Table of contents. ABB DCS800

13

Table of contents

Safety instructions 5

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

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

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

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

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

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

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

Table of contents 13

Introduction 16

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

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

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

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

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

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

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

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

Fault Tracing Thyristors 21

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Handling the Semiconductors 27

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

Exchange of Thyristors for Size D1 to D4 29

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

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

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

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

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

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

Table of contents

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

3ADW000195R0501 DCS800 Service Manual e e

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

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

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

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

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

Exchange of Thyristors for Size D5 41

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

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

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

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

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

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


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

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

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

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


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



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

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



Exchange of SDCS-CON-4 75

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

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

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

Service 83

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Preventive Maintenance 135

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

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

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

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



Appendix A - Spare Parts List 145

Table of contents



Table of contents. ABB DCS800

Table of contents

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Table of contents

Table of contents. ABB DCS800

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Table of contents