ABB DCS880 series Service Manual Download Page 9

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Introduction to this manual

3ADW000488R0101 DCS880 Service manual e a

Introduction to this manual

Chapter overview

This chapter describes the purpose, contents and the intended use of this manual.

Before You Start

The purpose of this service manual is to provide detailed information on how to service DCS880 power

converters. The

Safety instructions

at the beginning of this manual needs to be studied before attempting any

work on or with the drive. Read this manual before servicing the drive.

What this manual contains

The

Safety instructions

can be found at the beginning of this manual.

Introduction to this manual

, the chapter you are currently reading, introduces you to this manual.

Fault Tracing Thyristors

, this chapter describes how to detect a faulty thyristor or SDCS-BAB-F0x.

Handling the Semiconductors

, this chapter describes the handling of thyristors and thyristor modules.

Exchange thyristors sizes H1 … H4

, this chapter describes the exchange of thyristors and SDCS-BAB-F0x in

converters sizes H1 … H4.

Exchange thyristors size H5

, this chapter describes the exchange of thyristors in converters size H5.

Exchange thyristors size H6

, this chapter describes the exchange of thyristors in converters size H6.

Exchange thyristors size H7

, this chapter describes the exchange of thyristors in converters size H7.

Exchange thyristors size H8

, this chapter describes the exchange of thyristors in converters size H8.

Exchange SDCS-CON-H01

, this chapter describes the exchange of a SDCS-CON-H01.

Service

, this chapter contains hardware change information, firmware download and technical hints.

Preventive Maintenance

, this chapter describes preventive maintenance of thyristor converters.

Appendix: Spare Parts list

, the Appendix contains the spare parts list.

Target group

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

power converters.

These people should possess:

−

Basic knowledge of physics, electrical engineering, electrical wiring principles, components as well as

symbols used in electrical engineering.

−

Basic experience with DC drives and DC products.

Related documents

A list of related manuals is shown on the inside of the front cover under

DCS880 Drive Manuals

The above listed documentation can be found as DCS880 - Documentation pack following this link:

DCS880 - Documentation pack

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

DCS880 Hardware Manual

Summary of Contents for DCS880 series

Page 1: ... DCS880 DCS880 Service manual ...

Page 2: ...en adapter module 3AFE68615500 3AUA0000121752 x x FDNA 01 DeviceNet adapter module 3AFE68573360 x FECA 01 EtherCAT adapter module 3AUA0000068940 3AUA0000083936 x x FENA 01 11 21 Ethernet adapter module 3AUA0000093568 x FEPL 02 Ethernet POWERLINK adapter module 3AUA0000123527 3AUA0000133138 x x FPBA 01 PROFIBUS DP adapter module 3AFE68573271 3AFE68989078 x x FSCA 01 RS 485 adapter module 3AUA000010...

Page 3: ...urity disclaimer 15 Fault Tracing Thyristors 16 Tools 16 For commissioning and fault tracing 16 Additionally for service and preventive maintenance 17 How to detect a faulty thyristor 17 A fuse is blown 17 DC current pulses measured using an oscilloscope 17 Thyristor test 18 Ripple monitor 18 How to find a faulty thyristor 18 Converters size H1 H4 20 1000 A 19 Blown fuses 19 Converters size H5 H8 ...

Page 4: ... 50 Install new thyristor 53 Location of thyristors in frame H7 4 Q bridge with single thyristors 55 Location of thyristors in frame H7 4 Q bridge with BCTs 56 Location of thyristors in frame H7 2 Q bridge with single thyristors 57 Location of branch fuses frame H7 58 Exchange thyristors size H8 59 Installation of thyristor modules in converters size H8 2500 5200 A 59 Required tools 59 Find faulty...

Page 5: ...transformers for size H8 103 Exchange current transformers size H6 104 Exchange current transformers size H7 105 Exchange current transformers size H8 106 DCS880 firmware download 107 General 107 Download SDCS CON H01 firmware using the Drive loader 2 x 107 Set type code 113 DC Motor neutral zone adjustment 114 Types concerned 114 Summary 114 General 114 Preventive Maintenance 115 Recommended regu...

Page 6: ...he equipment 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 w...

Page 7: ...required 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 ...

Page 8: ...P 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 ...

Page 9: ...thyristors in converters size H6 Exchange thyristors size H7 this chapter describes the exchange of thyristors in converters size H7 Exchange thyristors size H8 this chapter describes the exchange of thyristors in converters size H8 Exchange SDCS CON H01 this chapter describes the exchange of a SDCS CON H01 Service this chapter contains hardware change information firmware download and technical h...

Page 10: ...9 Production year 2017 and week 29 U1IEC Rated input voltage according to IEC U2IEC Rated output voltage according to IEC U1UL Rated input voltage according to UL U2UL Rated output voltage according to UL I1 Rated input current I2 Rated output current If Rated internal field exciter current f1 Rated frequency of mains voltage UFan Rated fan voltage Airflow Rated cooling air flow UAux Rated auxilia...

Page 11: ... 10 450 VAC 990 VAC 12 540 VAC 1200 VAC Power connection e X Standard H1 H7 L Left side H8 R Right side H8 Revision code f 0 1st generation Field exciter configuration 0S163 S164 H1 H4 without OnBoard field exciter H5 and H6 with internal field exciter supply external H5 and H6 25 A Rebuild kit 16 A 25 A Fan voltage Standard S171 Size H4 Fan voltage 230 V 1 ph Fan voltage 115 V 1 ph Application pr...

Page 12: ...must be reduced Mains voltage Maximum DC voltage Ideal DC voltage DC voltage class UVN VAC Ud max 2 Q VDC Ud max 4 Q VDC Ud0 VDC 230 265 240 310 04 380 440 395 510 04 400 465 415 540 04 415 480 430 560 04 440 510 455 590 05 460 530 480 620 05 480 555 500 640 05 500 580 520 670 05 525 610 545 700 05 575 670 600 770 06 600 700 625 810 06 660 765 685 890 07 690 800 720 930 07 800 915 820 1060 08 990 ...

Page 13: ...150 X X 180 200 X X 225 250 X X 270 300 X X H3 290 320 X 315 350 X X 405 450 X X 470 520 X X H4 590 650 X 610 680 X X 740 820 X X 900 1000 X X H5 1190 1190 X X H6 900 900 X X 1200 1200 X X 1500 1500 X X X X 2000 X X X X 2000 X X H7 1900 1900 X 2050 2050 X X X 2500 2500 X X X X X 3000 3000 X X X X X H8 2050 2050 X 2600 2600 X X 3300 3300 X X X X X X X 4000 4000 X X X X X X X 4800 4800 X X X 5200 52...

Page 14: ...pter FDCO 0x Optional DDCS communication module FDIO 01 Optional digital I O extension module FDNA 01 Optional DeviceNet adapter FEA 03 Optional I O extension adapter FECA 01 Optional EtherCAT adapter FEN 01 Optional TTL encoder interface module FEN 11 Optional absolute encoder interface module FEN 21 Optional resolver interface module FEN 31 Optional HTL encoder interface module FENA 11 Optional ...

Page 15: ...power supply equipment with battery to maintain output voltage during power failure Cybersecurity disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is the customer s sole responsibility to provide and continuously ensure a secure connection between the product and the customer network or any other network as the case may be Th...

Page 16: ...oscope 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...

Page 17: ...r 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 nex...

Page 18: ...in order to keep the average current constant Such a compensation results in a ripple monitoring fault during motoring mode operation with alpha 90 The reason for a current less thyristor may be A blown line fuse This is possible only for converters with 20 1000 A A fuse has disconnected one of the six thyristors This is possible only for converters with 900 5200 A six internal branch fuses A loos...

Page 19: ...sistance 1 kOhm Target Find a short circuit indicated by low resistance 1 Ohm destroyed thyristor If the converter is designed with thyristor modules then a module consists of two thyristors In this case it is sufficient to know which thyristor module has a defective thyristor because the complete module must be replaced After a thyristor module is replaced the above mentioned measurement should b...

Page 20: ...istance 1 Ohm destroyed thyristor Size H5 is designed with thyristor modules then a module consists of two thyristors In this case it is sufficient to know which thyristor module has a defective thyristor because the complete module must be replaced Continue with related part Exchange of Thyristors for Size H5 section Find faulty thyristor For sizes H6 H8 the OHM test should be performed when the ...

Page 21: ...ristor 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 loose gate connector Are all electrical connections still healthy Can the thyristor be fired with the applied firing pulse Is the pulse form of the ...

Page 22: ...is suspected the problem is caused most often by a faulty SDCS BAB F0x To make sure that the SDCS BAB F0x 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 obey...

Page 23: ...stor or diode If one of the measurements shows a short circuit replace the SDCS BAB F0x A measurement showing less resistance than 1 Ω should be made for a second time Apply the test leads with opposite polarity if this measurement shows the same result the SDCS BAB F0x is faulty and needs to be replaced After the SDCS BAB F0x is replaced the above mentioned measurement should be done another time...

Page 24: ...s F401 F403 Thus fuses F401 F403 need to be measured before the SDCS BAB F0x is checked The converter must be disconnected from the mains Follow the instructions Remove faulty thyristor modules until step 8 is done 9 Remove the marked plugs at the SDCS PIN H01 10 Remove the plastic cover 11 Remove field connection plug X10 from the top of the DCS880 ...

Page 25: ...is indicated by a low resistance 1 kΩ destroyed thyristor or diode If one of the measurements shows a short circuit replace the SDCS BAB F0x A measurement showing less resistance than 1 Ω should be made for a second time Apply the test leads with opposite polarity if this measurement shows the same result the SDCS BAB F0x is faulty and needs to be replaced After the SDCS BAB F0x is replaced the ab...

Page 26: ...d 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 accordi...

Page 27: ...exchange of thyristor modules Torx screwdrivers TX10 TX20 TX25 Torque spanner Mounting torques for the the thyristor modules and SDCS BAB F0x to heat sink and electrical connections see table Nominal mounting torque for thyristor modules and SDCS BAB F0x Torque spanner for electrical connections 13Nm M8 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts Tissue paper Solvent e g ethano...

Page 28: ...s H1 H4 3ADW000488R0101 DCS880 Service manual e a Remove faulty thyristor modules 1 Remove control panel and design cover 2 Disconnect all I O plugs from the control unit 3 Disconnect all connections from present plug in options ...

Page 29: ...nual e a 4 Remove the grounding holding screws from the control unit 5 To unhinge the control unit pull it up and then out 6 Before removing the control unit completely unplug the flat cables XC12 XS13 and the cable connected at X38 7 Remove the control unit completely ...

Page 30: ...ture sensor 10 Keep the winding direction and amount of windings through T100 in mind Size Converter type Used type Used fuses T100 threads IF A H1 DCS880 S01 0020 DCS880 S02 0025 SDCS BAB F01 F100 F102 on SDCS PIN H01 KTK 25 25 A 4 0 3 6 H1 DCS880 S01 0045 DCS880 S02 0100 SDCS BAB F01 F100 F102 on SDCS PIN H01 KTK 25 25 A 3 1 12 H2 DCS880 S01 0135 DCS880 S02 0300 SDCS BAB F01 F100 F102 on SDCS PI...

Page 31: ...yristors sizes H1 H4 3ADW000488R0101 DCS880 Service manual e a 11 The result should look like this 12 Remove the SDCS PIN H01 13 Remove the gate leads from the faulty thyristor module and mark the connectors clearly ...

Page 32: ...essary to get full access to the faulty thyristor module 15 If a current transformer must be removed mark its position direction and the connections clearly Note Remove only as many parts as needed around the faulty thyristor module 16 Remove the faulty thyristor module and mark it clearly as defective ...

Page 33: ...inal mounting torque for thyristor modules and SDCS BAB F0x Thyristor modules and SDCS BAB F0x Nominal mounting torque Size width Type Electrical connections Thyristor module to heat sink 20 mm block SKKT27 57 106 2 6 3 4 Nm 4 25 5 75 Nm 20 mm block MCC26 56 95 2 5 4 Nm 2 5 4 Nm 34 mm block MCC162 200 4 5 5 5 Nm 2 25 2 75 Nm 50 mm block MCC255 312 11 13 Nm 4 5 7 Nm 50 mm block TT250 10 8 13 2 Nm 4...

Page 34: ...le from SDCS CON H01 to SDCS PIN H01 X99 auxiliary power supply 13 At the SDCS CON H01 reconnect the flat cables XC12 XS13 the cable connected at X38 and re hinge the control unit 14 Reconnect the grounding holding screws at the control unit 15 Reconnect all I O plugs at the control unit and all connetions at the present plug in options 16 Reinstall the design cover and the control panel ...

Page 35: ...B F0x Follow the instructions Remove faulty thyristor modules until step 8 is done 9 If existing remove the plastic cover 10 Remove all connectors SDCS BAB F01 or cables SDCS BAB F02 from the faulty SDCS BAB F0x and mark them clearly 11 Remove the faulty SDCS BAB F0x and mark it clearly as defective ...

Page 36: ...h a rubber spatula or by hand 3 Apply a thin layer of heat conducting compound to the new SDCS BAB F0x bridge 4 Spread the heat conducting compound evenly by moving the SDCS BAB F0x 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...

Page 37: ...37 Exchange thyristors sizes H1 H4 3ADW000488R0101 DCS880 Service manual e a Thyristor module and SDCS BAB F0x location in DCS880 S01 2 Q units 400 VAC and 525 VAC types ...

Page 38: ...istors sizes H1 H4 3ADW000488R0101 DCS880 Service manual e a 600 VAC types Note These drawings are only showing the location of the thyristor modules and the SDCS BAB F0x the actual converter module sizes are different ...

Page 39: ...39 Exchange thyristors sizes H1 H4 3ADW000488R0101 DCS880 Service manual e a Thyristor module and SDCS BAB F0x location in DCS880 S02 4 Q units 400 VAC and 525 VAC types ...

Page 40: ...of the thyristor modules and the SDCS BAB F0x the actual converter module sizes are different Thyristor module terminals and SDCS BAB F0x The terminal description is stamped or marked by a sticker on all thyristor modules and the bride connected at the SDCS BAB F0x For all firing pulse cables is valid Yellow is gate lead Red is cathode lead ...

Page 41: ...or fuse and busbar connections 17 mm ring spanner for press clamp Tissue paper Solvent e g ethanol Thermal joint compound grease Type Berulub FZ1 E3 Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 011 P 0051 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 instructio...

Page 42: ... V1 W1 and C1 D1 Bridge configuration H5 H8 3 Disconnect the branching fuses of the defective branches 4 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 5 In a 4 quadrant converter exchange both thyristors clamped between the same heatsinks Note Because Disc Type semiconductors need a certain compression force to operate properly a measurement outside ...

Page 43: ...s if possible 4 Loosen the mounting clamp 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 Do not remove the nuts totally otherwise the treaded rods will fall down 5 Attach the disassembly tool 3ADT 621 023 P1 at the faulty thyristor and prize open the upper and lower heat sinks 6 Remo...

Page 44: ...er spatula 4 Connect the gate leads if possible 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 7 Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surfac...

Page 45: ...istors size H6 3ADW000488R0101 DCS880 Service manual e a Location of thyristors in frame H6 4 Q bridge Attention Exchange both thyristors clamped between the same heatsinks Location of thyristors in frame H6 2 Q bridge ...

Page 46: ...46 Exchange thyristors size H6 3ADW000488R0101 DCS880 Service manual e a Location of branch fuses frame H6 ...

Page 47: ...for fuse and busbar connections 24 mm ring spanner for press clamp Tissue paper Solvent e g ethanol Thermal joint compound grease Type Berulub FZ1 E3 Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 011 P 0051 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 instructio...

Page 48: ...d Thyristors are used BCTs 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 Note The Faston connectors of the gates are of different size Gate A should always be in front of the clamped heat sinks due to cooling reasons Location of BCTs gate A when built in ...

Page 49: ...5 H8 3 Disconnect the branching fuses of the defective branches 4 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 5 In a 4 quadrant converter with BCTs change the BCT 6 In a 4 quadrant converter with 2 single thyristors exchange both thyristors clamped between the same heatsinks Note Because Disc Type semiconductors need a certain compression force to ...

Page 50: ...rews of the DC busbar plates adjacent to the defective thyristors Note It depends on the location of the defective thyristor which DC busbar plates have to be disconnected 3 Write down the direction and location of the thyristors to be removed and mark their gate leads In case of BCTs add the position of the gates 4 Remove the gate leads if possible 5 Loosen the mounting clamp at the top of the th...

Page 51: ... Service manual e a 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 ...

Page 52: ... the faulty thyristor and prize open the upper and lower heat sinks 8 Remove the thyristors with e g a pair of pliers Attention To center 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 ...

Page 53: ...s 3 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of conducting paste on both sides of the thyristor if necessary use a rubber spatula 4 Centre the thyristors by means of the spring pins Note Be sure that the thyristor is installed in the right direction Do not pinch or cut the gate leads or any other cable...

Page 54: ...t 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 Note The correct torque is indicated by means of the welded indicating spring 11 Perform an OHM test to make sure the thyristor is ok 12 Reconnect all other dismantled parts 13 Perform an OHM t...

Page 55: ...change thyristors size H7 3ADW000488R0101 DCS880 Service manual e a Location of thyristors in frame H7 4 Q bridge with single thyristors Attention Exchange both thyristors clamped between the same heatsinks ...

Page 56: ...56 Exchange thyristors size H7 3ADW000488R0101 DCS880 Service manual e a Location of thyristors in frame H7 4 Q bridge with BCTs ...

Page 57: ...57 Exchange thyristors size H7 3ADW000488R0101 DCS880 Service manual e a Location of thyristors in frame H7 2 Q bridge with single thyristors ...

Page 58: ...58 Exchange thyristors size H7 3ADW000488R0101 DCS880 Service manual e a Location of branch fuses frame H7 ...

Page 59: ...paper Solvent e g ethanol Thermal joint compound grease Type Berulub FZ1 E3 Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 011 P 0051 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 ca...

Page 60: ...nual e a Find faulty thyristor modules 1 Check the branch fuses by performing an OHM test 2 Find the defective branches by performing an OHM test both polarities between U1 V1 W1 and C1 D1 Bridge configuration H5 H8 3 Remove the AC busbars of the defective branches ...

Page 61: ... and the heat sink to insulate the anti parallel thyristors from each other 6 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 2 quadrant converter 7 Find the defective thyristors by performing an OHM test both polarities over their heat sinks Note Because Disc Type semiconductors need a certain compression force to operate properly a measurement outsid...

Page 62: ... busbars have to be disconnected 2 Loosen the screws holding the backplate and make sure the backplate can move up 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 Attention While loosen the mounting clamp the indicating spring must be pulled ...

Page 63: ... the faulty thyristor and prize open the upper and lower heat sinks 7 Remove the thyristors with e g a pair of pliers Attention To center 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 ...

Page 64: ...onds Dry all surfaces 3 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of conducting paste on both sides of the thyristor if necessary use a rubber spatula 4 Centre the thyristors by means of the spring pins Note Be sure that the thyristor is installed in the right direction Do not pinch or cut the gate lead...

Page 65: ...ing clicks into position correct torque 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 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 ...

Page 66: ...66 Exchange thyristors size H8 3ADW000488R0101 DCS880 Service manual e a Location of thyristors in frame H8 4 Q bridge Location of thyristors in frame H8 2 Q bridge ...

Page 67: ...67 Exchange thyristors size H8 3ADW000488R0101 DCS880 Service manual e a Location of branch fuses frame H8 busbars on the right ...

Page 68: ...68 Exchange thyristors size H8 3ADW000488R0101 DCS880 Service manual e a Location of branch fuses frame H8 busbars on the left ...

Page 69: ...ect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Overview of control unit exchange 1 Write down type code of the drive 2 Set the jumpers on the new control unit according to the old control unit 3 Exchange the control unit 4 Set type code of the drive 1 Write down type code of...

Page 70: ...plugged into X205 on the control unit The memory unit contains the firmware the parameters and the application program as option When a control unit is replaced the parameter settings can be retained by transferring the memory unit from the defective control unit to the new control unit WARNING Do not remove or insert a memory unit when the drive is powered Replacing the memory unit Unscrew the me...

Page 71: ...71 Exchange the control unit SDCS CON H01 3ADW000488R0101 DCS880 Service manual e a 3 Remove all F type extension modules 4 Disconnect all I O plugs from the control unit ...

Page 72: ...13 and the cable connected to X38 Install the new control unit 1 Reconnect the flat cables at the control unit XC12 XS13 the cable at X38 and re hinge the it 2 Reconnect the grounding holding screws at the control unit 3 Reconnect all I O plugs at the control unit 4 Reinstall all plug in options do not forget the screws the memory unit the design cover and the control panel 4 Set type code of the ...

Page 73: ...ble electronic safety related systems Part 1 General requirements IEC 61508 2 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 2 Requirements for electrical electronic programmable electronic safety related systems IEC 61800 5 2 2016 EN 61800 5 2 2017 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 62061...

Page 74: ...e test Fault Trip If the drive was repaired and the changed hardware is not in the revalidation check list below no test is needed After a fault trip the STO function shall be tested depending on the type of repair If the complete drive module has been exchanged do the following Repetitive function test Acceptance test If the drive was repaired and the changed hardware is in the revalidation check...

Page 75: ...DCS CON H01 X X X X X X X X SDCS PIN H01 X X X X X SDCS POW H01 X X X SDCS PIN H41 X X X SDCS PIN H51 X X X SDCS OPL H01 X X SDCS DSL H10 SDCS DSL H12 X X SDCS DSL H14 X SDCS SUB H01 X X X X X SDCS DPI H01 Line fuse Branch fuse X X X X Thyristor X X X X X X X X Converter fan Ribbon cable X X X X X X X X Control panel ACS AP x F type plug in option except FSE 31 FSO 21 FSO 21 FSE 31 X X X X X X X X...

Page 76: ... 3 Create a custom workspace 31 22 STO indication run stop 31 94 STO time 1 31 95 STO time 2 31 98 STO actual status 31 100 STO Test mode 4 Create monitor with 31 98 STO actual status and select following bits XSTO1 XSTO1 Diag XSTO2 XSTO2 Diag Mask F Set the Max in the monitor to 0x10 5 Set the drive to local 6 If open close the STO terminal circuit 7 Give a run press Start command and zero speed ...

Page 77: ...ice manual e a Step Action Comment 8 Start the monitor value must be 0xF 9 Set 31 100 STO Test mode No Block 10 Open the STO terminal circuit 11 Remove the run command press Stop if it is still given 12 Stop the monitor 13 Set 31 100 STO Test mode None ...

Page 78: ...f 31 98 STO actual status must be 0xA 3 After about 500 ms the value of 31 98 STO actual status must be 0x2 or 0x8 Shortly after the value of 31 98 STO actual status must be 0x0 4 Compare the values of 31 94 STO time 1 and 31 95 STO time 2 Their values must be within 20 ms of each other and within 70 ms of 500 ms 5 Document and sign the STO revalidation test which verifies that the safety function...

Page 79: ...nce The root cause could be the Drive composer pro Close the program and reconnect There could be a current flow through the machine This is very likely if 31 94 STO time 1 and 31 95 STO time 2 are about 300 ms and fault 5093 Safe off main contactor XSMCSTO is present If the failure persists exchange the SDCS CON H01 Then re do the test ...

Page 80: ...tion Comment 1 Set 31 22 STO indication run stop No indication No indication 2 Write down the values of 31 94 STO time 1 31 95 STO time 2 3 Create a custom workspace 31 22 STO indication run stop 31 94 STO time 1 31 95 STO time 2 31 98 STO actual status 31 100 STO Test mode 06 24 Current Controller status word 1 4 Create monitor with 31 98 STO actual status and select following bits XSTO1 XSTO1 Di...

Page 81: ...troller status word 1 06 24 b09 0 Drive is motoring 06 24 b12 0 Discontinuous armature current recommendation not mandatory 06 24 b13 0 Armature current not zero 9 Start the monitor value must be 0x20F 10 Set 31 100 STO Test mode No Block 11 Open the STO terminal circuit 12 Remove the run command press Stop if it is still given ...

Page 82: ...top the monitor 14 Set 31 100 STO Test mode back to None Evaluation of the graph and observations Step Action Comment 1 At the start of the procedure the monitor value of 31 98 STO actual status must be 0x20F 2 After opening the STO circuit the value of 31 98 STO actual status must be 0x20A ...

Page 83: ...onnected to XSMC STO must have been opened 8 The control board must be rebooted cycle auxiliary power afterwards as relay XSMC STO is only closed once during the boot of the drive 9 Test the function of connector XSMC when the motor is stopped Give a stop command for the drive if running and wait until the motor shaft is at a standstill Ensure that the drive operates as follows Unplug connector XS...

Page 84: ...should not generate torque The drive generates an indication if one is defined for running state in 31 22 STO indication run stop see DCS880 Firmware Manual Reset any active faults and try to start the drive Ensure that the motor stays at standstill and the drive operates as described above in testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the...

Page 85: ...ect the thyristor power controller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 0045 dd DCS880 S0b 0100 dd using one 24 VDC fan Removing the converter fan 1 Remove the control panel and the design cover ...

Page 86: ...86 Service 3ADW000488R0101 DCS880 Service manual e a 2 Remove the two fan arrangement screws 3 Move the fan arrangement forward and up ...

Page 87: ...ervice manual e a 4 Remove plug X41 on the SDCS PIN H01 5 Remove the fan holding screws of the broken fan 6 Attach the new fan reassemble everything and check for correct blow direction the fan The air should be sucked out of the module ...

Page 88: ...the thyristor power controller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 0135 dd DCS880 S0b 0450 dd and using two 24 VDC fans Removing the converter fan 1 Remove the control panel and the design cover ...

Page 89: ...89 Service 3ADW000488R0101 DCS880 Service manual e a 2 Remove the two fan arrangement screws 3 Move the fan arrangement forward and up ...

Page 90: ... manual e a 4 Remove plugs X41 and X42 on the SDCS PIN H01 5 Remove the fan holding screws of the broken fan 6 Attach the new fan reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module ...

Page 91: ...e thyristor power controller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 0470 dd DCS880 S0b 0520 dd and using four 24 VDC fans Removing the converter fan 1 Remove the control panel and the design cover ...

Page 92: ...92 Service 3ADW000488R0101 DCS880 Service manual e a 2 Remove the two fan arrangement screws 3 Move the fan arrangement forward and up ...

Page 93: ...ce manual e a 4 Remove plugs X41 X44 on the SDCS PIN H01 5 Remove the fan holding screws of the broken fan 6 Attach the new fan reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module ...

Page 94: ...the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 0610 dd DCS880 S0b 1000 dd using either one 230 VAC or one 115 VAC fan Removing the converter fan 1 Remove the control panel the design cover and the fan connection plug X52 on the top of the converter housing ...

Page 95: ...Service 3ADW000488R0101 DCS880 Service manual e a 2 Remove the two fan arrangement screws 3 Remove the holding plugs by pulling out the head use a flat screwdriver 4 Move the fan arrangement forward and up ...

Page 96: ...rvice manual e a 5 Remove the fan holding screws 6 Remove the Faston plugs from X52 and the broken fan 7 Attach the new fan reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module ...

Page 97: ... controller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 1190 dd using one 230 VAC fan 1 Remove both screws at the bottom of the fan arrangement 2 Disconnect the plug 3 Now the fan arrangement can be pulled out ...

Page 98: ...ntroller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 0900 dd DCS880 S0b 2000 dd using one 230 VAC fan 1 Remove both screws at the top of the pull out box 2 Disconnect the plug 3 Now the fan box can be pulled out ...

Page 99: ...ee condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 1900 d DCS880 S0b 3000 dd using one fan in delta connection 400 VAC 50 Hz or 460 VAC 60 Hz Unit sizes DCS880 S0b 1900 dd DCS880 S0b 3000 dd using one fan in star connection 500 VAC 50 Hz 1 Disconnect the cables 2 Remove the three screws at the top of the fan 3 Lift the fan up and p...

Page 100: ...er controller completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Unit sizes DCS880 S0b 2050 dd DCS880 S0b 5200 dd using one fan 1 Disconnect the cables 2 Remove the three screws at the bottom of the fan 3 Lift the fan up and pull it out ...

Page 101: ...rrent The control electronic of the drives is designed to use either 2 or 3 standard current transformers They are located on the AC side of the bridge to measure the armature current Wiring The wiring of the current transformers is basically identical for all drives The figure below shows the most common configurations ...

Page 102: ...d secondary current 1 2 AAC Ratio 2500 1 Magnetic overload capacity for a short time 3 times rated primary current Maximum rated voltage 1500 VAC Maximum test voltage 5000 VAC for less than 3 seconds Dimensions In mm see figure below Weight 1 7 kg Maximum ambient e g cooling air temperature at rated current 55 C Maximum conductor wire busbar temperature at rated current 90 C ...

Page 103: ...current 1 25 AAC Ratio 4000 1 Magnetic overload capacity for a short time 3 times rated primary current Maximum rated voltage 1200 VAC Maximum test voltage 4000 VAC for less than 60 seconds Dimensions In mm see figure below Weight 1 7 kg Maximum ambient e g cooling air temperature at rated current 55 C Maximum conductor wire busbar temperature at rated current 90 C ...

Page 104: ...e wired in the same way Take additional care in case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located in the H6 module AC busbars are routed through the current transformers The current transformers are kept in place by design and need no further mounting The connection to the electronics is done via twisted pair cables with code...

Page 105: ...n case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located in the H7 module AC busbars are routed through the current transformers The current transformers are kept in place by design and need no further mounting The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends Exchange Remove th...

Page 106: ... Wiring It is important that all current transformers are wired in the same way Take additional care in case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located outside the H8 module AC busbars are routed through the current transformers The current transformers are mounted on the busbars by means of screws The connection to the ele...

Page 107: ...ad The firmware download is setting all parameters back to default Before starting make a parameter backup using either the control panel or Drive composer The firmware download deletes all application programs Make sure that it is possible to re load the application programs The firmware download is done via a USB port and the control panel Firmware download Make sure The drive composer is closed...

Page 108: ...108 Service 3ADW000488R0101 DCS880 Service manual e a Click Open Go to the folder containing the desired firmware file Mark the desired firmware file and click Open ...

Page 109: ...W000488R0101 DCS880 Service manual e a Mark All compatible and click Select Choose the proper COM port in this case COM4 How to find the proper COM port see below Find COM port To find the proper COM port click Start ...

Page 110: ... 3ADW000488R0101 DCS880 Service manual e a Click Control Panel Click Devices and Printers Double click ABB Drives Assistant control panel Choose Hardware The COM port can be found under Device Functions Here COM5 ...

Page 111: ...DW000488R0101 DCS880 Service manual e a Continue firmware download Make sure the proper COM port here COM4 is chosen Click Download Click OK Please wait and go for lunch The firmware download is complete now Click OK ...

Page 112: ...112 Service 3ADW000488R0101 DCS880 Service manual e a Close the Drive loader 2 x Check for proper firmware version in 07 05 Firmware ver ...

Page 113: ...ction e X Standard H1 H7 L Left side H8 R Right side H8 Revision code f 0 1st generation Attention When using H1 H5 modules the current and voltage range of the type code setting is limited to max 1190 ADC and max 600 VAC The change of the type code is immediately taken over and 95 24 Service mode is automatically set back to Normal mode The new values can be seen in group 7 07 34 Drive block brid...

Page 114: ...xcitation cables and connect 110 240 VAC 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...

Page 115: ...sitive to electrostatic discharge Use 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 protecti...

Page 116: ... is strongly recommended Preventive maintenance 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 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...

Page 117: ...ed symptoms appear Check the cooling air pressure switch of units H7 and H8 Actions Make sure electrical safety is performed Open the module s door and hold it in position to prevent any movement Repeat it with the cabinet s door Start the drive The air pressure switch is ok when the converter is either switched off by 5080 Drive fan acknowledge or shows warning A518 Drive fan acknowledge see 20 3...

Page 118: ...e s door if needed secure them Pull the torque indication spring a little bit out Release the torque indication spring It has to snap back into position correct torque If the torque indicating spring does not snap back into position correct torque the stack has to be retorqued otherwise everything is fine Tighten each nut in turn half a turn at a time with the help of a ring spanner until the indi...

Page 119: ...ible copper busbar have to withstand different types of mechanical stress Therefore each fixing needs to be checked for correct torque Actions Make sure all supply voltages are switched off most important the supply for the power part armature for the drive electronics SDCS POW H01 for the converter fan and for other auxiliaries Open the cabinet s and module s door if needed secure them Set a latc...

Page 120: ...are not clean Pre clean the heatsinks using an ESD vacuum cleaner then use compressed air to remove the dust from the heatsinks the airflow 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 corrosi...

Page 121: ...the bearings The cooling fans are used in DCS880 S0b 1900 dd DCS880 S0b 3000 dd H7 GR28C 2DK 400 V 500 V DCS880 S0b 2050 dd DCS880 S0b 5200 dd H8 GR35C 2DD 400 V Aging of the components result in Increased vibration due to the imbalance of the cooling fan can last for several months Increased temperature due to the stopped cooling fan drive trips with overtemperature Check the tightness of all ter...

Page 122: ...the cooling fan sizes H2 H3 two fans Exchange the cooling fan size H3 four fans Exchange the cooling fan size H4 The manufacturer s estimation for the operational time of the classic cooling fans is 3110UL 70 000 hours at 25 AFB122 100 000 hours at 25 W2E200 45 000 hours at 60 C W2E250 40 000 hours The mayor problem is the failure of the bearings The cooling fans are used in DCS880 S0b 0045 dd DCS...

Page 123: ...use breakdown time Replace the power supply board SDCS POW H01 of units H6 H8 DCS880 S0b 0900 dd DCS880 S0b 5200 dd and DCS880 R Rebuild and Upgrade Kits The SDCS POW H01 is located between the module door on the electronic tray It operates continuously because it supplies the drive electronics even when the armature current is switched off Therefore all its components are exposed to hot condition...

Page 124: ...124 Preventive Maintenance 3ADW000488R0101 DCS880 Service manual e a Replace the snubber capacitors of units H8 990 VAC and 1190 VAC only ...

Page 125: ...replace clean if IP54 or if needed yearly Fins of fan yearly Heat sinks yearly 2 2 Relays connections Inspect relays contacts for proper functionality 3 years Inspect electrical connections for tightness 3 years Inspect for proper grounding yearly Inspect for corrosion yearly Inspect tightness of stacks torque indicating spring yearly Inspect tightness of heatsink terminals 25 Nm required yearly I...

Page 126: ...1 SDCS POW H01 X38 9 years SDCS OPL H01 SDCS PIN H51 XC12 9 years SDCS OPL H01 SDCS PIN H41 XS13 9 years SDCS PIN H41 SDCS PIN H41 XS23 XS13 9 years SDCS OPL H01 SDCS POW H01 X38 9 years 4 2 Boards and other parts SDCS PIN H01 9 years SDCS POW H01 9 years Snubber capacitors frame size H8 990 VAC and 1190 VAC only 9 years 4 3 Fans Cooling fan frame size H1 H6 6 years Cooling fan frame size H7 H8 3 ...

Page 127: ...127 Appendix Spare Parts List 3ADW000488R0101 DCS880 Service manual e a Appendix Spare Parts List ...

Page 128: ...ly ABB Automation Products Wallstadter Straße 59 68526 Ladenburg Germany Tel 49 0 6203 71 0 Fax 49 0 6203 71 76 09 www abb com dc drives 488R0101A7450000 488R0101A7450000 Ident No 3ADW000488R0101 Rev A 11 2017 ...

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