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Service
How to remove the converter fans in frames D1 to D3 (two fans)
Converters types DCS800-S01-0045-0x to DCS800-S02-0350-0x using two 115
VAC fans. Depending on the supply voltage they are either connected in series, for
230 VAC. or in parallel, for 115 VAC:
Fan configuration D1 to D3
In case a fan fails there are different approaches due to the incoming voltage.
230 VAC:
With a supply voltage of 230 VAC fans M55 and M56 are connected in series.
Consequently both fans have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. In this case both fans have to be changed.
115 VAC:
With a supply voltage of 115 VAC all fans are connected in parallel. Thus it is possible to change only the broken fan.
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Removing the converter fans
1.
Remove the DCS Control Panel, the design cover and the fan connection plug
X2 on the top of the converter housing:
Remove
DCS Control Panel
Design cover
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2.
Remove the two fan arrangement screws:
85
Fan arrangement
3.
Move the fan arrangement forward:
Move fan arrangement
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4.
Remove the fan holding screws:
Fan holding screws
5.
Remove Faston plugs and fans:
Faston plugs
6.
Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module.
Service
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87
How to remove the converter fans in a frame D3 (four fans)
Converters types DCS800-S01-0405-0x to DCS800-S02-0520-0x using four 115
VAC fans. Depending on the supply voltage they are either connected in series, for
230 VAC. or in parallel, for 115 VAC:
Fan configuration D3
In case a fan fails there are different approaches due to the incoming voltage.
230 VAC:
With a supply voltage of 230 VAC fans M55 and M56 are connected in series as well as fans M57 and M58. Consequently fans connected in series have to be of the same manufacturer and type. Thus it is not possible to change only the broken fan. Always change the two fans connected in series.
115 VAC:
With a supply voltage of 115 VAC all fans are connected in parallel. Thus it is possible to change only the broken fan.
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Removing the converter fans
1.
Remove the DCS Control Panel, the design cover and the fan connection plug
X2 on the top of the converter housing:
Design cover
Remove
DCS Control Panel
Service
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2.
Remove the two fan arrangement screws:
89
Fan arrangement
3.
Move the fan arrangement forward:
Move fan arrangement
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4.
Remove the fan holding screws:
Fan holding screws
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5.
Remove Faston plugs and fans:
91
Faston plugs
6.
Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module.
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How to remove the converter fan in a frame D6
1.
Remove the three screws at the top of the fan.
2.
Disconnect the cables.
3.
Lift the fan up and pull it out.
screws cables
Converter fan in frame D6
Service
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How to remove the converter fan in a frame D7
1.
Remove the three screws at the bottom of the fan.
2.
Disconnect the cables.
3.
Pull the fan out.
cables
Converter fan in frame D7
screws
93
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94
DCS800 firmware download
General
This chapter describes how to download firmware into the SDCS-CON-4 and
SDCS-COM-8.
Download SDCS-CON-4 firmware
Requirements:
The Hitachi Flash Development Toolkit 2.2 has to be installed.
A recent workspace including firmware file and text file should be saved on the
PC.
Workspaces
ABB provides workspaces called DCS800.fdt. New workspaces have to be saved in:
C:\ABB\DCS800\Firmware\CON-4\Ver x.x
Firmware / text file
The firmware consists of two parts. The firmware file itself and the text file. New firmware files (*.rec) have to be saved in:
C:\ABB\DCS800\Firmware\CON-4\Ver x.x\Firmware
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New text files (*.cde) have to be saved in:
C:\ABB\DCS800\Firmware\ CON-4\Ver x.x\Text
95
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Download firmware file
The firmware download is done via a PC COM Port.
Attention:
If there is no COM Port available an adapter PCMCIA to COM Port has to be used.
Adapters USB to COM Port do not work reliable.
The download of the firmware is done in two steps:
1.
first the firmware file itself and
2.
then the text file.
