Dcs 800 abb руководство по эксплуатации

5

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

6

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

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

7

Grounding

These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic interference.

WARNING!

•Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and pick-up.

•Make sure that grounding conductors are adequately sized and marked as required by safety regulations.

•In a multiple-drive installation, connect each drive separately to protective earth (PE ).

•Minimize EMC emission and make a 360° high frequency grounding (e.g. conductive sleeves) of screened cable entries at the cabinet lead-through plate.

•Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

•Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations.

•As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

Safety instructions

8

Printed circuit boards and fiber optic cables

These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions

9

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

10

Operation

These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

WARNING!

•Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

•Do not control the motor with the disconnecting device

(disconnecting mains); instead, use the control panel keys and , or commands via the I/O board of the drive.

•Mains connection

You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker’s main contacts to open. The mains disconnect must be locked in its «OPEN» position during any installation and maintenance work.

•EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals «RUN», «drive OFF» or «Emergency Stop» respectively «control panel» or «PC tool».

•Intended use

The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in industrial installations.

If in special cases the electrical machines and devices are intended for use in non-industrial installations — which may require stricter safety regulations (e.g. protection against contact by children or similar) — these additional safety measures for the installation must be provided by the customer during assembly.

Safety instructions

11

Note:

•When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not

stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key .

Safety instructions

Table of contents

Table of contents

16

Introduction

How to use this manual

The purpose of this service manual is to provide detailed information on how to service power converters from the DCS800 series.

Contents of this manual

Safety instructions

This chapter is located at the beginning of this manual.

Introduction

This chapter informs about the contents and the use of this manual as well as the boundary conditions applying and the thyristor power converter rating plate.

Fault Tracing Thyristors

This chapter describes how to detect and select a faulty thyristor.

Handling the Semiconductors

This chapter describes the handling of thyristors and thyristor modules.

Exchange of Thyristors of Sizes D1 to D4

This chapter describes the exchange of thyristors in converters sizes D1 to D4.

Exchange of Thyristors of Size D5

This chapter describes the exchange of thyristors in converters size D5.

Exchange of Thyristors of Size D6

This chapter describes the exchange of thyristors in converters size D6.

Exchange of Thyristors of Size D7

This chapter describes the exchange of thyristors in converters size D7

Exchange of SDCS-CON-4

This chapter describes the exchange of a SDCS-CON-4

Service

This chapter contains hardware information and technical hints.

Preventive Maintenance

This chapter describes the measures for preventive maintenance of the thyristor converters.

Appendix A Spare Parts list

The Appendix A contains the spare parts list of the converters.

Target group

This manual is designed to help those responsible for planning, installing, starting up and servicing the thyristor power converter.

These people should possess:

basic knowledge of physics and electrical engineering, electrical wiring principles, components and symbols used in electrical engineering, and

basic experience with DC drives and products.

Associated publications

A list of associated publications is published on the inner page of this manual’s cover, see DCS800 Drive Manuals. Here is a list of the most important ones:

The DCS800 Hardware Manual (3ADW000194) describes all hardware

Introduction

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.

exciter current Rated fan voltage

Plus code

Example of a name plate

Introduction

18

Type code

The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. DCS800-S01- 2005). The optional selections are given thereafter, on the name plate by plus code. The main selections are described below. Not all selections are available for all types.

Introduction

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

1 only available as 2-Q drive

Introduction

21

Fault Tracing Thyristors

Tools

For commissioning and fault tracing

Following software tools are mandatory:

DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program and

DriveWindow for fast drive monitoring using SDCS-COM-8.

Following tools are mandatory in addition to standard tools:

An oscilloscope including memory function with either galvanically isolating transformer or isolating amplifier (probe) for safe measurements. It can also be a hand held (portable) oscilloscope.

A clamp on current probe. In case the scaling of the DC load current needs to be checked it must be a DC clamp on current probe.

A voltmeter (at least CAT III 1000 V):

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

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

23

DC-current pulses measured by an oscilloscope

Connect an oscilloscope to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3) and check for the proper amount of current pulses:

Six current pulses in positive direction

There should be six current pulses in positive direction.

In case of a 4-Q converter also the six current pulses for the negative direction have to be checked.

Thyristor diagnosis

Also the thyristor diagnosis provided by the firmware can be used:

Switch the drive to local mode (DriveWindow, DriveWindow Light, DCS Control Panel or local I/O).

Start the thyristor diagnosis by means of ServiceMode (99.06) = ThyDiagnosis and set On and Run within 20 s.

During the thyristor diagnosis the main contactor will be closed and the thyristors are checked. The field current is not released while the thyristor diagnosis is active and thus the motor should not turn.

When the thyristor diagnosis is finished check Diagnosis (9.11) for details.

Ripple monitor

The ripple monitor indicates that the ripple of the DC current is much higher than normal. In such a case, most often one thyristor does not work. It’s missing current contribution causes a deep dip in the direct current.

The structure of the current loop (current controller) will force the other thyristors to compensate the dip by a certain overcurrent in order to keep the average current constant. Such a compensation results in a ripple monitoring fault during motoring mode operation with 90°.

The reason for a current less thyristor may be:

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

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, 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.

26

Fault Tracing Thyristors

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

28

Handling the Semiconductors

29

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:

Screws are metric type; use appropriate nuts

Tissue paper

Solvent (e.g. ethanol)

Thermal joint compound: type Berulub FZ1 E3

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

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 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

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

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:

X8

use screw driver

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

33

8. Remove the SDCS-PIN-4 board:

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

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

35

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 on 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

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

37

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

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

38

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

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

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

Exchange of Thyristors for Size D1 to D4

40

Terminals of the OnBoard bridge and all thyristor modules

Exchange of Thyristors for Size D1 to D4

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:

Torque spanner for electrical connections:

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)

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

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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:

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

Original thyristor type

Exchange of Thyristors for Size D5

43

Second thyristor type (900 A)

Converter with second thyristor type T460Nxxx Id code: 3ADC340105P0001

Original thyristor type (1200 A)

Converter with original thyristor type T589Nxxx Id code: DCA0012015P0001

Original thyristor type

Exchange of Thyristors for Size D5

44

Second thyristor type (1200 A)

Converter with second thyristor type T590Nxxx Id code: 3ADC340106P0001

Exchange of Thyristors for Size D5

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)

U1

V1

W1

branch

V14 V21 V16V23 V12 V25

D1 (-)

principle_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.

Exchange of Thyristors for Size D5

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

mountcl_b.dsf

Front view

How to use the disassembly tool

Exchange of Thyristors for Size D5

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.

Heatsink

Correct torque

Aluminum spring with welded indicating spring

Exchange of Thyristors for Size D5

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.

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

Exchange of Thyristors for Size D5

5

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

6

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

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

7

Grounding

These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic interference.

WARNING!

•Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and pick-up.

•Make sure that grounding conductors are adequately sized and marked as required by safety regulations.

•In a multiple-drive installation, connect each drive separately to protective earth (PE ).

•Minimize EMC emission and make a 360° high frequency grounding (e.g. conductive sleeves) of screened cable entries at the cabinet lead-through plate.

•Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

•Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations.

•As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

Safety instructions

8

Printed circuit boards and fiber optic cables

These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions

9

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

10

Operation

These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death and/or damage to the equipment.

WARNING!

•Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

•Do not control the motor with the disconnecting device

(disconnecting mains); instead, use the control panel keys and , or commands via the I/O board of the drive.

•Mains connection

You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker’s main contacts to open. The mains disconnect must be locked in its «OPEN» position during any installation and maintenance work.

•EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals «RUN», «drive OFF» or «Emergency Stop» respectively «control panel» or «PC tool».

•Intended use

The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in industrial installations.

If in special cases the electrical machines and devices are intended for use in non-industrial installations — which may require stricter safety regulations (e.g. protection against contact by children or similar) — these additional safety measures for the installation must be provided by the customer during assembly.

Safety instructions

11

Note:

•When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not

stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key .

Safety instructions

Table of contents

Table of contents

16

Introduction

How to use this manual

The purpose of this service manual is to provide detailed information on how to service power converters from the DCS800 series.

Contents of this manual

Safety instructions

This chapter is located at the beginning of this manual.

Introduction

This chapter informs about the contents and the use of this manual as well as the boundary conditions applying and the thyristor power converter rating plate.

Fault Tracing Thyristors

This chapter describes how to detect and select a faulty thyristor.

Handling the Semiconductors

This chapter describes the handling of thyristors and thyristor modules.

Exchange of Thyristors of Sizes D1 to D4

This chapter describes the exchange of thyristors in converters sizes D1 to D4.

Exchange of Thyristors of Size D5

This chapter describes the exchange of thyristors in converters size D5.

Exchange of Thyristors of Size D6

This chapter describes the exchange of thyristors in converters size D6.

Exchange of Thyristors of Size D7

This chapter describes the exchange of thyristors in converters size D7

Exchange of SDCS-CON-4

This chapter describes the exchange of a SDCS-CON-4

Service

This chapter contains hardware information and technical hints.

Preventive Maintenance

This chapter describes the measures for preventive maintenance of the thyristor converters.

Appendix A Spare Parts list

The Appendix A contains the spare parts list of the converters.

Target group

This manual is designed to help those responsible for planning, installing, starting up and servicing the thyristor power converter.

These people should possess:

basic knowledge of physics and electrical engineering, electrical wiring principles, components and symbols used in electrical engineering, and

basic experience with DC drives and products.

Associated publications

A list of associated publications is published on the inner page of this manual’s cover, see DCS800 Drive Manuals. Here is a list of the most important ones:

The DCS800 Hardware Manual (3ADW000194) describes all hardware

Introduction

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.

exciter current Rated fan voltage

Plus code

Example of a name plate

Introduction

18

Type code

The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. DCS800-S01- 2005). The optional selections are given thereafter, on the name plate by plus code. The main selections are described below. Not all selections are available for all types.