ABB DCS800 Service manual

DCS800

Service manual

DCS800 Drives (20 to 5200 A)

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DCS800 Drive Manuals

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

2011 ABB Automation Products GmbH. All rights reserved.


DCS800 Drives

20 to 5200 A

Service Manual

Code: 3ADW000195R0501 Rev E

DCS800 Service Manual e e.doc

EFFECTIVE:

SUPERSEDES:

03.2011


Safety instructions

What this chapter contains

This chapter contains the safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

To which products this chapter applies

The information is valid for the whole range of the product DCS800, the converter modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the

Rebuild Kit DCS800-R00-9xxx.

Usage of warnings and notes

There are two types of safety instructions throughout this manual: warnings and notes. Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment, and advise on how to avoid the danger.

Notes draw attention to a particular condition or fact, or give information on a subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause

physical injury or death and/or damage to the equipment.

General danger warning warns about conditions, other than those

caused by electricity, which can result in physical injury or death and/or damage to the equipment.

Electrostatic sensitive devices warning warns of electrostatic

discharge which can damage the equipment.

5

Safety instructions


3ADW000195R0501 DCS800 Service Manual e e

6

Installation and maintenance work

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

WARNING!

•

Only qualified electricians are allowed to install and maintain the drive!

• Never work on the drive, motor cable or motor when main power is applied.

Always ensure by measuring with a multimeter (impedance at least

1 Mohm) that:

1.

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

2.

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

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

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

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

• When reconnecting the motor cable, always check that the C+ and

D- cables are connected with the proper terminal.

•

Note:

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

• Depending on the external wiring, dangerous voltages (115 V,

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

220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO).




Grounding

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

WARNING!

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

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

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

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

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

•

Note:

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

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

AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

7



8

Printed circuit boards and fiber optic cables

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

WARNING! The printed circuit boards contain components sensitive to

electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging

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




Mechanical installation

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

WARNING!

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

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

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

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding.

9



10

Operation

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

WARNING!

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

• Do not control the motor with the disconnecting device

(disconnecting mains); instead, use the control panel keys and

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

You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regulations, or a 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 disconnect must be locked in its

"OPEN" position during any installation and maintenance work.

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

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

"control panel" or "PC tool".

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.




11

Note:

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

LOC/REM key and then the stop key .



12




13

Table of contents

Safety instructions 5

What this chapter contains..........................................................................................................5

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

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

Installation and maintenance work..............................................................................................6

Grounding........................................................................................................................7

Mechanical installation ................................................................................................................9

Operation ..................................................................................................................................10

Table of contents 13

Introduction 16

How to use this manual.............................................................................................................16

Contents of this manual ............................................................................................................16

Target group .............................................................................................................................16

Associated publications ............................................................................................................16

Storage and transport ...............................................................................................................17

Name plate and type code ........................................................................................................17

Type code .................................................................................................................................18

Current and voltage ratings.......................................................................................................19

Fault Tracing Thyristors 21

Tools .........................................................................................................................................21

For commissioning and fault tracing..............................................................................21

Additionally for service and preventive maintenance ....................................................22

How to detect a faulty thyristor..................................................................................................22

A fuse is blown ..............................................................................................................22

DC-current pulses measured by an oscilloscope ..........................................................23

Thyristor diagnosis ........................................................................................................23

Ripple monitor ...............................................................................................................23

How to find a faulty thyristor......................................................................................................24

Converters size D1 to D4 (20...1000 A).........................................................................24

Blown fuses ...................................................................................................................24

Converters size D5, D6, and D7 (900...5200 A) ............................................................25

Blown fuses ...................................................................................................................25

Ripple monitor ...............................................................................................................25

Handling the Semiconductors 27

General Instruction how to handle the Semiconductors ...........................................................27

Exchange of Thyristors for Size D1 to D4 29

Installation of OnBoard bridge and thyristor modules in converters size D1 to D4

(20...1000 A) .............................................................................................................................29

Required Tools ..............................................................................................................29

Find faulty thyristor modules .........................................................................................29

Remove faulty thyristor modules ...................................................................................30

Install new thyristor modules .........................................................................................34

Table of contents



14

Remove faulty OnBoard bridge (V1) ............................................................................ 36

Install new OnBoard bridge (V1) .................................................................................. 36

OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units.......... 37

OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units.......... 38

OnBoard bridge and thyristor module terminals ........................................................... 39

Exchange of Thyristors for Size D5 41

Installation of "Disc Type" thyristor in converters size D5 (900...2000 A) ................................ 41

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

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

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

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

Install new thyristor....................................................................................................... 47


Installation of "Disc Type" thyristor in converters size D6 (1900...3000 A) .............................. 51

Required Tools ............................................................................................................. 51

Disk type thyristors ....................................................................................................... 52

BCT thyristors ............................................................................................................... 53


Remove faulty thyristor ................................................................................................. 55



Installation of "Disc Type" thyristor in converters size D7 (2050...5200 A) .............................. 65

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



Exchange of SDCS-CON-4 75

General .................................................................................................................................... 75

Required Tools ............................................................................................................. 75

Overview SDCS-CON-4 exchange............................................................................... 75

Service 83

How to remove the converter fans in frames D1 to D3 (two fans) ........................................... 83

How to remove the converter fans in a frame D3 (four fans) ................................................... 87

How to remove the converter fan in a frame D6 ...................................................................... 92

How to remove the converter fan in a frame D7 ...................................................................... 93

DCS800 firmware download .................................................................................................... 94

General ......................................................................................................................... 94

Download SDCS-CON-4 firmware................................................................................ 94

Add firmware or text files ............................................................................................ 107

Create a workspace.................................................................................................... 114

Download SDCS-COM-8 firmware ............................................................................. 129

Set type code ......................................................................................................................... 131

Type code table .......................................................................................................... 133

DC-Motor neutral zone adjustment ........................................................................................ 134

Types concerned ........................................................................................................ 134

Summary .................................................................................................................... 134

General ....................................................................................................................... 134

Table of contents



15

Preventive Maintenance 135

Recommended regular maintenance ......................................................................................136

Maintenance schedule ............................................................................................................136

Annual preventive maintenance..............................................................................................137

3 years preventive maintenance .............................................................................................140



Appendix A - Spare Parts List 145

Table of contents



16

Introduction

How to use this manual

The purpose of this service manual is to provide detailed information on how to service power converters from the DCS800 series.

Contents of this manual

Safety instructions

This chapter is located at the beginning of this manual.

Introduction

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.

Fault Tracing Thyristors

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

Handling the Semiconductors

This chapter describes the handling of thyristors and thyristor modules.

Exchange of Thyristors of Sizes D1 to D4

This chapter describes the exchange of thyristors in converters sizes D1 to D4.

Exchange of Thyristors of Size D5

This chapter describes the exchange of thyristors in converters size D5.


This chapter describes the exchange of thyristors in converters size D6.


This chapter describes the exchange of thyristors in converters size D7

Exchange of SDCS-CON-4

This chapter describes the exchange of a SDCS-CON-4

Service

This chapter contains hardware information and technical hints.

Preventive Maintenance

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.

Target group

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.

Associated publications

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

cover, see DCS800 Drive Manuals . Here is a list of the most important ones:



The DCS800 Hardware Manual (3ADW000194) describes all hardware

Introduction



17

components of the DCS800, their connections and settings (e.g. jumpers)



The DCS800 Firmware Description (3ADW000193) gives an overview of the

DCS800 firmware, describes all parameters, describes the function of the DCS

Control Panel, gives support in case of faults and alarms and gives information about communication.

The above listed documentation can be found on the CD-ROM being attached to the DCS800 Quick Guide (3ADW000191).

Storage and transport

If the unit has been in storage prior to installation or is transported to another location, care must be taken to ensure that the environmental conditions are complied with (see Hardware Manual).

Name plate and type code

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

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

ABB Automation Products

Type: DCS800-S02-0025-05

Ser No: 0025421A06294264

U1

I1 f1

SCCR

3  525 V

U2 610 V

20 A

50/60 Hz

65 kA

I2

I f

Fan

25 A

6 A

----

Made in Germany

+K454

+J409

Production year

2006 and week 29

Rated input voltage

Rated input current

Example of a name plate

Rated output current

Rated internal field exciter current

Rated fan voltage

Plus code

Introduction



18

Type code

The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. DCS800-S01-

2005). The optional selections are given thereafter, on the name plate by plus

Type code

Position

Position

A

Product series

Type

X

Y

ZZ

B code. The main selections are described below. Not all selections are available for all types.

Bridge type

Rated DC current

Rated AC voltage

Power connection

Internal field exciter configuration

Fan voltage

Current measurement

Voltage measurement

SDCS-DSL-4

D C S 8 0 0 - A A X - Y Y Y Y - Z Z - plus code

A X Y Z B

+S164

+0S163

+S171

+S172

+S175

+S186

+S180

+S181

+S182

+S183

+S189

+S199

+0S199

Plus code

DCS800

S0 = Standard converter module IP00

R0 = Rebuild system

E0 = Panel solution

A0 = Enclosed converter

1 = Single bridge (2-Q)

2 = 2 anti parallel bridges (4-Q)

YYYY = Rated current (e.g. 0025 = 25 ADC)

04 = 400 VAC

05 = 525 VAC

06 = 600 VAC

07 = 690 VAC

08 = 800 VAC

10 = 990 VAC

12 = 1200 VAC

- = Standard D1 ... D6

L = Left side D7

R = Right side D7 a = Second thyristor type D5, D6

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

Without internal field exciter (only D1 ... D4)

Size D4

Standard fan voltage: 230 V / 1-ph

Additional fan voltage: 115 V / 1-ph

Size D6

Standard fan voltage for 400 V / 500 V / 800 V units:

Standard fan voltage for 600 V / 690 V units:

Additional fan voltage for 600-690 V units:

SDCS-CMA-2 for sizes D5 to D7

120 V SDCS-SUB-4 for sizes D1 ... D4

600 V for sizes D6 and D7

690 V for sizes D6 and D7

800 V for sizes D6 and D7.

990 V for sizes D6 and D7.

Galvanic isolation for sizes D6 and D7

With SDCS-DSL-4

Without SDCS-DSL-4

400-500 V / 3-ph

525-690 V / 3-ph

400-500 V / 3-ph

+ plug-in options

DCS Control Panel

Fieldbus

I/O and DDCS

0J400

J409

K454

K451

K466

K458

L500

L501

L508

L509

Without DCS Control Panel

Door mounting Kit (cable length 3 m)

Profibus RPBA

DeviceNet RDNA

Ethernet IP + Modbus TCP RETA

Modbus RMBA

Analogue Extension RAIO

Digital Extension RDIO

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

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

Introduction



19

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.

