Exchange of Thyristors for Size D6. ABB DCS800

51

Exchange of Thyristors for Size D6

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

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

Required Tools

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



Torx TX10,



Torque spanner for electrical connections: 13 Nm (M8)

TX25

50



Screws are metric type; use appropriate nuts.



17 mm ring spanner for fuse and busbar connections.



24 mm ring spanner for press clamp.



Tissue paper / solvent (e.g. ethanol).



Thermal joint compound: type BECHEM-RHUS SU 2

(grease)

Manufacturer: Carl Bechem GmbH, 58089 Hagen

ABB Service: GHSN 390 001 P 0001



Disassembly tool

Note:

DCF 1066721 P1

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

Manual.

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

accordance with the spare part list ( see Appendix A)

.

Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage. Avoid touching the contact surfaces. Do not lift the semiconductor with the gate wire. Do not lift the semiconductor by touching the current contact surfaces. Do not damage the welding flange or the contact surface.

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

Exchange of Thyristors for Size D6

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

3ADW000195R0501 DCS800 Service Manual e e

52

Disk type thyristors

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

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

Converter with original thyristor type T 1329Nxxx

Id code: 3ADC340081P0001

DCS800-S01-1900-08

DCS800-S02-1900-08

DCS800-S01-2050-05

DCS800-S02-2050-05

DCS800-S01-2050-06

U

1

3 ~ 800 VAC

3 ~ 800 VAC

3 ~ 525 VAC

3 ~ 525 VAC

3 ~ 600 VAC

Converter with second thyristor type T 1xxx-24

Id code: 3ADC340098P0001

DCS800-S01-1900-08

DCS800-S02-1900-08

DCS800-S01-2050-06

a a

DCS800-S01-2050-05

a

DCS800-S02-2050-05

a a

DCS800-S02-2050-06

DCS800-S01-2050-07

3 ~ 600 VAC

3 ~ 690 VAC

DCS800-S02-2050-06

DCS800-S01-2050-07

a a

DCS800-S02-2050-07 3 ~ 690 VAC

DCS800-S02-2050-07

a

Parts list

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

Attention: Use always the correct spare thyristor!

Original thyristor type

Thyristor T 1329Nxxx with Id code 3ADC340081P0001

Original thyristor type




Gate (4):

Cathode (5):

Faston 2.8 x 0.8 mm

Faston 4.8 x 0.8 mm

Conductive plate: Diameter 48 mm

Second thyristor type

Thyristor T 1xxx-24 with Id code 3ADC340098P0001

53

Second thyristor type

Gate (y): Round terminal D = 1.5 mm

Cathode (K

1

): Faston 4.8 x 0.5 mm

Conductive plate: Diameter 50 mm

BCT thyristors

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

Thyristors) are used. BCT’s are a pair of anti-parallel thyristors in one disk type

housing. They can easily identified by the second pair of gate leads. The second gate is marked with Gate B on the thyristor.

Faston 4.8 x 0.5

Gate A

Faston 6.3 x 0.8

Gate B

Gate B

BCT.dsf

Gate A

Gates of BCT




54

Note:

The Faston connectors of the gates are of different size.

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

Location of BCT’s gate A when built in

Find faulty thyristor

1.

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

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

Anti-parallel B6-bridges with branching fuses

on page 45).

2.

Disconnect the branching fuses of the defective branches.

3.

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

4.

In a 4 - quadrant converter with BCT’s change the BCT.

5.

In a 4 - quadrant converter with 2 single thyristors change both thyristors clamped between the same heatsinks at once.

Note:

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




55

Remove faulty thyristor

1.

Replace all blown fuses and reconnect all fuses taken out during search for the faulty thyristor.

2.

Remove the screws of the DC - busbar plates adjacent to the defective thyristors

DCbusbar plates

Location of the DC - busbar plates

Note:

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




56

3.

Write down the direction and location of the thyristors to be removed and mark their gate leads. In case of BCT’s add the position of the gates.

4.

Remove the gate leads if possible.

5.

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

Handling of indicating spring and mounting clamp

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

out a little, otherwise the spring will be damaged!

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

6.

Pull out both DC-busbar plates.

DCbusbar plates

DC-busbar plates




7.

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

57

push down push down

Use of disassembly tool

8.

Remove the thyristors with e.g. a pair of pliers.

Attention: To centre the thyristors spring pins are used. The pins are inlayed into

all lower heat sinks. Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor!




58

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.

Prepare disk type thyristor

3.

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

4.

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.

5.

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

Gates of BCT

on

page 53).

6.

Connect the gate leads if possible.

7.

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




DC-busbar plates and heatsinks

DC-busbar plates and adjacent heat sinks

Note:

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

8.

Reconnect the DC-busbars.

9.

Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks.

59

Torque indicating spring loose condition

Mounting clamp; loose condition

Note:

The indicating spring is a very sensitive instrument and must be handled with care.

10.

Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further.




60

Torque indicating spring correct torque

Mounting clamp, correct torque

Note:

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

11.

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

12.

Reconnect all other dismantled parts.

13.

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




61

front

Stack

rear

C1(+)

V11

V24

U1

V21

V14

D1(-)

V16

V23

V1

V26

V13

C1(+)

V15

V22

W1

D1(-)

V25

V12

View from the right

A6_thyr_locat.dsf

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




62

front

stack

rear

C1(+)

V11 / V24

U1

V14 / V21

D1(-)

V16 / V23

V1

V13 / V26

C1(+)

V15 / V22

W1

D1(-)

V12 / V25


A6_thyr_locat.dsf

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




63

front

stack

rear

C1(+)

V11

U1

V14

D1(-)

V16

V1

V13

C1(+)

V15

W1

D1(-)

V12


A6_thyr_locat.dsf

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




64

C1(+)

D1(-)

U1

V1

W1

F11

F14

F16

F13

F15

F12

C1(+)

F11

U1

F14

D1(-)

F16

V1

F13

C1(+)

F15

W1

F12

D1(-)

A6_branch_fuse_locat.dsf

Location of parallel branch fuses frame D6




Exchange of Thyristors for Size D6. ABB DCS800

Exchange of Thyristors for Size D6

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

Required Tools

Note:

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

Disk type thyristors

Id code: 3ADC340081P0001

U

Id code: 3ADC340098P0001

Attention: Use always the correct spare thyristor!

Original thyristor type

Second thyristor type

BCT thyristors

Thyristors) are used. BCT’s are a pair of anti-parallel thyristors in one disk type

Note:

Find faulty thyristor

Note:

Remove faulty thyristor

Note:

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

Attention: To centre the thyristors spring pins are used. The pins are inlayed into

Install new thyristor

Note:

Note:

Note:

Note:

Note:

Key Features

Related manuals

Frequently Answers and Questions

What are the main benefits of using the DCS800 drive?

What are some of the applications that the DCS800 drive is suitable for?

How do I install and operate the DCS800 drive?

Table of contents

Exchange of Thyristors for Size D6. ABB DCS800

Exchange of Thyristors for Size D6

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

Required Tools

Note:

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

Disk type thyristors

Id code: 3ADC340081P0001

U

Id code: 3ADC340098P0001

Attention: Use always the correct spare thyristor!

Original thyristor type

Second thyristor type

BCT thyristors

Thyristors) are used. BCT’s are a pair of anti-parallel thyristors in one disk type

Note:

Find faulty thyristor

Note:

Remove faulty thyristor

Note:

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

Attention: To centre the thyristors spring pins are used. The pins are inlayed into

Install new thyristor

Note:

Note:

Note:

Note:

Note:

Key Features

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Frequently Answers and Questions

What are the main benefits of using the DCS800 drive?

What are some of the applications that the DCS800 drive is suitable for?

How do I install and operate the DCS800 drive?

Table of contents