ABB DCS800 Service Manual

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DCS800

(

)

Service manual DCS800 Drives

20 to 5200 A

Page 2

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

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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

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3ADW000195R0501 DCS800 Service Manual e e

3ADW000195R0101 DCS800 Service Manual e a

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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.

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

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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

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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

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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

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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

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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

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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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Safety instructions

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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

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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

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

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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

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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:

Page 17

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

SCC

3  525 V

20 A I

50/60 Hz If 6 A

65 kA

U2 610 V

25 A

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

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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

Page 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]

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]

Introduction

3ADW000195R0501 DCS800 Service Manual e e

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Introduction

3ADW000195R0501 DCS800 Service Manual e e

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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

Page 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

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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

Page 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

Page 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

Page 26

Fault Tracing Thyristors

3ADW000195R0501 DCS800 Service Manual e e

Page 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

Page 28

Handling the Semiconductors

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Page 29

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

Page 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

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Page 31

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):

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

3ADW000195R0501 DCS800 Service Manual e e

Page 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 in mind.

How to handle X8:

use screw dr iver

T100

Remove all cables

and plugs

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

3ADW000195R0501 DCS800 Service Manual e e

Page 33

8. Remove the SDCS-PIN-4 board:

OnBoard field exciter

bridge module

Thyristor modules

Snubber resistor

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

3ADW000195R0501 DCS800 Service Manual e e

Page 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

3ADW000195R0501 DCS800 Service Manual e e

Page 35

OnBoard bridge and thyristor modules

Size Type Electrical

29 mm bridge block VVZF 70-16 - 5 Nm

20 mm block SKKT 27, 42, 57, 106 3 Nm 5 Nm

20 mm block MCC 26, 44, 56, 95 2.5 ... 4 Nm 2.5 ... 4 Nm

34 mm block MCC 162 4.45 … 5.5 Nm 2.25 … 2.75 Nm

34 mm block SKKT 162 5 Nm 5 Nm

34 mm block TT 162 6 Nm 6 Nm

50 mm block MCC 255 11 … 13 Nm 4.5 … 7 Nm

50 mm block TT 250, 330 12 Nm 6 Nm

60 mm block TT 425, 570 12 Nm 6 Nm

Nominal mounting torque

Thyristor module

connections

to heat sink

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

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

3ADW000195R0501 DCS800 Service Manual e e

Page 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

3ADW000195R0501 DCS800 Service Manual e e

Page 37

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

V1 V1

DCS800-S01-0020 ... 0180

DCS800-S01-0230

V14/V11

1234 12

V14/V11

G1K1K2

AK A

V16/V13

V1 V1

V16/V13 V12/V15

KAK A

V12/V15

1234

G1K1K2

KAK A

V14/V11

K2 G2

K1 G1

V14/V11

V16/V13 V12/V15

K2G2

K1G1

K2G2

DCS800-S01-0610 ... 0900DCS800-S01-0315 ... 0470

V16/V13 V12/V15

A K

K1G1

A K AK

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

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Page 38

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

DCS800-S02-0025 ... 0200

V1 V1

V14/V21 V16/V23

1234 1234 123

V12/V25

DCS800-S02-0260

V14/V21

K2G2

K1G1

V16/V23 V12/V25

K2G 2

K1G 1

K2G 2

K1G 1

1234 1234 1234

V11/V24

V13/V26 V15/V22

K1G1

V11/V24

K2G 2

K2G2

K1G 1

V13/V26

K1G 1

V15/V22

K2G 2

DCS800-S01-0680 ... 1000DCS800-S02-0350 ... 0520

V26/V13 V22/V15

A K AK

A K

V23/V16

DCS800 loc of mod 4Q.dsf

A K AK

A K

V25/V12

V11

V24

V15 V22

V13 V26

K1 G1 G2 K2

KAK A

K2 G2

V14

G1 K1

V21

V12

G1 K1

V25

V16

G2 G1 K1

V23

V24/V11

A K AK

V21/V14

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

3ADW000195R0501 DCS800 Service Manual e e

Page 39

)

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.

VVZF 70-16

(K)

(AK)

2 3

MCC26, 44, 56, 95

7 G 6 K

5 K 4 G

(AK)

(K)

SKKT 27, 42, 57, 106

6 G 7 K

4 K 5 G

(A)

6 7

(AK)

(K)

4 5

MCC162

SKTT 162

Exchange of Thyristors for Size D1 to D4

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Page 40

K2 G2

TT 162

K2 G2

K1 G1

MCC255

(A)

AK A

TT 250, 330

G1 K1

TT 425, 570

(K)

4K5G

Terminals of the OnBoard bridge and all thyristor modules

(AK)

Exchange of Thyristors for Size D1 to D4

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Page 41

Exchange of Thyristors for Size D5

Installation of "Disc Type" thyristor in converters size D5 (900...2000 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 screwdrivers: TX10, TX20, TX25  Torque spanner for electrical connections: 13 Nm (M8)

25 Nm (M10) 50 Nm (M12)

 Screws are metric type; use appropriate nuts.  17 mm ring spanner for fuse and busbar connections.  17 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 3ADT 621 023 P1

Note:

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 D5

3ADW000195R0501 DCS800 Service Manual e e

Page 42

Disk type thyristors

Some converter modules size D5 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 T459Nxxx

Id code: DCA0012007P0001

DCS800-S01-0900-06 3 ~ 600 VAC DCS800-S02-0900-06 3 ~ 600 VAC DCS800-S01-0900-07 3 ~ 690 VAC DCS800-S02-0900-07 3 ~ 690 VAC

Converter with original

thyristor type T589Nxxx

Id code: DCA0012015P0001

DCS800-S01-1200-04 3 ~ 400 VAC DCS800-S02-1200-04 3 ~ 400 VAC DCS800-S01-1200-05 3 ~ 525 VAC DCS800-S02-1200-05 3 ~ 525 VAC

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 (900 A)

Converter with original thyristor type T459Nxxx Id code: DCA0012007P0001

Converter with second

thyristor type T460Nxxx

Id code: 3ADC340105P0001

DCS800-S01-0900-06a DCS800-S02-0900-06a DCS800-S01-0900-07a DCS800-S02-0900-07a

Converter with second

thyristor type T590Nxxx

Id code: 3ADC340106P0001

DCS800-S01-1200-04a DCS800-S02-1200-04a DCS800-S01-1200-05a DCS800-S02-1200-05a

Original thyristor type

Exchange of Thyristors for Size D5

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Page 43

Gate (G): Faston 2.8 x 0.8 mm

Cathode (HK): Faston 4.8 x 0.8 mm Conductive plate: Diameter 36 mm

Second thyristor type (900 A)

Converter with second thyristor type T460Nxxx Id code: 3ADC340105P0001

Second thyristor type

Gate (4): Round terminal D = 1.5 mm

Cathode (5): Faston 4.8 x 0.5 mm Conductive plate: Diameter 36 mm

Original thyristor type (1200 A)

Converter with original thyristor type T589Nxxx Id code: DCA0012015P0001

Original thyristor type

3ADW000195R0501 DCS800 Service Manual e e

Exchange of Thyristors for Size D5

Page 44

Gate (G): Faston 2.8 x 0.8 mm

Cathode (HK): Faston 4.8 x 0.8 mm Conductive plate: Diameter 36 mm

Second thyristor type (1200 A)

Converter with second thyristor type T590Nxxx Id code: 3ADC340106P0001

Second thyristor type

Gate (4): Round terminal D = 1.5 mm

Cathode (5): Faston 4.8 x 0.5 mm Conductive plate: Diameter 36 mm

Exchange of Thyristors for Size D5

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Page 45

Find faulty thyristor

1. Find the defective branches by performing an OHM test (both polarities) between U1, V1, W1 and C1, D1 (see fig. Anti-parallel B6-bridges with

branching fuses on page 45)

C1 (+)

V11 V13 V15V24 V26 V22

F11 F13 F15

F14 F16 F12

V14 V16 V12V21 V23 V25

branching fuse

D1 (-)

princi ple_B6_a .dsf

Anti-parallel B6-bridges with branching fuses

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 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.

branch

Exchange of Thyristors for Size D5

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Page 46

Remove faulty thyristor

1. Remove the screws of the DC – busbars and branch fuses preventing the stack to be prized open. Note: It depends on the location of the defective thyristor which DC – busbar and fuses have to be disconnected.

2. Write down the direction and location of the thyristors to be removed and mark their gate leads.

3. Remove the gate leads if possible.

4. Loosen the mounting clamp (see fig. Aluminum spring with welded indicating

spring on page 47) at the top of the thyristor stack.

Attention: While loosen the mounting clamp the indicating spring must be pulled out a little, otherwise the spring will be damaged!

5. Attach the disassembly tool at the faulty thyristor and prize open the upper and

lower heat sinks (see fig. How to use the disassembly tool

page 46).

6. Remove the thyristors.

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!

Mounting clamp

View from the left

Disassembly tool

mountc l_b.dsf

Front view

View from the right

How to use the disassembly tool

Exchange of Thyristors for Size D5

3ADW000195R0501 DCS800 Service Manual e e

Page 47

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.

3. Connect the gate leads if possible.

4. 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.

5. 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.

6. Turn the thyristor so that the gate leads point in the right direction.

Loose condition

TORQUE INDICATING SPRING

Insulating plate

In- sulating tube

Correct torque

Heatsink

Aluminum spring with welded indicating spring

Exchange of Thyristors for Size D5

3ADW000195R0501 DCS800 Service Manual e e

Page 48

7. Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks. Note: The indicating spring is a very sensitive instrument and must be handled with care.

8. 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” (see fig. Aluminum

spring with welded indicating spring

on page 47). Do not tighten the screws any

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

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

10. Reconnect the DC – busbars, branch fuses and all other dismantled parts.

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

U1 V1 W1

left stack

rear front

V24 V11

V13 V26

V22 V15

View from the left Front view View from the right

Location of thyristors in frame D5 (4-Q bridge)

right stack

front rear

V14 V21

V23 V16

V12 V25

Exchange of Thyristors for Size D5

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Page 49

U1 V1 W1

left stack

rear front

V11

V13

V15

View from the left Front view View from the right

right stack

front rear

V14

V16

V12

Location of thyristors in frame D5 (2-Q bridge)

Exchange of Thyristors for Size D5

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Page 50

D1 (-)

C1 (+)

Exchange of Thyristors for Size D5

Location of branch fuses frame D5

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Page 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

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 for electrical connections: 13 Nm (M8)

25 Nm (M10) 50 Nm (M12)

 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 DCF 1066721 P1

Note:

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)

Exchange of Thyristors for Size D6

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Page 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 3 ~ 800 VAC DCS800-S02-1900-08 3 ~ 800 VAC DCS800-S01-2050-05 3 ~ 525 VAC DCS800-S02-2050-05 3 ~ 525 VAC DCS800-S01-2050-06 3 ~ 600 VAC DCS800-S02-2050-06 3 ~ 600 VAC DCS800-S01-2050-07 3 ~ 690 VAC DCS800-S02-2050-07 3 ~ 690 VAC

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

Converter with second

thyristor type T 1xxx-24

Id code: 3ADC340098P0001

DCS800-S01-1900-08a DCS800-S02-1900-08a DCS800-S01-2050-05a DCS800-S02-2050-05a DCS800-S01-2050-06a DCS800-S02-2050-06a DCS800-S01-2050-07a DCS800-S02-2050-07a

Original thyristor type

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Gate (4): Faston 2.8 x 0.8 mm

Cathode (5): Faston 4.8 x 0.8 mm Conductive plate: Diameter 48 mm

Second thyristor type

Thyristor T 1xxx-24 with Id code 3ADC340098P0001

Second thyristor type

Gate (y): Round terminal D = 1.5 mm

Cathode (K

): Faston 4.8 x 0.5 mm

Conductive plate: Diameter 50 mm

BCT thyristors

Gates of BCT

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

BCT.ds f

Gate A

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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.

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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.

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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 sprin

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

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

push down

Use of disassembly tool

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

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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.

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

page 53).

6. Connect the gate leads if possible.

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

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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.

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.

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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.

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Stack

front rear

C1(+)

D1(-)

C1(+)

V11

V21

V16

V26

V15

V24

V14

V23

V13

V22

V25

V12

D1(-)

View from the right

A6_thy r_loca t.dsf

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

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Gate A

Gate B

stack

front rear

C1(+)

V11 / V24

V14 / V21

D1(-)

C1(+)

D1(-)

V16 / V23

V13 / V26

V15 / V22

V12 / V25

View from the right

A6_thyr_lo cat.dsf

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

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stack

front rear

C1(+)

V11

V14

D1(-)

C1(+)

D1(-)

V16

V13

V15

V12

View from the right

A6_thyr_lo cat.dsf

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

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C1(+)

D1(-)

F11

F14

F16

F13

F15

F12

C1(+)

F11

F14

D1(-)

F16

F13

C1(+)

F15

F12

D1(-)

A6_branc h_fuse_l ocat.dsf

Location of parallel branch fuses frame D6

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Exchange of Thyristors for Size D7

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

All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The

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 for electrical connections: 13 Nm (M8)

25 Nm (M10) 50 Nm (M12)

(grease)

Manufacturer: Carl Bechem GmbH, 58089 Hagen ABB Service: GHSN 390 001 P 0001

 Disassembly tool: DCF 1066721 P1

Note:

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

All thyristors are always mounted in the same direction, independent of current, voltage, number of quadrants (2-Q or 4-Q), left or right side connection. 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.

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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. Remove the AC busbars, of the defective branches.

4-quadrant converter:

3. Remove all screws of the DC - busbars either above or below the fuses of the defective branches. Note: The connection is made with a screw socket, which may fall down, when all screws are removed.

Isolator

removed screws

loose AC busbar

DC busbars

Location of busbars

4. Put a small piece of isolator (e.g. paper) between the DC - busbar and the heat sink to insulate the anti-parallel thyristors from each other.

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

2 - quadrant converter:

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

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Remove faulty thyristor

1. Remove the screws of all DC / AC - busbars preventing the stack to be prized open. Remove the branch fuses, if the defective thyristors are covered by them. Note: It depends on the location of the defective thyristors, which DC / AC - busbars have to be disconnected.

2. Loosen the screws holding the backplate and make sure the backplate can move up.

screws

backplate

Backplate

3. Write down the direction and location of the defective thyristors to be removed and mark their gate leads.

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

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

push down

Use of disassembly tool

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

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Install new thyristor

1. Ensure that the new thyristor is of the correct type (see appendix A of this manual). 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.

Prepare disk type thyristor

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.

6. Connect the gate leads if possible.

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

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Torque indicating spring

loose condition

Mounting clamp; loose condition

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

8. 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.

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Torque indicating spring

correct torque

Mounting clamp; correct torque

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

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

10. Reconnect the backplate, branch fuses, DC- / AC-busbars and all other dismantled parts.

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

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V11

V24

V13

V26

V15

V22

Assembly D7 Busbars on the right; view from the front

V21

V14

V23

V16

V25

V12

D7_ass.dsf

V21

V23

V25

V12

V14

V16

Assembly D7 Busbars on the left; view from the front

Location of thyristors in frame D7 (4-Q bridge)

V11

V24

V13

V26

V15

V22

V11

V14

V13

V16

V15

V12

Assembly D7 Busbars on the right; view from the front

D7_ass.dsf

Assembly D7 Busbars on the left; view from the front

Location of thyristors in frame D7 (2-Q bridge)

V11

V13

V15

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AC-busbar

D1(-)

DC-busbar

A7_branch_fuse_lopcat.dsf

C1(+)

DC-busbar

Location of branch fuses frame D7 (busbars on the right)

AC-busbar

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AC-busbar

C1(+)

DC-busbar

D1(-)

A7_branch_fuse_lopcat.dsf

DC-busbar

Location of branch fuses frame D7 (busbars on the left)

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Exchange of SDCS-CON-4

General

All DCS800 size D1 to D7 are equipped with the same controller board SDCS-

CON-4, thus the exchange of the board is similar for all module sizes.

Required Tools

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

the SDCS-CON-4:  Torx screwdrivers: TX10, TX20, TX25

Overview SDCS-CON-4 exchange

1. Save parameters,

2. Write down type code of the drive,

3. Set jumpers on the new SDCS-CON-4 according to the old SDCS-CON-4,

4. Exchange the SDCS-CON-4,

5. Set type code of the drive,

6. Enable application program and

7. Download and compare parameters.

1. Save parameters

DCS Control Panel

Parameters can be saved by various means:

 Press Soft key 1 until the main menu is shown (see picture above),  Press LOC/REM button, display will show LOC on the upper left side,

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 Press Soft key 2 (MENU),  Scroll with UP / DOWN buttons to menu item PAR BACKUP,  Confirm with Soft key 2 (ENTER),  Select UPLOAD TO PANEL and confirm with Soft key 2 (SEL), the upload

progress bar will be shown on the display,

 Successful upload will be shown by message,  Confirm with Soft key 1 (OK),  Press Soft key 1 until back to the main menu (see picture above),  The actual parameter set is now stored in the DCS Control Panel.

DriveWindow

 Click File then Save As…

Light

DriveWindow

 Click Save:

 Click File then Parameters and Save As…

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 Click Save:

2. Write down type code of the drive

Write down the contents of TypeCode (97.01). This information must be manually set in the new SDCS-CON-4.

3. Set jumpers on the new SDCS-CON-4 according to the old SDCS-CON-4

Copy the jumper settings (S1 to S4) of the old SDCS-CON-4 onto the new SDCSCON-4 accordingly.

4. Exchange the SDCS-CON-4

Remove the

1. Remove the DCS Control Panel and design cover:

old SDCSCON-4

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),

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 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 o ptions, so that the

intermediate cover is empty

Remove plug in options

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):

Disconnect all plugs from SDCS-

CON-4 and SDCS-DSL-4 boards

Disconnect all plugs

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5. Remove screws and studs:

Remove these

screws and studs

Remove screws and studs

6. Unplug the flat cables (X12, X13, X37):

Remove fla t

cables

Unplug the flat cables

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Install the new SDCSCON-4

1. Reconnect the flat cables at the SDCS-CON-4 (X12, X13, X37),

2. Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7) and the plugs at the SDCS-DSL-4 (X51 to X54) and

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

5. Set type code of the drive

Follow the instructions in chapter Set type code

6. Enable application program

If a SDCS-MEM-8 (Memory Card) is used the application program must be enabled before the parameters are downloaded. Set:

 ParApplSave (16.06) = EnableAppl

7. Download and compare parameters

Parameters can be downloaded and compared by various means:

DCS Control Panel

 Press Soft key 1 until the main menu is shown,  Press LOC/REM button, display will show LOC on the upper left side,  Press Soft key 2 (MENU),  Scroll with UP / DOWN buttons to menu item PAR BACKUP,  Confirm with Soft key 2 (ENTER),  Select DOWNLOAD FULL SET and confirm with Soft key 2 (SEL), the

download progress bar will be shown on the display,

 Successful download will be shown by message,  Confirm with Soft key 1 (OK),  Press LOC/REM button, display will show REM on the upper left side,  Press Soft key 1 until back to the main menu and  The actual parameter set is now downloaded into the new SDCS-CON-4.

DriveWindow

 Click File then Open…

Light

 Choose correct parameter file and click Open:

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 Click Drive then Parameters & Signals and Download All Parameters

 To check if the parameter download was successful connect the drive with

DriveWindow Light and compare drive memory the downloaded parameter set. Click Drive then Parameters & Signals and Compare…

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DriveWindow

 Click File then Parameters and Download…

 Click Open and follow the instructions:

 To check if the parameter download was successful connect the drive with

DriveWindow and compare drive memory the downloaded parameter set. Click

File then Parameters and Compare…

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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:

115 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.

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:

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.

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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:

Remove DCS Control Panel

Design cover

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2. Remove the two fan arrangement screws:

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:

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

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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

screws

Converter fan in frame D7

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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:

Workspaces

ABB provides workspaces called DCS800.fdt. New workspaces have to be saved

 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.

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

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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

 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

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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100

Download firmware file to device:

 Select desired firmware with a right mouse click and choose Download File to

Device from the pop up menu

Service

3ADW000195R0501 DCS800 Service Manual e e