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DCS800 Service Manual - Galco Industrial Electronics

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1.
2. ET g Ls Lee lu vit D V21 V21 e i V11 V24 TT V14 V14 L I V24 V13 To v23 V23 T_T ni V13 V26 ET V16 V16 TA V26 V15 di V25 V25 V15 v22 CT vi2 V12 EI ii v22 IC Assembly D7 Pee Che Assembly D7 Busbars on the right Busbars on the left view from the front view from the front Location of thyristors in frame D7 4 Q bridge m J rd Dex E V11 B_ V11 o i i amp V16 V16 aT V15 B uum li TT V15 li lE J J ii V12 V12 TED Assembly D7 D7 ass dsf Assembly D7 Busbars on the right Busbars on the left view from the front view from the front Location of thyristors in frame D7 2 Q bridge Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 73 U1 AC busbar AC busbar AC busbar gt D1 DC busbar o 3 A SV i Y j8 NV L LIN ne C1 DC busbar Location of branch fuses frame D7 busbars on the right Exchange of Thyristors for Size D7 ice Manu 3ADW000195R0501 DCS800 Serv 74 ran U O v Hx q 4 A C busbar WI Y AC busbar D1 DC busbar Location of branch fuses frame D7 busbars on the left Exchange of Thyristors for Size D7 ice Manua 3ADW000195R0501 DCS800 Serv Exchange of SDCS CON 4 General 75 All DCS800 size D1 to D7 are equipped with the same controller board SDCS
3. DCS800 S01 4800 08 amp DCS800 S02 4800 08 800 V my 6 te ooo ssTp4sQux Semiconductorfuses 6 6 abc77000P0002 UR3000KA 1000V Flush end contact fase 65 00 DCS800 S01 5200 04 05 amp DCS800 502 5200 04 05 400V 500V SCS Thyistor 6 12 3Abcs483PO0 5STP45Qex SSCS Semiconductor fuses 6 6 3ADC770030P0001 UR 3500 A 6900V Fiush end contact uss Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 157 Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e DCS800 family DCS800 S modules a The versatile drive for any E application E E PO x 5200 Ae Gwe 1480 Vos E 230 su TODO Vie E IPOO DCS800 A enclosed E converters a Complete drive solutions E 20 we 20 1000 Ass 0 ww ADO Mas DI 290 ALU E IP21 1P54 E DCS800 E series H Pre assembled drive kits E 20 4 240006 E 0 T KOO Y 230 600 V B IPOO a DCS800 R Rebuild Kit E Digital control kit for existing powerstacks a 20 20 000A T O 1 160 V B 230 1200V n IPOO n Ah HD ED PA DID ABB Automation Products GmbH Wallstadter StraBe 59 68526 Ladenburg GERMANY Tel 49 0 6203 71 0 Fax 49 0 6203 71 7609 www abb com motors amp drives Compact Highest power ability Simple operation Comfortable assistants e g for commissioning or fault tracing Scalable to all applications Free programmable by means of in
4. O Flyer DOS800 A S3ADWOO213 x Technical CatalogueDCS800 A 1 S3ADWO0018 x J j J Installation of DCS800 A 1 S3ADWO009 x x Ca AAA ed NE DCS800 R Rebuild System E recs ii cl Flyer DCS800 R S3ADWO007 x x j j j DCS800 R Manual 1S3ADWO00197 x J po DCS500 DCS600 Size A5 A7 C2b C3 and C4 Upgrade Kits 3ADWO002566 x ETT AE ES de AE e EE Extension Modules ea dedica RAIO 01 Analogue IO Extension 3AFE64484567 x __RDIO 01 Digital IO Extension 3AFE64485733 x _RRIA 01 Resolver Interface Module 3AFE68570760 x RTAC 01 Pulse Encoder Interface 3AFE64486853 x J RTAC 03 TTL Pulse Encoder Interface 3AFE68650500_ x AIMAR slotextension CSC SAFE64661442 x rr fr AAA A NE ANI E Serial Communication J j J Drive specific serial communication Z o NETARemotediagnosticinerface SAFE64005002 x Ti iii Fieldbus Adapter with DC Drives RPBA PROFIBUS 3AFE64504215 x l Fieldbus Adapter with DC Drives RCAN 02 CANopen J j Fieldbus Adapter with DC Drives RCNA 01 ControlNet SAFE6450005 x J J
5. 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 Ta Doom Ubi A ee Ae Be Fa AAA ig EX B EX i ta CD E C 00 D E C D A YE Fraide Service 3ADW000195R0501 DCS800 Service Manual e e 120 Connection Type Select connection BOOT Mode Select Interface Direct Connection un tick Kernel already resident and confirm with Next Connection Type D a pal xc P y TO TERR Service 3ADW000195R0501 DCS800 Service Manual e e Programming Options Protection Automatic and Messaging Advanced confirm with Finish Programming Options eN MH fe Drive mot IM Ei ol B i FO Now the project for the firmware file is finished FLASH Development Toolkit 2 2 ISCR Bus a li G x fie a DiCS800 User defined 1 Project mEEEDCS800 Firmware user defined ol Device Image fg Target Files 3ADW000195R0501 DCS800 Service Manual e e 121 Service 122 Create the project for the text file Select Workspace with a right mouse click and choose New Project FLASH Development Toolkit 2 2 Bie Edit View Project Device Image Tools Window Help Mew Project Insert Project into Workspace Open Workspace Chrl4 yy Save Work
6. FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help a S os ki 5 Sm Add Files to Project Add Files to Project From Kernel Dir Setas Active Project Remove Project Connect to Device Erase FLASH blocks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target files Properties Alt Shift R 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 Hate Attention For firmware version 80x130 80x130Demo and higher set the Target Baud Hate to 38400 Project Properties Text E 3 x User settings COM Port com Use default baud Target Baud Rate 38400 Default Baud Currently connected Ho Service 3ADW000195R0501 DCS800 Service Manual e e 104 Download text file to device Service Select desired text file with a right mouse click and choose Download File to Device from the pop up menu FLASH Development Toolkit 2 2 DCS800 File Edit view Project Device Image Tools Window Help ae C Device Image 3 Target files 80x110text cde 80x111text cde 80x111stext cde RM cde Download File to Device Freshen Local File Properties Alt Shift R After the download is complete the 7 segment display shows a Attention Do not de ener
7. 8ADT220090R0043 SDCS PIN 48 SDCS PIN 48 replaces DCS PNA Puls transformer bora 2 36SE004990R1003 SDCS PIN46 lonywsedforBCTs DESCRIPTION 2 Q 4 Q CODE TYPE DATA NOTES Thyertrpcse sonza 6 sAxcwooronz sSTP3Rubexk O O OoOO O O Thyristor or DCS800 502 ro 6 3aDcs40079P0001 5 STB 24 Qux Bdireciona Contoled Tyrstor BCT Puls transformer bord 1 SADTz20090R0043 SDCS PIN 48 _ SDCS PIN 48 replaces SDCS PIN 4T Puls transformer bora 2 36SE004920R1003 SDCS PIN46 lonyusedforBCTs Item 50 00 to 65 00 Modules D7 2050 A 5200 A 400 V 500 V 600 V 690 V 800 V 990 V and 1200 V 50 00 Common parts for modules D7 2050 A 5200A Control Board 1 1 3ADT313900R1001 SDCSCON4 __ Power supply board 1 1 3ADT315100R1001 SOCSPOW4 Power interface board 1 1 3ADT22000R0000 SDCSPINS __ Air Flow detector P1 1 1 bDcrt066659P0001 P283A4AHC Module contains 51 00 DCS800 S01 2050 10 amp DCS800 S02 2050 10 990 V DESCRIPTION CODE TYPE DATA NOTES Thyristor 6 12 3ADC340086PO001 TV989 2700 Semiconductor fuses 6 6 3ADC770030P0003 UR 1800 A 1250V Flush end contact fuse Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 155 52 00 DCS800 S01 2600 10 amp DCS800 S02 2600 10 990
8. 6 Remove the thyristors Attention To centre the thyristors spring pins are used The pins are inlayed into all lower heat sinks Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor Mounting clamp N EA AA i EA MNR O cc E E DIC CT END OCOS DN Z O E E di UNI ESA Ll 2 Y ES ne View from View from PAUL the left CO aN the right Disassembly tool E i mountcl b dsf Front view How to use the disassembly tool Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 47 Install new thyristor 1 Ensure that the new thyristor is of the correct type see Appendix A Keep the semiconductor and its surroundings clean lf necessary clean them with a piece of tissue paper moistened with solvent Note Do not touch the polished surfaces of the thyristor 2 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of heat conducting paste on both sides of the thyristor if necessary use a rubber spatula 3 Connect the gate leads if possible 4 Clean all parts with tissue paper moistened with solvent which have had or will have contact with the thyristor or each other lower upper heat sink Do not clean the surfaces of grease too thoroughly because the aluminum surfaces will oxidize in a
9. Download Ctrl D p Click Open and follow the instructions 2x Look in C3 Temp2 e ex E3 125800 Using L WL dwp File name ocseoo Using L WL dwp Files of type Parameter files dwp Cancel LZ 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 PE DriveWindow ABB SMP DCS 800 D1 0 1 File Edit View Network Drive Desktop Monitor Data Workspace FE alal Fade c e Parameters Li Open Chrl 0 System Software k Glose Graph k oo Save Cs w Status Refresh Export k Print Exit comment fai a Faulk Memory Download O Parameters Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 83 Service How to remove the converter fans in frames D1 to D3 two fans Converters types DCS800 S01 0045 0x to DCS800 S02 0350 0x using two 115 VAC fans Depending on the supply voltage they are either connected in series for 230 VAC or in parallel for 115 VAC 230 Vac al O Connector X2 on top 115 Vac i of converter housing gt O Fan configuration D1 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 t
10. c X A vt MM amos s WA a Fan holding screws Remove Faston plugs Fan connection plug X2 Faston plugs 6 Reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module 3ADW000195R0501 DCS800 Service Manual e e 87 How to remove the converter fans in a frame D3 four fans Converters types DCS800 S01 0405 0x to DCS800 S02 0520 0x using four 115 VAC fans Depending on the supply voltage they are either connected in series for 230 VAC or in parallel for 115 VAC n 1 o O NEM X2 1 2 3 4 5 Connector X2 on top 115 Vac m I x of converter housing oO Fan configuration D3 In case a fan fails there are different approaches due to the incoming voltage 230 VAC With a supply voltage of 230 VAC fans M55 and M56 are connected in series as well as fans M57 and M58 Consequently fans connected in series have to be of the same manufacturer and type Thus it is not possible to change only the broken fan Always change the two fans connected in series 115 VAC With a supply voltage of 115 VAC all fans are connected in parallel Thus it is possible to change only the broken fan Service 3ADW000195R0501 DCS800 Service Manual e e 88 Removing the converter fans 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on the top of the converter housing Remove DCS Control Panel
11. 61 C1 C14 C16 o IA Im III la e V25 V12 View from the right ell LI Location of thyristors in frame D6 4 Q bridge with single thyristors Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 62 TER 8 k iii a J m ml EJE Gate B E A V11 V24 V14 V21 V16 V23 V13 V26 V15 V22 V12 V25 View from the right Location of thyristors in frame D6 4 Q bridge with BCT s Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 63 IA View from the right Location of thyristors in frame D6 2 Q bridge with single thyristors Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 64 AE A ee it Bd E S oe ie AA i TLE Lu n Li HID e E e in d ne Art il i il a ail r A Tio fil DA 5 zi JJ L n di aa 7 40 Ver o m E i j rj Y b H Y mi L I Di re Nh vw Me Ly Uh AN ea Y ki a JR l N t 9 1 pi a O n 1 i DEI A6 branch fuse locat dsf Location of parallel branch fuses frame D6 Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 65 Exchange of Thyristors for Size D7 Installation of Disc Type thyristor in converters size D7 2050 5200 A All DCS800 converters sizes D5 D6 D7 are equipped with disk type thyristors The structure of the Disc type s
12. Depress the locks by means of a screwdriver to remove the design cover Design cover Service 3ADW000195R0501 DCS800 Service Manual e e 89 Remove the two fan arrangement screws 2 jm E era Remove the fan e gt arrangement screws 5S Fan arrangement 3 Move the fan arrangement forward gt Move fan arrangement Service 3ADW000195R0501 DCS800 Service Manual e e 90 4 Remove the fan holding screws UE EA L iii eee i 9 m n na Remove the fan holding screws Fan holding screws Service 3ADW000195R0501 DCS800 Service Manual e e 91 5 Remove Faston plugs and fans A Fan connection AA plug 2 Remove Faston plugs V lei ace pe Faston plugs 6 Reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module Service 3ADW000195R0501 DCS800 Service Manual e e 92 How to remove the converter fan in a frame D6 1 Remove the three screws at the top of the fan 2 Disconnect the cables 3 Lift the fan up and pull it out Converter fan in frame D6 Service 3ADW000195R0501 DCS800 Service Manual e e How to remove the converter fan in a frame D7 1 Remove the three screws at the bottom of the fan 2 Disconnect the cables 3 Pull the fan out APRDORPAPARDPRPAPAPAPNPS 2 MMM Converter fan in frame D7 3ADW000195R0501 DCS8
13. Fieldbus Adapter with DC Drives RDNA DeviceNet 1l 3AFEe4502083 x l Fieldbus Adapter with DC Drives RMBA MODBUS 3AFE64498851 x J J Fieldbus Adapter with DC Drives RETA Ethemet 1 3AFE64539736 x DCS800 Drive Manuals List j doc gt lt gt lt X x lt 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 2011 ABB Automation Products GmbH All rights reserved 3ADW000195R0501 DCS800 Service Manual e e Safety instructions What this chapter contains This chapter contains the safety instructions you must follow when installing operating and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive the motor or driven equipment Read the safety instructions before you work on the unit To which products this chapter applies The information is valid for the whole range of the product DCS800 the converter modules DCS800 S0x size D1 to D7 field exciter units DCF80x etc like the Rebuild Kit DCS800 R00 9xxx Usage of warnings and notes There are two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger Notes draw attention to a particular
14. i i m Remove screws and studs 6 Unplug the flat cables X12 X13 X37 raid Remove flat cables ai Unplug the flat cables 3ADW000195R0501 DCS800 Service Manual e e 79 Exchange of SDCS CON 4 80 Install the new SDCS CON 4 1 2 3 Reconnect the flat cables at the SDCS CON 4 X12 X13 X37 Reconnect all I O plugs at the SDCS CON 4 X3 to X7 and the plugs at the SDCS DSL 4 X51 to X54 and Reinstall the intermediate cover all plug in options and the design cover 5 Set type code of the drive Follow the instructions in chapter Set type code 6 Enable application program If a SDCS MEM 8 Memory Card is used the application program must be enabled before the parameters are downloaded Set ParApplSave 16 06 EnableAppl 7 Download and compare parameters Parameters can be downloaded and compared by various means DCS Control Panel DriveWindow Light Press Soft key 1 until the main menu is shown Press LOC REM button display will show LOC on the upper left side Press Soft key 2 MENU Scroll with UP DOWN buttons to menu item PAR BACKUP Confirm with Soft key 2 ENTER Select DOWNLOAD FULL SET and confirm with Soft key 2 SEL the download progress bar will be shown on the display Successful download will be shown by message Confirm with Soft key 1 OK Press LOC REM button display will show REM on the upper left side Press Soft key 1 until back
15. 3 6 sacs000esPo00i TTS70Nux mr SSCS Item 30 00 to 36 00 Modules D5 900 A 2000 A 400 V 525 V 600 V and 690 V 30 00 Common parts for modules D5 900 A 2000 A 0 Power supply board 1 1 3ADT315100R1001 SDCSPOW4 Power interface board 1 1 S3ADT22000R006 SDCSPINS Temperatur sensor R57 1 1 sADT710003P0001 KTY2KM4800 Cooingfan 1 1 3ADT754018P0001 D2E160 AH02 55 Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 151 73100 pcs800 501 0900 06 07 amp DC 800 502 0900 06 07 600 V 690 V TTD yw az bcAcooreooi Tason orginal hyrstortye Semiconducioriuses 6 6 3Apcr7O0P000 UR6S0A 1250V Screw ype fuse Tais 6 1 SDcs40 05P0001 Tason pecondtyrstorppe Semiconductor fuses 6 6 sADCr70009FO007 UR630A 1250V Sorewype fuse Module contains 2 Q 4 Q 32 00 DCS800 S01 1200 04 05 amp DCS800 S02 1200 04 05 400 V 500 V Thyristor 6 12 DCAO012015P0001 T589Nox original thyristor type lt Semiconductor fuses 6 6 3ADC770010P0005 UR800A 660V screwtypetuse 32 002 DCS800 S01 1200 04a 05a amp DCS800 502 1200 04a 05a 400 VS Www A 1 SADco40 06P0001 T590Nx pecondtyrstorppe Semiconductortuses 6 6 sADC770010P0005 UR800A 060V Seew pefuse 3300 DC
16. Blank check Cancel PLASH Operation Build Device Image Freshen all Target files Service 3ADW000195R0501 DCS800 Service Manual e e 110 Goto the directory containing the desired firmware file e g Add files to Project x Look in Firmware do ft E E E El com Desktop E nie My Documents n My Computer DE L 01 30005 DELH 038 s 80x15 zs Local Disk E 5 0x15 e ABR 5 80x1 3 DCS800 s 80x1 Dj Firmware i CONA a Ver 1 7en RUE aie O DVD CD Rw Drive D j Deu109895 on De s 0117949 Hi Files FM Se DEAPR Projects on De s 0117949 Ro Comcel Ca PILA TATTO lI n me 2 AAT Choose the desired firmware file and press Open Add files to Project x Look in Co Firmware do ft E EE Ei oOUx 140 rec 80 sl adr ec f 00x1400emo rec o0x1S00emo rec 5 80x150 rec 5 o0x150Demo rec s 80x170 rec E o0x1700emo rec File name 8041 Bl rec Cancel E Files of type FDT Data Files for rec mots a20 a37 T Service 3ADW000195R0501 DCS800 Service Manual e e Add text files 111 If the text file to be downloaded is not shown under Target files the text file has to be added FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help 48 as a Sad BR o xl HS Workspace DiCS800 2 Projects ea Firmware EE Text Device Image
17. Ctrl F Sa FaultjAlarm Words ISS in Start Stan Salart 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 amp Signals and Compare E Drive Window Light 2 Parameter Browser DCSE00 E File View Options File View Options Drive Tools Communication Window Help SE Eg Control Panel boo Online D xn step Function ecc Parameter Subset k xb ca lt gt amp Monitor Open All Parameters Launch Wizard Show Mo Mapping Table Drive Status DOS800 247 99 Start up Data Upload Remote 1 Phys Act Values Downoad sims 2 SPC Signals Ea 3 Ref Act Values Upload All Parameters Du Ml 4 Information Download 4ll Parameters D 5 Analog Infout Restore D 6 Drive Log Signals Backup 4 rpm e OF IS 7 Control Words 8 StatiLimit Word ELTON NOM E eee Mera Search Parameters Ctrl F Sa Fault Alarm Words i IS in Shark Stan Salart Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 82 DriveWindow Click File then Parameters and Download BS DriveWindow ABB SMP DCS 800 D1 0 1 File Edit View Network Drive Desktop Monitor Date Workspace FE al alized sala c G Parameters k Open Chrl 0 System Software Close Graph G Lo O Saves HS w Status Refresh Export KI MC IE Print d dm Comment Compare
18. FLASH Workspace Manager l i x The workspace DCS800 has been modified would you like to save your changes o cme Creating of projects is complete now Service 3ADW000195R0501 DCS800 Service Manual e e 129 Download SDCS COM 8 firmware Requirements Incase the PCMCIA adapter NDPA 02 with NDPC 12 is used the NtNisa drivers have to be installed see NtNisa5x zip or NtNisa5x exe before downloading the firmware Incase 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 Attributes A Name F com s Bax160 zip SOKB Winzip File 15 12 2008 17 07 Open with Winzip Print Explore Explore From Here Scan For viruses Col Winzip k E Extract to here _ 5 Extract to folder C ABB OCSS00 Firmware COM Sx test COM 8 88160 Send To CB Extract to Folder Cut tS E Mail COM 8 88x160 zip Copy i Encrypt n 5 Create Self Extractor Exe Create Shorto Configure Delete 3 Rename Properties Following files and folders will be created Date Modified 15 12 2008 17 07 COM 56x160 2ip winzip File File Folder 16 12 2006 09 13 Prag File Folder 16 12 200
19. OnBoard bridge V1 and thyristor module location in DCS800 S01 2 Q units ENT 3 3 CNN sia Aldo DCS800 S01 0020 0180 V14 V11 V16 V13 V12 V15 IPSA V16 V13 V12 V15 si JE E 00 00 0000 Do T D a X ES x 5 x x d i x x Ol O O O 9 9 V14 V11 V16 V13 V12 V15 V14 V11 V16 V13 V12 V15 e pa e e pi e e ng e sj le e le ej Fe 985v 985v 2585 m m EE 5 5 C O O O e s 3 s s s E fs ame O Ie S DCS800 loc of mod 10 dsf Location of the OnBoard bridge and thyristor modules in DCS800 S01 2 Q units
20. STA ai po DO 00 001100 goan i uc dich Ex E JOE JOE V11 V24 V13 V26 V15 V22 o Qn de V11 V24 V13 V26 V15 V22 IS DCS800 S01 0680 1000 Im V26 V13 V22 N15 levz4avia 9 E d Vi E 0 iv ax SE V14 C V24 el E va V15 an v12 SE allio E G Ow ax ky a G2 6 e e v22 ES 9 i j REI V25 el_Je e le e le V13 El m o a V16 MR di E Ze O GI vas 8 e e fe e V21 V14 V23 V16 V25 V12 DCS800 loc of mod 40 dsf Location of the OnBoard bridge and thyristor modules in DCS800 S02 4 Q units Note This drawing is only showing the location of the OnBoard bridge and thyristor modules the actual
21. 3000 A 400 V 500 V 600 V 690 V and 800 V 50 00 65 00 Modules D7 2050 A 5200 A 400 V 500 V 600 V 690 V 800 V 990 V and 1200 V Item 8 03 Control Panels and plug in options D1 D7 8 03 Control Panels and plug in options D1 D7 DCS Control Panel 1 3ADT220129R0002 DCS CP P ControlPanelforDCs800 CDP312RD Control Panel 1 38ADT220071R0006 CDP312RDRev G Possiblevia SDCS COM 8ony DCSLink board 1 3ADT200005R0001 SDCS DSL4 j 9199 1 O DDCS communication board 1 3ADT220134R0001 SDCS COM 81 1508 10 Mbd eg AC800M DDCS communication board 1 3ADT220134R0002 sDcs com 82 L509 5Mbd fieldbus PROFIBUSDP 1 3AFE6 6068598 RPBAO gt pas DeviceNet gt gt gt 1 3AFEG4606891 X RDNAO K45 Modbus 1 G3AFE6460078 RMBAO1 l rkas8 CANopen 1 G3AFE6460005 RCAN 9K457 ConroNet 1 G3AFE64751700 RCNAO 462 Ethernet Adapter Module 1 3AFE64751727 RETAO1 K466 O EtherCat Adapter Module 1 3AUA0000045102 RECAO1 K469 0 0000000 Analog I O Extension 2 3AFE64606841 RAIOCO 500 Digital I O Extension 2 3AFE64606816 RDIO M 501 Pulse Encoder Interface 12 V 1 3AFE64610805 RTAC O j 9150 _ ______
22. 400 V 525 V DESCRIPTION CODE TYPE DATA NOTES Thyistormodues 3 6 SADCa40068P000 SKKT57Bhex MCCS t6x Semiconductor fuses 3ADT730004R0007 UR 125A 660V Blade or knife fuse Cooling fan 115V 50 60Hz 3ADT754014P0001 CN2B2 4715 MS 12T B5Axxx Semiconductor fuses as field 3ADV050092P0036 UR 200 A 660V When used as field in D6 or D7 cabinets 15 00 DCS800 501 0125 04705 8 DCS800 502 0140 04 05 400 V 528 Vj CT Tnyristor modules 3 6 3ADC340064PO001 skkrioesrxx mocos tew Tnyristor modules 3 6 3ADcs4004P0001 skkriosemx _ MCC95 1emx SSS Thyristor modules 3 6 3ADC340094PO00I MOCTO2 1G0q TT162Nxx fiviistor modues 3 6 sabcaaoovepoonr mocz2 O oO 719 00 DCS800 S01 0315 04 05 amp DC S800 502 0350 04 05 400 V 528 V Tnyristor modules 3 6 GrsnetoossPoooz TT260Nxx mocs Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 149 20 00 pcs800 501 0405 04 05 amp DCS800 502 0450 04 05 400 V B28 TT Tiyristor modues 3 6 GHsnetoossPo0o2 TT250Nwx ME SS 2100 DCS800 501 0470 04 05 amp DCS800 S02 0520 04105 400 V 828 V TTT Tnyrstor modules 3 6 sADOsao0s2p0001 TIASON MECSIE SOS 22 00 pcs800 501 0599 06 amp DCS800 502 0650 06 600 YY Tnyristor modules 3 6 3ADC340097P00
23. 94 Add titmware Or text lessi ec P 107 reate a WorksDacOrsirnda tasadores 114 Download SDCS COM 8 firmware i 129 SELDE COE ae vaio 131 Type code Table iaa 133 DC Motor neutral zone adjustMent c occccocncccnncocnccncncnonononononnnnonononnnnnnnnnnnnnnnnonnnonannnnnninanenos 134 Types CONCE Ml O nds 134 SUM RAR SR RR N eer E 134 eI Mc TT ner 134 Table of contents 3ADW000195R0501 DCS800 Service Manual e e Preventive Maintenance 135 Recommended regular maintenance iii 136 Maintenance schedule iii 136 Annual preventive Manten ace e eeu 137 3 years preventive maintenance iii 140 o years preventive Malntenance siluri lalla 141 9 years preventive maintenance iii 143 Appendix A Spare Parts List 145 Table of contents 3ADW000195R0501 DCS800 Service Manual e e 16 Introduction How to use this manual The purpose of this service manual is to provide detailed information on how to service power converters from the DCS800 series Contents of this manual Safety instructions This chapter is located at the beginning of this manual Introduction This chapter informs about the contents and the use of this manual as well as the boundary conditions applying and the thyristor power converter rating plate Fault Tracing Thyristors This chapter describes how to detect and select a faulty thyristor Handling the Semico
24. Air Cooled Unit L L L L L4 gt Cooling fan DCS800 D6 D7 itt PR TIR 1 PRI i GL PRI i PRI i PRI PRI gt Cooling fan DCS800 D1 gt 45 A D5 1 1 E i 1 EE i 1 E i EE l l tit i l l i i tft ee eue TT TR TROTA SDCS PIN 4 Er DT ELICIT ISCEELETIELT SDCS POW 4 Connections amp Surroundings J gt 0000 000000000 S Connections amp Surroundings gt _Flatcabes O oO ot it o ti L gt Tightness of terminals S Nm NM EN NM EM I gt Tightness of terminals heatsink D7 TT TT TT ET prprprprpr ET EE TT tT Sfl gt Doorfites o Z o o o O pr ET ET ET ET ET TT tT tT Sr gt Condition of contacto il i il prf t TT gt Fiber optic cables connections tl t t t t 1 t a 1 1 NE i MEAN AMEN AREA MEE MEAN NNI ad E aaa gt Based on product notes EREE EEEE EEIE EEEE EEEE DIE DDD ESSE Measurements gt Basic measurements with supply voltage P PIPIPI PIPIP PIPIPI PIPIP PIPIPI PIPIPIP P Spare Parts O Spare Parts gt Spare Pats a TII I III The service intervals and component replacements are based on the operational environment specified by ABB omera epee iol oa 1a a 48 9 4748 TO 20 par Start up CS PS Legend R Replacement of component I Inspection visual inspection correction and replac
25. CON 4 thus the exchange of the board is similar for all module sizes Required Tools Special tools or material needed in addition to standard tools for the exchange of the SDCS CON 4 Torx screwdrivers Overview SDCS CON 4 exchange IN c Save parameters 1 Save parameters Parameters can be saved by various means DCS Control Panel Status LED Green for normal operation Flashing green for alarms Red for faults Soft key 1 Function varies and is defined by the text in the lower left comer of the LCD display Up Scrolls up through a menu or list displayed in the middle of the LCD display Increments a value if a parameter is selected Increments the reference if the upper right corner is highlighted in reverse video LOC REM Changes between local and remote control of the drive STOP Stops the drive in local control from DCS800 panel and when the Start up Assistant is used T X10 TX20 TX25 Write down type code of the drive Set jumpers on the new SDCS CON 4 according to the old SDCS CON 4 Exchange the SDCS CON 4 Set type code of the drive Enable application program and Download and compare parameters LCD display Divided into three main areas Topline variable depending on the mode of operation Middle area variable in general shows parameter values menus or lists Bottom line display if enabled B C I2RORFM a RPH Loc 1 12 H
26. Note This drawing is only showing the location of the OnBoard bridge and thyristor modules the actual converter module size is different Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 38 OnBoard bridge V1 and thyristor module location in DCS800 S02 4 Q units DCS800 S02 0025 0200 V12 V25 8 B 8 5 8 5 V14 V21 V16 V23 V12 V25 2 z S z y z DO OD nolo do Dda V Iw
27. Parts List 3ADW000195R0501 DCS800 Service Manual e e 147 Item 8 09 Parts for 12 pulse supply voltage gt 800 VAC hardparallel D7P and galvanic isolation Parts for 12 pulse supp Current measurement aid 1 Q 1 1 1 1 1 1 3 voltage gt 800 VAC hardparallel D7P and galvanic isolation DC DC transducer Knick A92 Ml 3ADN260008P0001 P42000D3 0111 For U gt 690 VAC 12 pulse replaches Knick 8680 A1 A92 High volt fuses for U gt 750 VAC 3 3 3ADVO50092PO015 CC 1051CP 10A 1000V 3 for T90 and capacitors Item 10 00 to 29 00 Modules D1 D4 20 A 1000 A 400 V 525 V and 600 V Insulation monitor Voltage adaption for IRDH Voltage adaption for IRDH ei 10 00 Common parts for modules D1 D4 20 A 1000 A 1100 D65800 501 0020 04 05 amp DC 800 502 0025 04 05 400 V 828 V TTT Tiyistor modules 8 6 9ADC94006PO001 Skkrzrhox MGG26 16xe 12 00 DCS800 S01 0045 04 05 amp DC 800 502 0050 04 05 400 V 528 YY Tuysormodues 3 6 sADCs4006sPO00 SKKT27BMIT MCC26 6 x 713 00 DC800 501 0065 04 05 amp DC S800 502 0075 04 05 400 V 528 V lt Tiiyristor modules 3 6 3ADC340067P0001 SKKT amp 28 _ WCOM toox SCS Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 148 Module contains 2 Q 4 Q 14 00 DCS800 S01 0090 04 05 amp DCS800 S02 0100 04 05
28. R 2ll 00000000 H 000003FF Length H OOL H ooooo400 H O003207F Length H OOC H OOOSFFS0 H OOOSFFFF Length H OOL 200 25 E programmed in 40 seconds Image successfully written to device Download operation complete 4 e Dependencies A Firmware A Text Disconnect from the device 3ADW000195R0501 DCS800 Service Manual e e Service 102 Download text file De energize the DCS800 electronics Set jumper S5 on SCDS CON 4 from position 1 2 to position 3 4 S5 Energize the DCS800 electronics In case the 7 segment 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 Es FLASH Development Toolkit 2 2 DCSBOD 8 os A re sua y ms Workspace DCS800 2 Projects EN Firmware 3 Device Image 2 3 Target files 8 80x110 rec 5 801115 rec BUX111 REC BOx112s rec 0x 112 REC Add Files to Project Add Files ta Praject From Kernel Dir Set as Active Project Remove Project Service 3ADW000195R0501 DCS800 Service Manual e e 103 Choose COM Port and communication speed Select Text with a right mouse click and choose Properties from the pop up menu
29. 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 pe e ee OOOO 05199 Without SDCS DSL 4 EL Cont Panet o ADA O plug in options Without DCS Control Panel J409 Door mounting Kit cable length 3 m Profibus RPBA DeviceNet RDNA Ethernet IP Modbus TCP RETA Modbus RMBA IO and DDCS Analogue Extension RAIO Digital Extension RDIO DDCS Communication board 10 Mbaud CHO SDCS COM 81 DDCS Communication board 5 Mbaud CHO SDCS COM 82 Introduction 3ADW000195R0501 DCS800 Service Manual e e 19 The technical data and specifications are valid as of going to press ABB reserves the right to make subsequent alterations If you have any questions concerning your drive system please contact your local ABB agent Current and voltage ratings Unit size 2 Q rated current 4 Q rated current Supply voltage VAC DCS800 01 ADC DCS800 02 ADC 2901005 000 1 890 900 990 1200 poi 70 Bo XX 90 231400 x x j 90 90 xix tao teo XJ X 460 21590 X XxX xIx 800 200 J X XT XTX two 190 x 2800 280 xXx xix 8500 2500 X x xix x _ 800 300 XxX x XxX XxX x J 800 200 x 8600 20 j Xx x 4800 480 j X Xx
30. and current at all 3 phases at the same time Fault Tracing Thyristors 26 Fault Tracing Thyristors 3ADW000195R0501 DCS800 Service Manual e e 27 Handling the Semiconductors General Instruction how to handle the Semiconductors Thyristor modules busbars and fuses have to be mounted with the correct torque using a torque screw driver or torque wrench In converters sizes D5 900 2000 A D6 1900 3000 A and D7 2050 5200 A the mounting force is indicated by an indicating spring welded to the mounting clamp which is inside the unit Always mark suspected damaged components clearly after removing them from the circuit to avoid confusion with good components When removing a damaged semiconductor write down how and where it was installed direction location connected gate leads and with BCT s the position of the gate connectors Check that the new and old components have the same type designation or that the new component can replace the old one A semiconductor can be replaced by different compatible semiconductor according to the codes in the manufacturers table Semiconductor components are high precision products All unnecessary used tools and objects might damage the easily dented and scratched surfaces of the semiconductors 1 Keep new semiconductors as long as possible in their original packages 2 Use protective gloves if possible 3 Clean work area and hands frequently 4 Use good illumina
31. change the type code as whole follow the instructions below un protect the type code by means of ServiceMode 99 06 SetTypeCode set TypeCode 97 01 S01 0020 04 to S02 5200 05 details see table below he drive s basic type code DCS800 AAX YYYY ZZB roduct family DCS800 DCS800 Type AA O Modules Rebuild system anel solution nclosed converter 1 single bridge 2 Q 2 2 anti parallel bridges 4 Q Il Il TI o O converter type current 30 VAC 400 VAC 30 VAC 525 VAC 70 VAC 600 VAC 15 VAC 700 VAC 60 VAC 800 VAC 450 VAC 990 VAC 540 VAC 1200 VAC Power connection Standard D1 D6 Left side D7 Right side D7 econd thyristor type D5 D6 g ge 2 Q 2 anti parallel bridges 4 Q _ i converter type current A 540 VAC 1200VAC Standard D1 D6 RightsideD7 Attention When using D1 D2 D3 or D4 modules the current and voltage range of the type code setting is limited to max 1000 ADC and max 600 VAC the change of the type code is immediately taken over and ServiceMode 99 06 is automatically set back to NormalMode the new values can be seen in group 4 ConvNomCur 4 05 ConvNom Volt 4 04 MaxBridge Temp 4 17 and QuadrantType 4 15 Service 3ADW000195R0501 DCS800 Service Manual e e 132 Service To change the type code individually follow the instructions below un protect the type code by means of ServiceMode 99 06 SetTypeC
32. converter module size is different Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 39 OnBoard bridge and thyristor module terminals The next figures show the terminals of the OnBoard bridge and all used thyristor modules The terminal description is also stamped or marked by a sticker on the OnBoard bridge and all thyristor modules For all firing pulse cables is valid Yellow is gate lead Red is cathode lead E dE FAN ES A G j O ES ES E ir we El a E MCC162 VVZF 70 AK K A 45 7 6 1 2 3 aleala ers V AE MCC26 44 56 95 SKTT 162 Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 40 AK K A o 0K1G1 K2 G2 O AK K A o 0 2 c2 AIAIA E a DOG TT 162 A AK K A EN MCC255 AK K ae K1 G1 K2 G2 TT 250 330 i Gil TT 425 570 Terminals of the OnBoard bridge and all thyristor modules Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e eh Fara TY PERY 41 Exchange of Thyristors for Size D5 Installation of Disc Type thyristor in converters size D5 900 2000 A All DCS800 converters sizes D5 D6 D7 are equipped with disk type thyristors The structure of the Disc type semiconductor component is
33. faulty thyristor module 11 If a current transformer must be removed mark its position and the connections clearly Note Remove only as many parts as needed around the faulty thyristor module 12 Remove the faulty thyristor module and mark it clearly as defective Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 34 Install new thyristor modules 1 Ensure that the new thyristor module is of the correct type see appendix A of this manual 2 Remove old heat conducting compound grease from the heat sink Clean the mounting surfaces heat sink and thyristor module with an appropriate solvent e g ethanol by means of tissue paper When the heat sink is clean spread out the heat conducting compound with a rubber spatula or by hand 3 Apply a thin layer of heat conducting compound to the new thyristor module Application of heat conducting compound 4 Spread the heat conducting compound evenly by moving the thyristor module forward and backward on the heat sink 5 Tighten all clamping screws by hand until the screw heads touch the bottom of the thyristor module Then tighten the screws to 2 0 Nm torque Note If the thyristor module is mounted by means of four screws tighten the screws crosswise 6 Tighten the screws to nominal torque according to table Nominal mounting torque for OnBoard bridge and thyristor modules page 35 Exchange of Thyristors for Size D1 to D4 3ADW000195R0
34. files to Project x Look in C Text de t E Ex E B x14 DemoText cde E e0x140Text cde ol EPSDUDBIST Ej amp 0 150DemoText cde Ij Text cpi E Ed 80x 150Text cde S0x170DemoText cde 30x170Text cde E ape cde File name 8041 OUT ext cde Cancel Files of type FDT Data Files for rec mots a20 237 T Li Close download tool When closing the FDT2 2 confirm with Yes FLASH Workspace Manager E x The workspace DCS800 has been modified would you like to save your changes e cone Adding of files is complete now Service 3ADW000195R0501 DCS800 Service Manual e e 114 Create a workspace General In case the Hitachi Flash Development Toolkit 2 2 is not installed at its default location e g using Windows in an different language than English C 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 Ms programs O m Settings Search amp Help 2 Bun Log Off Thomas Vinziide abb com 3 Eject PC amp Shut Down Astat 2 19 el Create new workspace Choose File gt New Workspace Open Workspace Ctri W Save Workspace Ctrl E Clase Workspace Save CEri
35. for Size D7 3ADW000195R0501 DCS800 Service Manual e e 70 Pd Lu E gt 3 LH c t B e gt e gt B gt gt E Torque indicating spring loose condition Mounting clamp loose condition Note The indicating spring is a very sensitive instrument and must be handled with care 8 Tighten each nut in turn half a turn at a time with the help of a ring spanner until the indicating spring clicks into position correct torque Do not tighten the screws any further Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e i i TT TT LLL Eh DDD DD A a A eh bee IAAAAMAMA MAA AMARA ARR HAA Me E Appennino nere ca MEL anm Torque indicating spring correct torque Mounting clamp correct torque Note The correct torque is indicated by means of the welded indicating spring 9 Perform an OHM test to make sure the thyristor is ok 10 Reconnect the backplate branch fuses DC AC busbars and all other dismantled parts 11 Perform an OHM test between U1 V1 W1 and C1 D1 to make sure the power part is ok Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 72
36. ges f Target files 5 S0x170Text cde 3 80x170DemoText cde Select Text with a right mouse click and choose Add Files to Project from the pop up menu FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window iB os je oe o 5 5 m ts Workspace DCS800 2 Projects HEE Firmware aem i Add Files to Project Add Eiles to Project From Kernel Dir Set as Active Project Remove Project Connect to Device Erase FLASH blocks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target files Properties Service 3ADW000195R0501 DCS800 Service Manual e e 112 Goto the directory containing the desired text file e g Add files to Project x Look in Text e t er El Desktop My Documents y My Computer DE L 01 30005 BELT O38 z Local Disk C 5 ABB c DCSE0O Dj Firmware Sy CON 4 y Ver 1 7en e MEE Filename O DYD CD RW Drive D Se Deu1038958 on De s 0117349 H a E SE DEAPR Frojects on De s 011 7343 j ance Wax oc l4 7447 A IS Cdd7n4 Files of ty si To display the desired text file write in File name and press Open Add files to Project Look in E Text amp t Files of type FOT Data Files for recs mot acz0 as T Service 3ADW000195R0501 DCS800 Service Manual e e 113 Choose the desired text file and press Open Add
37. left Front view View from the right Location of thyristors in frame D5 4 Q bridge Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 49 i i a Ig DIU V16 ee si mmi p pa mmm FIR 00 Te Hel INR bono TO V12 View from the left Front view View from the right Location of thyristors in frame D5 2 Q bridge Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 50 Nc fa Ku Trga C1 Location of branch fuses frame D5 Exchange of Thyristors for Size D5 51 Exchange of Thyristors for Size D6 Installation of Disc Type thyristor in converters size D6 1900 3000 A All DCS800 converters sizes D5 D6 D7 are equipped with disk type thyristors The structure of the Disc type semiconductor component is such that it requires a certain compression force to operate The prevention of overheating of the component essentially depends on a good heat dissipation between the semiconductor and the conducted heat sink It is thus important that all joints have good thermal and electrical conduction Required Tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules Torx screwdrivers TX10 TX20 TX25 Torque spanner for electrical connections 13 Nm M8 25 Nm M10 50 Nm M12 Scre
38. to the main menu and The actual parameter set is now downloaded into the new SDCS CON 4 Click File then Open File View Options Drive Tools Communication Help Mew Online Drive Ctrl M Ctrl M New Offline Drive Print Setup Exit Remote Charmed Choose correct parameter file and click Open Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 81 A as Look in E Temp2 e ex En C5800 Using COM1 dwp My Recent Documents Desktop TA My Documents gr My Computer DE L 01 7885 a OS File name DCS800 Using COM1 dwp Places Files of type Drive Files dwp Cancel Click Drive then Parameters amp Signals and Download All Parameters E Drive Window Light 2 Parameter Browser DCSE00 E Fie View Options File View Options Drive Tools Communication Window Help Eg Control Panel b Pefre Step Function Parameter Subset F Sai Unline vi Parameters amp Signals P k d D gt OB Monitor Launch Wizard Show Ma Mapping Table Open All Parameters Drive Status DESETO 247 P EA Upload Remate 1 Phys Act Values Download cant E 2 SPC Signals ESE E 3 Ref Act Values Upload All Parameters B d fas Download Al Parameters 1A 5 Analog InfGut Restore s 6 Drive Log Signals Backup 2 J v 7 Control Words DUE BS a stat Limit Words M Search Parameters
39. 0 R Rebuild and Upgrade Kits SDCS POW 4 Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 144 The SDCS POW 4 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 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 50x 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 their connections Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 145 Appendix A Spare Parts List Item Content 8 03 Control Panels and plug in options D1 D7 8 04 8 05 Field exciters FEX 425 Int DCF803 0035 and DCF503 4B 8 06 Overvoltage protection DCF506 for fieldexciter DCS800 S0x 0020 0520 20A 520A 8 07 Common parts for DCS800 A0 Enclosed Converters 8 08 Parts for DCS800 RO Rebuild Kit 8 09 Parts for 12 pulse supply voltage gt 800 VAC and hardparallel D7P 10 00 29 00 Modules D1 D4 20 A 1000 A 400 V 525 V and 600 V 30 00 36 00 Modules D5 900 A 2000 A 400 V 525 V 600 V and 690 V 40 00 49 00 Modules D6 1900 A
40. 0 5 Gate A Gates of BCT Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 54 Find faulty thyristor 1 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 n gt n L E wl y A 44 I 4 I I I x I r J du 4 Y r p L i r x lt I i i D P I i E P x o gt ei en D A 155 mag Location of BCT s gate A when built in Find the defective branches by performing an OHM test both polarities between U1 V1 W1 and C1 D1 see picture Anti parallel B6 bridges with branching fuses on page 45 2 Disconnect the branching fuses of the defective branches 3 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 4 Ina4 quadrant converter with BCT s change the BCT 5 Ina 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 operate properly a measurement outside the clamped heat sinks might be wrong To be sure which thyristor is broken change only one thyristor clamp the heat sinks again and repeat step three Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 55 Remove faulty thyristor 1 Replace all blown fu
41. 00 07 46 SO1 2500 05 96 S02 0520 05 146 S02 4800 08 48 S01 2500 07 98 S02 0680 04 148 S02 5200 05 49 S01 2500 08 99 S02 0680 05 149 So1 4000 12 Lo 1 E Ss02 400012 Service 3ADW000195R0501 DCS800 Service Manual e e 134 DC Motor neutral zone adjustment Types concerned Summary General Service DC Motors Procedure to adjust the neural zone of a DC motor Loosen the bolts holding the brush bridge Connect a scope or a voltmeter between two adjacent brush holder assemblies holders with different polarity Set the scaling on the scope or voltmeter to mV AC Disconnect the excitation 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 the voltage Sometimes you have to do a little offset to compensate for movements during tightening Finally mark the correct neutral zone position in case the motor will be taken apart in the future 3ADW000195R0501 DCS800 Service Manual e e 135 Preventive Maintenance WARNING Before performing any maintenance the chapter Safety I
42. 00 Service Manual e e 93 Service 94 DCS800 firmware download General This chapter describes how to download firmware into the SDCS CON 4 and SDCS COM 8 Download SDCS CON 4 firmware Requirements The Hitachi Flash Development Toolkit 2 2 has to be installed Arecent 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 fe C ABB DCS800 Firmware CON 4 Yer 1 7en File Edit wiew Favorites Tools Help iQ Back gt Bi 9 Search Folders ES s E x ie Hab El Local Disk C File Folder A C ABB File Folder E i pcsann ai 5300 Fat FDT Workspace C3 Docu FS File C3 DW Workspaces El 5 Firmware DD COM 8x E Di CON 4 ED ver 1 7en ic Firmware ic Text 09 11 2006 13 11 09 11 2006 13 11 09 11 2006 07 54 03 11 2006 07 54 Type FOT Workspace Date Modified 09 11 2006 07 54 Size 78 bytes E bytes E My Computer 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 B CABE DCS800 Firmware CON 4 Ver 1 7en Firmware File Edit View Favorites Tools Help Q e 2 JJ Search Folders 4 Es E X ie F E e Local Disk C E Firmware cpj E S ABB 5 80x140 rec E 3 pcsenn E 80
43. 01 SKKT43020ox T7480 Nom MTS 430 Cooling tan 230v 500z 1 1 Dcaoorz171P0001 wee 200HHoe06 23 00 _ DCS800 S01 0590 06 amp DCS800 S02 0650 06 5171 600 V Thyristor modules 3 6 3ADC340007P0001 SKKT 4300 TT430 Noo MTS 3O x 2400 DCS800 S01 0610 04 05 amp DCS800 502 0680 D4 05 400 V 828 V O O O U U OUOU Tiyistor modules s 6 SADC340082PO001 Tr425Nex meca Cooling fan 230 w 50 60 Hz 1 1 ocaoorzizipooos wzezooHmaeo 25 00 _ DCS800 501 0740 04 05 amp DC 800 502 0820 04 05 400 V 528 V Tyristor modues 3 6 sADCS4006sPO00i TrS 0Nex massa Cooling fan 230 5060Hz 1 1 Dcaoorz1r1poo01 wer200HH8806 O O OoOO o ooo y O Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 150 26 00 _ DCS800 S01 0900 04 05 amp DCS800 S02 1000 04 05 400 V 828 V Thyristor modules 3 6 ADC3400060P0001 TTS70Nox MT36950q Cooling fan 230 v 5060Hz 1 1 oabtresoreooo1 _waE260 Ho6 10 OO oOo O Thyristor modules 3 6 3ADCs4002P0000 TT425Nex moco x DESCRIPTION 2 Q 4 Q CODE TYPE DATA NOTES Tnyristor modules 3 6 saDcsooosepooor TrS 0Nex mrss 25 90 DC5800 501 0900 04 05 amp DCS800 502 1000 04 05 8171 400 V 828 V UUU Tiyrstor modules
44. 0A 1500V Flusiwend contactfuse Module contains 59 00 DCS800 S01 4000 04 05 amp DCS800 S02 4000 04 05 400 V 500 V DESCRIPTION CODE TYPE DATA NOTES Thyristor 6 12 3ADC340088PO001 T980 3300px Semiconductor fuses 6 6 DCA0012830P0001 UR 3000 A 660V Flush end contact fuse Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 156 DCS800 S01 4000 06 07 amp DCS800 S02 4000 06 07 600 V 690 V Thyistr e 12 8ADC340046P0002 5STP332800x Semiconductor fuses 6 6 8ADC770080P0002 UR3000A 1000V _ Flush end contact fuse 61 00 DCS800 S01 4000 08 amp DCS800 S02 4000 08 800 V Thyistr 6 12 3ADC340046P0002 5STP3328Lxx Semiconductor fuses 6 6 8ADC770080P0002 UR3000A 1000V Flush end contact fuse 62 00 DCS800 S01 4000 10 amp DCS800 S02 4000 10 990 V Thyistr 6 12 3ADC340084P0001 5STP3B0 x Semiconductor fuses 6 6 3ADC770030P0000 UR2500A 1250V_ Flush end contaotfuse 62 10 DCS800 S01 4000 12 amp DCS800 S02 4000 12 1200 V Tiviso ANC 1 sApcsaowroi sstpssamx SS Semiconductor tuses 6 6 SADCr70080P0006 UR 3300A 1500V_ Flush end contact fuse 63 00 IDCS800 S01 4800 06 07 amp DCS800 S02 4800 06 07 600 V 690 V myso 6 1 wooo sstpasamx Semiconductor fuses 6 6 SADCr70080P0002 UR3000A 1000v_ Fiushend contact use
45. 0goP000I Tv 980 270020q Tnyristor fr DCS800 S02 40 6 3ADC340079P0001 5 STB 24 Qxx Bidirectional Controlled Thyristor BCT Puls transformer boar 1 3ADT220090R0043_ SDCS PIN 48__ SDCS PIN 48 replaces SDCS PIN 41 Puls transformerboard 2 sBSE004939RI003 SDCSPIN46 ony wsedforBCTs DCS800 S01 2500 08 amp DCS800 S02 2500 08 800 V Thyristor for DCS800 S01 2 0 6 3ADC340087P0001_ Tv 989 2770xxx I ThyristorforDCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qxxx Bidirectional Controlled Thyristor BCT Puls transformer board 1 3ADT220090R0043 SDCS PIN48 _ SDCS PIN 48replaces SDCS PIN 41 Puls transformer board 2 3BSE004939R1003 sDcs PIN46 onlyusedforBCTs Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 154 Thyristor for D0S800 501 2 0 e saDcesoossrooor Tosso Thyristor for D6S800 802 4 6 3abcs40079P000T 8 STS 24 Gux Brediona Controlled Trysor GOT Puss transformer bora 1 SADT220090R0043 SDOSPIN48 SDCS PIN 48 replaces SDCS PIN H Puls tansformerboard 2 968E004999R1008 SDCSPIN46 loiywsedforBCTs Thyfistor for D0S800 S01 20 6 3ADG340046P0002 SSTP 332810 Thyrstor forDCS800 502 4 0 6 3aDca40079P0001 5 STB 2400x Bdieciona Contolea myrtor BCT Puls transformer board 1
46. 3B0060 1 Q 60 A 4 3ADT209019R0211 DCF503B0060 DCF504B0060 4 Q 60 A 1 3ADT209019R0212 DCF504B0060 Fan for DCF50xB0060 2 GHSN700002P0001 AC220V 8556V Fan M55 M56 for DCF50xB0060 Item 8 06 Overvoltage protection DCF506 for fieldexciter DCS800 S0x 0020 0520 20 A 520 A 8 06 Overvoltage protection DCF506 for fieldexciter DCS800 S0x 0020 0520 20 A 520 A DESCRIPTION QTY X COD TYPEDATA NOTES Control board DCF505 500 1 3ADT220090R0021 SDCS FEP 1400V forDCFS05 500 Overvoltage protection field 1 DCF1127101R0001 DCF506014051 Field exciter25A 100A Overvoltageprotectionfieid 1 DCF1127119Rooot DCF506 0520 51 Field exciter200A 520A Item 8 07 Common parts for DCS800 A Enclosed Converters Common parts for DCS800 A Enclosed Converters DDO connection board 1 3ADT220090RO014 SDCSIOB21 24VDC 48VDC digital A9 UDO connection board 1 3ADT220090Ro013 SDCS IOB 22 115 VAC digital A9 DDO connection board 1 3ADT220090R0023 SDCS I0B 23___ 230 VAC digital A AVAO connection board 1 3ADT220090R0020 sDcsoB 3 Analog and encoder A10 Item 8 08 Parts for DCS800 R Rebuild Kit Pusemtfacebord 1 1 aabT220000R0009 SbceREBi SOS Puse amplifier board 1 1 3AbTz2000R0 socsresa Pulse distribution board 1 1 aADT309300R0001_ SbceREBa Appendix A Spare
47. 501 DCS800 Service Manual e e 35 OnBoard bridge and thyristor modules Nominal mounting torque Type Electrical Thyristor module connections to heat sink 20 mm block MCC 26 44 56 95 2 5 4Nm 2 5 4Nm Nominal mounting torque for OnBoard bridge and thyristor modules T 8 10 11 12 13 Reconnect all I O plugs at the SDCS CON 4 X3 to X7 and the plugs at the 14 15 Reinstall the current transformer make sure its position is correct Reinstall the busbars make sure the correct torque is applied according to table Nominal mounting torque for OnBoard bridge and thyristor modules on page 35 Reconnect all gate leads to the thyristor module Reinstall the SDCS PIN 4 board Reconnect all cables and plugs at the SDCS PIN 4 Snubber resistor X30 X31 temperature sensor X22 current transformers X8 X4 X5 OnBoard excitation X8 X9 X11 use proper winding direction and amount of windings for T100 gate leads first X16 X18 then X15 X17 OnBoard excitation line voltage X1 X2 X7 all plugs X10 X96 X99 and all flat cables X12 X13 X37 use the lock connectors at the SDCS PIN 4 econo the flat cables at the SDCS CON 4 X12 X13 X37 and re hinge the electronic tray Reconnect the grounding plug and the holding screw at the electronic tray SDCS DSL 4 X51 to X54 Reinstall the intermediate cover all plug in options and the design cover Exchange of Thyristors fo
48. 8 09 13 L AMC DC BAT SKE MS DOS Batch File 06 10 008 17 14 ERead me 4KB ME File 17 10 2008 16 30 Service 3ADW000195R0501 DCS800 Service Manual e e 130 Connect the DCS800 directly with the PC fiber optic cable from SDCS COM 8 channel 3 to 1 PCMCIA adapter NDPA 02 with NDPC 12 or 2 USB adapter RUSB 02 Switch on the DCS800 Set Ch3 HW Config 70 21 Ring Set Ch3 NodeAddr 70 22 1 Start firmware download by a double click on file L_AMC_DC BAT Date Modified COM 8 88x160 zip 680 KB Winzip File 15 12 2008 17 07 5 Files File Folder 16 12 2008 09 13 Prog File Folder 16 12 2008 09 13 El AMC DC BAT SKB MS DOS Batch File 06 10 2008 17 14 E Read me 4KEB ME File 17 10 2008 16 30 ADOS 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 Com8SWYVersion 4 11 for proper firmware version Set Ch3 HW Config 70 21 back to its original setting Set Ch3 NodeAdar 70 22 back to its original setting Re connect the drive to the DriveWindow network Service 3ADW000195R0501 DCS800 Service Manual e e 131 Set type code The type code TypeCode 97 01 is preset in the factory and is write protected It identifies the drives current voltage temperature measurement and its quadrant type The type code can be changed as whole or individually To
49. Anti parallel B6 bridges with branching fuses 2 Disconnect the branching fuses of the defective branches 3 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 4 Ina 4 quadrant converter change both thyristors clamped between the same heatsinks at once Note Because Disc Type semiconductors need a certain compression force to operate properly a measurement outside the clamped heat sinks might be wrong To be sure which thyristor is broken change only one thyristor clamp the heat sinks again and repeat step three Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 46 Remove faulty thyristor 1 Remove the screws of the DC busbars and branch fuses preventing the stack to be prized open Note It depends on the location of the defective thyristor which DC busbar and fuses have to be disconnected 2 Write down the direction and location of the thyristors to be removed and mark their gate leads 3 Remove the gate leads if possible 4 Loosen the mounting clamp see fig Aluminum spring with welded indicating spring on page 47 at the top of the thyristor stack Attention While loosen the mounting clamp the indicating spring must be pulled out a little otherwise the spring will be damaged 5 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks see fig How to use the disassembly tool page 46
50. DC busbars via flexible copper busbars These busbars consist of 10 layers of pre shaped sheet copper This construction is able to compensate for small changes in length caused by temperature rise when current is flowing The screw fixings between heatsink and flexible 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 4 for the converter fan and for other auxiliaries Open the cabinet s and module s door if needed secure them Seta latching torque spanner to 25 Nm 18 lb ft A 17 mm nut is needed too Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 138 Check the torque of the screws marked within picture Power part 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 screws ta be checked Screws to be checked screws ta be checked Screws ta be checked located behind the busbar Power part of a converter module type D7 Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 139 Check the door air filters Door filters Clocked up filters prevent proper coo
51. DCS800 Service manual DCS800 Drives 20 to 5200 A m DCS800 Drive Manuals DCS800 Quick Guide DCS800 Tools amp Documentation CD DCS800 Converter module Flyer DCS800 Technical Catalogue DC S800 Hardware Manual DCS800 Hardware Manual DCS800 update DCF503B DCF504B wm gt o e o co O T A Technical Guide CC AMDB Jx j Service Manual DCS800 1 SADWoootg____ x x 12 PulseManual 2 23 S3ADWO0f190 dx J j CMA2Board o S3ADWO0139 de J j Flyer Hard Parallel 3ADwoo0218___ x late DriveTools o 0 0 o J j j 3 05 ee ee ee e ee eee Ec LE p AAA AAA PU INN CR EEE A A i NA AE AE META PLC Programming with CoDeSys CoDeSys_V23 x ix A eh 61131 DCS800 target tool description Application Program 3ADW000199 p Xx NS IO E E RI a A AE Eo eq DCS800Crae Drive J j DCS800CraneDriveManulsupp 3ASTO443 0x NENNEN CNN I NNI LLL loas le e alo ee E E SE EY AE AAA AA AAA eli sp og spe cr o Roque cp e g T DCS800 Crane Drive Product note PDC5 EN REVA ri 4 AAA DCS800 Winder ITC AAA x A AY DCS800 E Panel Solution _____ xum A E A ee HER E NM PR ENS tt A AAA MNAE AE EA ETE DCS800 AEnclosedConveters
52. I second thyrstortype 42 00 DCS800 S01 2050 05 amp DCS800 S02 2050 05 500 V Thyistr 6 12 3ADC340081P0001 T1329Nx0x original thyristor type Semiconductor fuses 6 6 3ADC770010P0011 UR 1500 A 660 V _ Screwtypefuse 1 my O 1 SADcs4oesPo0p Tio second thyrstortype Semiconductor fuses 6 6 SADCr70010POO1 UR 1500A 660V_ Screw type fuse Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 153 43 00 DCS800 S01 2050 06 07 amp DCS800 S02 2050 06 07 600 V 690 V Thyistr 6 12 3ADC340081P0001 T1329Nxx originalthyristortype _ __ DCS800 S01 2050 06a 07a 8 DCS800 S02 2050 06a 07a 600 V 690 V Thyristor CT 6 12 3ADC340098P0001 Ttxxx24 second thyristor type DCS800 S01 2500 04 05 8 DCS800 S02 2500 04 05 400 V 500 V ThyristorforDCS800 801 2 0 6 3ADC340089P0001_ T989 3030xx 0 O Thyristor for DCS800 802 4 6 sADC340079P0001_ 5STB24Q0x _ Bidirectional Controlled Thyristor BCT Puls transformer board 1 3ADT220090R0043 SDCS PIN 48 _ SDCS PIN 48replaces SDCS PIN 41 Puls transformer board 2 3BSE004939R1003 SDCS PIN 46 lonlyusedforBCT s Z 45 00 DCS800 S01 2500 06 07 amp DCS800 S02 2500 06 07 600 V 690 V Tinyrstor fr DCS800 S01 22 6 sADCS40
53. S800 501 1500 04 05 amp DCS800 502 1500 04 05 400 V 500 Vj Twist e 12 3Abcsw2P00i TAR _ Semiconductor fuses 6 6 3Apcz7000P0000 UR 1250A 600V Screw type fuse SSCS 34 90 _ DCS800 S01 1500 06 07 amp DCS800 S02 1500 06 07 600 V 690 V Two 6 12 SAD C30008P0001 TIMO Semiconductor fuses 6 6 aapcrromeroorz UR1100A 1260V Screw type use DCS800 S01 2000 04 05 amp DCS800 S02 2000 04 05 400 V 500 V Thyristor 6 12 3ADC340102P0000 T2 XXxxx Semiconductor fuses 6 6 8ADC770010P0012 UR1600A 660V Screwtypefuse gt gt gt Ryo 6 34Dcs4oworooi Tv 989 2700 SSC Semiconductor tuses 6 sabc770009P0013 UR140A M00V Screw type fase Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 152 Item 40 00 to 49 00 Modules D6 1900 A 3000 A 400 V 500 V 600 V 690 V and 800 V Power supply board 1 1 3ADT315100R1001 SDCSPOW4 gt S Power interface board 1 1 3ADT220090R0006 SDCSPINS Air Flow detector P1 1 1 DCF1066659p0001 P233A AHC _ _ 3 3u 74135 DC5800 501 1900 08 amp DCS800 502 1900 08 800 V OOOO O UOO muito 6 o 3ADC340081P0007 Trono origina myristorype Tyr 6 1 sAocoooePonpi TIZ
54. Thyristor problems can be noticed differently A fuse is blown This is an indication that a strong overcurrent has happened due to one of the following reasons An internal short circuit between the phases line side because of a defective thyristor short circuit inside a thyristor from anode to cathode An internal short circuit between the phases line side because of circulating current in a 4 Q converter malfunction of the control electronics no thyristor defective An external short circuit at the DC terminals of the converter without sufficient impedance A commutation fault during generating active braking with high current high EMF and with low AC voltage of a 4 Q converter Note In case of parallel fuses If one of the parallel fuses is blown all parallel fuses have to be changed The undamaged fuses might be half blown and will blow with the next high current Fault Tracing Thyristors 3ADW000195R0501 DCS800 Service Manual e e 23 DC current pulses measured by an oscilloscope Connect an oscilloscope to the fixed AO l act X4 9 10 on the SDCS CON 4 or X4 5 6 on the SDCS IOB 3 and check for the proper amount of current pulses li e 2 00ms A Netz Y 810 V E 10 040 3 u 45 40 T Six current pulses in positive direction There should be six current pulses in positive direction In case of a 4 Q converter also the six current pulses for the negative direction have to
55. V Thyistr 6 12 3ADC8340086P0001 TV98927000x Semiconductor fuses 6 6 3ADC770030P0003 UR1800A 1250V Flush endcontactfuse 53 00 DCS800 S01 2600 12 amp DCS800 S02 2600 12 1200 V Thyistr 6 12 DCAO0012066P0001 5STP28box Semiconductor fuses 6 6 3ADC770025P0001 UR1700A 1500V Flush endcontactfuse 54 00 DCS800 501 3300 04 05 amp DCS800 502 3300 04 05 400 V 800 V myso 6 te sAxcseoesroo reswaosoex Semiconductor uses 6 6 Dcaoo12821Po001 UR 2500 A7660 V Fiushend conagus 5530 D C5800 501 3300 06 07 amp DCS800 502 3300 06 07 600 V 690V mysw 6 te sAxcmiooreoo Tvoee z7r0mx SSSSSOSC CS Semiconductor tuses 6 6 DcAoozessPoo uR2500A 1000V Fiusmend conac tuss 56 00 DCS800 501 3300 08 amp DCS800 502 3300 08 800 Vj SECTS Two f 6 1 sApcwooereopi wvosozrroo O O O OoOO o o o o y O Semiconductortases 6 6 Dca0o12856P0001_ UR2500A 1000V _ Flushrend contactfuse __ Two 6 1 SApcwoePoo sSTP38Qox Semiconductor fuses 6 6 sa0770030P0005 UR2500A 1250V _ Flushrend contactfuse _ Ty az SApcwoPoo sswP38Qex Semiconductor fuses 6 6 8ADG770030P0006 UR230
56. _ Pulse Encoder Interface TTL 1 3AFE68654947 RTAC 08 517 I O Extension Adapter 1 3AFE68286778_ AMAT Item 8 04 to 8 05 Field exciters FEX 425 Int DCF803 0035 DCF503 4B DESCRIPTION QTY CODE TYPEDATA NOTES FEX 425 Int 1 0 25A 1 3ADT209022RO001 FEX 425nt intemal fieldexciterforD5_ FusesforFEX425 nt 3 3aDC770032P0025 KTK25 25A 600V DCF803 0016 1 Q 160A 1 3ADT209027R0001 DCF8030016 Complete unit DCF803 0035 1 0 35A 1 3ADT209023R0001 DCF803 0035 Competeunt gt Semiconductorfusesfieid 3 3ADT730004RO001 UR10A 660V Forfiedcurent 6 ADC Semiconductor fuses fied 3 3ADT730004R0002 UR16A 660V Forfieldcurent 12 ADC Semiconductor fuses field 3 3ADT730004R0003 UR25A 660V Forfiedcurent 16 ADC Semiconductor fuses fied 3 3ADT730004RO004 URSOA 660V Forfieldcurent 35ADC Semiconductor fuses field 3 3ADT730004R0005 UR63A 660V Forfieldcurent gt 50ADC____ Appendix A Spare Parts List 3ADW000195R0501 DCS800 Service Manual e e 146 8 05 Field exciters 50 A and 60 A overvoltage protection included DESCRIPTION QTY CODE TYPEDATA NOTES DCF503B0050 1 Q 50A 1 3ADT209019R0201 DCF503B0050 Competeunt DCF5040050 4Q 50A 1 3ADT209019RO202 DCF50480050 Competeunt DCF50
57. a T z uri 4 12 52 de cai VE G START Starts the drive in local control from DCS800 panel and when the Start up assistant is used E il D el n E FEA H ta m A shows current function of the two soft keys and the clock Soft key 2 Function varies and is defined by the text in the lower right corner of the LCD display Down Scrolls down through a menu or li displayed in the middle of the LCD Display Decrements a value if a parameter Is selected Decrements the reference if the upper right corner is highlighted in reverse video Help Displays context sensitive information when the button is pressed The information displayed describes the item currently highlighted in the middle area of the display DCEBOD FW pan sum dsf Press Soft key 1 until the main menu is shown see picture above Press LOC REM button display will show LOC on the upper left side Exchange of SDCS CON 4 76 Press Soft key 2 MENU Scroll with UP DOWN buttons to menu item PAR BACKUP Confirm with Soft key 2 ENTER Select UPLOAD TO PANEL and confirm with Soft key 2 SEL the upload progress bar will be shown on the display Successful upload will be shown by message Confirm with Soft key 1 OK Press Soft key 1 until back to the main menu see picture above The actual parameter set is now stored in the DCS Control Pa
58. age nf 5 a Target filas 15 LED mot ESN JF C E LAICA asas ee EN E A c P 5 SA ee ma m E HERRIA Service 3ADW000195R0501 DCS800 Service Manual e e 125 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 Ta Doom Ubi A ee Ae Be Fa AAA ig EX B EX i ta CD E C 00 D E C D A YE Fraide Service 3ADW000195R0501 DCS800 Service Manual e e 126 Connection Type Select connection BOOT Mode Select Interface Direct Connection tick Kernel already resident and confirm with Next Connection Type D a pal xc P y TO TERR Service 3ADW000195R0501 DCS800 Service Manual e e Programming Options Protection Automatic and Messaging Advanced confirm with Finish Programming Options eN arae Ho 43 Drive mat P tt il o i FO Now the project for the text file is finished FLASH Development Toolkit 2 2 NES 8 ww o Wi g mx fie Workspace DCSS00 User defined 2 Projects Ele sal DCS800 Firmware user defined 8 Device Image m Target files a ER E DCS800 Text user defined 9 Device Image wf Target files 3ADW000195R0501 DCS800 Service Manual e e 127 Service 128 Close download tool When closing the FDT2 2 confirm with Yes
59. aintenance i 22 How to detect a faulty thyriStor e 22 AUSES DION Desine ea EE RENE 22 DC current pulses measured by an oscilloscope 23 TAN SIO RATA ONOS silice 23 RIDICE MONTO emer 23 ROWO Mara Taula YASTO ers ria a Ded iA CE dob amos 24 Converters size D1 to D4 20 1000 A i 24 OA cy ere ee heel 24 Converters size D5 D6 and D7 900 5200 A 25 BION TOSE nale 25 PIDDE MONIO enea a ii 25 Handling the Semiconductors 27 General Instruction how to handle the Semiconductors 27 Exchange of Thyristors for Size D1 to D4 29 Installation of OnBoard bridge and thyristor modules in converters size D1 to D4 0E GELS eletta 29 o ROO PENITUS 29 FING tatlivAinyistor moqueta 29 Remove faulty thyristor modules e 30 Install Mew THYTISIOM MOGUICS usara ade 34 Table of contents 3ADW000195R0501 DCS800 Service Manual e e 14 Remove faulty OnBoard bridge V1 oocccccccccoccconcnconcnnccncnononononnnnonannonorononnnnonanoss 36 Install new OnBoard bridge V1 e 36 OnBoard bridge V1 and thyristor module location in DCS800 S01 2 Q units 37 OnBoard bridge V1 and thyristor module location in DCS800 S02 4 Q units 38 OnBoard bridge and thyristor module terminals 39 Exchange of Thyristors for Size D5 41 Installat
60. ardware Manual BADW000194 describes all hardware Introduction 3ADW000195R0501 DCS800 Service Manual e e 17 components of the DCS800 their connections and settings e g jumpers The DCS800 Firmware Description GADW0001983 gives an overview of the DCS800 firmware describes all parameters describes the function of the DCS Control Panel gives support in case of faults and alarms and gives information about communication The above listed documentation can be found on the CD ROM being attached to the DCS800 Quick Guide 3ADW000191 Storage and transport If the unit has been in storage prior to installation or is transported to another location care must be taken to ensure that the environmental conditions are complied with see Hardware Manual Name plate and type code For purposes of identification each thyristor power converter is fitted with name plates stating the type code and the serial number which serve for each unit s individual identification The type code contains information about the characteristics and the configuration of the unit ABB Automation Products W Type DCS800 S02 0025 05 u K454 DEE Ee pe Tum DT IND CONT EQ Production year Rated input voltage Rated output current 2006 and week 29 Rated input current Rated internal field exciter current Rated fan voltage Plus code Example of a name plate Introduction 3ADW000195R0501 DCS800 Service Manual e e 18 Type code The type c
61. are intended for all who install the drive Handle the unit carefully to avoid damage and injury WARNING DCS800 sizes D4 D7 The drive is heavy Do not lift it alone Do not lift the unit by the front cover Place units D4 and D5 only on its back DCS800 sizes DS D7 The drive is heavy Lift the drive by the lifting lugs only Do not tilt the unit The unit will overturn from a tilt of about 6 degrees Make sure that dust from drilling does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction Ensure sufficient cooling Do not fasten the drive by riveting or welding Safety instructions 3ADW000195R0501 DCS800 Service Manual e e 10 Operation These warnings are intended for all who plan the operation of the drive or operate the drive Ignoring the instructions can cause physical injury or death and or damage to the equipment WARNING e Before adjusting the drive and putting it into service make sure Safety instructions that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the base speed Do not control the motor with the disconnecting device disconnecting mains instead use the control panel keys and or commands via the l O board of the drive Mains connection You can use a disconnect switch w
62. at sinks Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 67 Remove faulty thyristor 1 Remove the screws of all DC AC busbars preventing the stack to be prized open Remove the branch fuses if the defective thyristors are covered by them Note It depends on the location of the defective thyristors which DC AC busbars have to be disconnected 2 Loosen the screws holding the backplate and make sure the backplate can move up screws backplate Backplate 3 Write down the direction and location of the defective thyristors to be removed and mark their gate leads 4 Remove the gate leads if possible 5 Loosen the mounting clamp at the top of the thyristor stack mounting clamp indicating spring Handling of indicating spring and mounting clamp Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 68 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 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks WUD GUO et nm 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 t
63. be checked Thyristor diagnosis Also the thyristor diagnosis provided by the firmware can be used Switch the drive to local mode DriveWindow DriveWindow Light DCS Control Panel or local I O Start the thyristor diagnosis by means of ServiceMode 99 06 ThyDiagnosis and set On and Run within 20 s During the thyristor diagnosis the main contactor will be closed and the thyristors are checked The field current is not released while the thyristor diagnosis is active and thus the motor should not turn When the thyristor diagnosis is finished check Diagnosis 9 11 for details Ripple monitor The ripple monitor indicates that the ripple of the DC current is much higher than normal In such a case most often one thyristor does not work It s missing current contribution causes a deep dip in the direct current The structure of the current loop current controller will force the other thyristors to compensate the dip by a certain overcurrent in order to keep the average current constant Such a compensation results in a ripple monitoring fault during motoring mode operation with a lt 90 The reason for a current less thyristor may be Fault Tracing Thyristors 24 A fuse has disconnected one of the six thyristors This is possible only for converters with 900 5200 A six internal branch fuses A converter with three external fuses stops working completely at once when one of the three AC input fuses inte
64. condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltage which can cause physical injury or death and or damage to the equipment caused by electricity which can result in physical injury or death and or damage to the equipment Electrostatic sensitive devices warning warns of electrostatic i 4 discharge which can damage the equipment f General danger warning warns about conditions other than those Safety instructions 3ADW000195R0501 DCS800 Service Manual e e Installation and maintenance work These warnings are intended for all who work on the drive motor cable or motor Ignoring the instructions can cause physical injury or death and or damage to the equipment WARNING A e Only qualified electricians are allowed to install and maintain the drive e Never work on the drive motor cable or motor when main power is applied Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 Voltage between drive input phases U1 V1 and W1 and the frame is close to 0 V 2 Voltage between terminals C and D and the frame is close to 0 V e Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off e Do not make any insulation resistance o
65. d other damage Avoid touching the contact surfaces Do not lift the semiconductor with the gate wire Do not lift the semiconductor by touching the current contact surfaces Do not damage the welding flange or the contact surface Before you start work disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrically and mechanically safe condition Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 66 Find faulty thyristor 1 Find the defective branches by performing an OHM test both polarities between U1 V1 W1 and C1 D1 see picture Anti parallel B6 bridges with branching fuses on page 45 2 Remove the AC busbars of the defective branches 4 quadrant converter 3 Remove all screws of the DC busbars either above or below the fuses of the defective branches Note The connection is made with a screw socket which may fall down when all screws are removed bose AC ear Isolator removed screws DC busbars Location of busbars 4 Puta small piece of isolator e g paper between the DC busbar and the heat sink to insulate the anti parallel thyristors from each other 5 Find the defective thyristors by performing an OHM test both polarities over their heat sinks 2 quadrant converter 3 Find the defective thyristors by performing an OHM test both polarities over their he
66. d S Save As Save AI Recent Files F Close File Recent Workspaces P Exit Service 3ADW000195R0501 DCS800 Service Manual e e 115 Name new workspace Name the new workspace choose its location and confirm with OK Mew Workspace D CSS User defined C Program FilessHitachiFD T 2 2 ww arkspaces LK _ cane Choose Yes FLASH Workspace Manager e Service 3ADW000195R0501 DCS800 Service Manual e e 116 Create the project for the firmware file Name the new project and confirm with Next ng sal Soo JP TRA ACER UR Ri ws det ET gi De c ENEG nof Em TES J DA ES Bg O A La DCS500 Firmware user defined Service 3ADW000195R0501 DCS800 Service Manual e e 117 Choose Device And Kernel Select Device H8S 2633F and confirm with Next Choose Device And Kernel Hitachi 4 04 C Program fileziHitachiF D T2 2 kernel 1 0 nn Service 3ADW000195R0501 DCS800 Service Manual e e 118 Communication Port Select the proper COM port Select Baud Rate 38400 un tick Use Default Baud Rate and confirm with Next x Pris EU De tu j om l OC xe BE i n DL gt Ts i SI TUNE Device Irnage nf 5 a Target filas 15 LED mot ESN JF C E LAICA asas ee EN E A c P 5 SA ee ma m E HERRIA Service 3ADW000195R0501 DCS800 Service Manual e e 119 Device Settings
67. d is done via a PC COM Port Attention If there is no COM Port available an adapter PCMCIA to COM Port has to be used Adapters USB to COM Port do not work reliable The download of the firmware is done in two steps 1 first the firmware file itself and 2 then the text file Attention A firmware download does not influence the parameter settings The previous parameter settings are kept De energize the DCS800 electronics Set jumper S5 on SCDS CON 4 from position 3 4 to position 1 2 e i IL dps nad da A me ES pa J n ia br oats ipa ILS d E n a POSS coro PIDIO Connect a RS232 cable between a PC COM Port and DCS800 X34 Energize the DCS800 electronics the 7 segment display shows i 3ADW000195R0501 DCS800 Service Manual e e 97 Start download tool Start the Hitachi Flash Development Toolkit 2 2 by means of Start Programs Hitachi Flash Development Toolkit 2 2 Flash Development Toolkit 2 2 Choose workspace Mark Open an existing Workspace Confirm with OK Welcome to the FLASH Development Toolkit CABE DCS S00 Fimware DCSS00 1 3en DCS800 fdt Service 3ADW000195R0501 DCS800 Service Manual e e 98 Select the workspace in directory C ABB DCS800 Firmware CON 4 Ver x x Confirm with Open 2 x Look ir E Vert fem ds Firmware a 7 File name pcs Bu fdt Files af tupe EDT Workspace Files
68. e of the cooling fan versus ambient temperature Where used DCS800 S0x 0140 y1 DCS800 S0x 0260 y1 DCS800 S0x 0350 y1 DCS800 S0x 0520 y1 DCS800 S0x 0820 y1 D4 4 DCS800 S0x 0610 y1 1x W2E200 115 V DCS800 S0x 0820 y1 plus code E171 DCS800 S0x 1000 y1 DCS800 S0x 1000 y1 plus code E171 DCS800 S0x 2000 y1 Aging of the components result in 1 Increased vibration due to the imbalance of the cooling fan can last for several months 2 Increased temperature due to the stopped cooling fan drive trips with overtemperature Preventive Maintainance 3ADWOO0195R0501 DCS800 Service Manual e e 143 9 years preventive maintenance Following additional actions have to take place Replace the power interface board SDCS PIN 4 of units D1 to D4 SDCS PIN 4 The SDCS PIN 4 is located between the heat sink and 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 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 Di to D4 Aging of the electronic card result in 1 Damage other devices 2 Trip the drive and cause break down time Replace the power supply board SDCS POW 4 of units D5 to D7 and DCS80
69. ement if needed P Performance of on site work commissioning tests measurements etc R Replacement if high ambient temperature or cyclic heavy duty Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 137 Annual preventive maintenance The following actions have to take place C Check the cooling fans of units D1 to D7 The lifetime of the cooling fan is about 30 000 to 45 000 hours depending on the converter type The actual lifetime depends on the usage of the DCS and the ambient temperature Fan failure can be predicted by means of increasing noise from its bearings and a gradual rise of the heatsink temperature If the DCS operates in a critical part of the process it is recommended to replace the fan once the above mentioned symptoms appear Check the cooling air pressure switch of units D6 and D7 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 switched off 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
70. emiconductor component is such that it requires a certain compression force to operate The prevention of overheating of the component essentially depends on a good heat dissipation between the semiconductor and the conducted heat sink It is thus important that all joints have good thermal and electrical conduction Required Tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules Torx screwdrivers TX10 TX20 TX25 Torque spanner for electrical connections 13 Nm M8 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts 17mm ring spanner for fuse and busbar connections 24 mm ring spanner for press clamp Tissue paper solvent e g ethanol Thermal joint compound type BECHEM RHUS SU 2 grease Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 001 P 0001 Disassembly tool DCF 1066721 P1 Note For more detailed information about the wiring of the power part see Hardware Manual Therefore strict observance of the build in instructions given below is of utmost importance Make sure that the new component can replace the old one in accordance with the spare part list see Appendix A All thyristors are always mounted in the same direction independent of current voltage number of quadrants 2 Q or 4 Q left or right side connection Semiconductors and heat sinks are to be handled carefully to avoid scratches an
71. en the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 58 Install new thyristor 1 Ensure that the new thyristor is of the correct type see appendix A Keep the semiconductor and its surroundings clean lf necessary clean them with a piece of tissue paper moistened with solvent Note Do not touch the polished surfaces of the thyristor Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of heat conducting paste on both sides of the thyristor if necessary use a rubber spatula 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 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 Turn the thyristor so that the gate leads point in the right direction When changing BCT s make sure that gate A is in front see fig Gates of BCT on page 53 Connect the gate leads if possible Insert first the top DC busbar plate and then
72. ete now Service 3ADW000195R0501 DCS800 Service Manual e e 107 Add firmware or text files Start download tool Start the Hitachi Flash Development Toolkit 2 2 by means of Start Programs Hitachi Flash Development Toolkit 2 2 Flash Development Toolkit 2 2 Choose workspace Mark Open an existing Workspace Confirm with OK welcome to the FLASH Development Toolkit Service 3ADW000195R0501 DCS800 Service Manual e e 108 Service Select the workspace in directory C ABB DCS800 Firmware CON 4 Ver x x Confirm with Open Ope sx Look in 3 Ver 1 7en 1 Firmware Text o Dc Se00 ft File name pcs Bu fdt Files af tupe EDT Workspace Files fdt Lancel E 3ADW000195R0501 DCS800 Service Manual e e 109 Add firmware files If the firmware file to be downloaded is not shown under Target files the firmware file has to be added FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help pa ms em Sud X mmo o Z xl q workspace DCS800 2 Projects Select Firmware with a right mouse click and choose Add Files to Project from the pop up menu FLASH Development Toolkit 2 2 DCS800 Ele Edit view Project Device Image Tools Window E Add Files to Project Add Files to Project From Kernel Dir Set as Active Project Remove Project Connect to Device Erase FLASH blocks
73. eter 36 mm Second thyristor type 900 A Converter with second thyristor type T460Nxxx Id code 3ADC340105P0001 D3 5x3 5 both sides 5 Connector 4 8x0 5 L Connector 21 5 Dased on AMP60598 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 Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 44 Gate G Faston 2 8 x 0 8 mm Cathode HK Faston 4 8 x 0 8 mm Conductive plate Diameter 36 mm Second thyristor type 1200 A Converter with second thyristor type T590Nxxx Id code 3ADC340106P0001 dea D3 5x3 5 both sides 5 Connector i Auf E 4 0XU 5 IPS Connector 1 5 ased on AMP60598 Second thyristor type Gate 4 Round terminal D 2 1 5 mm Cathode 5 Faston 4 8 x 0 5 mm Conductive plate Diameter 36 mm Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 45 Find faulty thyristor 1 Find the defective branches by performing an OHM test both polarities between U1 V1 W1 and C1 D1 see fig Anti parallel B6 bridges with branching fuses on page 45 C1 V11 N SZ V24 V13 JIN SZ V26 V15 N Y V22 F15 branching fuse V147N SZ v21 v16 ZN SZ v23 V127N Y v25 eases
74. ew SDCS CON 4 accordingly 4 Exchange the SDCS CON 4 Remove the 1 Remove the DCS Control Panel and design cover old SDCS Lud d CON 4 pv 65 DCS800 Remove DCS Control Panel n E 5 F _ Maca 2s a Later Depress the locks by means of a screwdriver to remove the design y d cover Remove design cover 2 Remove all plug in options on the intermediate cover e g serial communication modules R type Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 78 extension I O modules RAIO RDIO extension modules for second encoder RTAC or resolver RRIA communication board SDCS COM 8 isolated I O SDCS IOB 2x SDCS IOB 3 and SDCS MEM 8 Memory Card 3 Remove the intermediate cover by depressing the two locks on the upper right and left hand side of the cover TN E Depress the locks to remove the design cover TR 33 0736 OSO IAS SIO he OI aa YY ey IT LIS iS 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 Q ae Y raro ie E n gt E ym 7 rm x red ye n e e ve gt Disconnect all plugs from SDCS lo CON 4 and SDCS DSL 4 boards SEEN a s Disconnect all plugs Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 5 Remove screws and studs Remove these screws and studs t gt
75. fdt Lancel E Activate firmware download Select Firmware with a right mouse click and choose Set as Active Project from the pop up menu FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help pa qs m Sad amp renje s Jai Hrs Workspace DCSS800 2 Projects Add Elles to Project Add Files to Project From Kernel Dir Set as Active Project Remove Project Connect to Device Erase FLASH blocks Upload Image Blank check Cancel FLESH Operation Build Device Image Freshen all Target files Properties Alt Shift R Service 3ADW000195R0501 DCS800 Service Manual e e 99 Choose COM Port and communication speed Select Firmware with a right mouse click and choose Properties from the pop up menu FLASH Development Toolkit 2 2 DCS800 Ele Edit View Project Device Image Tools Window Help ood X 8s den ca ms Y Workspace DCSSO00 2 Projects JD De amp ddElesto Project EC Ta Add Files to Project From Kernel Dir Set as Active Project Remove Project Conmect to Device Erase FLASH blocks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target files Properties Alt Shift R 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 Projec
76. few seconds Dry all surfaces 5 Centre the thyristors by means of the spring pins Note Be sure that the thyristor is installed in the right direction Do not pinch or cut the gate leads or any other cable 6 Turn the thyristor so that the gate leads point in the right direction Loose _ condition N A UL TORQUE INDICATING SPRING Aluminum spring with welded indicating spring Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 48 7 Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks Note The indicating spring is a very sensitive instrument and must be handled with care 8 Tighten each nut in turn half a turn at a time with the help of a ring spanner until the indicating spring clicks into position correct torque see fig Aluminum spring with welded indicating spring on page 47 Do not tighten the screws any further Note The correct torque is indicated by means of the welded indicating spring 9 Perform an OHM test to make sure the thyristor is ok 10 Reconnect the DC busbars branch fuses and all other dismantled parts 11 Perform an OHM test between U1 V1 W1 and C1 D1 to make sure the power part is ok c Dex left stack right stack rear front front rear Dalai EAA View from the
77. gize the drive or disconnect the tool while the seven segment display shows the u Wait until the 7 segment display shows and 5 3ADW000195R0501 DCS800 Service Manual e e Disconnect tool 105 Now FDT2 2 has to be disconnected Select Text with a right mouse click and choose Disconnect from the pop up menu FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help 5 e Saa Be zd xil fe Workspace DC3800 2 Projects Es Firmware I Add Files to Project 24 Add Files to Project From Kernel Dir Set as Active Project Li Remove Project Disconnect Erase FLASH blocks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target files Properties Alt Shift F A 0001E000 H OOOIEOUFF Length H OOC H OOOLELOO H OOOLELTF Length H OOC A o0001E150 H OOUS64FF Length H OOL 153 E programmed in 15 seconds Image successfully written to device Download operation complete Al IA Dependencies A Firmware A Text Disconnect fram the device 3ADW000195R0501 DCS800 Service Manual e e Service 106 Close download tool When closing the FDT2 2 save the workspace only if firmware files or text files have been added FLASH Workspace Manager x The workspace DCSS00 has been modified Would you like to save your changes Cancel Yes The firmware download is compl
78. grounding e g conductive sleeves of screened cable entries at the cabinet lead through plate e Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance grounded over 30 ohms power system Note e Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations e As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Safety instructions 3ADW000195R0501 DCS800 Service Manual e e ta Safety instructions Printed circuit boards and fiber optic cables These instructions are intended for all who handle the circuit boards and fiber optic cables Ignoring the following instructions can cause damage to the equipment WARNING The printed circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Use grounding strip ABB order no 3ADV050035P0001 WARNING Handle the fiber optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt The minimum allowed bend radius is 35 mm 1 38 in 3ADW000195R0501 DCS800 Service Manual e e Mechanical installation A These notes
79. he thyristor and the pins are not damaged while removing the thyristor Exchange of Thyristors for Size D7 3ADW000195R0501 DCS800 Service Manual e e 69 Install new thyristor 1 Ensure that the new thyristor is of the correct type see appendix A of this manual Keep the semiconductor and its surroundings clean If necessary clean them with a piece of tissue paper moistened with solvent Note Do not touch the polished surfaces of the thyristor Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of heat conducting paste on both sides of the thyristor if necessary use a rubber spatula Prepare disk type thyristor 3 Noo 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 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 Turn the thyristor so that the gate leads point in the right direction Connect the gate leads if possible Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks Exchange of Thyristors
80. inance 3ADW000195R0501 DCS800 Service Manual e e 141 Where used DCS800 S0x 1900 y4 5 8 GR31M DCS800 S0x 3000 y 5 8 400 500 V L 7 asa DCS800 S0x 3000 y6 7 500 690 V DCS800 S0x 5200 y1 400 V 690 V Aging of the components result in 1 Increased vibration due to the imbalance of the cooling fan can last for several months 2 Increased temperature due to the stopped cooling fan drive trips with overtemperature Check the tightness of all terminals All 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 DI to D3 two fans How to remove the converter fans in a frame D3 four fans The manufacturers estimation for the operational time of the cooling fan is CN2B2 40 000 hours at 60 C W2E200 45 000 hours at 60 C W2E250 40 000 hours D2E160 30 000 hours at 40 C Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 142 The mayor problem is the failure of the bearings 1 1 speed A 1 2 speed LIFETIMER i A AA A UIL L Y d 20 40 60 eL 100 AWIBIEFMT TEMPERATORE CE Typical lifetim
81. ion of Disc Type thyristor in converters size D5 900 2000 A 41 REQUIFESA HOOIS wale TR 41 ISK TY DC TMV EI SIONS pc 42 FINGIIUINANYISIO rail 45 Remove faulty INVISION ai 46 Install NeWihyrisiolhcaret lalla 47 Exchange of Thyristors for Size D6 51 Installation of Disc Type thyristor in converters size D6 1900 3000 A 51 Required TOO e REA 51 PISKAVDSMIOYASIOLS pc sto 52 BC TNyIsiorsi iaia cea 53 Find TAUILY TAY VISION spora eee 54 miae aigu g ile 55 PVG Tan NSW TIVA LT 58 Exchange of Thyristors for Size D7 65 Installation of Disc Type thyristor in converters size D7 2050 5200 A 65 misero te PEU 65 FindfaultyNyristor 66 Iristall new TAY ISION uocat arbor rt 69 Exchange of SDCS CON 4 75 ec TL TU NM E 75 Required Tools NE D UU m 75 Overview SDCS CON 4 exchange i 75 Service 83 How to remove the converter fans in frames D1 to DS two fans esses 83 How to remove the converter fans in a frame D3 four fans 87 How to remove the converter fan in a frame DG nennen 92 How to remove the converter fan in a frame D7_ i 93 DCS800 firmware download iii 94 CER O RR IU UM BTE NE 94 Download SDCS CON 4 firmware seeessseesssesseseeeneee nennen nennen nennen nnns
82. ions which may require stricter safety regulations e g protection against contact by children or similar these additional safety measures for the installation must be provided by the customer during assembly 3ADW000195R0501 DCS800 Service Manual e e 11 Note e When the control location is not set to Local L not shown in the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key Safety instructions 3ADW000195R0501 DCS800 Service Manual e e 12 Safety instructions 3ADW000195R0501 DCS800 Service Manual e e 13 Table of contents Safety instructions 5 What this chapter CONTAINS cutres ritos asi 5 To WHICH products IMIS chapter AD DIGS ii dl 5 Usage of warnings and notes ie 5 Installation and Maintenance Work Lillian 6 CO MOWING Lilla 7 Mechanical INS taa O A 9 se USE T TN Es 10 Table of contents 13 Introduction 16 FOWrio use this Manlio 16 Contents ortnismantal selena ES 16 EO Or OUD Icd 16 Associated PUDICAlONS ostia le 16 Storage and Tans pOl nen onae E a N ee 17 Name plate and type code iii 17 TYDE COIE a TON 18 Current and voltage ratings e 19 Fault Tracing Thyristors 21 A ERE 21 For commissioning and fault tracing 21 Additionally for service and preventive m
83. ith fuses to disconnect the electrical components of the drive from the mains for installation and maintenance work The type of disconnect switch used must be as per EN 60947 3 Class B so as to comply with EU regulations or a circuit breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker s main contacts to open The mains disconnect must be locked in its OPEN position during any installation and maintenance work EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor nor will the drive be disconnected from any dangerous potential To avoid unintentional operating states or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals RUN drive OFF or Emergency Stop respectively control panel or PC tool Intended use The operating instructions cannot take into consideration every possible case of configuration operation or maintenance Thus they mainly give such advice only which is required by qualified personnel for normal operation of the machines and devices in industrial installations If in special cases the electrical machines and devices are in tended for use in non industrial installat
84. ling of the drive Wash dirty filters with water 60 C and detergent Check for dust corrosion and temperature inside the module cabinet The DCS will run into overtemperature faults if the heatsinks are not clean fa 4 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 at ground components must be removed Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 140 Ground components Check the quality of the supply voltage 3 years preventive maintenance Following additional actions have to take place Replace the cooling fans of 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 1 1 speed ey Sera 1 2 speed LIFETIMER IAN EEE RE n __ pg EA al ON HD d 20 40 ono eL 100 AMBIENT TElWVIPER_A TORES Typical lifetime of the cooling fan versus ambient temperature Preventive Mainta
85. nductors This chapter describes the handling of thyristors and thyristor modules Exchange of Thyristors of Sizes D1 to D4 This chapter describes the exchange of thyristors in converters sizes D1 to D4 Exchange of Thyristors of Size D5 This chapter describes the exchange of thyristors in converters size D5 Exchange of Thyristors of Size D6 This chapter describes the exchange of thyristors in converters size D6 Exchange of Thyristors of Size D7 This chapter describes the exchange of thyristors in converters size D7 Exchange of SDCS CON 4 This chapter describes the exchange of a SDCS CON 4 Service This chapter contains hardware information and technical hints Preventive Maintenance This chapter describes the measures for preventive maintenance of the thyristor converters Appendix A Spare Parts list The Appendix A contains the spare parts list of the converters Target group This manual is designed to help those responsible for planning installing starting up and servicing the thyristor power converter These people should possess basic knowledge of physics and electrical engineering electrical wiring principles components and symbols used in electrical engineering and basic experience with DC drives and products Associated publications A list of associated publications is published on the inner page of this manual s cover see DCS800 Drive Manuals Here is a list of the most important ones The DCS800 H
86. nel DriveWindow Click File then Save As Light View Options Drive Tools Communication Window Hew Online Drive Cll New Offline Drive Cbrl h Open in Browser Ctrl 0 lesi Close Save Chris Print X Ctrl F y Print Setup Exil ct Values Lir Click Save Saveas E Save in E Temp2 ck E3 Fe My Recent Documents Desktop e My Documents My Computer DE L 01 7885 T AE File name Net sue Save as type Drive Files dwp Cancel DriveWindow Click File then Parameters and Save As BE Drive Window ABB 5MP DCS 500 DI 0 1 File Edit View Network Drive Desktop Monitor Data Workspace FN al clined alal gg Parameters k Open Chrl 0 System Software k Close Graph w Status Refresh Export Prin Comment Exit Compare Download Ctrl D Par ameters ban a Prhanerliez Exchange of SDCS CON 4 3ADW000195R0501 DCS800 Service Manual e e 7 Click Save Saveas x Save in O Temp2 ex E3 File name pcs 800 Using LWL dwp Save as type Parameter files dwp Cancel AL 2 Write down type code of the drive Write down the contents of TypeCode 97 01 This information must be manually set in the new SDCS CON 4 3 Set jumpers on the new SDCS CON 4 according to the old SDCS CON 4 Copy the jumper settings S1 to S4 of the old SDCS CON 4 onto the n
87. nstructions at the beginning of this manual must be followed Negligence of these instructions can cause injury or death WARNING The printed circuit boards contain components sensitive 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 protective package that is sealed It is easiest to use the spare parts ESD package Place the protective package on the ESD mat before opening Preventive Maintainance 3ADW000195R0501 DCS800 Service Manual e e 136 Recommended regular maintenance The DCS requires very little maintenance if installed in an appropriate environment Regular inspection according to the maintenance schedule is strongly recommended Preventive maintenance prevents unexpected production stop and production loss lt 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 Maintenance schedule gt
88. ode set the type code individually by means of S ConvScaleCur 97 02 S ConvScaleVolt 97 03 5 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 MaxBridge Temp 4 17 and QuaarantType 4 15 3ADW000195R0501 DCS800 Service Manual e e 133 Type code table O None 50 S01 2050 10 S02 0820 04 S01 0020 04 S01 2600 10 S02 0820 05 5 S01 0065 04 55 S01 3000 06 105 S02 0900 07 6 S01 0065 05 56 S01 3000 07 106 S02 1200 04 8 SOt 0090 05 58 SOt 3300 04 108 S02 1500 04 9 01 0125 04 59 S01 3300 05 109 S02 1500 05 iG sotatasas feo swiswnae sto soatso006 11 S01 0180 04 61 S01 3300 07 111 S02 1500 07 12 S01 0180 05 62 S01 3300 08 112 S02 1900 08 Ho sot 0230 04 es S01 5300 12 9 802200004 16 SO1 0315 05 66 S01 4000 06 116 S02 2050 06 18 S01 0405 04 68 SOt 4000 08_ 118 S02 2500 04 19 S01 0405 05 69 S01 3300 10 119 SO2 2500 05 amp S01 0900 04 S02 0025 05 S02 3000 06 30 S01 0900 07 80 S02 0075 04 130 S02 3000 08 36 S01 1500 07 86 S02 0200 04 136 SO2 3300 12 39 S01 2000 05 89 02 0260 05 139 S02 4000 06 40 S01 2000 00 90 S02 0350 04 140 S02 40
89. ode 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 DCS800 AAX YYYY ZZ plus code Position A X Y Z B Poston aas ee TT rouets Type Standard converter module IP00 RO Rebuild system AO Enclosed converter Bridge type 1 Single bridge 2 Q 2 2 anti parallel bridges 4 Q re Rated DC current YYYY Rated current e g 0025 25 ADC Rated AC voltage 04 400 VAC 05 525 VAC 06 600 VAC 07 690 VAC 08 800 VAC 10 990 VAC 12 1200 VAC Power connection Standard D1 D6 L Left side D7 R Right side D7 a Second thyristor type D5 D6 Internal field exciter S 164 With internal field exciter external supply only D5 25 A Rebuild kit 25 A 16 A configuration 05163 Without internal field exciter only D1 D4 Fan voltage Size D4 Standard fan voltage 230 V 1 ph 5171 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 5172 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 120
90. oltage identification Converter with original Converter with second thyristor type T 1329Nxxx thyristor type T 1xxx 24 Id code 3ADC340081P0001 Id code 3ADC340098P0001 DCS800 S02 1900 08 3 800 VAC DCS800 S02 1900 08a DCS800 S01 2050 05 3 525 VAC DCS800 501 2050 05a DCS800 S02 2050 05 3 525 VAC DCS800 S02 2050 05a Parts list The current and voltage ratings of original and second thyristor type are the same but the sizes of gate and cathode terminals are different Thus it is not possible to interchange both thyristor types as spares Attention Use always the correct spare thyristor Original thyristor type Thyristor T 1329Nxxx with Id code 3ADC340081P0001 V 5 4 8x0 8 4 2 8x0 8 Original thyristor type Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 53 Gate 4 Faston 2 8 x 0 8 mm Cathode 5 Faston 4 8 x 0 8 mm Conductive plate Diameter 48 mm Second thyristor type Thyristor T 1xxx 24 with Id code 3ADC340098P0001 Second thyristor type Gate y Round terminal D 1 5 mm Cathode K Faston 4 8 x 0 5 mm Conductive plate Diameter 50 mm BCT thyristors 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
91. onverter a special thyristor clamping device is needed For 4 Q converters with anti parallel thyristors or BCT s The selection of a forward or reverse thyristor or BCT Bidirectional Controlled Thyristor is done during the disassembly Continue with related part Exchange of Thyristors for Size D5 D6 or D7 section Find faulty thyristor After a thyristor was replaced the OHM test should be done another time to make sure that all faulty thyristors have been detected If the motor is still connected to the converter the result of the measurement may be wrong If the ripple monitor fault occurred a fault tracing as described above must be carried out Check the fuses and the thyristors according to the statements before If the power section seems to be ok but still one or more thyristors don t take current something went wrong in between the firing pulse generation and the thyristor s gate in this case check ls firing pulse present on the primary side of the firing pulse transformer Isa firing pulse present on the secondary side of the firing pulse transformer Is the firing pulse transferred to the gate of the thyristor Are there all electrical connections still healthy Can the thyristor be fired with the applied firing pulse Is the pulse form of the firing pulse identical at all measuring positions Check the settings of the current controller Check the AC mains network by taking recordings of the line voltage
92. r Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 36 Remove faulty OnBoard bridge V1 1 2 3 Follow the instructions Remove faulty thyristor modules until step 8 is done Remove all connectors from the faulty OnBoard bridge and mark the connectors clearly Remove the faulty OnBoard bridge and mark it clearly as defective Install new OnBoard bridge V1 1 2 Ensure that the new OnBoard bridge is of the correct type see appendix A of this manual Remove old heat conducting compound grease from the heat sink Clean the mounting surfaces heat sink and OnBoard bridge with an appropriate solvent e g ethanol by means of tissue paper When the heat sink is clean spread out the heat conducting compound with a rubber spatula or by hand Apply a thin layer of heat conducting compound to the new OnBoard bridge opread the heat conducting compound evenly by moving the OnBoard bridge forward and backward on the heat sink 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 Tighten the screws to nominal torque according to table Nominal mounting torque for OnBoard bridge and thyristor modules on page 35 Reconnect all connectors to the OnBoard bridge Follow the instructions nstall new thyristor modules beginning with step 10 Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 37
93. r voltage withstand tests on the drive or drive modules e solate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor e When reconnecting the motor cable always check that the C and D cables are connected with the proper terminal Note e The motor cable terminals on the drive are at a dangerously high voltage when the main power is on regardless of whether the motor is running or not e Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the relay outputs of the drive system e g SDCS IOB 2 and RDIO e DCS800 with enclosure extension Before working on the drive isolate the whole drive system from the supply Safety instructions 3ADW000195R0501 DCS800 Service Manual e e Grounding These instructions are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury death and or equipment malfunction and increase electromagnetic interference WARNING e Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up e Make sure that grounding conductors are adequately sized and marked as required by safety regulations e Ina multiple drive installation connect each drive separately to protective earth PE e Minimize EMC emission and make a 360 high frequency
94. rget find a short circuit indicated by low resistance 1 Q destroyed thyristor lf the converter is designed with half bridge thyristor modules then a module consists of two anti parallel thyristors In this case it is sufficient to know which thyristor pair or module has a defective thyristor because the complete module must be replaced After a thyristor module is replaced the above mentioned measurement should be done another time to make sure that all faulty thyristors have been detected Note The RC circuit could also cause 0 2 result for a short time The measurement showing less resistance than 1 Q should be made a second time with test leads applied to the terminals with opposite polarity if this measurement shows the same result one or two thyristors located in that path are faulty they need to be replaced Fault Tracing Thyristors 3ADW000195R0501 DCS800 Service Manual e e 25 Converters size D5 D6 and D7 900 5200 A These converters are equipped with fuses in the branches of the power part Blown fuses Ripple monitor The converter must be disconnected from the mains In case of a blown fuse the faulty thyristor or the faulty pair of thyristors are already isolated at one side from the others and therefore the faulty branch is known see picture Anti parallel B6 bridges with branching fuses on page 45 The OHM test should be performed when the thyristor is still clamped Outside the c
95. rrupts a phase input of the converter A thyristor does not get firing pulses or does not react to firing pulses The current controller may be totally mismatched to the DC load The AC mains network is causing that fault message In this case asymmetrical phase shift uneven phase voltage or critical designed power factor correction equipment or harmonic reduction equipment can be the reason How to find a faulty thyristor If a blown fuse is suspected in the converter the problem is caused most often by a faulty thyristor To make sure that a thyristor is the reason and needs to be exchanged fault tracing must be done in two different ways depending on the size of the converter In general make sure that all safety instructions given within this manual or within the safety instructions related to the machine or the application itself are obeyed Converters size D1 to D4 20 1000 A Blown fuses 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 Using the OHM function of a normal multimeter measurements must be made from each AC terminal to each DC terminal U1 to C1 V1 to C1 W1 to C1 U1 to D1 V1 to D1 and W1 to D1 see picture Anti parallel B6 bridges with branching fuses on page 45 Normally every measurement should show high resistance gt 1 KQO Ta
96. s 5 Remove the grounding plug and the holding screw at the electronic tray ng Remove the grounding plug and the gt holding screw amp j E Remove grounding and screws Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 32 6 To unhinge the electronic tray including the SDCS CON 4 pull it up and then out Before remove tray completely unplug the flat cables X12 X13 X37 A Electronic tray with SDCS CON 4 Unhinge electronic 7 Remove all cables and plugs at the SDCS PIN 4 Keep winding direction and amount of windings for T100 in mind T100 Remove all cables and plugs How to handle X8 use screw driver Remove cables at the SDCS PIN 4 Attention Write down the winding direction of the cable through T100 D1 thread the wire 4 times through the hole in T100 that equals 3 loops D2 D4 thread the wire 1 time through the hole in T100 that equals no loops Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 33 8 Remove the SDCS PIN 4 board OnBoard field exciter BB Snubber resistor ED Gee eee Thyristor modules Temperature sensor MET gt ie d 4 DI NEP T ULER vi Remove SDCS PIN 4 9 Remove the gate leads from the faulty thyristor module and mark the connectors clearly 10 Remove the busbars necessary to get full access to the
97. ses and reconnect all fuses taken out during search for the faulty thyristor 2 Remove the screws of the DC busbar plates adjacent to the defective thyristors DC busbar plates Location of the DC busbar plates Note It depends on the location of the defective thyristor which DC busbar plates have to be disconnected Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 56 Write down the direction and location of the thyristors to be removed and mark their gate leads In case of BCT s add the position of the gates 4 Remove the gate leads if possible 5 Loosen the mounting clamp at the top of the thyristor stack mounting clamp indicating sprino d 4 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 Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 57 7 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks guum 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 Op
98. space Ctrl E Close Workspace Alt Shift R Properties Name the new project and confirm with Next Project Name E X Welcome to the FLASH Development Toolkit Project Wizard The met k space vies Project Wizard ill guide ou through the steps necessary to uu cc MN create a new project PO Workspace m o ET En Displa Held The first step is to specify the name of your project 4 project pi ia Device Menon name must be no more than 100 characters in length and Fy Target files contain only valid filename characters ii LCD mot ES eybosrd m Project Name pu iJ Comme mot re ul pe Dcseoo Text user defined E Tar get Files cr Drive mot zd Algorithm You may alza add some comments to the project Comments may be edited after creation and serve as a useful means to fully describe the purpose of a project Add Commenta Back Lancel Service 3ADW000195R0501 DCS800 Service Manual e e 123 Choose Device And Kernel Select Device H8S 2633F and confirm with Next Choose Device And Kernel Hitachi 4 04 C Program fileziHitachiF D T2 2 kernel 1 0 nn Service 3ADW000195R0501 DCS800 Service Manual e e 124 Communication Port Select the proper COM port Select Baud Rate 38400 un tick Use Default Baud Rate and confirm with Next x Pris EU De tu j om l OC xe BE i n DL gt Ts i SI TUNE Device Irn
99. such that it requires a certain compression force to operate The prevention of overheating of the component essentially depends on a good heat dissipation between the semiconductor and the conducted heat sink It is thus important that all joints have good thermal and electrical conduction Required Tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules Torx screwdrivers TX10 TX20 TX25 Torque spanner for electrical connections 13 Nm M8 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts 17mm ring spanner for fuse and busbar connections 17 mm ring spanner for press clamp Tissue paper solvent e g ethanol Thermal joint compound type BECHEM RHUS SU 2 grease Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 001 P 0001 Disassembly tool 3ADT 621 023 P1 Note For more detailed information about the wiring of the power part see Hardware Manual Therefore strict observance of the build in instructions given below is of utmost importance Make sure that the new component can replace the old one in accordance with the spare part list see Appendix A Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage Avoid touching the contact surfaces Do not lift the semiconductor with the gate wire Do not lift the semiconductor by touching the current contact surfaces Do no
100. supply completely then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Find faulty thyristor modules See Fault Tracing Thyristors of this publication Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 30 Remove faulty thyristor modules 1 Removet he DCS Control Panel and design cover i Depress the locks by means of a screwdriver to remove the design cover Remove design cover 2 Remove all plug in options on the intermediate cover e g serial communication modules R type extension I O modules RAIO RDIO extension modules for second encoder RTAC or resolver RRIA communication board SDCS COM 8 isolated I O SDCS IOB 2x SDCS IOB 3 and SDCS MEM 8 Memory Card 3 Remove the intermediate cover by depressing the two locks on the upper right and left hand side of the cover dia O NS 2 ES E 1 o 4 Depress the locks to remove the design cover MIS Remove plug in options Exchange of Thyristors for Size D1 to D4 3ADW000195R0501 DCS800 Service Manual e e 31 4 Disconnect all I O plugs X3 to X7 at the SDCS CON 4 and the plugs at the E xi Vee Disconnect all plugs from SDCS CON 4 and SDCS DSL 4 boards ora MIN LJ d rp EA dela SETTI Bats pe we wm TERI 2125219424212 21945 Disconnect all plug
101. t Properties Firmware 31 xl User settings LOM Port comi Use default baud Target Baud Rate 38400 Default Baud 115200 Currently connected No Service 3ADW000195R0501 DCS800 Service Manual e e 100 Download firmware file to device Select desired firmware with a right mouse click and choose Download File to Device from the pop up menu FLASH Development Toolkit 2 2 DCS800 Ele Edit View Project Device Image Tools Window Help ub E X Bw cs ify Workspace DCS800 2 Projects Ed Firmware C3 Device Image 343 Target files 3 30x110 rec 90x111s rec Remove File from Project Download File to Device Freshen Local File Properties Alt Shift R Service 3ADW000195R0501 DCS800 Service Manual e e Disconnect tool 101 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 FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tool Window Help MESE Sud ea zl HA Workspace DCSS00 2 Projects ae Firn al a Add Files to Project PAY Add Files to Project From Kernel Dir l Set as Active Project Remove Project Disconnect Erase FLASH blocks Upload Image Blank check cancel FLASH Operation Build Device Image Freshen all Target files Properties Alt Shift
102. t damage the welding flange or the contact surface Before you start work disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrically and mechanically safe condition Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 42 Disk type thyristors Some converter modules size D5 are equipped with different disc type thyristors For easy identification the name plate of the converter module is marked with a after the voltage identification Converter with original Converter with second thyristor type T459Nxxx thyristor type T460Nxxx Id code DCA0012007P0001 Id code 3ADC340105P0001 Converter with original Converter with second thyristor type T589Nxxx thyristor type T590Nxxx Id code DCA0012015P0001 Id code 3ADC340106P0001 Parts list The current and voltage ratings of original and second thyristor type are the same but the sizes of gate and cathode terminals are different Thus it is not possible to interchange both thyristor types as spares Attention Use always the correct spare thyristor Original thyristor type 900 A Converter with original thyristor type T459Nxxx Id code DCA0012007P0001 Original thyristor type Exchange of Thyristors for Size D5 3ADW000195R0501 DCS800 Service Manual e e 43 Gate G Faston 2 8 x 0 8 mm Cathode Hk Faston 4 8 x 0 8 mm Conductive plate Diam
103. tegrated IEC61131 PLC Individually adaptable to customer requirements User defined accessories like external PLC or auto mation systems can be included High power solutions in 6 and 12 pulse up to 20 000 A 1 500 V In accordance to usual standards Individually factory load tested Detailed documentation DCS800 module with all necessary accessories mounted and fully cabled on a panel Very fast installation and commissioning Squeezes shut down times in revamp projects to a minimum Fits into Rittal cabinets Compact version up to 450 A and Vario version up to 2 000 A Proven long life components are re used such as power stacks main contactors cabinets and cabling busbars cooling systems Use of up to date communication facilities Increase of production and quality Very cost effective solution Open Rebuild Kits for nearly all existing DC drives tallor made solutions for BBC PxD BBC SZxD ASEA TYRAK other manufacturers Ident No SADW 000 195 R0501 Rev E 02 2011 195R0401A9370000
104. the bottom one Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 59 DC busbar plates and 1 heatsinks P_i DC busbar plates and adjacent heat sinks Note The DC busbar plates should line up with the adjacent heat sinks Reconnect the DC busbars Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks a AA Torque indicating Cs pring e loose condition Mounting clamp loose condition Note The indicating spring is a very sensitive instrument and must be handled with care 10 Tighten each nut in turn half a turn at a time with the help of a ring spanner until the indicating spring clicks into position correct torque Do not tighten the screws any further Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 60 gt Torque indicating uF LF D J pp mL ma a MS iL a n Y Che 1 m K i 4 8B le li iiil B T ga TE Y y B i E E E y Mounting clamp correct torque Note The correct torque is indicated by means of the welded indicating spring 11 Perform an OHM test to make sure the thyristor is ok 12 Reconnect all other dismantled parts 13 Perform an OHM test between U1 V1 W1 and C1 D1 to make sure the power part is ok Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e
105. tion Handling the Semiconductors 3ADW000195R0501 DCS800 Service Manual e e 28 Handling the Semiconductors 3ADW000195R0501 DCS800 Service Manual e e 29 Exchange of Thyristors for Size D1 to D4 Installation of OnBoard bridge and thyristor modules in converters size D1 to D4 20 1000 A All DCS800 size D1 to D4 are equipped with an OnBoard bridge excitation and thyristor modules In order to keep the operating temperature of the semiconductor module low the joint between the heat sink and the module should have a good heat conducting ability The electrical conductivity of the connectors must also be good For this reason the following instructions must be observed with particular care Required Tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules 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 ES grease Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 011 P 0051 Or thermal joint compound type WLPF 20 10 ml ABB Service GHSN 390 011 P 10 Before the work is started disconnect the converter from the power
106. ws are metric type use appropriate nuts 17 mm ring spanner for fuse and busbar connections 24mm ring spanner for press clamp Tissue paper solvent e g ethanol Thermal joint compound type BECHEM RHUS SU 2 grease Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 001 P 0001 Disassembly tool DCF 1066721 P1 Note For more detailed information about the wiring of the power part see Hardware Manual Therefore strict observance of the build in instructions given below is of utmost importance Make sure that the new component can replace the old one in accordance with the spare part list see Appendix A Semiconductors and heat sinks are to be handled carefully to avoid scratches and other damage Avoid touching the contact surfaces Do not lift the semiconductor with the gate wire Do not lift the semiconductor by touching the current contact surfaces Do not damage the welding flange or the contact surface Before you start work disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrically and mechanically safe condition Exchange of Thyristors for Size D6 3ADW000195R0501 DCS800 Service Manual e e 52 Disk type thyristors Some converter modules size D6 are equipped with different disc type thyristors For easy identification the name plate of the converter module is marked with a after the v
107. x sao s800 x Tx only available as 2 Q drive Introduction 3ADW000195R0501 DCS800 Service Manual e e 20 Introduction 3ADW000195R0501 DCS800 Service Manual e e 21 Fault Tracing Thyristors Tools For commissioning and fault tracing Following software tools are mandatory DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program and DriveWindow for fast drive monitoring using SDCS COM 8 Following tools are mandatory in addition to standard tools An oscilloscope including memory function with either galvanically isolating transformer or isolating amplifier probe for safe measurements It can also be a hand held portable oscilloscope A clamp on current probe In case the scaling of the DC load current needs to be checked it must be a DC clamp on current probe A voltmeter at least CAT III 1000 V 1000 V probes and test leads An ESD field service kit ABB Service Finland code 0001ESD MS Antistatic Make sure that all equipment in use is suitable for the voltage level applied to the power part Fault Tracing Thyristors 3ADWOO0195R0501 DCS800 Service Manual e e 22 Additionally for service and preventive maintenance Following additional tools are mandatory for cleaning An ESD safe blower ESD vacuum cleaner ABB Service Finland code 0006ESD MUNTZ 555 ESD S E How to detect a faulty thyristor
108. x140Demo rec 5 Docu s BUx150 rec ic DW Workspaces ES S0x150Demo rec E Di Firmware El S0x170 rec C3 COM 8x s a0x1 0Demo rec E 5 CON 4 El Di Ver 1 7en cel Firmware ma Text Type S Record file Date Modified 03 11 2006 17 05 Size 658 KB Service 3ADW000195R0501 DCS800 Service Manual e e FDOT Project S Record File S Record File S Record File S Record File S Record File S Record File 13 10 2006 13 27 6 2006 09 er 5 2006 09 07 07 2006 10 07 07 2006 10 05 11 2006 17 03 11 2006 17 1 95 New text files cde have to be saved in C ABB DCS800 Firmware CON 4 Ver x x Text fe 7 ABBDC56800 Firmware CON 4 Ver 1 7en Text File Edit View Favorites Tool Help Qe J gt Search Folder IS m X I gt Folders Date Modified 3 s Local Disk C si 80x140DemoText cde CDE File 27 06 2006 09 E ic ABB 80x140Text cde CDE File 27 06 2006 09 E 5 pcsaenn E 80x150DemoText cde CDE File 07 07 2006 10 D Docu E s0x150Text cde CDE File 07 07 2006 10 E DW_workspaces 20x170DemoText cde CDE File 03 11 2006 17 1 E 5 Firmware iz 80x 170Text cde CDE File 03 11 2006 17 1 5 COM 8x Text cpj FDT Project 19 10 2008 13 E E CON 4 El 5 Ver 1 7en ica Firmware c Text Type CDE File Date Modified 03 11 2006 17 05 Size 374 KB 374 KB e My Computer Service 3ADW000195R0501 DCS800 Service Manual e e 96 Download firmware file Service The firmware downloa
109. ype 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 parallel Thus it is possible to change only the broken fan Service 3ADW000195R0501 DCS800 Service Manual e e 84 Removing the converter fans 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on the top of the converter housing Ze connection plug X2 a r a A A u n Remove DCS Control Panel Depress the lacks by means of a screwdriver to remove the design cover Design cover Service 3ADW000195R0501 DCS800 Service Manual e e 85 2 Remove the two fan arrangement screws DZ i x AAA E Remove the fan k ME gement screws e Fan arrangement 3 Move the fan arrangement forward SE iO Move the fan arrangement fonward Move fan arrangement Service 3ADW000195R0501 DCS800 Service Manual e e 86 Service 4 Remove the fan holding screws nn dna VT a fre Ca 1 o Swan Ee o cm eee ED A e I lt UL Remove the fan gt e 6 MO 2 0052202 n holding screws GE e CA A O E e lm _ EUM Es EES SAO GE ELS SA GEE O eee ro EEE amp 6 eS a 00 al E To Ge aa Me 2 5

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