-

2 3BSE004939R1003 SDCS-PIN-46

Semiconductor fuses 12 12 3ADC770009P0012

NOTES

Bidirectional-Controlled-Thyristor (BCT)

Replaces SDCS-PIN-41 / SDCS-PIN-48

Only used for BCT's

UR 1100 A / 1250 V Screw type fuse (double fuses)

Cooling fan 1 1 3ADT754008P0002 GR31M-..(690V) 525 V - 690 V / 50/60 Hz

Module contains:

Thyristor for DCS800-S01, 2-Q

2-Q 4-Q

49.00

DCS800-S01-3000-08 & DCS800-S02-3000-08 (800 V)

DESCRIPTION 2-Q 4-Q CODE

6

-

3ADC340046P0002

Thyristor for DCS800-S02, 4-Q

Puls transformer board

-

1

6

-

3ADC340079P0001

3BSE004939R1012

Puls transformer board

-

2 3BSE004939R1003

TYPE/DATA

5STP 3328Lxxx

5 STB 24-Qxxx

SDCS-PIN-48-SD

SDCS-PIN-46

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770009P0012

3ADT754008P0001

NOTES

Bidirectional-Controlled-Thyristor (BCT)

Replaces SDCS-PIN-41 / SDCS-PIN-48

Only used for BCT's

UR 1100 A / 1250 V Screw type fuse (double fuses)

GR31M-..(500V) 400 V - 500 V / 50/60 Hz

Item 50.00 to 65.00

Modules D7, 2050 A - 5200 A, 400 V, 500 V, 600 V, 690 V, 800 V, 990 V and 1200 V

50.00

Common parts for modules D7, 2050 A - 5200 A

DESCRIPTION 2-Q 4-Q CODE

Control Board

Pow er supply board

1

1

1

1

3ADT313900R1001

3ADT315100R1012

Puls transformer board

Pow er interface board

Air Flow detector (P1)

Temperatur Sensor (R57)

Current Transformer 4000 / 1 A

Cooling fan

1

1

1

1

2

1

2

1

1

1

2

1

3BSE004939R1012

3ADT220090R0006

DCF1066659P0001

DCA0012139P0005

3ADT751007P0001

3ADT754020P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4-SD

SDCS-PIN-48-SD

SDCS-PIN-51

P233 A-4 AHC

KTY 10-6 -M4

4000/1A

GR 35C

NOTES

Replaces SDCS-POW-4

Replaces SDCS-PIN-41 / SDCS-PIN-48

Cable 1750 mm

T51 / T52 for D7

400 V - 690 V / 50/60 Hz

51.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-2050-10 & DCS800-S02-2050-10 (990 V)

2-Q 4-Q CODE

Thyristor 6 12 3ADC340086P0001

TYPE/DATA

TV 989-2700-xxx

Semiconductor fuses 6 6 3ADC770030P0003

NOTES

UR 1800 A / 1250 V Flush-end contact fuse

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

Module contains: 2-Q 4-Q

52.00

DCS800-S01-2600-10 & DCS800-S02-2600-10 (990 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor 6 12 3ADC340086P0001

TYPE/DATA

TV 989-2700-xxx

Semiconductor fuses 6 6 3ADC770030P0003

NOTES

UR 1800 A / 1250 V Flush-end contact fuse

Module contains: 2-Q 4-Q

53.00

DCS800-S01-2600-12 & DCS800-S02-2600-12 (1200 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 DCA0012066P0001 5 STP 28Lxxx

Pow er Interface U>=750 VAC

Semiconductor fuses

1

6

1

6

NOTES

3ADT780007R0002 SDCS-PIN-5x-1190 meas. Prepared for galvanic isolation (A92)

3ADC770025P0001 UR 1700 A / 1500 V Flush-end contact fuse

Module contains:

54.00

DCS800-S01-3300-04/05 & DCS800-S02-3300-04/05 (400 V - 500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor

Semiconductor fuses

2-Q 4-Q

6

6

12

6

3ADC340089P0001

DCA0012821P0001

T 989-3030xxx

NOTES

DCR 3400V18 (3ADC340121P0001)

UR 2500 A / 660 V Flush-end contact fuse

Module contains:

55.00

DCS800-S01-3300-06/07 & DCS800-S02-3300-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor

Semiconductor fuses

2-Q 4-Q

6

6

12

6

3ADC340087P0001

DCA0012856P0001

TV 989-2770xxx

NOTES

DCR 2760V28 (3ADC340120P0001)

UR 2500 A / 1000 V Flush-end contact fuse

56.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-3300-08 & DCS800-S02-3300-08 (800 V)

2-Q 4-Q CODE

Thyristor

Semiconductor fuses

6

6

12

6

3ADC340087P0001

DCA0012856P0001

TYPE/DATA NOTES

TV 989-2770xxx DCR 2760V28 (3ADC340120P0001)

UR 2500 A / 1000 V Flush-end contact fuse

57.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-3300-10 & DCS800-S02-3300-10 (990 V)

2-Q 4-Q CODE

Thyristor

Semiconductor fuses

6

6

12

6

3ADC340084P0001

3ADC770030P0005

TYPE/DATA NOTES

5 STP 38 Qxxx

UR 2500 A / 1250 V Flush-end contact fuse

Module contains: 2-Q 4-Q

58.00

DCS800-S01-3300-12 & DCS800-S02-3300-12 (1200 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340084P0001 5 STP 38 Qxxx

Pow er Interface U>=750 VAC

Semiconductor fuses

1

6

1

6

NOTES

3ADT780007R0002 SDCS-PIN-5x-1190 meas. Prepared for galvanic isolation (A92)

3ADC770030P0006 UR 2300 A / 1500 V Flush-end contact fuse

137

3ADW000195R0601 DCS800 Service Manual e f

Appendix A: Spare Parts List

138

Module contains: 2-Q 4-Q

59.00

DCS800-S01-4000-04/05 & DCS800-S02-4000-04/05 (400 V - 500 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340088P0001 T 989-3300xxx

Semiconductor fuses 6 6 DCA0012830P0001

NOTES

UR 3000 A / 660 V Flush-end contact fuse

Module contains: 2-Q 4-Q

60.00

DCS800-S01-4000-06/07 & DCS800-S02-4000-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340046P0002 5 STP 3328 Lxxx

Semiconductor fuses 6 6 3ADC770030P0002

NOTES

UR 3000 A / 1000 V Flush-end contact fuse

61.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-4000-08 & DCS800-S02-4000-08 (800 V)

2-Q 4-Q CODE

Thyristor

Semiconductor fuses

6

6

12

6

3ADC340046P0002

3ADC770030P0002

TYPE/DATA NOTES

5 STP 3328 Lxxx

UR 3000 A / 1000 V Flush-end contact fuse

Module contains: 2-Q 4-Q

62.00

DCS800-S01-4000-10 & DCS800-S02-4000-10 (990 V)

DESCRIPTION 2-Q 4-Q CODE

Thyristor 6 12 3ADC340084P0001

Semiconductor fuses 6 6 3ADC770030P0005

TYPE/DATA

5 STP 38 Qxxx

NOTES

UR 2500 A / 1250 V Flush-end contact fuse

Module contains: 2-Q 4-Q

62.10

DCS800-S01-4000-12 & DCS800-S02-4000-12 (1200 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor 6 12 3ADC340084P0001 5 STP 38 Qxxx

Pow er Interface U>=750 VAC

Semiconductor fuses

1

6

1

6

NOTES

3ADT780007R0002 SDCS-PIN-5x-1190 meas. Prepared for galvanic isolation (A92)

3ADC770030P0006 UR 3300 A / 1500 V Flush-end contact fuse

Module contains:

63.00

DCS800-S01-4800-06/07 & DCS800-S02-4800-06/07 (600 V - 690 V)

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor

Semiconductor fuses

2-Q 4-Q

6

6

12

6

3ADC340083P0001

3ADC770030P0002

5 STP 45 Qxxx

NOTES

DCR 6430M24 (3ADC340125P0001)

UR 3000 A / 1000 V Flush-end contact fuse

64.00

Module contains:

DESCRIPTION

2-Q 4-Q

DCS800-S01-4800-08 & DCS800-S02-4800-08 (800 V)

2-Q 4-Q CODE

Thyristor

Semiconductor fuses

6

6

12

6

3ADC340083P0001

3ADC770030P0002

TYPE/DATA NOTES

5 STP 45 Qxxx DCR 6430M24 (3ADC340125P0001)

UR 3000 A / 1000 V Flush-end contact fuse

65.00

Thyristor

Module contains:

DCS800-S01-5200-04/05 & DCS800-S02-5200-04/05 (400 V - 500 V)

DESCRIPTION

Semiconductor fuses

2-Q 4-Q

2-Q 4-Q

6

6

12

6

CODE

3ADC340083P0001

3ADC770030P0001

TYPE/DATA

5 STP 45 Qxxx

NOTES

DCR 6430M24 (3ADC340125P0001)

UR 3500 A / 690 V Flush-end contact fuse

Appendix A: Spare Parts List

3ADW000195R0601 DCS800 Service Manual e f

139

3ADW000195R0601 DCS800 Service Manual e f

Appendix A: Spare Parts List



ABB Automation Products

Wallstadter-Straße 59

68526 Ladenburg • Germany

Tel: +49 (0) 6203-71-0

Fax: +49 (0) 6203-71-76 09 www.abb.com/motors&drives

*195R0601A2390000*

*195R0601A2390000*

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