ABB DCS 500B, DCS 600 MultiDrive Series Service Manual

DCS Thyristor Power Converters for DC Drive Systems

25 to 5200 A

Service Manual

DCS 500B

DCS 600 MultiDrive

4

2

3

1

How to use the DCS Documentation System

The matrix below indicates all available product documentation and its corresponding order numbers on its left columns as well as all existing DC Drive systems on its top rows. System descriptions, Technical data and Operating instructions (as far as they are available for the corresponding drive) are the basic documents and will be delivered together with each drive. All other documentation has to be ordered separately.

DC drive systems System Drive

Cabinet Module

Standard Drive

Cabinet Module

Rebuild

Product documentation

System description

3ADW000066

3ADW000072

3ADW000121

➀

3ADW000095 (Manual)

➁

3ADW000139

3ADW000071 (Flyer)

3ADW000152

3ADW000173 (Flyer)

Language

EN, DE,FR

EN, DE

EN

EN,DE,FR,IT,SP

EN

EN, DE

EN, DE,FR,IT,SP

EN

Volume

II D

II F

II F1

II K

II F x x x x x

Technical Data

3ADW000165

Operating Instructions

3ADW000055

3ADW000080

3ADW000091 (Installation)

Quick Guide

3ADW000177 (DCS 500B)

3ADW000179 (DCS 600)

Software description

3ADW000078

3ADW000076

3AST000953

➂

EN

Language

Language

EN,DE,FR,SP

EN, DE

EN, DE

Volume

III

Volume

IV A

IV F

IV F1

Language

EN,DE,FR,IT,SP

EN,DE,FR,IT,SP

EN

EN

Language

EN

Volume

I

I

Volume

V D1

V F 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

Tools

3AFE61178775 CMT/DCS500

EN 5926915-1 GAD

3ADW000048 (Application blocks)

3AFY61296123 Drive Window

EN

EN

EN

Language

EN

Volume

-

-

V A2

x x

Service Instructions

3ADW000093

3ADW000131

Language

EN, DE

EN

Volume

VI A

VI K x x

Fieldbus

3ADW000086

3ADW000097

EN

Language

EN

Volume

-

x x

Others

3ADW000115 12-Pulse operation EN

Language

3ADW000092 Rebuild manual EN

3ADW000128 Paralleling DCS Conv.

EN

3ADW000040 12-Puls operation EN, DE

Volume

VIII F2

XI H1

VIII D1

VIII A2 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

Status: 14.June 2004

➀

Covers information of Technical data

➁

Covers information of Technical data, Operating Instructions, Software Description

➂

Covers information of Operating Instructions, Software Description

Note: For clearness the type designation in this brochure is shown in the following way:

Designation is valid for

DCS 500B

3ADW000093R0701_DCS500B/DCS600_Service manual_e_g

DCS Thyristor Power Converters for DC Drive Systems

25 to 5200 A

Service Manual

DCS 500B

DCS 600 MultiDrive

Code: 3ADW 000 093 R0701 Rev G

S_M_E_G.DOC

EFFECTIVE: Jul. 9th, 2004

SUPERSEDES: Rev F Jul. 4th, 2002



2004 ABB Automation Products GmbH. All rights reserved.


DCS 500 / DCS 600 Service Manual


Attention

Overview

Warnings

Safety Instructions

The manual Safety and operating instructions for drive converters

(3ADW 000 033) has to be followed strictly.

This chapter contains safety instructions which must be complied with during installation, operation and maintenance of the power converters series DCS 500B or DCS 600 . If these instructions are not complied with, this may result in injuries (perhaps even with fatal) or in damage to the power converter, the motor and the driven machine. Before starting with any work whatsoever at or with this unit, you must read the information given in this chapter.

Warnings provide information on states which if the specified procedure for the state concerned is not meticulously complied with may result in a serious error, in major damage to the unit, in injury to persons and even in death.

They are identified by the following symbols:

Danger: High Voltage!

This symbol warns you of high voltages which may result in injuries to persons and/or damage to equipment. Where appropriate, the text printed adjacent to this symbol describes how risks of this kind may be avoided.

● All electrical installation and maintenance work on the thyristor power converter must be carried out by properly qualified staff who have been thoroughly trained in electrical engineering.

● The thyristor power converter and its adjacent units must be properly earthed by qualified professionals.

● You must NEVER perform any work on the thyristor power converter while it is still switched on. First switch the unit off, use a measuring instrument to make absolutely sure that the power converter has really been de-energized, and only then you may start with the work concerned.

● Due to external control circuits, there may be dangerously high voltages present at the thyristor power converter even after the line voltage has been switched off. So always work at the unit with appropriate caution! Non-compliance with these instructions may result in injury (or even death!).


3ADW000093R0701_DCS500B/DCS600_Service manual_e_g i

ii

Safety Instructions

General warning: this symbol warns you of nonelectrical risks and dangers which may result in serious or even fatal injury to persons and/or in damage to equipment. Where appropriate, the text printed adjacent to this symbol describes how risks of this kind may be avoided.

●

When thyristor power converters are in use, the electric motors, power transmission elements and the driven machines are working in an extended operating range, which means they have to cope with a relatively high loading.

● You should have made sure that all units, devices and appliances used are actually suitable for this higher loading.

● If you have to operate the thyristor power converter at a rated motor voltage and/or a rated motor current significantly below the figures stated in the thyristor power converter's output data, you must take appropriate precautionary measures to protect the unit against overspeed, overload, breakage, etc., by modifying the software or hardware appropriately.

● For insulation testing, you must disconnect all cables from the thyristor power converter. You should avoid operating your unit at values other than the rated data. Non-compliance with these instructions may cause lasting damage to the thyristor power converter.

●

The thyristor power converter possesses a number of automatic reset functions. When these functions are executed, the unit will be reset after an error and will then resume operation. These functions should not be used if other units and devices are not suitable for an operating mode of this kind, or if their use might entail dangerous situations.

Warning of electrostatic discharge: this symbol warns you against electrostatic discharges which may damage the unit. Where appropriate, the text printed next to this symbol describes how a risk of this kind may be avoided.



Safety Instructions

Notes

Mains connection

EMERGENCY STOP buttons

Intended use

Notes supply information on states requiring particular attention, or indicate that additional information is available on a specific topic.

For this purpose, the following symbols are used:

CAUTION!

Cautions are designed to draw your attention to a particular state of affairs.

Note A note contains or refers you to additional information available on the particular topic concerned.

You can use a switch disconnector (with fuses) in the power supply of the thyristor power converter to disconnect the electrical components of the unit from the power supply for installation and maintenance work. The type of disconnector used must be a switch disconnector as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main contacts to open. The mains disconnector 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 CDP 31x control panel of the thyristor power converter will neither cause an emergency motor stop, 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“.

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.


3ADW000093R0701_DCS500B/DCS600_Service manual_e_g iii

Safety Instructions iv DCS 500 / DCS 600 Service Manual


Contents

VI A

S ERVICE M ANUAL

Chapter 1 - Introduction

How to use this manual........................................................................................................... 1-1

Contents of this manual .......................................................................................................... 1-1

Target group ........................................................................................................................... 1-2

Associated publications ......................................................................................................... 1-2

Storage and transport ............................................................................................................. 1-2

Rating plate and type code ..................................................................................................... 1-2

Chapter 2 - Fault Tracing Thyristors

How to detect, if a thyristor is faulty ........................................................................................ 2-1

A fuse is blown ............................................................................................................ 2-1

Ripple monitor ............................................................................................................. 2-1

How to find a faulty thyristor.................................................................................................... 2-2

Converters size C1 and C2/C2b (25...1000 A) ............................................................ 2-2

Blown fuses ................................................................................................................. 2-2

Converters size A5, A6, A7, C3 and C4 (900...5200 A) .............................................. 2-3

Blown fuses ................................................................................................................. 2-3

Ripple monitor ............................................................................................................. 2-3

Chapter 3 - Handling the Semiconductors

General Instruction how to handle the Semiconductors ......................................................... 3-1

Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b

Installation of thyristor modules in converters size C1/C2/C2b (25...1000 A) ......................... 4-1

Required Tools ............................................................................................................ 4-1

Remove faulty thyristor modules ................................................................................. 4-1

Install new thyristor modules ....................................................................................... 4-2

Thyristor module location ............................................................................................ 4-3

Module terminals ......................................................................................................... 4-8

Chapter 5 - Exchange of Thyristors for Size A5

Installation of "Disc Type" thyristor in converters size A5 (900...2000 A) ............................... 5-1

Required Tools ............................................................................................................ 5-1

Find faulty thyristor ...................................................................................................... 5-2

Remove faulty thyristor................................................................................................ 5-3

Install new thyristor...................................................................................................... 5-4


Installation of "Disc Type" thyristor in converters size A6 (1900...3000 A) ............................. 6-1

Required Tools ............................................................................................................ 6-1

BCT thyristors.............................................................................................................. 6-2


Remove faulty thyristor................................................................................................ 6-4



DCS 500 / DCS 600 Service Manual v


Contents

Installation of "Disc Type" thyristor in converters size A7 (2050...5200 A) ............................. 7-1

Required Tools ............................................................................................................ 7-1



Chapter 8 - Exchange of Thyristors for Size C3

Installation of "Disc Type" thyristor in converters size C3 (900...2000 A) ............................... 8-1

Required Tools ............................................................................................................ 8-1

Remove faulty thyristor ................................................................................................ 8-2



Fasten the clamp ......................................................................................................... 8-3


Installation of "Disc Type" thyristor in converters size C4 (2050...5150 A) ............................. 9-1

Required Tools ............................................................................................................ 9-1



Chapter 10 - Service

Compatibility of SDCS-PIN-2 boards .................................................................................... 10-1

Description of SDCS-PIN-20xB boards ..................................................................... 10-1

Hardware coding ..................................................................................................... 10-1

Snubber circuit ........................................................................................................ 10-1

Compatibility of SDCS-PIN-20x boards ..................................................................... 10-2

Compatibility of SDCS-PIN-20x and SDCS-PIN-2x boards....................................... 10-2

Change SDCS-PIN-2x boards ................................................................................... 10-3

Compatibility of thyristor modules for DCSxxx-0200 and DCSxxx-0250............................... 10-4

Types concerned: ...................................................................................................... 10-4

Actual status .............................................................................................................. 10-4

Hardware: .................................................................................................................. 10-4

Subject:...................................................................................................................... 10-4

Time schedule: .......................................................................................................... 10-4

Compatibility: ............................................................................................................. 10-4

DC-Motor neutral zone adjustment ....................................................................................... 10-5

Types concerned ....................................................................................................... 10-5

Summary ................................................................................................................... 10-5

General

..................................................................................................................... 10-5

How to remove the converter fan in a frame A6.................................................................... 10-6

How to remove the converter fan in a frame A7.................................................................... 10-7

SDCS-CON-x Firmware download instructions for Windows 2000 and NT 4.0 .................... 10-8

Hardware Configuration............................................................................................. 10-8

Firmware download Kit............................................................................................ 10-8

NPCU-02 ................................................................................................................. 10-8

Bus cable ................................................................................................................ 10-8

Installation ............................................................................................................... 10-9

Software Configuration .............................................................................................. 10-9

PC Operating Systems............................................................................................ 10-9

Drive Software Versions.......................................................................................... 10-9

vi DCS 500 / DCS 600 Service Manual


Contents

Programs / Files ...................................................................................................... 10-9

Firmware download with Windows 2000 ................................................................. 10-10

Recommendation .................................................................................................. 10-10

Preparation............................................................................................................ 10-12

HyperTerminal Private Edition .............................................................................. 10-15

Flash Erase ........................................................................................................... 10-15

Flash Program....................................................................................................... 10-16

Firmware download with Windows NT 4.0 .............................................................. 10-18

Recommendation .................................................................................................. 10-18

Preparation............................................................................................................ 10-18

HyperTerminal....................................................................................................... 10-19

Flash Erase ........................................................................................................... 10-20

Flash Program....................................................................................................... 10-20

DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows

2000 ............................................................................................................................. 10-22

Types concerned................................................................................................... 10-22

Summary............................................................................................................... 10-22

Download DCS600 MultiDrive firmware ............................................................ 10-22

DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows

NT 4.0 .......................................................................................................................... 10-23

Types concerned................................................................................................... 10-23

Summary............................................................................................................... 10-23

Download firmware with PCMCIA card (notebook or desktop)

...................... 10-23

Installation of NtNisa drivers ................................................................................. 10-23

Configure PC......................................................................................................... 10-24

Download DCS600 MultiDrive firmware ............................................................ 10-24

DCS600 MultiDrive - How to download parameter files on a SDCS-AMC-DC x board ...... 10-25

Types concerned................................................................................................... 10-25

Summary............................................................................................................... 10-25

Reload DCS600 MultiDrive parameters ............................................................. 10-25

Chapter 11 - Preventive Maintainance

Recommended regular maintenance .................................................................................... 11-1

Air Filters ................................................................................................................... 11-1

Cooling air pressure switch in converter modules type A6/A7/C4............................. 11-1

Fan ............................................................................................................................ 11-1

Heatsink .................................................................................................................... 11-1

Internal high current connections in converters type A7/C4 ...................................... 11-2

Relays and electrical connections ............................................................................. 11-2

Appendix A - Spare Parts List


3ADW000093R0701_DCS500B/DCS600_Service manual_e_g vii

Contents viii DCS 500 / DCS 600 Service Manual



How to use this manual

The purpose of this service manual is to provide detailed information on how to service power converters from the DCS 500B or

DCS 600 series.

Note: If it is not mentioned explicitly all details given in this Service Manual will be valid for both,series

DCS 500B and series DCS 600!

Contents of this manual


This chapter informs about the contents and the use of this manual as well as the boundary conditions applying and the thyristor power converter rating plate.


This chapter describes how to detect and select a faulty thyristor.


This chapter describes the handling of thyristors and thyristor modules.

Chapter 4 - Exchange of Thyristors of Sizes C1/C2/C2b

This chapter describes the exchange of thyristors in converters sizes C1/C2.

Chapter 5 - Exchange of Thyristors of Size A5

This chapter describes the exchange of thyristors in converters size A5.





Chapter 8 - Exchange of Thyristors of Size C3

This chapter describes the exchange of thyristors in converters size C3.

Chapter 9 - Exchange of Thyristors of Size C4

This chapter describes the exchange of thyristors in converters size C4.


This chapter contains hardware information and technical hints.


This chapter describes the measures for preventive maintenance of the thyristor converters.

Appendix A - Spare Parts list

The Appendix A contains the spare parts list of the converters.



VI A 1 - 1

Chapter 1 - Introduction

Target group

Associated publications

Storage and transport

Rating plate and type code

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

These people should possess

• basic knowledge of physics and electrical engineering, electrical wiring principles, components and symbols used in electrical engineering, and

• basic experience with DC drives and products.

