ABB DCS 500B, DCS 600 MultiDrive Series Service Manual

DCS Thyristor Power Converters
for DC Drive Systems
25 to 5150 A
Service Manual
DCS 500
DCS 600
4
2
3
1
How to use the DCS Documentation System
The matrix below indicates all available product documentation and its corresponding order numbers on its left columns
as well as all existing DC Drive systems on its top rows. System descriptions, Technical data and Operating instructions
(as far as they are available for the corresponding drive) are the basic documents and will be delivered together with each
drive. All other documentation has to be ordered separately.
Language
Language
Operating Instructions
3ADW000055
3ADW000080
3ADW000091 (Installation)
EN,DE,FR,SP
EN, DE
EN, DE
Software description
3ADW000078
3ADW000076
3AST000953 ➂
EN
EN
EN
Tools
3AFE61178775 CMT/DCS500
EN 5926915-1 GAD
3ADW000048 (Application blocks)
3AFY61296123 Drive Window
EN
EN
EN
EN
Service Instructions
3ADW000093
3ADW000131
EN, DE
EN
Fieldbus
3ADW000086
3ADW000097
EN
EN
Others
3ADW000115 12-Pulse operation
3ADW000092 Rebuild manual
3ADW000128 Paralleling DCS Conv.
3ADW000040 12-Puls operation
Language
Language
Language
Language
Language
EN
EN
EN
EN, DE
DCR
DCS/DCF 500B
x
DCS 400
x
DCS 400 Easy Drive
DCS 600 CraneDrive
x
x
DCS/DCF 600 MultiDrive
x
x
Rebuild
Module
x
x
x
x
x
x
x
x
x
x
Volume
III
Volume
IV A
IV F
IV F1
Volume
V D1
VF
Volume
V A2
-
Volume
VI A
VI K
Volume
-
Volume
VIII F2
XI H1
VIII D1
VIII A2
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
available only for: DCS 500B / 600 drive systems
EN
Volume
II D
II F
II F1
II K
II F
Cubicle
DCS 500 Easy Drive
Technical Data
3ADW000165
Language
Standard Drive
Module
DCA 500 / DCA 520
EN, DE,FR
EN, DE
EN
EN,DE,FR,IT,SP
EN
EN, DE
EN, DE,FR,IT,SP
EN
DCA 620
Product documentation
System description
3ADW000066
3ADW000072
3ADW000121 ➀
3ADW000095 (Manual) ➁
3ADW000139
3ADW000071 (Flyer)
3ADW000152
3ADW000173 (Flyer)
DCA 600
Cubicle
DCE 400
System Drive
DC drive systems
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Status: 25.March.2002
➀ Covers information of Technical data
➁ Covers information of Technical data, Operating Instructions, Software Description
➂ Covers information of Operating Instructions, Software Description
Note: For clearness the type designation in this
brochure is shown in the following way:
Designation
DCS 500
DCS 600
is valid for
DCS 500
DCS 500B
DCS 600
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Thyristor Power Converters
Series
DCS 500 / DCS 500B
DCS 600
25 to 5150 A
Service Manual
Code: 3ADW 000 093 R0601 Rev F
S_M_E_F.DOC
EFFECTIVE:
Jul. 4th, 2002
SUPERSEDES: Rev E Oct. 26th, 2001
2002 ABB Automation Products GmbH. All rights reserved.
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Safety Instructions
Overview
This chapter contains safety instructions which must be complied
with during installation, operation and maintenance of the power
converters series DCS 500 or DCS 600. If these instructions are
not complied with, this may result in injuries (perhaps even with fatal) or in damage to the power converter, the motor and the driven
machine. Before starting with any work whatsoever at or with this
unit, you must read the information given in this chapter.
Warnings
Warnings provide information on states which if the specified procedure for the state concerned is not meticulously complied with
may result in a serious error, in major damage to the unit, in injury
to persons and even in death.
They are identified by the following symbols:
Danger: High Voltage! This symbol warns you of
high voltages which may result in injuries to persons
and/or damage to equipment. Where appropriate, the
text printed adjacent to this symbol describes how
risks of this kind may be avoided.
●
●
●
●
All electrical installation and maintenance work on the thyristor
power converter must be carried out by properly qualified staff
who have been thoroughly trained in electrical engineering.
The thyristor power converter and its adjacent units must be
properly earthed by qualified professionals.
You must NEVER perform any work on the thyristor power converter while it is still switched on. First switch the unit off, use a
measuring instrument to make absolutely sure that the power
converter has really been de-energized, and only then you may
start with the work concerned.
Due to external control circuits, there may be dangerously high
voltages present at the thyristor power converter even after the
line voltage has been switched off. So always work at the unit
with appropriate caution! Non-compliance with these instructions
may result in injury (or even death!).
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
i
Safety Instructions
General warning: this symbol warns you of nonelectrical risks and dangers which may result in serious or even fatal injury to persons and/or in damage
to equipment. Where appropriate, the text printed adjacent to this symbol describes how risks of this kind
may be avoided.
● When thyristor power converters are in use, the electric motors,
power transmission elements and the driven machines are
working in an extended operating range, which means they have
to cope with a relatively high loading.
● You should have made sure that all units, devices and appliances used are actually suitable for this higher loading.
● If you have to operate the thyristor power converter at a rated
motor voltage and/or a rated motor current significantly below
the figures stated in the thyristor power converter's output data,
you must take appropriate precautionary measures to protect
the unit against overspeed, overload, breakage, etc., by modifying the software or hardware appropriately.
● For insulation testing, you must disconnect all cables from the
thyristor power converter. You should avoid operating your unit
at values other than the rated data. Non-compliance with these
instructions may cause lasting damage to the thyristor power
converter.
● The thyristor power converter possesses a number of automatic
reset functions. When these functions are executed, the unit will
be reset after an error and will then resume operation. These
functions should not be used if other units and devices are not
suitable for an operating mode of this kind, or if their use might
entail dangerous situations.
Warning of electrostatic discharge:
this symbol warns you against electrostatic discharges
which may damage the unit. Where appropriate, the
text printed next to this symbol describes how a risk of
this kind may be avoided.
ii
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Safety Instructions
Notes
Notes supply information on states requiring particular attention, or
indicate that additional information is available on a specific topic.
For this purpose, the following symbols are used:
CAUTION!
Cautions are designed to draw your attention to a
particular state of affairs.
Note
A note contains or refers you to additional information available on the particular topic concerned.
Mains connection
You can use a switch disconnector (with fuses) in the power supply
of the thyristor power converter to disconnect the electrical components of the unit from the power supply for installation and maintenance work. The type of disconnector used must be a switch disconnector as per EN 60947-3, Class B, so as to comply with EU
regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main
contacts to open. The mains disconnector must be locked in its
"OPEN" position during any installation and maintenance work.
EMERGENCY STOP
buttons
EMERGENCY STOP buttons must be installed at each control
desk and at all other control panels requiring an emergency stop
function. Pressing the STOP button on the CDP 31x control panel
of the thyristor power converter will neither cause an emergency
motor stop, nor will the drive be disconnected from any dangerous
potential.
To avoid unintentional operating states, or to shut the unit down in
case of any imminent danger according to the standards in the
safety instructions it is not sufficient to merely shut down the drive
via signals „RUN“, „drive OFF“ or „Emergency Stop“ respectively
„control panel“ or „PC tool“.
Intended use
The operating instructions cannot take into consideration every
possible case of configuration, operation or maintenance. Thus,
they mainly give such advice only, which is required by qualified
personnel for normal operation of the machines and devices in
industrial installations.
If in special cases the electrical machines and devices are intended
for use in non-industrial installations - which may require stricter
safety regulations (e.g. protection against contact by
children or similar) -, these additional safety measures for the installation must be provided by the customer during assembly.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
iii
Safety Instructions
iv
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Contents
VI A SERVICE MANUAL
Safety Instructions
Chapter 1 - Introduction
How to use this manual......................................................................................................... 1-1
Contents of this manual ........................................................................................................ 1-1
Target group ......................................................................................................................... 1-2
Associated publications........................................................................................................ 1-2
Storage and transport ........................................................................................................... 1-2
Rating plate and type code ................................................................................................... 1-2
Chapter 2 - Fault Tracing Thyristors
How to detect, if a thyristor is faulty....................................................................................... 2-1
A fuse is blown .......................................................................................................... 2-1
Ripple monitor ........................................................................................................... 2-1
How to find a faulty thyristor.................................................................................................. 2-2
Converters size C1 and C2/C2b (25...1000 A)........................................................... 2-2
Blown fuses ............................................................................................................... 2-2
Converters size A5, C3 and C4 (900...5150 A) .......................................................... 2-3
Blown fuses ............................................................................................................... 2-3
Ripple monitor ........................................................................................................... 2-3
Chapter 3 - Handling the Semiconductors
General Instruction how to handle the Semiconductors ........................................................ 3-1
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Installation of thyristor modules in converters size C1/C2/C2b (25...1000 A) ........................ 4-1
Required Tools .......................................................................................................... 4-1
Remove faulty thyristor modules................................................................................ 4-1
Install new thyristor modules...................................................................................... 4-2
Thyristor module location........................................................................................... 4-3
Module terminals ....................................................................................................... 4-8
Chapter 5 - Exchange of Thyristors for Size A5
Installation of "Disc Type" thyristor in converters size A5 (900...2000 A)............................... 5-1
Required Tools .......................................................................................................... 5-1
Find faulty thyristor .................................................................................................... 5-2
Remove faulty thyristor .............................................................................................. 5-3
Install new thyristor .................................................................................................... 5-4
Chapter 6 - Exchange of Thyristors for Size C3
Installation of "Disc Type" thyristor in converters size C3 (900...2000 A) .............................. 6-1
Required Tools .......................................................................................................... 6-1
Remove faulty thyristor .............................................................................................. 6-2
Find faulty thyristor .................................................................................................... 6-2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
v
Contents
Install new thyristor.................................................................................................... 6-3
Fasten the clamp ....................................................................................................... 6-3
Chapter 7 - Exchange of Thyristors for Size C4
Installation of "Disc Type" thyristor in converters size C4 (2050...5150 A) ............................ 7-1
Required Tools .......................................................................................................... 7-1
Find faulty thyristor .................................................................................................... 7-2
Install new thyristor.................................................................................................... 7-3
Chapter 8 - Compatibility of SDCS-PIN-2 boards
Description of SDCS-PIN-20xB boards ................................................................................. 8-1
Hardware coding ....................................................................................................... 8-1
Snubber circuit........................................................................................................... 8-1
Compatibility of SDCS-PIN-20x boards ..................................................................... 8-2
Compatibility of SDCS-PIN-20x and SDCS-PIN-2x boards........................................ 8-2
Change SDCS-PIN-2x boards ................................................................................... 8-3
Chapter 9 - Preventive Maintainance
Recommended regular maintenance .................................................................................... 9-1
Air Filters ................................................................................................................... 9-1
Cooling air pressure switch in converter modules type C4......................................... 9-1
Fan ............................................................................................................................ 9-1
Heatsink .................................................................................................................... 9-1
Internal high current connections in converters type C4 ............................................ 9-2
Relays and electrical connections.............................................................................. 9-2
Appendix A - Spare Parts List
vi
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 1 - 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 DCS 500 or DCS
600 series.
