ABB DCS800 Service Manual
DCS800
(
)
Service manual
DCS800 Drives
20 to 5200 A
_
DCS800 Drive Manuals
Langu age
Public. number
DCS800 Quick Guide
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x x x
Technical Catalogue DCS800 3ADW000192 x x x x x x x
Hardware Manual DCS800 3ADW000194 x x x x x x x x
Hardware Manua l DCS800 update DCF503B/DCF504 B 3ADW000194Z0301 x
Firmware Manual DCS8 00 3ADW000193 x x p x x x x x
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x x
12-Pulse Manual 3ADW000196 x
CMA-2 Board 3ADW000136 p
Flyer Hard - Parallel 3ADW000213 x
Drive Tools
DriveWindo w 2. x - Us er's Manu al 3BFE 64560 981 x
DriveOPC 2.x - User' s Manual 3BFE 00073 846 x
Optical D DCS Co mmunication Link 3AFE 63988 235 x
DDCS Branchin g Units - User’s Ma nual 3BFE 64285 513 x
DCS800 Applications
PLC Programming with CoDeSys CoDe Sys_V 23 x x x
61131 DCS800 target +tool descr iption - Application Prog ram 3ADW000 199 x
DCS800 Crane Drive
DCS80 0 Crane Drive Manual suppl. 3AST 00414 3 x
DCS80 0 Crane Drive Produc t note PDC5 E N REVA p
DCS800 Winder ITC
DCS80 0 Wi nder Product n ote PDC2 EN x
DCS80 0 Wi nder description IT C 3ADW000308 x
Wind er Questio nnaire 3ADW000253z x
DCS800-E Panel Solution
Flyer DCS800-E Panel solution 3ADW000210 x
Hardware Manua l DCS800-E 3 ADW000224 x
DCS800-A Enclose d Conver ters
Flyer DCS800-A 3ADW000213 x
Technical Catalogue DCS800-A 3ADW000198 x
Installation of DCS800 -A 3ADW000091 x x
DCS800-R Rebuild System
Flyer DCS8 00-R 3ADW000007 x x
DCS80 0-R Manual 3ADW000197 x
DCS50 0/DCS6 00 Si ze A5...A7, C2b, C3 and C4 Upgrade Kit s 3ADW000256 x
Extension Modules
RAIO-01 Analogue IO E xtension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
RRIA -01 Resolver Interf ace Module 3AFE 68570 760 x
RTAC- 01 P ulse Encode r Interface 3AFE 64486 853 x
RTAC- 03 TTL Pulse Encode r Interface 3AFE 68650 500 x
AIMA R-slot e xtension 3AFE 64661 442 x
Serial Communication
Drive specific serial co mmunication
NETA Re mote diagnostic interface 3 AFE64 60506 2 x
Fieldbus Ada pter with DC Drives RPBA- (PROFIBUS) 3AFE 64504 215 x
Fieldbus Ada pter wi th DC Drives RCAN-02 (C ANopen)
Fieldbus Ada pter with DC Dr ives RCNA-01 (ControlNet) 3AFE 64506 005 x
Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x
Fieldbus Ada pter with DC Drives RMBA (MODBU S) 3AFE 64498 851 x
Fieldbus Ada pter with DC Drives RETA (Ethe rnet) 3AFE 64539 736 x
x -> existing p -> planned
Status 04.2010
DCS800 Drive Manuals-List
j.doc
3ADW000191 x x x x x
E D I ES F CN RU PL
DCS800 Drives
20 to 5200 A
Service Manual
Code: 3ADW000195R0501 Rev E
DCS800 Service Manual e e.doc
EFFECTIVE: 03.2011
SUPERSEDES: Rev D 09.2009
2011 ABB Automation Products GmbH. All rights reserved.
3ADW000195R0501 DCS800 Service Manual e e
3ADW000195R0101 DCS800 Service Manual e a
Safety instructions
What this chapter contains
This chapter contains the safety instructions you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
To which products this chapter applies
The information is valid for the whole range of the product DCS800, the converter
modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the
Rebuild Kit DCS800-R00-9xxx.
Usage of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment, and advise on how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause
physical injury or death and/or damage to the equipment.
5
General danger warning warns about conditions, other than those
caused by electricity, which can result in physical injury or death
and/or damage to the equipment.
Electrostatic sensitive devices warning warns of electrostatic
discharge which can damage the equipment.
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable
or motor. Ignoring the instructions can cause physical injury or death
and/or damage to the equipment.
• Never work on the drive, motor cable or motor when main power is
• Do not work on the control cables when power is applied to the
• Do not make any insulation resistance or voltage withstand tests
• Isolate the motor cables from the drive when testing the insulation
• When reconnecting the motor cable, always check that the C+ and
• Depending on the external wiring, dangerous voltages (115 V,
• DCS800 with enclosure extension: Before working on the drive,
WARNING!
•
Only qualified electricians are allowed to install and maintain
the drive!
applied.
Always ensure by measuring with a multimeter (impedance at least
1 Mohm) that:
1. Voltage between drive input phases U1, V1 and W1 and
the frame is close to 0 V.
2. Voltage between terminals C+ and D- and the frame is
close to 0 V.
drive or to the external control circuits. Externally supplied control
circuits may cause dangerous voltages inside the drive even when
the main power on the drive is switched off.
on the drive or drive modules.
resistance or voltage withstand of the cables or the motor.
D- cables are connected with the proper terminal.
Note:
• The motor cable terminals on the drive are at a dangerously high
voltage when the main power is on, regardless of whether the
motor is running or not.
220 V or 230 V) may be present on the relay outputs of the drive
system (e.g. SDCS-IOB-2 and RDIO).
isolate the whole drive system from the supply.
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
7
Grounding
These instructions are intended for all who are responsible for the
grounding of the drive. Incorrect grounding can cause physical injury,
death and/or equipment malfunction and increase electromagnetic
interference.
WARNING!
• Ground the drive, motor and adjoining equipment to ensure
personnel safety in all circumstances, and to reduce
electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized and
marked as required by safety regulations.
• In a multiple-drive installation, connect each drive separately to
protective earth (PE ).
• Minimize EMC emission and make a 360° high frequency
grounding (e.g. conductive sleeves) of screened cable entries at
the cabinet lead-through plate.
• Do not install a drive equipped with an EMC filter to an
ungrounded power system or a high resistance-grounded (over 30
ohms) power system.
Note:
• Power cable shields are suitable as equipment grounding
conductors only when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA
AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective
earth connection is required.
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
3ADW000195R0101 DCS800 Service Manual e a
8
Printed circuit boards and fiber optic cables
These instructions are intended for all who handle the circuit boards
and fiber optic cables. Ignoring the following instructions can cause
damage to the equipment.
WARNING! The printed circuit boards contain components sensitive to
electrostatic discharge. Wear a grounding wrist band when handling
the boards. Do not touch the boards unnecessarily.
Use grounding strip:
ABB order no.: 3ADV050035P0001
WARNING! Handle the fiber optic cables with care. When unplugging
optic cables, always grab the connector, not the cable itself. Do not
touch the ends of the fibers with bare hands as the fiber is extremely
sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
9
Mechanical installation
These notes are intended for all who install the drive. Handle the unit
carefully to avoid damage and injury.
• Make sure that dust from drilling does not enter the drive when
• Ensure sufficient cooling.
• Do not fasten the drive by riveting or welding.
WARNING!
• DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do
not lift the unit by the front cover. Place units D4 and D5 only on its
back.
DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the
lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt
of about 6 degrees.
installing. Electrically conductive dust inside the unit may cause
damage or lead to malfunction.
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
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10
Operation
These warnings are intended for all who plan the operation of the drive
or operate the drive. Ignoring the instructions can cause physical injury
or death and/or damage to the equipment.
WARNING!
• Before adjusting the drive and putting it into service, make sure
that the motor and all driven equipment are suitable for operation
throughout the speed range provided by the drive. The drive can
be adjusted to operate the motor at speeds above and below the
base speed.
• Do not control the motor with the disconnecting device
(disconnecting mains); instead, use the control panel keys
and
, or commands via the I/O board of the drive.
• Mains connection
You can use a disconnect switch (with fuses) to disconnect the
electrical components of the drive from the mains for installation
and maintenance work. The type of disconnect switch used must
be 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 disconnect must be locked in its
"OPEN" position during any installation and maintenance work.
• 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 control panel of the
drive will neither cause an emergency stop of the motor, 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.
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
11
Note:
• When the control location is not set to Local (L not shown in the
status row of the display), the stop key on the control panel will not
stop the drive. To stop the drive using the control panel, press the
LOC/REM key and then the stop key
.
Safety instructions
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12
Safety instructions
3ADW000195R0501 DCS800 Service Manual e e
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
3ADW000195R0501 DCS800 Service Manual e e
14
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
Exchange of Thyristors for Size D6 51
Installation of "Disc Type" thyristor in converters size D6 (1900...3000 A) .............................. 51
Required Tools ............................................................................................................. 51
Disk type thyristors ....................................................................................................... 52
BCT thyristors............................................................................................................... 53
Find faulty thyristor ....................................................................................................... 54
Remove faulty thyristor................................................................................................. 55
Install new thyristor....................................................................................................... 58
Exchange of Thyristors for Size D7 65
Installation of "Disc Type" thyristor in converters size D7 (2050...5200 A) .............................. 65
Required Tools ............................................................................................................. 65
Find faulty thyristor ....................................................................................................... 66
Install new thyristor....................................................................................................... 69
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
Table of contents
3ADW000195R0501 DCS800 Service Manual e e
15
Preventive Maintenance 135
Recommended regular maintenance......................................................................................136
Maintenance schedule ............................................................................................................136
Annual preventive maintenance..............................................................................................137
3 years preventive maintenance .............................................................................................140
6 years preventive maintenance .............................................................................................141
9 years preventive maintenance .............................................................................................143
Appendix A - Spare Parts List 145
Table of contents
3ADW000195R0501 DCS800 Service Manual e e
16
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 DCS800 series.
Contents of this manual
Safety instructions
This chapter is located at the beginning of this manual.
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.
Fault Tracing Thyristors
This chapter describes how to detect and select a faulty thyristor.
Handling the Semiconductors
This chapter describes the handling of thyristors and thyristor modules.
Exchange of Thyristors of Sizes D1 to D4
This chapter describes the exchange of thyristors in converters sizes D1 to D4.
Exchange of Thyristors of Size D5
This chapter describes the exchange of thyristors in converters size D5.
Exchange of Thyristors of Size D6
This chapter describes the exchange of thyristors in converters size D6.
Exchange of Thyristors of Size D7
This chapter describes the exchange of thyristors in converters size D7
Exchange of SDCS-CON-4
This chapter describes the exchange of a SDCS-CON-4
Service
This chapter contains hardware information and technical hints.
Preventive Maintenance
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.
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
A list of associated publications is published on the inner page of this manual’s
cover, see DCS800 Drive Manuals
The DCS800 Hardware Manual (3ADW000194) describes all hardware
Introduction
3ADW000195R0501 DCS800 Service Manual e e
. Here is a list of the most important ones:
17
R
components of the DCS800, their connections and settings (e.g. jumpers)
The DCS800 Firmware Description (3ADW000193) gives an overview of the
DCS800 firmware, describes all parameters, describes the function of the DCS
Control Panel, gives support in case of faults and alarms and gives information
about communication.
The above listed documentation can be found on the CD-ROM being attached to
the DCS800 Quick Guide (3ADW000191).
Storage and transport
If the unit has 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 Hardware Manual).
Name plate and type code
For purposes of identification, each thyristor power converter is fitted with name
plates, stating the type code and the serial number, which serve for each unit's
individual identification.
The type code contains information about the characteristics and the configuration
of the unit.
ABB Automation Products
Type: DCS800-S02-0025-05
Ser No: 0025421A06294264
Production year
2006 and week 29
Example of a name plate
Rated input voltage
Rated input current
U
1
I
1
f
1
SCC
3 525 V
20 A I
50/60 Hz If 6 A
65 kA
U2 610 V
25 A
2
Fan
----
Rated output current
Rated internal field
exciter current
Rated fan voltage
Plus code
Made in Germany
+K454
+J409
Introduction
3ADW000195R0501 DCS800 Service Manual e e
18
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. DCS800-S01-
2005). The optional selections are given thereafter, on the name plate by plus
code. The main selections are described below. Not all selections are available for
Position Plus code
Product series DCS800
A Type S0 = Standard converter module IP00
X Bridge type 1 = Single bridge (2-Q)
Y Rated DC current YYYY = Rated current (e.g. 0025 = 25 ADC)
ZZ Rated AC voltage 04 = 400 VAC
B Power connection - = Standard D1 ... D6
Internal field exciter
configuration
Fan voltage
Current measurement +S175 SDCS-CMA-2 for sizes D5 to D7
Voltage measurement +S186
SDCS-DSL-4 +S199
+ plug-in options
DCS Control Panel
Fieldbus
I/O and DDCS L500
all types.
Type code D C S 8 0 0 -AAX-YYYY-ZZ- plus code
Position A X Y Z B
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter
2 = 2 anti parallel bridges (4-Q)
05 = 525 VAC
06 = 600 VAC
07 = 690 VAC
08 = 800 VAC
10 = 990 VAC
12 = 1200 VAC
L = Left side D7
R = Right side D7
a = Second thyristor type D5, D6
+S164
+0S163
+S171
+S172
+S180
+S181
+S182
+S183
+S189
+0S199
0J400
J409
K454
K451
K466
K458
L501
L508
L509
With internal field exciter, external supply (only D5:25 A, Rebuild kit: 25 A/16 A)
Without internal field exciter (only D1 ... D4)
Size D4
Standard fan voltage: 230 V / 1-ph
Additional fan voltage: 115 V / 1-ph
Size D6
Standard fan voltage for 400 V / 500 V / 800 V units: 400-500 V / 3-ph
Standard fan voltage for 600 V / 690 V units: 525-690 V / 3-ph
Additional fan voltage for 600-690 V units: 400-500 V / 3-ph
120 V SDCS-SUB-4 for sizes D1 ... D4
600 V for sizes D6 and D7
690 V for sizes D6 and D7
800 V for sizes D6 and D7.
990 V for sizes D6 and D7.
Galvanic isolation for sizes D6 and D7
With SDCS-DSL-4
Without SDCS-DSL-4
Without DCS Control Panel
Door mounting Kit (cable length 3 m)
Profibus RPBA
DeviceNet RDNA
Ethernet IP + Modbus TCP RETA
Modbus RMBA
Analogue Extension RAIO
Digital Extension RDIO
DDCS Communication board (10 Mbaud CH0) SDCS-COM-81
DDCS Communication board (5 Mbaud CH0) SDCS-COM-82
Introduction
3ADW000195R0501 DCS800 Service Manual e e
19
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.
Current and voltage ratings
Unit size 2-Q rated current
DCS800-01 [ADC]
D1
D3
D4
D5
D6
D7
1
only available as 2-Q drive
20 25 X X
45 50 X X
65 75 X X
90 100 X X
125 140 X X
180 200 X X D2
230 260 X X
315 350 X X X
405 450 X X
470 520 X X
610 680 X X X
740 820 X X
900 1000 X X
900 900 X X
1200 1200 X X
1500 1500 X X X X
2000 2000 X X X
1900 1900 X
2050 2050 X X X
2500 2500 X X X X X
3000 3000 X X X X X
2050 2050 X
2600 2600 X X
3300 3300 X X X X X X X
4000 4000 X X X X X X X
4800 4800 X X X
5200 5200 X X
4-Q rated current
DCS800-02 [ADC]
400 525 600 690 800 990 1200
Supply voltage [VAC]
1
X1
Introduction
3ADW000195R0501 DCS800 Service Manual e e
20
Introduction
3ADW000195R0501 DCS800 Service Manual e e
21
Fault Tracing Thyristors
Tools
For commissioning and fault tracing
Following software tools are mandatory:
DriveWindow Light including commissioning wizard and DWL AP for Adaptive
Program and
DriveWindow for fast drive monitoring using SDCS-COM-8.
Following tools are mandatory in addition to standard tools:
An oscilloscope including memory function with either galvanically isolating
transformer or isolating amplifier (probe) for safe measurements. It can also be
a hand held (portable) oscilloscope.
A clamp on current probe. In case the scaling of the DC load current needs to
be checked it must be a DC clamp on current probe.
A voltmeter (at least CAT III 1000 V):
Make sure that all equipment in use is suitable for the voltage level applied to the
Fault Tracing Thyristors
1000 V probes and test leads:
An ESD-field service kit (ABB Service
Finland code 0001ESD / MS-Antistatic):
power part!
3ADW000195R0501 DCS800 Service Manual e e
3ADW000195R0501 DCS800 Service Manual e e
22
Additionally for service and preventive maintenance
Following additional tools are mandatory for cleaning:
An ESD safe blower / ESD vacuum
cleaner (ABB Service Finland code
0006ESD / MUNTZ 555-ESD-S-E):
How to detect a faulty thyristor
Thyristor problems can be noticed differently:
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 defective
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
defective).
An external short circuit at the DC terminals of the converter without sufficient
impedance.
A commutation fault during generating (active braking with high current, high
EMF and with low AC voltage) of a 4-Q converter.
Note:
In case of parallel fuses: If one of the parallel fuses is blown, all parallel fuses have
to be changed. The ‘undamaged’ fuses might be ‘half-blown’ and will blow with the
next high current.
Fault Tracing Thyristors
3ADW000195R0501 DCS800 Service Manual e e
23
DC-current pulses measured by an oscilloscope
Connect an oscilloscope to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or
X4:5/6 on the SDCS-IOB-3) and check for the proper amount of current pulses:
Six current pulses in positive direction
There should be six current pulses in positive direction.
In case of a 4-Q converter also the six current pulses for the negative direction
have to be checked.
Thyristor diagnosis
Also the thyristor diagnosis provided by the firmware can be used:
Switch the drive to local mode (DriveWindow, DriveWindow Light, DCS Control
Panel or local I/O).
Start the thyristor diagnosis by means of ServiceMode (99.06) = ThyDiagnosis
and set On and Run within 20 s.
During the thyristor diagnosis the main contactor will be closed and the
thyristors are checked. The field current is not released while the thyristor
diagnosis is active and thus the motor should not turn.
When the thyristor diagnosis is finished check Diagnosis (9.11) for details.
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 (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 90°.
The reason for a current less thyristor may be:
Fault Tracing Thyristors
24
A fuse has disconnected one of the six thyristors. This is possible only for
converters with 900 ... 5200 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 or does not react to 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 equipment can be the
reason.
How to find a faulty thyristor
If a blown fuse is suspected in the converter, the problem is caused most often by
a faulty thyristor. 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 D1 to D4 (20...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 picture Anti-parallel B6-bridges with
branching fuses on page 45). Normally, every measurement should show high
resistance (> 1 k).
Target: find a short circuit, indicated by low resistance ( <1 ) (destroyed
thyristor).
If the converter is designed with half-bridge thyristor modules, then a module
consists of two anti-parallel 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:
The RC circuit could also cause 0 result for a short time.
The measurement, showing less resistance than 1 should be made a second
time with test leads applied to the terminals with opposite polarity; if this
measurement shows the same result, one or two thyristors located in that path are
faulty; they need to be replaced.
Fault Tracing Thyristors
3ADW000195R0501 DCS800 Service Manual e e
25
Converters size D5, D6, and D7 (900...5200 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
therefore the faulty branch is known (see picture Anti-parallel
B6-bridges with branching fuses on page 45).
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 anti-parallel thyristors or BCT’s:
The selection of a forward or reverse thyristor or BCT
(Bidirectional-Controlled-Thyristor) is done during the
disassembly. Continue with related part Exchange of Thyristors
for Size D5
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.
, D6 or D7 section Find faulty thyristor.
Ripple monitor
If the ripple monitor fault occurred, a fault tracing as described
above must be carried out:
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 transferred 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.
Fault Tracing Thyristors
26
Fault Tracing Thyristors
3ADW000195R0501 DCS800 Service Manual e e
27
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.
In converters sizes D5 (900 ... 2000 A), D6 (1900 ... 3000 A) and D7 (2050 ... 5200
A) 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, connected gate leads and with BCT’s the position of
the gate connectors).
Check that the new and old components 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.
Handling the Semiconductors
3ADW000195R0501 DCS800 Service Manual e e
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Handling the Semiconductors
3ADW000195R0501 DCS800 Service Manual e e
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Exchange of Thyristors for Size D1 to D4
Installation of OnBoard bridge and thyristor modules in converters size
D1 to D4
All DCS800 size D1 to D4 are equipped with an OnBoard bridge (excitation) and
(20...1000 A)
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: TX10, TX20, TX25
Torque spanner: 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:
(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!
type Berulub FZ1 E3
Find faulty thyristor modules
See Fault Tracing Thyristors
of this publication.
Exchange of Thyristors for Size D1 to D4
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
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:
cover
Depress the locks to remove the
design cover
Remove all o ptions, so that the
intermediate cover is empty
Remove plug in options
Exchange of Thyristors for Size D1 to D4
3ADW000195R0501 DCS800 Service Manual e e
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