Attention:
A firmware download does not influence the parameter settings! The previous parameter settings are kept.
De-energize the DCS800 electronics
Set jumper S5 on SCDS-CON-4 from position 3-4 to position 1-2
2
S5
4
1 3
Connect a RS232 cable between a PC COM Port and DCS800 X34
Energize the DCS800 electronics, the 7-segment display shows:
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Start download tool:
Start the Hitachi Flash Development Toolkit 2.2 by means of
Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development
Toolkit 2.2
97
Choose workspace:
Mark Open an existing Workspace,
Confirm with OK
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Select the workspace in directory:
C:\ABB\DCS800\Firmware\CON-4\Ver x.x
Confirm with Open
Activate firmware download:
Select Firmware with a right mouse click and choose Set as Active Project from the pop up menu
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Choose COM Port and communication speed:
Select Firmware with a right mouse click and choose Properties from the pop up menu
Select the Communications tap, choose the desired COM Port, un-tick the box
Use default baud from the pop up menu and set the Target Baud Rate to
38400.
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Download firmware file to device:
Select desired firmware with a right mouse click and choose Download File to
Device from the pop up menu
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Disconnect tool:
After the download is complete the FDT2.2 has to be disconnected. Select
Firmware with a right mouse click and choose Disconnect from the pop up menu
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Download text file:
De-energize the DCS800 electronics
Set jumper S5 on SCDS-CON-4 from position 1-2 to position 3-4
2
1
S5
4
3
Energize the DCS800 electronics. In case the 7-segment display shows a the firmware’s corresponding text file has to be downloaded from the workspace.
If the 7-segment display shows something else, it is not necessary to download the text file and the download is complete.
Activate text download:
Select Text with a right mouse click and choose Set as Active Project from the pop up menu
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Choose COM Port and communication speed:
Select Text with a right mouse click and choose Properties from the pop up menu
Select the Communications tap, choose the desired COM Port, un-tick the box
Use default baud from the pop up menu and set the Target Baud Rate.
Attention:
For firmware version 80x130/80x130Demo and higher set the Target Baud
Rate to 38400.
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Download text file to device:
Select desired text file with a right mouse click and choose Download File to
Device from the pop up menu
After the download is complete the 7-segment display shows a:
Attention:
Do not de-energize the drive or disconnect the tool while the seven segment display shows the u.
Wait until the 7-segment display shows:
and
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Disconnect tool:
Now FDT2.2 has to be disconnected. Select Text with a right mouse click and choose Disconnect from the pop up menu
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Close download tool
When closing the FDT2.2 save the workspace only if firmware files or text files have been added.
The firmware download is complete now.
Service
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Add firmware or text files
Start download tool:
Start the Hitachi Flash Development Toolkit 2.2 by means of
Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development
Toolkit 2.2
107
Choose workspace:
Mark Open an existing Workspace,
Confirm with OK
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Select the workspace in directory:
C:\ABB\DCS800\Firmware\CON-4\Ver x.x
Confirm with Open
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Add firmware files
If the firmware file to be downloaded is not shown under Target files the firmware file has to be added
109
Select Firmware with a right mouse click and choose Add Files to Project… from the pop up menu
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Go to the directory containing the desired firmware file e.g.
Choose the desired firmware file and press Open:
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Add text files
If the text file to be downloaded is not shown under Target files the text file has to be added
Select Text with a right mouse click and choose Add Files to Project… from the pop up menu
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Go to the directory containing the desired text file e.g.
To display the desired text file write
*.*
in File name and press Open:
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Choose the desired text file and press Open:
113
Close download tool:
When closing the FDT2.2 confirm with Yes
Adding of files is complete now.
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Create a workspace
General
In case the Hitachi Flash Development Toolkit 2.2 is not installed at its default location (e.g. using Windows in an different language than English):
C:\Program Files\Hitachi\FDT2.2 it is not possible to use the standard ABB workspace called DCS800.fdt. Thus the user has to create a new workspace.
