DCS 400 Service Manual
Contents
1. DCS 402 4 Q units for DCS 402 0025 0200 for DCS 402 0260 V14 V21 V16 V23 V12 V25 amp 5 5 14 21 V16 V23 V12 V25 k k k k k k JOE O O rmm O O O 5 5 10 m 19 e 5 e o9 g 9 2 C3 2 A 2 9 o fe MD DN nal Gon J QE 3 QE V11 V24 V13 V26 V15 V22 E b V11 V24 V13 V26 V15 V22 for DCS 402 0350 0550 for DCS 402 0680 1000 V24N11 V26 V13 V22N15 e Le v11 E V14 O O O V24 V21 le V15 ef LE v12 ome s Q Q i 22 5 T A V25 s e e via E o BE V26 9 A V23 6 6 V21 V14 V23N16 V25 N12 Figure 6 5 Location of thyristor modules in DCS402 40 units VIK6 12 DCS 400 Service Manual Module terminals Chapter 6 Thyristor Modules The nex2. TT 3 5 Overview burden adaptation per converter module 2 3 6 COnVeltel9 ___ _ C Do tI aaa 3 6 PE 3 6 E a a Eng E 3 7 Chapter 4 Power interface board SDCS PIN 3 A movisse re emer 4 1 2 agak jantan abar aga aaa Beh nang 4 2 Field CNK CONNECCION m Temm 4 3 VI K iv DCS 400 Service Manual Contents SPIN SEE ea Se Oe I CR ag 4 3 SDC IN AAK aa anakane ect EE 4 3 SG SANE Da eso dono a a naa Ka a 4 3 Chapter 5 Field Exciter Unit SDCS FIS 3 A FESTO E 5 1 Dla COM saang 5 1 I FS AU AU ON Mm ak aaa pct MA nanda a NG aa a 5 1 Necessary drive 4 7 14 44442 4 20 40 14 14 nnne nnn nns 5 1 ASST MGIC OAC irl HH 5 2 i SY we CUNEN ara aa at ee 5 3 Exchange of Field Exciter Unit 5 65 5 5 5 DRE 5 5 DISASSEMDIE Field Exciter dnt cca tence Gale
3. Sons 5 5 Assemble NEW Field Exciter Unit aaa noce aa ajam GE KE Pae uo 5 7 Chapter 6 Thyristor Modules A Aa EA a BA AN NG 6 1 5 6 ES an a ga OS IU ET 6 1 DIAGNOSIS A a a aa 6 1 IO VV NI SE Pr 6 2 ai a a Da ajaa A aa a aa ngk a aa Baga 6 2 PAE DUS OS d NE 6 3 NOI A a eh IM m C d 6 3 Power measuring values c 6 4 Temperature of thyristor 6 5 EM 6 6 General Instruction for Handling Semiconductors 6 7 Exchange OF MOGUIC em 6 8 Rodured TOOS A 6 8 Disassemble Thyristor 6 8 ASSemDle Me New InodUule deeem ah aa a a d aa a a a aa aan aaa aa 6 9 Thyristor module location DCS 401 2 0 6 11 Thyristor module location DCS 402 4 Q 6 12 6 eed 6 13 Chapter 7 Preventive Maintenance Recommended Regular
4. 2 3 2 3 Controller frame maintenance 4440040001 nennen 2 4 Remove controller board 5 5 4 464400 0000000 nnns nna nnn nnn 2 5 Remove the entire controller 2 5 Remove power interface board 5 5 2 6 Remove eld exciter SDC iere de o AAN AN aa a A 2 6 Chapter 3 Controller board SDCS CON 3 A SHON ESE Or INDUIS A iin aa 3 1 PATO GUC MDU age a vasi anaa E Rt ute orden dtu ag ana 3 1 Analogue sasing aa aia ag ARA Kang Gaga a ga a a ARA Kn 3 1 Digtal NDUT m 3 1 Digital OUT OU eae es ee ee eee et eee ee ee 3 2 SUPPI V OMAGSS aa aaa aaa a Da 3 2 Voltage for reference 3 2 ENCOOGEE SUDDINM kakang au aaa a aa aa a A KB GN A 3 2 Digital Inputs Digital Output circuits 3 2 PICIGIDUS AGA DIC s unite tas 3 2 Other helpful measuring 3 4
5. 7 1 WUC ere TET 7 1 aan na ai 7 1 TH CLUS IN cae 7 1 Appendix Spare Parts List Spare parts quick finder for 2 Quadrant 2 0 DCS 400 series DCS 401 0 A 1 Spare parts quick finder for 4 Quadrant 4 Q DCS 400 series DCS 402 0 A 2 Appendix B Circuit diagrams Block diagramiDOS 40 oe te KAG EL WA B 1 Block diagram DOS 402 aa aga an ADE Nak SEN BES a Na a Ba An A BK aa ka BA B 2 Appendix C Compatibility Hardware Software DCS 400 Service Manual V Contents POB S Renn ee ee ner nee ee ee een ee ene C 1 eee ace nck m EI MM MM RUE MEE MM E C 2 Drive Firmware Update Replace Firmware 107 3 or earlier to 108 0 on an existing SDCS CON 3 board C 3 Replace SDCS CON 3 with firmware 107 x by SDCS CON 3 with firmware108 0 C 5 Replace SDCS CON 3 SDCS CON 3A Naga C 6 Replace SDCS CON 3A SDCS CON 3A VI K vi DCS 400 Service Manual Chapter 1 Introduction How to use this manual purpose of this service manual is to provide detailed informa tion on how to exchange thyristors and Printed Circuit Boards PCB installed in power converters from the DCS 400 series
6. Select parameter Act 6 26 at the operating panel e Changes of the potentiometer are displayed at the panel Al2 e Connect a potentiometer to Al2 e Select parameter Al2 Act 6 27 at the operating panel e Changes of the potentiometer are displayed at the panel Analogue Outputs AO1 Connect potentiometer to or Al2 e Set parameter AO1 Assign 6 05 to Al1 Act or Al2 Act Connect a voltmeter to terminal X2 8 and X2 5 OV e Changes of the potentiometer are shown at the voltmeter 2 Connect potentiometer to or 12 e Set parameter AO2 Assign 6 08 to All Act or Al2 Act Connect a voltmeter to terminal X2 9 and X2 5 OV e Changes of the potentiometer are shown at the voltmeter Set back parameter AOx Assign 6 0x to the original value Digital Inputs e Select parameter DI Act 6 28 at the operating panel e Switch off all digital inputs e Incase of faults or alarms press ENTER button State of digital inputs must be displayed as 0000HEX Switch on amp panel display 0001HEX switch off DI Switch 012 panel display 0002HEX switch off 012 Switch DIS amp panel display 0004HEX switch off DIS Switch on 4 panel display 0008HEX switch off DIA Switch on panel display 0010 switch off Switch on DI6 z panel display 0020HEX switch off DI6 Switch on DI7 amp panel display 0040HEX switch off 017 Switch
7. Lo 5 5 for DCS 401 0315 0500 for DCS 401 0610 0900 V14 V11 V16 v13 V12N15 V14N11 V16 V13 V12 V15 mml e e te te ej O O O O o e e e e e Figure 6 4 Location of thyristor modules in DCS 401 2Q units DCS 400 Service Manual VIK 6 11 Chapter 6 Thyristor Modules Thyristor module location in
8. DI8 z panel display 0080HEX switch off 018 DCS 400 Service Manual VIK 3 17 Chapter 3 Controller board SDCS CON 3 A Digital Outputs Disconnect terminal at the desired digital output DO1 X5 1 or DO2 X5 2 or X5 3 or DO4 5 4 or 005 98 1 98 2 DO1 DO4 e Connect a voltmeter to the desired terminal X5 1 2 3 4 and X5 5 OV Set parameter DOx Assign 6 1x to none Voltmeter OV Set parameter DOx Assign 6 1x to constant 1 Voltmeter gt 24V Connect an ohmmeter to terminal X98 1 and X98 2 Set parameter DO5 Assign 6 15 to none Ohmmeter gt Set parameter 005 Assign 6 15 to constant 1 Ohmmeter 0 Set back parameter DOx Assign 6 1x to the original value Supply Voltages All of the supply voltages are measurable at the terminals If a voltage is missing at the terminals it is also measurable at IC s at the controller board be carefully Controller board SDCS CON S A Voltage for refer 2 5 OV Frame ence potenti 2 6 10V IC A200 8 ometer X2 7 10V E IC A200 14 Encoder supply X3 7 OV gt X3 8 0 depends 52 52 10 11 5V 52 10 S2 11 12 24V gt IC A300 heatsink Digital Inputs X4 9 24V IC A501 heatsink Digital Output 4 10 OV 25 Frame circuits Fieldbus Adapter X8 1 24V gt IC A501 heatsink X8 2 OV Frame VIK 3 2 DCS 400 Service Manual Chapter 3 Controll
9. V LV 2215 10 pasn JUO YY 8215 104 pasn LV 9215 104 pasn EENE E EE 86X 0051 10 02 69 1 01 9X 9X a a aa aaa laa p KESAN KA Gg AG BAN E SAN NA An anaa aa ANNA T 92 L i i viX 008A T i omm ex n i 9X Ve Sla i eee M aes i i A 2 2 74 ney sz C SX x D ERN NATA ANA KEN NA 91 5 1 poe 15 V NOO lOHINOO 32V3H3LNI JINON H3183ANOO L VIKB 1 Manual rvice DCS 400 Se agrams ircuit di Appendix B C V LV 9215 10 JUO 9215 juo LV 9215 10 aan anan riak WA KA E WA AKA DAN a WAN AH AA NANA 28 062 61 1 i mmm i i 514 L vLX 9LX a i i 9 0 39 66X i 2 s SIN po 00 ree DX 2 i 1 2 15
10. Chapter 6 Thyristor Modules Assemble the new Remove old thermal joint compound grease from the heatsink module and prepare the heatsink as follows if the area is clean spread out the remaining heat conducting compound with a rubber spatula or with the hand If the area is dirty wipe the heatsink surface clean with tissue paper Clean the mounting surfaces with an appropriate solvent Apply a thin coat of thermal joint compound to the new module Spread the thermal joint compound evenly by moving the mod ule forward and backward on the heatsink DCS 400 Service Manual VIK6 9 Chapter 6 Thyristor Modules Tighten the clamping screws until the screw heads touch the bottom of the module Then tighten the screws to 2 5 Nm pre torque If the module is mounted using four screws tighten the screws crosswise Tighten the screws to nominal torque see Table 6 1 Reinstall the busbars make sure the correct torque is applied and reconnect all leads Reattach the transparent plastic insulation and PIN board see Figures 5 6 and 5 7 Ensure that the connecting cables for the connectors X1 X2 X7 as well as X4 X5 are led through the corresponding holes or slits to the front of the PIN board Reattach the connectors X1 X2 X7 as well as X4 Kb and X6 Reattach the connectors X11 X14 X15 X16 and X22 Lead connecting cable from filter choke L1 once for 16 20 A or three times for 4
11. 212 7 SoS LISS SSS RSS Select panel function Set Typecode see DCS 400 Manual page 6 4 Pin number is 400 Read Type from converter name plate e g DCS401 0045 Select type in the list and confirm Confirm converter type and wait 10 sec Switch off and on electronics Download parameter from panel into the drive Do the commissioning if analogue tacho is used adjust potentiometer R115 if encoder is used correct Jumper S2 Check the behavior of the drive New parameter and signals in firmware 108 0 Arm Curr Lev 3 25 Ramp In Act 5 33 Tacho Offset 5 34 CON Board 7 21 Disable Bridge 1 9 19 Disable Bridge 2 9 20 VIKC 5 Appendix C Compatibility Hardware Software Replace SDCS CON 3 by SDCS CON 3A VIKC 6 Requirements SDCS CON 3A with firmware 108 0 Operating panel DCS400PAN with text version 4 00 Connect operating panel version 4 00 to the converter Upload parameter into the panel see DCS 400 manual page 6 5 Switch off electronics Replace SDCS CON 3 by SDCS CON 3A Connect operating panel to the updated converter Switch on electronics Ignore possible faults to begin Check software version Parameter SW Version 7 04 108 0 Pan Text Vers 7 19 4 00 Maybe it s necessary to select long parameter list in panel function Long Short Par List Select panel function Set Typecode see DCS 400 manual page 6 4 Pin number is 40
12. 1000 0 75A 0 150 0 225 0 300 0 375 0 450 0 525 0 600 0 675 0 750 0 825 0 900 0 975 0 1050 then the burden voltage 1 0 2 V corresponds to VIK 3 6 DCS 400 Service Manual Example DCS 400 Service Manual Chapter 3 Controller board SDCS CON 3 A Burden voltage 0 2 V depends on chosen burden resistor and parameter Arm Cur Nom 1 01 e g Used converter should be DCS401 0740 Armature current Arm Cur Nom 1 01 should be 670 A Armature current 670 A is in a range of 651 700 A that means 0 700 A corresponds to O 2 V burden voltage 10096 of actual armature current is 670 A the corresponding burden voltage is 2 V 700 Ax 670A 1 91 V The burden circuitry is able to process values up to 4 V therefore a maximum armature current of 200 is possible to represent VIK 3 7 Chapter 3 Controller board SDCS CON 3 A VIK 3 8 DCS 400 Service Manual Chapter 4 Power interface board SDCS PIN 3 A Power supply DCS 400 Service Manual The power supply of the DCS 400 series is a wide range input fly back converter Regulation for the 5 V is done on the SDCS PIN 3 A board with the reference value coming from the controller board SDCS CON 3 A The output of the 5 V regulator is send to the primary side of the power supply via an opto coupler All volt ages will follow the regulated 5 V supply depending on the load of each output The following voltages
13. 30054 Thyristor Diagnosis 00 bridge 1 not concerned thyristors V11 V16 o k 5 bridge 2 affected thyristor V25 is faulty 4 bridge 2 affected thyristor V24 is faulty 31200 Thyristor Diagnosis 1 bridge 1 affected thyristor V11 is faulty 2 bridge 1 affected thyristor V12 is faulty 00 bridge 2 not concerned thyristors V21 V26 o k DCS 400 Service Manual VIK6 1 Chapter 6 Thyristor Modules Blown fuse This is an indication that a strong overcurrent has happened due to one of the following reasons internal short circuit between the phases line side because of a defective thyristor short circuit inside a thyristor from anode to cathode internal short circuit between the phases line side because of circulating current in a 4 Q converter malfunction of the con trol electronics no thyristor defective an external short circuit at the DC terminals of the converter without sufficient impedance acommutation fault during inverting mode operation active braking with high current high EMF and with low AC voltage Faulty thyristor If a blown fuse is suspected in the converter the problem is caused most often by a faulty thyristor To be sure whether a thyristor is the reason and needs to be exchanged fault tracing must be done as described below In general make sure that all safety instructions given within this manual or within the safety instruc tions related to the machine or the application itse
14. A2 0 25 0 125 0 150 0 175 0 200 0 225 0 250 then the burden voltage 0 2 V corresponds to Size from4A 26A to25A 50A if parameter Arm Cur Nom 1 01 is a range DCS401 0315 A3 111 EE DCS401 0500 A3 DCS401 0610 DCS401 0740 4 0 50A Fe ee ae er Es 0 550A 0 600A 0 650A 0 700A 0 750A then the burden voltage 1 0 2 V corresponds to if parameter Arm Cur Nom 1 01 is in a range Size from4A 76A to 75 A 150A then the burden voltage 0 2 V corresponds to Current transformer 1500 1 DCS402 0025 DCS402 0050 DCS402 0075 DCS402 0100 A1 DCS402 0140 DCS402 0200 A2 0 25A 0 50 0 75A 0 100A 0 125A 0 150A 0 175A 0 200A 0 225A 0 250A 0 275A then the burden voltage 0 2 V corresponds to if parameter Arm Cur Nom 1 01 is in a range DCS402 0350 A3 DCS402 0550 DCS402 0680 4 0 50A pm 0 500A 0 550A 0 600A 0 650A 0 700A then the burden voltage 1 0 2 V corresponds to if parameter Arm Cur Nom 1 01 is in a range Current Size from 4A 76A 151A 226A 301A 376A 451A 526A 601A 676A 751A 826A 901A 976A transformer to 75 Al 150A 225A 300A 375A 450A 525A 600A 675A 750A 825A 900A 975A 1050A DCS402 0820 DCS402
15. Contents of this manual Chapter 1 Introduction This chapter informs about the contents and the use of this manual as well as about the boundary conditions applying Chapter 2 Dismounting the converter This chapter describes how to dismount the converter Chapter 3 Controller board SDCS CON 3 A This chapter describes how to test the controller board and the bur den adaptation Chapter 4 Power interface board SDCS PIN 3 A This chapter describes specialities of the power interface board Chapter 5 Field Exciter Unit SDCS FIS 3 A This chapter describes the exchange of field exciter unit mounted in converter Chapter 6 Thyristor modules This chapter describes the fault tracing handling and exchanging of thyristor modules for frame sizes A1 A4 as well as some special data firing pulses temperature of thyristor bridge values and so on Chapter 7 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 Appendix B Circuit diagrams The appendix B shows specific circuit diagrams Appendix C Compatibility of Hardware Software This appendix describes the permissible configurations depending on the different hard and software possibilities Furthermore the procedures for updating the Drive s firmware is shown Target group This manual is designed to help those responsible
16. GHSN 39 00 11 P1 Before the work is started disconnect the con verter from the power supply completely then check the voltage free condition and make sure everything is located in an electrical and mechani cal safe condition Dismount field exciter unit as described in chapter 2 additionally pay attention to the following information In order to remove the power interface board SDCS PIN 3 A loosen the screws C1 U1 V1 W1 and D1 as well as the bolts with an 8 mm socket wrench left and right on the PIN board detach the connectors X11 X14 X15 X16 and X22 on the PIN board unclamp the connecting cable of the filter choke L1 sits directly on heatsink from plug X100 and unwind the cable from the current transformer T2 see Figure 5 3 detach the connectors X1 X2 X7 as well as X8 X4 X5 and X6 from the PIN board and remove the PIN board remove the transparent plastic insulation see Figure 5 6 The busbars thyristors and their connecting wires or cables can now be accessed Remove the gate wires from the faulty thyristor module and mark the position of the trigger connections on the cable Remove the busbars necessary to obtain full access to faulty thyristor module s Remove only as many parts as needed around the faulty mod ule If the current transformer must be removed mark the posi tion and the connections Remove the faulty thyristor module and mark it DCS 400 Service Manual
17. REV A 1 3 230 500 V U2 240 520 Voc Ser No 7042176 A049 1234 oh A A R 50 A TT 50 60 H IF 6 A DCS402 0050 REV A 1 rating plate DCS402 4 Q converter 0050 nominal DC current in Amps 50 A DCS401 0230 REV A 1 rating plate DCS401 2 Q converter 0230 nominal DC current in Amps 230 A Revision status A new PCB s SDCS CON 3A SDCS PIN 3A SDCS FIS 3A improved analogue I O resolution 12 bit new internal field choke increased field current rating 4 6 16 20 A increased field voltage range 50 440 V DCS 400 Service Manual DCS 400 Service Manual Chapter 1 Introduction No Revision status depending on SDCS CON 3 A Analogue resolution 10 8 12 Bit independing on used PCB s Field current rating 6 16 16 A Field voltage range 50 350 V Ser No 7042176 A 0 49 1234 Serial no 7042176 Manufacturing number for identification A Index 0 Year of production double character up to Oct 99 af terwards single character 49 week of production 1234 current number Fan 115 230 V Fan supply 115 V or 230 5401 0020 DCS402 0025 with out fan U 3 230 500 V Mains supply 230 V to 500 V 3 phase U 240 520 Vic Converter nominal DC voltage 240 V to 520 V U 240 V at U 230 V U 520 V at U 500 V ma Converter nominal AG curent AT A oa Converter nominal DC current 50 A f Field current nominal 6 A The technical da
18. T CIK 494 Eg E 1 1 1 1 1 1 1 1 r 1 1 1 1 1 1 1 1 V NOO 10H1NOO 32V3H31NI i i i i i i i i i i i i i i i i i i i i i i 1 i i i i i i i i i i i i i i i L i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i X pM Llslll H3183ANOO Block diagram DCS 402 Overview of DCS 402 4 Q converter Manual DCS 400 Se VIKB 2 Appendix C Compatibility Hardware Software PCB s as spare parts Note e The old PCB s SDCS CON 3 PIN 3 FIS 3 from DCS 400 classic can be replaced by new PCB s like SDCS CON 3A PIN 3A FIS 3A he existing field choke 3ADT748069 70 must not be re placed by a new field choke type e The DCS 400 Rev A expect PCB s with index A only Hints for service affairs e Keep only new PCB s on stock SDCS CON 3A SDCS PIN 3A SDCS FIS 3A e New PCB s are compatible to old PCB s but not vice versa DCS 400 classic permissible configuration 107 x 3 00 CON 3 PIN 3 FIS 3 or 108 0 4 00 107 3 00 108 0 4 00 107 x 3 00 108 0 4 00 107 3 00 4 CON 3 PIN 3A FIS 3A or 108 0 4 00 108 0 4 00 6 FIS 3A 108 0 4 00 FIS 3 108 0 4 00 8 PIN 3A 1
19. X11 1 X11 3 FIS 3 A 1 15u S50v field choke X14 1 X112 KIT 3 AGND E In d Lin Fig 4 2 Connection of old new field choke DCS 400 Service Manual VIK4 3 Chapter 4 Power interface board SDCS PIN 3 A VIK 4 4 DCS 400 Service Manual Chapter 5 Field Exciter Unit SDCS FIS 3 A Test of SDCS FIS 3 A Start conditions Preparation Necessary drive modifications DCS 400 Service Manual The test includes a check of the field voltage and field current op eration Previously some measures have to be taken e Drive software version 108 0 or higher e Parameter Arm Volt Nom 1 02 is in accordance to the Mains Supply Voltage see DCS 400 Manual page 2 3 table 2 2 4 Parameter Net Underv Trip 1 10 is in a range of 10 5 e Parameter Field Heat Ref 4 10 0 or greater than Field Low Trip 4 06 e Needed tools Voltmeter 0 1000 V DC perhaps an ON switch or customer s panel Switch all power OFF Disconnect the motor field at terminals X10 1 and 2 Connect a Voltmeter to terminals X10 1 and 2 Connect an ON switch to terminals X4 7 DI7 ON and X4 9 24V or use customer s panel Mains Supply K1 Main Contactor K1 is controlled by DO5 Unet DC link DCS400 for this check V V parameter DO5 Assign 6 15 has to be set to Constant 1 for resident mains supply voltmeter 0 1000V_DC Fig 5 1 Measures for test VIK 5 17 Chapter 5 Field Exciter Unit SDCS FI
20. connectors X12 X13 e Remove plugs at the DC link ca pacitor e Loose don t re move fixing ET ES screws of con troller frame j controller frame e Removel 0 Set ni AA terminal plugs X1 X8 If necessary re move optical ca ble at V800 e Lift up the frame around 1 cm and take it out to the front DCS 400 Service Manual VIK2 5 Chapter 2 Dismounting the Converter Remove power interface Pay attention to board SDCS PIN 3 A the wire at termi nal X100 Please remem ber the number of windings through current transformer T2 Module size 1 three 2 4 one e Disconnect all the electrical plugs e Remove all fixing screws and bolts e Pull board downward about 5 cm from clutch and remove straight forward Fig 2 10 Remove PIN board Remove field exciter Caution SDCS FIS 3 A After power down please wait at least 30 s for discharging the capacitor e Disconnect all the electrical plugs e Remove all fixing screws Do not forget add thermal joint compound when exchanging Fig 2 12 Remove field exciter VIK2 6 DCS 400 Service Manual Chapter 3 Controller board SDCS CON 3 A Short test of inputs Precondition for the short tests is to switch on the electronics supply outputs voltage Analogue Inputs SDCS CON 3 A Alt Al2 OV 10V Connect a potentiometer to
21. from converter name plate e g DCS401 0045 Select type in the list and confirm Select Revision Rev A 1 and confirm Confirm converter type and wait 10 sec Switch off and on electronics Download parameter from panel into the drive Do the commissioning if analogue tacho is used adjust potentiometer R115 if encoder is used correct Jumper S2 VIKC 7 ED ER ABB Automation Products GmbH Postfach 1180 D 68619 Lampertheim Tel 49 0 62 06 5 03 0 Fax 49 0 62 06 5 03 6 09 www abb com motors amp drives Ident No 3ADW 000 131 R0101 Rev A 05 01 131R0101A1190000
22. 0 Read Type from converter name plate e g DCS401 0045 Select type in the list and confirm Select Revision without and confirm Confirm converter type and wait 10 sec Switch off and on electronics Download parameter from panel into the drive Do the commissioning if analogue tacho is used adjust potentiometer R115 if encoder is used correct Jumper S2 New parameter and signals in firmware 108 0 Arm Curr Lev 3 25 Ramp In Act 5 33 Tacho Offset 5 34 CON Board 7 21 Disable Bridge 1 9 19 Disable Bridge 2 9 20 DCS 400 Service Manual Replace SDCS CON e 3A by SDCS CON 3A DCS 400 Service Manual Appendix C Compatibility Hardware Software Requirements SDCS CON 3A with firmware 108 0 Operating panel DCS400PAN with text version 4 00 Connect operating panel version 4 00 to the converter Upload parameter into the panel E see DCS 400 manual page 6 5 Ex d 1 Switch off electronics Replace controller board SDCS CON 3A by the new Connect operating panel to the b converter Switch on electronics Ignore possible faults to begin Check software version Parameter SW Version 7 04 108 0 Pan Text Vers 7 19 4 00 Maybe it s necessary to select long parameter list in panel function Long Short Par List Select panel function Set Typecode see DCS 400 manual page 6 4 Pin number is 400 Read Type
23. 08 0 4 00 SDCS CON 3 runs with firmware 107 x or 108 0 SDCS CON 3A runs with firmware 108 0 only Caution Even if all PCB s are replaced by new PCB s with index A the unit is stilla DCS 400 classic Therefore use panel function Set Typecode and select Revision without old Field choke inside SDCS CON 3 Firmware lt 108 0 DCS 400 Rev A permissible configuration new field choke SDCS SDCS SDCS inside Caution PCB s with index A can be replaced by PCB s with index A only Therefore use panel function Set Typecode and select Revision Rev A x DCS 400 Service Manual VIKC 1 Appendix C Compatibility Hardware Software Comparison of features The table below shows the features depending on the different hard and software possibilities Advanced new Classic DCS 400 Classic DCS 400 Classic DCS 400 DCS 400 without Rev without Rev without Rev but but CON 3A SW 108 0 SW 107 x SW 108 0 SW 108 0 Hardware Configuration SDCS CON 3A SDCS CON 3 SDCS CON 3 SDCS CON 3A SDCS PIN 3A SDCS PIN 3 SDCS PIN 3 SDCS PIN 3 other board configurations are SDCS PIN 3A not allowed SDCS FIS 3A SDCS FIS 3 or SDCS FIS 3 or SDCS FIS 3 or SDCS FIS 3A SDCS FIS 3A SDCS FIS 3A started at converter serial new field choke old field choke old field choke old field choke d 3ADT748073 74 3ADT748069 70 3ADT748069 70 3ADT74806
24. 6 A through the current transformer T2 and clamp it to connector X100 see Figure 5 3 Screw the PIN board into place Reattach the ribbon cables on the controller panel to the con nectors X12 and X13 on the PIN board and screw the controller panel back into place Reattach the connecting cables to the dc link capacitor Attach the top cover with fan in case of l 2 45 and the front cover and tighten the screws fe UE m connections heatsink 34 mm block SKKT 162 Table 6 1 Nominal mounting torque for thyristor modules VI K 6 10 DCS 400 Service Manual Chapter 6 Thyristor Modules Thyristor module location in DCS 401 2 Q units for DCS 401 0020 0180 for DCS 401 0230 V16 V13 V12 V15 V14 V11 V16 V13 V12 V15 E E 00 mojn O Ol Ej
25. 9 70 inside inside inside inside 108 0 107 3 108 0 108 0 DCS400PAN Version 40 150 40 3400 7 R0501 Rev E Documentation Manual ee for HW Rev D PIN 3 FIS 3 Rev D 3ADW 000 095 R0401 Rev D for SW Rev E CON 3A SW Rev E Resolution Analogue Inputs 1 2 12 bits incl sign 10 bits incl sign 10 bits incl sign 12 bits incl sign Accuracy 0 05 0 2 0 2 0 05 Analogue Outputs 1 2 12 bits incl sign 8 bits incl sign 8 bits incl sign 12 bits incl sign Accuracy 0 05 0 8 0 8 0 05 Tacho Input 12 bits incl sign 10 bits incl sign 10 bits incl sign 12 bits incl sign Accuracy 0 06 0 25 0 25 0 06 Analogue Outputs 1 2 max scaling Field Current range 1 20 25A unit A1 45 140A unit A2 A3 A4 New Features Signal for Speed Ref at Ramp Gen erator Input e The old PCB s SDCS CON 3 PIN 3 FIS 3 from DCS 400 classic can be replaced by all or single new PCB s like SDCS CON 3A PIN 3A FIS 3A The existing field choke 3ADT748069 70 must not replaced by a new field choke type e The DCS 400 Rev A with the new field choke 3ADT748073 74 expect PCB s with index A only VIKC 2 DCS 400 Service Manual Drive Firmware Update Replace Firmware 107 3 or earlier to 108 0 on an existing SDCS CON 3 board DCS 400 Service Manual Appendix C Compatibility Hardware Software Hint In Lotus Notes database DC Drives News DCS 400 Firmware Free Download is always available the la
26. CB Panel adapter PCB SDCS CON 3 A MP capacitor PCB SDCS PIN 3 A Current transformer Thyristor modul Choke Thermal sensor PCB SDCS FIS 3 A Housing Fan Fan terminal Top plate Base plate of electronic Spacer stud Busbars Heatsink Terminal block Screws Fig 2 2 3 D drawing of the DCS 400 Frame size A2 Frame size A3 Lid Cover Edional Cover Base plate of electronic MP capacitor PCB SDCS CON 3 A PCB Panel adapter Spacer stud PCB SDCS PIN 3 A Current transformer Busbars Distanz nut Terminal block Choke Terminal sensor PCB SDCS FIS 3 A Thyristor modul Heatsink Housing Fan Fan terminal Top plate 59 1272 Fig 2 3 3 D drawing of the DCS 400 Frame size A3 VIK2 2 DCS 400 Service Manual Chapter 2 Dismounting the Converter Frame size A4 Lid Cover Edional Cover Base plate of electronic MP capacitor PCB SDCS CON 3 A PCB Panel adapter Spacer stud PCB SDCS PIN 3 A Current transformer Busbars Distanz nut Heatsink Choke Terminal sensor PCB SDCS FIS 3 A Thyristor modul Heatsink Housing Fan Fan terminal Fig 2 4 3 D drawing of the DCS 400 Frame size 4 c ON OAR WN N C1 N mm nm MN Open the converter
27. DCS Thyristor Power Converters for DC drive systems 20 to 1000 A Service Manual DCS 400 Thyristor Power Converters Series DCS 400 Service Manual Code 3ADW 000 131 R0101 Rev A SM4 E A DOC EFFECTIVE May 17th 2001 SUPERSEDES none 2001 ABB Automation Products GmbH All rights reserved DCS 400 Service Manual Safety Instructions Overview This chapter contains safety instructions that must be complied with during installation operation and maintenance of the power con verter series DCS 400 If these instructions are not complied with this may result in injuries perhaps even with fatal consequences in damage to the power converter the motor and the driven ma chine Before starting with any work whatsoever at or with this unit you must read the information given in this chapter Warnings Warnings provide information on states which if the specified pro cedure for the state concerned is not meticulously complied with may result in a serious error in major damage to the unit in injury to persons and even in death They are identified by the following symbols Danger High Voltage This symbol warns you of high voltages which may result in injuries to persons and or damage to equipment Where appropriate the text printed adjacent to this symbol describes how risks of this kind may be avoided All electrical installation and maintenance work on the thyristor power converter must be carr
28. S 3 A Test field voltage Field disconnected _ _ Be careful now because of high Up to 700 V possible at termi voltage at the unit nals X10 Connect mains supply If main contactor is controlled by digital output 005 set parameter DO5 Assign 6 15 Constant 1 to connect DCS 400 power part to mains supply but re member old value of parameter 6 15 mostly macro depend Voltmeter should show 0 If not SDCS FIS 3 A is faulty short Circuit _______ Volt meter should show the DC If not link voltage of the IGBT field SDCS FIS 3 A is faulty bro exciter ken DC link voltage mains sup ply voltage 1 35 Switch off ON 0 the drive Otherwise an alarm Field Volt within 10 sec Limited A7 and a fault Field Undercurrent F12 will occur and switch off the drive In any case Voltmeter should show 0 V again VIK5 2 DCS 400 Service Manual Restore the drive to the original state Test field current DCS 400 Service Manual Chapter 5 Field Exciter Unit SDCS FIS 3 A Original state means Mains Supply KA Main Contactor K1 is controlled by DO5 DCS400 voltmeter 0 1000V_DC Fig 5 2 Original state Test if field current regulator works right field connected BENE Switch all power OFF p Disconnect the plug of terminal X10 and measure resistance _ measured value of field Re of motor field using an resistance Ohmmete
29. SKKT 57B 16 E 3ADC 340068 P0001 0 1 TT 250 N 16 KOF AK34 3ADC 340060 P0002 3ADC 340032 P0001 1 5 3ADC 340066 P0001 170 M 1566 80 660V DCZ 9838791 P0001 170 3817 315A 660V 3ADC770024 P0010 0 170 M 6166 1250A 660V DCA 0012741 P0001 KTY 10 6 M4 230 mm DCA 0012139 P0002 10 6 4 550 mm DCA 0012139 P0001 h oio iS Ni lt lt oo L I N iN N Z m uv X X Qo gt gt oi oN S zs din 8 8 oa S io 2 i2 aim 09 O lt lt SSE SOE Oo io io Tiwi N iN j N N m m N N O10 ep I I r rr eo Qo gt gt g NOON oo 0 7 eio 5 h Note Spare parts for DCS 400 differ from those for DCS 500 DCS 600 even if the type names are identical If you have any questions concerning additional spare parts please contact your local ABB agent VIKA 2 DCS 400 Service Manual t diagrams II CUI Appendix B C X l m 19 Les X peel Overview of DCS 401 2 Q converter 39 66X Block diagram DCS 401 T i i i i i i i i i i i i i i i i d N N N
30. and devices in industrial installations If in special cases the electrical machines and devices are intended for use in non industrial installations which may require stricter safety regulations e g protection against contact by children or similar these additional safety measures for the in stallation must be provided by the customer during assembly VI K iii Contents VI K Service Manual Safety Instructions Chapter 1 Introduction TOMS lig cies Lk Ba NA LEG hoc Coste 1 1 Contents ortis MANU all a io dades A KA S DR BA ag aa aan a 1 1 mr 1 1 Associated DUDUGANONS asian an ae a kag Ag aaa ia aa 1 2 gt a a NG 1 2 T 1 2 EXOTIC Um RD EI I CUM te IM CAM UEM cM Ie 1 2 Chapter 2 Dismounting the Converter Main components of DCS400 4 20 20000000000 2 1 Fame SIZ pr HE 2 1 Frame AZ 2 2 LANG SIZE a a 2 2 Frame size Jd
31. are available at SDCS PIN 3 A board 5V 0 1V 0 5A to supply the controller the digital logic and an encoder 15V 5 to supply analogue integrated circuits 24V 5 0 4A to supply the digital inputs outputs encoder and fieldbus adapter 40V 5 0 2A to supply the firing pulse amplifiers The voltages with there tolerances are designed to feed their nomi nal load With suppressed firing pulses for example the output of the 40 V will rise up to 50 V At the controller board SDCS CON 3 A there are some additional voltage regulators available Encoder 24V 0 2 set by jumper short circuit protected Reference 10V 0 01A generated from 15V Panel 12V generated from 15V Fieldbus adapter digital inputs outputs 24V 0 2A continuously 0 6A for a short time short circuit protected VIK 4 17 Chapter 4 Power interface board SDCS PIN 3 A U SDCS FIS 3 A control monitor windings of the choke a connection passing the current transformer 3 times with 4 6 A units once with 16 20A units connection for converter signal on heatsink shows typical voltage of SMP primary side max 600 V firing pulses lt 0V WW connection to 2525 SDCS CON 3 A DEES EKA KNOG cl ti Soca Ground Ve 0 V reference pe w f of SMP sig
32. ave to be re moved completely by detaching the connectors X1 X2 X7 as well as X3 X4 X5 from the PIN board Remove the field exciter unit FIS board by carrying out the fol lowing instructions Detach all connectors X1 to X5 X7 and X14 from the FIS Be careful not to mix up the connectors Unscrew the field exciter unit see Figure 5 4 and mark it clearly VIK5 6 DCS 400 Service Manual Chapter 5 Field Exciter Unit SDCS FIS 3 A Umains U pc Link Ground Upc Link zero volt signal on high voltage side Connection to Mounting holes SDCS PIN 3 A Figure 5 4 Field Exciter Unit SDCS FIS 3A Assemble new Field 1 Remove old thermal joint compound grease from the heatsink Exciter Unit Preparation of the heatsink if the area is clean spread out the remaining heat conducting compound with a rubber spatula or with the hand If the area is dirty wipe the heatsink surface clean with tissue paper Clean the mounting surfaces with an appropriate solvent 2 Apply a thin coat of thermal compound to the new IGBT module of the new field exciter unit refer to Figure 5 5 Spread the thermal joint compound evenly by moving the module forward and backward on the heatsink F Se Sie Figure 5 5 Application of thermal compound to IGBT module DCS 400 Service Manual VIK5 7 Chapter 5 Field Exciter Unit SDCS FIS 3 A 3 Tighten the clamping screws IGBT module to heatsi
33. controller panel back into place 12 Reattach the connecting cables to the dc link capacitor 13 Attach the top cover with fan in case of lj 2 45 A and the front cover and tighten the screws DCS 400 Service Manual VIK5 9 Chapter 5 Field Exciter Unit SDCS FIS 3 A VIK 5 10 DCS 400 Service Manual Chapter 6 Thyristor Modules Fault tracing Thyristor problems can be noticed in two ways Thyristor diagnosis For testing that all the thyristors are o k or any is faulty an auto matically thyristor diagnosis procedure can be started in parameter Contr Service 7 02 Thyr Diag see also DCS 400 Manual page 4 38 e A test of short circuit and earth fault will be done for each single thyristor Aconductivity test of all thyristors will be done in pairs of two test fails Alarm 10 Autotuning Failed will be displayed at the panel e A faulty result will be shown as a number of the affected thyris tors in parameter Diagnosis 7 03 Diagnosis result Display format of diagnosis result 3bbbb faulty thyristor diagnosis b thyristor bridge 3 3zThyristor Diagnosis conductivity test b 1 6 bridge 1 thyristor V11 V16 faulty b 1 6 bridge 1 thyristor V11 V16 faulty b 1 6 bridge 2 thyristor V21 V26 faulty b 1 6 bridge 2 thyristor V21 V26 faulty 4 Q twothyristors 2 Q in onemodule Example of 31200 7 03 ids V25 V24 V11 V12 Meaning of diagnosis messages
34. d If not there is something wrong calculated by using actual val with the SDCS FIS 3 A ues Ue le have to be al most identical VIK 5 4 DCS 400 Service Manual Exchange of Field Exciter Unit SDCS FIS 3 A Required Tools Disassemble Field Exciter Unit DCS 400 Service Manual Chapter 5 Field Exciter Unit SDCS FIS 3 A All DCS 400 converters are equipped with field exciter unit based on IGBT technology In order to keep the operating temperature of the IGBT module low the joint between the heatsink 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 Special tools or material needed in addition to standard tools for the exchange of field exciter units torque socket spanner 5 Nm case to heatsink torque screwdriver 3 Nm electrical connection screws are metric type use appropriate nuts thermal joint compound silicon free grease type Berlub FZ1 E3 number GHSN 39 00 11 P1 Field exciter units are always mounted in the same direction inde pendent of current voltage number of quadrants 2 Q or 4 Q 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 Dismount field exciter unit as d
35. e Remove the panel DCS400PAN e Loose not re move the screws 7 pes 400 at the top of the converter and behind the flap e Remove the top cover plate incl fan M e Remove the front cover loose Fig 2 5 Open the converter DCS 400 Service Manual VIK2 3 Chapter 2 Dismounting the Converter Controller frame in maintenance position VIK2 4 For test purposes the controller frame can be set in a maintenance position Danger Remove controller frame e Loose don t re move fixing screws of con troller frame e Lift up the frame approx 1 and take it out to the front board for fixing in mainte nance position Attach controller frame in mainte nance position Fix clamp of the mounting plate upper left to eye in the hous ing upper right e Establish ground potential be tween housing and mounting plate High voltage Mains voltage 1 35 Fig 2 7 Controller board in mainte nance position DCS 400 Service Manual Chapter 2 Dismounting the Converter Remove controller e Remove flat ca board SDCS CON 3 A ble connectors X12 X13 e Remove panel adapter PCB at 7 Hemovel O terminal plugs remove m CON e f necessary re B m NIAI from controller frame move optical ca XE VA ble at V800 e Remove fixing screws of con troller board Remove the entire con Remove flat ca troller frame ble
36. e same type des ignation or that the new component can replace the old one A semiconductor can be replaced by different manufacturers com patible semiconductor according to the codes in the table refer to Appendix A Semiconductor components are high precision products All unnec essary tools and articles constitute a risk of damage to the easily dented and scratched surfaces and to the semiconductors in gen eral 1 Keep new semiconductors as long as possible in their original packages 2 Use protective gloves if possible 3 Clean work station and hands frequently 4 Use good lighting VIK 6 7 Chapter 6 Thyristor Modules Exchange of Thyristor Module Required Tools Disassemble Thyris tor modules VIK 6 8 All DCS 400 converters are equipped with thyristor modules In order to keep the operating temperature of the semiconductor module low the joint between the heatsink 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 in structions must be observed with particular care Special tools or material needed in addition to standard tools for the exchange of thyristor modules torque spanner 5or6Nm thyristor module to heatsink 3 5 9 or 12 Nm electrical connections see Table 6 2 Screws are metric type use appropriate nuts thermal joint compound silicon free grease type Berlub FZ1 E3 number
37. eneration Internal FIREN signal FIRE Not Internal FIREND signal FIRE Not Delayed first pulse delayed 8 us done by a counter PULSETRAIN PULSETRAIN DCS 400 Service Manual Chapter 6 Thyristor Modules The firing pulses are designed to drive thyristor modules The amplitude of the pulses is min 300 mA typ 600 mA with min 500mA typ 800 at the beginning The current rise is more than 1A us _________ 833 ______ 10 us done by RC SDCS PIN 3 A 7 40V ua un m m um m power part PULSETRAIN _1_ SDCS CON 3 A M uum ue Gm A Wm mm Figure 6 1 Generation of firing pulses VIK6 3 Chapter 6 Thyristor Modules Power measuring values zoom of the start firing pulses total length of pulsetrain 833 us pulse sequence per phase Figure 6 2 GEILE 25M5 75 4 48 57 800mA 1045 thi z 128mVv 1 100m 10 GEILE 2 5M S fs 57 0 000 1005 128mVv LE 100m 100p5 Tek 500 5 ss Fo 0 000 Be PR Ga an 5 thi 128mVv Measuring values of firing pulses with an AC current probe VIK6 4 DCS 400 Service Manual Chapter 6 Thyristor Modules Temperature of thyristor Maximum permitted temperatu
38. er board SDCS CON 3 A 0120 sangang 1 0 2 A1300 ianh 8 T2 Encoder a Fieldbus Dig Inputs qut d e s Fg e E aga dts cmo DE mt Pos gut gom Ba I a 74 TUM Y 12 4 PL E img a TIRE n 5W Encoder a NEU gt um im al Fig 3 1 Supply voltages on CON 3 A board DCS 400 Service Manual VIK 8 3 Chapter 3 Controller board SDCS CON 3 A Other helpful meas uring points VIK 3 4 Ground Temp 100 C 3 0 It PTC is broken 5 0 Panel connector ika 7 el Connection ta 3D C aS PIM 305 supply voltages actual values Be Bridge 2 40 Bridge 1 active 4v Connection ta SOC 5 1 4 3 fring pulses current directions tk G amped ara by 4 RxDP 3 GND 594 far intemal use only DCS 400 Service Manual Chapter 3 Controller board SDCS CON 3 A Burden adaptation DCS400 is equipped with 16 step burden resistor adaptation con trolled by software Depending on ac
39. er loading e f you have to operate the thyristor power converter at a rated motor voltage and or a rated motor current significantly below the figures stated in the thyristor power converter s output data you must take appropriate precautionary measures to protect the unit against overspeed overload breakage etc by modifying the software or hardware appropriately e Forinsulation testing you must disconnect all cables from the thyristor power converter You should avoid operating your unit at values other than the rated data Non compliance with these instructions may cause lasting damage to the thyristor power converter The thyristor power converter possesses a number of automatic reset functions When these functions are executed the unit will be reset after an error and will then resume operation These functions should not be used if other units and devices are not suitable for an operating mode of this kind or if their use might entail dangerous situations Warning of electrostatic discharge this symbol warns you against electrostatic dis charges which may damage the unit Where appro priate the text printed next to this symbol describes how a risk of this kind may be avoided VI K ii DCS 400 Service Manual Notes Mains connection EMERGENCY STOP buttons Intended use DCS 400 Service Manual Safety Instructions Notes supply information on states requiring particular attention or indicate that addi
40. escribed in chapter 2 additionally pay attention to the following information In order to obtain access to the field exciter unit from the power in terface board SDCS PIN 3 A loosen the screws C1 U1 V1 W1 and D1 as well as the bolts with an 8 mm socket wrench left and right on the PIN board detach the connectors X11 X14 X15 X16 and X22 on the PIN board unclamp the connecting cable of the filter choke L1 sits directly on heatsink from plug X100 and unwind the cable from the current transformer T2 see Figure 5 3 VIK5 5 Chapter 5 Field Exciter Unit SDCS FIS 3 A Filter choke L1 on Heatsink gt T2 on PIN Board to clamp connector X100 Note 1 Winding for A2 A3 A4 Frames Field current 16 20 A Filter choke L1 T2 on PIN Board to clamp connector X100 Note 3 Windings for A1 Frames Field current 4 6 Figure 5 3 Direction and number of windings depending on the field current type of frame shift the power interface board together with the transparent plastic insulation see Figure 5 6 towards the bottom of the converter and detach the connector X6 from the field exciter unit FIS boardq If the connecting cables of the connectors X1 X2 X7 as well as X3 X4 X5 are long enough the PIN board can be shifted in order ac cess the field exciter unit FIS board Otherwise the power inter face board and the transparent plastic insulation h
41. for planning in stalling 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 en gineering and e basic experience with DC drives and products DCS 400 Service Manual VIK 1 1 Chapter 1 Introduction Associated publications Storage and transport Rating plate Example Type VIK 7 2 The Manual DCS 400 publication no 3ADW 000 095 includes the following System overview Technical data Overview of software Installation Operating instructions Serial interfaces If the unit had been in storage prior to installation or is transported to another location care must be taken to ensure that the environ mental conditions are complied with see Manual DCS 400 CAUTION The thyristor power converter weighs quite a lot and should therefore not be held by the front cover Please put the unit down only on its back Always use due care when handling the unit SO as to avoid injuries or damage For purposes of identification each thyristor power converter is fit ted with a rating plate stating the type code and the serial number which serve as individual identification of each unit The type code contains information on the characteristics and the configuration of the unit ABB Automation Products GmbH Made in German Fan 115 230 V Type DCS402 0050
42. ied out by properly qualified staff who has been thoroughly trained in electrical engineering The thyristor power converter and its adjacent units must be properly earthed by qualified professionals You must NEVER perform any work on the thyristor power con verter while it is still switched on First switch the unit off use a measuring instrument to make absolutely sure that the power converter has really been de energised and only then you may start with the work concerned Due to external control circuits there may be dangerously high voltages present at the thyristor power converter even after the line voltage has been switched off So always work at the unit with appropriate caution Non compliance with these instructions may result in injury or even death DCS 400 Service Manual Safety Instructions General warning this symbol warns you of non electrical risks and dangers which may result in seri ous or even fatal injury to persons and or in damage to equipment Where appropriate the text printed ad jacent to this symbol describes how risks of this kind may be avoided When thyristor power converters are in use the electric motors power transmission elements and the driven machines are working in an extended operating range which means they have to cope with a relatively high loading e You should have made sure that all units devices and appli ances used are actually suitable for this high
43. l function Set Typecode see DCS 400 Manual page 6 4 Pin number is 400 Read Type from converter name plate e g DCS401 0045 Select type in the list and confirm Confirm converter type and wait 10 s Switch off and on electronics e Download parameter from harddisk into the drive using Drive Window Light e Upload parameter into the operating panel see DCS 400 Man ual page 6 5 e Check the behavior of the drive e New parameter and signals in firmware 108 0 Arm Curr Lev 3 25 Ramp In Act 5 33 Tacho Offset 5 34 CON Board 7 21 Disable Bridge 1 9 19 Disable Bridge 2 9 20 VIKC 4 DCS 400 Service Manual Replace SDCS CON 3 with firmware 107 by SDCS CON 3 with firmware108 0 DCS 400 Service Manual Appendix C Compatibility Hardware Software Starting situation DCS 400 with firmware 107 3 or earlier Operating panel DCS400PAN with text version 3 00 or earlier New controller board SDCS CON 3 incl firmware 108 0 New operating panel DCS400PAN with text version 4 00 Connect operating panel DCS400PAN version 4 00 to the converter Upload parameter into the panel Switch off electronics Replace controller board by the new one Switch on electronics Ignore possible faults to begin Check software version Parameter SW Version 7 04 108 0 Pan Text Vers 7 19 4 00 Maybe it s necessary to select long parameter list in panel function Long Short Par List
44. lf are obeyed These converters require semiconductor fuses in the 3 lines the converter must be disconnected from the mains one motor armature lead should be disconnected from the con verter 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 W1 to D1 see ba sic drawing of the power section normally every measurement should show high resistance gt 1 kQ target find a short circuit indicated by low resistance 1 Q destroyed thyristor fthe converter is designed with half bridge thyristor modules as in the case of four quadrant 4Q converters then a module con sists of two anti parallel thyristors In this case it is sufficient to know which thyristor pair or module has a defective thyristor be cause the complete module must be replaced After a thyristor module is replaced the above mentioned meas urement should be done another time to make sure that all faulty thyristors have been detected Note The RC snubber circuit could also cause 0 Q result for a short time The measurement showing less resistance than 1 2 should be made a second time with test leads applied to the terminals with the opposite polarity if this measurement shows the same result one or two thyristors located in that path are faulty they need to be re placed VIK6 2 DCS 400 Service Manual Firing pulses G
45. n order to prevent bearing wear VIK 7 1 Chapter 7 Preventive Maintenance VIK 7 2 DCS 400 Service Manual Appendix A Spare Parts List Spare parts quick finder for 2 Quadrant 2 Q DCS 400 series DCS 401 0xxx e e e lt e TT N e e X IX XIX X X power interface board SDCS PIN 3 3ADT 312200 0001 field supply SDCS FIS 3 A 3ADT 312100 80001 SKKT 162 16 E DCA 0011965 P0001 0 3 thyristormodule TT 425 16 ____ SADC 340032 P0001 1 5 thyristormodule TT 570 N 16 KOF 3ADC 340066 P0001 1 5 170 1564 50 660V DCZ 9838767 P0001 3ADC770024 P0009 0 4 170 M 6811 700A 660V DCA 0012716 P0001 1 2 170 M 6813 900A 660V DCA 0012724 P0001 170 M 6166 1250A 660V DCA 0012741 P0001 fan 115V S0 60Hz CN2B2 0 SADT 754014 Pooo1 OG _ h fan 2307 50 60 2 WaE 250 06 08 7 3ADT 754015 P0001 h 0 2 O1 lt L N N m N L e P e Note Spare parts for DCS 400 differ from those for DCS 500 DCS 600 even if the type names are identical DCS 400 Service Manual VIKA 1 Appendix A Spare Parts List Spare parts quick finder for 4 Quadrant 4 Q DCS 400 series DCS 402 0xxx SKKT 27B 16 E 3ADC 340063 P0001 0 SKKT 42B 16 E SADE 340067 P0001 Es A M Ros
46. nal ground potential IP 2 s b 4 Ground z TA 9f bX ELA AE 4 t connectors of the current transformers Es fuses for field supply field supply 5 SMP supply voltage Fig 4 1 SDCS PIN 3 A Behavior of fault If there is a short circuit at one or more outputs or the fly back con verter will be overloaded the power supply tries to start If it is not successful it tries again in a few seconds interval This behaviour could be heard and be seen at the blinking seven segment display if the 5 V is not short circuited Nevertheless there are running modes of the power supply possible in case of a short circuit which will damage diodes at the secondary side of the fly back converter During running the power supply without controller board the volt ages will rise to values outside the specified tolerances These volt ages are not very stable they will not endanger any parts of the power supply VIK 4 2 DCS 400 Service Manual Chapter 4 Power interface board SDCS PIN 3 A Field choke connection SDCS PIN 3 Old field choke SADT 748069 70 connected to 11 2 X11 3 SDCS PIN SAX Temporary PCB C503 R512 manually mounted at the PCB Will be replaced by SDCS PIN 3A New field choke SADT 748073 74 connected to 11 1 X11 3 SDCS PIN 3A Final PCB C503 R512 included in PCB layout New field choke S8ADT748073 74 connected to
47. nk to 5 Nm mounting torque and the screw for electrical connection to 3 Nm mounting torque refer to Figure 5 4 4 Reattach all connectors X1 to X5 X7 and X14 to the field exciter unit 5 In order to ensure compatibility between revision stands of field exciter unit FIS board and power interface board PIN board refer to Appendix C Compatibility Hardware Software for more information before continuing with step 6 Figure 5 6 The transparent plastic insulation 6 Push the transparent plastic insulation Figure 5 6 and the PIN board back into place see Figure 5 7 if they were not removed completely Otherwise put them back in place Reattach the connector X6 from PIN board to FIS board Ensure that the connecting cables for the connectors X1 X2 X7 as well as X3 X4 X5 are led through the corresponding holes or slits to the front of the PIN board VIK5 8 DCS 400 Service Manual Chapter 5 Field Exciter Unit SDCS FIS 3 A Figure 5 7 Positioning of the PIN board 7 Heattach the connectors X1 X2 X7 as well as X4 X5 8 Reattach the connectors X11 X14 X15 X16 and X22 9 Lead connecting cable from filter choke L1 once for 16 20 A or three times for 4 6 A through the current transformer T2 and clamp it to connector X100 see Figure 5 3 10 Screw the PIN board into place 11 Reattach the ribbon cables on the controller panel to the con nectors X12 and X13 on the PIN board and screw the
48. r Calculate the resistance of motor field using field voltage nominal Ue and field current Re 5 nominal le of motor plate warm state 35 Compare the measured and 5 approx Re calculated values in considera It s only a first rough estimation tion of warm and cold state of If the comparison is out of this the motor Remember the de range there is something viation between warm and cold wrong with the motor field motor field is approx 35 calc VIK 5 3 Chapter 5 Field Exciter Unit SDCS FIS 3 A Be careful now because of high Up to 700 V possible at termi voltage at the unit nals X10 Switch on ONz1 RUN 0 the Mains supply has to be avail drive able now Measure field voltage actual Because of warm or cold state Ue of the motor using a of motor field the deviation of Voltmeter the field voltage can be approx 35 referring to the motor name plate Measure field current actual If Field Cur Act 4 02 is not le_j using parameter Field Cur stable check stability of mains Act 4 02 supply voltage additionally refer to fault description F12 F13 chapter 6 of the DCS400 Man ual Set temporary Net Underv Trip 1 10 0 and Net Fail Time 0 5s Calculate the resistance of Re Ue a le motor field again using le_ values of the field Values of motor field resistance Re meas act measured by Ohmmeter an
49. re of thyristor bridge are given in the bridge table below Converter module Fault level F7 Alarm level A4 F7 5 C C C DCS401 0045 cDCS4010068 68 a 4 8i _ DCS401 0125 DCS4010080 7 e DCS401 0315 DCS401 0610 DCS401 0740 DCS4001 09D 5 8 6 _ DCS402 0075 rDes402 0100 87 e 985 _ DCS402 0200 DCS4020850 DCS402 0450 DCS402 0820 93 88 005402 1000 90 85 __ DCS 400 Service Manual VIK6 5 Chapter 6 Thyristor Modules Snubber circuit VIK 6 6 In the modules of the DCS 400 series the snubber circuit is divided in two parts the dV dt limitation and the over voltage protection The advantage is that the RC snubber circuit is very small and so the power consumption is small Because every thyristor has its own RC snubber there is no point of operation in which a thyristor is unprotected The voltage rise is limited to less than 1000 V us The overvoltage protection is laid out as a combined snubber circuit at the AC side of the thyristors The normally used discharging resistor of this work is substituted by a step down chopper which feeds the motor field This reduces the power losses in the converter very much E g with a 700 A unit about 800 W are saved The overvoltage protection is only needed when the converter is running in the continuos current flow of the armature current During pulsa
50. t figures show the terminals of thyristor modules The termi nals of modules are also stamped or marked by a sticker on the modules Cr n I EleG E3 E V FS 9 E ES G 4G 11250 330 11425 570 Figure 6 6 Terminals of half bridge thyristor modules DCS 400 Service Manual 6 173 Chapter 6 Thyristor Modules VI K 6 14 DCS 400 Service Manual Recommended Regular Maintenance Air Filters Fan Heatsink DCS 400 Service Manual Chapter 7 Preventive Maintenance Certain items should be checked regularly to ensure a problem free operation If air filters are used the cleanliness of filters should be checked according to the ambient conditions so that obstructed filters do not prevent the cooling of the DCS 400 Bearings of the cooling fan motor should be checked e g once a year and the fan should be replaced if the bearings are not in good condition The DCS converter can run into overtemperature faults if the heat sink is not clean In normal environment the heatsink should be checked and cleaned annually Use compressed dry air to remove dust from the heatsink The air flow direction must be from bottom to top Also use a vacuum cleaner at the air outlet to trap the dust Fan rotation must be pre vented i
51. ta 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 VIK1 3 Chapter 1 Introduction VIK 1 4 DCS 400 Service Manual Chapter 2 Dismounting the Converter 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 Main components of The main components of DCS 400 4 Q units are shown in the fig DCS400 module ures below Frame size Lid Cover PCB Panel adapter PCB SDCS CON 3 A Base plate of electronic MP capacitor PCB SDCS PIN 3 A InsulationPlate Spacer stud Current transformer Busbars Terminal sensor Choke PCB SDCS FIS 3 A Thyristor modul Distanz nut Terminal block Heatsink Housing Fan Top plate Fan terminal Screws NM m nm O Fig 2 1 3 D drawing of the DCS 400 Frame size 1 DCS 400 Service Manual VIK2 1 Chapter 2 Dismounting the Converter N ol ol kk o TOO OAH WBN N NY e Lo o CE N DAN Frame size A2 Lid Cover P
52. test DCS 400 firmware includ ing a detailed description and required PC Tool 04 1080A exe also in Internet www abb com motors amp drives DC Drives DC 400 Downloads Drive software Starting situation DCS 400 classic with firmware 107 3 or earlier Operating panel DCS400PAN with text version 3 00 or ear lier Attention Parameter stored in operating panel will be lost Requirements PC incl Drive Window Light PC tool D4_1080A exe Connect PC to DCS 400 Start Drive Window Light Upload parameter from drive to PC and save to harddisk Switch off electronics Set jumper S4 3 4 to 1 2 Switch on electronics Ls FSS 4 p Pa aaa Oe 2 2 dt Load panel text file 4 00 into the drive using Flash PC tool Switch off electronics Set jumper S4 1 2 to 3 4 Hint Switch on electronics Do the panel update before firmware update Update the operating panel Switch off electronics Set jumper S4 3 4 to 1 2 Switch on electronics Load firmware 108 0 into the drive using Flash PC tool Switch off electronics Set jumper S4 1 2 to 3 4 Switch on electronics VIKC 3 Appendix C Compatibility Hardware Software e Ignore possible faults to begin Check software version Parameter SW Version 7 04 108 0 Pan Text Vers 7 19 4 00 Maybe it s necessary to select long parameter list in panel function Long Short Par List e Select pane
53. ting D C operation there is nothing to commutate and there fore there is no overvoltage There are no inverse currents in the thyristors that will cause overvoltages together with the line chokes Because the discharging of the capacitor of the overvoltage protec tion is done by the chopper it is necessary that a field current is flowing all the time An operation without connected motor field is not allowed The minimum current that has to flow is 0 1 A for A1 converter units and 0 3 A for A2 A4 units This is guaranteed by the converter typecode The field exciter should not be tried to work without load because of risk of damaging the output filter capacitors of the field exciter unit The capacitor of the field exciter unit is chosen to withstand the transient overvoltages defined in EN61800 3 and to protect the semiconductors of the converter There are no longer any varistors needed to protect the thyristors DCS 400 Service Manual General Instruction for Handling Semiconduc tors DCS 400 Service Manual Chapter 6 Thyristor Modules Thyristor modules and busbars have to be mounted to the correct torque using a torque screw driver or torque wrench Always mark components suspected to be damaged clearly after removing them from the circuit to avoid confusion with good com ponents When removing a damaged semiconductor note which way it was installed on the heatsink Be sure that the new and old component have th
54. tional information is available on a specific topic For this purpose the following symbols are used CAUTION Cautions are designed to draw your attention toa particular state of affairs Note A note contains or refers you to additional informa tion available on the particular topic concerned You can use a switch disconnector with fuses in the power supply of the thyristor power converter to disconnect the electrical compo nents of the unit from the power supply for installation and mainte nance work The type of disconnector used must be a switch dis connector as per EN 60947 3 Class B so as to comply with EU regulations or circuit breaker type which switches off the load cir cuit by means of an auxiliary contact causing the breaker s main contacts to open The mains disconnector 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 func tion Pressing the STOP button on the DCS400 PAN control panel of the thyristor power converter will neither cause an emergency motor stop nor will the drive be disconnected from any dangerous potential 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
55. tual armature current of the motor set in parameter Arm Cur Nom 1 01 the right burden re sistor is switched on It is necessary to increase the current transfer ratio when increasing motor current With the smallest step of 25 A and 16 steps a current up to 400 A could be handled by using a current transformer ratio of 1500 1 Currents greater then 400 A need a greater transformer ratio Used current transformer ratios 25 Ato 275A 1500 1 276 Ato 800A 3000 1 801 A to 1200 A 4500 1 For that the possible current ranges are Transformer ratio Current range 1500 1 25 400 A in steps of 25 A 3000 1 50 A 800 A steps of 50 A 4500 1 75 A 1200 A in steps of 75 A If armature current nominal set by parameter Arm Cur Nom 1 01 fits to the steps given by the switched steps then the burden volt age is 2 V The switched burden resistors are 120 250 mW t 0 1 96 60 250 mW 0 1 30 Q 500 mW 0 1 159 1 W 0 1 current transformer 1500 1 burden adaptation controlled by software 1 i 1209 base burden resistor Fig 3 3 Switched burden resistors DCS 400 Service Manual VIK3 5 Chapter 3 Controller board SDCS CON 3 A Overview burden adaptation per converter module 2 Q converters if parameter Arm Cur Nom 1 01 is in a range Current transformer 1500 1 DCS401 0020 DCS401 0045 DCS401 0065 iii DCS401 0125 1 DCS401 0230
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