Home

DCS800 Service Manual

1. ma 4 V11 2 IT V21 V21 T_T E 2 V11 V24 g TS V1
2. 8 84 DCS800 S02 0025 0200 mm m a IO La IS V12 V25 V14 V21 V16 V23 V12 V25 i i s ESAS 4 a PES Sloe JE IVE Oo oo dojoq do 0 t O O O 2 2 3 m E E x o o loj OI lo O E E 5 z 8 al o O o g o O e fe O e 3 C3 i O 5 O 9 O a E O O O Dmm HM am nm O o O JOE 3 QE JOE V11 V24 V13 V26 V15 V22 a a le V11 V24 V13 V26 V15 V22 0520 dO DCS800 S01 0680 1000 m V26 V13 V22 V15 6 NV24N11 Le 6 ie K2 Tm pa Ene v11 8E V14 V24 e V21 e V15 3 v12 ti SS In E e e e v2 E C jo OJ B o O WIE vos 9 gt e 6 e e Pu G 3 ejL ej ej lle e e e V16 V13 Els O 69 G A RAE v26 ae Z T RE v23 da 9 6 6 e e e e V21 V14 V23 V16 V25 V12 DCS800 loc of mod 40 dsf Note This drawing is only showing the location of the OnBoard bridge and thyristor modules the actual converter module size is different Excha
3. iii 123 9 years preventive maintenance ii 124 Preventive maintenance Checklist DCS800 cece eeeceeeeceeeeseeeeeeeeseeeeseeeeseeeeeeeesaeesaeeeseeeeaes 125 Appendix A Spare Parts List 127 Table of contents 3ADW000195R0601 DCS800 Service Manual e f 11 Introduction Chapter overview This chapter describes the purpose contents and the intended use of this manual Before You Start The purpose of this service manual is to provide detailed information on how to service DCS800 power converters The Safety instructions at the beginning of this manual needs to by studied before attempting any work on or with the drive Read this manual before servicing the drive What this manual contains The Safety instructions are at the beginning of this manual Introduction the chapter you are currently reading introduces you to this manual and the thyristor power converter rating plate Fault Tracing Thyristors this chapter describes how to detect and select a faulty thyristor Handling the Semiconductors this chapter describes the handling of thyristors and thyristor modules Exchange of Thyristors for sizes D1 to D4 this chapter describes the exchange of thyristors in converters sizes D1 to D4 Exchange of Thyristors for size D5 this chapter describes the exchange of thyristors in converters sizes D5 Exchange of Thyristors for size D6 this chapter describes the exchange of thyristors in
4. mo d Bux3 Dbemao rec S B x350 rec HEN 2 BOxseope Edit SOx37U ri Remove File From Project Download File to Device Freshen Local File Alt ShiFE F Properties i FLASH Development Toolkit 2 2 DC S800 File Edit View Project Device Image Tools Window Help e s i av D Be Ek ill Add Files ta Project Add Files to Project From Kernel Dir a Set as Active Project Remove Project Erase FLASH Upload Image HES Tex Blank check Cancel FLASH Operation Build Device Image Freshen all Target Files Properties Alt Shift R Service 3ADW000195R0601 DCS800 Service Manual e f 94 Download text file De energize the DCS800 electronics S4 Set jumper S5 on SCDS CON 4 from l position 1 2 to position 3 4 n 4 l 3 Energize the DCS800 electronics In case the 7 segment display shows a d the firmware s corresponding text file has to be downloaded from the workspace Note 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 FLASH Development Toolkit 2 2 DCS800 choose Set as Active Project from the pop up menu File Edit View Project Device Image Tools Window Help iB os i td g l xl fred Workspace DCSBO0 2 Projects Ele Firmware o3
5. view Favorites Tools Help tak E a Search Folders y 37 X 19 H Address E c MABBIDESSOOIFirmwarelCON AWer 3 xen FI E Go Bi Mame Size Type Date Modified O Local Disk C Firmware Folder 07 02 2012 12 31 E ABB ext Folder 20 06 2012 11 07 i Dcss5n A 1 KE FOT Workspace 20 06 2012 11 08 El ie pcsann E DCS800 Fws 1KB FWS File 20 05 2012 11 11 I Drivewindow E I Firmware I COM 8x ED CON 4 Falders DD H85 2633 E L3 Ver 3 xen c Firmware ic Text Service 3ADW000195R0601 DCS800 Service Manual e f 89 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 CAABB DCS800 Firmware CON 4 Ver x x Firmware le CLABB DCSSO0O Firmware CON 4 Ver 3 xen Firmware File Edit View Favorites Tools Help Qs O A i seah E roer 5 3 X 9 Folders Mame Size Type Date Modified E Local Disk Er Firmware cpj 1KB FDT Project 20 06 2012 11 08 E ABB s B x35 rec 646 KB S Record file OF 04 2009 17 16 pessso s B x35 Demn rec 646 KB S Record File 07 04 2009 16 15 s 80x360 rec 656 KB 5 Record File 01 02 2010 13 46 E ic pesano Drivewindow s S0x360Demo rec 657 KB S Record file 01 02 2010 13 49 E Firmware s BO 370 rec 5563KB 5 Record File 17 11 2011 13 05 s 80x37 pemno rec 663 KB 5 Record File 17 11 2011 13 06 I COM 8x E I
6. 6 12 3ADC340087P0001 TV 989 2770xxx DCR2760V28 3ADC340120P0001 Semiconductor fuses 6 6 DCAO012856F0001 UR2500A 1000V jFlush endcontactfuse 56 00 DCS800 S01 3300 08 amp DCS800 S02 3300 08 800 V Thyristor 6 12 3ADC340087P0001 TV 989 2770xxx DCR2760V28 3ADC340120P0001 Semiconductor fuses 6 6 DCAO012856F000 UR2500A 1000V Flush endcontactfuse Thyristor 6 12 3ADCS4008P0001 5STP38Qox Semiconductor fuses 6 6 8ADC770080P0005 UR2500A 1250V Flush endcontactfuse Thyristor 6 12 3ADC340084P0001 5STP388Qox S Semiconductor fuses 6 6 3ADC770030P0006 UR2300A 1500V Flush end contact fuse Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 138 99 00 DCS800 S01 4000 04 05 amp DCS800 S02 4000 04 05 400 V 500 V Thyristor 6 12 3ADCS40088P0001 T989 33000x S O Semiconductor fuses 6 6 DCAO012830P0001 UR3000A 660V Flush endcontactfuse 60 00 DCS800 S01 4000 06 07 amp DCS800 S02 4000 06 07 600 V 690 V Thyristor 6e 12 3ADC340046P0002 5STP3328box Semiconductor fuses 6 6 3ADC770080P0002 UR3000A 1000V Flush endcontactfuse 61 00 DCS800 S01 4000 08 amp DCS800 S02 4000 08 800 V Thyristor 6 12 3ADC340046P0002 5STP3328Lxxx 00 O Semico
7. 6 Tighten the screws to nominal torque according to table Nominal mounting torque for OnBoard bridge and thyristor modules Thyristor modules and SDCS BAB F Nominal mounting torque Type Electrical Thyristor module connections to heat sink 29 mm bridge block VVZF 70 16 7 Reinstall the current transformer Make sure its position and direction is correct 8 Reinstall the busbars Make sure the correct torque is applied according to table Nominal mounting torque for OnBoard bridge and thyristor modules 9 Reconnect all gate leads to the thyristor module 10 Perform an OHM test to make sure the thyristor is ok 11 Reinstall the SDCS PIN 4 board 12 Reconnect all cables and plugs at the SDCS PIN 4 1 snubber resistor X30 X31 temperature sensor X22 current transformers X3 X4 X5 OnBoard excitation X8 X9 X11 use proper winding direction and amount of windings for T100 gate leads first X16 X18 then X15 X17 OnBoard excitation line voltage X1 X2 X7 all plugs X10 X96 X99 and all flat cables X12 X13 X37 use the lock connectors at the SDCS PIN 4 13 Reconnect the flat cables at the SDCS CON 4 X12 X13 X37 and re hinge the electronic tray 14 Reconnect the grounding plug and the holding screw at the electronic tray 15 Reconnect all I O plugs at the SDCS CON 4 X3 to X7 and the plugs at the SDCS DSL 4 X51 to X54 16 Reinstall the intermediate cover all plug in options do not forget th
8. Control Board 1 1 3ADT313900R1001 SDCS CONA Power interface boari 1 1 3ADT220000R0000 sDos PN 51 Air Flow detector PI 1 1 DCFIO66650P0001 P233A MAHC Module contains 51 00 DCS800 S01 2050 10 amp DCS800 S02 2050 10 990 V DESCRIPTION CODE TYPE DATA NOTES Thyristor 6 12 3ADC340086P00001 TV989 270000x Cd Semiconductor fuses 6 6 3ADC 70030P0003 UR1800A 1250V Flush end contact fuse Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 137 52 00 DCS800 S01 2600 10 amp DCS800 S02 2600 10 990 V Thyristor 6 12 3ADC340086F0001 Tv989 2700 xxx Semiconductor fuses 6 6 3ADC770030P0003 UR1800A 1250V JFlush end contactfuse DCS800 S01 2600 12 amp DCS800 S02 2600 12 1200 V Thyristor 6 12 DCAO0120089p9p U 5STP28box 00000 Semiconductor fuses 6 6 3ADC770025P0001 UR1700A 1500V Fiush endcontactfuse 54 00 DCS800 S01 3300 04 05 amp DCS800 S02 3300 04 05 400 V 500 V Thyristor 6 12 3ADC340089P0001 T989 3030xxx DCR3400v18 3ADC340121P0001 Semiconductor fuses 6 6 DCAO012821F0001 UR2500A 660V jFlusheendcontactfuse 55 00 DCS800 S01 3300 06 07 amp DCS800 S02 3300 06 07 600 V 690 V Thyristor
9. Location of thyristors in frame D6 4 Q bridge with single thyristors 51 Location of thyristors in frame D6 4 Q bridge with BCTS nnnnnnnnnannnnnnnnnnnnnnnnnnnnnna 52 Location of thyristors in frame D6 2 Q bridge with single thyristors 53 Location of branch fuses frame DG ii 54 Exchange thyristors size D7 55 Installation of disc type thyristors in converters size D7 2500 5200 A eccceeeeeeeeeeeeeeeseeeees 55 Required TOOL e cx EP 55 Fina faulty thyrister Module S os du on o dote a 56 Remove faulty tBVEISIOF x sisa tad eibi a g eb ei 58 IVS CAMS We TDOVETS tO eitis reas ha v a acc trance ha iacu ax eat ano ana Roem e NL Ce aden aos 60 Location of thyristors in frame D7 4 Q bridge i 62 Location of thyristors in frame D7 2 Q bridge nnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanannnnnnnnnta 62 Location of branch fuses frame D7 busbars on the right ennennnnnnnnnnnnnnnnnnnnnnnnn 63 Location of branch fuses frame D7 busbars on the left nnennnnnnnnnnnnnnnnenzznnzn 64 Exchange SDCS CON 4 65 GACT AN e ER M xe CAPE 65 Redurre Hero cm Ihr HP EP 65 Overview SDCS CON 4 exchange iii 65 Service 73 Exchange converter fans sizes D1 to D3 two fans e 73 Exchange converter fans siz
10. bT AERE Display e first step is to specify the name of your project A proje Fl bi Tal cd The first step is t ify th f ject A project EJ Device 15 name must be no more than 100 characters in length and pe Target P ii contain only valid filename characters ie LED mot E kesvybeard m Project Mame Ij Comm nme Dy Jed Desena Text user defined Device Image i Target Files dz Drive mot Fat Dra mot adigorithm m You may alzo add some comments to the project Comments may be edited after creation and serve az a useful means to Tully describe the purpose of a project Add Comments lt Back Cancel Choose Device And Kernel Select Device H8S 2633F and xl confirm with Next i The FLASH Development Toolkit supports a number of Hitachi Workshace FLASH devices Select the device vou wish to use with this project from the list pace TAductp je n E T EP Display JS Cd select Device Other I Device Ira TE ATOMS Rey Target Filan Protocol 2 LED ome Compiler Hitachi 4 0 4 E Keyboard m Kernel Path CoProgram fileziHitachiFDT2 2ikKernel IS Comms net Kernel version 1 0 OO Device Image E 3 Target Files se Drive mot fot Dia mol i adigorithm m DI Back Cancel Service 3ADW000195R0601 DCS800 Service Manual e f 108 Communication port Select the proper COM port Communications Port Select Baud Rate 38400 un tick Use D
11. 121 TET al Z 521112 z H zl pE f1 221 1221 321 12 1 2 E 1 1E E E LL Epi pe Pea Da La Ln Spe V14 V21 k in E Eci amp V16 V23 V13 V26 THE i ARONA V15 V22 V12 V25 View from the right Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 53 Location of thyristors in frame D6 2 Q bridge with single thyristors ell II el Er i ff RESI li LJ H EL IL Exchange thvristors size D6 3ADW000195R0601 DCS800 Service Manual e f 54 Location of branch fuses frame D6 ee l FP I i zw PEE ae FIST eee ilni A6 branch fuse locat dsf Exchange thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 55 Exchange thyristors size D7 Installation of disc type thyristors in converters size D7 2500 5200 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 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 TX2
12. 122 3 years preventive maintenance Maps additional actions have to take place Replace the cooling fans of units D6 and D7 o Remove the cooling fan in a frame D6 o Remove the cooling fan in a frame D7 The manufacturers estimation for the operational time of the cooling fan is o GR31M 30 000 hours at 40 C o GR35C 30 000 hours at 40 C The mayor problem is the failure of the bearings Where used Aging of the components result in LIFETIMEA 1 1 speed 1 2 speed AMBIENT TEMPERATUREFSC DCS800 S0x 1900 y4 5 8 bad GR31M DCS800 S0x 3000 y 5 8 400 500 V DCS800 S0x 1900 y6 7 Ld GR31M DCS800 S0x 3000 y6 7 500 690 V DCS800 S0x 3300 y1 D7 GR35C DCS800 S0x 5200 y1 400 V 690 V 3 Increased vibration due to the imbalance of the cooling fan can last for several months 4 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 Contactors and relays should be checked for proper function Check the fiber optic cables and their connections Preventive Maintainance 3ADW000195R0601 DCS800 Service Manual e f 123 6 years preventive maintenance Foll owing additional actions have to take place Replace the cooling fans of units D1 to D5 esse n o Remove the co
13. COM 8 88x160 zip and higher no additional actions have to be taken 111 In case 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 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 Date Modified Name la Ta OM 86160 zip Open with Winzip Print Explore Explore From Here J Scan for viruses a Call Extract Eo Open With e Call Extract to here EU ERR Ca Extract to folder C ABBIDCSSOD Firmware COM ax test COM 8 58x160 Cal Extract to Folder Cut Call E Mail COM 8 58x160 zip Copy call Encrypt 0 0 Create Self Extractor Exe Create Shorkcut 3i Sonia Delete FRename Properties Following files and folders will be created SO KB Winzip File 15 12 2009 17 07 Attributes A X d COM 6 58x160 zip Date Modified 15 12 2008 17 07 winzip File File Folder 16 12 2006 09 13 File Folder 15 12 2008 09 13 5 KB MS DOS Batch File 06 10 2008 17 14 4KB ME File 17 10 2008 16 30 Connect the DCS800 directly with the PC fiber optic cable from SDCS COM 8 channel 3 to 1 USB adapter RUSB 02 or 2 PCMCIA adapter NDPA 02 with NDPC 12 Switch on the DCS800 Set Ch3 HW Config 70 21 Ring Set Ch3 NodeAddr 70 22 1 3ADWO000195R0601 DCS80
14. Device Image Target Files Bux3z pemo rec B x3S5n rec B x3s pemoa rec B x3e rec B x3e pemo rec Bux3 rec Add Files to Project Add Files to Project From Kernel Dir Set as Active Project Remove Project Connect to Device Erase FLASH blacks Upload Image Blank check cancel FLASH Operation Build Device Image Freshen all Target Files Properties Alt Shift F Service 3ADW000195R0601 DCS800 Service Manual e f 95 Choose COM Port and communication speed Select Text with a right mouse click and FLASH Development Toolkit 2 2 DCS800 choose Properties from the pop up menu File Edit View Project Device Image Tools Window Help 45 ms m a od e zl xi rs Workspace DC Sa 0 2 Projects Add Files to Project Add Files to Project From Kernel Dir Set as Active Project Remove Project Connect to Device Erase FLASH blacks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target files Properties n AlE ShiFE F Select the Communications tab choose Project Properties Text the desired COM Port un tick the box Use Project Kemel Communications Device Programmer Modules Comments default baud from the pop up menu and set the Target Baud Rate to 38400 PUO Currently connected No Service 3ADW000195R0601 DCS800 Service Manual e f 96