Start download tool:
Start the Hitachi Flash Development Toolkit 2.2 by means of
Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development
Toolkit 2.2
Create new workspace:
Choose File
New Workspace…
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Name new workspace:
Name the new workspace,
choose its location and
confirm with OK
Choose Yes
115
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Create the project for the firmware file:
Name the new project and
confirm with Next
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Choose Device And Kernel:
Select Device: H8S/2633F and
confirm with Next
117
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Communication Port:
Select the proper COM port,
Select Baud Rate: 38400,
un-tick Use Default Baud Rate and
confirm with Next
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Device Settings:
Enter the CPU crystal frequency for the selected device: 6.25 MHz,
Select the multiplier for the main clock frequency (CKM): 4 and
confirm with Next
119
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Connection Type:
Select connection: BOOT Mode,
Select Interface: Direct Connection,
un-tick Kernel already resident and
confirm with Next
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Programming Options:
Protection: Automatic and
Messaging: Advanced,
confirm with Finish
121
Now the project for the firmware file is finished:
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Create the project for the text file:
Select Workspace with a right mouse click and choose New Project…
Name the new project and
confirm with Next
Service
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Choose Device And Kernel:
Select Device: H8S/2633F and
confirm with Next
123
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Communication Port:
Select the proper COM port,
Select Baud Rate: 38400,
un-tick Use Default Baud Rate and
confirm with Next
Service
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Device Settings:
Enter the CPU crystal frequency for the selected device: 6.25 MHz,
Select the multiplier for the main clock frequency (CKM): 4 and
confirm with Next
125
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Connection Type:
Select connection: BOOT Mode,
Select Interface: Direct Connection,
tick Kernel already resident and
confirm with Next
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Programming Options:
Protection: Automatic and
Messaging: Advanced,
confirm with Finish
127
Now the project for the text file is finished:
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Close download tool:
When closing the FDT2.2 confirm with Yes
Creating of projects is complete now.
Service
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129
Download SDCS-COM-8 firmware
Requirements:
In case the PCMCIA adapter NDPA-02 with NDPC-12 is used the NtNisa drivers have to be installed (see NtNisa5x.zip or NtNisa5x.exe) before downloading the firmware.
In case the USB adapter RUSB-02 is used together with DriveWindow 2.22
(and higher) and firmware package COM-8 88x160.zip (and higher) no additional actions have to be taken.
Firmware download:
Close all applications especially DriveWindow and DriveWindow Light!
Unzip the SDCS-COM-8 firmware (file COM-8 88xxxx.zip) by right click on the zip file:
Following files and folders will be created:
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Connect the DCS800 directly with the PC, fiber optic cable from SDCS-COM-8 channel 3 to:
1.
PCMCIA adapter NDPA-02 with NDPC-12 or
2.
USB adapter RUSB-02
Switch on the DCS800
Set Ch3 HW Config (70.21) = Ring
Set Ch3 NodeAddr (70.22) = 1
Start firmware download by a double click on file L_AMC_DC.BAT:
A DOS window will appear. Wait until the download is finished (the DOS window will close automatically)
Attention:
Do not touch the PC during the download of the firmware!
Check Com8SWVersion (4.11) for proper firmware version
Set Ch3 HW Config (70.21) back to its original setting
Set Ch3 NodeAddr (70.22) back to its original setting
Re-connect the drive to the DriveWindow network
Service
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Set type code
The type code - TypeCode (97.01) - is preset in the factory and is write protected.
It identifies the drives current-, voltage-, temperature measurement and its quadrant type. The type code can be changed as whole or individually.
To change the type code as whole follow the instructions below:
un-protect the type code by means of ServiceMode (99.06) = SetTypeCode
set TypeCode (97.01) = S01-0020-04 to S02-5200-05 (details, see table below)
The drive’s basic type code: DCS800-AAX-YYYY-ZZB
Product family: DCS800
Bridge type:
Module type:
X
YYYY
Rated AC Voltage: ZZ
= R0 Rebuild system
= E0 Panel solution
= A0 Enclosed converter
= 1 single bridge (2-Q)
= 2 2 anti parallel bridges (4-Q)
= converter type current
= 04 230 VAC - 400 VAC
= 05 230 VAC - 525 VAC
= 06 270 VAC - 600 VAC
= 07 315 VAC - 700 VAC
= 08 360 VAC - 800 VAC
= 10 450 VAC - 990 VAC
= 12 540 VAC - 1200 VAC
Power connection: B = - Standard D1 - D6
= L Left side D7
= R Right side D7
= a Second thyristor type D5, D6
Attention:
When using D1, D2, D3 or D4 modules the current and voltage range of the type code setting is limited to max 1000 ADC and max 600 VAC.
the change of the type code is immediately taken over and ServiceMode
(99.06) is automatically set back to NormalMode
the new values can be seen in group 4
ConvNomCur (4.05),
ConvNomVolt (4.04),
MaxBridgeTemp (4.17) and
QuadrantType (4.15)
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To change the type code individually follow the instructions below:
un-protect the type code by means of ServiceMode (99.06) = SetTypeCode
set the type code individually by means of
S ConvScaleCur (97.02),
S ConvScaleVolt (97.03),
S MaxBrdgTemp (97.04) and
S BlockBridge2 (97.07)
the change of the type code is immediately taken over and ServiceMode
(99.06) has to be set back to NormalMode by the user
the new values can be seen in group 4
ConvNomCur (4.05),
ConvNomVolt (4.04),
MaxBridgeTemp (4.17) and
QuadrantType (4.15)
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Type code table
25
S01-0740-04
26
S01-0740-05
27
S01-0900-04
28
S01-0900-05
29
S01-0900-06
30
S01-0900-07
31
S01-1200-04
32
S01-1200-05
33
S01-1500-04
34
S01-1500-05
35
S01-1500-06
36
S01-1500-07
37
S01-1900-08
38
S01-2000-04
39
S01-2000-05
40
S01-2000-06
41
S01-2000-07
42
S01-2050-05
43
S01-2050-06
44
S01-2050-07
45
S01-2500-04
46
S01-2500-05
47
S01-2500-06
48
S01-2500-07
49
S01-2500-08
4
5
6
7
8
9
0
1
2
3
None
S01-0020-04
S01-0020-05
S01-0045-04
S01-0045-05
S01-0065-04
S01-0065-05
S01-0090-04
S01-0090-05
S01-0125-04
10
S01-0125-05
11
S01-0180-04
12
S01-0180-05
13
S01-0230-04
14
S01-0230-05
15
S01-0315-04
16
S01-0315-05
17
S01-0290-06
18
S01-0405-04
19
S01-0405-05
20
S01-0470-04
21
S01-0470-05
22
S01-0590-06
23
S01-0610-04
24
S01-0610-05
75
S01-5200-05
76
S02-0025-04
77
S02-0025-05
78
S02-0050-04
79
S02-0050-05
80
S02-0075-04
81
S02-0075-05
82
S02-0100-04
83
S02-0100-05
84
S02-0140-04
85
S02-0140-05
86
S02-0200-04
87
S02-0200-05
88
S02-0260-04
89
S02-0260-05
90
S02-0350-04
91
S02-0350-05
92
S02-0320-06
93
S02-0450-04
94
S02-0450-05
95
S02-0520-04
96
S02-0520-05
97
S02-0650-06
98
S02-0680-04
99
S02-0680-05
50
S01-2050-10
51
S01-2600-10
52
S01-2600-12
53
S01-3000-04
54
S01-3000-05
55
S01-3000-06
56
S01-3000-07
57
S01-3000-08
58
S01-3300-04
59
S01-3300-05
60
S01-3300-06
61
S01-3300-07
62
S01-3300-08
63
S01-3300-12
64
S01-4000-04
65
S01-4000-05
66
S01-4000-06
67
S01-4000-07
68
S01-4000-08
69
S01-3300-10
70
S01-4000-10
71
S01-4800-06
72
S01-4800-07
73
S01-4800-08
74
S01-5200-04
S02-2500-06
S02-2500-07
S02-3000-06
S02-3000-07
S02-2500-08
S02-3000-08
S02-3300-04
S02-3300-05
S02-3300-06