Note:
If it is not mentioned explicitly all details given in
this Service Manual will be valid for both,series
DCS 500 and series DCS 600!
Contents of this manual
Chapter 1 - 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.
Chapter 2 - Fault Tracing Thyristors
This chapter describes how to detect and select a faulty
thyristor.
Chapter 3 - Handling the Semiconductors
This chapter describes the handling of thyristors and thyristor
modules.
Chapter 4 - Exchange of Thyristors of Sizes C1/C2/C2b
This chapter describes the exchange of thyristors in converters
sizes C1/C2.
Chapter 5 - Exchange of Thyristors of Size A5
This chapter describes the exchange of thyristors in converters
size A5.
Chapter 6 - Exchange of Thyristors of Size C3
This chapter describes the exchange of thyristors in converters
size C3.
Chapter 7 - Exchange of Thyristors of Size C4
This chapter describes the exchange of thyristors in converters
size C4.
Chapter 8 - Compatibility of SDCS-PIN-2 boards
This chapter describes the compatibility, utilization and removing/mounting of power interface boards PIN-2x/PIN-20x.
Chapter 9 - Preventive Maintainance
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.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 1 - 1
Chapter 1 - Introduction
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
The DCS 500 or DCS 600 documentation includes the following:
Technical Data DCS Thyristor Power Converter
Operating Instructions
System Description DCS 500 and DCS 500B
System Description DCS 600
CAUTION! The thyristor power converter weighs quite a lot and
should therefore not be held by the front cover. Please put the unit
down only on its back (sizes C1 to C3). Always use due care when
handling the unit, so as to avoid injuries or damage.
Storage and transport
If the unit had been in storage prior to installation or is transported
to another location, care must be taken to ensure that the environmental conditions are complied with (see "System Descriptions").
Rating plate and type
code
For purposes of identification, each thyristor power converter is fitted with rating plates, stating the type code and the serial number,
which serve for each unit's individual identification.
The type code contains information on the characteristics and the
configuration of the unit.
Figure 1-1
VI A 1 - 2
Example of a rating plate
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 1 - Introduction
System
Des.
Rev.
OEM
D C S 5 0 1 B 0 9 0 0 - 5 1 - 2 1 0 2 0 5 0 - 0 0 0 0 0 0 0 0 0
DC Drives
Type
S = Standard
F = Fieldexciter
Product family
50 = DCS500 converter module
60 = DCS600 converter module
Bridge type
1 = single (2-Q)
2 = double (4-Q)
Version (Salestyp)
B = modules with SDCS-CON-2
- = for all DCS600/DCF600
Type
(Rated DC 4-Q-current (IP00))
Rated AC voltage
4 = 220...400V
5 = 415...500V
6 = 525...600V
7 = 660...690V
8 = 700...830V
9 = 800...999V
1 = 1190V
Frequency
1 = 50/60 Hz
Power connection (C4 or A7)
- = no option (size C1...A6)
R = on the right
L = on the left
Option
Softwaretyp
15 = Multidrive
18 = Crane drive
21 = OEM
Control panel
0 = no panel
P = panel included
Fieldexciter
0 = no field exciter
1 = SDCS-FEX1
2 = SDCS-FEX2..
Fan voltage
0 = standard
5 = 400-500V only size A6/7
6 = 525-690V only size A6/7
Communication boards
0 = no communication board
5 = SDCS-COM5-board
A = SDCS-AMC-DCx-board
C = SDCS-AMC-DC-Clasx-board
Coated version
0 = no coating
X = coated version
Special Options
UL-approval
0 = standard module with UL-certificaion
U = modification for UL-certification (C3, A6/7)
Interfaces
0 = no fieldbus module included
Current measurement modification
0 = no modification
C = CMA-2 included
M = Paralleling Master converter
S = Paralleling Slave converter
Voltage measurement modification
0 = no modification
5 = PIN=51 modified for 500 V
6 = PIN=51 modified for 600 V
7 = PIN=51 modified for 700 V
8 = PIN=51 modified for 800 V
9 = PIN=51 modified for 1000 V
A = PIN-51 modified for 235V
B = PIN-51 modified for 120V
C = PIN-51 modified for 70V
D = PIN-51 modified for 40V
X = Galvanic Isolation
Special Customer Software
000= Standard
Design revision
Thyristor type (only for disc types)
1 = ABB Lenzburg
2 = Eupec
Design rev. index
only used for internal informations
Figure 1-2
Type code
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 1 - 3
Chapter 1 - Introduction
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.
VI A 1 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 2 - Fault Tracing Thyristors
How to detect, if a thyristor is faulty
Thyristor problems can be noticed by two ways:
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 defect thyristor (short circuit inside a thyristor from anode to
cathode).
- An internal short circuit between the phases (line side) because
of circulating current in a 4-Q converter (malfunction of the control electronics, no thyristor defect).
- An external short circuit at the DC terminals of the converter
without sufficient impedance.
- A commutation fault during inverting mode operation (active
braking with high current, high EMF and with low AC voltage).
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, the current controller will force the
other thyristors to compensate the dip by a certain overcurrent in
order to keep the average current constant. Such a compensation
results in a ripple monitoring fault during motoring mode operation
with α ≤ 90°.
During braking or inverting mode operation most often fuses are
blown.
The reason for a currentless thyristor may be:
- A fuse has disconnected one of the six thyristors. This is possible only for converters with 900...5150 A (six internal branch
fuses). A converter with three external fuses stops working completely at once when one of the three AC input fuses interrupts a
phase input of the converter.
- A thyristor does not get firing pulses.
- The current controller may be totally mismatched to the DC load.
- The AC mains network is causing that fault message. In this
case, asymmetrical phase shift, uneven phase voltage or critical
designed power factor correction equipment or harmonic reduction equippment can be the reason.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 2 - 1
Chapter 2 - Fault Tracing Thyristors
How to find a faulty thyristor
If a blown fuse is suspected in the converter, the problem is caused
most often by a faulty thyistor. To make sure, that a thyristor is the
reason and needs to be exchanged fault tracing must be done in
two different ways, depending on the size of the converter.
In general, make sure, that all safety instructions,
given within this manual or within the safety instructions, related to the machine or the application itself,
are obeyed.
Converters size C1
and C2/C2b
(25...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
Figure 4-3). Normally, every measurement should show high resistance (> 1 kΩ). Target: find a short circuit, indicated by low
resistance ( <1 Ω ) (destroyed thyristor).
- If the converter is designed with half-bridge thyristor modules,
then a module consists of two antiparallel thyristors. In this case
it is sufficient to know which thyristor pair or module has a defective thyristor because the complete module must be replaced.
- After a thyristor module is replaced, the above mentioned measurement should be done another time to make sure that all faulty
thyristors have been detected!
Note
VI A 2 - 2
The RC circuit could also cause 0 Ω result for a short
time.
The measurement, showing less resistance than 1 Ω
should be made a second time with test leads applied
to the terminals with the opposite polarity; if this
measurement shows the same result, one or two thyristors located in that path are faulty; they need to be
replaced.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 2 - Fault Tracing Thyristors
Converters size A5,
C3 and C4
(900...5150 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
therefor the faulty branch is known (see Figure 4-4).
- The OHM test should be performed, when the thyristor is still
clamped. Outside the converter a special thyristor clamping device is needed.
- For 4-Q converters with antiparallel thyristors:
The selection of a forward or reverse thyristor is done during the
disassembly. Continue with related chapter 5, 6 or 7
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 occured, the fault tracing must be adapted
to the reasons listed before:
- Check the fuses and the thyristors, according to the statements
before.
- If the power section seems to be ok, but still one or more thyristors don´t take current, something went wrong in between the
firing pulse generation and the thyristor´s gate; in this case
check:
• Is a firing pulse present on the primary side of the firing pulse
transformer?
• Is a firing pulse present on the secondary side of the firing
pulse transformer?
• Is the firing pulse transfered to the gate of the thyristor? Are
there all electrical connections still healthy?
• Can the thyristor be fired with the applied firing pulse? Is the
pulse form of the firing pulse identical at all measuring positions?
- Check the settings of the current controller.
- Check the AC mains network by taking recordings of the line
voltage and current at all 3 phases at the same time.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 2 - 3
Chapter 2 - Fault Tracing Thyristors
VI A 2 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 3 - 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.
Disc type thyristors in converters size C3 (900...2000 A DC) are
normally mounted using a dial gauge, for repair reasons, they can
be mounted using a torque wrench.
In converters sizes A5 (900...2000 A DC) and C4
(2050...5150 A DC) the mounting force is indicated by an indicating
spring welded to the mounting clamp, which is inside the unit.
Always mark suspected damaged components clearly after removing them from the circuit, to avoid confusion with "good" components.
When removing a damaged semiconductor, write down how and
where it was installed (direction, location and connected gate
leads).
Check that the new and old component have the same type designation or that the new component can replace the old one. A semiconductor can be replaced by different compatible semiconductor
according to the codes in the manufacturers' table.
Semiconductor components are high-precision products. All unnecessary used tools and objects might damage the easily dented and
scratched surfaces of the semiconductors.
1. Keep new semiconductors as long as possible in their original
packages.
2. Use protective gloves if possible.
3. Clean work area and hands frequently.
4. Use good illumination.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 3 - 1
Chapter 3 - Handling the Semicinductors
VI A 3 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Installation of thyristor
modules in converters
size C1/C2/C2b
(25...1000 A)
Required Tools
All DCS 500 and DCS 600 size C1/C2/C2b are equipped with thyristor modules.
In order to keep the operating temperature of the semiconductor
module low, the joint between the heat sink and the module should
have a good heat conducting ability. The electrical conductivity of
the connectors must also be good. For this reason the following instructions must be observed with particular care.