15. Download text file to device Select desired text file with a right mouse click and choose Download File to Device from the pop up menu After the completed download the 7 segment display shows a u Attention Do not de energize the drive or disconnect the tool while the seven segment display shows the u Wait until the 7 segment display shows an 8 and after the boot a Service i FLASH Development Toolkit 2 2 DC S800 l File Edit View Project Device Image Tools Window Help Isgajiss zzi HEE Firmware apga Text ol Device Image E Target Files 8 80x370Text cde 2 80x350DemoText cde s 80x350Text cde ul 5 80x360DemoText cde 20x360Text c E s0x370Demot Edit Remove File from Project Download File to Device Freshen Local File amp lt Shift F Properties 3ADW000195R0601 DCS800 Service Manual e f Disconnect tool Now FDT2 2 has to be disconnected Select Text with a right mouse click and choose Disconnect from the pop up menu Close download tool When closing FDT2 2 save the workspace only if firmware files or text files have been added The firmware text download is complete now 97 FLASH Development Toolkit 2 2 DC S800 l File Edit View Project Device Image Tools Window Help lis os g e oe IER xl Hrs Workspace DCS800 2 Projects ea Firmware metile MI i Add Files to Project Eg 7 Ad
16. FP en e a ta E Po ee branch V14 N NZ v21 V167N NZv23 i V12 N Y V25 ud te at Ba R6 5 5351 7481 1 a gg88 uunsuua D1 principle BB a dsf Bridge configuration D1 to D4 Normally every measurement should show high resistance gt 1 KQ Target find a short circuit indicated by low resistance lt 1 Q destroyed thyristor If the converter is designed with thyristor modules then a module consists of two thyristors In this case it is sufficient to know which thyristor module has a defective thyristor because the complete module must be replaced After a thyristor module is replaced the above mentioned measurement should be done another time to make sure that all faulty thyristors have been detected Note The RC snubber circuit could also cause 0 02 results 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 Converters size D5 D6 and D7 900 5200 A These converters are equipped with fuses in the branches of the power part The converter must be disconnected from the mains Blown fuses Make sure that the connection to the motor is open e g disconnect motor cables n case of a blown fu
17. 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 thyristors size D5 3ADW000399R0101 DCS550 Service Manual e a 37 Remove faulty thyristor 1 p 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 Write down the direction and location of the thyristors to be removed and mark their gate leads Remove the gate leads if possible Loosen the mounting clamp at the top of the thyristor stack Loose condition TORQUE INDICATING SPRING a Ll PEE Attention While loosen the mounting clamp the indicating spring must be pulled out a little sulating tube otherwise the spring will be damaged 5 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks Mounting clamp PA l EEE l IIIA LLL ICT EE GERE INI SER CO TT_ Wes SS MIN Z7 Ooo JI EVA ES TAL View from View from ma the left IMITA NN the right Disassembly tool ka 3 mountcl b dsf Front view 6 Remove the thyristors Attention To centre the thyristors sp
18. 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 Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 43 Original thyristor type Thyristor T 1329Nxxx with Id code 3ADC340081P0001 ae 077 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 Gate y Round terminal D 1 5 mm Cathode K1 Faston 4 8 x 0 5 mm Conductive plate Diameter 50 mm Exchange thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 44 Bidirectional Controlled Thyristors BCTs In some converter modules size D6 so called BCTs Bidirectional Controlled Thyristors are used BCTs are a pair of anti parallel thyristors in one disk type housing They can easily identified by the second pair of gate leads The second gate is marked with Gate B on the thyristor Gate A Faston 4 8 x 0 5 Gate A Gate B BCT dsf Faston 6 3 x 0 8 Gate B Note The Faston connectors of the gates are of different size Gate A should always be in front of the clamped heat sinks due to cooling reasons Location of BCTs gate A when built in Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 45 Find faulty thyristor modules 1 Find
19. converters sizes D6 Exchange of Thyristors for size D7 this chapter describes the exchange of thyristors in converters sizes D7 Exchange of SDCS CON 4 this chapter describes the exchange of a SDCS CON 4 Service this chapter contains hardware change information firmware download and technical hints Preventive Maintenance this chapter describes preventive maintenance of thyristor converters Appendix A Spare Parts list Appendix A contains the spare parts list Target group This manual is designed to help those responsible for planning installing starting up and servicing thyristor power converters These people should possess basic knowledge of physics electrical engineering electrical wiring principles components as well as symbols used in electrical engineering and basic experience with DC drives and DC products Associated publications A list of associated publications is published on the inner page of this manual s cover see DCS800 Manuals The above listed documentation can be found on the CD ROM being attached to the DC S600 Quick Guide 3ADW 000191 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 DCS800 Hardware Manual Introduction 3ADWO000195R0601 DCS800 Service Manual e f 12 Name plate For purposes of identification each thyristor power c
20. i oa Dustiness corrosion and temperature ES E Ee d XE i l AE ji l E i l 2M Quality of supply voltage E Li A DIP LL Bp SETTE II RT TE IT STI TETTI Based on product notes SS LL LIL lite tUe UU MUN rP T gt gt 222 gt 9 gt T3 Y FE_ P gt yYY2_ C T E y 9 TTESAVENAZ 2 Basic measurements with supply voltage P P P P EEP PRRP PREP PREP PREP PEN pum ENERO Spare Parts ESEE SESE FESE FESE SERE FENE FENE The service intervals and component replacements are based on the operational environment specified by ABB Legend R Replacement of component I Inspection visual inspection correction and replacement if needed P Performance of on site work commissioning tests measurements etc R Replacement if high ambient temperature or cyclic heavy duty Preventive Maintainance 3ADWO000195R0601 DCS800 Service Manual e f 119 Annual preventive maintenance The following actions have to take place 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 coolin
21. mn 5 Remove Faston plugs and fans Remove Faston plugs Fan connection plug X2 6 Reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module Service 3ADW000195R0601 DCS800 Service Manual e f 75 76 Exchange converter fans size D3 four fans Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition 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 Connector X2 on top of converter housing 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 3ADW000195R0601 DCS800 Service Manual e f Removing the converter fans 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on
22. 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 It also increases availability of the drive The environmental and operating conditions of the drive are also to be considered A harsh environment such as high ambient temperature humidity dust and cyclic heavy load not only shortens the components lifetime but also the preventive maintenance and replacement intervals Maintenance schedule a jYeasfromstat up S O O S S SSO O MEN 0 1 2i9 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Startup nn HEESE SERE MENE EESE uu QE ME Cooling i tipi Air Cooled Unit 2828 o_o di M eo WM Cooling fanDCS800D6 07 ER ER ER ERE ERE RE RR Cooling fan DCS800 D1 gt 45 A D5 Li SESE SESE SESE SESE SESE SESE i CIRO TI IT DCS800 Power interface board SDCS PIN 4 i i i m 1 Ri Gi 3 y mi DCS800 Power supply board SDOS POW 4 i i Qi i il A di ME eci B UON TA Flat cables nni ir i a A A m jJ Ho 1 Jightness of terminals nni ii de 1m ME m ED 0 m i Tightness of terminals heatsink D7 0 HU UNE LL Shee SESE SESE SERE Door filters nni EE EE Lil Condition of contactors i ME 3 ME 3 Mm 0 S e ue Ga Fiber optic cables connections inerte ilis p m p ME E qu
23. reserves the right to make subsequent alterations If you have any questions concerning your drive system please contact your local ABB agent Introduction 3ADWO000195R0601 DCS800 Service Manual e f 14 Voltage ratings The maximum available armature voltages have been calculated using the following assumptions Uw rated mains voltage 3 phase Voltage tolerance 10 Internal voltage drop approximately 1 If a deviation or a voltage drop has to be taken into account in compliance with IEC and VDE standards the output voltage and or the output current must be reduced Uso Voc 430 l des 0 510 1200 1380 1235 1590 The maximum available field voltage can be calculated using following formula 0 ej lt 1 35 x Us 100 TOL with 100 Ur field voltage Uvn mains voltage and TOL tolerance of the mains voltage in Introduction 3ADW000195R0601 DCS800 Service Manual e f 15 Current ratings Unit size 2 Q rated current 4 Q rated current Supply voltage Vac DCS800 01 Apc DCS800 02 Apc 400 525 600 690 800 990 1200 20 25 X X J j 45 80 X X j j amp _L__ _LLl_1_k____ HE x x JL e d only available as 2 Q drive Introduction 3ADWO000195R0601 DCS800 Service Manual e f 16 Fault Tracing Thyristors Tools For commissioning and fault tracing Follo
24. 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 EET Backplate Ji Screws Write down the direction and location of the defective thyristors to be removed and mark their gate leads Remove the gate leads if possible Loosen the mounting clamp at the top of the thyristor stack pre pere bi c f Mounting clamp Torque j indicating spring i 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 Exchange thyristors size D7 3ADW000195R0601 DCS800 Service Manual e f 59 6 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks 7 Remove the thyristors with e g a pair of pliers Attention To 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 Exchange thyristors size D7 3ADW000195R0601 DCS800 Service Manual e f 60 Install new thyristor 1 TE Ensure that the new thyristor is of the correct type see A
25. the position of the gates 4 Remove the gate leads if possible Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 4 Loosen the mounting clamp at the top of the thyristor stack Vu B Y Mi Indicating springg EN l jii l a a rene 3 LEY wr Wa MAS T p jid jali Ne os E de b n yn V a TY JS 4 Ae d B E ww a A k w KI A 25 FAN KI v T te ed Mae f a L ala L w ba udi Ru nl AM f 31 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 a NIIUUULESE C UC DR LAO NAAN i DC busbar plates M ui b JULI tI EI DEP LEER la L TI TTT AJ ey Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 48 7 Attach the disassembly tool at the faulty thyristor and prize open the upper and lower heat sinks d UUUUUUUUUUUUUIM y rar 8 Remove the thyristors with e g a pair of pliers Attention To centre the thyristors spring pins are used The pins are inlayed into all lower heat sinks Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor Exchange thyristors size D6 3ADW000195R0601 DCS800 Servi
26. 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 For more information consult the DCS800 Firmware Manual 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 Its 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 x 90 The reason for a current less thyristor may be A blown line fuse This is possible only for converters with 20 1000 A A fuse has disconnected one of the six thyristors This is possible only for converters with 900 5200 A six internal branch fuses A loose gate cathode connector Athyristor does not get firing pulses or does not react to firing pulses The cur
27. 0 TX25 Torque spanner for electrical 13 Nm M8 connections 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts 17 mm ring spanner for fuse and busbar connections 24 mm ring spanner for press clamp Tissue paper Solvent e g ethanol Thermal joint compound grease type BECHEM RHUS SU 2 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 of this manual 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 oemiconductors 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 the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Exchange thyristo
28. 0 Service Manual e f Service 112 Start firmware download by a double click on file L_ AMC DC BAT Date Modified LOM 68 eax1560 zip 680 KB Winzip File 15 12 2008 17 07 Files File Falder 16 12 2008 09 13 Prag File Folder 15 12 2008 09 13 L AMC DC BAT SKB MS DOS Batch File 06 10 2008 17 14 2 Read me 4KB ME File 17 10 2008 16 30 A DOS window will appear Wait until the download is finished the DOS window will close automatically Attention Do not touch the PC during the download of the firmware Check Coma8SW Version 4 11 for proper firmware version Set Ch3 HW Config 70 21 back to its original setting Set Ch3 NodeAddr 70 22 back to its original setting Re connect the drive to the DriveWindow network Service 3ADWO000195R0601 DCS800 Service Manual e f 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 only be changed as whole or individually To 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 SO1 0020 04 to S02 5200 05 details see table below he drive s basic type code DCS800 AAX YYYY ZZB roductfamiy pesso J Type RO Rebuild system EO Panel solution AO0 Enclosed converter Bridge type X 71 sin
29. 0 X34 Energize the DCS800 electronics the 7 segment display shows a 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 Service 3ADW000195R0601 DCS800 Service Manual e f 91 Choose workspace Mark Open an existing Workspace Welcome to the FLASH Development Toolkit x Confirm with OK Het Create a new Workspace More Workspaces CWABBSDCS 800 F irmuvareSlON 44 Ver 3 ens DCS 800 fdt CNWABBSDCS S50 F mares CE N FUT Ser 1 sens DCS 550 fdt Select the workspace in directory open 2x CAABB DCS800 Firmware CON 4 Ver em x Look in 3 Ver J uen t pf EJ Confirm with Open File name pcs BUL Fat Files af type JFDT Workspace Files fdt Cancel ji Service 3ADW000195R0601 DCS800 Service Manual e f 92 Activate firmware download Select Firmware with a right mouse click and choose Set as Active Project from the l File Edit View Project Device Image Tools Window Help pop up menu see a nn ecc el X ae CSB8DU 2 Projects Add Files to Project Add Files to Project From Kernel Dir Set as Active Project x 8 Remove Project 5 8 Connect to Device PU Et 8 Erase FLASH blacks Ule E EI Text Upload Image Blank check cancel FLASH Operation Build Device Image Freshen all Target f