Current and voltage ratings

Unit size 2-Q rated current

DCS800-01 [ADC]

D1 20

45

D2

D3

65

90

125

180

230

315

405

4-Q rated current

DCS800-02 [ADC]

25

50

Supply voltage [VAC]

400 525 600 690 800 990 1200

75

100 X

140 X

200 X

260 X

350 X X

450 X

D4

D5

D6

D7

470

610

740

900

900

1200

520

680

820

1000

X

X

X

X

X

900 X X

1200 X

1900

2050 2050

1

X

1

1900 X

2500

3000

2050

2600

3300

4000

4800

5200

1

only available as 2-Q drive

2500 X X X X X

3000 X X X X X

2050 X

2600 X

3300

4000

4800

X X X X X X X

X X X X X X X

X X X

5200 X

Introduction



20

Introduction



21

Fault Tracing Thyristors

Tools

For commissioning and fault tracing

Following software tools are mandatory:



DriveWindow Light including commissioning wizard and DWL AP for Adaptive

Program

and



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

Following tools are mandatory in addition to standard tools:



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



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



A voltmeter (at least CAT III 1000 V):



1000 V probes and test leads:



An ESD-field service kit (ABB Service

Finland code 0001ESD / MS-Antistatic):

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

Fault Tracing Thyristors


22

Additionally for service and preventive maintenance

Following additional tools are mandatory for cleaning:



An ESD safe blower / ESD vacuum cleaner (ABB Service Finland code

0006ESD / MUNTZ 555-ESD-S-E):

How to detect a faulty thyristor

Thyristor problems can be noticed differently:

A fuse is blown

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



An internal short circuit between the phases (line side) because of a defective 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 defective).



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



A commutation fault during generating (active braking with high current, high

EMF and with low AC voltage) of a 4-Q converter.

Note:

In case of parallel fuses: If one of the parallel fuses is blown, all parallel fuses have to be changed. The ‘undamaged’ fuses might be ‘half-blown’ and will blow with the next high current.




DC-current pulses measured by an oscilloscope

Connect an oscilloscope to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or

X4:5/6 on the SDCS-IOB-3) and check for the proper amount of current pulses:

23

Six current pulses in positive direction

There should be six current pulses in positive direction.

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

Thyristor diagnosis

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



Switch the drive to local mode (DriveWindow, DriveWindow Light, DCS Control

Panel or local I/O).



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



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



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

Ripple monitor

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

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

 

90°.

The reason for a current less thyristor may be:



24



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 or does not react to firing pulses.



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



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

How to find a faulty thyristor

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

In general, make sure, that all safety instructions, given within this manual or within the safety instructions, related to the machine or the application itself, are obeyed.

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

These converters require semiconductor fuses in the 3 AC lines.



The converter must be disconnected from the mains.



One motor armature cable should be disconnected from the converter.

Blown fuses



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 picture

Anti-parallel B6-bridges with

branching fuses

on page 45). Normally, every measurement should show high

resistance (> 1 k



).



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



) (destroyed thyristor).



If the converter is designed with half-bridge thyristor modules, then a module consists of two anti-parallel 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



result for a short time.

The measurement, showing less resistance than 1



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




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

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



The converter must be disconnected from the mains.

Blown fuses



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

Anti-parallel

B6-bridges with branching fuses on page 45).



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



For 4-Q converters with anti-parallel thyristors or BCT’s:



The selection of a forward or reverse thyristor or BCT

(Bidirectional-Controlled-Thyristor) is done during the disassembly. Continue with related part Exchange of Thyristors

for Size

D5

,

D6 or

D7

section Find faulty thyristor.



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

Ripple monitor

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



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



If the power section seems to be ok, but still one or more thyristors don’t take current, something went wrong in between the firing pulse generation and the thyristor’s gate; in this case check:



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 transferred 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.

25



26




27

Handling the Semiconductors

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.

In converters sizes D5 (900 ... 2000 A), D6 (1900 ... 3000 A) and D7 (2050 ... 5200

A) the mounting force is indicated by an indicating spring welded to the mounting clamp, which is inside the unit.

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

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

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

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

1.

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

2.

Use protective gloves if possible.

3.

Clean work area and hands frequently.

4.

Use good illumination.

Handling the Semiconductors



28

Handling the Semiconductors



29

Exchange of Thyristors for Size D1 to D4

Installation of OnBoard bridge and thyristor modules in converters size

D1 to D4

(20...1000 A)

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

Required Tools

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



Torx screwdrivers:



Torque spanner:

TX10, TX20, TX25 mounting torques for the OnBoard bridge and the thyristor modules to heat sink and electrical connections see table

Nominal mounting torque for

OnBoard bridge and thyristor modules

on page 35



Screws are metric type; use appropriate nuts



Tissue paper



Solvent (e.g. ethanol)



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)


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

Find faulty thyristor modules

See

Fault Tracing Thyristors

of this publication.

Exchange of Thyristors for Size D1 to D4



30

Remove faulty thyristor modules

1.

Remove the DCS Control Panel and design cover:

Remove DCS Control Panel

Depress the locks by means of a screwdriver to remove the design cover

Remove design cover

2.

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

 serial communication modules (R-type),

 extension

I/O modules (RAIO, RDIO),

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

 communication

board (SDCS-COM-8)

,

 isolated I/O (SDCS-IOB-2x, SDCS-IOB-3) and



SDCS-MEM-8 (Memory Card).

3.

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

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

Remove plug in options




4.

Disconnect all I/O plugs (X3 to X7) at the SDCS-CON-4 and the plugs at the

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

31

Disconnect all plugs from SDCS-

CON-4 and SDCS-DSL-4 boards

Disconnect all plugs

5.

Remove the grounding plug and the holding screw at the electronic tray:

Remove the grounding plug and the holding screw

Remove grounding and screws




32

6.

To unhinge the electronic tray including the SDCS-CON-4 pull it up and then out. Before remove tray completely unplug the flat cables (X12, X13, X37):

Electronic tray with SDCS-CON-4

Remove flat cables

Unhinge electronic tray

7.

Remove all cables and plugs at the SDCS-PIN-4:

Keep winding direction and amount of windings for T100

T100 in mind.

Remove all cables and plugs

How to handle X8:

X8 use screw driver

Remove cables at the SDCS-PIN-4

Attention:

Write down the winding direction of the cable through T100!

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

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




8.

Remove the SDCS-PIN-4 board:

OnBoard field exciter bridge module

Thyristor modules

Snubber resistor

33

Current transformer Temperature sensor

Remove SDCS-PIN-4

9.

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

10.

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

11.

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

Note:

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

12.

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




34

Install new thyristor modules

1.

Ensure that the new thyristor module is of the correct type (

see appendix A

of this manual).

2.

Remove old heat conducting compound (grease) from the heat sink. Clean the mounting surfaces (heat sink and thyristor module) with an appropriate solvent

(e.g. ethanol) by means of tissue paper. When the heat sink is clean, spread out the heat conducting compound with a rubber spatula or by hand.

3.

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

Application of heat conducting compound

4.

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

5.

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

Note:

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

6.

Tighten the screws to nominal torque according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

page 35.




35

OnBoard

bridge

and thyristor modules

Size Type

Nominal mounting torque

29 mm bridge block VVZF 70-16

20 mm block SKKT 27, 42, 57, 106

20 mm block

34 mm block

MCC 26, 44, 56, 95

MCC 162

connections

-

3 Nm

2.5 ... 4 Nm

4.45 … 5.5 Nm

to heat sink

5 Nm

5 Nm

2.5 ... 4 Nm

2.25 … 2.75 Nm

34 mm block

34 mm block

50 mm block

50 mm block

SKKT 162

TT 162

MCC 255

TT 250, 330

5 Nm

6 Nm

11 … 13 Nm

12 Nm

5 Nm

6 Nm

4.5 … 7 Nm

6 Nm

60 mm block TT 425, 570 12 Nm 6 Nm


7.

Reinstall the current transformer, make sure, its position is correct.

8.

Reinstall the busbars, make sure, the correct torque is applied according to table


on page 35.

9.

Reconnect all gate leads to the thyristor module.

10.

Reinstall the SDCS-PIN-4 board.

11.

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

 snubber resistor (X30, X31),

 temperature sensor (X22),

 current transformers (X3, X4, X5),



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

 gate leads (first X16, X18 then X15, X17),



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

 all plugs (X10, X96, X99) and

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

12.

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

13.

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

14.

Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7) and the plugs at the

SDCS-DSL-4 (X51 to X54).

15.

Reinstall the intermediate cover, all plug in options and the design cover.




36

Remove faulty OnBoard bridge (V1)

1.

Follow the instructions

Remove faulty thyristor modules

until step 8 is done.

2.

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

3.

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

Install new OnBoard bridge (V1)

1.

Ensure that the new OnBoard bridge is of the correct type (

see appendix A

of this manual).

2.

Remove old heat conducting compound (grease) from the heat sink. Clean the mounting surfaces (heat sink and OnBoard bridge) with an appropriate solvent

(e.g. ethanol) by means of tissue paper. When the heat sink is clean, spread out the heat conducting compound with a rubber spatula or by hand.

3.

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

4.

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

5.

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

6.

Tighten the screws to nominal torque according to table


on page 35.

7.

Reconnect all connectors to the OnBoard bridge.

8.

Follow the instructions Install new thyristor modules

beginning with step 10.




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

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

V1 V1

37

V14/V11

4 2 3 1

V16/V13

4 2 3 1

V12/V15

4 2 3 1

V14/V11

V16/V13 V12/V15

V1

V14/V11

G1 K1

DCS800-S01-0315 ... 0470

V12/V15 V16/V13

G1 K1

V1

V14/V11

DCS800-S01-0610 ... 0900

V16/V13 V12/V15

DCS800 loc of mod 1Q.dsf

Location of the OnBoard bridge and thyristor modules in DCS800-S01 (2-Q) units

Note:

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




38

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

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

V1 V1

V14/V21 V16/V23 V12/V25

V14/V21

4 2 3 1

V16/V23

4 2 3 1

V12/V25

4 2 3 1

1 3 2 4

V11/V24

1 3 2 4

V13/V26

1 3 2 4

V15/V22

V11

V24

G1

G2

K1

K2

A

V1

K

DCS800-S02-0350 ... 0520

AK

AK K A

K2

G2

G1

K1

V14

V21

V15

V22

K2

G2

K1

G1

A K AK

AK K A

K2

G2

G1

K1

V12

V25

V13

V26

K2

G2

K1

G1

A K AK

AK K A

K2

G2

G1

K1

V16

V23

V11/V24

V1

V13/V26

V15/V22

V24/V11

DCS800-S01-0680 ... 1000

V26/V13 V22/V15

V21/V14

V23/V16

V25/V12

DCS800 loc of mod 4Q.dsf

Location of the OnBoard bridge and thyristor modules in DCS800-S02 (4-Q) units

Note:

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




OnBoard bridge and thyristor module terminals

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

OnBoard bridge and all thyristor modules.