The DCS 500B or DCS 600 documentation includes the following:

Technical Data DCS Thyristor Power Converter

Operating Instructions

System Description DCS 500B

System Description DCS 600 MultiDrive

CAUTION! The thyristor power converter weighs quite a lot and should therefore not be held by the front cover. Please put the unit down only on its back (sizes C1 to C3). Always use due care when handling the unit, so as to avoid injuries or damage.

If the unit had 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 "System Descriptions").

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

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

Figure 1-1 Example of a rating plate

VI A 1 - 2 DCS 500 / DCS 600 Service Manual


System

D C S 501B 1203-

OEM

512102050000000000

Des.Rev.

DC Drives

Type

S = Standard

F = Fieldexciter

Product family

50 = DCS500 converter module

60 = DCS600 converter module

Bridge type

1 = single (2Q)

2 = double (4Q)

Version (Salestyp)

B = modules with SDCS-CON-2

- = for all DCS600/DCF600

Module type

Converter type current, e.g. 1203A

Rated AC voltage

4 = 220...400V

5 = 415...500V

6 = 525...600V

7 = 660...690V

8 = 700...830V

9 = 800...999V

1 = 1190V

Frequency

1 = 50/60 Hz

Power connection

- = no option (size C1...A6)

R = on the right (A7)

L = on the left (A7)

Option

Softwaretyp

15 = Multidrive

18 = Crane drive

21 = OEM

Control panel

0 = no panel

P = panel included

Fieldexciter

0 = no field exciter

1 = SDCS-FEX1

2 = SDCS-FEX2..

Fan voltage

0 = standard

5 = 400-500V only size A6

6 = 525-690V only size A6

Communication boards

0 = no communication board

5 = SDCS-COM-5-board

A = SDCS-AMC-DCx-board

C = SDCS-AMC-DC-Clasx-board

Coated version

0 = no coating

X = coated version

Special Options

UL-approval

0 = standard module with UL-certificaion

U = modification for UL-certification (C3, A6/7)

Interfaces

0 = no fieldbus module included

Current measurement modification

0 = no modification

C = CMA-2 included

M = Paralleling Master converter

S = Paralleling Slave converter

Voltage measurement modification

0 = no modification

5 = PIN=51 modified for 500 V





A = PIN-51 modified for 235V

B = PIN-51 modified for 120V

C = PIN-51 modified for 70V

D = PIN-51 modified for 40V

X = Galvanic Isolation

Special Customer Software

000= Standard

Design revision

Thyristor type (only for disc types)

1 = ABB Lenzburg

2 = Eupec

3 = IXYS

4 = Semikron

Design rev. index only used for internal information

Figure 1-2 Type code




VI A 1 - 3


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.




How to detect, if a thyristor is faulty

A fuse is blown

Ripple monitor

Thyristor problems can be noticed by two ways:

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) because of a defect thyristor (short circuit inside a thyristor from anode to cathode).

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

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

- A commutation fault during inverting mode operation (active braking with high current, high EMF and with low AC voltage).

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.

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. It´s missing current contribution causes a deep dip in the direct current.

The structure of the current loop, the 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°.

During braking or inverting mode operation most often fuses are blown.

The reason for a currentless thyristor may be:

- A fuse has disconnected one of the six thyristors. This is possible only for converters with 900...5200 A (six internal branch fuses). A converter with three external fuses stops working completely at once when one of the three AC input fuses interrupts a phase input of the converter.

- A thyristor does not get 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 equippment can be the reason.



VI A 2 - 1

Chapter 2 - Fault Tracing Thyristors

How to find a faulty thyristor

Converters size C1 and C2/C2b

(25...1000 A)

Blown fuses

If a blown fuse is suspected in the converter, the problem is caused most often by a faulty thyistor. 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.

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.

- 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; see

Figure 4-3 ). Normally, every measurement should show high re-

sistance (> 1 k

Ω

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

Ω

) (destroyed thyristor).

- If the converter is designed with half-bridge thyristor modules, then a module consists of two antiparallel thyristors. In this case it is sufficient to know which thyristor pair or 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 circuit could also cause 0

Ω

result 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 the 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 A5,

A6, A7, C3 and C4

(900...5200 A)

Blown fuses

Ripple monitor

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

- The converter must be disconnected from the mains.

- 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 therefor the faulty branch is known (see

Figure 5-1 ).

- 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 antiparallel thyristors or BCT’s:

The selection of a forward or reverse thyristor or BCT (Bidirectional-Controlled-Thyristor) is done during the disassembly. Continue with related chapter

5 ,

6 ,

7 ,

8 ,

or

9

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.

If the ripple monitor fault occured, the fault tracing must be adapted to the reasons listed before:

- 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:

•

Is a firing pulse present on the primary side of the firing pulse transformer?

•

Is a firing pulse present on the secondary side of the firing pulse transformer?

•

Is the firing pulse transfered to the gate of the thyristor? Are there all electrical connections still healthy?

•

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.



VI A 2 - 3




General Instruction how to handle the Semiconductors


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

Disc type thyristors in converters size C3 (900...2000 A DC) are normally mounted using a dial gauge, for repair reasons, they can be mounted using a torque wrench.

In converters sizes A5 (900...2000 A DC), A6 (1900...3000 A DC),

A7 (2050...5200 A DC) and C4 (2050...5150 A DC) 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 component 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.



VI A 3 - 1

Chapter 3 - Handling the Semicinductors



Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b

Installation of thyristor modules in converters size C1/C2/C2b

(25...1000 A)

Required Tools

All DCS 500B and DCS 600 size C1/C2/C2b are equipped with 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.

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

- torque spanner: mounting torques for thyristor module to heat sink and elelectrical connections see table “Nominal mounting torques for thyristor modules” in this chapter;

- screws are metric type; use appropriate nuts

- tissue paper / solvent

- thermal joint compound: type BERULUB FZ1 E3

(grease)

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 011 P 0051 or

- thermal joint compound: type WLPF 20 (10 ml)

ABB Service: GHSN 390 011 P 10

Remove faulty thyristor modules

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

- Tilt out the electronics casing.

- Remove the gate leads from the faulty thyristor module and mark the position of the trigger connections on the cable.

- Remove only as many parts as is needed around the faulty module. If the current transformer must be removed, mark the position and the connections!

- Remove the faulty thyristor module and mark it.



VI A 4 - 1

Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b

Install new thyristor modules

- Remove old thermal joint compound (grease) from the heat sink.

Preparation of the heat sink: if the area is clean, spread out the heat-conducting compound with a rubber spatula or by hand. If the area is dirty, clean the heat sink surface with tissue paper.

Clean the mounting surfaces with an appropriate solvent (e.g. ethanol).

- Apply a thin coat of thermal joint compound to the new module.

Spread the thermal joint compound evenly by moving the module forward and backward on the heat sink.

- Tighten the clamping screws by hand until the screw heads touch the bottom of the module. Then tighten the screws to 2.5

Nm torque. If the module is mounted using four screws, tighten the screws crosswise.

- Tighten the screws to nominal torque (see Table below).

- Reinstall the busbars; make sure, the correct torque is applied and reconnect all cables.

Thyristor module Nominal mounting torques

Size (width) Type Electrical connections

Module to heat sink

20 mm block SKKT…..

20 mm block MCC 95-16io1B


34 mm block TT…..

3 Nm

3 Nm

5 Nm

6 Nm

5 Nm

3 Nm

5 Nm

6 Nm


50 mm block TT…..

9 Nm

12 Nm

5 Nm

6 Nm

50 mm block

(single thyrist.)

50 mm block

(single thyrist.)

SKET…..

TZ…..

9 Nm

12 Nm

5 Nm

6 Nm

60 mm block TT425/TT570 12 Nm 6 Nm

Table 4-1 Nominal mounting torques for thyristor modules




Thyristor module location for: DCS 501B0100 to 0140 for: DCS 501B0200 to 0520

V14/V11 V16/V13 V12/V15

1 3 2 4 1 3 2 4 1 3 2 4

V11/V14 V13/V16 V12/V15

V15 d

1 b

2 a c

V13 d

1 b

2 a c

V11 d

1 b

2 a c for: DCS 501B0700 d b

2 a c

1

V14 d b

2 a c

1

V12 d b

2 a c

1

V16 for: DCS 501B0680 ... 1000

V14/V11 V16/V13 V12/V15 pp_1qdr_b.dsf

Figure 4-1 Location of thyristor modules in DCS 501B/601-

0100...1000 units

Note : This drawing is only for showing the location of the modules, the module size can be different!



VI A 4 - 3

Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b for: DCS 50xB0025 to 0075 and

DCS 502B0100 to 0140 for: DCS 502B0200 to 0520

V11/V24 V14/V21

V14/V21

4 2 3 1

V16/V23

4 2 3 1

V12/V25

4 2 3 1

V15/V22 V12/V25

V13/V26 V16/V23

1 3 2 4 1 3 2 4 1 3 2 4

V11/V24 V13/V26 V15/V22 a a d d d

1

1 b d

2

2 a

V11 c a c

1

V24 b d for: DCS 502B0700 b b d b d

V21

1 b

2

2 a c a

1 d

V14 b d

V25

1 b c

2

2

V15

1 c a b d

1 c

V22 b

2

2 a c a

1 d

V12 b d

V23

1 b c

2

V13 c a

2

1 c

V26

2 a

1

V16 c a

2 c for: DCS 502B0680 ... 1000

V24/V11

V21/V14

V26/V13

V23/V16

V22/V15

V25/V12

Figure 4-2 Location of thyristor modules in

DCS 50xB/60x-0025...0075 units

DCS 502B/602-0100...0700 units

DCS 502B/602-0680...1000 units

Note : This drawing is only for showing the location of the modules, the module size can be different!



3

4

1

2

5

6

FORWARD

REVERSE


G

K

G

K

G

K

K

G

K

G

K

G

G

K

G

K

G

K

K

G

K

G

K

G

POWER INTERFACE BOARD

SDCS-PIN-1x / -2x

Units with

0025 to

0075 ADC

U1

T51 S1

V1 W1

1500/1

S2

T52 S1

S2

T53 S1

1500/1

S2

1500/1

G

K

1.4

G

K

1.3

1.5

1.3

G

K

V11

V13

1.6

G

K

1.5

G

K 1.2

G

K

1.2

1.4

1.6

Snubber circuit

V15

V14

V16

V12

Snubber circuit

Snubber circuit

Units with 0100 to 0350 ADC

X3:1

L (S2)


T51 K (S1)

1000/1

* 2330/1 for units with 0700 ADC

T51

S1

P2

600/1 *

S2 P1

X3:3

X4:1

X4:3

T53 K (S1)

1000/1

L (S2)

T53

S1

S2

P2

600/1 *

P1

X22:1

3 O

R 57

C1

Basic drawing / not all elements are shown

Figure 4-3 Basic drawing of DCS 501B/601 units with SDCS-PIN-1x/-2x

D1



VI A 4 - 5


1

2

3

4

5

6

FORWARD

REVERSE

2.1

1.2

2.3

1.4

2.5

1.6

G

K

G

K

G

K

G

K

G

K

G

K

G

K

G

G

K

K

G

K

G

K

G

K

POWER INTERFACE BOARD

SDCS-PIN-1x / -2x

2.4

G

K

K

Units with

0025 to

0075 ADC

U1 V1 W1

T51 S1

1500/1

S2

T52 S1

S2

T53 S1

1500/1

S2

1500/1

X3:1

X3:3

X4:1

X4:3


T51 K (S1)

1000/1

L (S2)


* 2330/1 for units with 0700 ADC

T51

S1

P2

600/1 *

S2 P1

T53 K (S1)

1000/1

L (S2)

T53

S1

S2

P2

600/1 *

P1

G

V11

1.4

G

K

2.1

G

K

V14

2.2

1.3

2.4

1.5

2.6

1.3

G

K

2.6

G

K

1.5

G

K

2.2

G

K

Snubber circuit

V24

V13

V26

V15

V22

1.6

2.3

G

K

G

K

1.2

2.5

G

K

G

K

Snubber circuit

V21

V16

V23

V12

V25

Snubber circuit

R 57 X22:1

3 O

C1

Basic drawing / not all elements are shown

Figure 4-4 Basic drawing of DCS 502B/602 units with SDCS-PIN-1x/-2x

D1




Figure 4-5 Typical armature circuit of DCS 50xB/60x with

SDCS-PIN-20xB

DCS 500 / DCS 600 Service Manual VI A 4 - 7



Module terminals The next figures show a few examples and terminals of thyristor modules. The terminals of modules are also stamped or marked by a sticker.

For all firing pulse cables is valid:

Yellow is gate lead.

Red is cathode lead.

1 (A1K2) 2 (K1) 3 (A2)

7 (K2)

6 (G2)

5 (K1)

4 (G1)

SKKT27...SKKT106

Thyr_mod_b.dsf

Note : This drawing is not valid for the types SKKT.…B…

Figure 4-6 Terminals of half-bridge thyristor modules

VI A 4 - 8

1 (A1K2) 2 (K1) 3 (A2)

6 (G2)

7 (K2)

4 (K1)

5 (G1)

MCC95-16io1 B

Thyr_mod_b.dsf


1 2 3 AK K A

K5 G4 K7 G6 K1 G1 K2 G2

1 2 3 AK K A

SKKT132,162 TT162




AK


AK K

K1 G1 K2 G2

A

K A

AK K A

K2

G2

G1

K1

SKKT210, SKKT250,

TT250...AK34


2 1

4 5 a d

2 1 c b

2 1

4

5

TZ425 or SKET 400

Figure 4-10 Terminals of single thyristor modules

(A)

3

(AK)

1

6G 7K 5G

(K)

4K

2

3 2 1

TT425, 570

Figure 4-11 Terminals of half bridge thyristor modules



VI A 4 - 9





Installation of "Disc

Type" thyristor in converters size A5

(900...2000 A)


All DCS 500B and DCS 600 converters sizes A5/A6/A7/C3/C4 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 a well heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.


- Torque spanner for electrical connections: 13 Nm (M8)

Nm

Nm

- 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: type BECHEM-RHUS SU 2

(grease)



- Disassembly tool 3ADT 621 023 P1

Note: For more detailed information about the wiring of the power part, see manual Technical Data .

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 ).

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 you start work, disconnect the converter completly from the power supply then check the voltage free condition and make sure, everything is located in an electrically and mechanically safe condition!



VI A 5 - 1

Chapter 5 - Exchange of Thyristors for Size A5

Find faulty thyristor 1. Find the defective branches by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1 (see figure 5-1 )

C1 (+)

V11

F11

V24 V13

F13

V26 V15

F15

V22 branching fuse

U1

V1

W1

F14 F16 F12

V14 V21 V16 V23 V12 V25 branch

D1 (-) principle_B6_a.dsf

Figure 5-1 Anti-parallel B6-bridges with branching fuses

2. Disconnect the branch 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 change only one thyristor, clamp the heat sinks again and repeat step three.




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 (

see figure 5-3 ) at the top of the thy-

ristor stack.

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 (see figure 5-2 ).

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!

Mounting clamp

View from the left

Disassembly tool

View from the right mountcl_b.dsf

Front view

Figure 5-2 How to use the disassembly tool



VI A 5 - 3


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

see Appendix A ). Keep the semiconductor and its surroundings clean. If

necessary clean them with a piece of tissue paper moistened with solvent.

Note : Do not touch the polished surfaces of the thyristor.

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

3. Connect the gate leads if possible.

4. Clean all parts with tissue paper moistened with solvent, witch 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 aluminium surfaces will oxidise in a few seconds. Dry all surfaces.

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.

Loose condition

TORQUE INDICATING SPRING

Insulating plate

Heatsink

Correct torque

Figure 5-3 Aluminium spring with welded indicating spring




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” (

see figure 5-3 ). Do not tighten the screws any fur-

ther.

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.

U1 V1 W1 rear left stack front right stack front rear

V24 V11

V13 V26

V22 V15

V14 V21

V23 V16

V12 V25

View from the left Front view View from the right

Figure 5-4 Location of thyristors in frame A5 (4-Q bridge)



VI A 5 - 5

Chapter 5 - Exchange of Thyristors for Size A5 rear left stack front

U1 V1 W1 right stack front rear

V11

V13

V15

V14

V16

V12

View from the left Front view View from the right




U1


W1

V1

D1 (-)

C1 (+)

Figure 5-6 Location of branch fuses frame A5



VI A 5 - 7







(1900...3000 A)




- Torque spanner for electrical connections:


13 Nm (M8)

Nm

Nm





(grease)



- Disassembly tool DCF 1066721 P1

Note: For more detailed information about the wiring of the power part, see manual Technical Data .


see Appendix A ).

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.




VI A 6 - 1


BCT thyristors In some converter module size A6 so called BCT’s ( B idirectional-

C ontrolledT hyristors) are used. BCT’s 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

Faston 4.8 x 0.5

Gate A

Faston 6.3 x 0.8

Gate B

Figure 6-1 Gates of BCT

Note : The faston connectors of the gates are of different size.

Gate B should always be in front of the clamped heat sinks due to cooling reasons.

VI A 6 - 2

Figure 6-2 Location of BCT’s gate B when built in




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

see figure 5-1 ).

2. Disconnect the branch fuses of the defective branches.


4. In a 4 - quadrant converter with BCT’s 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 change only one thyristor, clamp the heat sinks again and repeat step three.



VI A 6 - 3



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.

DCbusbar plates

VI A 6 - 4

Figure 6-3 Location of the DC - busbar plates

Note : It depends on the location of the defective thyristor which DCbusbar 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 BCT’s add the position of the gates.


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

Figure 6-4 Handling of indicating spring and mounting clamp

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.

DCbusbar plates

Figure 6-5 DC-busbar plates



VI A 6 - 5


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

Figure 6-6 Use of disassembly tool

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!




Install new thyristor

1. Ensure that the new thyristor is of the correct type ( see appendix A ). Keep the semiconductor and its surroundings clean. If




Figure 6-7 Prepare disk type thyristor


(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.




5. Turn the thyristor so that the gate leads point in the right direction. When changing BCT’s make sure, that gate B is in front

( see figure 6-1 ).


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



VI A 6 - 7


DC-busbar plates and heatsinks

Figure 6-8 DC-busbar plates and adjacent heat sinks

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

8. Reconnect the DC-busbars.


Torque indcating spring loose condition

Figure 6-9 Mounting clamp; loose condition

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.




Torque indcating spring correct torque

Figure 6-10 Mounting clamp, correct torque

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


12. Reconnect all other dismantled parts.




VI A 6 - 9


VI A 6 - 10

C1(+) front

Stack rear

V11 V24

U1

D1(-)

V21 V14

V16 V23

V1

V26 V13

C1(+)

V15 V22

W1

D1(-)

V25 V12

View from the right

A6_thyr_locat.dsf

Figure 6-11 Location of thyristors in frame A6 (4-Q bridge with single thyristors).



Chapter 6 - Exchange of Thyristors for Size A6 front stack rear

C1(+)

V11 / V24

U1

D1(-)

V14 / V21

V16 / V23

V1

V13 / V26

C1(+)

V15 / V22

W1

D1(-)

V12 / V25


A6_thyr_locat.dsf

Figure 6-12 Location of thyristors in frame A6 (4-Q bridge with

BCT’s)



VI A 6 - 11


VI A 6 - 12 front stack rear

C1(+)

V11

U1

D1(-)

V14

V16

V1

V13

C1(+)

V15

W1

D1(-)

V12


A6_thyr_locat.dsf

Figure 6-13 Location of thyristors in frame A6 (2-Q bridge with single thyristors)



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

Figure 6-14 Location of parallel branch fuses frame A6

VI A 6 - 13







(2050...5200 A)





Nm

Nm






(grease)



- Disassembly tool: DCF 1066721 P1

Note: For more detailed information about the wiring of the power part, see publication Technical Data .


see Appendix A ).

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.




VI A 7 - 1


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

see Figure 5-1 ).

2. 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. loose AC busbar

Isolator removed screws

DC busbars

Figure 7-1 Location of busbars

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


2 - quadrant converter:






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.

screws backplate

Figure 7-2 Backplate

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


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

Figure 7-3 Handling of indicating spring and mounting clamp

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!



VI A 7 - 3


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

push down

Figure 7-4 Use of disassembly tool

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!




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 surroun-

dings clean. If necessary clean them with a piece of tissue paper moistened with solvent.

Note: Do not touch the polished surfaces of the thyristor.


Figure 7-5 Prepare disk type thyristor


(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.


Note: Be sure that the thyristor is installed in the right direction.


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





VI A 7 - 5


Torque indcating spring loose condition

Figure 7-6 Mounting clamp; loose condition

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.

Torque indcating spring correct torque

Figure 7-7 Mounting clamp; correct torque

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


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





V11

V24

V13

V26

V15

V22

V21 V21

V14 V14

V 23 V23

V16 V16

V25 V25

V12 V12

V15

V22

V11

V 24

V 13

V26

A ssemb ly A 7

B usba rs o n th e ri ght ; vie w f ro m the fr ont

A7_ass.dsf

A ssemb ly A 7

B usba rs o n th e lef t; view from the front


V11 V11

V14 V14

V13 V 13

V16 V 16

V15 V15

V12 V12

A ssemb ly A 7

B usba rs o n th e ri ght ; view from the front

A7_ass.dsf

A ssemb ly A 7

B usba rs o n th e lef t; view from the front




VI A 7 - 7


VI A 7 - 8

F14

U1

AC-busbar

F11

F16

V1

AC-busbar

F13

F12

W1

AC-busbar

F15

D1(-)

DC-busbar

A7_branch_fuse_lopcat.dsf

Figure 7-10 Location of branch fuses frame A7 (busbars on the right)

C1(+)

DC-busbar




F11

F14

U1

AC-busbar

F13

V1

AC-busbar

F16

F12

F15

W1

AC-busbar

C1(+)

DC-busbar

A7_branch_fuse_lopcat.dsf

D1(-)

DC-busbar

Figure 7-11 Location of branch fuses frame A7 (busbars on the left)



VI A 7 - 9






Type" thyristor in converters size C3

(900...2000 A)


All DCS 500B and DCS 600 converters sizes A5/A6/A7/C3/C4 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 a well heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.


- Torque spanner: mounting torques and forces for disc

type

electrical connections: 13 Nm (M8)

Nm

50 Nm (M12)


- 13 mm nut for thyristor fixing with 20 mm max outer diameter.


(MSO

2

).


(grease)




Therefore strict observance of the build in instructions given below is of utmost importance. Different press clamps are used, depending on the size of the semiconductor. Make sure that the new component can replace the old one in accordance with the spare part

list ( see Appendix A ).




VI A 8 - 1

Chapter 8 - Exchange of Thyristors for Size C3


- Remove the plastic cover in front of the heat sinks; the screws are accessible, if the SDCS-PIN-x1 boards will be unfastened; there is no need to disconnect the electrical connections at the

PIN-x1 boards.

- Remove the fuse, connected to that thyristor (pair) which needs to be exchanged.

- Disconnect the lead of a snubber capacitor connected to the heat sink; if the very right or left plastic cover is fixed at the heat sink, which needs to be removed remove the screw.

- If you have a 2 quadrant converter:

•

Loosen the screws, which keep the press clamp and the heat sink in position; remove the heat sink, mark the direction of the thyristor and the positition of the gate leads, then remove the thyristor.

- If you have a 4-quadrant type converter:

•

Always start working at that thyristor which is part of the reverse bride (V21, V22 a.s.o.) loosen the screws, which keep the press clamp and the heat sink in position; remove the heat sink, mark the direction of the thyristor and the positition of the Gate leads, then remove the thyristor.

Find faulty thyristor - Perform the OHM test with both polarities. Use the DC terminal of the antiparallel thyristors connected as one measuring point and the remaining heat sink as the other.

Case a) If this test indicates high resistance, the remaining thyristor is all right healthy and the one already removed should be marked and needs to be

replaced.

Case b) If this test indicates low resistance, the remaining thyristor is faulty and needs to be replaced.

Remove it in the way described above.

The other thyristor is ok!

- In case a) of the OHM test described above mount a new thyristor at the position of the reverse bridge.

- In case b) of the OHM test described above a new thyristor for the forward bridge and afterwards the thyristor of the reverse bridge which was removed first have to be mounted.




Install new thyristor - Ensure that the new thyristor is of the correct type (


necessary clean them with a piece of tissue paper moistened with solvent. Make sure the insulator of the thyristor and the connections are fine.


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

- Clean all parts with tissue paper moistened with solvent, witch have had or will have contact with the thyristor or each other

(bottom of upper heat sink, busbar on both sides and upper side of the DC and AC busbar). Do not clean the surfaces of grease too thoroughly, because the aluminium surfaces will oxidise in a few seconds. Dry all surfaces.

- Connect the gate leads if possible.

Fasten the clamp

- Place the thyristor with the right direction into the guiding tool.

Spread the head conducting paste by turning the thyristor 90° left and right.

Note : Do not pinch or cut the gate leads or any other cable.

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

- Spread a thin layer of Molikote (MSO

2

) on the thread and under the lower side of the head of each of the srews, keeping the heat sink by means of the press clamp in place. Spread Molikote also on the side of the washers, which comes in contact with the screw. Spread a thin layer of heat conducting paste on the bottom of the heat sink with a rubber spatula. Place the busbar and the heat sink above the thyristor and fix them with the press clamp. Tighten the clamping screws by hand until the screw heads touch the bottom of the module.

Molikote



VI A 8 - 3


- Find the required torque from the table below. Tighten the screws alternatively 1/4 turn at a time until the correct torque is reached.

Converter type Torque / Nm Force / kN Press clamp

400 V - 500 V

DCS x0x-0900-4(5) 5,5 - 6

DCS x0x-1200-4(5) 5,5 - 6

DCS x0x-1500-4(5) 11,5 - 12

DCS x0x-2000-4(5) 11,5 - 12

600 V - 690 V

DCS x0x-0900-6(7) 7,5 - 8

DCS x0x-1500-6(7) 11,5 - 12

8 - 12

8 - 12

14,4 - 24

14,4 - 24

10 - 15

14,4 - 24

SLZF 89A

SLZF 89A

SLZF 89B

SLZF 89B

SLZF 89A

SLZF 89B

Table 8-1 Mounting torques and forces for disc type thyristors

- In case of a 4-quadrant type converter:

•

Perform the OHM test with both polarities another time to make sure, the thyristor, which was used for the reverse bridge, is definitly healthy.

•

If this test indicates high resistance, the thyristor is healthy and can be used.

•

If this test indicates low resistance, the thyristor of the reverse bridge is faulty and needs to be replaced: remove it again mount a new one as described above.

- Install in the fuse(s).

- Connect the lead of the snubber capacitor, if it was removed before.

- Reconnect all parts, which were removed before:

•

plastic covers, etc.




T51

Connect wiring of snubber circuits !!

View from the left

Figure 8-1 Location of thyristors in modules size C3



Front view

Z265_7A_a.dsf

VI A 8 - 5


Thyristors only in the case of 4-Q converters

Figure 8-2 Location of thyristors in modules size C3

Note : Removed fuses, busbars and upper parts of heat sinks





Type" thyristor in converters size C4

(2050...5150 A)


All DCS 500B and DCS 600 converters sizes A5/A6/A7/C3/C4 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 a well heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all joints have good thermal and electrical conduction.



Nm


Nm





(grease)



- Disassembly tool: DCF 1066721 P1



see Appendix A ).

Thyristors are always mounted in the same direction, independent of current, voltage, number of quadrants (2-Q or 4-Q) version or 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 unit by touching the current contact surfaces. Do not damage the welding flange or the contact surface.




VI A 9 - 1


Find faulty thyristor - Find the defective branch(es) by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1 (

see Figure 5-1 ).

- Remove the screws of the left and right branch fuses. Remove the busbar, leading to the AC connection, too (not necessary at

2-quadrant converters, left version!).

- If you have a 4-quadrant converter:

•

Remove the screws of the DC busbar either above or below the blown fuse.

Note: the connection is made with a screw socket, which may fall down, if the last screw is removed.

•

Put a small piece of isolator (paper, cardboard, plastic, etc.)

Remove faulty thyristor between the DC busbar and the heat sink.

•

Perform the OHM test with both polarities between the DC busbar and the heat sink as the second measuring point.

•

Now perform the OHM test with both polarities between the isolated heat sink and the heat sink, which was connected to the fuse as the second measurement point.

•

Depending on the result, the thyristor located between the measuring terminals of the first test or the second one needs to be removed.

- If the thyristor is partly covered by a fuse, loosen the screws and move the fuse some centimeters up or down; fix the fuse.

- Remove the gate leads if possible.

- Loosen the mounting clamp ( see Figure 9-2 ) at the top of the thy-

ristor stack.

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

- Attach the disassembly tool at the faulty thyristor and prise open

the upper and lower heat sinks ( see Figure 9-1 ). The copper bars

need not be loosened .

- Remove the thyristor.




Mounting clamp

View from the left

View from the right

Disassembly tool mountcl_c4.dsf

Front view

Figure 9-1 How to use the disassembly tool (at a left thyristor stack of a converter)

Install new thyristor - Ensure that the new thyristor is of the correct type (




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

- Connect the gate leads if possible.

- Clean all parts with tissue paper moistened with solvent, witch 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 aluminium surfaces will oxidise in a few seconds. Dry all surfaces.

- Push the thyristor until it snaps into its mounting clamp.



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



VI A 9 - 3


Loose condition

TORQUE INDICATING SPRING

Insulating plate

Correct torque

Heatsink

Figure 9-2 Aluminium spring with welded indicating spring

- 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.

- 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 “cor-

rect torque” ( see Figure 9-2 ). Do not tighten the screws any

further.

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

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

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

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




V11

V24

V13

V26

V15

V22

V21 V21

V14 V14

V 23 V23

V16 V16

V25 V25

V12 V12

Assemb ly C4

Busba rs o n th e ri ght

( fr ont o f th e mod ule )

A ssemb ly C4

B usba rs o n th e lef t


Figure 9-3 Location of thyristors in size C4 (4-Q bridge)

V11

V24

V13

V26

V15

V22

V11 V11

V14 V 14

V13 V 13

V16 V 16

V15 V15

V12 V12

A ssemb ly C4

B usba rs o n th e ri ght


Assemb ly C4

Busba rs o n th e lef t


Figure 9-4 Location of thyristors in frame C4 (2-Q bridge)



VI A 9 - 5





Compatibility of SDCS-PIN-2 boards

Description of SDCS- In general the SDCS-PIN-20xB board has the same features as

PIN-20xB boards its predecessors (SDCS-PIN-20xA/20x or SDCS-PIN-2x).

- It is used for all DCS converters Module sizes C1 (

≥

100A), C2 and C2b regardless of software version and function (armature or field supply).

- Converters equipped with the SDCS-PIN-20xB/20xA/20x boards can be identified by serial number. Every serial number is divided into two parts by a letter. With the SDCS-PIN-20xB/20xA/20x the serial number looks like 1234567B1234567. For the SDCS-PIN-

2x an A is used.

- There are two types of SDCS-PIN-20xB boards:

• SDCS-PIN-205B for converters with a incoming voltage of

400V/500V

• SDCS-PIN-206B for converters with a incoming voltage of

600V

- The advantage of the SDCS-PIN-20xB/20xA/20x is the replacement of 6 other boards plus a small RC network. Thus the spare part handling becomes easier.

Hardware coding On the SDCS-PIN-20xB resistors are used for hardware coding of the module, zero current detection and current scaling. In a new converter the resistors are already cut according to application. If the SDCS-PIN-20xB board is used as spare part all resistors are still uncut. The resistors have to be cut according to the table ‘Settings of the SDCS-PIN-20xB board’ as described in the manual

Technical Data .

Snubber circuit The incoming AC voltage is connected to the SDCS-PIN-20xB board via integrated fuses. The snubber circuit (RC network) is integrated as well and connected in parallel to the thyristors. This configuration leads to lower losses thus to a higher efficiency of the converter. Before larger converters had external RC networks.

These are no longer needed.

Compatibility of SDCS-PIN-2 boards



VI A 10 - 1

Chapter 10 - Service

Compatibility of

SDCS-PIN-20x boards

U

AC

I

DC

SDCS-PIN-205B

SDCS-PIN-206B

SDCS-PIN-21

The SDCS-PIN-20xB boards replaces SDCS-PIN-20xA and SDCS-

PIN-20x boards, but not vice versa.

Note: SDCS-PIN-20xA replaces SDCS-PIN-20x, but not vice versa.

405A-520A 700A

- -

- -

- - - - -

- - - -

-

-

SDCS-PIN-205A/205

SDCS-PIN-206A/206 - - - -

: possible : not possible 1 together with SDCS-PIR-21 2 together with RC network

Table 10-1 Compatibility of SDCS-PIN-2xx boards

Compatibility of Converters 100A

≤

I

DC

≤

350A and U

AC

: 400V/500V

SDCS-PIN-20x and

SDCS-PIN-2x boards - SDCS-PIN-205B/205A/205 can be used as spare parts.

Converters 405A

≤

I

DC

≤

520A and U

AC

: 400V/500V

- SDCS-PIN-22 together with SDCS-PIR-21 or

- SDCS-PIN-205B/205A/205 can be used as spare parts.

Converters I

DC

= 700A and U

AC

: 400V/500V (type C2)

- SDCS-PIN-25 together with RC network (possible only in converters with an A in their serial number) or

- SDCS-PIN-205B/205A/205 can be used as spare parts (possible in converters with an A or B in their serial number). In an A converter do not connect the RC network.

Note: In a B converter only SDCS-PIN205B/205A/205 boards are usable, because the RC network is missing.

Converters 610A

≤

I

DC

≤

1000A and U

AC

: 400V/500V (type C2b) only

- SDCS-PIN-205B can be used as spare part.

Converters 100A

≤

I

DC

≤

270A and U

AC

: 600V

- SDCS-PIN-23


Converters I

DC

= 405A/450A and U

AC

: 600V

- SDCS-PIN-24 together with SDCS-PIR-21 or


Note : In addition to above mentioned limitations make sure that the resistors are cut properly according to the table ‘Settings of the SDCS-PIN-20xB board’ as described in the manual Technical Data . Especially when a board is reused!




Change SDCS-PIN-2x boards

The converter is equipped with a SDCD-PIN-21/22/23/24 board:

- Make sure, electrical and mechanical safety is obtained!

- Mark the cables connected to U1, V1, W1 and C1, D1. Mark the plugs connected to X22, X3 and X4.

- Disconnect all cables and plugs.

- Remove the SDCS-PIN-2x board.

Note: If the converter is equipped with a SDCS-PIR-21 there is no need to remove this board separately, because it is mounted on the SDCS-PIN-2x board.

- Make sure that the resistors on the new board are cut properly according to the table ‘Settings of the SDCS-PIN-20xB board’ as described in the manual Technical Data.

- Install the new SDCS-PIN-20xB board.

Note: SDCS-PIN-205B replaces SDCS-PIN21/23 and SDCS-

PIN-206B replaces SDCS-PIN-22/24.

- Reconnect all cables and plugs.

The converter is equipped with a SDCD-PIN-25 board:

- Make sure, electrical and mechanical safety is obtained!

- Mark the cables connected to U1, V1, W1 and C1, D1. Mark the plugs connected to X22, X3 and X4.

- Disconnect all cables and plugs.

- Remove the SDCS-PIN-25 board.

Note: The additional RC network is not needed anymore. Due to safety reasons remove the cables marked U1 – C14, V1 – C16,

W1 – C12, C1 – R15 and D1 – R12.

- Make sure that the resistors on the new board are cut properly according to the table ‘Settings of the SDCS-PIN-205B board’ as described in the manual Technical Data.

- Install the new SDCS-PIN-205B board.

Note: SDCS-PIN-205B replaces SDCS-PIN25.

- Reconnect all cables and plugs.



VI A 10 - 3


Compatibility of thyristor modules for

DCSxxx-0200 and DCSxxx-0250

Types concerned: DCS500B and DCS600

Actual status

Hardware:

Subject:

All converter types with rated current 200A and 250A are now equipped with thyristor modules type MCC 95-16io1B.

The thyristor module was changed from: SKKT 106/16 E

(DCA0011931P0001) to MCC 95-16io1B (3ADC340012P0002)

The two types of thyristor modules are not compatible. The connectors for gate ( G2 ) and cathode ( K2 ) are exchanged. See also following drawing:

SKKT 106/16 E MCC 95-16IO1B

A1K2

K1

A2

K2

G2

K1

G1

A1K2

K1

A2

G2

K2

K1

G1

Time schedule:

Compatibility:

Attention: The connectors of the new firing pulse cable harness fit on the old thyristor module, but the leads (G2 and K2) for thyristor 2 are exchanged. There is no change for thyristor 1.

The wire for the gate is yellow. The one for the cathode is red.

Spare parts:

For the new converter modules with type code

DCSxxx-xxxx-00-0000000-0000000 3 0 use thyristor modules MCC 95-16io1B.

For the old converter modules with type code

DCSxxx-xxxx-00-0000000-0000000 4 0 or

DCSxxx-xxxx-00-0000000-0000000 use thyristor modules SKKT 106/16E.

MCC 95-16io1B have been used since:

DCS500B / DCS600: 14.10.2003 with serial number

001941B3406813

The technical data of new converter modules are the same.




DC-Motor neutral zone adjustment

Types concerned

Summary

DC-Motors

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 brushholder assemblies (holders with different polarity).

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

- Disconnect the excitation cables and connect 110 – 240 VAC between F+ and F- (a normal extension cord is sufficient).

- 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 50mV AC. The less 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.



VI A 10 - 5


How to remove the converter fan in a frame A6

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

2. Disconnect the cables.

3. Lift the fan up and pull it out. screws cables

VI A 10 - 6

Figure 10-1 Converter fan in frame A6




How to remove the converter fan in a frame A7

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

2. Disconnect the cables.

3. Pull the fan out. cables screws

Figure 10-2 Converter fan in frame A7



VI A 10 - 7


SDCS-CON-x Firmware download instructions for Windows 2000 and NT 4.0

Hardware Configuration

Firmware download Kit

The Firmware download kit (3ADT 220106 R0001) handles the

SDCS-CON-x firmware download process for DCS 500B and DCS

600 MultiDrive converters. It consists of an interface RS232 to

RS485 and a bus cable (same as for panel connection).

Note : SDCS-CON-x resembles SDCS-CON-2 and higher.

NPCU-02

Bus cable

Figure 10 - 3 Firmware download kit

The NPCU-02 is a RS232 to RS485 interface without any galvanic isolation.

The bus cable (DCA 0021499 R0001) connects the interface with the DCS converter.




Installation

DCS 500B / DCS 600

X33

RS232 to RS485

Interface

X34

COM1

NPCU-02

COM2

Desktop or

Laptop female

Bus cable

DCA 0021499R0001 Housing of drive is grouded

Figure 10 - 4 Connection of the interface between PC and the converter

Software Configuration

PC Operating

Systems

The download kit supports the following PC operating systems:

Windows 2000 and NT 4.0.

Drive Software

Versions

The download kit supports the following Drive software versions:

21.2xx

DCS 500B (with SDCS-CON-2 board or higher)

15.2xx

DCS 600 MultiDrive (with SDCS-CON-2 board or higher)

Programs / Files HyperTerminal HyperTerminal Private Edition under Windows 2000 or HyperTerminal under Windows NT 4.0 distributed from ABB:

CON2 download.ht

INIT-file for HyperTerminal Private Edition or HyperTerminal: Download of the relevant version from the ABB LotusNotes database.

DC21X2yy.ROM

DCS 500B firmware and boot software:

Download of the relevant version from the

ABB LotusNotes database.

DC15X2yy.ROM

DCS 600 firmware and boot software:

Download of the relevant version from the

ABB LotusNotes database.



VI A 10 - 9


Firmware download with Windows 2000

Recommendation It is strongly recommended:

To use the ABB bus cable (DCA 0021499R 0001).

To disconnect the laptop from mains supply during download.

The drive has to be grounded .

To switch off all other drives beside the destined unit (disturbances possible). to provide save download transmission.

HyperTerminal Private Edition

Under Windows 2000 the HyperTerminal takes a very long time to download the firmware. For a faster download an updated version of the HyperTerminal, called "HyperTerminal Private Edition"

(HTPE), is needed. Download it from: www.hilgraeve.com/htpe/download.html

Attention : The installation of the HyperTerminal Private Edition will delete all default Windows 2000 HyperTerminals!

Double-click on the downloaded file to start the installation:

Choose: HyperTerminal Private Edition




Choose: Yes

Choose: Install HyperTerminal to its default location

The program will be installed into the directory:

C:\Program Files\Windows NT\HyperTerminal

The executable will be found under:

Start\Programs\HyperTerminal Private Edition



VI A 10 - 11


To finish installation press proceed.

Preparation

•

Switch off auxiliary supply voltage of SDCS-POW-1.

•

Disconnect and remove SDCS-AMC x board (only

DCS 600).

•

Disconnect any other equipment from X33 and X34.

•

Connect bus cable from NPCU-02 to X33 or X34 at DCS converter.

•

Connect the interface NPCU-02 to COM1 at the PC.

•

Set Jumper S2 on SDCS-CON-x from position 7-8 or 3-4 to 5-6.

•

Copy the files distributed from ABB (

see Software configuration )

into designated pathes e.g.

C:\Program Files\Windows NT\HyperTerminal and

C:\...\DCSx00

•

Start HyperTerminal Private Edition by double-click on CON2 download.ht.

VI A 10 - 12

This setup file configures HyperTerminal Private Editon to communicate with the SDCS-CON-x board.




In case the setup file cannot be used (e.g. usage of COM2) the HyperTerminal Private Edition has to be started by double click on HyperTrm.exe.

The setting can be checked and set via menu item

FILE/PROPERTIES and



VI A 10 - 13


CONFIGURE.

The properties for COM1 are shown below

•

Switch on auxiliary supply voltage of SDCS-POW-1

•

The LED-display on the SDCS-CON-x shows a small u

•

The terminal program detects communication



HyperTerminal

Private Edition

Active communication is shown by the *


Flash Erase

Note:

Syntax error indicates EMI (Electromagnetic interference) in the installation.

• check grounding

• switch off all other electronic equipment

• close and re-open HyperTerminal Private Edition

•

Type ls (+ Return).



VI A 10 - 15


Flash Program

•

Type rp (+ Return).

•

Terminal program shows a small rp

•

Open menu item TRANSFERS / SEND TEXT FILE… and select the suitable firmware

Attention: Use DC21A2yy.rom

with DCS 500B and

DC15A2yy.rom

with DCS 600 .

Note :

Additional information about the selection see Update.txt

or Lotus

Notes database .

After clicking OPEN the download starts immediately and SDCS-

CON-x LED-display shows a small r .

DCS 500B download lasts about 20 minutes.

DCS 600 download lasts about 5 minutes .




After the download is finished the display shows a small u again and the terminal program gives the message Program command successful completed .

•

Switch off auxiliary supply (SDCS-POW-1).

•

Set jumper S2 5-6 back to position 3-4 (or 7-8 if two jumpers are present).

•

Assemble the SDCS-AMC x board (only DCS 600). Take care on the plastic washer of the screw near CH0.

The download of the SDCS-CON-x is finished now .

The firmware version can be checked with signal 112.18

signal 4.11

for DCS 500B and for DCS 600.



VI A 10 - 17


Firmware download with Windows NT 4.0

Recommendation It is strongly recommended:

To use the ABB bus cable (DCA 0021499 R0001).

To disconnect the laptop from mains supply during download.

The drive has to be grounded .

To switch off all other drives beside the destined unit (distur-

Preparation bances possible). to provide save download transmission

•

Switch off auxiliary supply voltage of SDCS-POW-1.

•

Disconnect and remove SDCS-AMC x board (only

DCS 600).

•

Disconnect any other equipment from X33 and X34.

•

Connect bus cable from NPCU-02 to X33 or X34 at DCS converter.

•

Connect the interface NPCU-02 to COM1 at the PC.

•

Set Jumper S2 on SDCS-CON-x from position 7-8 or 3-4 to 5-6.

•

Copy the files distributed from ABB (

see Software configuration )

into designated pathes e.g.

C:\...\DCSx00

•

Start HyperTerminal by double-click on CON2 download.ht.

VI A 10 - 18

This setup file configures HyperTerminal to communicate with the

SDCS-CON-x board.




The correct setting can be checked and set to the required settings

(e.g. COMx connector) in the menu item:

FILE/PROPERTIES/CONFIGURE

The properties for COM1 are shown below

•

Switch on auxiliary supply voltage of SDCS-POW-1

•

The LED-display on the SDCS-CON-x shows a small u

•

The terminal program detects communication

HyperTerminal Active communication is shown by the *



VI A 10 - 19


Flash Erase

Note:

Syntax error indicates EMI (Electromagnetic interference) in the installation.

• check grounding

• switch off all other electronic equipment

• close and re-open HyperTerminal

•

Type ls (+ Return).

Flash Program

•

Type rp (+ Return).

•

Terminal program shows a small rp

•

Open menu item TRANSFERS / SEND TEXT FILE… and select the suitable firmware

Attention: Use DC21A2yy.rom

with DCS 500B and

DC15A2yy.rom

with DCS 600 .




Note :

Additional information about the selection see Update.txt

or Lotus

Notes database .

After clicking OPEN the download starts immediately and SDCS-

CON-x LED-display shows a small r .

DCS 500B download lasts about 10 minutes.

DCS 600 download lasts about 5 minutes .

After the download is finished the display shows a small u again and the terminal program gives the message Program command successful completed .

•

Switch off auxiliary supply (SDCS-POW-1).

•

Set jumper S2 5-6 back to position 3-4 (or 7-8 if two jumpers are present).

•

Assemble the SDCS-AMC x board (only DCS 600). Take care on the plastic washer of the screw near CH0.

The download of the SDCS-CON-x is finished now .

The firmware version can be checked with signal 112.18

for DCS 500B and signal 4.11

for DCS 600.



VI A 10 - 21


DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows 2000

Types concerned DCS600 MultiDrive

Summary

Download

DCS600 Multi-

Drive firmware

Instruction how to download firmware on a SDCS-AMC-DC 2 board under Windows 2000 . This download procedure is only valid for the basic firmware (AMC 15.6xx) from Lampertheim and not suitable for any application software.

Attention: Before downloading new firmware make a backup of the parameters!

1. Before download of the firmware the NtNisa drivers have to be installed (see NtNisa5x.zip or NtNisa5x.exe)

2. Unzip the SDCS-AMC-DC 2 firmware (file dc15x6yy.zip)

3. Connect the DCS600 MultiDrive with the PC (fibre optic cable from SDCS-AMC-DC 2 channel 3 to NDPA-02 / NDPC-12)

4. Switch on the DCS600 MultiDrive

5. Start firmware download by double click on:

L_AMC_DC.BAT

6. A DOS window will appear. Wait until the download is finished

(DOS window will close again)

7. Check signal 4.2 for proper software version




DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows NT 4.0


Summary

Download firmware with

PCMCIA card

(notebook or desktop)

Installation of

NtNisa drivers

Installation of NtNisa drivers and instruction how to download firmware on a SDCS-AMC-DC 2 board under Windows NT 4.0

. This download procedure is only valid for the basic firmware (AMC

15.6xx) from Lamperteim and not suitable for any application software.

In order to use the loading package under Windows NT, install

DriveWindow version 1.xx first. Afterwards the NT I/O handling has to be released.

The first step is to find the used I/O addresses (280h - 340h) for the

PCMCIA card (NDPA-02). The second is to reconfigure the I/O handling of NT.

Note: If You already done so go directly to:

Download DCS600 MultiDrive firmware !

Following programs and files are required (Put them all in the directory where the unzipped load package is located. All files are already available in the firmware load package dc15x620 or higher): ntnisa.exe (to release the I/O control for DOS - programs) nisareg.exe (to set the I/O base address and make the pcmcia.inf file) nisadump.exe (to monitor the I/O addresses) ntvddb.dll

The DOS prompt has to be set to full screen. To do that You have to right click the DOS prompt icon ( Attention: the DOS prompt icon has to be on the desktop of your PC). Go to properties , options and set display options to full screen.

To continue You have to be an ADMINISTRATOR on Your own

PC!!!



VI A 10 - 23


Configure PC

Download

DCS600 Multi-

Drive firmware

1. Install DriveWindow 1.xx

2. Shut down NT, switch off the PC and remove the PCMCIA card if present

3. Switch the PC on, start NT, open the DOS prompt and go to the directory which contains nisadump.exe

4. Execute nisadump.exe (type: nisadump.exe

↵

). In the result screen FF means a free address. This information is saved in the file nisadump.txt

5. Rename nisadump.txt or write down the results

6. Shut down NT, switch off the PC and insert the PCMCIA card

7. Switch the PC on, start NT, open the DOS prompt and go to the directory which contains nisadump.exe

8. Execute nisadump.exe and compare the new nisadump.txt with the renamed one. The base I/O address of the PCMCIA card is the first address which data’s have changed from FF to xx (usually 320)

9. Now execute nisareg.exe (type: nisareg

∪

<base I/O address>

↵ in the DOS prompt;

∪

= space; <base I/O address> = 280 to

340 use the one you discovered in step 7) to set the base I/O address for the PCMCIA card. This creates the file pcmcia.inf

10. Copy the file pcmcia.inf into the root directory C:\.

11. In the DOS prompt go to the directory which contains ntnisa.exe

12. Execute ntnisa.exe (type: ntnisa.exe

↵

) in order to release the

I/O control

Attention: Before downloading new firmware make a backup of the parameters!

1. Connect the DCS 600 MultiDrive with the PC (fibre optic cable from SDCS-AMC-DC 2 channel 3 to NDPA-02 / NDPC-12)

2. Switch on the DCS 600 MultiDrive

3. In the DOS prompt (full window!!) go to the root directory C:\ and type in CAPITAL letters (

∪

= space):

SET

∪

ABBDDCS=PCMCIA

4. Now You are ready to download the DCS 600 MultiDrive firmware

5. In the DOS prompt, go to the directory with the DCS 600 Multi-

Drive firmware load files and type:

L_AMC_DC

6. Check signal 4.2 for proper software version




DCS600 MultiDrive - How to download parameter files on a SDCS-AMC-DC x board


Summary

Procedure how to download parameter files on a SDCS-AMC-DC x.

Reload DCS600

MultiDrive parameters

Note: This procedure should be used for new or newly loaded

SDCS-AMC-DC x boards.

An actual parameter set of all drives should be always available. If this is not the case, please create actual parameter sets by means of DriveWindow and save them as *.DWP files. For DCS 600 MultiDrive a backup is not necessary, because the firmware is the same for all sizes and the autotuning results are saved as parameters.

1. Install and reconnect the new or newly loaded SDCS-AMC-DC x board in the DCS600 MultiDrive.

2. If a DriveWindow network is existing do not connect the

DCS600 MultiDrive with the network. When using a new or newly loaded board parameter 70.15 (CH3 NODE ADDR) is set to 1 by default. This leads to a conflict in case another drive in the network owns node number 1.

3. Connect the DCS600 MultiDrive with the new or newly loaded

SDCS-AMC-DC x board directly with DriveWindow.

4. Download the actual parameter set.

Note: Group 99 will not be downloaded and has to be set by hand.

5. To activate parameters 70.15 (CH3 NODE ADDR) and 97.01

(DEVICE NAME) deenergise and energize the DCS600 MultiDrive.

6. Check the downloaded parameters with the DriveWindow compare function.

7. As soon as parameter 70.15 is valid it is possible to connect the

DCS600 MultiDrive again with the DriveWindow network.

8. Set parameters in group 99 back to desired values.

Note: User macros have to be created manually by means of parameters 95.11 (APPLICATION MACRO) and 99.09 (APPLIC

RESTORE).



VI A 10 - 25





Recommended regular maintenance

Air Filters

Cooling air pressure switch in converter modules type

A6/A7/C4

Fan

Heatsink

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.

The DCS requires very little maintenance if installed in an appropriate environment. An annual check for dust accumulation and corrosion inside the module / cabinet is recommended.

When air filters are used, the filters should be checked regularly depending on environmental conditions. Clocked up filters prevent the proper cooling of the drive.

Wash dirty filters with water (60°C) and detergent.

The cooling air pressure switch must be checked regularly.

The following actions have to take place:

- Make sure electrical safety is performed.

- Open the module's door and hold it in position to prevent any movement.

- Repeat it with the cabinet’s door.

- Switch on the drive and try to turn the motor.

- The air pressure switch is ok when the converter is switched off by error “F50 NO C FAN”; crosscheck this result with the module’s door closed.

The lifetime of the cooling fan is about 20.000 to 40.000 hours depending on the converter type. The actual lifetime depends on the usage of the DCS and the ambient temperature.

Fan failure can be 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 mentioned symptoms appear.

The DCS will run into overtemperature faults if the heatsinks are not clean. In an appropriate environment the heatsinks should be checked and cleaned annually.

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.

Additionally use a vacuum cleaner to clean the dust from the air inlet and outlet.



VI A 11 - 1

Chapter 11 - Preventive Maintainance

Internal high current connections in converters type A7/C4

Relays and electrical connections

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 preshaped 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. This check should be done regularly, e.g. annually or together with all the other work to be done for preventive maintenance.

Actions:

- Make sure all supply voltages are switched off, most important the supply for the power part (armature), for the electronic power part (SDCS-POW-1), for the converter fan and for other auxiliaries!

- Open the cabinet’s and module’s door; if needed secure them.

- Set a latching torque spanner to 25 Nm (18 lb-ft); a 17 mm nut is needed too.

- Check the torque of the screws marked within Figure 11-1 at the end of this chapter:

- Apply the torque spanner to the screw and turn right until the right torque is indicated.

- Don’t loosen the screws by a left hand turn!

- Put on a new marking, if appropriate.

Relays should be checked for proper function and all connections should be inspected and checked for tightness. Any signs of corrosion, especially at ground components, must be removed.




Screws to be checked:



Screws to be checked

(located behind the busbar):

Figure 11-1: Power part of a converter module type A7/C4



VI A 11 - 3




Appendix A - Spare Parts List

2.00

PARTS FOR CONV. MODULES DCS500B; DCS600 and DCF500B/600 IN STANDARD VERS.

2.10

COMMON PARTS FOR CONV. DCS500B/DCF500Bxxxx-xx-21..(CON-2)

DESCRIPTION QTY CODE TYPE/DATA

Control board DCS500 B

Power supply board

1

1

3ADT220072R4

3ADT220090R3

SDCS-CON - 2

SDCS-POW-1 COAT

NOTES with actual software 21.xxx

2.20

COMMON PARTS FOR CONV. DCS600/DCF600xxxx-xx-15..MultiDrive; 18..Crane SW


Control board +AMC-DC-2 Board

Control board +AMC-Clas-2.

1*

1*

3ADT220072R5

3ADT220072R7

CON-2+AMC-DC-2

CON-2+AMC-Clas-2

NOTES w.act. SW.15.xxx+AMC-DC-2 B.

w.act.SW.15.xxx+AMC-C-2 B.

Control b.+AMC-DC-2 Crane

Control b.+AMC-Clas-2 Crane

Power supply board

*) Select only one Board

1*

1*

1

3ADT220072R22

3ADT220072R20

3ADT220090R3

CON-2-18+AMC-DC-2

CON-2-18+AMC-C-2

SDCS-POW-1 COAT

Crane SW18+AMC-DC-2; incl. Fee

Crane SW18+AMC-C-2; incl. Fee



VI A A - 1

Appendix A- Spare Parts List

2.30

COMMON PARTS FOR CONV. DCS500/DCS600 and DCF500/600


*)DI/DO connection board



AI/AO connection board

Communication Board

AMC-Communic. Board DCS600

1*

1*

1*

1

1

1

3BSE005176R1

3BSE005177R1

3BSE005178R1

3BSE004086R1

3ADT220059R1

3ADT312700R1

SDCS-IOB-21

SDCS-IOB-22

SDCS-IOB-23

SDCS-IOB-3

SCDS-COM-5

AMC-DC-2 Board

AMC-Communic. Board DCS600

Control Panel CDP312

I/O Extension Board

Adapt. Board /Analog Tacho


1

1

1

1

3ADT312700R2

3ADT220071R5

3BSE005851R1

3ADT300600R1

AMC-DC-Clas-2 B.

CDP312 Rev.F

SDCS-IOE-1

PS 5311- SET

NOTES

24V DC-48V DC; digital (A9)

115V AC ; digital (A9)


analog (A 10)

separate without Software f. DCS600 without Software f. DCS600

For DCS500B & DCS600

DCR-Kit contains: 2Q 4Q

2.40

PARTS FOR DCR REBUILD KITS, ( 12 Pulse etc. see item 2.41)

DESCRIPTION 2Q 4Q CODE TYPE/DATA

Cooling fan

Pulse Interface Board

Pulse Amplifier Board

Pulse Distribution Board

Power Supply for REB-2

1

1

1

1

2

1

1

1

1

2

DCA0017670P1

DCF1154914R1

DCF1192115R1

3ADT309300R1

DCE8920037P1

CN52B2

SDCS-REB-1

SDCS-REB-2

SDCS-REB-3

NPSM-01 below listed SDCS- PIN- 41A and PIN-51 are identical with A5/A6/A7 and C4 Modules

Pulstransformer Board

Power interface board

Current Transformer 2500/1A


1

1

2

2

2

1

2

2

3BSE004939R1

3BSE004940R1

3ADT751010P1

3ADT751007P1

SDCS-PIN-41 A

SDCS-PIN-51

LT2032 2500/1A

4000/1A

NOTES for DCR500B/600 Type

DCR >= 1 Stage

DCR >= 2 Stages

DCR >= 3 Stages

230V/24V DC/ 2A >= 2 Stages for 400V up to 1000V AC

T51/T52 for A5 and A6 Range

T51/T52 for A7/C4 Range

2.41

PARTS FOR 12 PULSE SYST.; SUPPLY > 800V-AC & HARD PAR. CONV. A7P

DESCRIPTION 2Q 4Q CODE TYPE/DATA

Current Measurement Aid

Insulation Monitor (10V)

1

1

1

1

3ADT220090R22

DCA0019192P1

SDCS-CMA-2

IRDH 265-4

NOTES

12 Pulse and Paralleling Converter mounted inside Cab.10-990kOhm

Insulation Monitor (10V) 1 1 3ADV050058P5 IRDH 365-4 Door mounted Vers.10- -990kOhm

Insulation Monitor (10V)

Volt. Adapt. Board f. IRDH 6P.

Volt. Adapt. Board f. IRDH 12P.

DC-DC Transducer (Knick) A92

High Volt. Transformer T 90

High Volt. Fuses for U >800V-AC

Paralleling Interface Board 1

Paralleling Interface Board 2

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

3ADV050058P1

DCA0019711P1

3ADV050058P2

3ADN260004P1

3ADT745047P1

DCE8063614P1

3ADT220090R31

3ADT220090R32

IRDH 265-3

AGH 204 S

AGH 150 W-4

8680 A1/A92

T 90; 500-1200V-AC

CC 1500CP GRD 20

SDCS-PAR-1-coat

SDCS-PAR-2-coat inside Cab.-EMBR; 2 - 200kOhm

For IRDH >= 690V-AC 6Pulse

For IRDH >= 690V-AC 12Pulse

For U-AC > 800V & 12 Pulse ser.

For U-AC > 800V & 12 Pulse ser.

2 pcs. for A92; 3 pcs. for T90 ;

Paralleling Master Conv.

Paralleling Slave Conv.

2.50

2-PHASE FIELD EXCITERS

DESCRIPTION QTY

Integrated uncontr. 6 A;FEX-1 1

Integrated single 16 A;FEX-2A 1

Control Board DCF503A0050

Thyristor/Diode Module 1Q 50A


Thyristor modules 4Q 50A

Ext. DCF503A0050; 1Q 50 A

Ext. DCF504A0050; 4Q 50 A

Ext. DCF503A0060; 1Q 60 A

Ext. DCF504A0060; 4Q 60 A

Addit. Fan for DCFxxxA0060

1

1

1

2

1

1

1

2

2

CODE

DCA0012317R1

DCA0012325R1

3ADT312400R2

DCA0003270P1

3ADT312400R1

DCA0011132P1

3ADT209019R1

3ADT209019R2

3ADT209019R11

3ADT209019R12

GHSN700002P1

TYPE/DATA

SDCS-FEX-1

SDCS-FEX-2 A

SDCS-FEX-32A

SKKH 57

SDCS-FEX-31A

SKKT 42

DCF503A0050

DCF504A0050

DCF503A00 60

DCF504A00 60

AC220V 8556V

NOTES

Sep. compl. Unit; incl. Diode M.

Sep. compl. Unit; incl. Thyristor M.

Control Board f. DCF503A0050 for DCF503A0050

Control Board f.DCF504A0050

for DCF504A0050

Complete unit DCF503A0050




Fan M55/M56 f. DCFxxxA0060

2.60

Parts for Three-Phase Fieldexc.; 25A ---520A; Overvolt.Protect. DCF506-..

DESCRIPTION 4 Q CODE TYPE/DATA

Control Board for DCF505/506 Units 1 3BSE006309R1 SDCS-FEP-1

Overvolt. Protect. for Motorfieldexc.

Overvolt. Protect. for Motorfieldexc.

Overvolt. Protect. for inductive Load

VI A A - 2

1

1

1

DCF1127101R1

DCF1127119R1

DCF1216235R1

DCF506-0140-51

DCF506-0520-51

DCF506-1200-51

NOTES

(1400V) for DCF505/506

3-Phase Fieldexc. 25A - 100A

3-Phase Fieldexc. 200A - 520A

3-Phase EMBR's 820-1200A



Appendix A - Spare Parts List

3.00

Coated Electr. Boards for DCS500B; DCS600; Fieldexc.; I/O Boards; DCR Kits & Mod.

3.10

Coated Boards forDCS500B (see item 2.10 )

DESCRIPTION QTY CODE

Control board DCS500 B 1 3ADT220072R12

Power supply board 1 3ADT220090R3

3.20

Coated Boards for DCS600/DCF600 (see item 2.20 )

Control board +AMC-DC-2 Board

Control board +AMC-Clas2.

1*

1*

3ADT220072R9

3ADT220072R11

TYPE/DATA

SDCS-CON - 2-21-coat

SDCS-POW-1 COAT

NOTES with actual software21.xxx

CON-2+AMC-DC-2 coat

CON-2+AMC-Cl.-2 coat w.act. SW.15.xxx+AMC-DC-2 B.

w.act.SW.15.xxx+AMC-Cl.-2 B.

Control b.+AMC-DC-2 Crane 1* 3ADT220072R40 CON-2-18+AMC-DC-2-coat Crane SW18+AMC-DC-2; incl. Fee

Control b.+AMC-Clas-2 Crane

Power supply board

1*

1

3ADT220072R41

3ADT220090R3

CON-2-18+AMC-C-2-coat Crane SW18+AMC-C-2; incl. Fee

SDCS-POW-1 COAT

3.30

Coated Interface Boards ; Panels for DCS500B/DCS600 Modules/Cabinets




AI/AO connection board

Communication Board

I/O Extension Board

Adapt. Board /Analog Tacho

1*

1*

1

1

1*

1

1

3ADT220090R14

3ADT220090R13

3ADT220090R23

3ADT220090R20

3ADT220090R26

3ADT220090R25

3ADT220090R29

SDCS-IOB-21-coat

SDCS-IOB-22-coat

SDCS-IOB-23-coat

SDCS-IOB-3-coat

SCDS-COM-5-coat

SDCS-IOE-1-coat

PS 5311- coat

24V DC-48V DC; digital (A9)



analog (A 10)

separate

3.40

Coated Boards for DCR Rebuild Kits and 12 Pulse-Systems (see item 2.30 )

Pulse Interface Board

Pulse Amplifier Board

1

1

1

1

3ADT220090R9

3ADT220090R34

SDCS-REB-1-coat

SDCS-REB-2-coat

Coated Board for DCR

Coated Board for DCR

Pulstransformer Board


1

1

2

1

3ADT220090R5

3ADT220090R6

SDCS-PIN-41 A-coat

SDCS-PIN-51-coat

Current Measurement Aid 1 1 3ADT220090R22 SDCS-CMA-2-coat

3.50

Coated Boards for 2-PHASE FIELD EXCITERS see item 2.50

Integrated single 16 A; FEX-2



1

1

1

3ADT220090R19

3ADT220090R37

3ADT220090R36

SDCS-FEX-2 A-coat

SDCS-FEX-32A-coat

SDCS-FEX-31A-coat

DCF503A0050-Coat

DCF504A0050-Coat for 400V up to 1000V AC

12 Pulse and Paralleling Converter

Sep. compl. Unit; coated Vers.

Coat. Contr. Board DCF503A..

Coat. Contr. Board DCF504A..



Ext. DCF503A-0050; 1Q 50 A




Puls transformer board



1 3ADT209019R0101

Ext. DCF504A0050; 4Q 50 A 1 3ADT209019R0102

3.60

Coated Boards for 25A - 5200A Modules

1

1

1

1

1

1

2

1

1

1

3ADT220090R27

3ADT220090R35

3ADT220090R38

3ADT220090R5

3ADT220090R6

SDCS-PIN-11-coat

SDCS-PIN 205B-Coat

SDCS-PIN 206B-Coat

SDCS-PIN-41 A-coat

SDCS-PIN-51-coat

25A; 50A and 75A Mod.

100A - 1000A/400/500V Mod.

110A,270A and 450A/600V M.

900A - 5150A for 400V up to 1000V AC



VI A A - 3


Item 4.00 to 10.00 Module DCS500B / DCS600 Size C1 25A----140A

4.00

Common Parts for C1, C2 and C2b Modules from 25A ---1000A (Item 4.10 - 18.30)

DESCRIPTION

Temperatur Sensor (R57)

2 Q

1

4 Q

1

CODE

DCA0012139P1

TYPE/DATA

KTY 10-6 M4

NOTES

(C1-C2b / 550mm cable)

Fuse F101; F102 and F103 on PIN205B and PIN206B see Modules from 100A till 1000A ; item 8.00 - 18.00

Module contains: 2Q 4Q

4.10

25 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q

Thyristor modules


Semiconductor fuses

3

1

3

6

1

3

CODE

DCA0008018P1

3ADT306100R1

DCZ9838767P1

TYPE/DATA

SKKT27/16E *

SDCS-PIN-11

170M1564

DCF501,502, DCF 601, 602 (1)

Cooling fan 1 1 DCA0017670P1 CN52B2

(1) If used as a spare part for DCF...

the resistors R113/R116/R119 must be removed. For further information see "Technical Data"

* DCS500/DCS600 Thyr. Modules SKKT 27 / 16E are not identical to Thyr. Modules SKKT 27 B/16E used for DCS400 Converter Modules


5.00


DESCRIPTION 2 Q 4 Q

Thyristor modules 3 6


Semiconductor fuses

1

3

1

3

CODE

DCA0011132P1

3ADT306100R1

DCZ9838791P1

TYPE/DATA

SKKT42/16E *

SDCS-PIN-11

170M1566

NOTES

DCF501,502, DCF 601, 602 (1)






6.00

50 A (600V) CONVERTER

DESCRIPTION 2 Q 4 Q


CODE

DCA0011906P1

TYPE/DATA

SKKT57/20E *

NOTES


Semiconductor fuses

1

3

1

3

3BSE005716R1

DCZ9838791P1

SDCS-PIN-12

170M1566 changed Oct.2001




7.00


DESCRIPTION 2 Q 4 Q


CODE

DCA0011914P1

TYPE/DATA

SKKT57/16E *

NOTES

Power interface board 1 1 3ADT306100R1 SDCS-PIN-11 DCF501,502, DCF 601, 602 (1)

Semiconductor fuses 3 3 DCA0012686P1 170M1568






8.00

100 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q

Thyristor modules


Fuse F101- F103 on PIN205B

Semiconductor fuses

3

1

3

3

6

1

3

3

CODE

DCA0011931P1

3ADT312500R1

3BSC770010R0101

DCA0012694P1

TYPE/DATA

SKKT 106/16E *

SDCS-PIN 205B

KTK-R6A/660V

170M3815

NOTES

Repl. SDCS PIN-21 and PIN205

Cooling fan 1 1 DCA0012678P1 W2E143-AA09-25



9.00

110 A (600V) CONVERTER

DESCRIPTION

Thyristor modules

2 Q

3

4 Q

6



Semiconductor fuses

Cooling fan

1

3

3

1

1

3

3

1

CODE

DCA0011922P1

3ADT312500R2

3BSC770010R0101

DCA0012694P1

DCA0012678P1

TYPE/DATA

SKKT72/20E

SDCS-PIN 206B

KTK-R6A/660V

170M3815

W2E143-AA09-25

NOTES



10.00 140 A (400V-500V) CONVERTER

DESCRIPTION

Thyristor modules

2 Q

3

4 Q

6

Power interface board 1 1


Semiconductor fuses

Cooling fan

3

3

1

3

3

1

CODE

DCA0011931P1

3ADT312500R1

3BSC770010R0101

DCA0012694P1

DCA0012678P1

TYPE/DATA

SKKT 106/16E *

SDCS-PIN 205B

KTK-R6A/660V

170M3815

W2E143-AA09-25

NOTES



VI A A - 4 DCS 500 / DCS 600 Service Manual


Item 11.00 to 17.10 Mod. DCS500B / DCS600 Size C2 200A-- 520A


11.00 200 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q CODE TYPE/DATA NOTES

Thyr. mod.; Unit Produced after

15.10.2003

3 6 3ADC340012P2 MCC 95-16IO1B * only for modules with type code e.g.

DCSxxx-0200-x1-2100000-0000000 3 0

Thyr. Mod.;Unit Produced before

14.10.2003



3

1

3

6

1

3

DCA0011931P1

3ADT312500R1

3BSC770010R0101

SKKT 106/16E **

SDCS-PIN 205B

KTK-R6A/660V only for modules with type code e.g.

DCSx0x-0200-x1-2100000-0000000

(instead of a 4 a 0 could be used)


Semiconductor fuses

Cooling fan

3

1

3

1

3ADC770024P9

DCA0012171P1

170M3816

W2E200-HH38-06

* Attention : Above listed Tyhristor modules MCC95 or SKKT...are differnt at Gate Connection; Please check the Type Code at the Name plate

4 0

** DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules

Module contains:

2Q 4Q

12.00 250 A (400V-500V) CONVERTER


Thyr. mod.; Unit Produced after

15.10.2003

3 6 3ADC340012P2 MCC 95-16IO1B * only for modules with type code e.g.

DCSx0x-0250-x1-2100000-0000000 3 0

Thyr. Mod.;Unit Produced before

14.10.2003



3

1

3

6

1

3

DCA0011931P1

3ADT312500R1

3BSC770010R0101

SKKT 106/16E **

SDCS-PIN 205B

KTK-R6A/660V only for modules with type code e.g.

DCSx0x-0250-x1-2100000-0000000 4 0

(instead of a 4 a 0 could be used)


Semiconductor fuses

Cooling fan

3

1

3

1

3ADC770024P10

DCA0012171P1

170M3817

W2E200-HH38-06

* Attention : Above listed Tyhristor modules MCC95 or SKKT...are differnt at Gate Connection; Please check the Type Code at the Name plate

** DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules


13.00 270 A (600V) CONVERTER

DESCRIPTION 2 Q 4 Q




Semiconductor fuses

Cooling fan

1

3

3

1

1

3

3

1

CODE

DCA0011957P1

3ADT312500R2

3BSC770010R0101

DCA0003547P1

DCA0012171P1

TYPE/DATA

SKKT132/20E

SDCS-PIN 206B

KTK-R6A/660V

170M3819

W2E200-HH38-06

NOTES



14.00 350 A (400V-500V) CONVERTER

DESCRIPTION

Thyristor modules


2 Q 4 Q

3

1

6

1


Semiconductor fuses

3

3

3

3

Cooling fan 1 1

CODE

DCA0011965P1

3ADT312500R1

3BSC770010R0101

DCA0012708P1

DCA0012171P1

TYPE/DATA

SKKT 162 / 16E

SDCS-PIN 205B

KTK-R6A/660V

170M5810

W2E200-HH38-06

NOTES alt.TT162N16KOF - GHSN610178P2



15.00 450 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q

Thyristor modules


3

1

6

1


Semiconductor fuses

Cooling fan

3

3

1

3

3

1

CODE

DCA0011973P1

3ADT312500R1

3BSC770010R0101

DCA0012716P1

DCA0012171P1

TYPE/DATA

SKKT250/16E

SDCS-PIN 205B

KTK-R6A/660V

170M6811

W2E200-HH38-06

NOTES alt.TT250N16KOF-GHSN610089P2



16.00 450 A (600V) CONVERTER

DESCRIPTION 2 Q 4 Q




Semiconductor fuses

Cooling fan

1

3

3

1

1

3

3

1

CODE

DCA0011981P1

3ADT312500R2

3BSC770010R0101

DCA0012716P1

DCA0012171P1


17.00 520 A (400V-500V) CONVERTER

DESCRIPTION

Thyristor modules

2 Q 4 Q

3 6



1

3

1

3

Semiconductor fuses

Cooling fan

3

1

3

1

CODE

DCA0011973P1

3ADT312500R1

3BSC770010R0101

DCA0012716P1

DCA0012171P1

TYPE/DATA

SKKT210/20E

SDCS-PIN 206B

KTK-R6A/660V

170M6811

W2E200-HH38-06

TYPE/DATA

SKKT250/16E

SDCS-PIN 205B

KTK-R6A/660V

170M6811

W2E200-HH38-06

NOTES alt.TT250N18KOF


NOTES alt.TT250N16KOF-GHSN610089P2





VI A A - 5


Item 18.10 till 18.30 ; New C2b Modules with 680A, 820A and 1000A


18.10 680 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q




Semiconductor fuses

Cooling fan

* Fuses used in Encl. Converter

1

3

3

1

3

1

3

3

1

3

CODE

3ADC340032P1

3ADT312500R1

3BSC770010R0101

DCA0012724P1

DCA0012171P1

3ADV050092P19


18.20 820 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q




Semiconductor fuses

Cooling fan


3

1

3

1

3

3

1

3

1

3

CODE

3ADC340066P1

3ADT312500R1

3BSC770010R0101

DCA0012724P1

DCA0012171P1

3ADV050092P19

TYPE/DATA

TT 425 N16KOF

SDCS-PIN 205B

KTK-R6A/660V

170M6813

W2E200-HH38-06

170M6013

TYPE/DATA

TT 570 N16KOF

SDCS-PIN 205B

KTK-R6A/660V

170M6813

W2E200-HH38-06

170M6013

NOTES


Fuses for Cabinets are differ.*

Fuses for Encl. Conv. w. OESA

NOTES





18.30 1000 A (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q




Semiconductor fuses/Module *

Cooling fan


3

1

3

1

3

3

1

3

1

3

CODE

3ADC3400066P1

3ADT312500R1

3BSC770010R0101

3ADC770010P9

3ADT754017P1

3ADV050092P20

TYPE/DATA

TT 570 N16KOF

SDCS-PIN 205B

KTK-R6A/660V

170M6166

W2E250-HL06-10

170M6016

NOTES



( ident. with W2E....06-08 )





Item 19.00 to 24.00 New A5 Module DCS500B/ DCS600 Size A5 900A----2000A

19.01 Common Parts for A5 Modules from 900A ---2000A (Item 19.00 - 24.00)

DESCRIPTION 2 Q 4 Q CODE TYPE/DATA

Temperatur Sensor (R57) 1 1 3ADT710003P1 KTY 2K-M4-800


19.00 DCSxxx-903-61/71; 900 A (600V-690V) CONVERTER

DESCRIPTION 2 Q 4 Q CODE

Thyristor


6

1

12

2

DCA0012007P1

3BSE004939R1

Power interface board 1 1 3BSE004940R1

Semiconductor fuses

Cooling fan

6

1

6

1

3ADC770009P7

3ADT754018P1

TYPE/DATA

T459N24TOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6144

D2E 160-AH02-15

NOTES

A5 Modules; item 19.00 - 24.00

NOTES


20.00 DCSxxx-1203-41/51…; 1200 A (400V-500V) CONV. (not used for "1200T" Cab.)


Thyristor



Semiconductor fuses

Cooling fan

1

6

6

1

1

12

2

1

6

1

DCA0012015P1

3BSE004939R1

3BSE004940R1

3ADC770010P5

3ADT754018P1

T589N18TOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6162

D2E 160-AH02-15


21.00 DCSxxx-1503-41/51…; 1500 A (400V-500V) CONV. (used for "1200T" Cab.)


Thyristor



Semiconductor fuses

Cooling fan

1

6

6

1

1

12

2

1

6

1

3ADC340077P1

3BSE004939R1

3BSE004940R1

3ADC770010P9

3ADT754018P1

T 918-1770-18

SDCS-PIN-41 A

SDCS-PIN-51

170M6166

D2E 160-AH02-15

NOTES

NOTES former Type 5STP18F1800


22.00 DCSxxx-1503-61/71…;1500 A (600V-690V) CONVERTER


Thyristor



Semiconductor fuses

Cooling fan

1

6

1

6

1

12

2

1

6

1

3ADC340085P1

3BSE004939R1

3BSE004940R1

3ADC770009P12

3ADT754018P1

TYPE/DATA

TV 918-1500-28

SDCS-PIN-41 A

SDCS-PIN-51

170M6149

D2E 160-AH02-15


23.00 DCSxxx-2003-41/51….; 2000 A (400V-500V) CONVERTER


Thyristor



Semiconductor fuses

Cooling fan

6

1

6

1

1

6

1

12

2

1

3ADC340078P1

3BSE004939R1

3BSE004940R1

3ADC770010P12

3ADT754018P1

TYPE/DATA

T 918-2000-18

SDCS-PIN-41 A

SDCS-PIN-51

170M6169

D2E 160-AH02-15

NOTES former Type 5STP16F2400/2800

NOTES former Type 5STP1818F0003

Module contains: 2Q * as 4 Quadrant Module with 600/690V not available

24.00 DCSxx1-2003-61/71….; 2000 A (600V-690V) CONVERTER

DESCRIPTION 2 Q CODE TYPE/DATA

Thyristor



Semiconductor fuses

Cooling fan

1

6

1

6

1

---

---

---

---

---

3ADC340090P1

3BSE004939R1

3BSE004940R1

3ADC770009P13

3ADT754018P1

TV 989-2700-28

SDCS-PIN-41 A

SDCS-PIN-51

170M6151

D2E 160-AH02-15



NOTES former Type 5STP24H2800

VI A A - 7


Item 40.00 to 49.00 Module DCS500B / DCS600 Size A6 1900A----3000A ; 400V - 790V-AC

40.00 Common Parts for all A6 Mod. from 1900A ----3000A (Item 40.00 - 56.00)

DESCRIPTION

Air Flow detector ( P1)



2 Q 4 Q

1

1

2

1

1

2

CODE

DCF1066659P1

DCA0012139P4

3ADT751010P1

TYPE/DATA

P 233A-4-AHC

KTY 10-6 M4

LT2032 2500/1A


41.00 DCSxxx-1903-81-.. (790V) ( AC-DC Connect. only on Left side )


Thyristor 6 12 3ADC340081P1 T 1329N22KOF



Semiconductor fuses

Cooling fan

1

1

12

1

2

1

12

1

3BSE004939R1

3BSE004940R1

3ADC770009P8

3ADT754008P1

SDCS-PIN-41 A

SDCS-PIN-51

170M6144

GR31M-..(500V)

NOTES

( replac. former P 33 AB )

( A6/1200mm cable)

T51/T52 for A5 and A6 Range

NOTES

F11 - F16/double fuses

380V - 500V/ 50/60Hz




Thyristor



6

1

1

12

2

1

3ADC340081P1

3BSE004939R1

3BSE004940R1

T 1329N22KOF

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses

Cooling fan

6

1

6

1

3ADC770010P11

3ADT754008P1

170M6145

GR31M-..(500V)

NOTES

F11 - F 16/single Fuses

380V - 500V/ 50/60Hz


43.00 DCSxxx-2053-61/71-.. (600V - 690V) ( AC-DC Connect. only on Left side )


Thyristor



Semiconductor fuses

Cooling fan

6

1

1

12

1

12

2

1

12

1

3ADC340081P1

3BSE004939R1

3BSE004940R1

3ADC770009P8

3ADT754008P2

T 1329N22KOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6145

GR31M-..(690V)

NOTES


525V - 690V/ 50/60Hz

Next bigger A6 Modules with AC-Supply 3 x 790V => DCSxxx-1903-xx-81 see item 41.00




Thyristor for DCSxx1--; 2Q


6

6

3ADC340089P1

3ADC340079P1

T 989-3030-18

5 STB 24 Q2800



Semiconductor fuses

Cooling fan

1

1

12

1

2

1

12

1

3BSE004939R1

3BSE004940R1

3ADC770010P6

3ADT754008P1

SDCS-PIN-41 A

SDCS-PIN-51

170M6163

GR31M-..(500V)

NOTES

B idirectional C ontr. T hyristor


380V - 500V/ 50/60Hz









6

6

3ADC340090P1

3ADC340079P1

TV 989-2700-28

5 STB 24 Q2800



Semiconductor fuses

Cooling fan

1

1

12

1

2

1

12

1

3BSE004939R1

3BSE004940R1

3ADC770009P11

3ADT754008P2

SDCS-PIN-41 A

SDCS-PIN-51

170M6148

GR31M-..(690V)

NOTES



525V - 690V/ 50/60Hz




Thyristor for DCSxx1--; 2Q 3ADC340087P1 TV 989-2770-28




Semiconductor fuses

Cooling fan

6

-

1

1

12

1

6

2

1

12

1

3ADC340079P1

3BSE004939R1

3BSE004940R1

3ADC770009P11

3ADT754008P1

5 STB 24 Q2800

SDCS-PIN-41 A

SDCS-PIN-51

170M6148

GR31M-..(500V)

NOTES



380V - 500V/ 50/60Hz

Module contains:


Semiconductor fuses 2Q M.

2Q 4Q






6

1

6

2

3ADC340088P1

3ADC340079P1

3BSE004939R1

T 989-3300-18

5 STB 24 Q2800

SDCS-PIN-41 A

1

12

1

-

3BSE004940R1

3ADC770010P11

SDCS-PIN-51

170M6168


Cooling fan

-

1

12

1

3ADC770010P9

3ADT754008P1

170M6166

GR31M-..(500V)

NOTES


F11 - F 16/double Fuses


380V - 500V/ 50/60Hz






6

6

3ADC340046P2

3ADC340079P1

5STP 3328L0003

5 STB 24 Q2800





Cooling fan

1

1

12

-

1

2

1

-

12

1

3BSE004939R1

3BSE004940R1

3ADC770009P12

3ADC770009P11

3ADT754008P2

SDCS-PIN-41 A

SDCS-PIN-51

170M6149

170M6148

GR31M-..(690V)

NOTES




525V - 690V/ 50/60Hz

Module contains:




Cooling fan

2Q 4Q






6

1

6

2

3ADC340046P2

3ADC340079P1

3BSE004939R1

5STP 3328L0003

5 STB 24 Q2800

SDCS-PIN-41 A

1

12

-

1

1

-

12

1

3BSE004940R1

3ADC770009P12

3ADC770009P11

3ADT754008P1

SDCS-PIN-51

170M6149

170M6148

GR31M-..(500V)

NOTES




380V - 500V/ 50/60Hz



VI A A - 9


Item 50.00 to 65.00 Module DCS500B / DCS600 Size A7 2053A----5203A ; 400V - 1190V-AC

50.00

Common Parts for all A7 Mod. from 2053A ----5203A (Item 50.00 - 65.00)

DESCRIPTION




2 Q 4 Q

1

1

2

1

1

2

CODE

DCF1066659P1

DCA0012139P5

3ADT751007P1

TYPE/DATA

P233 A-4 AHC

KTY 10-6 -M4

4000/1A

NOTES

(A7; 1750mm cable )

T51/T52 for C4/A7 Range /1200V


51.00 DCSxxx-2053-91-.. (1000V) ( AC-DC Conn.on Left side L ; or Right side R )


Thyristor



6

1

1

12

2

1

3ADC340086P1

3BSE004939R1

3BSE004940R1

TV 989-2700-30

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses 6 6 3ADC770030P3 170M 7976

Cooling fan 1 1 3ADT754020P1 GR 35C

For A7 Modules Ventilator is the same for left-side or right-side Busbar Connection

NOTES

400V - 690V/50/60Hz




Thyristor



6

1

1

12

2

1

3ADC340086P1

3BSE004939R1

3BSE004940R1

TV 989-2700-30

SDCS-PIN-41 A

SDCS-PIN-51




NOTES

400V - 690V/50/60Hz




Thyristor



6

1

1

12

2

1

DCA0012066P1

3BSE004939R1

3ADT780007R1

5 STP 28L 3600

SDCS-PIN-41 A

SDCS-PIN-51-1190




NOTES

400V - 690V/50/60Hz





54.00 DCSxxx-3303-41/51-.. (400-500V) ( AC-DC Conn.on Left side L ; or Right side R )


Thyristor



Semiconductor fuses

6

1

1

6

12

2

1

6

3ADC340089P1

3BSE004939R1

3BSE004940R1

DCA0012821P1

T 989-3030-18

SDCS-PIN-41 A

SDCS-PIN-51

170M 7026


NOTES

400V - 690V/50/60Hz





Thyristor



6

1

1

12

2

1

3ADC340087P1

3BSE004939R1

3BSE004940R1

TV 989-2770-28

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses 6 6 DCA0012856P1 170M 7036



NOTES

400V - 690V/50/60Hz




Thyristor



Semiconductor fuses

6

1

1

6

12

2

1

6

3ADC340087P1

3BSE004939R1

3BSE004940R1

DCA0012856P1

TV 989-2770-28

SDCS-PIN-41 A

SDCS-PIN-51

170M 7036



NOTES

400V - 690V/50/60Hz




Thyristor



Semiconductor fuses

6

1

1

6

12

2

1

6

3ADC340084P1

3BSE004939R1

3BSE004940R1

3ADC770030P5

5 STP 38 Q3600

SDCS-PIN-41 A

SDCS-PIN-51

170M 7978


NOTES

400V - 690V/50/60Hz





Thyristor



Semiconductor fuses

6

1

1

6

12

2

1

6

3ADC340084P1

3BSE004939R1

3ADT780007R1

3ADC770030P6

5 STP 38 Q3600

SDCS-PIN-41 A

SDCS-PIN-51-1190

170M 7589



NOTES

400V - 690V/50/60Hz



VI A A - 11




DESCRIPTION

Thyristor



2 Q

6

1

1

4 Q

12

2

1

CODE

3ADC340088P1

3BSE004939R1

3BSE004940R1

TYPE/DATA

T 989-3300-18

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses 6 6 DCA0012830P1 170M 7028



NOTES

400V - 690V/50/60Hz




Thyristor 6 12 3ADC340046P2 5 STP 3328 L0003



Semiconductor fuses

1

1

6

2

1

6

3BSE004939R1

3BSE004940R1

3ADC770030P2

SDCS-PIN-41 A

SDCS-PIN-51

170M 7156



NOTES

400V - 690V/50/60Hz




Thyristor



6

1

1

12

2

1

3ADC340046P2

3BSE004939R1

3BSE004940R1

5 STP 3328 L0003

SDCS-PIN-41 A

SDCS-PIN-51




NOTES

400V - 690V/50/60Hz




Thyristor



6

1

1

12

2

1

3ADC340084P1

3BSE004939R1

3BSE004940R1

5 STP 38 Q3600

SDCS-PIN-41 A

SDCS-PIN-51




NOTES

400V - 690V/50/60Hz




Thyristor 6 12 3ADC340083P1 5 STP 45 Q2800



Semiconductor fuses

1

1

6

2

1

6

3BSE004939R1

3BSE004940R1

3ADC770030P2

SDCS-PIN-41 A

SDCS-PIN-51

170M 7156



NOTES

400V - 690V/50/60Hz




Thyristor 6 12 3ADC340083P1 5 STP 45 Q2800



1

1

2

1

3BSE004939R1

3BSE004940R1

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses

Cooling fan

6

1

6

1

3ADC770030P2

3ADT754020P1

170M 7156

GR 35C


NOTES

400V - 690V/50/60Hz




Thyristor



Semiconductor fuses

Cooling fan

6

6

1

1

1

12

6

1

2

1

3ADC340083P1

3BSE004939R1

3BSE004940R1

3ADC770030P1

3ADT754020P1

5 STP 45 Q2800

SDCS-PIN-41 A

SDCS-PIN-51

170M 7057

GR 35C

NOTES

400V - 690V/50/60Hz




Item 25.00 to 38.00 Module DCS500B / DCS600 Size C4 2050A----5150A ; 400V - 1190V-AC

25.00

Common Parts for all C4 Mod. from 2050 ----5150 (Item 25.10 - 38.00)

DESCRIPTION



2 Q 4 Q

1

1

1

1

CODE

DCF1066659P1

DCA0012139P3

TYPE/DATA

P233 A-4 AHC

KTY 10-6 M4

NOTES

(C4 / 950mm cable )


25.10 DCSxxx-2050 (600V-690V-790V) CONVERTER Left & Right


Thyristor



6

1

1

12

2

1

DCA0016142P1

3BSE004939R1

3BSE004940R1

5STP16F2800

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses

*)Cooling fan (Bus Bars" L eft side")

*)Cooling fan (Bus Bars" R ight side")

6

1

1

6

1

1

DCA0017149P1

DCA0018692P1

DCA0012660P1

170M7031

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L

e.g. DCSxxx-2050-61 L 21P..

e.g. DCSxxx-2050-61

*) Select only one Cooling Fan for this C4 Modules; Please check Type designation or delivered Design about Busbar arrangment

R 21P..


26.00 DCSxxx-2050 (1000V) CONVERTER


Thyristor



6

1

1

12

2

1

DCA0012058P1

3BSE004939R1

3BSE004940R1

5STP18L3600

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses



6

1

1

6

1

1

DCA0012864P1

DCA0018692P1

DCA0012660P1

170M7510

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L

e.g. DCSxxx-2050-91 L 21P..

e.g. DCSxxx-2050-91


R 21P..


27.00 DCSxxx-2500 (400V-500V) CONVERTER


Thyristor


6

1

12

2

DCA0016169P1

3BSE004939R1

5STP24L2800

SDCS-PIN-41 A


Semiconductor fuses



1

6

1

1

1

6

1

1

3BSE004940R1

DCA0012848P1

DCA0018692P1

DCA0012660P1

SDCS-PIN-51

170M7034

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L

e.g. DCSxxx-2500-41 L 21P..

e.g. DCSxxx-2500-41


R 21P..



VI A A - 13





Thyristor 6 12 DCA0016169P1 5STP24L2800



Semiconductor fuses


1

1

6

1

2

1

6

1

3BSE004939R1

3BSE004940R1

DCA0012848P1

DCA0018692P1

SDCS-PIN-41 A

SDCS-PIN-51

170M7034

RG35P-4DK.7M.1R

e.g. DCSxxx-2500-x1 L 21P..

*)Cooling fan (Bus Bars" R ight side") 1 1 DCA0012660P1 RG35P-4DK.7M.1L

e.g. DCSxxx-2500-x1


R 21P..




Thyristor



6

1

1

12

2

1

DCA0012058P1

3BSE004939R1

3BSE004940R1

5STP18L3600

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses



6

1

1

6

1

1

DCA0012864P1

DCA0018692P1

DCA0012660P1

170M7510

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L


e.g. DCSxxx-2650-x1


R 21P..



DESCRIPTION

Thyristor


2 Q

6

1

4 Q

12

2

CODE

3ADC340070P1

3BSE004939R1

TYPE/DATA

5STP28L4200

SDCS-PIN-41 A

NOTES


Semiconductor fuses



1

1

1

6

1

6

1

1

3ADT780007R1

3ADC770025P1

DCA0018692P1

DCA0012660P1

SDCS-PIN-51-1190

170M7518

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L

e.g. DCSxxx-3200-x1 e.g. DCSxxx-3200-x1


L

R

21P..

21P..



DESCRIPTION 2 Q 4 Q

Thyristor 6 12

CODE

DCA0016169P1

TYPE/DATA

5STP24L2800

NOTES



1

1

2

1

3BSE004939R1

3BSE004940R1

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses


6

1

6

1

DCA0012848P1

DCA0018692P1

170M7034

RG35P-4DK.7M.1R

changed 09/02 ; bef. 170M7035 e.g. DCSxxx-3200-x1 L 21P..


e.g. DCSxxx-3200-x1


R 21P..




Thyristor



Semiconductor fuses

*)Cooling fan (Bus Bars"


L

R eft side") ight side")

6

1

1

6

1

1

12

2

1

6

1

1

DCA0012066P1

3BSE004939R1

3BSE004940R1

DCA0012872P1

DCA0018692P1

DCA0012660P1

5STP28L3600

SDCS-PIN-41 A

SDCS-PIN-51

170M7513

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..







Thyristor



6

1

1

12

2

1

3ADC340062P3

3BSE004939R1

3ADT780007R1

5STP38N4200

SDCS-PIN-41 A

SDCS-PIN-51-1190

Semiconductor fuses



6

1

1

6

1

1

DCA0012881P1

DCA0018692P1

DCA0012660P1

170M7520

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L


e.g. DCSxxx-3200-x1


R 21P..




Thyristor 6 12 DCA0016169P1 5STP24L2800



Semiconductor fuses


1

1

6

1

2

1

6

1

3BSE004939R1

3BSE004940R1

DCA0017271P1

DCA0018692P1

SDCS-PIN-41 A

SDCS-PIN-51

170M7035

RG35P-4DK.7M.1R



e.g. DCSxxx-3300-x1


R 21P..




Thyristor



Semiconductor fuses



L


6

1

1

6

1

1

12

2

1

6

1

1

DCA0016169P1

3BSE004939R1

3BSE004940R1

DCA0017271P1

DCA0018692P1

DCA0012660P1

5STP24L2800

SDCS-PIN-41 A

SDCS-PIN-51

170M7035

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..




Thyristor


6

1

12

2

DCA0016151P1

3BSE004939R1

TYPE/DATA

5STP27L1800

SDCS-PIN-41 A

NOTES


Semiconductor fuses



L


1

1

1

6

1

6

1

1

3BSE004940R1

DCA0012821P1

DCA0018692P1

DCA0012660P1

SDCS-PIN-51

170M7026

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..



VI A A - 15



DESCRIPTION

Thyristor



Semiconductor fuses


2 Q 4 Q

1

6

6

1

1

12

2

1

6

1

CODE

DCA0016177P1

3BSE004939R1

3BSE004940R1

DCA0012856P1

DCA0018692P1

TYPE/DATA

5STP33L2800

SDCS-PIN-41 A

SDCS-PIN-51

170M7036

RG35P-4DK.7M.1R

NOTES



e.g. DCSxxx-4000-x1


R 21P..



DESCRIPTION 2 Q 4 Q

Thyristor



Semiconductor fuses



1

6

6

1

1

1

12

2

1

6

1

1

CODE

DCA0016177P1

3BSE004939R1

3BSE004940R1

DCA0012856P1

DCA0018692P1

DCA0012660P1

TYPE/DATA

5STP33L2800

SDCS-PIN-41 A

SDCS-PIN-51

170M7036

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L

NOTES e.g. DCSxxx-4000-x1 e.g. DCSxxx-4000-x1


L

R

21P..

21P..



DESCRIPTION 2 Q 4 Q

Thyristor


6

1

12

2


Semiconductor fuses

1

6

1

6

CODE

DCA0012082P1

3BSE004939R1

3BSE004940R1

DCA0012881P1

TYPE/DATA

5STP38N3600

SDCS-PIN-41 A

SDCS-PIN-51

170M7520

NOTES



1

1

1

1

DCA0018692P1

DCA0012660P1

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..







Thyristor



Semiconductor fuses

6

1

1

6

12

2

1

6

DCA0016193P1

3BSE004939R1

3BSE004940R1

DCA0012856P1

5STP45N2800

SDCS-PIN-41 A

SDCS-PIN-51

170M7036



1

1

1

1

DCA0018692P1

DCA0012660P1

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..




Thyristor



Semiconductor fuses



L


6

1

1

6

1

1

12

2

1

6

1

1

DCA0016193P1

3BSE004939R1

3BSE004940R1

DCA0012856P1

DCA0018692P1

DCA0012660P1

5STP45N2800

SDCS-PIN-41 A

SDCS-PIN-51

170M7036

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L



L

R

21P..

21P..


38.00 DCSxxx-5150 (400 V-500 V) CONVERTER


Thyristor



6

1

1

12

2

1

DCA0016185P1

3BSE004939R1

3BSE004940R1

5STP45N2200

SDCS-PIN-41 A

SDCS-PIN-51

Semiconductor fuses



6

1

1

6

1

1

DCA0012830P1

DCA0018692P1

DCA0012660P1

170M7028

RG35P-4DK.7M.1R

RG35P-4DK.7M.1L


e.g. DCSxxx-5150-x1


R 21P..



VI A A - 17


Item 19.10 to 24.10 Modules DCS500B / DCS600 Size C3 900A----2000A

19.10


DCSxxx-900 (400V-500V) CONVERTER

DESCRIPTION 2 Q 4 Q

Thyristor



Semiconductor fuses

Cooling fan

1

6

6

1

1

12

2

1

6

1

CODE

DCA0012015P1

3BSE004939R1

3BSE004940R1

DCA0010683P1

3ADT754006P1

20.10

Module contains:


DESCRIPTION

Thyristor


2Q 4Q

2 Q

6

1

4 Q

12

2

CODE

DCA0012007P1

3BSE004939R1


Semiconductor fuses

Cooling fan

1

6

1

1

6

1

3BSE004940R1

DCA0012791P1

3ADT754006P1

21.10




Thyristor



Semiconductor fuses

Cooling fan

6

1

1

6

1

12

2

1

6

1

DCA0012015P1

3BSE004939R1

3BSE004940R1

DCA0010683P1

3ADT754006P1

22.10




Thyristor



Semiconductor fuses

Cooling fan

6

1

1

6

1

12

2

1

6

1

DCA0012031P1

3BSE004939R1

3BSE004940R1

3ADC770010P9

3ADT754006P1

23.10




Thyristor



Semiconductor fuses

Cooling fan

1

6

1

6

1

12

2

1

6

1

DCA0012023P1

3BSE004939R1

3BSE004940R1

DCA0012805P1

3ADT754006P1

TYPE/DATA

T589N18TOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6035

RD23P-4DW.4I.1R

TYPE/DATA

T459N24TOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6143

RD23P-4DW.4I.1R

TYPE/DATA

T589N18TOF

SDCS-PIN-41 A

SDCS-PIN-51

170M6035

RD23P-4DW.4I.1R

TYPE/DATA

5STP18F1800

SDCS-PIN-41 A

SDCS-PIN-51

170M6166

RD23P-4DW.4I.1R

NOTES

NOTES

NOTES

NOTES former Id. Nr.DCA0012741P1

TYPE/DATA

5STP16F2400

SDCS-PIN-41 A

SDCS-PIN-51

170L7299

RD23P-4DW.4I.1R

NOTES

24.10




Thyristor



Semiconductor fuses

Cooling fan

1

6

1

6

1

12

2

1

6

1

DCA0012031P1

3BSE004939R1

3BSE004940R1

3ADC770010P9

3ADT754006P1

TYPE/DATA

5STP18F1800

SDCS-PIN-41 A

SDCS-PIN-51

170M6166

RD23P-4DW.4I.1R

NOTES former Id. Nr.DCA0012741P1

If you have any questions concerning spare parts, please contact your local ABB-agent!






VI A A - 19

DCS 400

DC Drives Product Portfolio

The drive module for standard applications

●

Integrated field supply (max. 20 A)

● Accurate speed and torque control

● Extremely small and compact design

● Very easy installation and commissioning

● Express delivery

● Power range: 10...500 kW (13...670 HP)

DCS 500B / DCS 600 The drive module for demanding applications

● Free programming of software

● 6- and 12-pulse configuration up to 10 MW/

13,000 HP and more

●

Plain text display

● Power range: 10...5000 kW (13...6700 HP)

DCE 500 / DCE 600 Highly integrated panel

●

Excellent upgrade or revamp solution

●

Contains:

● DCS 500B / DCS 600 module

● AC fuses

● Auxiliary transformer

● Motor fan starter with protection

● Main contactor

●

Power range: 10...130 kW (26...300 HP)

DCS 400 / DCS 500

Easy Drive

The complete standard cabinet solution

● Pre-engineered

● Easy installation and commissioning

● Protection class: IP 21

●

Plain text display

●

Short delivery time

● Power range: 50...1350 kW (65...1800 HP)

DCA 500 / DCA 600 For complex, completely engineered Drive

System in common cabinet design

● Flexible and modular hardware structure

● 6- and 12-pulse configuration up to 18 MW/

23,000 HP and more

● Pre-programmed applications:

Metals, Cranes, P&P application, Mining

●

Power range: 10...18000 kW (13...23000 HP)

ABB Automation Products GmbH

Postfach 1180

68619 Lampertheim • GERMANY

Tel: +49 (0) 62 06-5 03-0

Fax: +49 (0) 62 06-5 03-6 09 www.abb.com/dc

*093R0701A4300000*

*093R0701A4300000*

ABB DCS 500B, DCS 600 MultiDrive Series Service Manual

DCS Thyristor Power Converters for DC Drive Systems

25 to 5200 A

Service Manual

DCS 500B

DCS 600 MultiDrive

DCS Thyristor Power Converters for DC Drive Systems

25 to 5200 A

Service Manual

DCS 500B

DCS 600 MultiDrive

Attention

Overview

Warnings

Safety Instructions

Notes

Mains connection

EMERGENCY STOP buttons

Intended use

Contents

S ERVICE M ANUAL

General

Chapter 1 - Introduction

How to use this manual

Contents of this manual

Target group

Associated publications

Storage and transport

Rating plate and type code

Chapter 2 - Fault Tracing Thyristors

How to detect, if a thyristor is faulty

How to find a faulty thyristor

General Instruction how to handle the Semiconductors

Chapter 3 - Handling the Semiconductors

Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b

Installation of thyristor modules in converters size C1/C2/C2b

(25...1000 A)

Chapter 5 - Exchange of Thyristors for Size A5

Installation of "Disc

Type" thyristor in converters size A5

(900...2000 A)

Chapter 6 - Exchange of Thyristors for Size A6

Installation of "Disc

Type" thyristor in converters size A6

(1900...3000 A)

Chapter 7 - Exchange of Thyristors for Size A7

Installation of "Disc

Type" thyristor in converters size A7

(2050...5200 A)

Chapter 8 - Exchange of Thyristors for Size C3

Installation of "Disc

Type" thyristor in converters size C3

(900...2000 A)

View from the left

Front view

Chapter 9 - Exchange of Thyristors for Size C4

Installation of "Disc

Type" thyristor in converters size C4

(2050...5150 A)

Chapter 10 - Service

Compatibility of SDCS-PIN-2 boards

Compatibility of thyristor modules for

DCSxxx-0200 and DCSxxx-0250

DC-Motor neutral zone adjustment

General

How to remove the converter fan in a frame A6

How to remove the converter fan in a frame A7

SDCS-CON-x Firmware download instructions for Windows 2000 and NT 4.0

DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows 2000

DCS600 MultiDrive - How to download firmware on a SDCS-AMC-DC 2 board under Windows NT 4.0

DCS600 MultiDrive - How to download parameter files on a SDCS-AMC-DC x board

Chapter 11 - Preventive Maintainance

Recommended regular maintenance

Appendix A - Spare Parts List

DC Drives Product Portfolio

Key Features

Related manuals

ABB

DCS 600 MultiDrive Series

ABB