Special tools or material needed in addition to standard tools for the
exchange of thyristor modules:
- torque spanner:
mounting torques for thyristor
module to heat sink and elelectrical
connections see table “Nominal
mounting torques for thyristor
modules” in this chapter;
- screws are metric type; use appropriate nuts
- tissue paper / solvent
- thermal joint compound:
type BERULUB FZ1 E3
(grease)
Manufacturer:
ABB Service:
Carl Bechem GmbH, 58089 Hagen
GHSN 390 011 P 0051
Before the work is started, disconnect the converter from the power supply completely, then
check the voltage free condition and make sure,
everythingis located in an electrical and mechanical safe condition!
Remove faulty thyris- tor modules
-
Tilt out the electronics casing.
Remove the gate leads from the faulty thyristor module and
mark the position of the trigger connections on the cable.
Remove only as many parts as is needed around the faulty
module. If the current transformer must be removed, mark the
position and the connections!
Remove the faulty thyristor module and mark it.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 4 - 1
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Install new thyristor
modules
- Remove old thermal joint compound (grease) from the heat sink.
Preparation of the heat sink: if the area is clean, spread out the
heat-conducting compound with a rubber spatula or by hand. If
the area is dirty, clean the heat sink surface with tissue paper.
Clean the mounting surfaces with an appropriate solvent (e.g.
ethanol).
- Apply a thin coat of thermal joint compound to the new module.
Spread the thermal joint compound evenly by moving the module forward and backward on the heat sink.
- Tighten the clamping screws by hand until the screw heads
touch the bottom of the module. Then tighten the screws to 2.5
Nm torque. If the module is mounted using four screws, tighten
the screws crosswise.
- Tighten the screws to nominal torque (see Table below).
- Reinstall the busbars; make sure, the correct torque is applied
and reconnect all cables.
Thyristor module
Nominal mounting torques
Size
Type
Electrical
connections
Module to
heat sink
20 mm block
SKKT…..
3 Nm
5 Nm
34 mm block
SKKT…..
5 Nm
5 Nm
34 mm block
TT…..
6 Nm
6 Nm
50 mm block
SKKT…..
9 Nm
5 Nm
50 mm block
TT…..
12 Nm
6 Nm
50 mm block
(single thyrist.)
SKET…..
9 Nm
5 Nm
50 mm block
(single thyrist.)
TZ…..
12 Nm
6 Nm
60 mm block
TT425/TT570
12 Nm
6 Nm
Table 4-1 Nominal mounting torques for thyristor modules
VI A 4 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Thyristor module location
for: DCS 501 0100 to 0140
for: DCS 501 0200 to 0520
V14/V11
4 2
1 3
2 4
1 3
2 4
V13/V16
V11/V14
1 3
3 1
V16/V13
4 2
3 1
V12/V15
4 2
3 1
2 4
V12/V15
for: DCS 501 0680 ... 1000
for: DCS 501 0700
1
b
d
a
b
d
2
2
c
a
c
V14/V11
V16/V13
V12/V15
1
V11
V14
A
K
K
AK
AK
A
A
1
d
b
2
a
K
c
a
b
d
2
c
1
V12
AK
V15
1
b
d
a
b
d
2
2
c
a
c
1
V13
V16
Figure 4-1
Location of thyristor modules in DCS 501/6010100...1000 units
Note: This drawing is only for showing the location of the modules,
the module size can be different!
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 4 - 3
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
for: DCS 50x 0025 to 0075 and
DCS 502 0100 to 0140
for: DCS 502 0200 to 0520
V11/V24
V14/V21
4 2
V16/V23
3 1
4 2
V12/V25
3 1
4 2
V14/V21
1
3
4
2
2
4
3
1
3 1
V15/V22
V12/V25
1
3
4
2
2
4
3
1
V16/V23
V13/V26
2 4
1 3
2 4
V13/V26
1 3
2 4
V24/V11
c
a
2
b
d
c
a
2
1
2
c
1
V25
1
b
d
b
d
K
V23
K
V12
1
b
d
c
c
a
1
2
c
a
b
d
2
2
2
b
a
A
d
A
b
A
1
V13
c
a
1
V22
V15
c
a
1
2
AK
c
a
AK
c
2
AK
AK
2
2
AK
b
d
AK
b
a
K
K
V14
K
V24
1
d
V22/V15
b
A
a
d
A
c
b
A
d
V11
a
V26/V13
1
b
2
d
for: DCS 502 0680 ... 1000
V21
1
a
3
1
V15/V22
for: DCS 502 0700
d
4
2
2
4
K
1 3
V11/V24
1
3
V21/V14
V23/V16
V25/V12
c
1
V26
V16
Figure 4-2
Location of thyristor modules in
DCS 50x/60x-0025...0075 units
DCS 502/602-0100...0700 units
DCS 502/602-0680...1000 units
Note: This drawing is only for showing the location of the modules,
the module size can be different!
VI A 4 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
POWER INTERFACE BOARD Units with
U1
0025 to
SDCS-PIN-1x / -2x
0075 ADC T51 S1
V1
Units with 0100 to 0350 ADC
W1
1000/1
1500/1
X3:1
S2
T52 S1
1500/1
X4:3
S2
G
K
P2
S2
P1
600/1 *
1.4
T53 K (S1)
1000/1
1500/1
K
T51
S1
X4:1
T53 S1
G
L (S2)
X3:3
S2
1
Units with 0450 to 0520 ADC
* 2330/1 for units with 0700 ADC
T51 K (S1)
L (S2)
T53
S1
P2
S2
P1
600/1 *
G
K
G
K
2
V11
V14
G
K
3
1.3
G
K
4
1.3
G
K
1.6
G
K
G
K
5
1.5
V13
V16
G
K
6
G
G
FORWARD
1.5
K
G
K
REVERSE
G
1.2
K
K
V15
V12
1.2
G
K
K
Snubber
circuit
Snubber
circuit
G
1.4
G
K
Snubber
circuit
G
K
1.6
R 57
X22:1
3
O
C1
D1
Basic drawing / not all elements are shown
Figure 4-3
Basic drawing of DCS 501/601 units with SDCS-PIN-1x/-2x
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 4 - 5
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
POWER INTERFACE BOARD
Units with
0025 to
0075 ADC
SDCS-PIN-1x / -2x
U1
V1
Units with 0100 to 0350 ADC
W1
Units with 0450 to 0520 ADC
* 2330/1 for units with 0700 ADC
T51 S1
T51 K (S1)
1000/1
1500/1
X3:1
S2
T52 S1
L (S2)
T51
S1
P2
S2
P1
600/1 *
X3:3
1500/1
X4:1
S2
X4:3
T53 S1
T53 K (S1)
1000/1
1500/1
S2
L (S2)
T53
S1
P2
S2
P1
600/1 *
G
1
K
G
G
G
2
K
2.4
G
K
1.3
G
K
G
3
K
K
K
6
K
1.6
G
K
V14
V21
G
2.6
K
1.5
G
K
2.2
G
K
V13
V16
G
2.3
K
1.2
G
K
2.5
G
K
2.6
V26
G
FORWARD
G
K
1.5
G
K
2.1
V24
2.4
G
5
K
V11
1.3
G
4
1.4
K
2.2
2.1
V23
G
REVERSE
K
1.2
G
K
V22
V25
1.4
Snubber
circuit
Snubber
circuit
G
K
V12
2.3
G
K
V15
2.5
G
K
1.6
Snubber
circuit
R 57
X22:1
O
3
Basic drawing / not all elements are shown
Figure 4-4
VI A 4 - 6
D1
C1
Basic drawing of DCS 502/602 units with SDCS-PIN-1x/-2x
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
X12:
11,12
Figure 4-5
5
7
15
4
14
16
6
HWCOD3
HWCDD5
UA -
UU
UV
VW
UA +
NC
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
ACOD2
ACOD1
15
13
1k5
12,14
GNDI
0V
+ 48 V1
FORWARD
4,2
SR2
10
11
BZP6
8,6
REVERSE
9
BZP5
SR1
5
7
BZP4
+48 V1
4
5
BZP3
820R
W80
1k5
W81
HW-coding
3k3
W82
Firing pulse channels
6
3
2
3
1
AC/DC voltage measuring circuits
BZP2
NC
W10
1
0V
Armature current measuring resistances
BZP1
X13:
1
2
HWCIN4
8,13
GNDI
ANTC
3
9,10
STWA
IDC
Control board
IDCM
5M / 6M
X6:
X5:
19
17
31
29
3
1
35
33
11
9
27
25
19
17
31
29
3
1
35
33
11
9
27
25
K
G
K
G
K
G
K
G
K
G
K
G
K
G
K
G
K
G
K
G
K
G
K
G
1.6
2.5
1.4
2.3
1.2
2.1
2.6
1.5
2.4
1.3
2.2
1.1
POWER INTERFACE BOARD SDCS-PIN-20xB
6 x 15 Ω
D1
3
1
3
1
3
1
C1
W1
V1
U1
6 x 0.1 µF
6A
F103
F102
F101
X22:
X4:
X3:
G
K
G
K
G
K
G
K
G
K
G
K
C1 (+)
1.5
2.2
1.3
2.6
1.1
2.4
R57
V15
V22
V13
V26
V11
V24
S2
S1
P1
N/1
T51 P2
S2
S1
P1
N/1
T53 P2
U1 V1 W1
only in case of 4-Q converters
PE
1.2
2.5
1.6
2.3
1.4
2.1
G
V12
V25
V16
V23
V14
V21
D1 (-)
K
G
K
G
K
G
K
G
K
G
K
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Typical armature circuit of DCS 50x/60x with SDCSPIN-20xB
VI A 4 - 7
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
Module terminals
The next figures show a few examples and terminals of thyristor
modules. The terminals of modules are also stamped or marked by
a sticker.
AK K
A
K1G1
K2 G2
K
AK
A
K2
G2
K1
G1
SKKT27...SKKT106
Note: This drawing is not valid for the types SKKT.…B…
Terminals of half-bridge thyristor modules
3
K5 G4
3
A
AK
K2 G2
K
SKKT132,162
Figure 4-7
A
K1
G1
G4
K5
2
K7
G6
1
AK K
K1 G1
K7 G6
G2
2
1
K2
Figure 4-6
TT162
Terminals of half-bridge thyristor modules
AK K
A
K1 G1
K2 G2
K
A
34
AK
AK
K
K2
G2
A
G1
K1
SKKT210, SKKT250,
TT250...AK34
Figure 4-8
VI A 4 - 8
Terminals of half-bridge thyristor modules
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
2
1
4 5
d
a
1
2
b
c
2
1
4
5
TZ425 or SKET 400
Figure 4-9
(A)
3
Terminals of single thyristor modules
(K) (AK)
2 1
5G 4K
6G 7K
4K
5G
3
2
1
7K
6G
TT425, 570
Figure 4-10
Terminals of half bridge thyristor modules
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 4 - 9
Chapter 4 - Exchange of Thyristors for Sizes C1/C2/C2b
VI A 4 - 10
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 5 - Exchange of Thyristors for Size A5
Installation of "Disc
Type" thyristor in converters size A5
(900...2000 A)
Required Tools
All DCS 500 and DCS 600 converters sizes A5/C3/C4 are equipped
with disk type thyristors. The structure of the "Disc type" semiconductor component is such that it requires a certain compression
force to operate. The prevention of overheating of the component
essentially depends on a well heat dissipation between the semiconductor and the conducted heat sink. It is thus important that all
joints have good thermal and electrical conduction.