For all firing pulse cables is valid:

Yellow is gate lead.

Red is cathode lead.

39

(AK) (K)

1 2

5 4

VVZF 70-16

6 7

(A)

3

(AK) (K)

1 2

4 5

7

6

(A)

3

1

2 3

7 G

6 K

5 K

4 G

SKKT 27, 42, 57, 106

1 2 3

6 G

7 K

4 K

5 G

MCC26, 44, 56, 95

(AK)

1

(K)

2

5 4

7 6

(A)

3

6 7

1

2 3

MCC162

5 4

SKTT 162

6 7

4 5




40

A K

K

K1

G1 K2 G2

A

A K

K

K1 G1

A K

K

A

TT 162

K2

G2

K2 G2

K1 G1

A

(A)

3

6G 7K

MCC255

5G 4K

AK K

K2

A

G2 3 2

TT 250, 330 TT 425, 570

Terminals of the OnBoard bridge and all thyristor modules

1

5G

4K

6G

7K




41

Exchange of Thyristors for Size D5

Installation of "Disc Type" thyristor in converters size D5 (900...2000 A)

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

Required Tools




Torx TX10,



Torque spanner for electrical connections: 13 Nm (M8)

TX25

50



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

Note:

3ADT 621 023 P1

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

Manual.

Therefore strict observance of the build in instructions given below is of utmost importance. Make sure that the new component can replace the old one in

accordance with the spare part list ( see Appendix A ).

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 completely from the power supply then check the voltage free condition and make sure, everything is located in an electrically and mechanically safe condition!

Exchange of Thyristors for Size D5



42

Disk type thyristors

Some converter modules size D5 are equipped with different disc type thyristors.

For easy identification the name plate of the converter module is marked with “

a

” after the voltage identification:

Converter with original thyristor type T459Nxxx

Id code: DCA0012007P0001

DCS800-S01-0900-06

DCS800-S02-0900-06

DCS800-S01-0900-07

DCS800-S02-0900-07

U

1

3 ~ 600 VAC

3 ~ 600 VAC

3 ~ 690 VAC

3 ~ 690 VAC

Converter with second thyristor type T460Nxxx

Id code: 3ADC340105P0001

DCS800-S01-0900-06

a

DCS800-S02-0900-06

a

DCS800-S01-0900-07

a

DCS800-S02-0900-07

a

Converter with original thyristor type T589Nxxx

Id code: DCA0012015P0001

DCS800-S01-1200-04

U

1

3 ~ 400 VAC

Converter with second thyristor type T590Nxxx

Id code: 3ADC340106P0001

DCS800-S01-1200-04

a

DCS800-S02-1200-04

DCS800-S01-1200-05

3 ~ 400 VAC

3 ~ 525 VAC

DCS800-S02-1200-04

a

DCS800-S01-1200-05

a

DCS800-S02-1200-05

Parts list

3 ~ 525 VAC DCS800-S02-1200-05

a

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

Attention: Use always the correct spare thyristor!

Original thyristor type (900 A)

Converter with original thyristor type T459Nxxx Id code: DCA0012007P0001

Original thyristor type




Gate (G):

Cathode (HK):

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm

Conductive plate: Diameter 36 mm

Second thyristor type (900 A)

Converter with second thyristor type T460Nxxx Id code: 3ADC340105P0001

43

Second thyristor type

Gate (4): Round terminal D = 1.5 mm

Cathode (5): Faston 4.8 x 0.5 mm


Original thyristor type (1200 A)

Converter with original thyristor type T589Nxxx Id code: DCA0012015P0001





44

Gate (G):

Cathode (HK):

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm


Second thyristor type (1200 A)

Converter with second thyristor type T590Nxxx Id code: 3ADC340106P0001


Gate (4): Round terminal D = 1.5 mm

Cathode (5): Faston 4.8 x 0.5 mm





Find faulty thyristor

1.

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

Anti-parallel B6-bridges with

branching fuses

on page 45)

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

Anti-parallel B6-bridges with branching fuses

2.

Disconnect the branching fuses of the defective branches.

3.

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

4.

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

Note:

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

45




46

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 fig.

Aluminum spring with welded indicating spring

on page 47) at the top of the thyristor stack.

Attention: While loosen the mounting clamp the indicating spring must be pulled

out a little, otherwise the spring will be damaged!

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

How to use the disassembly tool

page 46).

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

Front view

How to use the disassembly tool

Disassembly tool

View from the right mountcl_b.dsf




47

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

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





48

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 fig.


on page 47). Do not tighten the screws any

further.

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

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

View from the right




U1 V1 W1

rear

left stack

front

V11

V13

V15

View from the left Front view


View from the right right stack

front rear

V14

V16

V12

49




50

U1

V1

W1

D1 (-)

C1 (+)

Location of branch fuses frame D5




51




Required Tools




Torx TX10,




TX25

50
















(grease)





Disassembly tool

Note:

DCF 1066721 P1


Manual.


accordance with the spare part list ( see Appendix A)

.






52

Disk type thyristors

Some converter modules size D6 are equipped with different disc type thyristors.

For easy identification the name plate of the converter module is marked with “a” after the voltage identification:

Converter with original thyristor type T 1329Nxxx

Id code: 3ADC340081P0001

DCS800-S01-1900-08

DCS800-S02-1900-08

DCS800-S01-2050-05

DCS800-S02-2050-05

DCS800-S01-2050-06

U

1

3 ~ 800 VAC

3 ~ 800 VAC

3 ~ 525 VAC

3 ~ 525 VAC

3 ~ 600 VAC

Converter with second thyristor type T 1xxx-24

Id code: 3ADC340098P0001

DCS800-S01-1900-08

DCS800-S02-1900-08

DCS800-S01-2050-06

a a

DCS800-S01-2050-05

a

DCS800-S02-2050-05

a a

DCS800-S02-2050-06

DCS800-S01-2050-07

3 ~ 600 VAC

3 ~ 690 VAC

DCS800-S02-2050-06

DCS800-S01-2050-07

a a

DCS800-S02-2050-07 3 ~ 690 VAC

DCS800-S02-2050-07

a

Parts list

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

Attention: Use always the correct spare thyristor!

Original thyristor type

Thyristor T 1329Nxxx with Id code 3ADC340081P0001





Gate (4):

Cathode (5):

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm


Second thyristor type

Thyristor T 1xxx-24 with Id code 3ADC340098P0001

53


Gate (y): Round terminal D = 1.5 mm

Cathode (K

1

): Faston 4.8 x 0.5 mm


BCT thyristors

In some converter modules size D6 so called BCT’s (Bidirectional-Controlled-

Thyristors) 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.

Faston 4.8 x 0.5

Gate A

Faston 6.3 x 0.8

Gate B

Gate B

BCT.dsf

Gate A

Gates of BCT




54

Note:

The Faston connectors of the gates are of different size.

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

Location of BCT’s gate A when built in


1.

Find the defective branches by performing an OHM test (both polarities)

between U1, V1, W1 and C1, D1 (see picture


on page 45).

2.

Disconnect the branching fuses of the defective branches.

3.


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 which thyristor is broken change only one thyristor, clamp the heat sinks again and repeat step three.




55


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

Location of the DC - busbar plates

Note:

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




56

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.

4.


5.

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

Handling of indicating spring and mounting clamp

Attention: While loosen the mounting clamp the indicating spring must be pulled


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

6.

Pull out both DC-busbar plates.

DCbusbar plates

DC-busbar plates




7.

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

57

push down push down

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





58


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:


2.


Prepare disk type thyristor

3.


4.


Note:


5.

Turn the thyristor so that the gate leads point in the right direction. When changing BCT’s make sure, that gate A is in front (see fig.

Gates of BCT

on

page 53).

6.


7.

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




DC-busbar plates and heatsinks

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.

9.


59

Torque indicating spring loose condition

Mounting clamp; loose condition

Note:


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.




60

Torque indicating spring correct torque

Mounting clamp, correct torque

Note:


11.


12.

Reconnect all other dismantled parts.

13.





61

front

Stack

rear

C1(+)

V11

V24

U1

V21

V14

D1(-)

V16

V23

V1

V26

V13

C1(+)

V15

V22

W1

D1(-)

V25

V12


A6_thyr_locat.dsf

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




62

front

stack

rear

C1(+)

V11 / V24

U1

V14 / V21

D1(-)

V16 / V23

V1

V13 / V26

C1(+)

V15 / V22

W1

D1(-)

V12 / V25


A6_thyr_locat.dsf

Location of thyristors in frame D6 (4-Q bridge with BCT’s)




63

front

stack

rear

C1(+)

V11

U1

V14

D1(-)

V16

V1

V13

C1(+)

V15

W1

D1(-)

V12


A6_thyr_locat.dsf

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




64

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

Location of parallel branch fuses frame D6




65




Required Tools


 screwdrivers: TX10,




50
















(grease)





Disassembly tool:

Note:

DCF 1066721 P1


Manual.


accordance with the spare part list ( 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.






66


1.

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


on page 45).

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

Location of busbars

DC 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.

5.


2 - quadrant converter:

3.






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

67

Backplate

3.

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

4.


5.

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

Handling of indicating spring and mounting clamp




68

Attention: While loosen the mounting clamp the indicating spring must be pulled


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

6.

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

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






1.

Ensure that the new thyristor is of the correct type (

see appendix A

of this manual). Keep the semiconductor and its surroundings clean. If necessary clean them with a piece of tissue paper moistened with solvent.

Note:


2.


69

Prepare disk type thyristor

3.


4.


Note:


5.

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

6.


7.





70

loose condition

Torque indicating spring

Mounting clamp; loose condition

Note:


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.




71

Torque indicating spring correct torque

Mounting clamp; correct torque

Note:


9.


10.

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

11.





72

V11

V24

V13

V26

V15

V22

V21 V21

V14 V14

V 23 V23

V16 V16

V25 V25

V12 V12

A ssemb ly D7

B usba rs o n th e ri ght ;

D7_ass.dsf

A ssemb ly D7

B usba rs o n th e lef t; vie w f ro m the fr ont view from the front


V11 V11

V14 V 14

V13 V 13

V16

V 16

V15 V15

V12

V12

V15

V22

V11

V 24

V 13

V26

A ssemb ly D7

B usba rs o n th e ri ght ;

D7_ass.dsf

A ssemb ly D7

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





73

F14

U1

AC-busbar

F11

F16

V1

AC-busbar

F13

F12

W1

AC-busbar

F15

D1(-)

DC-busbar

A7_branch_fuse_lopcat.dsf

C1(+)

DC-busbar

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




74

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

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




Exchange of SDCS-CON-4

General

All DCS800 size D1 to D7 are equipped with the same controller board SDCS-

CON-4, thus the exchange of the board is similar for all module sizes.