S02-3300-07
S02-3300-08
S02-3300-12
S02-4000-04
S02-4000-05
S02-4000-06
S02-4000-07
S02-4000-08
S02-3300-10
S02-4000-10
S02-4800-06
S02-4800-07
S02-4800-08
S02-5200-04
S02-5200-05
S01-4000-12
S02-4000-12
S02-0820-04
S02-0820-05
S02-1000-04
S02-1000-05
S02-0900-06
S02-0900-07
S02-1200-04
S02-1200-05
S02-1500-04
S02-1500-05
S02-1500-06
S02-1500-07
S02-1900-08
S02-2000-04
S02-2000-05
S02-2050-05
S02-2050-06
S02-2050-07
S02-2500-04
S02-2500-05
S02-2050-10
S02-2600-10
S02-2600-12
S02-3000-04
S02-3000-05
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
125
126
127
128
129
130
131
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133
134
135
110
111
112
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114
115
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124
100
101
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109
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Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
3ADW000195R0501 DCS800 Service Manual e e
Service
134
DC-Motor neutral zone adjustment
Types concerned
DC-Motors
Summary
Procedure to adjust the neural zone of a DC-motor
General
Loosen the bolts holding the brush bridge.
Connect a scope or a voltmeter between two adjacent brush-holder assemblies
(holders with different polarity).
Set the scaling on the scope or voltmeter to mV AC.
Disconnect the excitation cables and connect 110 – 240 VAC between F+ and
F- (a normal extension cord is sufficient).
Start moving the brush bridge slowly in one direction and watch the scope or voltmeter. If the voltage is increasing move the brush bridge in the other direction.
Try to get the voltage down to less than 50 mV AC. The smaller the better.
When this is achieved, start tightening the brush bridge bolts and watch the voltage. Sometimes you have to do a little offset to compensate for movements during tightening.
Finally, mark the correct neutral zone position in case the motor will be taken apart in the future.
Service
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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Table of contents
- 1 DCS800
- 5 Safety instructions
- 5 What this chapter contains
- 5 To which products this chapter applies
- 5 Usage of warnings and notes
- 6 Installation and maintenance work
- 7 Grounding
- 9 Mechanical installation
- 10 Operation
- 13 Table of contents
- 16 Introduction
- 16 How to use this manual
- 16 Contents of this manual
- 16 Target group
- 16 Associated publications
- 17 Storage and transport
- 17 Name plate and type code
- 18 Type code
- 19 Current and voltage ratings
- 21 Fault Tracing Thyristors
- 21 Tools
- 21 For commissioning and fault tracing
- 22 Additionally for service and preventive maintenance
- 22 How to detect a faulty thyristor
- 22 A fuse is blown
- 23 DC-current pulses measured by an oscilloscope
- 23 Thyristor diagnosis
- 23 Ripple monitor
- 24 How to find a faulty thyristor
- 24 Converters size D1 to D4 (20...1000 A)
- 24 Blown fuses
- 25 Converters size D5, D6, and D7 (900...5200 A)
- 25 Blown fuses
- 25 Ripple monitor
- 27 Handling the Semiconductors
- 27 General Instruction how to handle the Semiconductors
- 29 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
- 30 Remove faulty thyristor modules
- 34 Install new thyristor modules
- 36 Remove faulty OnBoard bridge (V1)
- 36 Install new OnBoard bridge (V1)
- 37 OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units
- 38 OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units
- 39 OnBoard bridge and thyristor module terminals
- 41 Exchange of Thyristors for Size D5
- 41 Installation of "Disc Type" thyristor in converters size D5 (900...2000 A)
- 41 Required Tools
- 42 Disk type thyristors
- 42 Original thyristor type (900 A)
- 43 Second thyristor type (900 A)
- 43 Original thyristor type (1200 A)
- 44 Second thyristor type (1200 A)
- 45 Find faulty thyristor
- 46 Remove faulty thyristor
- 47 Install new thyristor
- 51 Exchange of Thyristors for Size D6
- 51 Installation of "Disc Type" thyristor in converters size D6 (1900...3000 A)
- 51 Required Tools
- 52 Disk type thyristors
- 52 Original thyristor type
- 53 Second thyristor type
- 53 BCT thyristors
- 54 Find faulty thyristor
- 55 Remove faulty thyristor
- 58 Install new thyristor
- 65 Exchange of Thyristors for Size D7
- 65 Installation of "Disc Type" thyristor in converters size D7 (2050...5200 A)
- 65 Required Tools
- 66 Find faulty thyristor
- 69 Install new thyristor
- 75 Exchange of SDCS-CON-4
- 75 General
- 75 Required Tools
- 75 Overview SDCS-CON-4 exchange
- 75 1. Save parameters
- 77 2. Write down type code of the drive
- 77 3. Set jumpers on the new SDCS-CON-4 according to the old SDCS-CON-4
- 77 4. Exchange the SDCS-CON-4
- 80 5. Set type code of the drive
- 80 6. Enable application program
- 80 7. Download and compare parameters
- 83 Service
- 83 How to remove the converter fans in frames D1 to D3 (two fans)
- 83 230 VAC:
- 83 115 VAC:
- 84 Removing the converter fans
- 87 How to remove the converter fans in a frame D3 (four fans)
- 87 230 VAC:
- 87 115 VAC:
- 88 Removing the converter fans
- 92 How to remove the converter fan in a frame D6
- 93 How to remove the converter fan in a frame D7
- 94 DCS800 firmware download
- 94 General
- 94 Download SDCS-CON-4 firmware
- 94 Requirements:
- 94 Workspaces
- 94 Firmware / text file
- 97 Start download tool:
- 97 Choose workspace:
- 98 Activate firmware download:
- 99 Choose COM Port and communication speed:
- 100 Download firmware file to device:
- 101 Disconnect tool:
- 102 Activate text download:
- 103 Choose COM Port and communication speed:
- 104 Download text file to device:
- 105 Disconnect tool:
- 106 Close download tool
- 107 Add firmware or text files
- 107 Start download tool:
- 107 Choose workspace:
- 113 Close download tool:
- 114 Create a workspace
- 114 Start download tool:
- 114 Create new workspace:
- 115 Name new workspace:
- 117 Choose Device And Kernel:
- 118 Communication Port:
- 119 Device Settings:
- 120 Connection Type:
- 121 Programming Options:
- 121 Now the project for the firmware file is finished:
- 123 Choose Device And Kernel:
- 124 Communication Port:
- 125 Device Settings:
- 126 Connection Type:
- 127 Programming Options:
- 127 Now the project for the text file is finished:
- 128 Close download tool:
- 129 Download SDCS-COM-8 firmware
- 131 Set type code
- 133 Type code table
- 134 DC-Motor neutral zone adjustment
- 134 Types concerned
- 134 Summary
- 134 General
- 135 Preventive Maintenance
- 136 Recommended regular maintenance
- 136 Maintenance schedule
- 137 Annual preventive maintenance
- 140 3 years preventive maintenance
- 141 6 years preventive maintenance
- 143 9 years preventive maintenance
- 145 Appendix A - Spare Parts List