30. 0650 06 600 V Thyristor modules 3 6 3ADC340097P0001 SKKT430 20xxx TT430 Nxxx MT3 4303x 00100000 Cooingfan230 V 50 60 Hz 1 1 DCAOOT217IFO001 W2E200 HH38 08 Thyristormodules 3 6 3ADCS40097P0001 SKKT430xxx TT430 Nxxx MT3 430 xx 0000 24 00 DCS800 S01 0610 04 05 amp DCS800 S02 0680 04 05 400 V 525 V Thyristor modules 3 6 3ADCS40103P0001 MCCS01 xxx TT425Nox SS Cooling fan 230 V 50 60 Hz 1 1 DCAOOT2171F0001 W2E200 HH38 06 25 00 DCS800 S01 0740 04 05 amp DCS800 S02 0820 04 05 400 V 525 V Thyristor modules 3 6 3ADCS40099F0001 MT3 505xxx TT570Nox O Cooling fan 230 V 50 60 Hz 1 1 DCA0012171P0001 W2E200 HH38 06 Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 132 26 00 DCS800 S01 0900 04 05 amp DCS800 S02 1000 04 05 400V 525V o Thyristor modules 3 6 3ADC3400099P0001 MT3 50bxxx TT57ONox y OO Cooling fan 230 V 50 60 Hz 1 1 3ADT S4017P0001 W2EZ50 HLO6 10 Thyristormodules 3 6 3ADC340108P0001 MCCS01 xxx JTTA2SNXXX y O Thyristor modules 3 6 3ADC340099P0001 MT3 595 xxx TT570Nox i O 29 00 DCS800 S01 0900 04 05 amp DCS800 S02 1000 04 05 S171 400 V 525 V Thyristor modules 3 6 3ADC340099P0001 MT3
31. 090 05 58 S01 3300 04 108 S02 1500 04 9 S01 0125 04 59 S01 3300 05 109 S02 1500 05 10 S01 0125 05 60 S01 3300 06 110 S02 1500 00 16 S01 0315 05 66 S01 4000 06 116 S02 2050 06 18 S01 0405 04 68 S01 4000 08 118 S02 2500 04 19 S01 0405 05 69 S01 3300 10 119 02 2500 05 30 S01 0900 07 80 S02 0075 04 130 S02 3000 08 36 S01 1500 07 86 S02 0200 04 136 802 3300 12 39 S01 2000 05 89 S02 0260 05 139 S02 4000 06 amp 40 S01 2000 06 90 S02 0350 04 140 S02 4000 07 46 S01 2500 05 96 S02 0520 05 146 S02 4800 08 48 S01 2500 07 98 S02 0680 04 148 02 5200 05 49 S01 2500 08 99 S02 0680 05 149 S01 4000 12 1 1150 802400042 Service 3ADWO000195R0601 DCS800 Service Manual e f 116 DC Motor neutral zone adjustment Types concerned DC Motors Summary Procedure to adjust the neural zone of a DC motor General 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 to 240 Vac between F and F a normal extension cord is sufficient Start moving the brush bridge slowly in one direction and watch the scop
32. 3 Fix the current transformers by means of 1 the mounting screws Nu Take care of proper electrical connections Note Mounting Some of the older converters require to screws Current drill a hole for the mounting screw When 4 transformers drilling the hole make sure no copper shavings are left in and at the drive Service 3ADW000195R0601 DCS800 Service Manual e f 88 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 Installation From the DCS800 Tools CD select the f Setup DCS800 DriveTools 5 xl tasks Firmware Download Tool 2 2 FDT Select Additional Tasks 7 E and SDCS CON 4 Firmware x xx Which additional tasks should be performed sl Select the additional tasks you would like Setup to perform while installing DCSSO0 DriveT ools then click Next Components DCSS00 Documentation DiveWindow Light 2 93 DCS800 add ons for OWL 2 70 and higher v Firmware Download Tool 2 2 FOT DriveWwindowWw orkspaces ControlBuilder for DCS800 CoDeSys 2 3 9 26 Back Cancel This installs the Hitachi Flash Development Toolkit 2 2 including workspace firmware text and needed file structure Workspaces ABB provides workspaces called DCS800 fdt New workspaces have to be saved in CAABB DCS800 Firmware CON 4 Ver x x le C ABB DCS800 Firmware CON 4 Ver 3 xen File Edit
33. 4 V14 TT i V24 V13 E f TOT v23 V23 T_T TT V13 i LJ m io V26 E g ET V16 V16 L I a V26 EN NE C J p E V15 T TS V25 V25 IE V15 n i ME ae V22 2 i TOT v12 V12 T_T ED V22 ms RI RSEN EN EN Ho L I i sels ee TIC XM MA DD Assembly D7 EN sree see 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 tes Oey V11 aT B_ V11 END V14 V14 ET V13 J r V13 J un L 4 B 2 V16 V16 TAT CJ NE CJ V15 TM ET V15 o Er mm uu m Te v12 V12 TIT EN mn IDA etch eee RE Ly ell O An Assembly D7 D7 ass dsf Assembly D7 Busbars on the right Busbars on the left view from the front view from the front Exchange thyristors size D7 3ADWO000195R0601 DCS800 Service Manual e f Location of branch fuses frame D7 busbars on the right s 7 s 2 oN P A PA SE FEN CU 5 Exchange thyristors size D7 ice Manu 3ADW000195R0601 DCS800 Serv 64 Location of branch fuses frame D7 busbars on the left C busbar G Q i gt T i AC busbar ot W1 nm 4 A Bh W busbar D1 DC Exchange thyristors size D7 ice Manua 3ADW000195R0601 DCS800 Serv 65 Exchange SDCS CON 4 General All DCS550 size D1 to D7 are equipped with the same controll
34. 505xxx TT570Nox y OO Item 30 00 to 36 00 Modules D5 900 A 2000 A 400 V 525 V 600 V and 690 V Replaces SDCS POW 4 EW Temperatur sensor R57 1 1 3ADT 10003PO0O1 KTVIK M4 800 Cooingfan 1 1 SADIZ amp 4018PO00 DPET60 AH02 15 Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 133 Thyristor 6 12 DCAO012007P0001 T459Nox Original thyristor type Semiconductor fuses 6 6 3ADC 70009F0007 UR630A 1250V Screw typefuse Thyristor 6 12 S3ADCS40105F0001 T460Nxxx Secondinyristoriype Semiconductor fuses 6 6 3ADC 70009F0007 UR630A 1250V jScrewtypefuse Thyristor 6 12 DCAO012015F0001 T589Nxxx Original thyristor type Semiconductor fuses 6 6 sanc77zoo1oPooo5 UR800A 660V JSorew tvpefuse Thyristor 6 12 3ADCS40106F0001 T590Nox Secondihyristortype Semiconductor fuses 6 6 3ADC770010P0005 UR800A 660V_ Screwtypefuse Thyristor 6 12 3ADCS40102P0000 T2D00 18 S Semiconductor fuses 6 6 3ADC770010PO009 UR1250A 660V Screwtypefuse 11110000 Thyristor 6 12 SADCS40008P0001 T1XXX 24 Semiconductor fuses 6 6 3ADC770009P0012 UR1100A 1250V Screwtypefuse DCS800 S01 2000 04 05 amp DCS800 S02 2000 04 05 400 V 500 V Thyristor 6 12 3ADC340102P0001 T2XXX 1
35. 601 DCS800 Service Manual e f 136 47 00 DCS800 S01 3000 04 05 amp DCS800 S02 3000 04 05 400 V 500 V Thyristor for DCS800 S01 2 Q 6 3ADC340088P0001 T989 33000x c y O Thyristor for DCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qexx Bidirectiona Controlled Thyristor BCT Puls transformer board 1 3BSE004939R1012 SDCS PN48 SD_ Replaces SDCS PIN 41 SDCS PN48 Puls transformer board 2 3BSE004939R1003 SDCS PN46 OnyusedforBCTs Thyristor for DCS800 S01 2 Q 6 3ADC340046P0002 5STP3328box Thyristor for DCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qexx JBidirectional Controlled Thvristor BCT Puls transformer board 1 3BSE004939R1012 SDCS PIN48 SD_ Replaces SDCS PIN 41 SDCS PIN 48 Puls transformer board 2 3BSE004939R1003 SDCS PIN46 JOnvusedforBCTS Thyristor for DCS800 S01 2 Q 6 3ADC340046P0002 SSTP3326Lxxx Thyristor for DCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qexx JBidirectional Controlled Thvristor BCT Puls transformer board 1 3BSE004939R1012 SDCS PIN48 SD _ Replaces SDCS PIN 41 SDCS PN48 Puls transformer board 2 38SE004930R1003 SDCS PIN46 Only usedfor BCTs 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
36. 8 Semiconductor fuses 6 6 3ADC770010P0012 UR1600A 660V Screwtypefuse Thyristor 6 SADC340090PO001 TV989 2700 xxx PP Semiconductor fuses 6 3ADC770009P0018 UR1400A 1100v Screwtypefuse Appendix A Spare Parts List 3ADW000195R0601 DCS800 Service Manual e f 134 Item 40 00 to 49 00 Modules D6 1900 A 3000 A 400 V 500 V 600 V 690 V and 800 V Air Flow detector PI 1 1 DCFIO66659P0001 P233AM AHC 41 00 JDCS800 SO1 1900 08 amp DCS800 S02 1900 08 800 V Thyristor 6 12 3ADCS40081P0001 T1329Nxxx Originalthyristor type Thyristor 6 12 3ADC340098P0001 T boo 24 Secondihyrstortype 42 00 DCS800 S01 2050 05 amp DCS800 S02 2050 05 500 V Thyrstr 6 12 SADC340081POOO1 T1329Nxxx Original thyristor type Semiconductor fuses 6 6 3ADC770010P0011_ UR1500A 660V JScrew tvpefuse Cooling fan DCS800 S01 2050 05a amp DCS800 S02 2050 05a 500 V Thyrstr 6 12 SADCa40098P0001 T1xxx 24 Secondthyristortype Semiconductor fuses 6 6 3ADC770010P0011 UR1500A 660V JSorew tvpefuse Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 135 Module contains 43 00 DCS800 S01 2050 06 07 8 DCS800 S02 2050 06 07 600 V 690 V DESCRI
37. AIR MU AI Tes LO Q Exchange thvristors size 41 Exchange thyristors size D6 Installation of disc type thyristors 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 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 13 Nm M8 connections 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts 17 mm ring spanner for fuse and busbar connections 24 mm ring spanner for press clamp Tissue paper Solvent e g ethanol Thermal joint compound grease type BECHEM RHUS SU 2 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 wit
38. CON 4 IE H85 2633 ED Ver 3 xen c Firmware ie Text New text files cde have to be saved in CAABB DCS800 Firmware CON 4 Ver x x Text le C ABB DCS800 Firmware CON 4 Yer 3 xen Text File Edit View Favorites Tools Help Q O ie i JO sn ips res 3 X 19 E Name Size Type l 80x350DemoTexk cde 479 KB CDE File I Folders E Local Disk C E Cj ABB C Dcssson E ic pesano I DriveWindow 3 ic Firmware Ey CoM 8x E i con 4 Di H85 2633 ED Ver 3 xen S0x350Text cde 479 KB CDE File I s0x360DemoText cde 490 KE CDE File SOx360Text cde 480 KB CDE File S0x370DemoText cde 484 KE CDE File S0x370Text cde 483KB CDE File Text cpi 1KB FDT Project Di Firmware c3 Text Service 3ADW000195R0601 DCS800 Service Manual e f 90 Download firmware file The firmware download is done via a PC COM Port Attention If there is no COM Port available an adapter PCMCIA ExpressCard to COM Port has to be used Adapters USB to COM Port are not reliable The download of the firmware is done in two steps 1 Firmware file rec 2 Text file cde Attention A firmware download does not influence the parameter settings The previous parameter settings are kept De energize the DCS8000 electronics Set jumper S5 on SCDS CON 4 from position 3 4 to position 1 2 ARREXRZRERRZRINCENTEEEEYEILILILLLLIIILI Connect a RS232 cable between a PC COM Port and DCS800
39. DCS800 Service Manual DCS800 Drives 20 A to 5200 A t au m m LLI E DCS800 Manuals Public number E D ES F CN RU PL PT SE DCS amp U Quick Guide jaw x x x x X x x DCS800 Tools amp Documentation CD 3ADWO0211 x j DCS800 Converter module Z o O 4 FiverDCSaBOD 3ADWO0190 jx x x x x Technical Catalog DCS800 3ADWO00012 x x x x x X x x x Hardware Manual DOS800 1 3ADWO00194 x x x x x X x x Hardware Manual DCS800 update DCF503B DCF504B 3ADW00019420301 x Firmware Manual DCS800 3ADWO00013 _ x x p x x x Installation according to EMC 3ADWO0032 x Technical Guide O 3ADWO000168 x Service Manual DCS800 3ADWO00195 __ x x Drive Tools y O x XIX X XIX X x X x x x HILLLLLLLBIE i E LJ p iew DriveOPC 2 x User s Manual 3BFE00073846 Optical DDCS Communication Link 3AFE63988235 DDCS Branching Units User s Manual 3BFE64285513 DCS800 Applications PLC Programming with CoDeSys CoDeSys_V23 X 61131 DCS800 target tool description Application Program 3ADW000199 DCS800 Crane Drive ba x DCS800Winder ITC x DCS800 E Panel Solution x DCS800 AEnclos
40. DT Data Files pr rec mot a20 7 8a37 Y Choose the desired text file and press Open Add files to Project 2 xJ Look in Co Test do E 80x 350DemoText cde S0x350Text cde l 80x360DemoText cde 50x360Text cde ken SOx370DemaText cde 50x370Text cde File name 2043607 ext cde FLIT Data Files fprz rec mot azD a37 U Files of type Close download tool When closing FDT2 2 save the workspace only if firmware files or text FLASH Workspace Manager X files have been added The workspace DCS800 has been modified Would vau like to save your changes w cma Adding of files is complete now Service 3ADW000195R0601 DCS800 Service Manual e f 102 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 a 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 18 e Create new workspace ENDO Serle New MOMS ae 4 FLASH Development Toolkit 2 2 DCS800 li File Edit View Project Device Image Tools Open Ctrl 0 Me W works Pace a Ctrl M Ctrl i trlHE
41. F503B0050 Completeunit replaced by DCF803 0050 DCF504B0050 4 Q 50A 1 3ADT209019RO202 DCF504B0050 Complete unit replaced by DCF804 0050 DCF503B0060 1 Q 60A 1 3ADT209019R0211 DOF503B0060 Completeuni replaced by DCF803 0060 DCF504B0060 4 Q 60A 1 3ADT209019R0212 DCF50480060 Completeunit replaced by DCF804 0060 Fan for DCF50xB0060 2 GHSN700002P0001_ AC220V3115FS Fan M55 M56 for DOF50xB0060 __ Item 8 06 Overvoltage protection DCF506 for fieldexciter DCS800 S0x 0020 0520 20 A 520A 8 06 Overvoltage protection DCF506 for fieldexciter DCS800 S0x 0020 0520 20 A 520A DESCRIPTION TY CODE TYPEIDATA NOTES Control board DCF505 506 1 SADT220090Ro021 SDCS FEP J 1400V for DCF505 506 Overvoltage protection field 1 DCF1127101R0001 DCF506 0140 51 Field exciter 25A 100A 7711 Overvoltage protection field 1 DCF1127119R0001 DCF506 0520 51 Field exciter 200A 520A Item 8 07 Common parts for DCS800 A Enclosed Converters Common parts for DCS800 A Enclosed Converters DIDO connection board 1 3ADT220090R0014 SDCS OB21 24VDC 48VDO digital A9 DIDO connection board 1 3ADT220090R0013 SDCS OB22 115 VAC digtal A9 DIDO connection board 1 3ADT220090R0023 SDCS OB23 230VAC dgial A9 JAVAO connection board 1 3ADT220090R0020 SDCS IOB 3 Analog and en
42. Open Workspace PI nun Save Workspace Close Workspace Save a Save OS Save All Glose File Recent Workspaces Recent Files d Exil Service 3ADW000195R0601 DCS800 Service Manual e f Name new workspace Name the new workspace choose its location and confirm with OK Choose Yes 103 Workspace Name DCSS00 User defined W Create workspace directory Location c Program FilessHitachisFD T 2 2w arkspaces m Workspace file L Pragram FilessHitachisFD T 2 2 w arkspacessD E SS User d can FLASH Workspace Manager i X J You have created a new Workspace Would you like to run the Project Wizard to add a Project ta Ehe Workspace Create the project for the firmware file Name the new project and confirm with Next Project Name l X Welcome to the FLASH Development Toolkit Project Wizard The Project Wizard will guide you through the steps necessary ta create a new project FTE im UT MEL d Workspace Industria Ep Display The first step is to specify the name of your project amp project E Device 1 name must be no more than 100 characters in length and Fre RF F rage 5 i Target Files contain only valid filename characters 15 LCD mot ig Keay beard m Project Mame OC S600 Firmware user defined LJ Device Image rl ja pa i A You may also add some comments to the project E i La Comments may be edited after creation
