ABB ACS 6000 Installation and user guide

ABB Switzerland Ltd. All Rights Reserved.
ACS 6000
Medium Voltage Drives
3 to 27 MVA
Service and Maintenance Manual
Document No.: 3BHS202077 ZAB E01 Rev. C
Issued: 21-01-2005
ABB

2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.

ABB
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1 (4)
Table of Contents
Chapter 1 - Introduction and Safety 1-1
1.1 Introduction 1-1
1.2 Safety 1-1
Chapter 2 - Checking IGCTs and Diodes 2-1
2.1 Safety 2-1
2.2 Checking IGCTs 2-1
2.2.1 Required Tools and Accessories 2-1
2.2.2 Test Procedure 2-1
Step 1 2-1
Step 2 2-2
2.3 Checking Diodes in 7/ 9 MVA Phase Modules 2-4
Chapter 3 - Changing Diodes and Thyristors in LSU 3-1
3.1 Required Tools and Accessories 3-1
3.2 Safety 3-2
3.3 Replacing Diodes and Thyristors 3-3
Chapter 4 - Changing 3/5 MVA Phase Modules 4-1
4.1 Required Tools and Accessories 4-1
4.2 Removing a Phase Module 4-2
Using the Hoist 4-6
Using a Crane 4-7
4.3 Installing a Phase Module 4-8
Chapter 5 - Changing RC-IGCTs
in 3/5 MVA Phase Modules 5-1
Chapter 6 - Changing Clamp Diodes
in 3/5 MVA Phase Modules 6-1
6.1 Required Tools and Accessories 6-1
6.2 Changing Procedure 6-1

ABB
2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
Chapter 7 - Changing 7/9 MVA Phase Modules 7-1
7.1 Required Tools and Accessories 7-1
7.2 Removing a Phase Module 7-2
7.3 Installing a Phase Module 7-5
Chapter 8 - Changing Diodes and IGCTs
in 7/9 MVA Phase Modules 8-1
8.1 Required Tools and Accessories 8-1
8.2 Overview 8-2
8.3 Safety 8-4
8.4 Replacing Clamp and NP Diodes 8-5
8.4.1 Preparatory Steps 8-5
8.4.2 Replacing Clamp Diodes 8-8
Upper Clamp Diode 8-8
Lower Clamp Diode 8-9
8.4.3 Replacing NP Diodes 8-11
Removing Upper NP Diode 8-11
Removing Lower NP Diode 8-12
Assembling the Stack 8-12
8.4.4 Finishing Steps 8-13
8.5 Replacing Free Wheeling Diodes 8-14
8.6 Replacing IGCTs 8-16
Chapter 9 - Changing Thyristors in EXU 9-1
9.1 Required Tools and Accessories 9-1
9.2 Safety 9-1
9.3 Replacing Thyristors in EXUs for Brushless Excitation 9-2
9.3.1 Preparatory Steps 9-2
9.3.2 Treating a New Thyristor before Installation 9-3
9.3.3 Mounting a New Thyristor 9-3
9.4 Replacing Thyristors in EXUs for Direct Excitation 9-5
9.4.1 Preparatory Steps 9-5
9.4.2 Treating a New Thyristor before Installation 9-6
9.4.3 Mounting a New Thyristor 9-6
9.5 Deflection Diagram 9-7
Chapter 10 - Changing Semiconductors in VLU 10-1
10.1 Required Tools and Accessories 10-1
10.2 Safety 10-1
10.3 Replacing the Semiconductors 10-2

