ABB DCS800 User manual

DCS800DCS800
Service manualService manual
DCS800 DCS800
Drives Drives
20 20
to to
5200 5200
AA

DCS800 Drive ManualsDCS800 Drive Manuals
LanguageLanguage
Public. numberPublic. number
E E
D D
I I
ES ES
F F
CN CN
RU RU
PLPL
DCS800 Quick GuideDCS800 Quick Guide
3ADW000191 3ADW000191
x x
x x
x x
x x
xx
DCS800 Tools & Documentation CDDCS800 Tools & Documentation CD
3ADW000211 3ADW000211
xx
DCS800 Converter moduleDCS800 Converter module
Flyer Flyer
DCS800 DCS800
3ADW000190 3ADW000190
x x
x x
x x
xx
Technical Technical
CatalogCatalog
ue ue
DCS800 DCS800
3ADW000192 3ADW000192
x x
x x
x x
x x
x x
x x
xx
Hardware Hardware
Manual Manual
DCS800 DCS800
3ADW000194 3ADW000194
x x
x x
x x
x x
x x
x x
x x
xx
Hardware Hardware
Manual Manual
DCS800 DCS800
update update
DCF503B/DCF504B DCF503B/DCF504B
3ADW000194Z03ADW000194Z0
301 301
xx
Firmware Firmware
Manual Manual
DCS800 DCS800
3ADW000193 3ADW000193
x x
x x
p p
x x
x x
x x
x x
xx
InstalInstal
lation lation
according according
to to
EMC EMC
3ADW000032 x3ADW000032 x
Technical Technical
Guide Guide
3ADW000163 3ADW000163
xx
Service Service
Manual Manual
DCS800 DCS800
3ADW000195 3ADW000195
x x
xx
12-Pulse 12-Pulse
Manual Manual
3ADW000196 3ADW000196
xx
CMA-2 CMA-2
Board Board
3ADW000136 3ADW000136
pp
Flyer Flyer
Hard Hard
- -
Parallel Parallel
3ADW000213 3ADW000213
xx
Drive ToolsDrive Tools
DriveWindow DriveWindow
2.x 2.x
- -
User's User's
Manual Manual
3BFE64560983BFE6456098
1 1
xx
DriveOPC DriveOPC
2.x 2.x
- -
User's User's
Manual Manual
3BFE00073843BFE0007384
6 6
xx
Optical Optical
DDCS DDCS
CommunicatiCommunicati
on on
Link Link
3AFE63988233AFE6398823
5 x5 x
DDCS DDCS
Branching Branching
Units Units
- -
User’s User’s
Manual Manual
3BFE64285513BFE6428551
3 3
xx
DCS800 ApplicationsDCS800 Applications
PLC PLC
Programming Programming
with with
CoDeSys CoDeSys
CoDeSys_V23 x CoDeSys_V23 x
x x
xx
61131 61131
DCS800 DCS800
target target
+tool +tool
description description
- -
Application Application
Program Program
3ADW000199 3ADW000199
xx
DCS800 Crane DriveDCS800 Crane Drive
DCS800 DCS800
Crane Crane
Drive Drive
Manual Manual
suppl. suppl.
3AST004143 3AST004143
xx
DCS800 DCS800
Crane Crane
Drive Drive
Product Product
note note
PDC5 PDC5
EN EN
REVA REVA
pp
DCS800 Winder ITCDCS800 Winder ITC
DCS800 DCS800
Winder Winder
Product Product
note note
PDC2 PDC2
EN EN
xx
DCS800 DCS800
Winder Winder
descriptiodescriptio
n n
ITC ITC
3ADW000308 3ADW000308
xx
Winder Winder
QuestQuest
ionnaire ionnaire
3ADW000253z 3ADW000253z
xx
DCS800-E Panel SolutionDCS800-E Panel Solution
Flyer Flyer
DCS800-E DCS800-E
Panel Panel
solution solution
3ADW000213ADW00021
0 0
xx
Hardware Hardware
Manual Manual
DCS800-E DCS800-E
3ADW000224 3ADW000224
xx
DCS800-A Enclosed ConvertersDCS800-A Enclosed Converters
Flyer Flyer
DCS800-A DCS800-A
3ADW000213 3ADW000213
xx
Technical Technical
CatalogCatalog
ue ue
DCS800-A DCS800-A
3ADW000198 3ADW000198
xx
InstalInstal
lation lation
of of
DCS800-A DCS800-A
3ADW000091 3ADW000091
x x
xx
DCS800-R Rebuild SystemDCS800-R Rebuild System
Flyer Flyer
DCS800-R DCS800-R
3ADW000007 3ADW000007
x x
xx
DCS800-R DCS800-R
Manual Manual
3ADW000197 3ADW000197
xx
DCS500/DCS600 DCS500/DCS600
Size Size
A5...A7A5...A7
, ,
C2b, C2b,
C3 C3
and and
C4 C4
Upgrade Upgrade
Kits Kits
3ADW000256 3ADW000256
xx
Extension ModulesExtension Modules
RAIO-01 RAIO-01
Analogue Analogue
IO IO
ExtensioExtensio
n n
3AFE64484563AFE6448456
7 7
xx
RDIO-01 RDIO-01
Digital Digital
IO IO
Extension Extension
3AFE64485733AFE6448573
3 3
xx
RRIA-01 RRIA-01
Resolver Resolver
InterfInterf
ace ace
Module Module
3AFE68570763AFE6857076
0 x0 x
RTAC-01 RTAC-01
Pulse Pulse
Encoder Encoder
InterfInterf
ace ace
3AFE64486853AFE6448685
3 3
xx
RTAC-03 RTAC-03
TTL TTL
Pulse Pulse
Encoder Encoder
InterfInterf
ace ace
3AFE68650503AFE6865050
0 0
xx
AIMA AIMA
R-slot R-slot
extension extension
3AFE64661443AFE6466144
2 2
xx
Serial Serial
CommunCommun
icationication
Drive specific serial Drive specific serial
communicommuni
cationcation
NETA NETA
Remote Remote
diagnostic diagnostic
interfinterf
ace ace
3AFE64605063AFE6460506
2 2
xx
FieldbuFieldbu
s s
Adapter Adapter
with with
DC DC
Drives Drives
RPBA- RPBA-
(PROFIBUS) (PROFIBUS)
3AFE64504213AFE6450421
5 5
xx
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
FieldbuFieldbu
s s
Adapter Adapter
with with
DC DC
Drives Drives
RCNA-01 RCNA-01
(Contr(Contr
olNet) olNet)
3AFE64506003AFE6450600
5 5
xx
FieldbuFieldbu
s s
Adapter Adapter
with with
DC DC
Drives Drives
RDNA- RDNA-
(DeviceNet) (DeviceNet)
3AFE64504223AFE6450422
3 3
xx
FieldbuFieldbu
s s
Adapter Adapter
with with
DC DC
Drives Drives
RMBA RMBA
(MODBUS) (MODBUS)
3AFE64498853AFE6449885
1 1
xx
FieldbuFieldbu
s s
Adapter Adapter
with with
DC DC
Drives Drives
RETA RETA
(Ethernet) (Ethernet)
3AFE64539733AFE6453973
6 6
xx
x x
-> ->
existing existing
p p
-> ->
plannedplanned
Status 04.2010Status 04.2010
DCS800 Drive Manuals-List_j.docDCS800 Drive Manuals-List_j.doc


2011 ABB Automation Products GmbH. All rights reserved.2011 ABB Automation Products GmbH. All rights reserved.
DCS800 DrivesDCS800 Drives
20 to 5200 A20 to 5200 A
Service ManualService Manual
Code: Code:
3ADW000195R0501 3ADW000195R0501
Rev Rev
EE
DCS800 Service Manual e e.docDCS800 Service Manual e e.doc
EFFECTIVE: 03.2011EFFECTIVE: 03.2011
SUPERSEDES: SUPERSEDES:
Rev Rev
D D
09.200909.2009

5
Safety instructions
What this chapter contains
This chapter contains the safety instructions you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
To which products this chapter applies
The information is valid for the whole range of the product DCS800, the converter
modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the
Rebuild Kit DCS800-R00-9xxx.
Usage of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment, and advise on how to avoid the danger.
Notes draw attention to a particular 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.
General danger warning
warns about conditions, other than those
caused by electricity, which can result in physical injury or death
and/or damage to the equipment.
Electrostatic sensitive devices warning
warns of electrostatic
discharge which can damage the equipment.

6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable
or motor. Ignoring the instructions can cause physical injury or death
and/or damage to the equipment.
WARNING!
•
Only qualified electricians are allowed to install and
maintain
the drive!
•
Never
work
on
the
drive,
motor
cable
or
motor
when
main
power
is
applied.
Always ensure by measuring with a multimeter (impedance at least
1 Mohm) that:
1.
Voltage between drive input phases U1, V1 and W1 and
the frame is close to 0 V.
2.
Voltage between terminals C+ and D- and the frame is
close to 0 V.
•
Do
not
work
on
the
control
cables
when
power
is
applied
to
the
drive or to the external control circuits. Externally supplied control
circuits may cause dangerous voltages inside the drive even when
the main power on the drive is switched off.
•
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:
•
The
motor
cable
terminals
on
the
drive
are
at
a
dangerously
high
voltage when the main power is on, regardless of whether the
motor is running or not.
•
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.

13
Table of contents
Safety
instructions
5
What this chapter contains..
........................................................................................................
5
To which products this chapter applies..
.....................................................................................
5
Usage o
f warnin
gs and
notes
..
...................................................................................................
5
Installation and maintenance work..
............................................................................................
6
Grounding..
......................................................................................................................
7
Mechanic
al
installat
ion
..
..............................................................................................................
9
Ope
rati
on
...
...............................................................................................................................
10
Table
of
contents
13
Introduction 16
How to use this manual...
..........................................................................................................
16
Contents
of this ma
nual
...
.........................................................................................................
16
Tar
get g
roup
...
..........................................................................................................................
16
Associa
ted pu
blication
s
...
.........................................................................................................
16
Storage a
nd trans
port
...
............................................................................................................
17
Name plate and t
ype code
...
.....................................................................................................
17
Typ
e cod
e
...
..............................................................................................................................
18
Current and voltage ratings...
....................................................................................................
19
Fault
Tracing
Thyristors
21
To
ols
..
.
......................................................................................................................................
21
For commissioning and fault tracing...
...........................................................................
21
Additional
ly for service and preventive maintena
nce
...
.................................................
22
How to detect a faulty thyristor...
...............................................................................................
22
A fuse i
s blow
n
...
...........................................................................................................
22
DC-cur
rent pulses measured by an
oscillos
cope
...
.......................................................
23
Thyris
tor diag
nosis
...
.....................................................................................................
23
Ripp
le monito
r
...
............................................................................................................
23
How to find a faulty thyristor...
...................................................................................................
24
Converters size D1 to D4 (20...1000 A)...
......................................................................
24
Blown
fuses
...
................................................................................................................
24
Converters size D5, D6, and D7 (900...5200 A)...
.........................................................
25
Blown
fuses
...
................................................................................................................
25
Ripp
le monito
r
...
............................................................................................................
25
Handling
the
Semiconductors
27
General Inst
ruction how to handle the Semicondu
ctors
...
........................................................
27
Exchange
of
Thyristors
for
Size
D1
to
D4
29
Installation of OnBoard bridge and thyristor modules in converters size D1 to D4
(20
...1
000 A)
...
..........................................................................................................................
29
Required
Tools
...
...........................................................................................................
29
Find fault
y thyri
stor mod
ules
...
......................................................................................
29
Remove faulty thyri
stor modules
...
................................................................................
30
Install new thyris
tor modules
...
......................................................................................
34

14
Remove fau
lty OnBoar
d bridge (V1)
...
.........................................................................
36
Install n
ew OnBoar
d bridge (
V1)
...
...............................................................................
36
OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units...
.......
37
OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units...
.......
38
OnBoard bridge and thyrist
or module terminals
...
........................................................
39
Exchange
of
Thyristors
for
Size
D5
41
Installation of "Disc Type" thyristor in
converters size D5 (900...2000 A)
...
.............................
41
Required
Tools
...
..........................................................................................................
41
Disk typ
e thyrist
ors
...
....................................................................................................
42
Find faulty t
hyrist
or
...
....................................................................................................
45
Remove faulty thyristor...
..............................................................................................
46
Install new thyristor...
....................................................................................................
47
Exchange
of
Thyristors
for
Size
D6
51
Installation of "Disc Type" thyristor in
converters size D6 (1900...3000 A)
...
...........................
51
Required
Tools
...
..........................................................................................................
51
Disk typ
e thyrist
ors
...
....................................................................................................
52
BCT thyristors...
............................................................................................................
53
Find faulty t
hyrist
or
...
....................................................................................................
54
Remove faulty thyristor...
..............................................................................................
55
Install new thyristor...
....................................................................................................
58
Exchange
of
Thyristors
for
Size
D7
65
Installation of "Disc Type" thyristor in
converters size D7 (2050...5200 A)
...
...........................
65
Required
Tools
...
..........................................................................................................
65
Find faulty t
hyrist
or
...
....................................................................................................
66
Install new thyristor...
....................................................................................................
69
Exchange
of
SDCS-CON-4
75
Gen
era
l
...
.................................................................................................................................
75
Required
Tools
...
..........................................................................................................
75
Overview SDCS-CON-4 exchange...
............................................................................
75
Service 83
How to remove the con
verter fans in fr
ames D1 to D3 (two fans)
...
........................................
83
How to remove the con
verter fans in a frame D3 (fo
ur fans)
...
................................................
87
How to remov
e the conve
rter fan in a fram
e D6
...
...................................................................
92
How to remov
e the conve
rter fan in a fram
e D7
...
...................................................................
93
DCS800
firmwar
e down
load
...
.................................................................................................
94
General...
......................................................................................................................
94
Download SDCS-CON-4 firmware...
.............................................................................
94
Add firmwar
e or text files
....
........................................................................................
107
Create a workspace....
................................................................................................
114
Download SDCS-
COM-8 firmwar
e
....
.........................................................................
129
Set ty
pe cod
e
....
.....................................................................................................................
131
Type code t
able
....
......................................................................................................
133
DC-Moto
r neutral zone adjustm
ent
....
....................................................................................
134
Types conce
rned
....
....................................................................................................
134
Summ
ary
....
................................................................................................................
134
General....
...................................................................................................................
134

15
Preventive
Maintenance
135
Recomme
nded regular
maintenan
ce
....
..................................................................................
136
Maintenan
ce schedule
....
........................................................................................................
136
Annual preventive maintenance....
..........................................................................................
137
3 years preventive mainte
nance
....
.........................................................................................
140
6 years preventive mainte
nance
....
.........................................................................................
141
9 years preventive mainte
nance
....
.........................................................................................
143
Appendix
A
-
Spare
Parts
List
145

1919
The The
technical technical
data data
and and
specifications specifications
are are
valid valid
as as
of of
going going
to to
press. press.
ABB ABB
reservesreserves
the right to make subsequent alterations.the right to make subsequent alterations.
If you have any questions concerning your drive system, please contact your localIf you have any questions concerning your drive system, please contact your local
ABB agent.ABB agent.
Current and voltage ratingsCurrent and voltage ratings
Supply voltage [VAC]Supply voltage [VAC]
Unit Unit
size size
2-Q 2-Q
rated rated
currentcurrent
DCS800-01 [ADC]DCS800-01 [ADC]
4-Q rated current4-Q rated current
DCS800-02 [ADC]DCS800-02 [ADC]
400 525 400 525
600 690 600 690
800 990 800 990
12001200
20 20
25 X 25 X
XX
45 45
50 X 50 X
XX
65 65
75 X 75 X
XX
90 90
100 100
X X
XX
D1D1
125 125
140 X 140 X
XX
180 180
200 X 200 X
XX
D2D2
230 230
260 X 260 X
XX
315 315
350 350
X X
X X
XX
405 405
450 X 450 X
XX
D3D3
470 470
520 X 520 X
XX
610 610
680 680
X X
X X
XX
740 740
820 X 820 X
XX
D4D4
900 900
1000 1000
X X
XX
900 900
900 900
X X
XX
1200 1200
1200 X 1200 X
XX
1500 1500
1500 1500
X X
X X
X X
XX
D5D5
2000 2000
2000 2000
X X
X X
XX
11
XX
11
1900 1900
1900 1900
XX
2050 2050
2050 2050
X X
X X
XX
2500 2500
2500 2500
X X
X X
X X
X X
XX
D6D6
3000 3000
3000 3000
X X
X X
X X
X X
XX
2050 2050
2050 2050
XX
2600 2600
2600 2600
X X
XX
3300 3300
3300 3300
X X
X X
X X
X X
X X
X X
XX
4000 4000
4000 4000
X X
X X
X X
X X
X X
X X
XX
4800 4800
4800 4800
X X
X X
XX
D7D7
5200 5200
5200 X 5200 X
XX
11
only available as 2-Q driveonly available as 2-Q drive

2020

2121
Fault Tracing ThyristorsFault Tracing Thyristors
ToolsTools
For commissioning and fault tracingFor commissioning and fault tracing
Following software tools are mandatory:Following software tools are mandatory:

DriveWindow Light including commissioning wizard and DWL AP for AdaptiveDriveWindow Light including commissioning wizard and DWL AP for Adaptive
ProgramProgram
andand

DriveWindow for fast drive monitoring using SDCS-COM-8.DriveWindow for fast drive monitoring using SDCS-COM-8.
Following tools are mandatory in addition to standard tools:Following tools are mandatory in addition to standard tools:

An oscilloscope including memory function with either galvanically isolatingAn oscilloscope including memory function with either galvanically isolating
transformer or isolating amplifier (probe) for safe measurements. It can also betransformer or isolating amplifier (probe) for safe measurements. It can also be
a hand held (portable) oscilloscope.a hand held (portable) oscilloscope.

A clamp on current probe. In case the scaling of the DC load current needs toA 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.be checked it must be a DC clamp on current probe.

A voltmeter (at least CAT III 1000 V):A voltmeter (at least CAT III 1000 V):

1000 V probes and test leads:1000 V probes and test leads:

An ESD-field service kit (ABB ServiceAn ESD-field service kit (ABB Service
Finland code 0001ESD / MS-Antistatic):Finland code 0001ESD / MS-Antistatic):
Make sure that all equipment in use is suitable for the voltage level applied to theMake sure that all equipment in use is suitable for the voltage level applied to the
power part!power part!

22
Additionally for service and preventive maintenance
Following additional tools are mandatory for cleaning:

An ESD safe blower / ESD vacuum
cleaner (ABB Service Finland code
0006ESD / MUNTZ 555-ESD-S-E):
How to detect a
faulty thyristor
Thyristor problems can be noticed differently:
A fuse is blown
This is an indication, that a strong overcurrent has happened due to one of the
following reasons:

An internal short circuit between the phases (line side) because of a defective
thyristor (short circuit inside a thyristor from anode to cathode).

An internal short circuit between the phases (line side) because of circulating
current in a 4-Q converter (malfunction of the control electronics, no thyristor
defective).

An external short circuit at the DC terminals of the converter without sufficient
impedance.

A commutation fault during generating (active braking with high current, high
EMF and with low AC voltage) of a 4-Q converter.
Note:
In case of parallel fuses: If one of the parallel fuses is blown, all parallel fuses have
to be changed. The ‘undamaged’ fuses might be ‘half-blown’ and will blow with the
next high current.

23
DC-current pulses measured by an oscilloscope
Connect an oscilloscope to the fixed AO I-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:
Six current pulses in
positive direction
There should be six current pulses in positive direction.
In case of a 4-Q converter also the six current pulses for the negative direction
have to be checked.
Thyristor diagnosis
Also the thyristor diagnosis provided by the firmware can be used:

Switch the drive to local mode (DriveWindow, DriveWindow Light, DCS Control
Panel or local I/O).

Start the thyristor diagnosis by means of
ServiceMode (99.06)
=
ThyDiagnosis
and set
On
and
Run
within 20 s.

During the thyristor diagnosis the main contactor will be closed and the
thyristors are checked. The field current is not released while the thyristor
diagnosis is active and thus the motor should not turn.

When the thyristor diagnosis is finished check
Diagnosis (9.11)
for details.
Ripple monitor
The ripple monitor indicates that the ripple of the DC current is much higher than
normal. In such a case, most often one thyristor does not work. It’s missing current
contribution causes a deep dip in the direct current.
The structure of the current loop (current controller) will force the other thyristors to
compensate the dip by a certain overcurrent in order to keep the average current
constant. Such a compensation results in a ripple monitoring fault during motoring
mode operation with


90°.
The reason for a current less thyristor may be:

24

A fuse has disconnected one of the six thyristors. This is possible only for
converters with 900 ... 5200 A (six internal branch fuses). A converter with
three external fuses stops working completely at once when one of the three
AC input fuses interrupts a phase input of the converter.

A thyristor does not get firing pulses or does not react to firing pulses.

The current controller may be totally mismatched to the DC load.

The AC mains network is causing that fault message. In this case,
asymmetrical phase shift, uneven phase voltage or critical designed power
factor correction equipment or harmonic reduction equipment can be the
reason.
How to find a
faulty thyristor
If a blown fuse is suspected in the converter, the problem is caused most often by
a faulty thyristor. To make sure, that a thyristor is the reason and needs to be
exchanged fault tracing must be done in two different ways, depending on the size
of the converter.
In general, make sure, that all safety instructions, given within
this manual or
within the safety instructions, related to the machine or the
application itself,
are obeyed.
Converters size D1 to D4 (20...1000 A)
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

Using the OHM function of a normal multimeter, measurements must be made
from each AC terminal to each DC terminal (U1 to C1, V1 to C1, W1 to C1, U1
to D1, V1 to D1 and W1 to D1; see picture
Anti-parallel B6-bridges with
branching fuses
on page
45
). Normally, every measurement should show high
resistance (> 1 k

).

Target: find a short circuit, indicated by low resistance ( <1

) (destroyed
thyristor).

If the converter is designed with half-bridge thyristor modules, then a module
consists of two anti-parallel thyristors. In this case it is sufficient to know which
thyristor pair or module has a defective thyristor because the complete module
must be replaced.

After a thyristor module is replaced, the above mentioned measurement should
be done another time to make sure that all faulty thyristors have been detected!
Note:
The RC circuit could also cause 0

result for a short time.
The measurement, showing less resistance than 1

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.

31
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
5.
Remove the grounding plug and the holding screw at the electronic tray:
Remove the grounding plug and the
holding screw
Remove grounding and screws
Disconnect all plugs from SDCS-
CON-4 and SDCS-DSL-4 boards

32
6.
To unhinge the electronic tray including the SDCS-CON-4 pull it up and then
out. Before remove tray completely unplug the flat cables (X12, X13, X37):
Electronic tray with SDCS-CON-4
Remove flat cables
Unhinge electronic tray
7.
Remove all cables and plugs at the SDCS-PIN-4:
Remove all cables
and plugs
T100
X8
How to handle X8:
use screw driver
Keep winding direction and
amount of windings for T100
in mind.
Remove cables at the SDCS-PIN-4
Attention:
Write down the winding direction of the cable through T100!
D1: thread the wire 4 times through the hole in T100 (that equals 3 loops)
D2 - D4: thread the wire 1 time through the hole in T100 (that equals no loops)

33
8.
Remove the SDCS-PIN-4 board:
OnBoard field exciter
bridge module
Snubber resistor
Thyristor modules
C
u
r
r
e
n
t
t
r
a
n
s
f
o
r
m
e
r
T
e
m
p
e
r
a
t
u
r
e
s
e
n
s
o
r 
Remove SDCS-PIN-4
9.
Remove the gate leads from the faulty thyristor module and mark the
connectors clearly.
10.
Remove the busbars necessary to get full access to the faulty thyristor module.
11.
If a current transformer must be removed, mark its position and the
connections clearly.
Note:
Remove only as many parts as needed around the faulty thyristor module.
12.
Remove the faulty thyristor module and mark it clearly as defective.

34
Install new thyristor modules
1.
Ensure that the new thyristor module is of the correct type (
see appendix A
of
this manual).
2.
Remove old heat conducting compound (grease) from the heat sink. Clean the
mounting surfaces (heat sink and thyristor module) with an appropriate solvent
(e.g. ethanol) by means of tissue paper. When the heat sink is clean, spread
out the heat conducting compound with a rubber spatula or by hand.
3.
Apply a thin layer of heat conducting compound to the new thyristor module:
Application of heat conducting compound
4.
Spread the heat conducting compound evenly by moving the thyristor module
forward and backward on the heat sink.
5.
Tighten all clamping screws by hand until the screw heads touch the bottom of
the thyristor module. Then tighten the screws to 2.0 Nm torque.
Note
:
If the thyristor module is mounted by means of four screws, tighten the screws
crosswise.
6.
Tighten the screws to nominal torque according to table
Nominal mounting
torque for OnBoard bridge and thyristor modules
page
35
.

35
OnBoard
bridge
and thyristor modules
Nominal mounting torque
Size
Type
Electrical
connections
Thyristor module
to heat sink
29
mm
bridge
block
VVZF
70-16
-
5
Nm
20
mm
block
SKKT
27,
42,
57,
106
3
Nm
5
Nm
20
mm
block
MCC
26,
44,
56,
95
2.5
...
4
Nm
2.5
...
4
Nm
34
mm
block
MCC
162
4.45
…
5.5
Nm
2.25
…
2.75
Nm
34
mm
block
SKKT
162
5
Nm
5
Nm
34
mm
block
TT
162
6
Nm
6
Nm
50
mm
block
MCC
255
11
…
13
Nm
4.5
…
7
Nm
50
mm
block
TT
250,
330
12
Nm
6
Nm
60
mm
block
TT
425,
570
12
Nm
6
Nm
Nominal mounting torque for OnBoard
bridge and thyristor modules
7.
Reinstall the current transformer, make sure, its position 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
on
page
35
.
9.
Reconnect all gate leads to the thyristor module.
10.
Reinstall the SDCS-PIN-4 board.
11.
Reconnect all cables and plugs at the SDCS-PIN-4:

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
12.
Reconnect the flat cables at the SDCS-CON-4 (X12, X13, X37) and re-hinge
the electronic tray.
13.
Reconnect the grounding plug and the holding screw at the electronic tray.
14.
Reconnect all I/O plugs at the SDCS-CON-4 (X3 to X7) and the plugs at the
SDCS-DSL-4 (X51 to X54).
15.
Reinstall the intermediate cover, all plug in options and the design cover.