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18

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

Y

Z B

Position

Plus code

Product series

DCS800

A

Type

S0 = Standard converter module IP00
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter

X

Bridge type

1 = Single bridge (2-Q)
2 = 2 anti parallel bridges (4-Q)

Y

Rated DC current

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

ZZ

Rated AC voltage

04 = 400 VAC
05 = 525 VAC
06 = 600 VAC
07 = 690 VAC
08 = 800 VAC
10 = 990 VAC
12 = 1200 VAC

B

Power connection

- = Standard D1 ... D6
L = Left side D7
R = Right side D7
a = Second thyristor type D5, D6

Internal field exciter
configuration

+S164
+0S163

With internal field exciter, external supply (only D5:25 A, Rebuild kit: 25 A/16 A)
Without internal field exciter (only D1 ... D4)

Fan voltage

+S171

+S172

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

Current measurement

+S175

SDCS-CMA-2 for sizes D5 to D7

Voltage measurement

+S186
+S180
+S181
+S182
+S183
+S189

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

SDCS-DSL-4

+S199
+0S199

With SDCS-DSL-4
Without SDCS-DSL-4

+ plug-in options

DCS Control Panel

0J400
J409

Without DCS Control Panel
Door mounting Kit (cable length 3 m)

Fieldbus

K454
K451
K466
K458

Profibus RPBA
DeviceNet RDNA
Ethernet IP + Modbus TCP RETA
Modbus RMBA

I/O and DDCS

L500
L501
L508
L509

Analogue Extension RAIO
Digital Extension RDIO
DDCS Communication board (10 Mbaud CH0) SDCS-COM-81
DDCS Communication board (5 Mbaud CH0) SDCS-COM-82

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

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Summary of Contents for DCS800

Page 1: ...DCS800 Service manual DCS800 Drives 20 to 5200 A Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 2: ...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...

Page 3: ...ll rights reserved 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 4: ...3ADW000195R0101 DCS800 Service Manual e a 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 5: ...d 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 wa...

Page 6: ...rnally 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 chec...

Page 7: ...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 N...

Page 8: ...ts 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 ...

Page 9: ...nit 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...

Page 10: ...cked 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 op...

Page 11: ... 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 12: ...12 Safety instructions 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 13: ...ing 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...

Page 14: ... 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...

Page 15: ...ded 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 16: ...xchange 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 c...

Page 17: ... 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 Automatio...

Page 18: ...ld exciter external supply only D5 25 A Rebuild kit 25 A 16 A Without internal field exciter only D1 D4 Fan voltage S171 S172 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 Current meas...

Page 19: ...d current DCS800 02 ADC 400 525 600 690 800 990 1200 20 25 X X 45 50 X X 65 75 X X 90 100 X X D1 125 140 X X 180 200 X X D2 230 260 X X 315 350 X X X 405 450 X X D3 470 520 X X 610 680 X X X 740 820 X X D4 900 1000 X X 900 900 X X 1200 1200 X X 1500 1500 X X X X D5 2000 2000 X X X1 X1 1900 1900 X 2050 2050 X X X 2500 2500 X X X X X D6 3000 3000 X X X X X 2050 2050 X 2600 2600 X X 3300 3300 X X X X...

Page 20: ...20 Introduction 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 21: ...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 k...

Page 22: ... 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 ...

Page 23: ...uring 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 mo...

Page 24: ...000 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 b...

Page 25: ... 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 curr...

Page 26: ...26 Fault Tracing Thyristors 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 27: ...ed 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 Semiconduct...

Page 28: ...28 Handling the Semiconductors 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 29: ... 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 Ma...

Page 30: ...cond 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 Remove DCS Control Panel Depress ...

Page 31: ...ugs at the SDCS DSL 4 board if used X51 to X54 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 Disconnect all plugs from SDCS CON 4 and SDCS DSL 4 boards Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 32: ...y 7 Remove all cables and plugs at the SDCS PIN 4 Remove all cables and plugs T100 X8 How to handle X8 use screw driver Keep winding direction and amount of windings for T100 in mind 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 hol...

Page 33: ...eads 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 Phone 800 8...

Page 34: ...a 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 th...

Page 35: ... 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 t...

Page 36: ... 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 ...