Special tools or material needed in addition to standard tools for the
exchange of thyristor modules:
- Torque spanner for electrical connections:
13 Nm (M8)
25 Nm (M10)
50 Nm (M12)
- Screws are metric type; use appropriate nuts.
- 17 mm ring spanner for fuse and busbar connections.
- 17 mm ring spanner for press clamp.
- Tissue paper / solvent (e.g. ethanol).
- Thermal joint compound:
type BECHEM-RHUS SU 2
(grease)
Manufacturer:
ABB Service:
- Disassembly tool
Note:
Carl Bechem GmbH, 58089 Hagen
GHSN 390 001 P 0001
3ADT 621 023 P1
For more detailed information about the wiring of
the power part, see manual Technical Data.
Therefore strict observance of the build in instructions given below
is of utmost importance. Make sure that the new component can
replace the old one in accordance with the spare part list (see Appendix A).
Semiconductors and heat sinks are to be handled carefully to avoid
scratches and other damage. Avoid touching the contact surfaces.
Do not lift the semiconductor with the gate wire. Do not lift the
semiconductor unit touching the current contact surfaces. Do not
damage the welding flange or the contact surface.
Before you start work, disconnect the converter
completly from the power supply then check the
voltage free condition and make sure, everything
is located in an electrically and mechanically safe
condition!
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 5 - 1
Chapter 5 - Exchange of Thyristors for Size A5
Find faulty thyristor
1. Find the defective branches by performing an OHM test (both
polarities) between U1, V1, W1 and C1, D1 (see figure 5-1)
C1 (+)
branching fuse
U1
V1
W1
branch
D1 (-)
Figure 5-1
Basic B6-bridge with branching fuses
2. Disconnect the branch fuses of the defective branches.
3. Find the defective thyristors by performing an OHM test (both
polarities) over their heat sinks.
4. In a 4-quadrant converter change both thyristors clamped between the same heatsinks at once.
Note: Because “Disc Type” semiconductors need a certain
compression force to operate properly a measurement outside
the clamped heat sinks might be wrong. To be sure change only
one thyristor, clamp the heat sinks again and repeat step three.
VI A 5 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 5 - Exchange of Thyristors for Size A5
Remove faulty thyris- 1. Remove the screws of the DC – busbars and branch fuses pretor
venting the stack to be prized open.
Note: It depends on the location of the defective thyristor which
DC – busbar and fuses have to be disconnected.
2. Write down the direction and location of the thyristors to be removed and mark their gate leads.
3. Remove the gate leads if possible.
4. Loosen the mounting clamp (see figure 5-3) at the top of the
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 figure 5-2).
6. Remove the thyristors.
Attention: To centre the thyristors spring pins are used. The pins
are inlayed into all lower heat sinks. Open the gap wide enough that
the thyristor and the pins are not damaged while removing the thyristor!
Mounting clamp
View from
the right
View from
the left
Disassembly tool
Front view
Figure 5-2
How to use the disassembly tool
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 5 - 3
Chapter 5 - Exchange of Thyristors for Size A5
Install new thyristor
1. Ensure that the new thyristor is of the correct type (see Appendix A). Keep the semiconductor and its surroundings clean. If
necessary clean them with a piece of tissue paper moistened
with solvent.
Note: Do not touch the polished surfaces of the thyristor.
2. Clean the polished surfaces of the semiconductor with a piece
of tissue paper moistened with solvent. Dry all surfaces. Spread
a thin layer of heat conducting paste on both sides of the thyristor, if necessary use a rubber spatula.
3. Connect the gate leads if possible.
4. Clean all parts with tissue paper moistened with solvent, witch
have had or will have contact with the thyristor or each other
(lower / upper heat sink). Do not clean the surfaces of grease
too thoroughly, because the aluminium surfaces will oxidise in a
few seconds. Dry all surfaces.
5. Centre the thyristors by means of the spring pins.
Note: Be sure that the thyristor is installed in the right direction.
Do not pinch or cut the gate leads or any other cable.
6. Turn the thyristor so that the gate leads point in the right direction.
Loose
condition
Insulating plate
In-
sulating tube
TORQUE INDICATING SPRING
Heatsink
Correct torque
Figure 5-3
VI A 5 - 4
Aluminium spring with welded indicating spring
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 5 - Exchange of Thyristors for Size A5
7. Tighten the nuts of the mounting clamp by hand so that the
clamp is in parallel with the contact surface of the heat sinks.
Note: The indicating spring is a very sensitive instrument and
must be handled with care.
8. Tighten each nut in turn, half a turn at a time with the help of a
ring spanner until the indicating spring clicks into position “correct torque” (see figure 5-3). Do not tighten the screws any 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
right stack
left stack
rear
W1
front
front
rear
V24
V11
V14
V21
V13
V26
V23
V16
V22
V15
V12
V25
View from the left
Figure 5-4
Front view
View from the right
Location of thyristors in frame A5 (4-Q bridge)
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 5 - 5
Chapter 5 - Exchange of Thyristors for Size A5
U1
V1
left stack
rear
right stack
front
front
rear
V11
V14
V13
V16
V15
V12
View from the left
Figure 5-5
VI A 5 - 6
W1
Front view
View from the right
Location of thyristors in frame A5 (2-Q bridge)
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 5 - Exchange of Thyristors for Size A5
W1
V1
U1
D1 (-)
C1 (+)
Figure 5-6
Location of branch fuses frame A5
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 5 - 7
Chapter 5 - Exchange of Thyristors for Size A5
VI A 5 - 8
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 6 - Exchange of Thyristors for Size C3
Installation of "Disc
Type" thyristor in converters size C3
(900...2000 A)
Required Tools
All DCS 500 and DCS 600 converters sizes A5/C3/C4 are equipped
with disk type thyristors.
The structure of the "disc type" semiconductor component is such
that it requires a certain compression force to operate. The prevention of overheating of the component essentially depends on a well
heat dissipation between the semiconductor and the conducted
heat sink. It is thus important that all joints have good thermal and
electrical conduction.
Special tools or material needed in addition to standard tools for the
exchange of thyristor modules:
- Torque spanner:
mounting torques and forces for disc
type thyristors see Table 6-1
electrical connections: 13 Nm (M8)
25 Nm (M10)
50 Nm (M12)
- Screws are metric type; use appropriate nuts.
- 13 mm nut for thyristor fixing with 20 mm max outer diameter.
- Tissue paper / solvent (e.g. ethanol).
- Molikote (MSO2 ).
- Thermal joint compound:
type BECHEM-RHUS SU 2
(grease)
Manufacturer:
ABB Service:
Note:
Carl Bechem GmbH, 58089 Hagen
GHSN 390 001 P 0001
For more detailed information about the wiring of
the power part, see publication Technical Data.
Therefore strict observance of the build in instructions given below
is of utmost importance. Different press clamps are used, depending on the size of the semiconductor. Make sure that the new component can replace the old one in accordance with the spare part
list (see Appendix A).
Before you start work, disconnect the converter
completly from the power supply then check the
voltage free condition and make sure, everything
is located in an electrically and mechanically safe
condition!
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 6 - 1
Chapter 6 - Exchange of Thyristors for Size C3
Remove faulty thyris- - Remove the plastic cover in front of the heat sinks; the screws
are accessible, if the SDCS-PIN-x1 boards will be unfastened;
tor
there is no need to disconnect the electrical connections at the
PIN-x1 boards.
- Remove the fuse, connected to that thyristor (pair) which needs
to be exchanged.
- Disconnect the lead of a snubber capacitor connected to the
heat sink; if the very right or left plastic cover is fixed at the heat
sink, which needs to be removed remove the screw.
- If you have a 2 quadrant converter:
• Loosen the screws, which keep the press clamp and the heat
sink in position; remove the heat sink, mark the direction of
the thyristor and the positition of the gate leads, then remove
the thyristor.
- If you have a 4-quadrant type converter:
• Always start working at that thyristor which is part of the reverse bride (V21, V22 a.s.o.) loosen the screws, which keep
the press clamp and the heat sink in position; remove the
heat sink, mark the direction of the thyristor and the positition
of the Gate leads, then remove the thyristor.
Find faulty thyristor
VI A 6 - 2
- Perform the OHM test with both polarities. Use the DC terminal
of the antiparallel thyristors connected as one measuring point
and the remaining heat sink as the other.
Case a) If this test indicates high resistance, the remaining
thyristor is all right healthy and the one already
removed should be marked and needs to be
replaced.
Case b) If this test indicates low resistance, the remaining
thyristor is faulty and needs to be replaced.
Remove it in the way described above.
The other thyristor is ok!
- In case a) of the OHM test described above mount a new thyristor at the position of the reverse bridge.
- In case b) of the OHM test described above a new thyristor for
the forward bridge and afterwards the thyristor of the reverse
bridge which was removed first have to be mounted.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 6 - Exchange of Thyristors for Size C3
Install new thyristor
- 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. Make sure the insulator of the thyristor and the
connections are fine.
Note: Do not touch the polished surfaces of the thyristor.
- Clean the polished surfaces of the semiconductor with a piece of
tissue paper moistened with solvent. Dry all surfaces. Spread a
thin layer of heat conducting paste on both sides of the thyristor,
if necessary use a rubber spatula.
- Clean all parts with tissue paper moistened with solvent, witch
have had or will have contact with the thyristor or each other
(bottom of upper heat sink, busbar on both sides and upper side
of the DC and AC busbar). Do not clean the surfaces of grease
too thoroughly, because the aluminium surfaces will oxidise in a
few seconds. Dry all surfaces.
- Connect the gate leads if possible.
- Place the thyristor with the right direction into the guiding tool.
Spread the head conducting paste by turning the thyristor 90°
left and right.
Note: Do not pinch or cut the gate leads or any other cable.
- Turn the thyristor so that the gate leads point in the right direction.
Fasten the clamp
- Spread a thin layer of Molikote (MSO2) on the thread and under
the lower side of the head of each of the srews, keeping the heat
sink by means of the press clamp in place. Spread Molikote also
on the side of the washers, which comes in contact with the
screw. Spread a thin layer of heat conducting paste on the bottom of the heat sink with a rubber spatula. Place the busbar and
the heat sink above the thyristor and fix them with the press
clamp. Tighten the clamping screws by hand until the screw
heads touch the bottom of the module.
Molikote
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 6 - 3
Chapter 6 - Exchange of Thyristors for Size C3
- Find the required torque from the table below. Tighten the
screws alternatively 1/4 turn at a time until the correct torque is
reached.
Converter type
Torque / Nm
Force / kN
Press
clamp
400 V - 500 V
DCS x0x-0900-4(5)
5,5 - 6
8
- 12
SLZF 89A
DCS x0x-1200-4(5)
5,5 - 6
8
- 12
SLZF 89A
DCS x0x-1500-4(5)
11,5 - 12
14,4 - 24
SLZF 89B
DCS x0x-2000-4(5)
11,5 - 12
14,4 - 24
SLZF 89B
10
- 15
SLZF 89A
14,4 - 24
SLZF 89B
600 V - 690 V
DCS x0x-0900-6(7)
7,5 - 8
DCS x0x-1500-6(7)
11,5 - 12
Table 6-1
Mounting torques and forces for disc type thyristors
- In case of a 4-quadrant type converter:
• Perform the OHM test with both polarities another time to
make sure, the thyristor, which was used for the reverse
bridge, is definitly healthy.
• If this test indicates high resistance, the thyristor is healthy
and can be used.
• If this test indicates low resistance, the thyristor of the reverse bridge is faulty and needs to be replaced: remove it
again mount a new one as described above.
- Install in the fuse(s).
- Connect the lead of the snubber capacitor, if it was removed
before.
- Reconnect all parts, which were removed before:
• plastic covers, etc.
VI A 6 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 6 - Exchange of Thyristors for Size C3
P2
P2
T51
T53
P1
P1
Direction of the thyristors
F11
F14
F13
F16
Indicator
F15
F12
Connect wiring of snubber circuits !!
Front view
Figure 6-1
View from the left
Location of thyristors in modules size C3
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 6 - 5
Chapter 6 - Exchange of Thyristors for Size C3
Thyristors only in the
case of 4-Q converters
Figure 6-2
VI A 6 - 6
Location of thyristors in modules size C3
Note: Removed fuses, busbars and upper parts of heat sinks
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 7 - Exchange of Thyristors for Size C4
Installation of "Disc
Type" thyristor in converters size C4
(2050...5150 A)
Required Tools
All DCS 500 and DCS 600 converters sizes A5/C3/C4 are equipped
with disk type thyristors.
The structure of the "Disc type" semiconductor component is such
that it requires a certain compression force to operate. The prevention of overheating of the component essentially depends on a well
heat dissipation between the semiconductor and the conducted
heat sink. It is thus important that all joints have good thermal and
electrical conduction.
Special tools or material needed in addition to standard tools for the
exchange of thyristor modules:
- Torque spanner for electrical connections:
13 Nm (M8)
25 Nm (M10)
50 Nm (M12)
- Screws are metric type; use appropriate nuts.
- 17 mm ring spanner for fuse and busbar connections.
- 24 mm ring spanner for press clamp.
- Tissue paper / solvent (e.g. ethanol).
- Thermal joint compound:
type BECHEM-RHUS SU 2
(grease)
Manufacturer:
ABB Service:
- Disassembly tool:
Note:
Carl Bechem GmbH, 58089 Hagen
GHSN 390 001 P 0001
DCF 1066721 P1
For more detailed information about the wiring of
the power part, see publication Technical Data.
Therefore strict observance of the build in instructions given below
is of utmost importance. Make sure that the new component can
replace the old one in accordance with the spare part list (see Appendix A).
Thyristors are always mounted in the same direction, independent
of current, voltage, number of quadrants (2-Q or 4-Q) version or left
or right side connection. Semiconductors and heat sinks are to be
handled carefully to avoid scratches and other damage. Avoid
touching the contact surfaces. Do not lift the semiconductor with the
gate wire. Do not lift the semiconductor unit by touching the current
contact surfaces. Do not damage the welding flange or the contact
surface.
Before you start work, disconnect the converter
completly from the power supply then check the
voltage free condition and make sure, everything
is located in an electrically and mechanically safe
condition!
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 7 - 1
Chapter 7 - Exchange of Thyristors for Size C4
Find faulty thyristor
- Find the defective branch(es) by performing an OHM test (both
polarities) between U1, V1, W1 and C1, D1 (see Figure 5-1).
- Remove the screws of the left and right branch fuses. Remove
the busbar, leading to the AC connection, too (not necessary at
2-quadrant converters, left version!).
- If you have a 4-quadrant converter:
• Remove the screws of the DC busbar either above or below
the blown fuse.
Note: the connection is made with a screw socket, which
may fall down, if the last screw is removed.
• Put a small piece of isolator (paper, cardboard, plastic, etc.)
between the DC busbar and the heat sink.
• Perform the OHM test with both polarities between the DC
busbar and the heat sink as the second measuring point.
• Now perform the OHM test with both polarities between the
isolated heat sink and the heat sink, which was connected to
the fuse as the second measurement point.
• Depending on the result, the thyristor located between the
measuring terminals of the first test or the second one needs
to be removed.
Remove faulty thyris- - If the thyristor is partly covered by a fuse, loosen the screws and
tor
move the fuse some centimeters up or down; fix the fuse.
- Remove the gate leads if possible.
- Loosen the mounting clamp (see Figure 7-2) 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!
- Attach the disassembly tool at the faulty thyristor and prise open
the upper and lower heat sinks (see Figure 7-1). The copper
bars need not be loosened .
- Remove the thyristor.
VI A 7 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 7 - Exchange of Thyristors for Size C4
Mounting clamp
View from
the right
View from
the left
Disassembly tool
Front view
Figure 7-1
Install new thyristor
How to use the disassembly tool (at a left thyristor
stack of a converter)
- 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.
- Clean the polished surfaces of the semiconductor with a piece of
tissue paper moistened with solvent. Dry all surfaces. Spread a
thin layer of heat conducting paste on both sides of the thyristor,
if necessary use a rubber spatula.
- Connect the gate leads if possible.
- Clean all parts with tissue paper moistened with solvent, witch
have had or will have contact with the thyristor or each other
(lower / upper heat sink). Do not clean the surfaces of grease
too thoroughly, because the aluminium surfaces will oxidise in a
few seconds. Dry all surfaces.
- Push the thyristor until it snaps into its mounting clamp.
Note: Be sure that the thyristor is installed in the right direction.
Do not pinch or cut the gate leads or any other cable.
- Turn the thyristor so that the gate leads point in the right direction.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 7 - 3
Chapter 7 - Exchange of Thyristors for Size C4
Loose
condition
Insulating plate
In-
sulating tube
TORQUE INDICATING SPRING
Heatsink
Correct torque
Figure 7-2
Aluminium spring with welded indicating spring
- Tighten the nuts of the mounting clamp by hand so that the
clamp is in parallel with the contact surface of the heat sinks.
Note: The indicating spring is a very sensitive instrument and
must be handled with care.
- Tighten each nut in turn, half a turn at a time with the help of a
ring spanner until the indicating spring clicks into position “correct torque” (see Figure 7-2). Do not tighten the screws any
further.
Note: The correct torque is indicated by means of the welded indicating spring.
- Perform an OHM test to make sure the thyristor is ok.
- Reconnect the DC / AC – busbars, branch fuses and all other
dismantled parts.
- Perform an OHM test between U1, V1, W1 and C1, D1 to make
sure the power part is ok.
VI A 7 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 7 - Exchange of Thyristors for Size C4
V11
V21
V21
V11
V24
V14
V14
V 24
V13
V 23
V23
V 13
V26
V16
V16
V26
V15
V25
V25
V15
V22
V12
V12
V22
Assemb ly C4
Busba rs o n th e ri ght
(fr ont o f the module)
Figure 7-3
A ssembly C4
B usbars on the left
( front of th e mod ule )
Location of thyristors in size C4 (4-Q bridge)
V11
V11
V14
V 14
V 13
V13
V16
V 16
V15
V15
V12
V12
A ssemb ly C4
B usba rs o n th e right
( front o f the module )
Figure 7-4
Assemb ly C4
Busba rs o n th e left
(fr ont o f th e mod ule )
Location of thyristors in frame C4 (2-Q bridge)
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 7 - 5
Chapter 7 - Exchange of Thyristors for Size C4
VI A 7 - 6
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 8 - Compatibility of SDCS-PIN-2 boards
Description of SDCSPIN-20xB boards
- In general the SDCS-PIN-20xB board has the same features as
its predecessors (SDCS-PIN-20xA/20x or SDCS-PIN-2x).
- It is used for all DCS converters Module sizes C1 (≥ 100A), C2
and C2b regardless of software version and function (armature
or field supply).
- Converters equipped with the SDCS-PIN-20xB/20xA/20x boards
can be identified by serial number. Every serial number is divided into two parts by a letter. With the SDCS-PIN20xB/20xA/20x the serial number looks like 1234567B1234567.
For the SDCS-PIN-2x an A is used.
- There are two types of SDCS-PIN-20xB boards:
• SDCS-PIN-205B for converters with a incoming voltage of
400V/500V
• SDCS-PIN-206B for converters with a incoming voltage of
600V
- The advantage of the SDCS-PIN-20xB/20xA/20x is the replacement of 6 other boards plus a small RC network. Thus the spare
part handling becomes easier.
Hardware coding
On the SDCS-PIN-20xB resistors are used for hardware coding of
the module, zero current detection and current scaling. In a new
converter the resistors are already cut according to application. If
the SDCS-PIN-20xB board is used as spare part all resistors are
still uncut. The resistors have to be cut according to the table ‘Settings of the SDCS-PIN-20xB board’ as described in the manual
Technical Data.
Snubber circuit
The incoming AC voltage is connected to the SDCS-PIN-20xB
board via integrated fuses. The snubber circuit (RC network) is integrated as well and connected in parallel to the thyristors. This
configuration leads to lower losses thus to a higher efficiency of the
converter. Before larger converters had external RC networks.
These are no longer needed.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 8 - 1
Chapter 8 - Compatibility of SDCS-PIN-2 boards
Compatibility of
SDCS-PIN-20x
boards
The SDCS-PIN-20xB boards replaces SDCS-PIN-20xA and SDCSPIN-20x boards, but not vice versa.
Note: SDCS-PIN-20xA replaces SDCS-PIN-20x, but not vice versa.
UAC
400V/500V
600V
IDC
100A-350A 405A-520A 700A
610A-1000A 100A-270A 405A/450A
Type
C1/C2
C2
C2
C2b
C1/C2
C2
9
9
9
9
SDCS-PIN-205B
9
9
SDCS-PIN-206B
9
SDCS-PIN-21
9j
SDCS-PIN-22
9
SDCS-PIN-23
9j
SDCS-PIN-24
9k
SDCS-PIN-25
9
9
9
SDCS-PIN-205A/205
9
9
SDCS-PIN-206A/206
9: possible - : not possible
j together with SDCS-PIR-21
k together with RC network
Table 8-1
Compatibility of SDCS-PIN-2xx boards
Compatibility of
SDCS-PIN-20x and
SDCS-PIN-2x boards
Converters 100A ≤ IDC ≤ 350A and UAC: 400V/500V
- SDCS-PIN-21 or
- SDCS-PIN-205B/205A/205 can be used as spare parts.
Converters 405A ≤ IDC ≤ 520A and UAC: 400V/500V
- SDCS-PIN-22 together with SDCS-PIR-21 or
- SDCS-PIN-205B/205A/205 can be used as spare parts.
Converters IDC = 700A and UAC: 400V/500V (type C2)
- SDCS-PIN-25 together with RC network (possible only in
converters with an A in their serial number) or
- SDCS-PIN-205B/205A/205 can be used as spare parts (possible in converters with an A or B in their serial number). In
an A converter do not connect the RC network.
Note: In a B converter only SDCS-PIN205B/205A/205 boards
are usable, because the RC network is missing.
Converters 610A ≤ IDC ≤ 1000A and UAC: 400V/500V (type C2b) only
- SDCS-PIN-205B can be used as spare part.
Converters 100A ≤ IDC ≤ 270A and UAC: 600V
- SDCS-PIN-23
- SDCS-PIN-206B/206A/206 can be used as spare parts.
Converters IDC = 405A/450A and UAC: 600V
- SDCS-PIN-24 together with SDCS-PIR-21 or
- SDCS-PIN-206B/206A/206 can be used as spare parts.
Note: In addition to above mentioned limitations make sure that
the resistors are cut properly according to the table ‘Settings of
the SDCS-PIN-20xB board’ as described in the manual Technical Data. Especially when a board is reused!
VI A 8 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 8 - Compatibility of SDCS-PIN-2 boards
Change SDCS-PIN-2x
boards
The converter is equipped with a SDCD-PIN-21/22/23/24 board:
- Make sure, electrical and mechanical safety is obtained!
- Mark the cables connected to U1, V1, W1 and C1, D1. Mark the
plugs connected to X22, X3 and X4.
- Disconnect all cables and plugs.
- Remove the SDCS-PIN-2x board.
Note: If the converter is equipped with a SDCS-PIR-21 there is
no need to remove this board separately, because it is mounted
on the SDCS-PIN-2x board.
- Make sure that the resistors on the new board are cut properly
according to the table ‘Settings of the SDCS-PIN-20xB board’ as
described in the manual Technical Data.
- Install the new SDCS-PIN-20xB board.
Note: SDCS-PIN-205B replaces SDCS-PIN21/23 and SDCSPIN-206B replaces SDCS-PIN-22/24.
- Reconnect all cables and plugs.
The converter is equipped with a SDCD-PIN-25 board:
- Make sure, electrical and mechanical safety is obtained!
- Mark the cables connected to U1, V1, W1 and C1, D1. Mark the
plugs connected to X22, X3 and X4.
- Disconnect all cables and plugs.
- Remove the SDCS-PIN-25 board.
Note: The additional RC network is not needed anymore. Due to
safety reasons remove the cables marked U1 – C14, V1 – C16,
W1 – C12, C1 – R15 and D1 – R12.
- Make sure that the resistors on the new board are cut properly
according to the table ‘Settings of the SDCS-PIN-205B board’ as
described in the manual Technical Data.
- Install the new SDCS-PIN-205B board.
Note: SDCS-PIN-205B replaces SDCS-PIN25.
- Reconnect all cables and plugs.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 8 - 3
Chapter 8 - Compatibility of SDCS-PIN-2 boards
VI A 8 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 9 - Preventive Maintainance
WARNING! Before performing any maintenance the chapter
‘Safety Instructions’ at the beginning of this manual and within the
corresponding Operating Instructions must be followed. Negligence of these instructions can cause injury or death.
Recommended
regular maintenance
The DCS requires very little maintenance if installed in an appropriate environment.
An annual check for dust accumulation and corrosion inside the
module / cabinet is recommended.
Air Filters
When air filters are used, the filters should be checked regularly
depending on environmental conditions. Clocked up filters prevent the proper cooling of the drive.
Wash dirty filters with water (60°C) and detergent.
Cooling air pressure switch in
converter modules type C4
The cooling air pressure switch must be checked regularly.
The following actions have to take place:
- Make sure electrical safety is performed.
- Open the module's door and hold it in position to prevent any
movement.
- Repeat it with the cabinet’s door.
- Switch on the drive and try to turn the motor.
- The air pressure switch is ok when the converter is switched
off by error “F50 NO C FAN”; crosscheck this result with the
module’s door closed.
Fan
The lifetime of the cooling fan is about 20.000 to 40.000 hours
depending on the converter type. The actual lifetime depends on
the usage of the DCS and the ambient temperature.
Fan failure can be predicted by means of increasing noise from
its bearings and a gradual rise of the heatsink temperature. If the
DCS operates in a critical part of the process it is recommended
to replace the fan once the above mentioned symptoms appear.
Heatsink
The DCS will run into overtemperature faults if the heatsinks are
not clean. In an appropriate environment the heatsinks should be
checked and cleaned annually.
Use compressed air to remove the dust from the heatsinks (the
air flow must be from bottom to top). Fan rotation caused by the
compressed air must be stopped in order to prevent damage.
Additionally use a vacuum cleaner to clean the dust from the air
inlet and outlet.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 9 - 1
Chapter 9 - Preventive Maintainance
Internal high current connections
in converters
type C4
The thyristors together with the heatsinks are stacked. Every single thyristor is connected to the DC+ and DC- busbars via flexible
copper busbars. These busbars consist of 10 layers of preshaped
sheet copper. This construction is able to compensate for small
changes in length caused by temperature rise when current is
flowing. The screw fixings between heatsink and flexible copper
busbar have to withstand different types of mechanical stress.
Therefore each fixing needs to be checked for correct torque.
This check should be done regularly, e.g. annually or together
with all the other work to be done for preventive maintenance.
Actions:
- Make sure all supply voltages are switched off, most important
the supply for the power part (armature), for the electronic
power part (SDCS-POW-1), for the converter fan and for other
auxiliaries!
- Open the cabinet’s and module’s door; if needed secure them.
- Set a latching torque spanner to 25 Nm (18 lb-ft); a 17 mm nut
is needed too.
- Check the torque of the screws marked within Figure 9-1 at the
end of this chapter:
- Apply the torque spanner to the screw and turn right until
the right torque is indicated.
- Don’t loosen the screws by a left hand turn!
- Put on a new marking, if appropriate.
Relays and electrical connections
Relays should be checked for proper function and all connections
should be inspected and checked for tightness. Any signs of corrosion, especially at ground components, must be removed.
VI A 9 - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Chapter 9 - Exchange of Thyristors 25 - 700 A
Screws to be checked:
Screws to be checked:
Screws to be checked:
Screws to be checked
(located behind the busbar):
Figure 9-1: Power part of a converter module type C4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A 9 - 3
Chapter 9 - Preventive Maintainance
VI A 9 - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Item 2.10 to Item 3.60 Common Electronic Parts
2.10 COMMON PARTS FOR CONV. DCS500B/DCF500Bxxxx-xx-21..(CON-2)
DESCRIPTION
QTY
CODE
TYPE/DATA
NOTES
Control board DCS500 B
1
3ADT220072R4
SDCS-CON - 2
Power supply board
1
3ADT220090R3
SDCS-POW-1 COAT
with actual software21.xxx
2.20 COMMON PARTS FOR CONV. DCS600 / DCF600xxxx-xx-15.MultiDrive; 18.Crane SW
DESCRIPTION
QTY
CODE
TYPE/DATA
NOTES
Control board +AMC-DC Board
1*
3ADT220072R5 SDCS-CON-2+AMC-DC w.act. SW.15.xxx+AMC-DC-Board.
Control board +AMC-C-Clas1.
1*
3ADT220072R7
Control b.+AMC-DC Crane
1*
3ADT220072R22
CON-2-18+AMC DC
Control b.+AMC-C-Clas1/Crane
1*
3ADT220072R20
CON-2-18+AMC-C
Power supply board
1
3ADT220090R3
SDCS-POW-1 COAT
SDCS-CON-2+AMC-C w.act.SW.15.xxx+AMC-C-Board.
Crane SW18+AMC-DC; incl.Fee
Crane SW18+AMC-C;incl.Fee
*) Select only one Board
2.30 Interface Boards; Panels for DCS500B/DCS600 Modules / Cabinets
DESCRIPTION
QTY
CODE
TYPE/DATA
NOTES
*)DI/DO connection board
1*
3BSE005176R1
SDCS-IOB-21
24V DC-48V DC
*)DI/DO connection board
1*
3BSE005177R1
SDCS-IOB-22
115V AC
*)DI/DO connection board
1*
3BSE005178R1
SDCS-IOB-23
230V AC
AI/AO connection board
1
3BSE004086R1
SDCS-IOB-3
Communication Board/DCS500B
1
3ADT220059R1
SCDS-COM-5
separate; only for DCS500B
AMC-Communic. Board DCS600
1
3ADT309900R1
AMC-DC Board
without Software f. DCS600
AMC-Communic. Board DCS600
1
3BSE017192R1
Control Panel
1
3ADT220071R5
CDP312 Rev.F
I/O Extension Board
1
3BSE005851R1
SDCS-IOE-1
Adapt. Board /Analog Tacho
1
3ADT300600R1
PS 5311- SET
AMC-DC_Clas1-Board without Software f. DCS600
For DCS500B & DCS600
*) Select only one Board
DCR-Kit contains: 2Q 4Q
2.40 PARTS FOR DCR REBUILD KITS, 12 PULSE AND PARALLELING DCS CONV.
2Q 4Q
CODE
TYPE/DATA
DESCRIPTION
Cooling fan
1
1
DCA0017670P1
CN52B2
Pulse Interface Board
1
1
DCF1154914R1
SDCS-REB-1
DCR
for DCR500B/600 Type
Pulse Amplifier Board
1
1
DCF1192115R1
SDCS-REB-2
DCR
Pulse Distribution Board
1
1
3ADT309300R1
SDCS-REB-3
DCR
Power Supply for REB-2
2
2
DCE8920037P1
NPSM-01
230V//24V DC// 2A
DCR
SDCS- PIN- 41A and PIN-51 see item 19.00 - 38.00 or below
Pulstransformer Board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Current Measurement Aid
1
1
3ADT220090R22
SDCS-CMA-2-Coat
Paralleling Interface Board 1
1
1
3ADT311200R1
SDCS-PAR-1
Paralleling Master Conv.
Paralleling Interface Board 2
1
1
3ADT311300R1
SDCS-PAR-2
Paralleling Slave Conv.
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
for 400V up to 1000V AC
12 Pulse and Paralleling Converter
VI A A - 1
Appendix A- Spare Parts List
2.50 2-PHASE FIELD EXCITERS
DESCRIPTION
QTY
CODE
TYPE/DATA
Integrated uncontr. 6 A; FEX-1
1
DCA0012317R1
SDCS-FEX-1
Integrated single 16 A; FEX-2
1
DCA0012325R1
SDCS-FEX-2 A
Sep. compl. Unit; incl. Thyristor M.
Control Board DCF503A0050
1
3ADT312400R2
SDCS-FEX-32A
Control Board f. DCF503A0050
Thyristor/Diode Module 1Q 50A
2
DCA0003270P1
SKKH 57/16 E
Control Board DCF504A0050
1
3ADT312400R1
SDCS-FEX-31A
Thyristor modules 4Q 50A
2
DCA0011132P1
SKKT42/16E
Ext. DCF503A0050; 1Q 50 A
1
3ADT209019R1
DCF503A0050
Complete unit DCF503A0050
Ext. DCF504A0050; 4Q 50 A
1
3ADT209019R2
DCF504A0050
Complete unit DCF504A0050
3.10 Coated Boards for DCS500B see item 2.10
DESCRIPTION
QTY
CODE
NOTES
Sep. compl. Unit; incl. Diode M.
for DCF503-0050
Control Board f.DCF504A0050
for DCF504-0050
TYPE/DATA
NOTES
Control board DCS500 B
1
3ADT220072R12 SDCS-CON - 2-21-coat with actual software21.xxx
Power supply board
1
3ADT220090R3
3.20
SDCS-POW-1 COAT Repl. for DCA0012279R0001
Coated Boards for DCS600 / DCF600 see item 2.20
Control board +AMC-DC Board
1*
3ADT220072R9
Control board +AMC-C-Clas1.
1*
3ADT220072R11
CON-2+AMC-C-coat
Power supply board
1
3ADT220090R3
SDCS-POW-1 COAT Repl. for DCA0012279R0001
3.30
CON-2+AMC-DC-coat w.act. SW.15.xxx+AMC-DC-Board.
w.act.SW.15.xxx+AMC-C-Board.
Coated Interface Boards; Panels for DCS500B / DCS600 Modules / Cabinets
*)DI/DO connection board
1*
3ADT220090R14
SDCS-IOB-21-coat
24V DC-48V DC
*)DI/DO connection board
1*
3ADT220090R13
SDCS-IOB-22-coat
115V AC
*)DI/DO connection board
1*
3ADT220090R23
SDCS-IOB-23-coat
230V AC
AI/AO connection board
1
3ADT220090R20
SDCS-IOB-3-coat
Communication Board
1
3ADT220090R26
SCDS-COM-5-coat
I/O Extension Board
1
3ADT220090R25
SDCS-IOE-1-coat
Adapt. Board /Analog Tacho
1
3ADT220090R29
PS 5311- coat
3.40
separate
Coated Boards for DCR Rebuild Kits and 12 PULSE-Systems See item 2.30
Pulse Interface Board
1
1
3ADT220090R9
SDCS-REB-1-coat
Coated Board for DCR
Coated Board for DCR
Pulse Amplifier Board
1
1
3ADT220090R34
SDCS-REB-2-coat
Pulstransformer Board
1
2
3ADT220090R5
SDCS-PIN-41 A-coat
Power interface board
1
1
3ADT220090R6
SDCS-PIN-51-coat
for 400V up to 1000V AC
Current Measurement Aid
1
1
3ADT220090R22
SDCS-CMA-2-coat
12 Pulse and Paralleling Converter
3.50
Coated Boards for 2-PHASE FIELD EXCITERS see item 2.50
Integrated single 16 A; FEX-2
1
3ADT220090R19
SDCS-FEX-2 A-coat
Control Board DCF503A0050
1
3ADT220090R37
SDCS-FEX-32A-coat Coat. Contr. Board DCF503A..
Sep. compl. Unit; coated Vers.
Control Board DCF504A0050
1
3ADT220090R36
SDCS-FEX-31A-coat Coat. Contr. Board DCF504A..
Ext. DCF503A-0050; 1Q 50 A
1
3ADT209019R0101 DCF503A0050-Coat
Complete unit DCF503A0050
Ext. DCF504A0050; 4Q 50 A
1
3ADT209019R0102 DCF504A0050-Coat
Complete unit DCF504A0050
VI A A - 2
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
3.60
Coated Boards for 25A - 5150A Modules
Power interface board
1
1
3ADT220090R27
Power interface board
1
1
3ADT220090R35
SDCS-PIN 205B-Coat 100A - 1000A/400/500V Mod.
SDCS-PIN-11-coat
Power interface board
1
1
3ADT220090R38
SDCS-PIN 206B-Coat 110A,270A and 450A/600V M.
Power interface board
1
1
3ADT220090R6
Puls transformer board
1
2
3ADT220090R5
SDCS-PIN-51-coat
25A; 50A and 75A Mod.
for 400V up to 1000V AC
SDCS-PIN-41 A-coat 900A - 5150A
*) Select only one Board
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A A - 3
Appendix A- Spare Parts List
Item 4.00 to 10.00 Modules DCS500B / DCS600 Size C1 25A----140A
4.00 Common Parts for C1, C2, C2b and C3 Modules
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Temperature Sensor (R57)
1
1
DCA0012139P1
KTY 10-6 M4
NOTES
(C1-C3 / 550mm cable)
Fuse F101; F102 and F103 on PIN205B and PIN206B see Modules from 100A to 1000A; item 8.00 - 18.00
Module contains: 2Q 4Q
4.10 25 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor modules
3
6
DCA0008018P1
SKKT27/16E *
Power interface board
1
1
3ADT306100R1
SDCS-PIN-11
Semiconductor fuses
3
3
DCZ9838767P1
170M1564
Cooling fan
1
1
DCA0017670P1
CN52B2
DCF501,502B, DCF 601, 602 (1)
(1) If used as a spare part for DCF... the resistors R113/R116/R119 must be removed. For further information see "Technical Data"
* DCS500/DCS600 Thyr. Modules SKKT 27 / 16E are not identical to Thyr. Modules SKKT 27 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
5.00 50 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor modules
3
6
DCA0011132P1
SKKT42/16E *
Power interface board
1
1
3ADT306100R1
SDCS-PIN-11
Semiconductor fuses
3
3
DCZ9838791P1
170M1566
Cooling fan
1
1
DCA0017670P1
CN52B2
NOTES
DCF501,502B, DCF 601, 602 (1)
(1) If used as a spare part for DCF... the resistors R113/R116/R119 must be removed. For further information see "Technical Data"
* DCS500/DCS600 Thyr. Modules SKKT 42 / 16E are not identical to Thyr. Modules SKKT 42 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
6.00 50 A (600V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor modules
3
6
DCA0011906P1
SKKT57/20E *
Power interface board
1
1
3BSE005716R1
SDCS-PIN-12
Semiconductor fuses
3
3
DCZ9838791P1
170M1566
Cooling fan
1
1
DCA0017670P1
CN52B2
NOTES
changed Oct.2001
* DCS500/DCS600 Thyr. Modules SKKT 57 / 16E are not identical to Thyr. Modules SKKT 57 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
7.00 75 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor modules
3
6
DCA0011914P1
SKKT57/16E *
Power interface board
1
1
3ADT306100R1
SDCS-PIN-11
Semiconductor fuses
3
3
DCA0012686P1
170M1568
Cooling fan
1
1
DCA0017670P1
CN52B2
NOTES
DCF501,502B, DCF 601, 602 (1)
(1) If used as a spare part for DCF... the resistors R113/R116/R119 must be removed. For further information see "Technical Data"
* DCS500/DCS600 Thyr. Modules SKKT 57 / 16E are not identical to Thyr. Modules SKKT 57 B/16E used for DCS400 Converter Modules
VI A A - 4
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Module contains: 2Q 4Q
8.00 100 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor modules
3
6
DCA0011931P1
SKKT 106/16E *
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012694P1
170M3815
Cooling fan
1
1
DCA0012678P1
W2E143-AA09-25
* DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
9.00 110 A (600V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor modules
3
6
DCA0011922P1
SKKT72/20E
Power interface board
1
1
3ADT312500R2
SDCS-PIN 206B
Repl. SDCS PIN-23 and PIN206
Fuse F101- F103 on PIN206B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN206B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012694P1
170M3815
Cooling fan
1
1
DCA0012678P1
W2E143-AA09-25
Module contains: 2Q 4Q
10.00 140 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor modules
3
6
TYPE/DATA
DCA0011931P1
SKKT 106/16E *
NOTES
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012694P1
170M3815
Cooling fan
1
1
DCA0012678P1
W2E143-AA09-25
* DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A A - 5
Appendix A- Spare Parts List
Item 11.00 to 17.10 Modules DCS500B / DCS600 Size C2 200A----520A
Module contains: 2Q 4Q
11.00 200 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor modules
3
6
DCA0011931P1
SKKT 106/16E *
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
3ADC770024P9
170M3816
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
* DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
12.00 250 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor modules
3
6
TYPE/DATA
DCA0011931P1
SKKT 106/16E *
NOTES
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
3ADC770024P10
170M3817
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
* DCS500/DCS600 Thyr. Modules SKKT 106 / 16E are not identical to Thyr. Modules SKKT 106 B/16E used for DCS400 Converter Modules
Module contains: 2Q 4Q
13.00 270 A (600V) CONVERTER
DESCRIPTION
2Q 4Q
Thyristor modules
3
6
CODE
TYPE/DATA
DCA0011957P1
SKKT132/20E
NOTES
Power interface board
1
1
3ADT312500R2
SDCS-PIN 206B
Repl. SDCS PIN-23 and PIN206
Fuse F101- F103 on PIN206B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN206B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0003547P1
170M3819
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
Module contains: 2Q 4Q
14.00 350 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor modules
3
6
changed in Oct.2001
TYPE/DATA
NOTES
DCA0011965P1
SKKT 162 / 16E
alt.TT162N16KOF - GHSN610178P2
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012708P1
170M5810
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
Module contains: 2Q 4Q
15.00 450 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor modules
3
6
TYPE/DATA
DCA0011973P1
SKKT250/16E
NOTES
alt.TT250N16KOF-GHSN610089P2
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012716P1
170M6811
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
VI A A - 6
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Module contains: 2Q 4Q
16.00 450 A (600V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor modules
3
6
DCA0011981P1
SKKT210/20E
Power interface board
1
1
3ADT312500R2
SDCS-PIN 206B
Repl. SDCS PIN-23 and PIN206
Fuse F101- F103 on PIN206B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN206B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012716P1
170M6811
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
Module contains: 2Q 4Q
17.00 520 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
alt.TT250N18KOF
NOTES
Thyristor modules
3
6
DCA0011973P1
SKKT250/16E
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012716P1
170M6811
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
Module contains: 2Q 4Q
17.10 700 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
6
12
TYPE/DATA
alt.TT250N16KOF-GHSN610089P2
NOTES
3ADC340041P1
TZ425N16KOF
SKET400/16E - DCA 0011990P1
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012724P1
170M6813
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A A - 7
Appendix A- Spare Parts List
Item 18.10 to 18.30 Modules DCS500B / DCS600 Size C2b 680A----1000A
Module contains: 2Q 4Q
18.10 680 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor modules
3
6
3ADC340032P1
TT 425 N16KOF
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses
3
3
DCA0012724P1
170M6813
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
Module contains: 2Q 4Q
18.20 820 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Fuses also used for Encl. Conv.
TYPE/DATA
NOTES
Thyristor modules
3
6
3ADC340066P1
TT 570 N16KOF
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses/Module *
3
3
DCA0012724P1
170M6813
Fuses for Cabinets are differ.*
Cooling fan
1
1
DCA0012171P1
W2E200-HH38-06
* Fuses used in Encl. Converter
3
3
3ADV050092P20
170M6016
Module contains: 2Q 4Q
18.30 1000 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Fuses for Encl. Conv. w. OESA
TYPE/DATA
NOTES
Thyristor modules
3
6
3ADC3400066P1
TT 570 N16KOF
Power interface board
1
1
3ADT312500R1
SDCS-PIN 205B
Repl. SDCS PIN-21 and PIN205
Fuse F101- F103 on PIN205B
3
3
3BSC770010R0101
KTK-R6A/660V
for PIN205B; min.QTY 10pcs
Semiconductor fuses/Module *
3
3
3ADC770010P9
170M6166
Fuses for Cabinets are differ.*
Cooling fan
1
1
3ADT754016P1
W2E250-HL06-08
* Fuses used in Encl. Converter
3
3
3ADV050092P20
170M6016
VI A A - 8
Fuses for Encl. Conv. w. OESA
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Item 19.00 to 24.00 Modules DCS500B / DCS600 Size A5 900A----2000A
19.01 Common Parts for A5 Modules
DESCRIPTION
2Q 4Q
CODE
Temperature Sensor (R57)
1
1
3ADT710003P1
Module contains: 2Q 4Q
19.00 900 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
KTY 2K-M4-800
TYPE/DATA
6
12
DCA0012007P1
T459N24TOF
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770009P7
170M6144
Cooling fan
1
1
3ADT754018P1
D2E 160-AH02-15
Module contains: 2Q 4Q
20.00 1200 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0012015P1
T589N18TOF
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770010P5
170M6162
Cooling fan
1
1
3ADT754018P1
D2E 160-AH02-15
Module contains: 2Q 4Q
21.00 1500 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0012031P1
5STP18F1800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770010P9
170M6166
Cooling fan
1
1
3ADT754018P1
D2E 160-AH02-15
Module contains: 2Q 4Q
22.00 1500 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
NOTES
TYPE/DATA
6
12
DCA0012023P1
5STP16F2400
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770009P12
170M6149
Cooling fan
1
1
3ADT754018P1
D2E 160-AH02-15
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
NOTES
NOTES
NOTES
NOTES
VI A A - 9
Appendix A- Spare Parts List
Module contains: 2Q 4Q
23.00 2000 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
3ADC340074P1
5STP1818F0003
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770010P12
170M6169
Cooling fan
1
1
3ADT754018P1
D2E 160-AH02-15
Module contains: 2Q
24.00 2000 A (600V-690V) CONVERTER
DESCRIPTION
2Q
CODE
TYPE/DATA
Thyristor
6
3ADC340075P1
5STP24H2800
Puls transformer board
1
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
3ADC770009P13
170M6151
Cooling fan
1
3ADT754018P1
D2E 160-AH02-15
NOTES
NOTES
Item 19.10 to 24.10 Modules DCS500B / DCS600 Size C3 900A----2000A
Module contains: 2Q 4Q
19.10 900 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012015P1
T589N18TOF
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0010683P1
170M6035
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
Module contains: 2Q 4Q
20.10 900 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0012007P1
T459N24TOF
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012791P1
170M6143
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
Module contains: 2Q 4Q
21.10 1200 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0012015P1
T589N18TOF
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0010683P1
170M6035
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
VI A A - 10
NOTES
NOTES
NOTES
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Module contains: 2Q 4Q
22.10 1500 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0012031P1
5STP18F1800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770010P9
170M6166
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
Module contains: 2Q 4Q
23.10 1500 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012023P1
5STP16F2400
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012805P1
170L7299
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
Module contains: 2Q 4Q
24.10 2000 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012031P1
5STP18F1800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
3ADC770010P9
170M6166
Cooling fan
1
1
3ADT754006P1
RD23P-4DW.4I.1R
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
NOTES
former Id. Nr.DCA0012741P1
NOTES
NOTES
former Id. Nr.DCA0012741P1
VI A A - 11
Appendix A- Spare Parts List
Item 25.00 to 38.00 Modules DCS500B / DCS600 Size C4 2050A----5150A
25.00 Common Parts for C4 Modules
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Air Flow detector ( P1)
1
1
DCF1066659P1
P 33 AB
Temperature Sensor (R57)
1
1
DCA0012139P3
KTY 10-6 M4
Module contains: 2Q 4Q
25.10 2050 A (600V-690V-790V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
NOTES
(C4 / 950mm cable )
TYPE/DATA
NOTES
Thyristor
6
12
DCA0016142P1
5STP16F2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
*)Cooling fan (Bus Bars"Left side") 1
6
DCA0017149P1
170M7031
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-2050-61L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-2050-61R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
26.00 2050 A (1000V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
6
12
DCA0012058P1
5STP18L3600
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012864P1
170M7510
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-2050-91L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-2050-91R21P..
Thyristor
1
NOTES
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
27.00 2500 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
6
12
DCA0016169P1
5STP24L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
NOTES
6
6
DCA0012848P1
170M7034
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-2500-41L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-2500-41R21P..
1
*) Select only one Cooling Fan for this C4 Modules
VI A A - 12
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Module contains: 2Q 4Q
28.00 2500 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
NOTES
6
12
DCA0016169P1
5STP24L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012848P1
170M7034
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-2500-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-2500-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
29.00 2650 A (1000V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012058P1
5STP18L3600
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
NOTES
6
6
DCA0012864P1
170M7510
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-2650-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-2650-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
30.00 3200 A (790V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
6
12
DCA0016169P1
5STP24L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0017271P1
170M7035
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-3200-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-3200-x1R21P..
Thyristor
1
NOTES
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
31.00 3200 A (1000V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012066P1
5STP28L3600
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012872P1
170M7513
*)Cooling fan (Bus Bars"Left side") 1
*)Cooling fan (Bus Bars"Right side 1
1
DCA0018692P1
RG35P-4DK.7M.1R
1
DCA0012660P1
RG35P-4DK.7M.1L
NOTES
e.g. DCSxxx-3200-x1L21P..
e.g. DCSxxx-3200-x1R21P..
*) Select only one Cooling Fan for this C4 Modules
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A A - 13
Appendix A- Spare Parts List
Module contains: 2Q 4Q
32.00 3300 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
NOTES
Thyristor
6
12
DCA0016169P1
5STP24L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0017271P1
170M7035
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-3300-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-3300-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
33.00 3300 A (600V-690V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0016169P1
5STP24L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
NOTES
6
6
DCA0017271P1
170M7035
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-3300-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-3300-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
34.00 4000 A (400V-500V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
NOTES
6
12
DCA0016151P1
5STP27L1800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012821P1
170M7026
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-4000-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-4000-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
35.00 4000 A (600V-690V-790V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0016177P1
5STP33L2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
NOTES
6
6
DCA0012856P1
170M7036
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-4000-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-4000-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
VI A A - 14
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
Appendix A - Spare Parts List
Module contains: 2Q 4Q
36.00 4000 A (1000V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0012082P1
5STP38N3600
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012881P1
170M7520
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-4000-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-4000-x1R21P..
1
NOTES
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
37.00 4750 A (600V-690V-790V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
TYPE/DATA
Thyristor
6
12
DCA0016193P1
5STP45N2800
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
NOTES
6
6
DCA0012856P1
170M7036
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-4750-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-4750-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
Module contains: 2Q 4Q
38.00 5150 A (400 V-500 V) CONVERTER
DESCRIPTION
2Q 4Q
CODE
Thyristor
TYPE/DATA
NOTES
6
12
DCA0016185P1
5STP45N2200
Puls transformer board
1
2
3BSE004939R1
SDCS-PIN-41 A
Power interface board
1
1
3BSE004940R1
SDCS-PIN-51
Semiconductor fuses
6
6
DCA0012830P1
170M7028
*)Cooling fan (Bus Bars"Left side") 1
1
DCA0018692P1
RG35P-4DK.7M.1R
e.g. DCSxxx-5150-x1L21P..
*)Cooling fan (Bus Bars"Right side
1
DCA0012660P1
RG35P-4DK.7M.1L
e.g. DCSxxx-5150-x1R21P..
1
*) Select only one Cooling Fan for this C4 Modules
If you have any questions concerning spare parts, please contact your local ABB-agent!
DCS 500 / DCS 600 Service Manual
3ADW000093R0601_DCS500B/DCS600_Service Manual_e_f
VI A A - 15