43. PTION 2 Q 4 Q CODE TYPE DATA NOTES Thyristor 6 12 3ADC340081P0001 T1329Nxxx Original thyristor type DCS800 S01 2050 06a 07a amp DCS800 S02 2050 06a 07a 600 V 690 V Thyrstr 6 12 SADCa40098P0001 T bxx 24 ___ Second thyristor type Replaces SDCS PIN 41 SDCS PIN 48 Screw type fuse double fuses DCS800 S01 2500 04 05 amp DCS800 S02 2500 04 05 400 V 500 V Thyristor for DCS800 S01 2 Q 6 3ADC340089P0001 T989 3030xxx DCR 3400V 18 3ADC340121P0001 Thyristor for DCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qxxx Bidirectional Controlled Thyristor BCT Puls transformer board 1 3BSE004939R1012 Replaces SDCS PIN 41 SDCS PIN 48 Puls transformer board 2 3BSED004939R1003 SDCS PN 46 _ Only used for BCT s crew type fuse double fuses 00 V 500 V 50 60 Hz CD 4 Q Thyristor for DCS800 S01 2 Q 6 3ADC340090P0001 TV 989 2700 2xxx ThyristorforDCS800 S02 4 Q 6 3ADC340079P0001 5STB24 Qvxx Bidirectiona Controled Thyrstor BCT BEN Puls transformer boari 2 3BSE004939R1003 DCS800 S01 2500 08 amp DCS800 S02 2500 08 800 V 2 Q 4 Q 1 Puls transformer board 2 UR 1000 A 1250 V Thyristor for DCS800 S02 4 Q 6 3ADC340079P0001 5 STB 24 Qxxx _ Bidirectional Controlled Thyristor BCT Appendix A Spare Parts List 3ADW000195R0
44. R 3E 7 ES EE i Saas lago TI i c ie fan p E ad d T x 2 LIST TSL ZA TH CS ml AAA ee FIAS zia ule 4 Disconnect all I O plugs X3 to X7 at the SDCS CON 4 and the plugs at the SDCS DSL 4 board if used X51 to X54 Disconnect all plugs from SDCS ili CON 4 and SDCS DSL 4 boards 7 3 E LT PE d i 1 1 en i e re QUE 3 Exchange SDCS CON 4 3ADW000195R0601 DCS800 Service Manual e f 5 Remove screws and studs 69 mate screws and studs k tiri 6 Unplug the flat cables X12 X13 X37 7 Remove the SDCS CON 4 Remove flat cables 3ADW000195R0601 DCS800 Service Manual e f Exchange SDCS CON 4 70 Install the new SDCS CON 4 1 Reconnect the flat cables at the SDCS CON 4 X12 X13 X37 2 Reconnect all I O plugs at the SDCS CON 4 X3 to X7 the plugs at the SDCS DSL 4 X51 to X54 and 3 Reinstall the intermediate cover all plug in options the design cover and the DCS Control Panel 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 Press Soft key 1 until the main menu is shown Press LOC REM button display will show LOC on th
45. S800 Type of drive Frame size 125 Serial number Year of initial start up Last inspection 1 Environment 1 1 Checking the environment 1 2 Documentation checked and available 1 3 Checking the spare parts 2 Maintenance with no voltage applied 2 1 Cleaning with ESD vacuum cleaner and or soft brushes Converter and cabinet Air inlet and outlet filters replace clean if IP54 or if needed Fins of fan Drive s heat sinks 2 2 Relays amp connections Inspect relays contacts for proper functionality Inspect electrical connections for tightness Inspect for proper grounding Inspect for corrosion Inspect tightness of heatsink terminals 25 Nm required Inspect connection of fiber optical cables Inspect connection of flat cables 3 Maintenance with main supply voltage applied Create parameter backup Test cooling air pressure switch Check level of all connected voltages Check E stop coast stop function Inspect condition of fans check that all fans are operational ABB Automation Products Inspection cycle yearly yearly yearly yearly yearly yearly yearly 3 years 3 years yearly yearly yearly 3 years 6 years yearly yearly yearly yearly yearly 3ADWO000195R0601 DCS800 Service Manual e f va ra JOL JUL JUL OOL JUO O LILI LILILJUI LILILILI JUO UI LILI LILILJUI LILILILI JLILILIUI LILI LILILJUI LILILILI JLILILILI LILILILILILILI LILILILI PADDED Preventive Maintenance 126 4 P
46. al installation These notes are intended for all who install the drive Handle the unit carefully to avoid damage and injury A Operation WARNING DCS800 sizes D4 D7 The drive is heavy Do not lift it alone Do not lift the unit by the front cover Place units D4 and D5 only on its back DCS800 sizes D5 D7 The drive is heavy Lift the drive by the lifting lugs only Do not tilt the unit The unit will overturn from a tilt of about 6 degrees Make sure that dust from drilling does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction Ensure sufficient cooling Do not fasten the drive by riveting or welding 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 A WARNING Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the base speed Do not control the motor with the disconnecting device disconnecting mains instead use the control panel keys D and or commands via the I O board of the drive Mains connection You can use a disconnect switch with fuses to disconnect the electrical components of the drive from th
47. and serve as a useful 3 algorithm means to fully describe the purpose of a project Add Comments lt Back Cancel Service 3ADW000195R0601 DCS800 Service Manual e f 104 Choose Device And Kernel Select Device H8S 2633F and xl confirm with Next The FLASH Development Toolkit supports a number of Hitachi work sp ace FLASH devices rs Walkspaces pp Select the device you wish to use with this project from the list pem t reli Is Ene E F ene di Select Device Reece Other i Device Imac Ec doa nis Protocol B 2 LCD punt Compiler Hitachi 4 04 E Kaybo rd m Kernel Path Program fileziHitaehiF DT2 2Wernel ia Comma mot Kernel Version 1 n Co Device Image i Gay Target Files Drive mal fatrData mot s adigerithm dm Back Cancel Communication port Select the proper COM port x Select Baud Rate 38400 un tick Use Default Baud Rate and The FLASH Development Toolkit supports connection through s l aCe the standard PC Serial port and the USE port Use this page ta confi rm with N ex t iral ro select your desired communications port All settings may be ma r Space 4 T gr Neustria changed after the project iz created Display BF D gel i a Ce Image com Pty Target Files Select port COM w is LCD mot Eaybibard m Sj Comme mat The Baud Rate setting specifiez a suitable speed for serial connection
48. anels and plug in options D1 D7 8 03 Control Panels and plug in options D1 D7 DESCRIPTION NOTES Control Panel for DCS800 5199 L508 10 Mbd e g AC 800M L509 5 Mbd fieldbus L517 Nr DDCS communication board DDCS communication board eiu 9 36 g a a s 2 E m DN O1 FI O T1 UJ C p g U E DN 2 gt CS I amp Modbus CANopen 1 Analog VO Extension Digital O Extension E Pulse Encoder interface TTL 1 E DN C1 3 DN O N x DN oO N TT io JT ITA DnjaojajR oloelolo AINIS EEA KE Item 8 04 to 8 05 Field exciters FEX 425 Int DCF803 0035 DCF503 4B Field exciters 25 A 16 A and 35 A overvoltage protection included DCF803 0016 1 Q16A 1 3ADT 30004R0001 UR 10A 660V For fieldcurrent lt 6 ADC Semiconductor fuses field fsi i 3ADT730004R0002 UR 16A 660V For fieldcurrent lt 12 ADC Semiconductor fuses field 3 3A DT730004R0004 3ADT730004R0006 Semiconductor fuses field Semiconductor fuses field ea Semiconductor fuses field E L ie Q Sy DCF803 0035 1 Q 35A 1 3ADT209023R0001_ DCF803 0035 Complete unit ET NEN ji b Appendix A Spare Parts List 3ADW000195R0601 DCS800 Service Manual e f 128 8 05 Field exciters 50 A and 60 A overvoltage protection included DESCRIPTION QY CODE TYPE DATA NOTES DCF503B0050 1 Q 50A 1 3ADT209019R0201 DC
49. based on the device characteristics and the Target clock The default baud rate is set up for use with a standard HMSE Evaluation Board If you have a different clock on your Target you may need ta select a different speed LJ Device Image i Target Files E Drive Mot aj Data mak sl Adigorithim m Select Baud rate Use Default Baud Rate Back Cancel Service 3ADWO000195R0601 DCS800 Service Manual e f 105 Device Settings Enter the CPU crystal frequency for the Device Settings selected device 6 25 MHz Select the multiplier for the main clock frequency CKM 4 and confirm with Next i MER EX SER stus aas i f och CD E soma cr a D o NISUS Connection Type Select connection BOOT Mode Connection Type Select Interface Direct Connection un tick Kernel already resident and confirm with Next BEB Cil Motor Control i TU Device Image pls Target Files Direct Connection Drive mot E Service 3ADW000195R0601 DCS800 Service Manual e f 106 Programming Options Protection Automatic and Messaging Advanced confirm with Finish Hrs Works ig Display Space Industrial Ci Device Image eg Target filas Er LCD moat Leg Kaybeard m Comme mat Device Image Target Files Te Drive mot Ia Data mot Programming Options q X The FLASH Development Toolkit offers a device protection system plus an advanced me
50. cal safe condition 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 115 Vac parallel for 115 Vac 230 Vac Connector X2 on top of converter housing In case a fan fails there are different approaches due to the incoming voltage 230 Vac With a supply voltage of 230 Vac fans M55 and M56 are connected in series Consequently both fans have to be of the same manufacturer and type Thus it is not possible to change only the broken fan In this case both fans have to be changed 115 Vac With a supply voltage of 115 Vac all fans are connected in parallel Thus it is possible to change only the broken fan Removing the converter fan 1 Remove the DCS Control Panel the design cover and the fan connection plug X2 on the top of the converter housing Depress the locks by means of a screwdriver to remove the design cover Service 3ADW000195R0601 DCS800 Service Manual e f 74 2 Remove the two fan arrangement screws _ 3 Move the fan arrangement forward Move the fan arrangement forward Service 3ADW000195R0601 DCS800 Service Manual e f 4 Remove the fan holding screws I 4 i e cure ae aD gt C P ee 0110 ML Gs Se Gi mmm GO GERD ea NERCUD c UR m
51. ce Manual e f 49 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 Note Do not touch the polished surfaces of the thyristor 2 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 3 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of conducting paste on both sides of the thyristor if necessary use a rubber spatula 4 Centre the thyristors by means of the spring pins Note Be sure that the thyristor is installed in the right direction Do not pinch or cut the gate leads or any other cable 5 Turn the thyristor so that the gate leads point in the right direction When changing BCTs make sure that gate A is in front see Bidirectional Controlled Thyristors 6 Connect the gate leads if possible 7 Insert first the top DC busbar plate and then the bottom one Note The DC busbar plates should line up with the adjacent heat sinks 8 Reconnect the DC busbars Exchange thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 50 9 Tighten the nuts of the mounting clamp by hand so t
52. coder A10 Item 8 08 Parts for DCS800 R Rebuild Kit Pulse interface board 1 1 3ADT220000R000 SDCS REBA Pulse amplifier board 1 1 3ADT2200008004 SDCSREB2 Pulse distribution board 1 1 3ADT309300R0001_ SDCSREBE3 4000 1 Appendix A Spare Parts List 3ADW000195R0601 DCS800 Service Manual e f Item 8 09 Parts for 12 pulse supply voltage gt 800 VAC hardparallel D7P and galvanic isolation Parts for 12 pulse suppl parallel D7P and galvanic isolation For IRDH gt 690 VAC 12 pulse DC DC transducer Knick A92 3ADN260008P0001 P42000D3 01 11 For U gt 690 VAC 12 pulse replaches Knick 8680 A 1 A92 Hardparallel master Item 10 00 to 29 00 Modules D1 D4 20 A 1000 A 400 V 525 V and 600 V 10 00 Common parts for modules D1 DA 20 A 1000 A 11 00 DCS800 S01 0020 04 05 amp DCS800 S02 0025 04 05 400 V 525 V Thyristormodules 3 6 3ADC340063F0001 SKKT27Bixxx MCC26 16xxx 12 00 DCS800 S01 0045 04 05 amp DCS800 S02 0050 04 05 400 V 525 V Thyristormodules 3 6 3ADC340063P0001 SKKT27Bkxx MCC26 16xxx 13 00 DCS800 S01 0065 04 05 amp DCS800 S02 0075 04 05 400 V 525 V Thyristormodules 3 6 3ADC340067P0001 SKKT42Bixxx MCC44 16 xxx 129 Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Man
53. connections Remount the fuses Bolts with sleeves on eee ee ee RE ur Jin C A LOT WA gt gh re z Adm a Service 3ADWO000195R0601 DCS800 Service Manual e f 87 Exchange current transformers size D7 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition If current transformers fail or need to be repaired the following has to be considered Itis important that all current transformers are orientated and mounted in the same way on the busbars Check the wiring of the old current transformers according the figure in subchapter Wiring It is important that all current transformers are wired in the same way Take additional care in case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located outside the D7 module AC busbars are routed through the current transformers The current transformers are mounted on the busbars by means of screws The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends Exchange Disconnect the AC wires busbars at the side of the drive Remove the mounting screws Remove the old current transformers A Install the new current transformers with proper orientation
54. d V OnBoard field exciter BE bridge module Snubber resistor 10 Remove the gate leads from the faulty thyristor module and mark the connectors clearly 11 Remove the busbars necessary to get full access to the faulty thyristor module 12 If a current transformer must be removed mark its position direction and the connections clearly Note Remove only as many parts as needed around the faulty thyristor module 13 Remove the faulty thyristor module and mark it clearly as defective 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 o Exchange thvristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f 27 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
55. d Files to Project From Kernel Dir Set as Active Project Remove Project Erase FLASH kos A Upload Image Blank check Cancel FL amp SH Operation Build Device Image Freshen all Target Files amp lt Shift R Properties FLASH Workspace Manager The workspace DESSDOD has been modified Would you like to save your changes Cancel Service 3ADW000195R0601 DCS800 Service Manual e f 98 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 Welcome to the FLASH Development Toolkit Confirm with OK EFA Create a new Workspace C Open an exiziting Image file More Workspaces CAABEBADCSS00 Firmware LU l A Mer 3 ens DCS 800 fdt ABB SDESBBUSFImeare s LUN FOT Yer 1 en D C5 550 Fdt ceca Select the workspace in directory CA ABB DCS800 Firmware CON 4 Ver X X Confirm with Open Firmware Text gi 25200 Fat File name DCS800 fdt Files of type JFDT Workspace Files fdt Cancel Li Service 3ADW000195R0601 DCS800 Service Manual e f Add firmware files f the firmware file to be downloaded is not shown under Target files the firmware file has to be added Select Firmware with a right mouse click and choose Add F