Page 37: ...15 V16 V13 V12 V15 K2 G2 K1 G1 V14 V11 V14 V11 V16 V13 V12 V15 V14 V11 V16 V13 V12 V15 A K AK DCS800 S01 0230 DCS800 S01 0610 0900 DCS800 S01 0315 0470 V1 V1 V1 V1 DCS800 loc of mod 1Q dsf DCS800 S01 0020 0180 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 m...

Page 38: ...15 V22 V14 V21 V16 V23 V12 V25 K2 G2 K1 G1 K2 G2 K1 G1 V13 V26 V15 V22 K2 G2 K1 G1 V11 V24 K2 G2 K1 G1 K2 G2 K1 G1 V16 V23 V12 V25 K2 G2 K1 G1 V14 V21 V24 V11 V22 V15 V26 V13 V23 V16 V25 V12 V21 V14 K AK A G2 G1 K1 K2 K AK A G2 G1 K1 K2 A K AK A K AK A K AK A K AK A K AK A K AK V26 V13 V22 V15 V24 V11 V23 V16 V25 V12 V21 V14 Location of the OnBoard bridge and thyristor modules in DCS800 S02 4 Q un...

Page 39: ...cription 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 A 5 4 6 7 AK 4 G 6 K 5 K 7 G SKKT 27 42 57 106 2 3 1 2 3 1 K A 4 5 7 6 AK 5 G 7 K 4 K 6 G MCC26 44 56 95 2 3 1 2 3 1 MCC162 5 4 6 7 3 2 1 SKTT 162 2 3 5 4 7 6 1 6 7 4 5 K A AK Phone 800 894 0412 Fax 888 723 4773 We...

Page 40: ... A K AK TT 162 K A K1 G1 K2 G2 AK K2G2 K1G1 MCC255 K AK A G2 G1 K1 K2 K A K1 G1 K2 G2 AK TT 250 330 AK 7K 6G 4K 5G A K 1 3 2 3 2 1 TT 425 570 7K 6G 5G4K Terminals of the OnBoard bridge and all thyristor modules Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 41: ...ections 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 ...

Page 42: ...2 0900 07a Converter with original thyristor type T589Nxxx Id code DCA0012015P0001 U1 Converter with second thyristor type T590Nxxx Id code 3ADC340106P0001 DCS800 S01 1200 04 3 400 VAC DCS800 S01 1200 04a DCS800 S02 1200 04 3 400 VAC DCS800 S02 1200 04a DCS800 S01 1200 05 3 525 VAC DCS800 S01 1200 05a DCS800 S02 1200 05 3 525 VAC DCS800 S02 1200 05a Parts list The current and voltage ratings of or...

Page 43: ...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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 44: ...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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 45: ...idges 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...

Page 46: ...he 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 ...

Page 47: ...a 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...

Page 48: ...num 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 V24 V11 V13 ...

Page 49: ...vice Manual e e U1 V1 W1 left stack rear front right stack front rear View from the left Front view View from the right V11 V13 V15 V14 V16 V12 Location of thyristors in frame D5 2 Q bridge Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 50: ... Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e U1 V1 W1 C1 D1 Location of branch fuses frame D5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 51: ...nections 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 ...

Page 52: ... DCS800 S01 2050 05 3 525 VAC DCS800 S01 2050 05a DCS800 S02 2050 05 3 525 VAC DCS800 S02 2050 05a DCS800 S01 2050 06 3 600 VAC DCS800 S01 2050 06a DCS800 S02 2050 06 3 600 VAC DCS800 S02 2050 06a DCS800 S01 2050 07 3 690 VAC DCS800 S01 2050 07a DCS800 S02 2050 07 3 690 VAC DCS800 S02 2050 07a Parts list The current and voltage ratings of original and second thyristor type are the same but the siz...

Page 53: ...Faston 4 8 x 0 5 mm Conductive plate Diameter 50 mm BCT thyristors In some converter modules size D6 so called BCT s Bidirectional Controlled Thyristors 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 d...

Page 54: ...onnect 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 Note Because Disc Type semiconductors need a certain compression force to oper...

Page 55: ...en out during search for the faulty thyristor 2 Remove the screws of the DC busbar plates adjacent to the defective thyristors Location of the DC busbar plates Note It depends on the location of the defective thyristor which DC busbar plates have to be disconnected DC busbar plates Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 56: ...mounting clamp at the top of the thyristor stack 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 DC busbar plates DC busbar plates mounting clamp indicating spring ...

Page 57: ...ks Use of disassembly tool 8 Remove the thyristors with e g a pair of pliers 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 push down push down Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 58: ...ype 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 righ...

Page 59: ...lel with the contact surface of the heat sinks 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 DC busbar plates and heatsinks Torque indicating s...

Page 60: ...cated 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 Torque indicating spring correct torque Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 61: ...l e e C1 U1 V1 W1 D1 C1 D1 A6_thyr_locat dsf Stack front rear View from the right V11 V24 V21 V14 V16 V23 V26 V13 V15 V22 V25 V12 Location of thyristors in frame D6 4 Q bridge with single thyristors Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 62: ... e e C1 U1 V1 W1 D1 C1 D1 A6_thyr_locat dsf stack front rear View from the right V11 V24 V14 V21 V16 V23 V13 V26 V15 V22 V12 V25 Gate A Gate B Location of thyristors in frame D6 4 Q bridge with BCT s Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 63: ...ervice Manual e e C1 U1 V1 W1 D1 C1 D1 A6_thyr_locat dsf stack front rear View from the right V11 V14 V16 V13 V15 V12 Location of thyristors in frame D6 2 Q bridge with single thyristors Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 64: ... DCS800 Service Manual e e F11 F14 F16 F13 F15 F12 F15 F12 F16 F13 F11 F14 C1 D1 C1 D1 U1 V1 W1 U1 V1 W1 C1 D1 A6_branch_fuse_locat dsf Location of parallel branch fuses frame D6 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 65: ...ol 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...

Page 66: ...he defective branches Note The connection is made with a screw socket which may fall down when all screws are removed 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...

Page 67: ...which DC AC busbars have to be disconnected 2 Loosen the screws holding the backplate and make sure the backplate can move up 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 Handling of indicating spring and mounting clamp screws ba...

Page 68: ...all down 6 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks Use of disassembly tool 7 Remove the thyristors with e g a pair of pliers 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 push down Ph...

Page 69: ...tula 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 in...

Page 70: ...ensitive 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 Torque indicating spring loose condition Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 71: ...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 Torque indicating spring correct torque Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 72: ...he right view from the front Assembly D7 Busbars on the left view from the front Location of thyristors in frame D7 4 Q bridge V12 V16 V14 V11 V13 V15 V12 V16 V14 V11 V13 V15 D7_ass dsf Assembly D7 Busbars on the right view from the front Assembly D7 Busbars on the left view from the front Location of thyristors in frame D7 2 Q bridge Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email in...

Page 73: ...ervice Manual e e F15 F12 F13 F16 F11 F14 A7_branch_fuse_lopcat dsf C1 DC busbar D1 DC busbar W1 AC busbar V1 AC busbar U1 AC busbar Location of branch fuses frame D7 busbars on the right Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 74: ...ervice Manual e e F12 F15 F16 F13 F14 F11 A7_branch_fuse_lopcat dsf D1 DC busbar C1 DC busbar W1 AC busbar V1 AC busbar U1 AC busbar Location of branch fuses frame D7 busbars on the left Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 75: ...view 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 Parameters can be saved by various means DCS Control Panel Press Soft key 1 until the main menu is shown see pict...

Page 76: ...he 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 Light Click File then Save As Click Save DriveWindow Click File then Parameters and Save As Phone 800 894 0412 Fax 888 723 4773 Web www clr...

Page 77: ...N 4 Copy the jumper settings S1 to S4 of the old SDCS CON 4 onto the new SDCS CON 4 accordingly 4 Exchange the SDCS CON 4 Remove the old SDCS CON 4 1 Remove the DCS Control Panel and design cover Remove design cover 2 Remove all plug in options on the intermediate cover e g serial communication modules R type Remove DCS Control Panel Depress the locks by means of a screwdriver to remove the design...

Page 78: ... 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 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 Disconnect all plugs from SDCS CON 4 and SDCS DSL 4 boa...

Page 79: ...uds Remove these screws and studs Remove these screws and studs Remove these screws and studs Remove screws and studs 6 Unplug the flat cables X12 X13 X37 Remove flat cables Remove flat cables Unplug the flat cables Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 80: ...arameters 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 disp...

Page 81: ...als 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 82: ... 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 83: ...to D3 In case a fan fails there are different approaches due to the incoming voltage 230 VAC With a supply voltage of 230 VAC fans M55 and M56 are connected in series Consequently both fans have to be of the same manufacturer and type Thus it is not possible to change only the broken fan In this case both fans have to be changed 115 VAC With a supply voltage of 115 VAC all fans are connected in pa...

Page 84: ...emoving the converter fans 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on the top of the converter housing Design cover Remove DCS Control Panel Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 85: ...5R0501 DCS800 Service Manual e e 2 Remove the two fan arrangement screws Fan arrangement 3 Move the fan arrangement forward Move fan arrangement Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 86: ... 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 87: ...re 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 ...

Page 88: ...emoving the converter fans 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on the top of the converter housing Design cover Remove DCS Control Panel Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 89: ...5R0501 DCS800 Service Manual e e 2 Remove the two fan arrangement screws Fan arrangement 3 Move the fan arrangement forward Move fan arrangement Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 90: ...90 Service 3ADW000195R0501 DCS800 Service Manual e e 4 Remove the fan holding screws Fan holding screws Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 91: ...nual e e 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 92: ...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 Converter fan in frame D6 screws cables Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 93: ...ow 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 Converter fan in frame D7 screws cables Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 94: ...ed A recent workspace including firmware file and text file should be saved on the PC Workspaces ABB provides workspaces called DCS800 fdt New workspaces have to be saved in C ABB DCS800 Firmware CON 4 Ver x x Firmware text file The firmware consists of two parts The firmware file itself and the text file New firmware files rec have to be saved in C ABB DCS800 Firmware CON 4 Ver x x Firmware Phone...

Page 95: ...ervice 3ADW000195R0501 DCS800 Service Manual e e New text files cde have to be saved in C ABB DCS800 Firmware CON 4 Ver x x Text Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 96: ...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 s...

Page 97: ... 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 98: ...pace 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 99: ...irmware 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 100: ...0 Service Manual e e Download firmware file to device Select desired firmware with a right mouse click and choose Download File to Device from the pop up menu Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 101: ...al e e Disconnect tool After the download is complete the FDT2 2 has to be disconnected Select Firmware with a right mouse click and choose Disconnect from the pop up menu Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 102: ...ent display shows a the firmware s corresponding text file has to be downloaded from the workspace If the 7 segment display shows something else it is not necessary to download the text file and the download is complete Activate text download Select Text with a right mouse click and choose Set as Active Project from the pop up menu 4 3 2 1 S5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com ...

Page 103: ...Properties from the pop up menu Select the Communications tap choose the desired COM Port un tick the box Use default baud from the pop up menu and set the Target Baud Rate Attention For firmware version 80x130 80x130Demo and higher set the Target Baud Rate to 38400 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 104: ...choose Download File to Device from the pop up menu After the download is complete the 7 segment display shows a Attention Do not de energize the drive or disconnect the tool while the seven segment display shows the u Wait until the 7 segment display shows and Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 105: ...CS800 Service Manual e e Disconnect tool Now FDT2 2 has to be disconnected Select Text with a right mouse click and choose Disconnect from the pop up menu Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 106: ...e Manual e e Close download tool When closing the FDT2 2 save the workspace only if firmware files or text files have been added The firmware download is complete now Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 107: ...oad 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 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 108: ...ice 3ADW000195R0501 DCS800 Service Manual e e Select the workspace in directory C ABB DCS800 Firmware CON 4 Ver x x Confirm with Open Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 109: ...If the firmware file to be downloaded is not shown under Target files the firmware file has to be added Select Firmware with a right mouse click and choose Add Files to Project from the pop up menu Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 110: ...195R0501 DCS800 Service Manual e e Go to the directory containing the desired firmware file e g Choose the desired firmware file and press Open Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 111: ...les If the text file to be downloaded is not shown under Target files the text file has to be added Select Text with a right mouse click and choose Add Files to Project from the pop up menu Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 112: ...1 DCS800 Service Manual e e Go to the directory containing the desired text file e g To display the desired text file write in File name and press Open Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 113: ...0 Service Manual e e Choose the desired text file and press Open Close download tool When closing the FDT2 2 confirm with Yes Adding of files is complete now Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 114: ... Program Files Hitachi FDT2 2 it is not possible to use the standard ABB workspace called DCS800 fdt Thus the user has to create a new workspace Start download tool Start the Hitachi Flash Development Toolkit 2 2 by means of Start Programs Hitachi Flash Development Toolkit 2 2 Flash Development Toolkit 2 2 Create new workspace Choose File New Workspace Phone 800 894 0412 Fax 888 723 4773 Web www c...

Page 115: ... 3ADW000195R0501 DCS800 Service Manual e e Name new workspace Name the new workspace choose its location and confirm with OK Choose Yes Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 116: ...rvice 3ADW000195R0501 DCS800 Service Manual e e Create the project for the firmware file Name the new project and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 117: ...117 Service 3ADW000195R0501 DCS800 Service Manual e e Choose Device And Kernel Select Device H8S 2633F and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 118: ...01 DCS800 Service Manual e e Communication Port Select the proper COM port Select Baud Rate 38400 un tick Use Default Baud Rate and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 119: ...anual e e Device Settings Enter the CPU crystal frequency for the selected device 6 25 MHz Select the multiplier for the main clock frequency CKM 4 and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 120: ...800 Service Manual e e Connection Type Select connection BOOT Mode Select Interface Direct Connection un tick Kernel already resident and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 121: ...800 Service Manual e e Programming Options Protection Automatic and Messaging Advanced confirm with Finish Now the project for the firmware file is finished Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 122: ...rvice Manual e e Create the project for the text file Select Workspace with a right mouse click and choose New Project Name the new project and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 123: ...123 Service 3ADW000195R0501 DCS800 Service Manual e e Choose Device And Kernel Select Device H8S 2633F and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 124: ...01 DCS800 Service Manual e e Communication Port Select the proper COM port Select Baud Rate 38400 un tick Use Default Baud Rate and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 125: ...anual e e Device Settings Enter the CPU crystal frequency for the selected device 6 25 MHz Select the multiplier for the main clock frequency CKM 4 and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 126: ...CS800 Service Manual e e Connection Type Select connection BOOT Mode Select Interface Direct Connection tick Kernel already resident and confirm with Next Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 127: ...CS800 Service Manual e e Programming Options Protection Automatic and Messaging Advanced confirm with Finish Now the project for the text file is finished Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 128: ...ADW000195R0501 DCS800 Service Manual e e Close download tool When closing the FDT2 2 confirm with Yes Creating of projects is complete now Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 129: ...In case the USB adapter RUSB 02 is used together with DriveWindow 2 22 and higher and firmware package COM 8 88x160 zip and higher no additional actions have to be taken Firmware download Close all applications especially DriveWindow and DriveWindow Light Unzip the SDCS COM 8 firmware file COM 8 88xxxx zip by right click on the zip file Following files and folders will be created Phone 800 894 041...

Page 130: ...ownload by a double click on file L_AMC_DC BAT A DOS window will appear Wait until the download is finished the DOS window will close automatically Attention Do not touch the PC during the download of the firmware Check Com8SWVersion 4 11 for proper firmware version Set Ch3 HW Config 70 21 back to its original setting Set Ch3 NodeAddr 70 22 back to its original setting Re connect the drive to the ...

Page 131: ...nclosed converter 1 single bridge 2 Q Bridge type X 2 2 anti parallel bridges 4 Q Module type YYYY converter type current 04 230 VAC 400 VAC 05 230 VAC 525 VAC 06 270 VAC 600 VAC 07 315 VAC 700 VAC 08 360 VAC 800 VAC 10 450 VAC 990 VAC Rated AC Voltage ZZ 12 540 VAC 1200 VAC Standard D1 D6 L Left side D7 R Right side D7 Power connection B a Second thyristor type D5 D6 Attention When using D1 D2 D3...

Page 132: ...ually by means of S ConvScaleCur 97 02 S ConvScaleVolt 97 03 S MaxBrdgTemp 97 04 and S BlockBridge2 97 07 the change of the type code is immediately taken over and ServiceMode 99 06 has to be set back to NormalMode by the user the new values can be seen in group 4 ConvNomCur 4 05 ConvNomVolt 4 04 MaxBridgeTemp 4 17 and QuadrantType 4 15 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email ...

Page 133: ... 04 73 S01 4800 08 123 S02 3000 04 24 S01 0610 05 74 S01 5200 04 124 S02 3000 05 25 S01 0740 04 75 S01 5200 05 125 S02 2500 06 26 S01 0740 05 76 S02 0025 04 126 S02 2500 07 27 S01 0900 04 77 S02 0025 05 127 S02 3000 06 28 S01 0900 05 78 S02 0050 04 128 S02 3000 07 29 S01 0900 06 79 S02 0050 05 129 S02 2500 08 30 S01 0900 07 80 S02 0075 04 130 S02 3000 08 31 S01 1200 04 81 S02 0075 05 131 S02 3300 ...

Page 134: ...C between F and F a normal extension cord is sufficient Start moving the brush bridge slowly in one direction and watch the scope or voltmeter If the voltage is increasing move the brush bridge in the other direction Try to get the voltage down to less than 50 mV AC The smaller the better When this is achieved start tightening the brush bridge bolts and watch the voltage Sometimes you have to do a...

Page 135: ...an ESD field service kit when handling the boards Do not touch the boards unnecessarily Handling the boards When ESD sensitive boards are removed from the drive and transferred to a temporary work surface they should be placed in a protective packaging Handle unprotected ESD sensitive boards only when connected to the system and always place them in a protective package that is sealed It is easies...

Page 136: ... prevents unexpected production stop and production loss It also increases availability of the drive The environmental and operating conditions of the drive are also to be considered Harsh environment A harsh environment such as high ambient temperature humidity dust and cyclic heavy load not only shortens the components lifetime but also the preventive maintenance and replacement intervals Mainte...

Page 137: ... by F527 ConvFanAck see ConvFanAck 10 30 Crosscheck this result with the module s door closed Attention Do not reach into the fan Negligence to this warning can cause injury Check for tightness of heatsink terminals of units D7 The thyristors together with the heatsinks are stacked Every single thyristor is connected to the DC and DC busbars via flexible copper busbars These busbars consist of 10 ...

Page 138: ...art of a converter module type D7 on page 138 Apply the torque spanner to the screw and turn right until the right torque is indicated Don t loosen the screws by a left hand turn Put on a new marking if appropriate Power part of a converter module type D7 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 139: ...erature faults if the heatsinks are not clean Heatsink Use compressed air to remove the dust from the heatsinks the air flow must be from bottom to top Fan rotation caused by the compressed air must be stopped in order to prevent damage Use an ESD vacuum cleaner to clean the dust from the air inlet air outlet the interior of the cabinet and the electronic boards Any signs of corrosion especially a...

Page 140: ...f units D6 and D7 How to remove the converter fan in a frame D6 How to remove the converter fan in a frame D7 The manufacturers estimation for the operational time of the cooling fan is GR31M 30 000 hours at 40 C D6 GR35C 30 000 hours at 40 C D7 The mayor problem is the failure of the bearings Typical lifetime of the cooling fan versus ambient temperature Phone 800 894 0412 Fax 888 723 4773 Web ww...

Page 141: ...connections should be inspected and checked for tightness Check the condition of the contactors and relays Relays Contactors and relays should be checked for proper function Check the fiber optic cables and their connections 6 years preventive maintenance Following additional actions have to take place Replace the cooling fans of units D1 to D5 How to remove the converter fans in frames D1 to D3 t...

Page 142: ...DCS800 S0x 0610 y1 DCS800 S0x 0820 y1 D4 1x W2E200 230 V DCS800 S0x 0610 y1 DCS800 S0x 0820 y1 D4 1x W2E200 115 V plus code E171 DCS800 S0x 0900 y1 DCS800 S0x 1000 y1 D4 1x W2E250 230 V DCS800 S0x 0900 y1 DCS800 S0x 1000 y1 D4 1x W2E250 115 V plus code E171 DCS800 S0x 0900 y1 DCS800 S0x 2000 y1 D5 D2E160 Aging of the components result in 1 Increased vibration due to the imbalance of the cooling fa...

Page 143: ...t is switched off Therefore all its components are exposed to hot conditions Additionally the electrolytic capacitors on the SDCS PIN 4 are aging The SDCS PIN 4 also is equipped with several capacitors which are sensitive to high ambient temperature Where used DCS800 S0x 0020 DCS800 S0x 1000 D1 to D4 Aging of the electronic card result in 1 Damage other devices 2 Trip the drive and cause break dow...

Page 144: ... exposed to hot conditions Additionally the electrolytic capacitors on the SDCS POW 4 are aging The SDCS POW 4 also is equipped with several capacitors which are sensitive to high ambient temperature Where used DCS800 S0x 1000 DCS800 S0x 5200 D5 to D7 and DCS800 R Aging of the electronic card result in 1 Damage other devices 2 Trip the drive and cause break down time Check the flat cables and thei...

Page 145: ...2 3AFE64606816 RDIO 01 L501 1 3AFE64610805 RTAC 01 L502 1 3AFE68654947 RTAC 03 L517 1 3AFE68286778 AIMA 01 Pulse Encoder Interface 12 V Pulse Encoder Interface TTL I O Extension Adapter Item 8 03 Control Panels and plug in options D1 D7 DCSLink board DDCS communication board DDCS communication board PROFIBUS DP DeviceNet Analog I O Extension EtherCat Adapter Module Digital I O Extension Modbus Con...

Page 146: ... REB 2 1 1 3ADT309300R0001 SDCS REB 3 2 2 3ADT200003P0001 QUINT 240 24 2A 115 240 VAC 24 VDC 1 2 3ADT220090R0043 SDCS PIN 48 SDCS PIN 48 replaces SDCS PIN 41 1 1 3ADT220090R0006 SDCS PIN 51 For 400 VAC 1000 VAC 2 2 3ADT751010P0001 LT2032 2500 1A T51 T52 for D5 and D6 2 2 3ADT751007P0001 4000 1A T51 T52 for D7 1 1 3ADT209022R0001 FEX 425 Int Internal field exciter for Rebuild Kit DESCRIPTION DI DO ...

Page 147: ... 1 1 3ADC340091R0001 VVZF 70 16xxx OnBoard field up to 525 VAC 1 1 3ADT710005P0001 KTY10 6 M4 250mm 20 A 260 A cable 250 mm 1 1 3ADT710005P0002 KTY10 6 M4 400mm 315 A 1000 A cable 400 mm 2 Q 4 Q 11 00 2 Q 4 Q CODE TYPE DATA NOTES 3 6 3ADC340063P0001 SKKT27B xxx MCC 26 16 xxx 3 3 3ADT730004R0004 UR 50 A 660 V Blade or knife fuse 3 3 3ADV050169P0050 UR 50 A 600 V When used as field in D6 or D7 cabin...

Page 148: ...1 CN2B2 4715 MS 12T B5Axxx 2 Q 4 Q 19 00 2 Q 4 Q CODE TYPE DATA NOTES 3 6 GHSN610089P0002 TT250 Nxxx MCC 255 xxx 3 3 3ADT730004R0013 UR 700 A 660 V Blade or knife fuse 2 2 3ADT754014P0001 CN2B2 4715 MS 12T B5Axxx 3 3 3ADV050092P0032 UR 450 A 660 V When used as field in D6 or D7 cabinets Module contains Module contains Module contains Module contains Thyristor modules Semiconductor fuses Cooling fa...

Page 149: ...r with OESA 2 Q 4 Q 25 00 2 Q 4 Q CODE TYPE DATA NOTES 3 6 3ADC340066P0001 TT 570 Nxxx MT3 595 xxx 3 3 3ADT730004R0015 UR 900 A 660 V Screw type fuse 1 1 DCA0012171P0001 W2E 200 HH38 06 3 3 DCA0012724P0001 170M6813 Fuses as Enclosed Converter with OESA Semiconductor fuses Cooling fan 230 V 50 60 Hz Fuses as Enclosed Converter Fuses as Enclosed Converter DCS800 S01 0740 04 05 DCS800 S02 0820 04 05 ...

Page 150: ... Replaces 3ADT313900R1001 1 1 3ADT315100R1001 SDCS POW 4 1 2 3ADT220090R0043 SDCS PIN 48 SDCS PIN 48 replaces SDCS PIN 41 1 1 3ADT220090R0006 SDCS PIN 51 1 1 3ADT710003P0001 KTY 2K M4 800 2 2 3ADT751010P0001 LT2032 2500 1A T51 T52 for D5 and D6 1 1 3ADT754018P0001 D2E 160 AH02 15 Cooling fan Puls transformer board Power interface board Modules D5 900 A 2000 A 400 V 525 V 600 V and 690 V Common par...

Page 151: ...0102P0001 T2 XXX xx 6 6 3ADC770010P0012 UR 1600 A 660 V Screw type fuse 2 Q n a 36 00 2 Q n a CODE TYPE DATA NOTES 6 3ADC340090P0001 TV 989 2700 xxx 6 3ADC770009P0013 UR 1400 A 1100 V Screw type fuse Module contains Module contains Module contains Module contains Module contains Module contains Semiconductor fuses DESCRIPTION Thyristor Semiconductor fuses DCS800 S01 2000 06 07 600 V 690 V Semicond...

Page 152: ...laces SDCS PIN 41 6 6 3ADC770010P0011 UR 1500 A 660 V Screw type fuse 1 1 3ADT754008P0001 GR31M 500V 400 V 500 V 50 60 Hz 2 Q 4 Q 42 00a 2 Q 4 Q CODE TYPE DATA NOTES 6 12 3ADC340098P0001 T 1xxx 24 second thyristor type 1 2 3ADT220090R0043 SDCS PIN 48 SDCS PIN 48 6 6 3ADC770010P0011 UR 1500 A 660 V Screw type fuse 1 1 3ADT754008P0001 GR31M 500V 400 V 500 V 50 60 Hz Puls transformer board Puls trans...

Page 153: ...50 V Screw type fuse double fuses 1 1 3ADT754008P0002 GR31M 690V 525 V 690 V 50 60 Hz 2 Q 4 Q 46 00 2 Q 4 Q CODE TYPE DATA NOTES 6 3ADC340087P0001 TV 989 2770xxx 6 3ADC340079P0001 5 STB 24 Qxxx Bidirectional Controlled Thyristor BCT 1 3ADT220090R0043 SDCS PIN 48 SDCS PIN 48 replaces SDCS PIN 41 2 3BSE004939R1003 SDCS PIN 46 only used for BCT s 12 12 3ADC770009P0011 UR 1000 A 1250 V Screw type fuse...

Page 154: ...043 SDCS PIN 48 SDCS PIN 48 replaces SDCS PIN 41 1 1 3ADT220090R0006 SDCS PIN 51 1 1 DCF1066659P0001 P233 A 4 AHC 1 1 DCA0012139P0005 KTY 10 6 M4 cable 1750 mm 2 2 3ADT751007P0001 4000 1A T51 T52 for D7 1 1 3ADT754020P0001 GR 35C 400 V 690 V 50 60 Hz 2 Q 4 Q 51 00 2 Q 4 Q CODE TYPE DATA NOTES 6 12 3ADC340086P0001 TV 989 2700 xxx 6 6 3ADC770030P0003 UR 1800 A 1250 V Flush end contact fuse Thyristor...

Page 155: ...x 1 1 3ADT780007R0002 SDCS PIN 5x 1190 meas Prepared for galvanic isolation A92 6 6 3ADC770030P0006 UR 2300 A 1500 V Flush end contact fuse 2 Q 4 Q 59 00 2 Q 4 Q CODE TYPE DATA NOTES 6 12 3ADC340088P0001 T 989 3300xxx 6 6 DCA0012830P0001 UR 3000 A 660 V Flush end contact fuse DCS800 S01 4000 04 05 DCS800 S02 4000 04 05 400 V 500 V DESCRIPTION Thyristor Semiconductor fuses DESCRIPTION Thyristor Sem...

Page 156: ...S 6 12 3ADC340083P0001 5 STP 45 Qxxx 6 6 3ADC770030P0002 UR 3000 A 1000 V Flush end contact fuse 2 Q 4 Q 65 00 2 Q 4 Q CODE TYPE DATA NOTES 6 12 3ADC340083P0001 5 STP 45 Qxxx 6 6 3ADC770030P0001 UR 3500 A 6900 V Flush end contact fuse Thyristor Semiconductor fuses Semiconductor fuses Module contains DCS800 S01 5200 04 05 DCS800 S02 5200 04 05 400 V 500 V DESCRIPTION Module contains DCS800 S01 4800...

Page 157: ...157 Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 158: ... 195R0401A9370000 195R0401A9370000 Ident No 3ADW 000 195 R0501 Rev E 02_2011 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

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