ABB
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3 (4)
10.3.1 Preperatory Steps 10-2
10.3.2 Replacing Upper Diode 10-2
10.3.3 Replacing IGCTs 10-3
10.3.4 Replacing Lower Diode 10-5
10.3.5 Finishing Steps 10-5
Chapter 11 - Changing IGCTs in DIU 11-1
11.1 Required Tools and Accessories 11-1
11.2 Safety 11-1
11.3 Removing an IGCT 11-2
11.4 Installing an IGCT 11-5
Chapter 12 - Replacing Printed Circuit Boards 12-1
12.1 Safety 12-1
12.2 Replacing an AMC3 Board 12-2
12.3 Changing the AMC3 Flash Memory 12-4
12.4 Replacing an INT Board 12-7
Transferring the EPLD Chips 12-10
Transferring the Pulse Pattern Flash 12-10
12.5 Replacing a CVMI Board 12-12
Chapter 13 - Function of LEDs 13-1
13.1 AMC Board 13-1
13.2 INT Board 13-3
13.3 GUSP 13-5
13.4 IGCT 13-6
Chapter 14 - Tightening Torques and
Threaded Connections 14-1
14.1 Water Cooling Unit 14-1
14.1.1 Tightening Torque for Pipe Coupling
(WCU Type 29 and 52) 14-1
14.1.2 Tightening Torque for Pumps
(WCU Type 29 and 52) 14-1
14.1.3 Tightening Torque for Flanges
(WCU Types 29, 52, 80, 106, 120) 14-3
14.2 Pipe Joints and Busbar Connections 14-3

ABB
4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

ABB
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1-1 (2)
Chapter 1 - Introduction and Safety
The manual mustbe thoroughly read andunderstoodbefore maintenance
work on the ACS 6000 is started.
The manual is addressed to qualified persons who are responsible for
maintaining and servicing the ACS 6000. Hence all general and safety
instructions given in the ACS 6000 User's Manual must be complied with.
Danger: The ACS 6000 is a high voltage device.
High voltage can cause physical injury and death.
Maintenance, parts replacement and other work on the ACS 6000 must
only be carried out by qualified personnel in compliance with local regula-
tions.
Danger: Do not access the ACS 6000 or work on the motor or the power
cables, if the drive system is energized and not properly grounded!
After switching off the mains and after the motor has come to a stop, wait
approximately 5 minutes for the DC link capacitors to discharge. The light
GND.- SWITCH UNLOCKED must be on before grounding the ACS 6000.
Danger: Make sure that the main power cannot be applied by accident.
Rack out the main circuit breaker and lock it.
Danger: Some loads can cause the motor to rotate!
Therefore, always disconnect, short-circuit or block the motor before work
is started.
1.1 Introduction
1.2 Safety

Chapter 1 - Introduction and Safety ABB
1-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
Danger: Before power is applied to the drive, check that:
• Mains and motor connections are ok
• Auxiliary power and control cable connections are ok
• No tools or other foreign objects are left in the cabinet
• All doors including the door of the power cable section are closed

ABB
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-1 (6)
Chapter 2 - Checking IGCTs and Diodes
IGCTsanddiodes ofphasemodulescan onlybetestedaftertheconverter
has been deenergized and grounded.
Danger: The ACS 6000 is a high violtage device.
Make sure that the drivehas been completely deenergized andthat power
cannot be applied by accident.
Failure to do so may result in injury or death.
2.2.1 Required Tools and Accessories
To test IGCTs the following is needed:
• Fiber optic cable (approx. 2 m long)
• Multimeter
2.2.2 Test Procedure
The IGCT to be tested can stay in the phase module. The test is carried
out in two steps:
Step 1 1Deenergize and ground the ACS 6000 but leave the power supply for
the gate units on.
2Check the IGCT for burned components. In this casethe whole IGCT
must be replaced. Check that both LEDs are on. See
Figure 2-1
(
Figure 2-1 depicts the horizontal fitting position of IGCTs as applied
in 7/9 MVA phase modules).
Figure 2-1 IGCT
2.1 Safety
2.2 Checking IGCTs
LEDs Fiber optic cable