56. d field exciter D1 D4 configuration S 164 With internal field exciter supply external DS 25 A Rebuild kit 16 A 25 A Size D4 Standard Fan voltage 230 V 1 ph 171 Fan voltage 115 V 1 ph Size D6 Standard 400 V 525 V 800 V units 400 V 500 V 3 ph Standard 600 V 690 V units 525 V 690 V 3 ph 172 600 V 690 V units 400 V 500 V 3 ph 120 V SDCS SUB 4 D1 D4 SDCS PIN 51 configured to 120 V D5 D7 SDCS PIN 51 configured to 600 V D5 D7 12 pulse serial serial sequential SDCS PIN 51 configured to 690 V D5 D7 12 pulse serial serial sequential SDCS PIN 51 configured to 800 V D6 D7 12 pulse serial serial sequential SDCS PIN 51 configured to 990 V D6 D7 12 pulse serial serial sequential Galvanic isolation D6 D7 Electronic boards are located in the D7 module Electronic boards are in a separate electronic housing outside the D7 module 08199 Without SDCS DSL 4 0J400 Without DCS Control Panel J409 Door mounting kit including 3 m cable Profibus RPBA 01 DeviceNet RDNA 01 Ethernet IP Modbus TCP RETA 01 Modbus RTU RMBA 01 Fan voltage Current measurement Voltage measurement SDCS DSL 4 DCS Control Panel I O and DDCS Analog Extension RAIO 01 Digital Extension RDIO 01 DDCS communication board 10 Mbaud CHO SDCS COM 81 DDCS communication board 5 Mbaud CHO SDCS COM 82 The technical data and specifications are valid as of going to press ABB
57. dow Light 2 Parameter Browser DCS800 File View Options Drive Tools Communication Window Help S a Control Panel Li Online EA S Petre Step Function Ld Parameters amp Signals H Parameter Subset xb Ba lt b gt B Monitor k X Open All Parameters Teena Launch Wizard Show Mo Mapping Table 39 DESEOU 247 Remate l Stopped S 5 Forward 3 oy 4 Rf B De E 6 U rp 7 4 NA E 5 Bs in Start up Data Upload Phys Act Values Dawnload SPC Signals Ref Act Values Upload All Parameters mirman Download All Parameters Analog Infout Restore Drive Log Signals Backup Control words Compare Stat Limit Words Faulk Alarm Words Shark Skan Zalarb Search Parameters Ctrl F Drive Window Light 2 Parameter Browser DCSE00 File view Options Drive Tools Communication Window Help a Contral Parel k Online Offline Refres _2 EP Function A Parameters amp Signals k Parameter Subset x zia lt gt m Monitor k Open All Parameters Drive Status Launch Wizard Show Mo Mapping Table DCS800 247 e pedis Upload Remote E 1 Phys Act Values Download Stopped 2 SPC Signals Forward BS 3 RefJAct Values Upload All Parameters Dv a a naain Downoad 4 l Parameters D 5 Analog In Out Restore D 6 Drive Log Signals Backup e k ie 7 Control Words pee Search Parameters N Ctrl F IB a Fault Alarm words IS i
58. e D3 four fans iii 76 EXcnange convertertanisize DO i aa a aea BAA 80 Exenan e converter Tan sIZe D ii i ee rote enable eaae ciae o ea 81 Exchange current transformers sizes D5 to D7 iii 82 Current transformers for sizes D5 and D6 n rna rn near ann anna rnnnnnnnnnnnnnn na 83 Current transformers for size D7 A iii ie ei 84 Exchange current transformers size DS 85 Exchange current transformers size D6 e 86 Exchange current transformers size D7 i 87 Table of contents 3ADW000195R0601 DCS800 Service Manual e f 10 DES800 jirmware downoad iii is ii een 88 E72 1 Ali a 88 Download SDCS CON 4 firmware iii 88 Add firmware or text fles ararnar taaa a a aa seis tot oan deua eeu eas 98 Create a WOrRSpate ti ss se a elle ale ea aa 102 Download SDCS COM 8 firmware e 111 Serpe 113 TYPE Code table er 115 DE Motorne tralzoneadusimen iaaa E E E TA 116 TYPES CONCEMIEO m TL ON 116 SUMMAN EET 116 Crece c t 116 Preventive Maintenance 117 Recommended regular maintenance iii 118 Maintenance schedule 118 Annual preventive maintenance suscitarono 119 3 years preventive maintenance scaena exei duse mum data titnieda 122 6 years preventive maintenance
59. e mains for installation and maintenance work The type of disconnect switch used must be as per EN 60947 3 Class B so as to comply with EU regulations or a circuit breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker s main contacts to open The mains disconnect must be locked in its OPEN position during any installation and maintenance work EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor nor will the drive be disconnected from any dangerous potential To avoid unintentional operating states or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals RUN drive OFF or Emergency Stop respectively control panel or PC tool Intended use The operating instructions cannot take into consideration every possible case of configuration operation or maintenance Thus they mainly give such advice only which is required by qualified personnel for normal operation of the machines and devices in industrial installations If in special cases the electrical machines and devices are intended for use in non industrial installations which may require stricter safety regulations e g protection aga
60. e 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 Service 3ADW000195R0601 DCS800 Service Manual e f 117 Preventive Maintenance WARNING Before performing any maintenance the chapter Safety Instructions 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 L IEC 171188 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 Maintenance 3ADWO000195R0601 DCS800 Service Manual e f 118 Recommended regular maintenance The DCS
61. e screws the design cover and the DCS Control Panel po 4 9 Dra poe Exchange thyristors sizes D1 to D4 3ADWO000195R0601 DCS800 Service Manual e f 28 Remove faulty OnBoard bridge V1 1 Follow the instructions Remove faulty thyristor modules until step 9 is done 2 Remove all connectors from the faulty OnBoard bridge and mark the connectors clearly 3 Remove the faulty OnBoard bridge and mark it clearly as defective Install new OnBoard bridge V1 1 2 8 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 Spread the heat conducting compound evenly by moving the OnBoard 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 Reconnect all connectors or cables to the OnBoard bridge Follow the instructions nstall new thyristor modules beginning with step 11 OnBoa
62. e 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 to the main menu and The actual parameter set is now downloaded into the new SDCS CON 4 DriveWindow Light Click File then Open File View Options Drive Tools Communication Help New Online Drive Ctrl M Ctrl M New Offline Drive Print Setup Exit Remote Charmed Choose correct parameter file and click Open My Recent Documents Desktop 2 My Documents My Computer DE L 017885 LY TINTE File name Dcs800 Using COM1 dwp Places Files of type Drive Files dwp Cancel Exchange SDCS CON 4 3ADW000195R0601 DCS800 Service Manual e f Click Drive then Parameters amp Signals and Download All Parameters Tocheck if the parameter download was successful connect the drive with DriveWindow Light and compare the drive memory with the downloaded parameter set Click Drive then Parameters amp Signals and Compare DriveWindow A Click File then Parameters and Download 1 Drive Win
63. ed Converters x X EE DCS800 RRebuild System OO x Extension Modules y x Door mounting kits o x Serial Communication AN Drive specific serialcommunication x Fieldbus Adapter with DC Drives RCAN 02 CANopen x x existing pp gt planned 1110 Status 06 20120 DCS800 Drive Manuals List 1 doc E p un mM mM MEE mM mM E po EE p pd pe pom mM up NN m E Bum mM E pr ES m mM p mM p NEN p mM us mM E mM E mM mM mM p elett DCS800 Drives 20 to 5200 A Service Manual Code 3ADW000195R0601 Rev F DCS800 Service Manual e f doc Effective 09 2012 Supersedes Rev E 03 2011 2012 ABB Automation Products GmbH All rights reserved 3ADW000195R0601 DCS800 Service Manual e f Safety instructions Chapter overview 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 SOx 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 a
64. efault Baud Rate and confirm with Next E ffe prm ppp B i Target files T JE A Lora c IE Device Settings Enter the CPU crystal frequency for the Device Settings _ selected device 6 25 MHz Select the multiplier for the main clock frequency CKM 4 and confirm with Next Service 3ADWO000195R0601 DCS800 Service Manual e f Connection Type Programming Options Select connection BOOT Mode Connection Type Select Interface Direct Connection un tick Kernel already resident and confirm with Next Some Programming Options Protection Automatic and Messaging Advanced confirm with Finish I D vice Image i Target files Les Drive mat Data mot 3ADW000195R0601 DCS800 Service Manual e f 109 Service 110 Now the project for the text file is finished S FLASH Development Dosis File Edit View Project Device Image Tools Winds Zi xl EIER DiCS800 Firmware user defined C Device Image l E Target fies ema Close download tool When closing the FDT2 2 confirm with Yes FLASH Workspace Manager X The workspace Di5800 has been modified Would vau like to save your changes NETTE Creating of projects is complete now Service 3ADWO000195R0601 DCS800 Service Manual e f Download SDCS COM 8 firmware Requirements In case the USB adapter RUSB 02 is used together with DriveWindow 2 22 and higher and firmware package
65. electrolytic capacitors on the SDCS PIN 4 are aging The SDCS PIN 4 also is equipped with several capacitors which are sensitive to high ambient temperature Where used DCS800 S0x 0020 DCS800 S0x 1000 D1 to D4 Aging of the electronic card result in 1 Damage other devices 2 Trip the drive and cause break down time Replace the power supply board SDCS POW 4 of units D5 to D7 and DCS800 R Rebuild and Upgrade Kits 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 D5 to D7 and DCS800 R DCS800 S0x 5200 A Aging of the electronic card result in 1 Damage other devices 2 Trip the drive and cause break down time A Replace the flat cables of all units D1 to D7 Environmental conditions especially temperature and humidity could cause corrosion on the contact surfaces and embitterment of the insulation A Aging of the flat cables result in 1 Contact problems 2 Flat cable breaks Preventive Maintainance 3ADW000195R0601 DCS800 Service Manual e f Preventive maintenance Checklist DC
66. eneral shows parameter values menus or lists Bottom line shows current function of the two soft keys and the clock display if enabled Flashing green for alarms Red for faults Soft key 2 Function varies and is defined by the text in the lower right corner of the LCD display Soft key 1 Function varies and is defined by the text in the lower left li corner of the LCD display 1288RPM FH Up aa Down Scrolls up through a menu or list FET a i Scrolls down through a menu or lis displayed in the middle of the 2 32 MENU f displayed in the middle of the LCD LCD display p Display Increments a value if a parameter X Decrements a value if a parameter is selected is selected Increments the reference if the Decrements the reference if the upper right corner is highlighted 4 J i upper right corner is highlighted in in reverse video i reverse video LOC REM Changes between local STO Sum Help Displays context sensitive and remote control of the drive information when the button is pressed The information displayed STOP Stops the drive in local START Starts the drive in local describes the item currently from DCS Control Panel and from DCS Control Panel and highlighted in the middle area of the when the Start up Assistant is used when the Start up assistant is used display Exchange SDCS CON 4 3ADWO000195R0601 DCS800 Service Manual e f 66 Pre
67. er board SDCS 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 TX10 TX20 TX25 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Before the work is started make sure the firmware versions of the old SDCS CON 4 and the new SDCS CON 4 match see FirmwareVer 4 01 when using DCSLink communication see parameters 94 12 to 94 35 The peer to peer P2P identifier for the DCSLink group 94 has been changed from firmware versions 3 6 to 3 7 Thus it is not possible to mix firmware versions 3 6 and lower with firmware versions 3 7 and higher when using mailbox communication Overview SDCS CON 4 exchange Save parameters 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 ART d o 1 Save parameters Parameters can be saved by various means DCS Control Panel Status LED Green for normal operation LCD display Divided into three main areas Top line variable depending on the mode of operation Middle area variable in g
68. erminal D 1 5 mm Cathode 5 Faston 4 8 x 0 5 mm Conductive plate Diameter 36 mm Exchange thyristors size D5 3ADW000399R0101 DCS550 Service Manual e a 35 Original thyristor type 1200 A Converter with original thyristor type T589Nxxx Id code DCA0012015P0001 w 2 8 x 08 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 D3 5x3 5 both sides 5 Connector 4 0x0 5 4 Connector 1 5 based on AMP60598 Gate 4 Round terminal D 1 5 mm Cathode 5 Faston 4 8 x 0 5 mm Conductive plate Diameter 36 mm Exchange thyristors size D5 3ADW000195R0601 DCS800 Service Manual e f 36 Find faulty thyristor modules 1 Find the defective branches by performing an OHM test both polarities between U1 VI W1 and C1 D1 C1 v1izk va VA37N NZ V26 V157 SZ V22 F15 Il branching fuse V1 W1 em izle branch M V23 MX V25 4 4 kl a Ld e D1 principle B6 a dsf 42 m s 4 Bridge configuration D5 to D7 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 n a 4 quadrant converter change both thyristors clamped between the same heatsinks at once Note Because Disc
69. ervice Manual e f 81 Exchange converter fan size D7 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition 1 Remove the three screws at the bottom of the fan 2 Disconnect the cables 3 Lift the fan up and pull it out Vim 7 7 DMI i i j ji Jj i Service 3ADW000195R0601 DCS800 Service Manual e f 82 Exchange current transformers sizes D5 to D7 Measuring the actual current The control electronic of the converters is designed to use either 2 or 3 standard current transformers They are located on the AC side of the bridge to measure the armature current Wiring The wiring of the current transformers is basically identical for all converters The figure below shows the most common configurations POWER INTERFACE BOARD SDCS PIN 951 POWER PART WT KOST X932 DARI X262 X251 X252 Size D7 X231 x232 Od X24 2 X2 X25 2 t Size D5 and D6 L HH ho 2500 1 Service 3ADW000195R0601 DCS800 Service Manual e f 83 Current transformers for sizes D5 and D6 Type Ordering number Rated primary current Rated secondary current Ratio Magnetic overload capacity for a short time Maximum rated voltage Maximum test voltage Dimensions Weight Maximum ambient e g cooling air temperature at rated current Maximu
70. for electrical 13 Nm M8 connections 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts Tissue paper Solvent e g ethanol Thermal joint compound grease type Berulub FZ1 E3 Manufacturer Carl Bechem GmbH 58089 Hagen ABB Service GHSN 390 011 P 0051 Or thermal joint compound type WLPF 20 10 ml ABB Service GHSN 390 011 P 10 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Find faulty thyristor modules oee Fault Tracing Thyristors of this publication Exchange thyristors sizes D1 to D4 3ADWO000195R0601 DCS800 Service Manual e f Remove faulty thyristor modules 1 Remove DCS Control Panel and 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 FL 23 m is Remove DCS Control Panel DCS8C 2 2x Te JIL di ani si T l ot ty l Depress the locks by means of a screwdriver to remove the design cove
71. free condition and make sure everything is located in an electrical and mechanical safe condition If current transformers fail or need to be repaired the following has to be considered Itis important that all current transformers are orientated and mounted in the same way on the busbars Check the wiring of the old current transformers according the figure in subchapter Wiring It is important that all current transformers are wired in the same way Take additional care in case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located in the D6 module Bolts with sleeves are routed through the current transformers The current transformers are kept in place by design and need no further mounting The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends Exchange Remove the fuses connected to the l EE busbars leading to the current 1 ZW transformers To get access to the current transformers remove the bolts with sleeves from the AC busbars outside the converter a I not falling down when removing the bolts L L 7 i A ji and sleeves T E i e immi Install the new current transformers with Tm ii proper orientation No extra mechanical Cus I mounting is necessary a transformers Fasten the bolts including sleeves Take care of proper electrical
72. g air pressure switch of units D6 and D7 Actions o 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 O O OQ Attention Do not reach into the fan Negligence to this warning can cause injury Check for tightness of heatsink terminals of units D7 The thyristors together with the heatsinks are stacked Every single thyristor is connected to the DC and DC busbars via flexible copper busbars These busbars consist of 10 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 o 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 Set a latching torque spanner to 25 Nm 18 lb ft A 17 mm nut is needed too Check the torque of the screws marked within the next figure Appl
73. gle bridge 2 Q 2 Zantiparallel bridges 4 Q Module type YYYY converter type current ae Power connection Rated AC Voltage ZZ 04 230 VAC 400 VAC 05 230 VAC 525 VAC 2 07 10 12 L eft side D7 Right side D7 Attention When using D1 D2 D3 or D4 modules the current and voltage range of the type code setting is limited to maximum 1000 Apc and maximum 600 Vac ConvNomCur 4 05 ConvNomVolt 4 04 MaxBridgeTemp 4 17 and QuadrantType 4 15 3ADW000195R0601 DCS800 Service Manual e f 113 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 Service 114 To change the type code individually follow the instructions below un protect the type code by means of ServiceMode 99 06 SetTypeCode setthe type code individually by means of S ConvScaleCur 97 02 S ConvScaleVolt 97 03 S MaxBrdgTemp 97 04 and S BlockBridge2 97 07 the change of the type code is immediately taken over and ServiceMode 99 06 has to be set back to NormalMode by the user the new values can be seen in group 4 ConvNomCur 4 05 ConvNomvolt 4 04 MaxBridge Temp 4 17 and QuadrantType 4 15 Service 3ADW000195R0601 DCS800 Service Manual e f 115 Type code table 0 None 50 S01 2050 10 100 S02 0820 04 6 S01 0065 05 56 S01 3000 07 106 802 1200 04 8 S01 0
74. h the spare part list see Appendix A of this manual oemiconductors 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 the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition Exchange thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 42 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 voltage identification Converter with original Converter with second thyristor type T 1329Nxxx thyristor type T 1xxx 24 Id code 3ADC340081P0001 Id code 3ADC340098P0001 DCS800 S01 1900 08 3 800 VAC DCS800 S01 1900 08a DCS800 S02 1900 08 3 800 VAC DCS800 S02 1900 08a DCS800 S01 2050 05 3 525 VAC DCS800 S01 2050 05a DCS800 S01 2050 06 DCS800 S01 2050 06a DCS800 S02 2050 06 DCS800 S02 2050 06a DCS800 S01 2050 07 DCS800 S01 2050 07a DCS800 S02 2050 07 DCS800 S02 2050 07a DCS800 S02 2050 05 3 525 VAC DCS800 S02 2050 05a The current and voltage ratings of original and second thyristor type
75. hat the clamp is in parallel with the contact surface of the heat sinks P A eye _ he a zz 9 yr gt 0 mm A NT tT g a Bl peme g Za d tit 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 Torque __ indicating mE 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 thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 51 Location of thyristors in frame D6 4 Q bridge with single thyristors G U FAK EL ma CL EI Exchange thyristors size D6 3ADW000195R0601 DCS800 Service Manual e f 52 Location of thyristors in frame D6 4 Q bridge with BCTs fii C14 C16 V11 V24 1 I I I Int Ip Li L E EN EN E3 fes EET FIRE IST EE En En E E 21 21 2 1E SEES Eee H GAIA ee esl E 2 2 3 EI IE H zl s eel esl E21 ELT TEV salis BILLI BLUE FEL FS zal Usi Usi Usi REL IELI IE PA 1 TTIE T 31 23 2 233 f 12 T f II EI JE 2 123 1221 321
76. his drawing is only showing the location of the OnBoard bridge and thyristor modules the actual converter module size is different Exchange thyristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f 29 OnBoard bridge V1 and thyristor module location in DCS800 S02 4 Q units
77. i 30 Table of contents 3ADW000195R0601 DCS800 Service Manual e f Exchange thyristors size D5 32 Installation of disc type thyristors in converters size D5 900 2000 A nn nnnnnnnnnnnnnnnnnnnnnnnnnnnnznnzi 32 aisle i acres ES 32 DISK YDE tiscali 33 Orginal thyristor type 900 A i i iei eerste oet in e e nsus Ea te e d eek od aaa ene 34 Second thyrister tyDe 900 A miresine a 34 Orginal thyristor type 1200A Jsir ille 35 second thyristor type T200 A errain 35 FING Taulty AVISO IMOGUICS eken E E a E rece eG tai 36 Remove faulty tyristor siirron a i 37 INStal NeW iINyrisior apicale 38 Location of thyristors in frame D5 4 Q bridge e 39 Location of thyristors in frame D5 2 Q bridge nennen 39 Location of branch fuses frame D5 leale alia det LUAM EUN LEE 40 Exchange thyristors size D6 41 Installation of disc type thyristors in converters size D6 1900 3000 A L nennnnnnnnnnnnnnnnznnnznnnznnni 41 Reguirea Woo ce 41 DISK TY DG INVESTORS M isla 42 ORIGINAL ig MAC T rr 43 second tAVFSOF nol M ied mc 43 Bidirectional Controlled Thyristors BCTS e 44 Fina tfalli thyristor MOdUlE SA i ss sio ost tom sente aue i eo e eu det pd astu sim acu ated tas fato 45 Remove faulty TA e 46 HSA Dew IDVEISEOL eod ous una de euo edad uod La iet nep oe ta mane LODS MPO I CE mE 49
78. iles amp lt Shift R Properties Choose COM Port and communication speed Select Firmware with a right mouse click and choose Properties from the pop up l File Edit View Project Device Image Tools Window Help menu dep C NU wr IIL ma m r Add Files to Project EH T Add Files to Project From Kernel Dir Set as Active Project m Remove Project Connect to Device Erase FLASH blacks Upload Image Blank check Cancel FLASH Operation Ea Text Build Device Image Freshen all Target files Properties amp lt Shift R Select the Communications tab choose Project Properties Firmware the desired COM Port un tick the box Use Project Kemel Communications Device Programmer Modules Comments default baud from the pop up menu and set the Target Baud Rate to 38400 Default Baud 115200 Currently connected No Service 3ADW000195R0601 DCS800 Service Manual e f Download firmware file to device Select desired firmware with a right mouse click and choose Download File to Device from the pop up menu Disconnect tool After the completed download the FDT2 2 has to be disconnected Select Firmware with a right mouse click and choose Disconnect from the pop up menu 93 FLASH Development Toolkit 2 2 DCS800 File Edit View Project Device Image Tools Window Help ar ld g i Device Image E1 2g Target Files
79. iles to Project from the pop up menu Goto the directory containing the desired firmware file e g 99 4 FLASH Development Toolkit 2 2 DC 5800 l File Edit View Project Device Image Tools Window Help e m MEAN yzl HA T Finn DCS5800 2 Projects EHE Firmware o L IT Device ie B taz Target Files 3 of 80x360 rec ze E Text FLASH Development Toolkit 2 2 DCS800 File Edit view Project Device Image Tools Window Help oe ed a XS Add JE to em Frori Set as Active Project if t 24 e Remove Project Connect to Device Erase FLASH blacks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target Files Properties amp lt Shift R Add files to Project l 2 x Look in Co Firmware 4 t E Er 2 Desktop 50 39 5 aux My Documents na ig My Computer DE L 01 78854 DELI O98 E BUXJA ee Local Disk C Bx 36 i ABB E 80x3 c DCS800 s S0x3 Dj Firmware 53 CON 4 Di Ver 3 xen File name DCS800 CD XT TD oen e V2 Work bi x Cancel Files of ty Deu1098954 an De e 183725 IH a ae 2 Service 3ADW000195R0601 DCS800 Service Manual e f 100 Choose the desired firmware file and Add files to Project 2 x press Open Look in E Firmware e cf E Bux 350 rec s a xss Demo rec 80x360 rec E 80x370 rec s Bux3 bemao rec File name E0x360 1ec File
80. inst contact by children or similar these additional safety measures for the installation must be provided by the customer during assembly Note When the control location is not set to Local L not shown in the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key Safety instructions 3ADW000195R0601 DCS800 Service Manual e f Table of contents DCS800 Manuals 2 Safety instructions 5 CHAPIT OV CIV CW m 5 To which products this chapter applieS iii 5 Usage of warnings and notes 4 tices i a aa 5 Installation and maintenance Work iii 5 Negnhanicalinsiallalion leali T OPTATO illa T Table of contents 8 Introduction 11 G aPIekOVEMVIEW NE 11 belore Tubolari 11 riet thissmantdalGOPEallis sa adit erit ina tare Saati eae coil letra aio ii a 11 TargeldoUDu entitas dara cuiu plo frate Echec ini ea iii ade 11 ASSoclated DUDIICATIONS iaia cieli Mon uS Mam a d su aaa 11 Storade anda transport viuis ouais ualeat iui liacle 11 Name Mori eet on c cct A 12 TWINS COGS canda RE CoUC aa DEM E eU E E occa ede 13 NM OMACS AU AG NR OT A A 14 RTT ACN Seite ceca e este ates ipo insists X RT 15 Fault Tracing Thyristors 16 MOL IS ii Lilli ilo 16 For commissioning and fault tracing e 16 Additionally for service and preventive mai
81. m conductor wire busbar temperature at rated current 120 LT 2032 3 ADT 751 010 P 0001 3 times rated primary current 1500 Vac 5000 Vac for less than 3 seconds In mm see figure below 1 7 kg 55 C 90 C No wires busbars are allowed within this area around the CT Faston 6 3 0 8 il 16 81 117 132 Service 3ADWO000195R0601 DCS800 Service Manual e f 84 Current transformers for size D7 Ordering number Rated primary current Rated secondary current Ratio Magnetic overload capacity for a short time Maximum rated voltage Maximum test voltage Dimensions Weight Maximum ambient e g cooling air temperature at rated current Maximum conductor wire busbar temperature at rated current Service 3 ADT 751 007 P 0001 5000 Aac 1 25 Aac 4000 1 3 times rated primary current 1200 Vac 4000 Vac for less than 60 seconds In mm see figure below 1 7 kg 55 C 90 C Mo wires busbars are allowed within this area around the CT Teminal Li Sz 7 4 x 1 i Teminal Ic 1 AMP type plug 63x08 DIN 46244 number 0 0926578 1 Not pointed on the devic Points to AC network 3ADW000195R0601 DCS800 Service Manual e f 85 Exchange current transformers size D5 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe conditio
82. ment 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 irm 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 Exchange thyristors size D5 3ADWO000399R0101 DCS550 Service Manual e a Location of thyristors in frame D5 4 Q bridge E ek U1 V1 W1 Em y d na ADDII V11 V21 LL LI v26 Ld V16 ILLI AURI Location of thyristors in frame D5 2 Q bridge ma NE U1 Lx HIM URI ACAN UK MDA LER 39 Exchange thyristors size D5 3ADWO000195R0601 DCS800 Service Manua lef Location of branch fuses frame D5 E P fas AN KAN DR 43 zz QR M Ya KA Wes UN A M A
83. mounted and fully cabled on a panel Very fast installation and commissioning squeezes shut down times in revamp projects to a minimum Fits into Hittal 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 DG drives tailor made solutions for g BBC PxD g BRC SZxD es ASEATYRAK mother manufacturers 195R0601A2390000 Ident No 3ADW000195R0601 Rev F 9 2012
84. mpara Download Ctrl D Exit Exchange SDCS CON 4 3ADW000195R0601 DCS800 Service Manual e f 67 Click Save Save As Ax Save in Temp2 3 ck E3 Filename DCS800 Using LWL dwp Save as type Parameter files dwp Cancel 77 2 Write down type code of the drive Write down the contents of TypeCode 97 01 This information must be set in the new SDCS CON 4 manually 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 new SDCS CON 4 accordingly 4 Exchange the SDCS CON 4 Remove the old SDCS CON 4 1 Remove design cover and DCS Control Panel Depress the locks by means of a screwdriver to remove the design cover Exchange SDCS CON 4 3ADW000195R0601 DCS800 Service Manual e f 68 2 Remove all plug in options on the intermediate cover e g serial communication modules R type extension I O modules RAIO RDIO E Depress the locks to remove the extension modules for second EG design cover encoder RTAC or resolver RRIA PRE NOE 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 Remove all options so that the intermediate cover is empty mm ri fe IT J TE SER TE
85. n If current transformers fail or need to be repaired the following has to be considered Itis important that all current transformers are orientated and mounted in the same way on the busbars Check the wiring of the old current transformers according the figure in subchapter Wiring It is important that all current transformers are wired in the same way Take additional care in case the connection is not done by coded twisted pair cables Current transformer type The current transformers are located in the D5 module AC busbars are routed through the current transformers The current transformers are kept in place by design and need no further mounting The connection to the electronics is done via twisted pair cables with coded faston plugs on both ends Exchange Disconnect the AC wires busbars at the top of the drive To get access to the current transformers remove the top panel of the converter s body Now the old current transformers can be removed nstall the new current transformers with proper orientation No extra mechanical mounting is necessary Take care of proper electrical connections Remount the top panel Reconnect the AC wires bus bars Service 3ADWO000195R0601 DCS800 Service Manual e f 86 Exchange current transformers size D6 Before the work is started disconnect the converter completely from the power supply then check the voltage
86. n Start Chan Galart f Drive Window Workspace Parameters System Software Graph w Status Refresh Exit ABB SMP DCS 800 Di 0 1 d aub cb uw al el Li Open CErI o H H Close Chrl 5 Export l Print d Comment Save As Compare ae Memory Download Ctrl D H Eo Le _ 83 cy Pee ee bie 3ADW000195R0601 DCS800 Service Manual e f Exchange SDCS CON 4 72 Click Open and follow the instructions aixi Look in C3 Temp2 49 t E Eil gi 5800 Using LWL dwp File name DCS800 Using LwL dwp Files of type Parameter files dwp Cancel E To check if the parameter download was BE DriveWindow ABB SMP DCS 800 Di 0 1 ful t the dri ith i i l dii File Edit View Network Drive Desktop Monitor Data memory with the downloaded parameter Workspace l ad ml zl alal set Click File then Parameters and Seana Open Che Compare System Software Close Graph k o Saed Certs w Status Refresh Export k l Print l Exit Cramer Memory Download vee e Parameters Exchange SDCS CON 4 3ADW000195R0601 DCS800 Service Manual e f 73 Service Exchange converter fans sizes D1 to D3 two fans Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechani
87. nd notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advice on how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltage which can cause physical injury or death and or damage to the equipment can result in physical injury or death and or damage to the equipment Electrostatic sensitive devices warning warn of electrostatic discharge which can damage i General danger warning warns about conditions other than those caused by electricity which the equipment A 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 Only qualified electricians are allowed to install and maintain the drive Never work on the drive motor cable or motor when main power is applied Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 Voltage between drive input phases U1 V1 and W1 and the frame is close to O V 2 Voltage between terminals C and D and the frame is close to 0 V Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous v
88. nductor 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 13 Nm M8 connections 25 Nm M10 50 Nm M12 Screws are metric type use appropriate nuts 17 mm ring spanner for fuse and busbar connections 17 mm ring spanner for press clamp Tissue paper Solvent e g ethanol Thermal joint compound grease type BECHEM RHUS SU 2 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 of this manual oemiconductors 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 the work is started disconnect the converter completely from the power supply then check the voltage free conditi
89. nductor fuses 6 6 3ADC770030P0002 UR3000A 1000V JFlush end contactfuse 62 00 DCS800 S01 4000 10 amp DCS800 S02 4000 10 990 V Thyrstr 6 12 8ADC340084Po001 5STP38 0x _ _ Semiconductor fuses 6 6 3ADC770030P0005 UR2500A 1250V Flush endcontactfuse 62 10 DCS800 S01 4000 12 amp DCS800 S02 4000 12 1200 V Thyristor 6 12 SADC340084P0000 5STP38Qxxx PL Semiconductor fuses 6 6 3ADC770030P0006_ UR3300A 1500v Flush endcontactfuse DCS800 S01 4800 06 07 amp DCS800 S02 4800 06 07 600 V 690 V Thyrstr 6 12 SADC340083P0001 5STP45Qxxx DCR6430M24 3ADC340125P0001 Semiconductor fuses 6 6 3ADC770030P0002_ UR3000A 1000v j Fush endcontactfuse DCS800 S01 4800 08 amp DCS800 S02 4800 08 800 V Thyrstr 6 12 SADC340083P0001 5STP45Qxxx DCR6430M24 3ADC340125P0001 Semiconductor fuses 6 6 3ADC770030P0002_ _UR3000 A 1000 V_ Flush end contact fuse 65 00 DCS800 S01 5200 04 05 amp DCS800 S02 5200 04 05 400 V 500 V gt Thyristor 6 12 3ADC340083P0001 5STP45Qxxx DCR6430M24 3ADC340125P0001 Semiconductor fuses 6 6 3ADC770030P0001_ UR3500A 690v jFlushtendcontactfuse Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 139 Appendix A Spare Parts Lis
90. nge thyristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f 30 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 Redis cathode lead VVZF 70 VVZF 0 16 AKJ K A AK K A 45 7 6 3 54 6 7 3 1 LIB MIC TET ES G O ana n Ed7G B Baer E Gis ISA AS SKKT 27 42 57 106 MCC26 44 56 95 lt occ 542 AK K A 1 2 3 SKTT 162 MCC162 Exchange thyristors sizes D1 to D4 3ADWO000195R0601 DCS800 Service Manual e f 31 MCC255 A AK fa Q zu WY eee TT 425 570 Exchange thyristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f 32 Exchange thyristors size D5 Installation of disc type thyristors in converters size D5 900 2000 A All DCS800 converters sizes D5 D6 D7 are equipped with disk type thyristors The structure of the disc type semiconductor component is such that it requires a certain compression force to operate The prevention of overheating of the component essentially depends on good heat dissipation between the semico
91. nnect each drive separately to protective earth PE Minimize EMC emission and make a 360 high frequency grounding e g conductive sleeves of screened cable entries at the cabinet lead through plate Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations As the normal leakage current of the drive is higher than 3 5 mAac or 10 mApe stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Printed circuit boards and fiber optic cables These instructions are intended for all who handle the circuit boards and fiber optic cables Ignoring the following instructions can cause damage to the equipment A WARNINGI The printed circuit boards contain components sensitive to electrostatic discharge Wear a ta grounding wristband when handling the boards Do not touch the boards unnecessarily Use grounding strip ABB order no 3ADV050035P0001 WARNING Handle the fiber optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt The minimum allowed bend radius is 35 mm 1 38 in Safety instructions 3ADWO000195R0601 DCS800 Service Manual e f Mechanic
92. ntenance 17 How to detect a faulty thyristor i 17 ATUS NSN OWI alleati 17 DC current pulses measured using an oscilloscope na 17 Rovigo enel m T 18 ailse Eoiemiiepgwm s LET 18 FIOW OTIC a TAUMNY in r i o peer 18 Converters sre DI t D4 120 5 M000A a aa a re nts a genu sete D uud 18 POW ISO odes emma EM te e e AD eT E E PE ER EN 18 Converters size D5 D6 and D7 900 5200 A LL i 19 BIOWNIUSeSL bullet 19 RIPPIEMONIO Rss ll lilla 20 Handling the Semiconductors 21 General Instruction how to handle semiconductors nennen nnn nnns 21 Exchange thyristors sizes D1 to D4 22 Installation of OnBoard bridge V1 and thyristor modules in converters size D1 to D4 20 1000 A 22 REJUN TOOS ccr Tc 22 Fina IQUly NyistormodUules ai laica 22 Remove faulty thyristor MOdUIES ii 23 install new thyrIstor Modules i sui oue tuia sed reo stilus ei du Vo i Se doro oa d 26 Remove faulty OnBoard bridge V1 ccccsscccseecceeeceseeceucecueeceeceuseceusessueesseessaeessusesseseseeeseas 28 Install new OnBoard bridge V1 ee 28 OnBoard bridge V1 and thyristor module location in DCS800 S01 2 Q units 28 OnBoard bridge V1 and thyristor module location in DCS800 S02 4 Q units 29 OnBoard bridge and thyristor module terminals
93. oling fans in frames D1 100 000 1 TT to D3 80 000 L i Remove the cooling fans in frame D3 A The manufacturers estimation forthe A fa operational time of the cooling fan is S 40 000 o CN2B2 40 000 hours at 60 C amp o W2E200 45 000 hours at 60 C EN NN o W2E250 40 000 hours o D2E160 30 000 hours at 40 C The mayor problem is the failure of the bearings AMBIENT TEMPERATUREFC DCS800 S0x 0140 y1 DCS800 S0x 0260 y1 DCS800 S0x 0350 y1 DCS800 S0x 0520 y1 DCS800 S0x 0820 y1 DCS800 S0x 0820 y1 plus code E171 DCS800 S0x 0900 y1 1x W2E250 230 V 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 Check the flat cables and their connections Preventive Maintenance 3ADWO000195R0601 DCS800 Service Manual e f 124 9 years preventive maintenance aes additional actions have to take place Replace the power interface board SDCS PIN 4 of units D1 to D4 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
94. oltages inside the drive even when the main power on the drive is switched off Do not make any insulation resistance or voltage withstand tests on the drive or drive modules Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor When reconnecting the motor cable always check that the C and D cables are connected with the proper terminal Note he motor cable terminals on the drive are at a dangerously high voltage when the main power is on regardless of whether the motor is running or not Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the relay outputs of the drive system e g SDCS IOB 2 and RDIO DCS800 with enclosure extension Before working on the drive isolate the whole drive system from the supply Safety instructions 3ADWO000195R0601 DCS800 Service Manual e f 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 A Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up Make sure that grounding conductors are adequately sized and marked as required by safety regulations Ina multiple drive installation co
95. on and make sure everything is located in an electrical and mechanical safe condition Exchange thyristors size D5 3ADWO000399R0101 DCS550 Service Manual e a 33 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 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 Exchange thyristors size D5 3ADWO000195R0601 DCS800 Service Manual e f 34 Original thyristor type 900 A Converter with original thyristor type T459Nxxx Id code DCA0012007P0001 w 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 900 A Converter with second thyristor type T460Nxxx Id code 3ADC340105P0001 53 5x3 5 noth sides 5 Connector 4 8x0 5 4 ConnectorD1 5 based on AMP60598 Gate 4 Round t
96. onverter 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 Made in Germany K454 J409 LISTED 78WN 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 Introduction 3ADWO000195R0601 DCS800 Service Manual e f 13 Type code The type code contains information on the specification and configuration of the drive The first digits from left show the basic configuration e g DCS800 S01 2000 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 The drive s basic type code DCS800 AAX YYYY ZZB plus code Product family DCS800 Standard converter module Rebuild system Panel solution Enclosed converter Bridge type Single bridge 2 Q 2 2 anti parallel bridges 4 Q Module type YYYY RatedDC current ZZ Rated AC voltage 230 Vac 400 Vac 230 Vac 525 Vac 270 Vac 600 Vac 315 Vac 690 Vac 360 Vac 800 Vac 450 Vac 990 Vac 540 Vac 1200 Vac Standard D1 D6 Second thyristor type D5 D6 Left side D7 Power connection Right side D7 Field exciter 0S163 Without OnBoar
97. ppendix A of this manual Keep the semiconductor and its surroundings clean Note Do not touch the polished surfaces of the thyristor 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 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of conducting paste on both sides of the thyristor if necessary use a rubber spatula 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 Note The indicating spring is a very sensitive instrument and must be handled with care Exchange thyristors size D 3ADW000195R0601 DCS800 Service Manual e f 61 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 salire eren l Torque indica
98. r Depress the locks to remove the design cover Exchange thyristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f 24 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 xe T p wwe ct Disconnect all plugs from SDCS 2 CON 4 and SDCS DSL 4 boards 5 Remove the grounding plug and the holding screw at the electronic tray Remove the grounding plug and the holding screw Exchange thvristors sizes D1 to D4 3ADW000195R0601 DCS800 Service Manual e f To unhinge the electronic tray including the SDCS CON 4 pull it up and then out Before removing the tray completely unplug the flat cables X12 X13 X37 8 Remove all cables and plugs at the SDCS PIN 4 Keep the winding direction and amount of windings through T100 in mind For X8 use a screw driver Attention Write down the winding direction of the field current cable through T100 25 _ Electronic tray with SDCS CON 4 e mca due PITE iL MC s AN CLAN s EI gt ni e A i gt d a H Mm a Lon mal ik PE gt i ae TOM E e AMI n g d Remove all cables an 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 3ADW000195R0601 DCS800 Service Manual e f Exchange thyristors sizes D1 to D4 26 9 Remove the SDCS PIN 4 boar
99. r can be replaced by different compatible semiconductor according to the codes in the manufacturers table Semiconductor components are high precision products All unnecessary used tools and objects might damage the easily dented and scratched surfaces of the semiconductors 1 Keep new semiconductors as long as possible in their original packages 2 Use protective gloves if possible 3 Clean work area and hands frequently 4 Use good illumination Handling the Semiconductors 3ADW000399R0101 DCS550 Service Manual e a 22 Exchange thyristors sizes D1 to D4 Installation of OnBoard bridge V1 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 Torque spanner
100. rd bridge V1 and thyristor module location in DCS800 S01 2 Q units me dddo DCS800 S01 0020 0180 V14 V11 V16 V13 V12 V15 VIANI V16 V13 V12 V15 di ToE JJe SUE 4 E 1 4 i 1 4 2 1 o ka DODO DOT oo 0 O O O 9 al C3 Q e IO 3 5 Ol O O e o O 9 9 DCS800 S01 0315 0470 0900 V14 V11 V16 V13 V12 V15 V14 V11 V16 V13 V12 V15 n e ej b ej d e s e e B e 6 e e e e ee lee jel 31e DCS800 loc of mod 10 dsf Note T
101. rent 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 the problem is caused most often by a faulty thyristor To make sure that a thyristor is the reason and needs to be exchanged fault tracing must be done in two different ways depending on the size of the converter In general make sure that all safety instructions given within this manual or within the Safety instructions related to the machine or the application itself are obeyed Converters size D1 to D4 20 1000 A These converters require semiconductor fuses in the 3 AC lines The converter must be disconnected from the mains One motor armature cable should be disconnected from the converter Blown fuses Make sure that the connection to the motor is open e g disconnect motor cables 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 Fault Tracing Thyristors 3ADWO000195R0601 DCS800 Service Manual e f 19 C1 V117N va V137N SZ v26 v MZ v22 s line fuse U1 V1 W1 a s ees
102. reventive Replacements 4 1 Flat cables SDCS CON 4 SDCS PIN 4 X12 X13 X37 X37 SDCS CON 4 SDCS PIN 51 X12 X13 SDCS CON 4 SDCS POW 4 SDCS PIN 51 SDCS PIN 4x X113 X213 4 2 Boards SDCS POW 4 SDCS PIN 4 4 3 Fan Cooling fan frame size D1 D5 Cooling fan frame size D6 D7 Inspect visual inspection correction and replacement if needed Remarks Date of inspection Name of field service engineer ABB Automation Products Preventive Maintainance Inspection cycle 9 years 9 years 9 years 9 years 9 years 9 years 6 years 3 years 3ADW000195R0601 DCS800 Service Manual e f 70 10 Gd 90 LG L JLILI L JLILI L JLILI L JLILI LILI 127 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 20 A 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 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 P
103. ring 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 Exchange thyristors size D5 3ADW000195R0601 DCS800 Service Manual e f 38 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 Note Do not touch the polished surfaces of the thyristor 2 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 3 Clean the polished surfaces of the semiconductor with a piece of tissue paper moistened with solvent Dry all surfaces Spread a thin layer of conducting paste on both sides of the thyristor if necessary use a rubber spatula Connect the gate leads if possible Centre the thyristors by means of the spring pins Note Be sure that the thyristor is installed in the right direction Do not pinch or cut the gate leads or any other cable 6 Turn the thyristor so that the gate leads point in the right direction 7 Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks Note The indicating spring is a very sensitive instru
104. rs size D7 3ADWO000195R0601 DCS800 Service Manual e f 56 Find faulty thyristor modules 3 Find the defective branches by performing an OHM test both polarities between U1 VI W1 and C1 D1 C1 vN NZV24 V137N NZ V26 V57N NZ v22 rina m n l branch V2 Ld st V14ZN NZ V21 V16 N SZ V23 Al 4 i principle B6 a dsf Bridge configuration D5 to D7 Exchange thyristors size D7 3ADWO000195R0601 DCS800 Service Manual e f 5 3 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 SC rewS LAE oe DT TA a TT i nr EI I LL 3 TM if n Loose AC EI E ee busbar gt 3 Putasmall piece of isolator e g paper between the DC busbar and the heat sink to insulate the anti parallel thyristors from each other 3 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 heat sinks Exchange thyristors size D7 3ADW000195R0601 DCS800 Service Manual e f 58 Remove faulty thyristor 1 Remove the screws of all DC AC busbars preventing the
105. s of oe FDT Data Files for rec mot a20 a37 U Cancel Add text files If the text file to be downloaded is not shown under Target files the text file has to be added File Edit View Project Device Image Tools Window Help El os e ted Ga Be ies Workspace DCS800 2 Projects HEE Firmware ES Text Device Image cc arae fies Select Text with a right mouse click and choose Add Files to Project from the pop up menu n le Edit View Project Device Image Tools Window Help Set as Active Project Remove Project Connect ta Device Erase FLASH blacks Upload Image Blank check Cancel FLASH Operation Build Device Image Freshen all Target Files Properties amp lt Shift R Service 3ADW000195R0601 DCS800 Service Manual e f 101 Go to the directory containing the desired Add files to Project x text file e g e 9 Look in Co Text ttr EJ 2 Desktop My Documents 4 kin Computer DE L 01 78854 DELITUSS Gap Local Disk C ABB DCS800 Dj Firmware CON 4 9 Ver 3 xen l e ext Filename G Desg00 CO 2 00 p j ES Gap V2 Work G Se Deu109995 on De s 0183726 H r fmt DAE A Dana Peete ate Cancel di Sq FIA r To display the desired text file write in File name and press Open Add files to Project 2 xl Look in Text e amp er E3 reme il F
106. se 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 Fault Tracing Thyristors 3ADWO000195R0601 DCS800 Service Manual e f 20 C1 V15 N Y V22 eta branching fuse U1 V1 m t UTI ji branch V167N SZ v23 v25 are principle B6 a dsf Bridge configuration D5 to D7 The OHM test should be performed when the thyristor is still clamped Outside the converter a special thyristor clamping device is needed For 4 Q converters with anti parallel thyristors or BCT s o The selection of a forward or reverse thyristor or BCT Bidirectional Controlled Thyristor is done during the disassembly Continue with related part Exchange of Thyristors for Size D5 D6 or D7 section Find faulty thyristor After a thyristor was replaced the OHM test should be done another time to make sure that all faulty thyristors have been detected If the motor is still connected to the converter the result of the measurement may be wrong Ripple monitor If the ripple monitor fault occurred a fault tracing as described above must be carried out Check the fuses and the thyristors according to the statements before If the power section seems to be ok but still one or more thyristors don t take current something went wrong in between the firing pulse generation and the thyristor s gate in this case check o lsatiring pulse present on the primary side of
107. ss Soft key 1 until the main menu is shown see figure above 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 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 figure above The actual parameter set is now stored in the DCS Control Panel DriveWindow Light Click File then Save As View Options Drive Tools Communication Window Hew Online Drive Cbr h New Offline Drive Ctrl M Open in Browser Ctrl D m x Close m a d Save Ctrl 5 Print Ctrl F Print Setup Exit ct Values Click Save Ad xl Save in E Temp2 e ct E3 My Recent Documents Desktop My Documents fr My Computer DE L 01 7885 ta e DIESE File name 1CS800 Using COM1 dwp Places Save as type Drive Files dwp Cancel DriveWindow Click File then Parameters and Save As lA I Ga Us ea File Edit wiew Network Drive Desktop Monitor Data Workspace el alse Sale B Parameters Ld Open Ctrl HO System Software l Close Graph Li w Status Refresh Export Print Comment M E Fault logg Co
108. ssaging level for use with hardware and kernel development What level of device protection would you like Protection E Automatic Interactive Mone When programming the device any blacks found ta have been written previously will automatically be erased What level of messaging would you like Messaging C Standard Bi algorithm me The Toolkit ill display verbose messages whenever it is communicating with the Target device This mode is useful for Interface hardware development and Kernel development Back Cancel FLASH Development Toolkit 2 2 File Edit View Project Device Image Tools Wind Now the project for the firmware file is finished B ip ceo00r Device Image t Target Files Service 3ADW000195R0601 DCS800 Service Manual e f 107 Create the project for the text file Select Workspace with a right mouse click and choose New Project Ete ES JEW ORI Device IE TRAB Window eke I xl Mew Project Bg Device Image a Target files Insert Project into Workspace Open Workspace Corl Save Workspace Chrl E Close Workspace Properties Alt4 Shift R Name the new project and ProjectName es confirm with Next Welcome to the FLASH Development Toolkit Project Wizard The ca a Project Wizard ill quide you through the steps necessary to create a new project m Watkspace 1 E 18 nd is
109. t 3ADW000195R0601 DCS800 Service Manual e f DCS family DCS550 S modules The compact drive for machinery application 20 31000A Q 610 Vic 230 525 Vic IPOD DCS800 S modules The versatile drive for processindustry 20 5200A O 11860VX 230 1 000V IPOO pe DCS800 A enclosed nM converters 1 7 i Complete drive solutions EE I EH 20 20 000 A ae O 1 500 V 230 1 200V IP21 IP54 DCS800 E series Pre assembled drive kits 20 2000A O 700W 230 600V IPOO DCS800 R Rebuild Kit Digital control kit for exi sting powerstacks 0 1160VX 230 1 2200V IPOO Ai HD HD PAID ED ABB Automation Products Wallstadter StraBe 59 68526 Ladenburg Germany Tel 49 0 6203 71 0 Fax 49 0 6203 71 76 09 www abb com motors amp drives Compact Robust design Adaptive and winder program High field exciter current Compact Highest power ability Simple operation Comfortable assistants e g for commissioning or fault tracing scalable to all applications Free programmable by means of integrated IEC61131 PLC Individually adaptable to customer requirements User defined accessories like external PLO 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 DCS 800 module with all necessary accessories
110. the defective branches by performing an OHM test both polarities between U1 V1 W1 and C1 D1 C1 V137K NZ V26 V157N NZ v22 F15 Il branching fuse m branch N7v23 X V127N XZ v25 Ld e D1 principle B6 a dsf Bridge configuration D5 to D7 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 n a 4 quadrant converter with BCTs change the BCT 5 In a 4 quadrant converter with 2 single thyristors change both thyristors clamped between the same heatsinks at once Note Because Disc Type semiconductors need a certain compression force to 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 thyristors size D6 3ADWO000195R0601 DCS800 Service Manual e f 46 Remove faulty thyristor 1 Replace all blown fuses 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 ie f Note It depends on the location of the defective thvristor which DC busbar plates have to be disconnected 3 Write down the direction and location of the thvristors to be removed and mark their gate leads In case of BCTs add
111. the firing pulse transformer o Isa firing pulse present on the secondary side of the firing pulse transformer o Is the firing pulse transferred to the gate of the thyristor loose gate connector Are all electrical connections still healthy o Can the thyristor be fired with the applied firing pulse Is the pulse form of the firing pulse identical at all measuring positions Check the settings of the current controller Check the AC mains network by taking recordings of the line voltage and current at all 3 phases at the same time Fault Tracing Thyristors 3ADWO000195R0601 DCS800 Service Manual e f 21 Handling the Semiconductors General Instruction how to handle 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 semiconducto
112. the top of the converter housing Remove DCS Control Panel Depress the locks by means of a screwdriver to remove the design cover 2 Remove the two fan arrangement screws Remove the fan arrangement screws 3ADW000195R0601 DCS800 Service Manual e f Service 3 Move the fan arrangement forward 78 LI IP Mill ul illi 41 Hh ji J TM ove the fan gement forwar ito MINI ETT SS fi emove the fan olding screws H h ll j NL Int gt La gt 4 Remove the fan holding screws 3ADW000195R0601 DCS800 Service Manual e f Service 79 5 Remove Faston plugs and fans Eu Fan connection 4 plug A7 Remove Faston plugs B Vs 6 Reassemble everything and check for correct blow direction of each fan The air should be sucked out of the module Service 3ADWO000195R0601 DCS800 Service Manual e f 80 Exchange converter fan size D6 Before the work is started disconnect the converter completely from the power supply then check the voltage free condition and make sure everything is located in an electrical and mechanical safe condition 1 Remove the three screws at the top of the fan 2 Disconnect the cables 3 Lift the fan up and pull it out Service 3ADW000195R0601 DCS800 S
113. ting spring Correct torque Note The correct torque is indicated bv means of the welded indicating spring Perform an OHM test to make sure the thyristor is ok Reconnect the backplate branch fuses DC AC busbars and all other dismantled parts Perform an OHM test between U1 V1 W1 and C1 D1 to make sure the power part is ok 10 11 Exchange thyristors size D7 3ADW000195R0601 DCS800 Service Manual e f 62 Location of thyristors in frame D7 4 Q bridge
114. tor from anode to cathode An internal short circuit between the phases line side AC 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 n 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 n case of serial fuses e g DC fuses If one of the serial fuses is blown all serial fuses have to be changed The undamaged fuses might be half blown and will blow with the next high current DC current pulses measured using 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 UE 10 0 A2 i 1 45 40 Fault Tracing Thyristors 3ADW000195R0601 DCS800 Service Manual e f 18 There should be six current pulses in positive direction In case of a 4 Q converter also the six current pulses for the negative current direction or other speed direction have to be checked Thyristor diagnosis Also the thyristor diagnosis provided by the firmware can be used Switch the drive
115. ual e f 130 14 00 DCS800 S01 0090 04 05 amp DCS800 S02 0100 04 05 400V 525V o Thyristor modules 3 6 3ADC340068P0001 SKKT57Bhox MCC 56 16 xxx 4715 MS 12T B5Axxx 15 00 JDCS800 SO1 0125 04705 amp DCS800 S02 0140 04 05 400 V 525 V Thyristor modules 3 6 3ADC340064P0001 SKKTi06Bixx JMCCO5 16xxx 16 00 DCS800 S01 0180 04 05 amp DCS800 S02 0200 04 05 400 V 525 V o Thyristor modules 3 6 3ADC340064P0001 SKKTi06Bixx McC95 16xxx O Thyristormodules 3 6 3ADC340094P0001 MCC 62 16ox TT162 Nox O 4715 MS 12T B5Axxx Thyristor modules 3 6 3ADCS400906P0000 MOC224xxx 4715 MS 12T B5Axxx 19 00 JDCS800 SO1 0315 04 05 amp DCS800 S02 0350 04 05 400 V 525 V Thyristor modules 3 6 3ADC340095P0001 MCC255 xxx TT250Nox O 4715 MS 12T B5Axxx Appendix A Spare Parts List 3ADWO000195R0601 DCS800 Service Manual e f 131 20 00 DCS800 S01 0405 04 05 amp DCS800 S02 0450 04 05 400 V 525 V TYPE DATA NOTES Thyristormodules 3 6 3ADC340095P0001 MCC255 xxx JIT2SONXXX O Blade or knife fuse 21 00 JDCS800 SO1 0470 04 05 amp DCS800 S02 0520 04 05 400 V 525 V Thyristormodules 3 6 3ADC340100P0001 MCC312 xxx 22 00 DCS800 S01 0590 06 amp DCS800 S02
116. wing 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 3ADWO000195R0601 DCS800 Service Manual e f 17 Additionally for service and preventive maintenance Following additional tools are mandatory for cleaning An ESD safe blower ESD vacuum cleaner ABB Service Finland code 0006ESD MUNTZ 555 ESD S E How to detect a faulty thyristor Thyristor problems can be noticed differently A fuse is blown This is an indication that a strong overcurrent has happened due to one of the following reasons An internal short circuit between the phases line side AC side because of a defective thyristor short circuit inside a thyris
117. y 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 O 0 0 O0 O Q Preventive Maintenance 3ADWO000195R0601 DCS800 Service Manual e f 120 Screws to be checked F 4 T s B BE 1 ama mei j E f f SN pini E dA my Li ja j E i F i E i a l l l 7 a d r f l ity 4 l x ji I pe Screws to be checked En rel Screws to be checked Screws to be checked located behind the busbar Preventive Maintainance 3ADW000195R0601 DCS800 Service Manual e f 121 Check the door air filters Clocked up filters prevent proper cooling 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 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 Usean 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 Check the quality of the supply voltage Preventive Maintenance 3ADW000195R0601 DCS800 Service Manual e f

DCS800 Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents