ABB DCS800 Service Manual

4 (1)

DCS800

Service manual

DCS800 Drives (20 to 5200 A)

DCS800 Drive Manuals

			Language
		Public. number	E	D	I	ES	F	CN	RU	PL
DCS800 Quick Guide		3ADW000191	x	x	x	x	x
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 Manual DCS800 update DCF503B/DCF504B		3ADW000194Z0301	x
Firmware Manual DCS800		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
DriveWindow 2.x - User's Manual		3BFE64560981	x
DriveOPC 2.x - User's Manual		3BFE00073846	x
Optical DDCS Communication Link		3AFE63988235	x
DDCS Branching Units - User’s Manual		3BFE64285513	x

DCS800 Applications
PLC Programming with CoDeSys		CoDeSys_V23	x	x			x
61131 DCS800 target +tool description - Application Program		3ADW000199	x

DCS800 Crane Drive
DCS800 Crane Drive Manual suppl.		3AST004143	x
DCS800 Crane Drive Product note		PDC5 EN REVA	p

DCS800 Winder ITC
DCS800 Winder Product note		PDC2 EN	x
DCS800 Winder description ITC		3ADW000308	x
Winder Questionnaire		3ADW000253z	x

DCS800-E Panel Solution
Flyer DCS800-E Panel solution		3ADW000210	x
Hardware Manual DCS800-E		3ADW000224	x

DCS800-A Enclosed Converters
Flyer DCS800-A		3ADW000213	x
Technical Catalogue DCS800-A		3ADW000198	x
Installation of DCS800-A		3ADW000091	x	x

DCS800-R Rebuild System
Flyer DCS800-R		3ADW000007	x	x
DCS800-R Manual		3ADW000197	x
DCS500/DCS600 Size A5...A7, C2b, C3 and C4 Upgrade Kits		3ADW000256	x

Extension Modules
RAIO-01 Analogue IO Extension		3AFE64484567	x
RDIO-01 Digital IO Extension		3AFE64485733	x
RRIA-01 Resolver Interface Module		3AFE68570760	x
RTAC-01 Pulse Encoder Interface		3AFE64486853	x
RTAC-03 TTL Pulse Encoder Interface		3AFE68650500	x
AIMA R-slot extension		3AFE64661442	x

Serial Communication
Drive specific serial communication
NETA Remote diagnostic interface		3AFE64605062	x

Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)		3AFE64504215	x
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet)		3AFE64506005	x
Fieldbus Adapter with DC Drives RDNA- (DeviceNet)		3AFE64504223	x
Fieldbus Adapter with DC Drives RMBA (MODBUS)		3AFE64498851	x
Fieldbus Adapter with DC Drives RETA (Ethernet)		3AFE64539736	x
x -> existing	p -> planned
Status 04.2010

DCS800 Drive Manuals-List_j.doc

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

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.

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

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.

WARNING!

•Only qualified electricians are allowed to install and maintain the drive!

•Never work on the drive, motor cable or motor when main power is applied.

Always ensure by measuring with a multimeter (impedance at least

1Mohm) 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.

•Do not work on the control cables when power is applied to the 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.

•Do not make any insulation resistance or voltage withstand tests on the drive or drive modules.

•Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor.

•When reconnecting the motor cable, always check that the C+ and 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.

•Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO).

•DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply.

Safety instructions

3ADW000195R0501 DCS800 Service Manual e e

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

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

Mechanical installation

These notes are intended for all who install the drive. Handle the unit carefully to avoid damage and injury.

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.

•Make sure that dust from drilling does not enter the drive when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

•Ensure sufficient cooling.

•Do not fasten the drive by riveting or welding.

Safety instructions

3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0101 DCS800 Service Manual e a

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

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

3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0101 DCS800 Service Manual e a

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

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	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

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. Here is a list of the most important ones:

The DCS800 Hardware Manual (3ADW000194) describes all hardware

Introduction

3ADW000195R0501 DCS800 Service Manual e e

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	U1	3 525 V	U2	610 V
		20 A			Made in Germany
					Made in Germany

Type: DCS800-S02-0025-05	I1		I2	25 A
Type: DCS800-S02-0025-05	I1		I2	25 A		+K454
Ser No: 0025421A06294264	f1	50/60 Hz	If	6 A		+J409
	SCCR	65 kA	Fan	----
	SCCR	65 kA	Fan	----

Production year	Rated input voltage	Rated output current

2006 and week 29	Rated input current	Rated internal field

exciter current Rated fan voltage

Plus code

Example of a name plate

Introduction

3ADW000195R0501 DCS800 Service Manual e e

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 all types.

Type code

D C S 8 0

0 - A A X - Y Y

Y Y - Z Z

- plus code

Position

A X

Position

Plus code

Product series

DCS800

Type

S0 = Standard converter module IP00

R0 = Rebuild system

E0 = Panel solution

A0 = Enclosed converter

Bridge type

1 = Single bridge (2-Q)

2 = 2 anti parallel bridges (4-Q)

Rated DC current

YYYY = Rated current (e.g. 0025 = 25 ADC)

Rated AC voltage

04 = 400 VAC

05 = 525 VAC

06 = 600 VAC

07 = 690 VAC

08 = 800 VAC

10 = 990 VAC

12 = 1200 VAC

Power connection

- = Standard D1 ... D6

L = Left side D7

R = Right side D7

a = Second thyristor type D5, D6

Internal field exciter

+S164

With internal field exciter, external supply (only D5:25 A, Rebuild kit: 25 A/16 A)

configuration

+0S163

Without internal field exciter (only D1 ... D4)

Fan voltage

Size D4

Standard fan voltage:

230 V / 1-ph

+S171

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

+S172

Additional fan voltage for 600-690 V units:

400-500 V / 3-ph

Current measurement

+S175

SDCS-CMA-2 for sizes D5 to D7

Voltage measurement

+S186

120 V SDCS-SUB-4 for sizes D1 ... D4

+S180

600 V for sizes D6 and D7

+S181

690 V for sizes D6 and D7

+S182

800 V for sizes D6 and D7.

+S183

990 V for sizes D6 and D7.

+S189

Galvanic isolation for sizes D6 and D7

SDCS-DSL-4

+S199

With SDCS-DSL-4

+0S199

Without SDCS-DSL-4

+ plug-in options

DCS Control Panel

0J400

Without DCS Control Panel

J409

Door mounting Kit (cable length 3 m)

Fieldbus

K454

Profibus RPBA

K451

DeviceNet RDNA

K466

Ethernet IP + Modbus TCP RETA

K458

Modbus RMBA

I/O and DDCS

L500

Analogue Extension RAIO

L501

Digital Extension RDIO

L508

DDCS Communication board (10 Mbaud CH0) SDCS-COM-81

L509

DDCS Communication board (5 Mbaud CH0) SDCS-COM-82

Introduction

3ADW000195R0501 DCS800 Service Manual e e

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	4-Q rated current			Supply voltage [VAC]
	DCS800-01 [ADC]	DCS800-02 [ADC]
			400	525	600	690	800	990	1200
D1	20	25	X	X
	45	50	X	X
	65	75	X	X
	90	100	X	X
	125	140	X	X
D2	180	200	X	X
	230	260	X	X
D3	315	350	X	X	X
	405	450	X	X
	470	520	X	X
D4	610	680	X	X	X
	740	820	X	X
	900	1000	X	X
D5	900	900			X	X
	1200	1200	X	X
	1500	1500	X	X	X	X
	2000	2000	X	X	X1	X1
D6	1900	1900					X
	2050	2050		X	X	X
	2500	2500	X	X	X	X	X
	3000	3000	X	X	X	X	X
D7	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

1 only available as 2-Q drive

Introduction

3ADW000195R0501 DCS800 Service Manual e e

Introduction

3ADW000195R0501 DCS800 Service Manual e e

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):

1000 V probes and test leads:

An ESD-field service kit (ABB Service Finland code 0001ESD / MS-Antistatic):

Make sure that all equipment in use is suitable for the voltage level applied to the power part!

Fault Tracing Thyristors

3ADW0000195R0501DCS8000ServiceManualeeee

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

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

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

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, D6 or D7 section Find faulty thyristor.

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.

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

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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

Handling the Semiconductors

3ADW000195R0501 DCS800 Service Manual e e

Exchange of Thyristors for Size D1 to D4

Installation of OnBoard bridge and thyristor modules in converters size

D1 to D4 (20...1000 A)

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

Required Tools

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

	Torx screwdrivers:	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: type Berulub FZ1 E3

(grease)
Manufacturer:	Carl Bechem GmbH, 58089 Hagen
ABB Service:	GHSN 390 011 P 0051
or
thermal joint compound:	type WLPF 20 (10 ml)
ABB Service:	GHSN 390 011 P 10

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

Find faulty thyristor modules

See Fault Tracing Thyristors of this publication.

Exchange of Thyristors for Size D1 to D4

3ADW000195R0501 DCS800 Service Manual e e

Remove faulty thyristor modules

1. Remove the DCS Control Panel and design cover:

Remove DCS Control Panel

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

Remove design cover

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

serial communication modules (R-type),

extension I/O modules (RAIO, RDIO),

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

communication board (SDCS-COM-8),

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

SDCS-MEM-8 (Memory Card).

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

Depress the locks to remove the design cover

Remove all options, so that the intermediate cover is empty

Remove plug in options

Exchange of Thyristors for Size D1 to D4

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