Chapter 2 - Checking IGCTs and Diodes ABB
2-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
Note: When checking be careful not to disconnect the fiber optic cable
while the IGCT is energized to prevent an undefined control state.
3Test the IGCT by measuring the voltage between gate and cathode.
Note: Whenmeasuring be carefulnot toshorten gate and cathode/anode
of the IGCT. A short circuit will destroy the semiconductor.
Figure 2-2 Testing IGCTs
To avoid shortening gate and cathode:
• Use short tipped probes
• Hold one probe against the cooler on the cathode
side and the otherprobe against ascrew head on the
gate side (see
Figure 2-2 ).
Result of the measurement: approx. -20 VDC (see
Figure 2-2 ).
4Disconnect the power supply of the gate unit (one of the following
circuit breakers in COU: -Q1041, -Q1042, -Q1043, see wiring dia-
gram).
5Wait approx. 20 sec. for the capacitors of the gate unit to discharge.
Step 2 1Verify that the power supply of the gate unit is off.
2Switch off the auxiliary power supply pertaining to the INT board in
the cabinet.
3Connect a temporary fiber optic cable at one end to the gate unit and
at the other end to a permanent light transmitter of the INT board.
• Inside ARU: connector A714 (see
Figure 2-3 )
• Inside INU: connector A712 or A713 (see
Figure 2-3 )
Cathode
Gate
Measuring results:
Step 1: -20 VDC
Step 2: +0.7 VDC
Side view

ABB Chapter 2 - Checking IGCTs and Diodes
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-3 (6)
Figure 2-3 INT Board
A712
A713
A714

Chapter 2 - Checking IGCTs and Diodes ABB
2-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
4Switch on the auxiliary power to the gate unit.
5Switch on the power supply of the INT board to apply a constant light
to the IGCT.
6Measure the voltage between gate and cathode.
Expected result of the measurement: approx. +0.7 VDC (see also
Figure 2-2 ).
Note: It is important that the following steps 5 and 6 are carried out in the
stated sequence to prevent damage of the gate unit.
7Disconnect the auxiliary power.
8Disconnect the temporary fiber optic cable.
9Reconnect the original fiber optic cable.
10 Switch on the auxiliary power supply.
11 Wait approx. 20 sec until both LEDs on the gate unit have lighted up.
To test a diode the phase module needs to be disconnected from the
busbarconnectors. Water hoses, optical fibers and gate unit power supply
leads can stay in place. The diodes can be accessed from the front of the
phase module.
1Deenergize and ground the ACS 6000.
2Switch off the auxiliary power supply.
3Remove the two fastening bolts at the bottom on each side of the
phase module.
4Disconnect the phase module from the rear busbar connectors. Pull
it towards the front of the cabinet until the lower water hose just
touches the support frame (see circle in
Figure 2-4 ).
5Check that the phase module is completely disconnected from the
busbar connectors.
Note: When pullingout the phasemodule take care that fiberoptic cables
and gate unit supply leads are not damaged.
2.3 Checking Diodes in 7/ 9 MVA Phase Modules

ABB Chapter 2 - Checking IGCTs and Diodes
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-5 (6)
Figure 2-4 Extracting the Phase Module
6Check the diode using the multimeter in diode verification mode and
suitable probes.
Expected result of the measurement:
If uncertain, verify the result by checking another diode of the same phase
module or of another phase module.
Table 2-1 Voltage Measurement
Diode Voltage between
Anode/Cathode Voltage between Cathode/Anode
VR1, VR4, VC1, VC2 ~ 0.2.....0.3 V out of range (diode is blocking)
VR2, VR3, VN1, VN2 ~ 0.2.....0.3 V ~ 2.2.....2.3 V

Chapter 2 - Checking IGCTs and Diodes ABB
2-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

ABB
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-1 (6)
Chapter 3 - Changing Diodes and Thyristors in LSU
The tools listed below are part of the tool set (ident. no. 3BHS130246)
delivered with the ACS 6000.
• Spreader tool
Figure 3-1 Spreader Tool
• ½ " reversible ratchet
• 100 mm ½ " extension bar
• 13 mm ½" hex socket
• Clamp pressure loading spanner
• Cable ties
3.1 Required Tools and Accessories

Chapter 3 - Changing Diodes and Thyristors in LSU ABB
3-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
1Deenergize and ground the ACS 6000.
2Stop the cooling water pumps and make sure that they cannot be
switched on by accident.
Danger: The ACS 6000 is a high voltage device.
Make sure that the cabinet has been completely deenergized and that
power cannot be applied by accident.
Failure to do so may result in injury or death.
Note: Afterswitchingoffthe mainsand after themotor has come toa stop,
allow the DC link capacitors to discharge. The light GND.- SWITCH
UNLOCKED must be on, before grounding the ACS 6000.
3Switch off the auxiliary power. Refer to the wiring diagram to identify
the circuit breaker.
3.2 Safety

ABB Chapter 3 - Changing Diodes and Thyristors in LSU
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-3 (6)
The replacement of diodes and thyristors is explained using the example
of a 9 MVA LSU.
Note: When replacing diodes or thyristors of the rectifier, the clamping
pressure of the stack must be released. Do not to release the pressure all
at once, as otherwise all semiconductors in the stack will become
misaligned.They mustthenberecenteredina timeconsumingprocedure.
The misalignment results from the flexible busbar connectors at the rear
of the stack, which push the coolers to which they are connected to the
front, thus misaligning the semiconductors. It is therefore highly
recommended that the instructions below are followed.
Figure 3-2 LSU Rectifier
3.3 Replacing Diodes and Thyristors
A Pressure adjusting bolts
B Pressure loading spanner
C Spreader tool

Chapter 3 - Changing Diodes and Thyristors in LSU ABB
3-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual
1Deenergize the drive. See section 3.2 Safety.
2Insert the clamp pressure loading spanner (see B in Figure 3-2 ).
3Insert the spreader tool into the openings of the coolers above and
below the diode or thyristor which is to be replaced (see
Figure 3-2 ).
Note: Do not use the extensions available for the spreader tool. The
extensions cause the cooler above the faulty semiconductor to be
depressed by the flexible connectors at the rear of the stack, thus
squeezing the semiconductor.
Note: When replacing a semiconductor which is next to a pulse
transformer, remove the wires before inserting the spreader tool. The
wires can be easily caught in the gears of the spreader tool.
4Alternately release the clamping pressure and then spread the
spreader tool to maintain the pressure in the stack above the
semiconductor to be changed.
Proceeding in this manner prevents the semiconductors from
becoming misaligned.
5Remove the semiconductor as soon as the clearance above the
semiconductor is big enough.
6Prepare the new semiconductor for reassembly.
Checkthe contactsurfaces of thenew diode for any dirt. If necessary,
clean the contact surfaces with an appropriate solvent (e. g. alcohol).
Using a fluff-free cloth wipe the surfaces paying attention not to
scratch the surfaces.
Note: Do not use any grease or any electrical joint compound.
7Insert the new semiconductor into the stack and center it.
Pay attention to the correct polarity. Always verify the polarity with the
corresponding wiring diagram.
8Alternately close the gap between the new semiconductor and the
cooler and increase the pressure in the stack until the pressure
adjustment spanner can be removed.
9Reconnect any disconnected wires.

ABB Chapter 3 - Changing Diodes and Thyristors in LSU
ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-5 (6)
In case a stack becomes misaligned, the coolers can be pushed back into
place and the semiconductors can be centered using a fixture as illus-
trated in
Figure 3-3 .
The two horizontal bars are fixed to the frame of the cabinet. By means of
the adjustment bolts, the wooden bar is pushed against the coolers thus
pushing the coolers back into place and holden them there. The semicon-
ductors can be centered one by one starting at the bottom of the stack.
The spreader tool is used to create the clearance for moving the semicon-
ductors into place. Since the space is very narrow it is recommended to
use a piece of wire shaped into a half moon to move the semiconductors.
Figure 3-3 Fixture
Wooden bar
Horizontal bar
Vertical bar
Horizontal bar
Adjustment bolts

Chapter 3 - Changing Diodes and Thyristors in LSU ABB
3-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual