29

Exchange of Thyristors for Size D1 to D4

Installation of OnBoard bridge and thyristor modules in converters size

D1 to D4

(20...1000 A)

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

Required Tools

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



Torx screwdrivers:



Torque spanner:

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

Nominal mounting torque for

OnBoard bridge and thyristor modules

on page 35



Screws are metric type; use appropriate nuts



Tissue paper



Solvent (e.g. ethanol)



Thermal joint compound: type Berulub FZ1 E3

(grease)

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 011 P 0051

or

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

ABB Service: GHSN 390 011 P 10

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

Find faulty thyristor modules

See

Fault Tracing Thyristors

of this publication.

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

30

Remove faulty thyristor modules

1.

Remove the DCS Control Panel and design cover:

Remove DCS Control Panel

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

Remove design cover

2.

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

 serial communication modules (R-type),

 extension

I/O modules (RAIO, RDIO),

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

 communication

board (SDCS-COM-8)

,

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



SDCS-MEM-8 (Memory Card).

3.

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

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

Remove plug in options

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

4.

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

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

31

Disconnect all plugs from SDCS-

CON-4 and SDCS-DSL-4 boards

Disconnect all plugs

5.

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

Remove the grounding plug and the holding screw

Remove grounding and screws

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

32

6.

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

Electronic tray with SDCS-CON-4

Remove flat cables

Unhinge electronic tray

7.

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

Keep winding direction and amount of windings for T100

T100 in mind.

Remove all cables and plugs

How to handle X8:

X8 use screw driver

Remove cables at the SDCS-PIN-4

Attention:

Write down the winding direction of the cable through T100!

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

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

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

8.

Remove the SDCS-PIN-4 board:

OnBoard field exciter bridge module

Thyristor modules

Snubber resistor

33

Current transformer Temperature sensor

Remove SDCS-PIN-4

9.

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

10.

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

11.

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

Note:

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

12.

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

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

34

Install new thyristor modules

1.

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

see appendix A

of this manual).

2.

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

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

3.

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

Application of heat conducting compound

4.

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

5.

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

Note:

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

6.

Tighten the screws to nominal torque according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

page 35.

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

35

OnBoard

bridge

and thyristor modules

Size Type

Nominal mounting torque

29 mm bridge block VVZF 70-16

20 mm block SKKT 27, 42, 57, 106

20 mm block

34 mm block

MCC 26, 44, 56, 95

MCC 162

connections

-

3 Nm

2.5 ... 4 Nm

4.45 … 5.5 Nm

to heat sink

5 Nm

5 Nm

2.5 ... 4 Nm

2.25 … 2.75 Nm

34 mm block

34 mm block

50 mm block

50 mm block

SKKT 162

TT 162

MCC 255

TT 250, 330

5 Nm

6 Nm

11 … 13 Nm

12 Nm

5 Nm

6 Nm

4.5 … 7 Nm

6 Nm

60 mm block TT 425, 570 12 Nm 6 Nm

Nominal mounting torque for OnBoard bridge and thyristor modules

7.

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

8.

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

Nominal mounting torque for OnBoard bridge and thyristor modules

on page 35.

9.

Reconnect all gate leads to the thyristor module.

10.

Reinstall the SDCS-PIN-4 board.

11.

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

 snubber resistor (X30, X31),

 temperature sensor (X22),

 current transformers (X3, X4, X5),



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

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



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

 all plugs (X10, X96, X99) and

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

12.

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

13.

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

14.

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

SDCS-DSL-4 (X51 to X54).

15.

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

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

36

Remove faulty OnBoard bridge (V1)

1.

Follow the instructions

Remove faulty thyristor modules

until step 8 is done.

2.

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

3.

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

Install new OnBoard bridge (V1)

1.

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

see appendix A

of this manual).

2.

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

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

3.

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

4.

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

5.

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

6.

Tighten the screws to nominal torque according to table

Nominal mounting torque for OnBoard bridge and thyristor modules

on page 35.

7.

Reconnect all connectors to the OnBoard bridge.

8.

Follow the instructions Install new thyristor modules

beginning with step 10.

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

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

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

V1 V1

37

V14/V11

4 2 3 1

V16/V13

4 2 3 1

V12/V15

4 2 3 1

V14/V11

V16/V13 V12/V15

V1

V14/V11

G1 K1

DCS800-S01-0315 ... 0470

V12/V15 V16/V13

G1 K1

V1

V14/V11

DCS800-S01-0610 ... 0900

V16/V13 V12/V15

DCS800 loc of mod 1Q.dsf

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

Note:

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

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

38

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

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

V1 V1

V14/V21 V16/V23 V12/V25

V14/V21

4 2 3 1

V16/V23

4 2 3 1

V12/V25

4 2 3 1

1 3 2 4

V11/V24

1 3 2 4

V13/V26

1 3 2 4

V15/V22

V11

V24

G1

G2

K1

K2

A

V1

K

DCS800-S02-0350 ... 0520

AK

AK K A

K2

G2

G1

K1

V14

V21

V15

V22

K2

G2

K1

G1

A K AK

AK K A

K2

G2

G1

K1

V12

V25

V13

V26

K2

G2

K1

G1

A K AK

AK K A

K2

G2

G1

K1

V16

V23

V11/V24

V1

V13/V26

V15/V22

V24/V11

DCS800-S01-0680 ... 1000

V26/V13 V22/V15

V21/V14

V23/V16

V25/V12

DCS800 loc of mod 4Q.dsf

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

Note:

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

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

OnBoard bridge and thyristor module terminals

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

OnBoard bridge and all thyristor modules.

For all firing pulse cables is valid:

Yellow is gate lead.

Red is cathode lead.

39

(AK) (K)

1 2

5 4

VVZF 70-16

6 7

(A)

3

(AK) (K)

1 2

4 5

7

6

(A)

3

1

2 3

7 G

6 K

5 K

4 G

SKKT 27, 42, 57, 106

1 2 3

6 G

7 K

4 K

5 G

MCC26, 44, 56, 95

(AK)

1

(K)

2

5 4

7 6

(A)

3

6 7

1

2 3

MCC162

5 4

SKTT 162

6 7

4 5

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e

40

A K

K

K1

G1 K2 G2

A

A K

K

K1 G1

A K

K

A

TT 162

K2

G2

K2 G2

K1 G1

A

(A)

3

6G 7K

MCC255

5G 4K

AK K

K2

A

G2 3 2

TT 250, 330 TT 425, 570

Terminals of the OnBoard bridge and all thyristor modules

1

5G

4K

6G

7K

Exchange of Thyristors for Size D1 to D4

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

3ADW000195R0501 DCS800 Service Manual e e