Required Tools

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



Torx screwdrivers: TX10, TX20, TX25

Overview SDCS-CON-4 exchange

1.

Save parameters,

2.

Write down type code of the drive,

3.

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

4.

Exchange the SDCS-CON-4,

5.

Set type code of the drive,

6.

Enable application program and

7.

Download and compare parameters.

1.

Save parameters

Parameters can be saved by various means:

DCS Control

Panel

75



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



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

Exchange of SDCS-CON-4


76

DriveWindow

Light



Press Soft key 2 (MENU),



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



Confirm with Soft key 2 (ENTER),



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



Successful upload will be shown by message,



Confirm with Soft key 1 (OK),



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



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



Click File then Save As…



Click Save:

DriveWindow



Click File then Parameters and Save As…






Click Save:

2.

Write down type code of the drive

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

3.

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

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

CON-4 accordingly.

4.

Exchange the SDCS-CON-4

Remove the 1.

Remove the DCS Control Panel and design cover: old SDCS-

CON-4

Remove DCS Control Panel

77

Depress the locks by means of a screwdriver to remove the design cover

Remove design cover

2.

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

 serial communication modules (R-type),




78

 extension

I/O modules (RAIO, RDIO),

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

 communication

board (SDCS-COM-8)

,

 isolated I/O (SDCS-IOB-2x, SDCS-IOB-3) and



SDCS-MEM-8 (Memory Card).

3.

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

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

Remove plug in options

4.

Disconnect all I/O plugs (X3 to X7) at the SDCS-CON-4 and the plugs at the

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

Disconnect all plugs from SDCS-

CON-4 and SDCS-DSL-4 boards

Disconnect all plugs




5.

Remove screws and studs:

79

Remove screws and studs

6.

Unplug the flat cables (X12, X13, X37):

Unplug the flat cables




80

Install the new SDCS-

CON-4

1.

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

2.

Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7) and the plugs at the

SDCS-DSL-4 (X51 to X54) and

3.

Reinstall the intermediate cover, all plug in options and the design cover.

5.

Set type code of the drive

Follow the instructions in chapter

Set type code

.

6.

Enable application program

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



ParApplSave (16.06) = EnableAppl

7.

Download and compare parameters

Parameters can be downloaded and compared by various means:

DCS Control

Panel

DriveWindow

Light



Press Soft key 1 until the main menu is shown,



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



Press Soft key 2 (MENU),



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



Confirm with Soft key 2 (ENTER),



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



Successful download will be shown by message,



Confirm with Soft key 1 (OK),



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



Press Soft key 1 until back to the main menu and



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



Click File then Open…



Choose correct parameter file and click Open:




81



Click Drive then Parameters & Signals and Download All Parameters



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

DriveWindow Light and compare drive memory the downloaded parameter set.

Click Drive then Parameters & Signals and Compare…




82

DriveWindow



Click File then Parameters and Download…



Click Open and follow the instructions:



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

DriveWindow and compare drive memory the downloaded parameter set. Click

File then Parameters and Compare…




83

Service

How to remove the converter fans in frames D1 to D3 (two fans)

Converters types DCS800-S01-0045-0x to DCS800-S02-0350-0x using two 115

VAC fans. Depending on the supply voltage they are either connected in series, for

230 VAC. or in parallel, for 115 VAC:

Fan configuration D1 to D3

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

230 VAC:

With a supply voltage of 230 VAC fans M55 and M56 are connected in series.

Consequently both fans have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. In this case both fans have to be changed.

115 VAC:

With a supply voltage of 115 VAC all fans are connected in parallel. Thus it is possible to change only the broken fan.



Service

84

Removing the converter fans

1.

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

X2 on the top of the converter housing:

Remove

DCS Control Panel

Design cover

Service



2.

Remove the two fan arrangement screws:

85

Fan arrangement

3.

Move the fan arrangement forward:

Move fan arrangement



Service

86

4.

Remove the fan holding screws:

Fan holding screws

5.

Remove Faston plugs and fans:

Faston plugs

6.

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

Service



87

How to remove the converter fans in a frame D3 (four fans)

Converters types DCS800-S01-0405-0x to DCS800-S02-0520-0x using four 115

VAC fans. Depending on the supply voltage they are either connected in series, for

230 VAC. or in parallel, for 115 VAC:

Fan configuration D3

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

230 VAC:

With a supply voltage of 230 VAC fans M55 and M56 are connected in series as well as fans M57 and M58. Consequently fans connected in series have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. Always change the two fans connected in series.

115 VAC:

With a supply voltage of 115 VAC all fans are connected in parallel. Thus it is possible to change only the broken fan.



Service

88

Removing the converter fans

1.

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

X2 on the top of the converter housing:

Design cover

Remove

DCS Control Panel

Service



2.

Remove the two fan arrangement screws:

89

Fan arrangement

3.

Move the fan arrangement forward:

Move fan arrangement



Service

90

4.

Remove the fan holding screws:

Fan holding screws

Service



5.

Remove Faston plugs and fans:

91

Faston plugs

6.

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



Service

92

How to remove the converter fan in a frame D6

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

Converter fan in frame D6

Service



How to remove the converter fan in a frame D7

1.

Remove the three screws at the bottom of the fan.

2.

Disconnect the cables.

3.

Pull the fan out.

cables

Converter fan in frame D7

screws

93



Service

94

DCS800 firmware download

General

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

SDCS-COM-8.

Download SDCS-CON-4 firmware

Requirements:



The Hitachi Flash Development Toolkit 2.2 has to be installed.



A recent workspace including firmware file and text file should be saved on the

PC.

Workspaces

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

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

Firmware / text file

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

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

Service



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

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

95



Service

96

Download firmware file

The firmware download is done via a PC COM Port.

Attention:

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

Adapters USB to COM Port do not work reliable.

The download of the firmware is done in two steps:

1.

first the firmware file itself and

2.

then the text file.

Attention:

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



De-energize the DCS800 electronics



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

2

S5

4

1 3



Connect a RS232 cable between a PC COM Port and DCS800 X34



Energize the DCS800 electronics, the 7-segment display shows:

Service



Start download tool:



Start the Hitachi Flash Development Toolkit 2.2 by means of

Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development

Toolkit 2.2

97

Choose workspace:



Mark Open an existing Workspace,



Confirm with OK



Service

98



Select the workspace in directory:




Confirm with Open

Activate firmware download:



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

Service



99

Choose COM Port and communication speed:



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



Select the Communications tap, choose the desired COM Port, un-tick the box

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

38400.



Service

100

Download firmware file to device:



Select desired firmware with a right mouse click and choose Download File to

Device from the pop up menu

Service



101

Disconnect tool:



After the download is complete the FDT2.2 has to be disconnected. Select

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



Service

102

Download text file:



De-energize the DCS800 electronics



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

2

1

S5

4

3



Energize the DCS800 electronics. In case the 7-segment display shows a the firmware’s corresponding text file has to be downloaded from the workspace.

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

Activate text download:



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

Service



103

Choose COM Port and communication speed:



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



Select the Communications tap, choose the desired COM Port, un-tick the box

Use default baud from the pop up menu and set the Target Baud Rate.

Attention:



For firmware version 80x130/80x130Demo and higher set the Target Baud

Rate to 38400.



Service

104

Download text file to device:



Select desired text file with a right mouse click and choose Download File to

Device from the pop up menu



After the download is complete the 7-segment display shows a:

Attention:

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



Wait until the 7-segment display shows:

and

Service



105

Disconnect tool:



Now FDT2.2 has to be disconnected. Select Text with a right mouse click and choose Disconnect from the pop up menu



Service

106

Close download tool



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

The firmware download is complete now.

Service



Add firmware or text files






Toolkit 2.2

107

Choose workspace:



Mark Open an existing Workspace,



Confirm with OK



Service

108



Select the workspace in directory:




Confirm with Open

Service



Add firmware files

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

109



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



Service

110



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



Choose the desired firmware file and press Open:

Service



111

Add text files

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



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



Service

112



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



To display the desired text file write

*.*

in File name and press Open:

Service





Choose the desired text file and press Open:

113

Close download tool:



When closing the FDT2.2 confirm with Yes

Adding of files is complete now.



Service

114

Create a workspace

General

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

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






Toolkit 2.2

Create new workspace:



Choose File



New Workspace…

Service



Name new workspace:



Name the new workspace,

 choose its location and

 confirm with OK



Choose Yes

115



Service

116

Create the project for the firmware file:



Name the new project and

 confirm with Next

Service



Choose Device And Kernel:



Select Device: H8S/2633F and


117



Service

118

Communication Port:



Select the proper COM port,



Select Baud Rate: 38400,

 un-tick Use Default Baud Rate and


Service



Device Settings:



Enter the CPU crystal frequency for the selected device: 6.25 MHz,



Select the multiplier for the main clock frequency (CKM): 4 and


119



Service

120

Connection Type:



Select connection: BOOT Mode,



Select Interface: Direct Connection,

 un-tick Kernel already resident and


Service



Programming Options:



Protection: Automatic and



Messaging: Advanced,

 confirm with Finish

121

Now the project for the firmware file is finished:



Service

122

Create the project for the text file:



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



Name the new project and


Service



Choose Device And Kernel:



Select Device: H8S/2633F and


123



Service

124

Communication Port:



Select the proper COM port,



Select Baud Rate: 38400,

 un-tick Use Default Baud Rate and


Service



Device Settings:



Enter the CPU crystal frequency for the selected device: 6.25 MHz,



Select the multiplier for the main clock frequency (CKM): 4 and


125



Service

126

Connection Type:



Select connection: BOOT Mode,



Select Interface: Direct Connection,

 tick Kernel already resident and


Service



Programming Options:



Protection: Automatic and



Messaging: Advanced,

 confirm with Finish

127

Now the project for the text file is finished:



Service

128

Close download tool:



When closing the FDT2.2 confirm with Yes

Creating of projects is complete now.

Service



129

Download SDCS-COM-8 firmware

Requirements:



In case the PCMCIA adapter NDPA-02 with NDPC-12 is used the NtNisa drivers have to be installed (see NtNisa5x.zip or NtNisa5x.exe) before downloading the firmware.



In case the USB adapter RUSB-02 is used together with DriveWindow 2.22

(and higher) and firmware package COM-8 88x160.zip (and higher) no additional actions have to be taken.

Firmware download:



Close all applications especially DriveWindow and DriveWindow Light!



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



Following files and folders will be created:



Service

130



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

1.

PCMCIA adapter NDPA-02 with NDPC-12 or

2.

USB adapter RUSB-02



Switch on the DCS800



Set Ch3 HW Config (70.21) = Ring



Set Ch3 NodeAddr (70.22) = 1



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



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

Attention:

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



Check Com8SWVersion (4.11) for proper firmware version



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



Set Ch3 NodeAddr (70.22) back to its original setting



Re-connect the drive to the DriveWindow network

Service



131

Set type code

The type code - TypeCode (97.01) - is preset in the factory and is write protected.

It identifies the drives current-, voltage-, temperature measurement and its quadrant type. The type code can be changed as whole or individually.

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

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

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

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

Product family: DCS800

Bridge type:

Module type:

X

YYYY

Rated AC Voltage: ZZ

= R0 Rebuild system

= E0 Panel solution

= A0 Enclosed converter

= 1 single bridge (2-Q)

= 2 2 anti parallel bridges (4-Q)

= converter type current

= 04 230 VAC - 400 VAC

= 05 230 VAC - 525 VAC

= 06 270 VAC - 600 VAC

= 07 315 VAC - 700 VAC

= 08 360 VAC - 800 VAC

= 10 450 VAC - 990 VAC

= 12 540 VAC - 1200 VAC

Power connection: B = - Standard D1 - D6

= L Left side D7

= R Right side D7

= a Second thyristor type D5, D6

Attention:

When using D1, D2, D3 or D4 modules the current and voltage range of the type code setting is limited to max 1000 ADC and max 600 VAC.

 the change of the type code is immediately taken over and ServiceMode

(99.06) is automatically set back to NormalMode

 the new values can be seen in group 4

ConvNomCur (4.05),

ConvNomVolt (4.04),

MaxBridgeTemp (4.17) and

QuadrantType (4.15)



Service

132

To change the type code individually follow the instructions below:

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

 set the type code individually by means of

S ConvScaleCur (97.02),

S ConvScaleVolt (97.03),

S MaxBrdgTemp (97.04) and

S BlockBridge2 (97.07)

 the change of the type code is immediately taken over and ServiceMode

(99.06) has to be set back to NormalMode by the user

 the new values can be seen in group 4

ConvNomCur (4.05),

ConvNomVolt (4.04),

MaxBridgeTemp (4.17) and

QuadrantType (4.15)

Service



Type code table

25

S01-0740-04

26

S01-0740-05

27

S01-0900-04

28

S01-0900-05

29

S01-0900-06

30

S01-0900-07

31

S01-1200-04

32

S01-1200-05

33

S01-1500-04

34

S01-1500-05

35

S01-1500-06

36

S01-1500-07

37

S01-1900-08

38

S01-2000-04

39

S01-2000-05

40

S01-2000-06

41

S01-2000-07

42

S01-2050-05

43

S01-2050-06

44

S01-2050-07

45

S01-2500-04

46

S01-2500-05

47

S01-2500-06

48

S01-2500-07

49

S01-2500-08

4

5

6

7

8

9

0

1

2

3

None

S01-0020-04

S01-0020-05

S01-0045-04

S01-0045-05

S01-0065-04

S01-0065-05

S01-0090-04

S01-0090-05

S01-0125-04

10

S01-0125-05

11

S01-0180-04

12

S01-0180-05

13

S01-0230-04

14

S01-0230-05

15

S01-0315-04

16

S01-0315-05

17

S01-0290-06

18

S01-0405-04

19

S01-0405-05

20

S01-0470-04

21

S01-0470-05

22

S01-0590-06

23

S01-0610-04

24

S01-0610-05

75

S01-5200-05

76

S02-0025-04

77

S02-0025-05

78

S02-0050-04

79

S02-0050-05

80

S02-0075-04

81

S02-0075-05

82

S02-0100-04

83

S02-0100-05

84

S02-0140-04

85

S02-0140-05

86

S02-0200-04

87

S02-0200-05

88

S02-0260-04

89

S02-0260-05

90

S02-0350-04

91

S02-0350-05

92

S02-0320-06

93

S02-0450-04

94

S02-0450-05

95

S02-0520-04

96

S02-0520-05

97

S02-0650-06

98

S02-0680-04

99

S02-0680-05

50

S01-2050-10

51

S01-2600-10

52

S01-2600-12

53

S01-3000-04

54

S01-3000-05

55

S01-3000-06

56

S01-3000-07

57

S01-3000-08

58

S01-3300-04

59

S01-3300-05

60

S01-3300-06

61

S01-3300-07

62

S01-3300-08

63

S01-3300-12

64

S01-4000-04

65

S01-4000-05

66

S01-4000-06

67

S01-4000-07

68

S01-4000-08

69

S01-3300-10

70

S01-4000-10

71

S01-4800-06

72

S01-4800-07

73

S01-4800-08

74

S01-5200-04

S02-2500-06

S02-2500-07

S02-3000-06

S02-3000-07

S02-2500-08

S02-3000-08

S02-3300-04

S02-3300-05

S02-3300-06

S02-3300-07

S02-3300-08

S02-3300-12

S02-4000-04

S02-4000-05

S02-4000-06

S02-4000-07

S02-4000-08

S02-3300-10

S02-4000-10

S02-4800-06

S02-4800-07

S02-4800-08

S02-5200-04

S02-5200-05

S01-4000-12

S02-4000-12

S02-0820-04

S02-0820-05

S02-1000-04

S02-1000-05

S02-0900-06

S02-0900-07

S02-1200-04

S02-1200-05

S02-1500-04

S02-1500-05

S02-1500-06

S02-1500-07

S02-1900-08

S02-2000-04

S02-2000-05

S02-2050-05

S02-2050-06

S02-2050-07

S02-2500-04

S02-2500-05

S02-2050-10

S02-2600-10

S02-2600-12

S02-3000-04

S02-3000-05

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

125

126

127

128

129

130

131

132

133

134

135

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

100

101

102

103

104

105

106

107

108

109

133



Service

134

DC-Motor neutral zone adjustment

Types concerned

DC-Motors

Summary

Procedure to adjust the neural zone of a DC-motor

General



Loosen the bolts holding the brush bridge.



Connect a scope or a voltmeter between two adjacent brush-holder assemblies

(holders with different polarity).



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



Disconnect the excitation cables and connect 110 – 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 50 mV AC. The smaller the better.



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



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

Service



135

Preventive Maintenance

WARNING! Before performing any maintenance the chapter ‘Safety

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

WARNING! The printed circuit boards contain components sensitive to

electrostatic discharge. Use an

ESD-field service kit

when handling the boards. Do

not touch the boards unnecessarily.

Handling the boards:

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

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

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

Preventive Maintainance



136

Recommended regular maintenance

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

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

Harsh environment

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

Maintenance schedule




137

Annual preventive maintenance

The following actions have to take place:



Check the cooling fans of units D1 to D7.

The lifetime of the cooling fan is about 30,000 to 45,000 hours depending on the converter type. The actual lifetime depends on the usage of the DCS and the ambient temperature.

Fan failure can be 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.



Check the cooling air pressure switch of units D6 and D7.

Cooling air pressure switch

Actions:



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.



Start the drive.



The air pressure switch is ok when the converter is switched off by F527

ConvFanAck - see ConvFanAck (10.30). Crosscheck this result with the

module’s door closed.

Attention:

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



Check for tightness of heatsink terminals of units D7.

The thyristors together with the heatsinks are stacked. Every single thyristor is connected to the DC+ and DC- busbars via flexible copper busbars. These busbars consist of 10 layers of pre-shaped sheet copper. This construction is able to compensate for small changes in length caused by temperature rise when current is flowing. The screw fixings between heatsink and flexible copper busbar have to withstand different types of mechanical stress.

Therefore each fixing needs to be checked for correct torque.

Actions:



Make sure all supply voltages are switched off, most important the supply for the power part (armature), for the drive electronics (SDCS-POW-4), for the converter fan and for other auxiliaries!



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.




138



Check the torque of the screws marked within picture

Power part of a converter module type D7

on page 138.



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.

Power part of a converter module type D7






Check the door air filters.

Door filters

Clocked up filters prevent proper cooling of the drive. Wash dirty filters with water (60°C) and detergent.



Check for dust, corrosion and temperature inside the module / cabinet.

The DCS will run into overtemperature faults if the heatsinks are not clean.

139

Heatsink

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

Use an

ESD vacuum cleaner

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

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




140

Ground components



Check the quality of the supply voltage.

3 years preventive maintenance

Following additional actions have to take place:



Replace the cooling fans of units D6 and D7.



How to remove the converter fan in a frame D6



How to remove the converter fan in a frame D7

The manufacturers estimation for the operational time of the cooling fan is:



GR31M:



GR35C:

30,000 hours at 40°C (D6)

30,000 hours at 40°C (D7)

The mayor problem is the failure of the bearings.

Typical lifetime of the cooling fan versus ambient temperature




141

DCS800-S0x-1900-y4/5/8…

DCS800-S0x-3000-y/5/8

DCS800-S0x-1900-y6/7

DCS800-S0x-3000-y6/7

D6 GR31M

400 … 500 V

D6 GR31M

500 … 690 V

DCS800-S0x-3300-y1…

DCS800-S0x-5200-y1

D7 GR35C

400 V / 690 V

Aging of the components result in:

1.

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

2.

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



Check the tightness of all terminals.

All connections should be inspected and checked for tightness.



Check the condition of the contactors and relays.

Relays

Contactors and relays should be checked for proper function.



Check the fiber optic cables and their connections.





Replace the cooling fans of units D1 to D5.



How to remove the converter fans in frames D1 to D3 (two fans)



How to remove the converter fans in a frame D3 (four fans)

The manufacturers estimation for the operational time of the cooling fan is:





W2E200:



CN2B2:



D2E160:

40,000 hours at 60°C

45,000 hours at 60°C hours

30,000 hours at 40°C




142

The mayor problem is the failure of the bearings.

Typical lifetime of the cooling fan versus ambient temperature

DCS800-S0x-0045-y1…

DCS800-S0x-0140-y1

DCS800-S0x-0180-y1…

DCS800-S0x-0260-y1

DCS800-S0x-0315-y1…

DCS800-S0x-0350-y1

DCS800-S0x-0405-y1…

DCS800-S0x-0520-y1

DCS800-S0x-0610-y1…

DCS800-S0x-0820-y1

DCS800-S0x-0610-y1…

DCS800-S0x-0820-y1

DCS800-S0x-0900-y1…

DCS800-S0x-1000-y1

D4

D4

D4

1x W2E200 (230 V)

1x W2E200 (115 V)

(plus code E171)

1x W2E250 (230 V)

DCS800-S0x-0900-y1…

DCS800-S0x-1000-y1

DCS800-S0x-0900-y1…

D4 1x W2E250 (115 V)

(plus code E171)

D5 D2E160

DCS800-S0x-2000-y1

Aging of the components result in:

1.

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

2.

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








Replace the power interface board SDCS-PIN-4 of units D1 to D4.

143

SDCS-PIN-4

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

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

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

Where used:

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

Aging of the electronic card result in:

1.

Damage other devices

2.

Trip the drive and cause break-down time



Replace the power supply board SDCS-POW-4 of units D5 to D7 and DCS800-

R (Rebuild- and Upgrade Kits).

SDCS-POW-4




144

The SDCS-POW-4 is located between the module door on the electronic tray.

It operates continuously, because it supplies the drive electronics even when the armature current is switched-off. Therefore all its components are exposed to hot conditions.

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

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

Where used:

DCS800-S0x-1000, …, DCS800-S0x-5200

Aging of the electronic card result in:

1.

Damage other devices

2.

Trip the drive and cause break-down time



Check the flat cables and their connections.

D5 to D7 and DCS800-R




Appendix A - Spare Parts List

Item

8.03

8.04 - 8.05

8.06

8.07

8.08

8.09

10.00 - 29.00

30.00 - 36.00

40.00 - 49.00

50.00 - 65.00

Content

Control Panels and plug-in options D1 - D7

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

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

Common parts for DCS800-A0 Enclosed Converters

Parts for DCS800-R0 Rebuild Kit

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

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

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

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

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

Item 8.03


145

8.03


DESCRIPTION QTY CODE

DCS Control Panel 1 3ADT220129R0002

CDP312RD Control Panel

DCSLink board

DDCS communication board

DDCS communication board

PROFIBUS-DP

DeviceNet

Modbus

CANopen

ControlNet

Ethernet Adapter Module

EtherCat Adapter Module

Analog I/O Extension

Digital I/O Extension

Pulse Encoder Interface (12 V)

Pulse Encoder Interface (TTL)

I/O Extension Adapter

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

3ADT220071R0006

3ADT200005R0001

3ADT220134R0001

3ADT220134R0002

3AFE64606859

3AFE64606891

3AFE64606778

3AFE64606905

3AFE64751701

3AFE64751727

3AUA0000045102

3AFE64606841

3AFE64606816

3AFE64610805

3AFE68654947

3AFE68286778

Item 8.04 to 8.05

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

8.04

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

DESCRIPTION QTY CODE TYPE/DATA

FEX-425-Int, 1-Q, 25 A 1 3ADT209022R0001 FEX-425-Int

Fuses for FEX-425-Int

DCF803-0016, 1-Q, 16 A

DCF803-0035, 1-Q, 35 A

Semiconductor fuses field





3

3

3

1

3

3

1

3

3ADC770032P0025

3ADT209027R0001

3ADT209023R0001

3ADT730004R0001

3ADT730004R0002

3ADT730004R0003

3ADT730004R0004

3ADT730004R0005

KTK 25

DCF803-0016

DCF803-0035

UR 10A / 660V

UR 16A / 660V

UR 25A / 660V

UR 50A / 660V

UR 63A / 660V

TYPE/DATA

DCS-CP-P

CDP312RD Rev.G

SDCS-DSL-4

SDCS-COM-81

SDCS-COM-82

RPBA-01

RDNA-01

RMBA-01

RCAN-01

RCNA-01

RETA-01

RECA-01

RAIO-01

RDIO-01

RTAC-01

RTAC-03

AIMA-01

NOTES

Control Panel for DCS800

Possible via SDCS-COM-8 only

(+S199)

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

(+L509), 5 Mbd (fieldbus)

(+K454)

(+K451)

(+K458)

(+K457)

(+K462)

(+K466)

(+K469)

(+L500)

(+L501)

(+L502)

(+L517)

NOTES

Internal field exciter for D5

25 A / 600 V

Complete unit

Complete unit

For fieldcurrent >= 6 ADC





Appendix A - Spare Parts List



146

8.05

Field exciters 50 A and 60 A, overvoltage protection included

DESCRIPTION

DCF503B0050, 1-Q, 50 A

QTY

1

CODE

3ADT209019R0201

TYPE/DATA

DCF503B0050

DCF504B0050, 4-Q, 50 A 1 3ADT209019R0202 DCF504B0050

DCF503B0060, 1-Q, 60 A

DCF504B0060, 4-Q, 60 A

Fan for DCF50xB0060

1

1

2

3ADT209019R0211

3ADT209019R0212

GHSN700002P0001

DCF503B0060

DCF504B0060

AC220V 8556V

Item 8.06

NOTES

Complete unit

Complete unit

Complete unit

Complete unit

Fan M55/M56 for DCF50xB0060


8.06


DESCRIPTION QTY CODE TYPE/DATA NOTES

Control board DCF505/506 1 3ADT220090R0021 SDCS-FEP-1 (1400 V) for DCF505/506

Overvoltage protection field

Overvoltage protection field

1

1

DCF1127101R0001

DCF1127119R0001

DCF506-0140-51

DCF506-0520-51

Field exciter 25 A - 100 A

Field exciter 200 A - 520 A

Item 8.07

Common parts for DCS800-A Enclosed Converters

8.07

Common parts for DCS800-A Enclosed Converters

DESCRIPTION QTY CODE

DI/DO connection board 1 3ADT220090R0014

DI/DO connection board

DI/DO connection board

AI/AO connection board

1

1

1

3ADT220090R0013

3ADT220090R0023

3ADT220090R0020

TYPE/DATA

SDCS-IOB-21

SDCS-IOB-22

SDCS-IOB-23

SDCS-IOB-3

NOTES

24 VDC - 48 VDC, digital (A9)

115 VAC, digital (A9)

230 VAC, digital (A9)

Analog and encoder (A10)

Item 8.08

Parts for DCS800-R Rebuild Kit

DCR-Kit contains:

Pulse interface board

2-Q 4-Q

8.08

Parts for DCS800-R Rebuild Kit

DESCRIPTION 2-Q 4-Q

1 1

Pulse amplifier board

Pulse distribution board

Power supply for SDCS-REB-2

Pulstransformer board

Power interface board

Current transformer 2500 / 1 A


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

2

1

1

1

1

2

2

1

2

2

1

1

1

2

2

1

CODE

3ADT220090R0009

3ADT220090R0034

3ADT309300R0001

3ADT200003P0001

3ADT220090R0043

3ADT220090R0006

3ADT751010P0001

3ADT751007P0001

3ADT209022R0001

TYPE/DATA

SDCS-REB-1

SDCS-REB-2

SDCS-REB-3

QUINT-240/24/2A

SDCS-PIN-48

SDCS-PIN-51

LT2032 2500/1A

4000/1A

FEX-425-Int

NOTES

115 - 240 VAC / 24 VDC

SDCS-PIN-48 replaces SDCS-PIN-41

For 400 VAC - 1000 VAC

T51 / T52 for D5 and D6

T51 / T52 for D7

Internal field exciter for Rebuild Kit




147

Item 8.09

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

8.09

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

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

Current measurement aid 1 1 3ADT220090R0022 SDCS-CMA-2 For D5 - D7 (12-pulse, hardparrallel)

Insulation monitor

Insulation monitor

Insulation monitor

Voltage adaption for IRDH

Voltage adaption for IRDH

DC-DC transducer (Knick) A92

1

1

1

1

1

1

1

1

1

1

1

1

DCA0019192P0001

3ADV050058P0005

3ADV050058P0001

DCA0019711P0001

3ADV050058P0002

3ADN260008P0001

IRDH 265-4

IRDH 365-4

IRDH 265-3

AGH 204 S

AGH 150 W-4

P42000D3-0111

Inside cabinet, 10 - 990 kOhm

Door mounted, 10 - 990 kOhm

Inside cabinet EMBR, 2 - 200 kOhm

For IRDH >= 690 VAC, 6-pulse

For IRDH >= 690 VAC, 12-pulse

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

8680 A1/A92

High volt. transformer T90

High volt. fuses for U >= 750 VAC

High volt. fuses for U >= 750 VAC

Power Interface U>=750 VAC

Hardparrallel board 1

Hardparrallel board 2

1

1

1

3

2

1

1

1

1

3

2

1

3ADT745047P0001

3ADV050092P0015

3ADV050092P0017

3ADT780007R0002

3ADT220090R0031

3ADT220090R0032

Item 10.00 to 29.00

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

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

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

CC 1551CP 10A/1500V 2 for A92

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

SDCS-PAR-1 Hardparallel master

SDCS-PAR-2 Hardparallel slave

10.00

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

DESCRIPTION 2-Q 4-Q CODE

Control board 1 1 3ADT313900R1501

Interface board and field supply

Fuses on SDCS-PIN-4

Half controlled bridge block

Temperatur sensor (D1and D2)

Temperatur Sensor (D3 and D4)

1

3

1

1

1

1

3

1

1

1

3ADT314100R1001

3ADC770032P0025

3ADC340091R0001

3ADT710005P0001

3ADT710005P0002

TYPE/DATA

SDCS-CON-4

SDCS-PIN-4

KTK 25

VVZF 70-16xxx

KTY10-6-M4/250mm

KTY10-6-M4/400mm

NOTES

Replaces 3ADT313900R1001

OnBoard field up to 525 VAC

25 A / 600 V

OnBoard field up to 525 VAC

20 A - 260 A, cable 250 mm

315 A - 1000 A, cable 400 mm

Module contains: 2-Q 4-Q

11.00

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

DESCRIPTION 2-Q 4-Q CODE TYPE/DATA

Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340063P0001

3ADT730004R0004

SKKT27B/xxx

UR 50 A / 660 V

Semiconductor fuses (as field) 3 3 3ADV050169P0050 UR 50 A / 600 V

NOTES

MCC 26 - 16 xxx

Blade- or knife fuse

When used as field in D6 or D7 cabinets


12.00

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


Thyristor modules 3 6 3ADC340063P0001 SKKT27B/xxx

Semiconductor fuses

Cooling fan 115 V, 50/60 Hz

Semiconductor fuses (as field)

3

2

3

3

2

3

3ADT730004R0005

3ADT754014P0001

3ADV050169P0080

UR 63 A / 660 V

CN2B2

UR 80 A / 600 V

NOTES

MCC 26 -16 xxx


4715 MS-12T-B5Axxx



13.00

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


Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340067P0001

3ADT730004R0007

SKKT42B/xxx

UR 125 A / 660 V



2

3

2

3

3ADT754014P0001

3ADV050169P0125

CN2B2

UR 125 A / 600 V

NOTES

MCC 44 -16 xxx


4715 MS-12T-B5Axxx





148

Module contains:

Thyristor modules

2-Q 4-Q

14.00

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


3 6 3ADC340068P0001 SKKT57B/xxx

Semiconductor fuses

Cooling fan 115V, 50/60Hz


3

2

3

3

2

3

3ADT730004R0007

3ADT754014P0001

3ADV050092P0036

UR 125 A / 660 V

CN2B2

UR 200 A / 660 V

NOTES

MCC 56 -16 xxx


4715 MS-12T-B5Axxx



15.00

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


Thyristor modules 3 6 3ADC340064P0001 SKKT106B/xxx

Semiconductor fuses


3

2

3

2

3ADT730004R0008

3ADT754014P0001

UR 200 A / 660 V

CN2B2

NOTES

MCC 95 -16 xxx


4715 MS-12T-B5Axxx

Module contains:

Thyristor modules

2-Q 4-Q

16.00

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


3 6 3ADC340064P0001 SKKT106B/xxx

Semiconductor fuses



3

2

3

3

2

3

3ADT730004R0009

3ADT754014P0001

3ADV050169P0250

UR 250 A / 660 V

CN2B2

UR 250 A / 660 V

NOTES

MCC 95 -16 xxx


4715 MS-12T-B5Axxx



17.00

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


Thyristor modules 3 6 3ADC340094P0001 MCC162-16xxx

Semiconductor fuses


3

2

3

2

3ADT730004R0010

3ADT754014P0001

UR 315 A / 660 V

CN2B2

NOTES

TT 162 Nxxx


4715 MS-12T-B5Axxx

Module contains:

Semiconductor fuses


2-Q 4-Q

18.00

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


Thyristor modules 3 6 3ADC340096P0001

3

2

3

2

3ADT730004R0012

3ADT754014P0001

TYPE/DATA

MCC 224-xxx

UR 500 A / 660 V

CN2B2

NOTES


4715 MS-12T-B5Axxx


19.00

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


Thyristor modules 3 6 GHSN610089P0002 TT250 Nxxx

Semiconductor fuses



3

2

3

3

2

3

3ADT730004R0013

3ADT754014P0001

3ADV050092P0032

UR 700 A / 660 V

CN2B2

UR 450 A / 660 V

NOTES

MCC 255 - xxx


4715 MS-12T-B5Axxx





149


20.00

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


Thyristor modules 3 6 GHSN610089P0002 TT250 Nxxx

Semiconductor fuses


3

4

3

4

3ADT730004R0013

3ADT754014P0001

UR 700 A / 660 V

CN2B2

NOTES

MCC 255 - xxx


4715 MS-12T-B5Axxx

Module contains:

Thyristor modules

2-Q 4-Q

21.00

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


3 6 3ADC340092P0001 TT330 Nxxx

Semiconductor fuses


3

4

3

4

3ADT730004R0013

3ADT754014P0001

UR 700 A / 660 V

CN2B2

NOTES

MCC 312 - xxx


4715 MS-12T-B5Axxx


22.00

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


Thyristor modules 3 6 3ADC340097P0001

Semiconductor fuses


3

1

3

1

3ADT730004R0014

DCA0012171P0001

TYPE/DATA

SKKT 430/20xxx

UR 900 A / 660 V

W2E 200-HH38-06

NOTES

TT430 Nxxx, MT3-430-xx



23.00

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


Thyristor modules 3 6 3ADC340097P0001 SKKT 430xxx

Semiconductor fuses


3

1

3

1

3ADT730004R0014

3ADT754012P0001

UR 900 A / 660 V

W2E 200-HH86-14

NOTES

TT430 Nxxx, MT3-430-xx


(+S171)


24.00

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


Thyristor modules

Semiconductor fuses

3

3

6

3

3ADC340032P0001

3ADT730004R0015

TT 425 Nxxx

UR 900 A / 660 V


Fuses as Enclosed Converter

1

3

1

3

DCA0012171P0001

DCA0012724P0001

W2E 200-HH38-06

170M6813

MCC 501 - xxx

Screw type fuse

NOTES

Fuses as Enclosed Converter with OESA


25.00

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

DESCRIPTION

Thyristor modules

2-Q 4-Q

3 6

CODE

3ADC340066P0001

TYPE/DATA

TT 570 Nxxx

Semiconductor fuses



3

1

3

3

1

3

3ADT730004R0015

DCA0012171P0001

DCA0012724P0001

UR 900 A / 660 V

W2E 200-HH38-06

170M6813

MT3-595-xxx

Screw type fuse

NOTES





150


26.00

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


Thyristor modules 3 6 3ADC3400066P0001 TT 570 Nxxx

Semiconductor fuses



3

1

3

3

1

3

3ADT730004R0016

3ADT754017P0001

3ADV050092P0020

UR 1250 A / 660 V

W2E250-HL06-10

170M6016

MT3-595-xxx

Screw type fuse

NOTES


Module contains:

Thyristor modules

2-Q 4-Q

27.00

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


3 6 3ADC340032P0001 TT 425 Nxxx MCC 501 - xxx

Semiconductor fuses



3

1

3

3

1

3

3ADT730004R0015

3ADT754012P0001

DCA0012724P0001

UR 900 A / 660 V

W2E 200-HH86-14

170M6813

NOTES

Screw type fuse

(+S171)



28.00

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


Thyristor modules 3 6 3ADC3400066P0001 TT 570 Nxxx MT3-595-xxx

Semiconductor fuses 3 3 3ADT730004R0015 UR 900 A / 660 V Screw type fuse



1

3

1

3

3ADT754012P0001

DCA0012724P0001

W2E 200-HH86-14

170M6813

NOTES

(+S171)



29.00

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


Thyristor modules 3 6 3ADC3400066P0001 TT 570 Nxxx MT3-595-xxx

Semiconductor fuses



3

1

3

3

1

3

3ADT730004R0016

3ADT754015P0001

3ADV050092P0020

UR 1250 A / 660 V

W2E250-HL08-09

170M6016

NOTES

Screw type fuse

(+S171)


Item 30.00 to 36.00

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

30.00

Common parts for modules D5, 900 A - 2000 A

DESCRIPTION

Control board

2-Q 4-Q

1 1

CODE

3ADT313900R1501

Power supply board

Puls transformer board


Temperatur sensor (R57)


Cooling fan

1

2

1

1

1

1

1

2

1

1

2

1

3ADT315100R1001

3ADT220090R0043

3ADT220090R0006

3ADT710003P0001

3ADT751010P0001

3ADT754018P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4

SDCS-PIN-48

SDCS-PIN-51

KTY 2K-M4-800

LT2032 2500/1A

D2E 160-AH02-15

NOTES

Replaces 3ADT313900R1001






Module contains:

Semiconductor fuses

2-Q 4-Q

31.00

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


Thyristor 6 12 DCA0012007P0001 T459Nxxx

6 6 3ADC770009P0007 UR 630 A / 1250 V


31.00a

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


Thyristor

Semiconductor fuses

6

6

12

6

3ADC340105P0001

3ADC770009P0007

T460Nxxx

UR 630 A / 1250 V

NOTES second thyristor type

Screw type fuse


32.00

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


Thyristor 6 12 DCA0012015P0001 T589Nxxx

Semiconductor fuses 6 6 3ADC770010P0005 UR 800 A / 660 V

NOTES original thyristor type

Screw type fuse


32.00a

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


Thyristor 6 12 3ADC340106P0001 T590Nxxx



Screw type fuse

Module contains:

Semiconductor fuses

2-Q 4-Q

33.00

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


Thyristor 6 12 3ADC340102P0001 T2 XXX-xx

6 6 3ADC770010P0009 UR 1250 A / 660 V


Screw type fuse

Screw type fuse

NOTES

Module contains:

Semiconductor fuses

2-Q 4-Q

34.00

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


Thyristor 6 12 3ADC340098P0001 T1 XXX-xx

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

NOTES

Module contains:

Semiconductor fuses

2-Q 4-Q

35.00

Thyristor

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

DESCRIPTION 2-Q 4-Q

6 12

CODE

3ADC340102P0001

TYPE/DATA

T2-XXX-xx

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

NOTES

Module contains:

Semiconductor fuses

2-Q n.a.

36.00

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

DESCRIPTION 2-Q n.a.

CODE

Thyristor 6 --3ADC340090P0001

6 --3ADC770009P0013

TYPE/DATA

TV 989-2700-xxx

UR 1400 A / 1100 V Screw type fuse

NOTES

151




152

Item 40.00 to 49.00

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

40.00



Control board 1 1 3ADT313900R1501

Power supply board


Air Flow detector (P1)

Temperatur Sensor (R57)


1

1

1

1

2

1

1

1

1

2

3ADT315100R1001

3ADT220090R0006

DCF1066659P0001

DCA0012139P0004

3ADT751010P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4

SDCS-PIN-51

P 233A-4-AHC

KTY 10-6 M4

LT2032 2500/1A

NOTES

Replaces 3ADT313900R1001 cable 1200 mm



41.00

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


Thyristor 6 12 3ADC340081P0001


Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3ADT220090R0043

3ADC770009P0007

3ADT754008P0001

TYPE/DATA

T 1329Nxxx

SDCS-PIN-48

UR 630 A / 1250 V

GR31M-..(500V)



Screw type fuse (double fuses)

400 V - 500 V / 50/60 Hz


41.00a

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


Thyristor


6

1

12

2

3ADC340098P0001

3ADT220090R0043

T 1xxx-24

SDCS-PIN-48

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770009P0007

3ADT754008P0001

UR 630 A / 1250 V

GR31M-..(500V)


SDCS-PIN-48


400 V - 500 V / 50/60 Hz

Thyristor


42.00

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


6 12 3ADC340081P0001


Semiconductor fuses

Cooling fan

1

6

1

2

6

1

3ADT220090R0043

3ADC770010P0011

3ADT754008P0001

TYPE/DATA

T 1329Nxxx

SDCS-PIN-48

UR 1500 A / 660 V

GR31M-..(500V)



Screw type fuse

400 V - 500 V / 50/60 Hz


42.00a

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


Thyristor 6 12 3ADC340098P0001 T 1xxx-24


Semiconductor fuses

Cooling fan

1

6

1

2

6

1

3ADT220090R0043

3ADC770010P0011

3ADT754008P0001

SDCS-PIN-48

UR 1500 A / 660 V

GR31M-..(500V)


SDCS-PIN-48

Screw type fuse

400 V - 500 V / 50/60 Hz





43.00

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


Thyristor 6 12 3ADC340081P0001 T 1329Nxxx


Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3ADT220090R0043

3ADC770009P0008

3ADT754008P0002

SDCS-PIN-48

UR 700 A / 1250 V

GR31M-..(690V)




525 V - 690 V / 50/60 Hz

153

Thyristor


43.00a

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


6 12 3ADC340098P0001 T 1xxx-24


Semiconductor fuses

Cooling fan

1

12

1

2

12

1

3ADT220090R0043

3ADC770009P0008

3ADT754008P0002

SDCS-PIN-48

UR 700 A / 1250 V

GR31M-..(690V)


SDCS-PIN-48


525 V - 690 V / 50/60 Hz


44.00

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

DESCRIPTION

Thyristor for DCS800-S01, 2-Q


2-Q 4-Q

6

-

-

6

CODE

3ADC340089P0001

3ADC340079P0001

TYPE/DATA

T 989-3030xxx

5 STB 24-Qxxx



1

-

-

2

3ADT220090R0043

3BSE004939R1003

SDCS-PIN-48

SDCS-PIN-46

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770010P0006

3ADT754008P0001

UR 900 A / 660 V

GR31M-..(500V)

NOTES

B

idirectional-Controlled-Thyristor (BCT)

SDCS-PIN-48 replaces SDCS-PIN-41 only used for BCT's


400 V - 500 V / 50/60 Hz

Module contains:

Semiconductor fuses

2-Q 4-Q

45.00

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

DESCRIPTION





2-Q 4-Q

6

-

1

-

-

6

-

2

CODE

3ADC340090P0001

3ADC340079P0001

3ADT220090R0043

3BSE004939R1003

TYPE/DATA

TV 989-2700-2xxx

5 STB 24-Qxxx

SDCS-PIN-48

SDCS-PIN-46

12 12 3ADC770009P0011 UR 1000 A / 1250 V

Cooling fan 1 1 3ADT754008P0002 GR31M-..(690V)

NOTES

B




525 V - 690 V / 50/60 Hz


46.00

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

DESCRIPTION





2-Q 4-Q

6

-

1

-

-

6

-

2

CODE

3ADC340087P0001

3ADC340079P0001

3ADT220090R0043

3BSE004939R1003

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770009P0011

3ADT754008P0001

TYPE/DATA

TV 989-2770xxx

5 STB 24-Qxxx

SDCS-PIN-48

SDCS-PIN-46

UR 1000 A / 1250 V

GR31M-..(500V)

NOTES

B




400 V - 500 V / 50/60 Hz




154

Cooling fan


47.00

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

DESCRIPTION





2-Q 4-Q

6

-

1

-

-

-

6

2

CODE

3ADC340088P0001

3ADC340079P0001

3ADT220090R0043

3BSE004939R1003

TYPE/DATA

T 989-3300xxx

5 STB 24-Qxxx

SDCS-PIN-48

SDCS-PIN-46


1 1 3ADT754008P0001 GR31M-..(500V)

NOTES

B




400 V - 500 V / 50/60 Hz


48.00

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

DESCRIPTION





2-Q 4-Q

6

-

1

-

-

-

6

2

CODE

3ADC340046P0002

3ADC340079P0001

3ADT220090R0043

3BSE004939R1003

TYPE/DATA

5STP 3328Lxxx

5 STB 24-Qxxx

SDCS-PIN-48

SDCS-PIN-46

Semiconductor fuses

Cooling fan

12

1

12

1

3ADC770009P0012

3ADT754008P0002

UR 1100 A / 1250 V

GR31M-..(690V)

NOTES

B




525 V - 690 V / 50/60 Hz

Cooling fan


49.00

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

DESCRIPTION





2-Q 4-Q

6

-

-

6

1

-

-

2

CODE

3ADC340046P0002

3ADC340079P0001

3ADT220090R0043

3BSE004939R1003

Semiconductor fuses 12 12 3ADC770009P0012

1 1 3ADT754008P0001

TYPE/DATA

5STP 3328Lxxx

5 STB 24-Qxxx

SDCS-PIN-48

SDCS-PIN-46

UR 1100 A / 1250 V

GR31M-..(500V)

NOTES

B




400 V - 500 V / 50/60 Hz

Item 50.00 to 65.00

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

50.00



Control Board 1 1 3ADT313900R1001

Power supply board 1 1 3ADT315100R1001



Air Flow detector (P1)

Temperatur Sensor (R57)

Current Transformer 4000 / 1 A

Cooling fan

1

1

1

1

2

1

2

1

1

1

2

1

3ADT220090R0043

3ADT220090R0006

DCF1066659P0001

DCA0012139P0005

3ADT751007P0001

3ADT754020P0001

TYPE/DATA

SDCS-CON-4

SDCS-POW-4

SDCS-PIN-48

SDCS-PIN-51

P233 A-4 AHC

KTY 10-6 -M4

4000/1A

GR 35C

NOTES

SDCS-PIN-48 replaces SDCS-PIN-41 cable 1750 mm

T51 / T52 for D7

400 V - 690 V / 50/60 Hz

Module contains:

Semiconductor fuses

2-Q 4-Q

51.00

Thyristor

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

DESCRIPTION 2-Q 4-Q

6 12

CODE

3ADC340086P0001

6 6 3ADC770030P0003

TYPE/DATA

TV 989-2700-xxx

UR 1800 A / 1250 V

NOTES

Flush-end contact fuse




155

Module contains:

Semiconductor fuses

2-Q 4-Q

52.00

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



6 6 3ADC770030P0003

TYPE/DATA

TV 989-2700-xxx

UR 1800 A / 1250 V

NOTES



53.00

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


Thyristor 6 12 DCA0012066P0001


Semiconductor fuses

1

6

1

6

3ADT780007R0002

3ADC770025P0001

TYPE/DATA

5 STP 28Lxxx

NOTES

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

UR 1700 A / 1500 V Flush-end contact fuse

Thyristor


54.00

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


6 12 3ADC340089P0001 T 989-3030xxx

Semiconductor fuses 6 6 DCA0012821P0001 UR 2500 A / 660 V

NOTES



55.00

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


Thyristor

Semiconductor fuses

6

6

12

6

3ADC340087P0001

DCA0012856P0001

TV 989-2770xxx

UR 2500 A / 1000 V

NOTES



56.00

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


Thyristor

Semiconductor fuses

6

6

12

6

3ADC340087P0001

DCA0012856P0001

TYPE/DATA

TV 989-2770xxx

UR 2500 A / 1000 V

NOTES


Module contains:

Semiconductor fuses

2-Q 4-Q

57.00

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



6 6 3ADC770030P0005

TYPE/DATA

5 STP 38 Qxxx

UR 2500 A / 1250 V

NOTES



58.00

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




Semiconductor fuses

1

6

1

6

3ADT780007R0002

3ADC770030P0006

TYPE/DATA

5 STP 38 Qxxx

NOTES


UR 2300 A / 1500 V Flush-end contact fuse

Module contains:

Semiconductor fuses

2-Q 4-Q

59.00

Thyristor

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

DESCRIPTION 2-Q 4-Q

6 12

CODE

3ADC340088P0001

TYPE/DATA

T 989-3300xxx

6 6 DCA0012830P0001 UR 3000 A / 660 V

NOTES





156

Module contains:

Semiconductor fuses

2-Q 4-Q

60.00

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


Thyristor 6 12 3ADC340046P0002 5 STP 3328 Lxxx

6 6 3ADC770030P0002 UR 3000 A / 1000 V

NOTES


Module contains:

Semiconductor fuses

2-Q 4-Q

61.00

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



6 6 3ADC770030P0002

TYPE/DATA

5 STP 3328 Lxxx

UR 3000 A / 1000 V

NOTES


Module contains:

Semiconductor fuses

2-Q 4-Q

62.00

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



6 6 3ADC770030P0005

TYPE/DATA

5 STP 38 Qxxx

UR 2500 A / 1250 V

NOTES

62.10

Module contains:

DESCRIPTION

Thyristor


2-Q 4-Q

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

2-Q 4-Q

6

1

12

1

CODE

3ADC340084P0001

3ADT780007R0002

TYPE/DATA NOTES

5 STP 38 Qxxx


Semiconductor fuses 6 6 3ADC770030P0006 UR 3300 A / 1500 V Flush-end contact fuse


63.00

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


Thyristor

Semiconductor fuses

6

6

12

6

3ADC340083P0001

3ADC770030P0002

5 STP 45 Qxxx

UR 3000 A / 1000 V


NOTES


Module contains:

Semiconductor fuses

2-Q 4-Q

64.00

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



6 6 3ADC770030P0002

TYPE/DATA

5 STP 45 Qxxx

UR 3000 A / 1000 V

NOTES


Module contains:

Semiconductor fuses

2-Q 4-Q

65.00

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


Thyristor 6 12 3ADC340083P0001 5 STP 45 Qxxx

6 6 3ADC770030P0001 UR 3500 A / 6900 V

NOTES





157




*195R0401A9370000*

*195R0401A9370000*


ABB DCS800 Service manual

DCS800

Service manual

DCS800 Drives (20 to 5200 A)

DCS800 Drive Manuals

DCS800 Drives

Service Manual

Safety instructions

What this chapter contains

To which products this chapter applies

Usage of warnings and notes

Dangerous voltage warning warns of high voltage which can cause

General danger warning warns about conditions, other than those

Electrostatic sensitive devices warning warns of electrostatic

Installation and maintenance work

WARNING!

Only qualified electricians are allowed to install and maintain the drive!

Note:

Grounding

WARNING!

Note:

Printed circuit boards and fiber optic cables

WARNING! The printed circuit boards contain components sensitive to

WARNING! Handle the fiber optic cables with care. When unplugging

Mechanical installation

WARNING!

Operation

WARNING!

Note:

Table of contents

Introduction

How to use this manual

Contents of this manual

Target group

Associated publications

Storage and transport

Name plate and type code

Type code

Current and voltage ratings

Fault Tracing Thyristors

Tools

For commissioning and fault tracing

Additionally for service and preventive maintenance

How to detect a faulty thyristor

A fuse is blown

Note:

DC-current pulses measured by an oscilloscope

Thyristor diagnosis

Ripple monitor

How to find a faulty thyristor

In general, make sure, that all safety instructions, given within this manual or within the safety instructions, related to the machine or the application itself, are obeyed.

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

Blown fuses

Note:

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

Blown fuses

Ripple monitor

Handling the Semiconductors

General Instruction how to handle the Semiconductors

Exchange of Thyristors for Size D1 to D4

Installation of OnBoard bridge and thyristor modules in converters size

D1 to D4

(20...1000 A)

Required Tools

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

Find faulty thyristor modules

Remove faulty thyristor modules

Attention:

OnBoard field exciter bridge module

Thyristor modules

Snubber resistor

Current transformer Temperature sensor

Note:

Install new thyristor modules

Note:

bridge

Remove faulty OnBoard bridge (V1)

Install new OnBoard bridge (V1)

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

Note: