ABB PCS6000 User manual

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SYSTEM DRIVES
PCS6000
Service manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DATE
2023-03-15
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
Service manual
DOCUMENT ID.
3BHS600000 E80
REV.
F
LANG.
en
PAGE
1/272
© Copyright 2012 ABB All rights reserved.

PRODUCT
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DOCUMENT KIND
Service manual
DOCUMENT ID.
3BHS600000 E80
REV.
F
LANG.
en
PAGE
2/272
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Legal disclaimer
This document contains information about one or more ABB products and may include a description of or
a reference to one or more standards that are relevant to the ABB products. The presence of any such
description of a standard or reference to a standard is not a representation that all of the ABB products
referenced in this document include all the features of the described or referenced standard. In order to
determine the specific features included in a particular ABB product, the product specifications for the
particular ABB product apply.
The buyer acknowledges the proprietary and confidential nature of the information contained in this
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The information in this document is subject to change without notice and should not be construed as a
binding declaration of ABB. ABB assumes no responsibility for any errors or omissions in this document.
Products described or referenced in this document are designed to be connected with networks and
provide information and data through network interfaces. The products must be connected to a secure
network. It is the sole responsibility of the buyer of the products to provide and continuously ensure a
secure connection between the product and the system network and/or any other networks that may be
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updates or patches, hardware change out, and so on) are compatible with the security measures
implemented. The buyer of the product must verify that the system and associated products function as
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—
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ABB is a registered trademark of ASEA BROWN BOVERI LTD.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2012 ABB
All rights reserved

CONTENTS
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Contents
1. About this manual................................................................................................................. 17
1.1. Equipment covered by this manual ...................................................................................... 17
1.2. Overview ...................................................................................................................................... 17
1.3. Contents of this manual ..........................................................................................................18
1.4. Related documents...................................................................................................................19
1.5. Target groups and required qualification.......................................................................... 20
1.5.1. Handling.......................................................................................................................... 20
1.5.2. Mechanical installation................................................................................................ 20
1.5.3. Electrical installation.................................................................................................... 20
1.5.4. Operation........................................................................................................................ 20
1.5.5. Maintenance................................................................................................................... 20
1.6. User's responsibilities ..............................................................................................................21
1.7. Intended use of the equipment.............................................................................................21
1.8. Document conventions........................................................................................................... 22
2. Important safety information............................................................................................. 23
2.1. Safety messages and safety signs in this document ..................................................... 23
2.1.1. Safety messages........................................................................................................... 23
2.1.2. Safety signs.................................................................................................................... 23
2.2. Product safety labels............................................................................................................... 24
2.3. Electrical safety......................................................................................................................... 25
2.3.1. General safety instructions ........................................................................................ 25
2.3.2. The 7 steps that save lives .......................................................................................... 26
2.4. Possible residual risks ............................................................................................................. 28
3. Service tools.......................................................................................................................... 31
3.1. Overview ......................................................................................................................................31
3.1.1. Converter service tools.................................................................................................31
3.1.2. Commissioning tools....................................................................................................31
3.1.3. Replacement tools.........................................................................................................31
3.2. Converter service tools ........................................................................................................... 32
3.2.1. Converter service toolbox........................................................................................... 32
3.2.2. Grounding kit ................................................................................................................. 35
3.2.3. Tube cutter ..................................................................................................................... 36
3.2.4. Polishing kit for fiber optics....................................................................................... 37
3.3. Commissioning tools .............................................................................................................. 38
3.3.1. RCI-Box XU D194............................................................................................................ 38
3.3.2. PCS6000 HMI................................................................................................................. 39
3.3.3. Filling kit for PCS6000 water cooling ......................................................................40
3.3.4. Filling kit extension tube..............................................................................................41
3.4. Replacement tools ....................................................................................................................41
3.4.1. Reactor replacement kit...............................................................................................41
3.4.2. Base beam lifting jack ................................................................................................. 42
3.4.3. Chain-block..................................................................................................................... 43
3.4.4. Pump maintenance table kit (Only for Swedewater WCU).................................44
3.4.5. Generator breaker replacement kit .......................................................................... 45
4. Preventive maintenance.......................................................................................................47

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4.1. General ........................................................................................................................................ 47
4.2. Safety information ................................................................................................................... 47
4.3. General directives.....................................................................................................................48
4.3.1. Preventive Maintenance Report ................................................................................48
4.4. Preventive maintenance schedule........................................................................................49
4.4.1. Preventive maintenance tasks...................................................................................49
4.4.2. Inspection ....................................................................................................................... 49
4.4.2.1. Checking semiconductor stack tightness.................................................. 52
4.4.2.2. Checking bolt connections............................................................................. 52
4.4.3. Cleaning .......................................................................................................................... 53
4.4.4. Replacing components ............................................................................................... 54
4.4.5. DC-link performance check........................................................................................ 56
4.4.6. DC-link component check........................................................................................... 57
4.4.7. Filter components performance check................................................................... 59
4.4.7.1. Grid side filter components performance check...................................... 59
4.4.7.2. Neutral point performance check..................................................................61
4.4.7.3. dv/dt filter components performance check..............................................61
4.4.8. Functionality and security procedure...................................................................... 62
4.4.9. GRB opening time verification .................................................................................. 63
4.4.10. Insulation Measurement 1CL ..................................................................................... 63
4.4.11. Insulation Measurement 2CL..................................................................................... 65
4.4.12. GDM performance check ............................................................................................ 66
4.4.13. Braking resistor performance check........................................................................ 67
5. De-energizing, grounding and start-up .............................................................................69
5.1. General ........................................................................................................................................ 69
5.2. Safety information ................................................................................................................... 69
5.3. Lockout/Tagout........................................................................................................................ 70
5.4. Start-up after maintenance or troubleshooting .............................................................. 70
6. Troubleshooting ................................................................................................................... 73
6.1. General ........................................................................................................................................ 73
6.2. Safety information ................................................................................................................... 73
6.3. Standard procedure for troubleshooting .......................................................................... 75
7. Checking control components ............................................................................................ 81
7.1. General .........................................................................................................................................81
7.2. Safety information ....................................................................................................................81
7.3. Checking procedure..................................................................................................................81
7.4. LED status indications.............................................................................................................81
7.4.1. LEDs on AC 800PEC ..................................................................................................... 82
7.4.2. LEDs on Combi IO......................................................................................................... 82
7.4.3. LEDs on PECINTM......................................................................................................... 83
7.4.4. LEDs on ASE2 board .................................................................................................... 83
7.4.5. LEDs on UPS...................................................................................................................84
8. Replacing control components ...........................................................................................85
8.1. General ........................................................................................................................................ 85
8.2. Safety information ................................................................................................................... 85
8.3. Overview of replaceable control components ..................................................................86
8.3.1. Replaceable control components in CCU ............................................................... 87
8.3.2. Replaceable control components in POU...............................................................88
8.3.3. Replaceable control components in FIU.................................................................88

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8.3.4. Replaceable control components in DLU ...............................................................89
8.3.5. Replaceable control components in DRU ...............................................................89
8.4. Replacing AC 800PEC..............................................................................................................90
8.5. Replacing Combi IO ................................................................................................................. 92
8.6. Replacing S800 I/O modules ................................................................................................ 93
8.7. Replacing voltage (AE01) and current (AE02) transducer boards................................ 95
8.8. Replacing PECINTM ................................................................................................................. 97
8.9. Replacing IPS ............................................................................................................................. 99
8.10. Replacing HVD......................................................................................................................... 100
8.11. Replacing VLSCD .....................................................................................................................101
8.12. Replacing ASE.......................................................................................................................... 102
8.13. Replacing AC/DC converter ................................................................................................. 103
8.13.1. Replacing AC/DC converter -G301 in CCU or -G401 in
POU................................................................................................................................. 103
8.14. Replacing AC/DC converter -G501 in FIU ......................................................................... 104
8.15. Replacing DC/DC converter................................................................................................. 105
8.16. Replacing UPS ......................................................................................................................... 106
8.16.1. Replacing UPS -G302 in CCU or -G402 in POU .................................................... 106
8.16.2. Replacing UPS -G502 in FIU ......................................................................................107
8.17. Replacing batteries................................................................................................................ 108
8.17.1. Replacing battery -G303 in CCU.............................................................................. 108
8.17.2. Replacing battery -G403 in POU ............................................................................. 109
8.17.3. Replacing battery in UPS -G502 in FIU ...................................................................110
8.18. Replacing fiber optic cables ..................................................................................................111
9. Checking diodes, IGCTs and IPS........................................................................................ 115
9.1. General .......................................................................................................................................115
9.2. Safety information ..................................................................................................................115
9.3. Fault Identification in triple stack (POM) ..........................................................................116
9.4. Location of components ....................................................................................................... 117
9.4.1. Freewheeling diode stack..........................................................................................118
9.4.2. Neutral point and clamp diode stack .....................................................................119
9.4.3. Clamp capacitors and symmetry resistors.......................................................... 120
9.5. Semiconductor checking sequence ................................................................................... 121
9.6. Checking IGCTs with FADEC 3..............................................................................................122
9.7. Checking power diodes with FADEC 3...............................................................................123
9.7.1. Preparation for checking power diodes ................................................................123
9.7.2. Checking freewheeling diodes................................................................................ 124
9.7.3. Checking clamp diodes..............................................................................................125
9.7.4. Checking neutral point (NP) diodes....................................................................... 126
9.8. Checking IGCTs with multimeter (if a FADEC 3 is unavailable)....................................127
9.9. Checking power diodes with multimeter......................................................................... 129
9.9.1. Preparation for checking power diodes ............................................................... 129
9.9.2. Checking freewheeling diodes................................................................................ 129
9.9.3. Checking clamp diodes............................................................................................. 130
9.9.4. Checking neutral point (NP) diodes........................................................................ 131
9.10. Checking IPS .............................................................................................................................132
10. Replacing power and cooling components...................................................................... 133
10.1. Overview ....................................................................................................................................133
10.2. Safety information ..................................................................................................................133
10.3. Overview of serialized power components ......................................................................135

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10.4. General directives....................................................................................................................135
10.4.1. Correct tightening torques of bolted connections.............................................135
10.4.1.1. Capacitors......................................................................................................... 136
10.4.2. Training for maintenance and repair personnel ................................................. 136
10.4.2.1. Service training................................................................................................ 136
10.4.3. List of PCS6000 components > 25 kg ................................................................. 136
10.5. Preparation of cooling liquid circuit before replacing components......................... 138
10.5.1. Releasing the over pressure from the cooling liquid
circuit ............................................................................................................................. 138
10.5.2. Emptying the cooling liquid circuit........................................................................ 139
10.6. Replacing components in POU ........................................................................................... 139
10.6.1. General procedure to replace power semiconductors ..................................... 140
10.6.2. Releasing the stacks ...................................................................................................141
10.6.3. Using the spreading tool ........................................................................................ 145
10.6.4. Replacing IGCTs .......................................................................................................... 149
10.6.5. Replacing power diodes ............................................................................................153
10.6.5.1. Replacing freewheeling diodes ....................................................................153
10.6.5.2. Replacing clamp diodes ................................................................................ 155
10.6.5.3. Replacing neutral point (NP) diodes ...........................................................157
10.6.6. Checking stacks alignment ...................................................................................... 159
10.6.6.1. Aligning an IGCT stack................................................................................... 159
10.6.6.2. Diode stack (freewheeling / neutral point and
clamping) ........................................................................................................... 161
10.6.6.3. Effects of stack misalignment on semiconductors pole
pieces ................................................................................................................. 164
10.6.7. Tightening the stacks ................................................................................................ 166
10.6.8. Replacing clamp capacitor....................................................................................... 169
10.6.9. Replacing symmetry resistor....................................................................................170
10.6.10. Replacing clamp resistor ...........................................................................................172
10.6.11. Replacing clamp reactor ............................................................................................173
10.6.12. Replacing LEM current transducer..........................................................................175
10.6.13. Replacing DC capacitor..............................................................................................176
10.7. Replacing components in DRU ............................................................................................178
10.7.1. General............................................................................................................................178
10.7.2. Releasing the stacks ...................................................................................................179
10.7.3. Centering misaligned stacks ................................................................................... 180
10.8. Replacing components in DLU............................................................................................ 182
10.8.1. Replacing grounding isolator .................................................................................. 182
10.8.2. Replacing resistor -R462_1, -R462_2 ...................................................................... 183
10.8.3. Replacing resistor -R751 to -R754 or capacitor -C751 to
-C752 .............................................................................................................................. 184
10.8.4. Replacing resistor -R461 ........................................................................................... 185
10.8.5. Replacing capacitor -C461........................................................................................ 186
10.8.6. Replacing IGCTs and diodes .....................................................................................187
10.8.7. Replacing VLM ............................................................................................................. 189
10.8.8. Replacing pre-charging transformer..................................................................... 190
10.8.9. Replacing dv/dt filter reactor in DLU...................................................................... 191
10.8.10. Replacing dv/dt filter resistor in DLU .....................................................................193
10.8.11. Replacing dv/dt filter capacitor in DLU................................................................. 194
10.8.12. Replacing grid/generator disconnector module in DLU.................................. 195
10.9. Replacing components in VFU............................................................................................203

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10.9.1. Replacing grid/generator disconnector module (GDM1) at
the front of the VFU ...................................................................................................203
10.9.2. Replacing grid/generator disconnector module (GDM2) at
the back of the VFU.................................................................................................... 210
10.9.3. Replacing dv/dt filter reactor at the front of the VFU
(VFM1) .............................................................................................................................213
10.9.4. Replacing dv/dt filter reactor at the back of the VFU
(VFM2).............................................................................................................................215
10.9.5. Replacing dv/dt filter resistor in VFU ..................................................................... 217
10.9.6. Replacing dv/dt filter capacitor in VFU ..................................................................219
10.10. Replacing components in WCU (Swedewater) ...............................................................220
10.10.1. Replacing or cleaning conductivity meter............................................................220
10.10.2. Replacing inlet water temperature meter ............................................................ 222
10.10.3. Replacing pressure gauge and pressure transmitter........................................ 223
10.10.4. Replacing deionizer flow meter .............................................................................. 224
10.10.5. Replacing the ion exchange vessel......................................................................... 225
10.10.6. Replacing the water filter.......................................................................................... 227
10.10.7. Replacing pump .......................................................................................................... 228
10.10.8. Replacing pump slip ring sealing ........................................................................... 232
10.10.9. Replacing the 3-way valve .........................................................................................234
10.10.10. Replacing expansion vessel...................................................................................... 235
10.10.11. Replacing automatic deaeration valve .................................................................. 237
10.10.12. Replacing (checking) ball valve ¾”..........................................................................238
10.10.13. Replacing (checking) ball valve ½”..........................................................................239
10.11. Replacing components in WCU (ARMATEC) ....................................................................240
10.12. Replacing components in FIU ............................................................................................. 241
10.12.1. Replacing HFM filter reactor....................................................................................242
10.12.2. Replacing HFM filter capacitor................................................................................243
10.12.3. Replacing HFM filter resistor ...................................................................................246
10.12.4. Replacing filter reactor.............................................................................................. 247
10.12.5. Replacing pressure transmitter ..............................................................................249
10.13. Replacing components in GBU ...........................................................................................250
10.13.1. Replacing generator breaker (GEB) / grid breaker (GRI) ..................................250
10.13.2. Replacing dv/dt filter reactor in GBU..................................................................... 261
10.13.3. Replacing dv/dt filter resistor in GBU....................................................................263
10.13.4. Replacing dv/dt filter capacitor in GBU ................................................................264
10.13.5. Replacing fan of GBU fan drawer............................................................................265
10.14. Replacing fans in miscellaneous units..............................................................................268
10.14.1. Replacing door fan with heater...............................................................................268
10.14.2. Replacing roof fan and air filter mats....................................................................269

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Figures
Figure 2–1 Product warning label examples (label placement depends on
the drive) ...........................................................................................................................24
Figure 3–1 Converter service toolbox ............................................................................. 32
Figure 3–2 Spreading tool (part of converter service toolbox) ................................... 33
Figure 3–3 Stabilizer plate (part of converter service toolbox) .................................. 34
Figure 3–4 Semiconductor test device FADEC 3 ........................................................... 34
Figure 3–5 Grounding kit ................................................................................................. 35
Figure 3–6 Tube cutter .................................................................................................... 36
Figure 3–7 Polishing kit for fiber optics (used with all connection types) ................ 37
Figure 3–8 RCI-Box XU D194 with power cables and fiber optic cables .................... 38
Figure 3–9 User interface of the PCS6000 HMI ............................................................ 39
Figure 3–10 Filling kit for PCS6000 water cooling ...................................................... 40
Figure 3–11 Filling kit extension tube ............................................................................ 41
Figure 3–12 Reactor replacement kit .............................................................................. 41
Figure 3–13 Base beam lifting jack (3BHE039648R0001) ............................................ 42
Figure 3–14 Chain-block .................................................................................................. 43
Figure 3–15 Pump maintenance table kit ..................................................................... 44
Figure 3–16 Generator breaker replacement kit ........................................................... 45
Figure 4–1 Bolt connections, checking the tightening torque markings ................... 52
Figure 4–2 ASM10 ............................................................................................................. 58
Figure 4–3 Insulation measurements PCS6000 Converter 1CL with PCM .................64
Figure 4–4 Insulation measurements PCS6000 Converter 1CL without PCM ...........64
Figure 4–5 Insulation measurements PCS6000 Converter 2CL .................................. 66
Figure 5–1 Key switch....................................................................................................... 71
Figure 5–2 DC-link grounding isolator in position “not grounded” ........................... 71
Figure 6–1 Commissioning tool (optional), error messages window ........................ 75
Figure 6–2 Standard procedure for troubleshooting (overview) ................................ 76
Figure 6–3 Commissioning tool (optional), typical window ....................................... 77
Figure 8–1 AC 800PEC ..................................................................................................... 90
Figure 8–2 UPS -G302 selector switch “Bat.-Select” .................................................. 90
Figure 8–3 Removing a AC 800PEC module .................................................................. 91
Figure 8–4 AC 800PEC Combi IO UA D155 ..................................................................... 92
Figure 8–5 S800 assembly .............................................................................................. 93

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Figure 8–6 S800 I/O module ...........................................................................................94
Figure 8–7 S800 I/O module address ............................................................................94
Figure 8–8 Voltage and current transducer boards UUD 148 AE01/2 ........................ 95
Figure 8–9 Short-circuit of current transducer ............................................................96
Figure 8–10 PECINTM PC D237 ........................................................................................ 97
Figure 8–11 UPS -G402 selector switch “Bat.-Select” ................................................... 97
Figure 8–12 GCT power supply (IPS) ..............................................................................99
Figure 8–13 HVD XV C770 .............................................................................................. 100
Figure 8–14 VLSCD XV C724 .......................................................................................... 101
Figure 8–15 ASE2B UD C920 ......................................................................................... 102
Figure 8–16 AC/DC converter Quint-PS/3AC/24DC/40 ............................................. 103
Figure 8–17 AC/DC converter Quint-PS/1P24/10 ........................................................ 104
Figure 8–18 DC/DC converter Quint-PS-24DC/24DC/10 ........................................... 105
Figure 8–19 Quint-DC-UPS/24DC/40 ........................................................................... 106
Figure 8–20 Quint-DC-UPS/24DC/10 ........................................................................... 107
Figure 8–21 Battery -G303 ............................................................................................. 108
Figure 8–22 Battery -G403............................................................................................. 109
Figure 9–1 ..................................................................................................... IGCT stack 117
Figure 9–2 Freewheeling diode stack .......................................................................... 118
Figure 9–3 Neutral point and clamp diode stack ........................................................ 119
Figure 9–4 Clamp capacitors and symmetry resistors .............................................. 120
Figure 9–5 Semiconductor orientation ....................................................................... 121
Figure 9–6 Correct measuring with FADEC 3 .............................................................. 123
Figure 9–7 FADEC 3 Indication of defective semiconductor ..................................... 123
Figure 9–8 Correct measuring with FADEC 3 .............................................................. 124
Figure 9–9 FADEC 3 Indication of defective semiconductor ..................................... 124
Figure 9–10 Correct measuring with FADEC 3 ............................................................ 125
Figure 9–11 FADEC 3 Indication of defective semiconductor .................................... 125
Figure 9–12 Correct measuring with FADEC 3 ............................................................ 126
Figure 9–13 FADEC 3 Indication of defective semiconductor ................................... 126
Figure 9–14 Correct measuring between gate and cathode ..................................... 128
Figure 9–15 Wrong measuring between gate and cathode ....................................... 128
Figure 9–16 Clamp resistor connections ................................................................... 130
Figure 9–17 IGCT power supply (IPS) ........................................................................... 132
Figure 10–1 ESD precautions ....................................................................................... 134
Figure 10–2 Clamping components ............................................................................ 140

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Figure 10–3 Pressure loading gauges ........................................................................ 141
Figure 10–4 Pressure loading gauges inserted.......................................................... 142
Figure 10–5 Gate unit fixation....................................................................................... 142
Figure 10–6 Order of loosening the clamping screws ............................................... 143
Figure 10–7 Stabilizer plate insertion ........................................................................ 144
Figure 10–8 Manual support during spreading tool insertion .................................. 145
Figure 10–9 Spreading tool insertion ......................................................................... 146
Figure 10–10 Spreading tool expansion ..................................................................... 146
Figure 10–11 Spreading tool applied over three heat sinks ....................................... 147
Figure 10–12 Spreading tool use example ................................................................... 148
Figure 10–13 Disconnecting cables from IGCT .......................................................... 149
Figure 10–14 Removing the gate unit fixations of the IGCT .................................... 149
Figure 10–15 Extracting the IGCT ................................................................................. 150
Figure 10–16 Correct handling of IGCT ........................................................................ 150
Figure 10–17 Inserting the IGCT ...................................................................................151
Figure 10–18 IGCT components .................................................................................. 152
Figure 10–19 Centering freewheeling and neutral point diodes ............................. 153
Figure 10–20 Diode marking ......................................................................................... 154
Figure 10–21 Clamp diodes ........................................................................................ 155
Figure 10–22 Centering upper (A) and lower (B) clamp diodes ............................... 156
Figure 10–23 NP diodes ............................................................................................. 157
Figure 10–24 Centering freewheeling and neutral point diodes ............................. 158
Figure 10–25 Example of positioning and stop device not fully
inserted yet ................................................................................................................... 159
Figure 10–26 Freewheeling diode stack with aligned heat sinks (A) and
misaligned heat sinks (B). .............................................................................................. 161
Figure 10–27 Heat sink with loosened flexible bus bar. ............................................. 162
Figure 10–28 Power module assembly (back view) .................................................. 162
Figure 10–29 Heat sink moved back into position...................................................... 163
Figure 10–30 Order of tightening the clamping screws ............................................ 166
Figure 10–31 Tightening the clamping screw ............................................................ 166
Figure 10–32 Adjusting clamp pressure of stack ...................................................... 167
Figure 10–33 Pressure loading gauges storage place .............................................. 167
Figure 10–34 Gate unit fixation .................................................................................. 168
Figure 10–35 Clamp capacitors .................................................................................... 169
Figure 10–36 Symmetry resistor ................................................................................... 170
Figure 10–37 Clamp resistor........................................................................................... 172

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Figure 10–38 Clamp reactor .......................................................................................... 173
Figure 10–39 LEM current transducers ...................................................................... 175
Figure 10–40 Mounting screws of ASM in front of DC capacitor .............................. 176
Figure 10–41 DC capacitor ............................................................................................ 177
Figure 10–42 Spreader tools ....................................................................................... 178
Figure 10–43 Applying spreader tool ......................................................................... 179
Figure 10–44 Rearranging misaligned stacks ........................................................... 181
Figure 10–45 Earth isolator mounting screws ............................................................ 182
Figure 10–46 Resistor -R462_1, -R462_2 ...................................................................... 183
Figure 10–47 Rear view of VLM ..................................................................................... 184
Figure 10–48 Resistor -R461 .......................................................................................... 185
Figure 10–49 Capacitor -C461 ....................................................................................... 186
Figure 10–50 VLM ........................................................................................................... 187
Figure 10–51 VLM ............................................................................................................ 189
Figure 10–52 Precharging transformer (VLM removed) ........................................... 190
Figure 10–53 dv/dt filter reactor ................................................................................... 191
Figure 10–54 dv/dt filter reactor mounting bolts (different VFM variants) ............ 192
Figure 10–55 dv/dt filter resistors ............................................................................... 193
Figure 10–56 dv/dt filter capacitors ............................................................................ 194
Figure 10–57 Framework for chain-block ................................................................... 203
Figure 10–58 GDM1 mounting screws and aluminum plate ..................................... 207
Figure 10–59 GDM1 with framework for chain block ............................................... 208
Figure 10–60 Framework for chain-block .................................................................. 210
Figure 10–61 dv/dt filter reactor ................................................................................. 213
Figure 10–62 dv/dt filter reactor mounting screws (different VFM
variants) .......................................................................................................................... 214
Figure 10–63 Position of VFM ....................................................................................... 215
Figure 10–64 dv/dt filter resistors ................................................................................ 217
Figure 10–65 Position of mounting screws dv/dt filter resistors ............................. 218
Figure 10–66 dv/dt filter capacitors ............................................................................ 219
Figure 10–67 Conductivity meter ................................................................................ 220
Figure 10–68 Conductivity meter ................................................................................. 221
Figure 10–69 Temperature meter ................................................................................. 222
Figure 10–70 Pressure gauge and transmitter ........................................................... 223
Figure 10–71 Deionizer flow meter ............................................................................... 224
Figure 10–72 Ion exchange vessel (right side: old version) ....................................... 225
Figure 10–73 Ion exchange vessel................................................................................. 226

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Figure 10–74 Water filter................................................................................................ 227
Figure 10–75 Pump support ........................................................................................ 229
Figure 10–76 Pump flange ........................................................................................... 229
Figure 10–77 Connecting pipes turned aside .............................................................. 230
Figure 10–78 Drilling plan .............................................................................................. 230
Figure 10–79 Pump maintenance table with long legs (for upper pump) ............... 231
Figure 10–80 Use of chain-block to lift out pump ...................................................... 231
Figure 10–81 Pump components (Swedewater) .......................................................... 232
Figure 10–82 Opening pump case ................................................................................ 232
Figure 10–83 Pump shaft ............................................................................................... 233
Figure 10–84 Pump sealing ........................................................................................... 233
Figure 10–85 3-way valve ............................................................................................... 234
Figure 10–86 Expansion vessel ..................................................................................... 235
Figure 10–87 Expansion vessel .................................................................................... 236
Figure 10–88 Automatic deaeration valve ................................................................... 237
Figure 10–89 Ball valve ¾” ........................................................................................... 238
Figure 10–90 Gland from the Ball valve ¾” ................................................................ 238
Figure 10–91 Ball valve ½” .............................................................................................. 239
Figure 10–92 FIU with FCM (left) and with FIM (right) ............................................ 241
Figure 10–93 HFM filter reactor .................................................................................. 242
Figure 10–94 HFM filter capacitor ................................................................................ 243
Figure 10–95 FCM removal (circles show bolt locations) ......................................... 244
Figure 10–96 Top and bottom views of capacitor ..................................................... 244
Figure 10–97 Lifting out capacitor ............................................................................... 245
Figure 10–98 HFM filter resistor ................................................................................... 246
Figure 10–99 Filter reactor ............................................................................................ 247
Figure 10–100 Removed filter reactor ..........................................................................248
Figure 10–101 Ground connection ................................................................................ 248
Figure 10–102 Pressure transmitter ............................................................................. 249
Figure 10–103 GBU ........................................................................................................ 250
Figure 10–104 Generator breaker (GEB)....................................................................... 251
Figure 10–105 Grid breaker (GRI) .................................................................................. 251
Figure 10–106 Drawer mounting screws ...................................................................... 252
Figure 10–107 Corner braces ......................................................................................... 252
Figure 10–108 GBM push button locking device ......................................................... 252
Figure 10–109 Lower front beam mounting screws ................................................... 253

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Figure 10–110 Differential pressure measurement device ......................................... 253
Figure 10–111 Fan drawer below the GEB .................................................................... 253
Figure 10–112 Protection cushion ................................................................................. 254
Figure 10–113 Breaker's lower power cable connections ........................................... 254
Figure 10–114 Breaker's upper power cable connection ............................................ 254
Figure 10–115 Breaker's protecting earth connection ................................................ 255
Figure 10–116 Fiber optic cable .................................................................................... 255
Figure 10–117 Breaker's protecting earth connection ................................................ 256
Figure 10–118 Trolley track beams ................................................................................ 256
Figure 10–119 Support by reactor replacement kit ..................................................... 257
Figure 10–120 Trolley track beams (top view) ............................................................. 257
Figure 10–121 Trolley with loose wing nuts ................................................................. 257
Figure 10–122 Fixing the GEB to the lever ................................................................... 258
Figure 10–123 Rising the lever ....................................................................................... 258
Figure 10–124 Unbolting the GEB ................................................................................. 258
Figure 10–125 GEB pulled out of the cabinet .............................................................. 259
Figure 10–126 Releasing the retaining spring (flap closed) ..................................... 260
Figure 10–127 Releasing the retaining spring (flap open) ........................................ 260
Figure 10–128 Flap open and engaged ....................................................................... 260
Figure 10–129 dv/dt filter reactor ................................................................................. 261
Figure 10–130 dv/dt filter reactor mounting bolts ................................................... 262
Figure 10–131 dv/dt filter resistors .............................................................................. 263
Figure 10–132 dv/dt filter capacitors ...........................................................................264
Figure 10–133 Fan of GBU fan drawer .......................................................................... 265
Figure 10–134 Drawer mounting screws ...................................................................... 265
Figure 10–135 Lower front beam mounting screws ................................................... 266
Figure 10–136 Fan drawer below the GEB ................................................................... 266
Figure 10–137 Fan drawer removed. ............................................................................. 266
Figure 10–138 Releasing the retaining spring (flap closed) ...................................... 267
Figure 10–139 Releasing the retaining spring (flap open) ......................................... 267
Figure 10–140 Flap open and engaged ........................................................................ 267
Figure 10–141 Door fan with heater.............................................................................. 268
Figure 10–142 Roof fan .................................................................................................. 269
Figure 10–143 Filter fan replacement ........................................................................... 270

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—
Tables
Table 1–1 Product-specific documentation ..........................................................................................19
Table 1–2 Standards....................................................................................................................................19
Table 3–1 Converter service tool list........................................................................................................31
Table 3–2 Commissioning tool list ..........................................................................................................31
Table 3–3 Replacement tool list ...............................................................................................................31
Table 3–4 Converter service toolbox content (3BHB008753R0002).............................................. 32
Table 4–1 Visual inspection ......................................................................................................................50
Table 4–2 Replacement procedures.......................................................................................................54
Table 7–1 LEDs on AC 800PEC................................................................................................................. 82
Table 7–2 LEDs on Combi IO UA D155 ................................................................................................... 82
Table 7–3 LEDs on PECINTM PC D237 ................................................................................................... 83
Table 7–4 ASE2 board UD C920 .............................................................................................................. 83
Table 7–5 UPS/24DC/40...........................................................................................................................84
Table 8–1 CCU control components replaceable by customer ....................................................... 87
Table 8–2 POU control components replaceable by customer.......................................................88
Table 8–3 FIU control components replaceable by customer.........................................................88
Table 8–4 DLU control components replaceable by customer.......................................................89
Table 8–5 DRU control components replaceable by customer.......................................................89
Table 9–1 State of gate unit (GU) and IGCT (x = irrelevant) ............................................................122
Table 9–2 State of gate unit (GU) and IGCT........................................................................................127
Table 9–3 Input and output voltages of IPS .......................................................................................132
Table 9–4 IPS analysis...............................................................................................................................132
Table 10–1 Serialized power components ...........................................................................................135
Table 10–2 Standard tightening torques for bolted connections................................................ 136
Table 10–3 List of components > 25kg of PCS6000 product family ............................................137

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1. About this manual
1.1. Equipment covered by this manual
This manual covers the standard PCS6000 equipment and provides generic information.
The manual does not claim to cover all variations and details of the equipment, nor to
consider all eventualities that may arise during installation, commissioning, operation and
maintenance of the equipment.
If the equipment is adapted to specific customer needs or applications, and if handling,
installation, and operation of the equipment are affected by these modifications, specific
information is provided in the appropriate documentation (eg, layout drawings, wiring
diagrams, technical data, and engineering notes) in the appendices.
If information is required beyond the instructions in this manual, refer the matter to ABB.
1.2. Overview
This manual covers the standard PCS6000 equipment and provides information for service
work. The manual contains information from product family 1 and 2. If necessary, the
differences are pointed out. It is for trained personnel according to the ABB service and
authorization concept. The manual does not claim to cover all variations and details of the
equipment, nor to consider all eventualities that may arise during service of the equipment.
The described units, modules or components need not always be present in the converter
layout.
Each person involved in the service must have read and fully understood the corresponding
chapters in this PCS6000 service manual.
If information is required beyond the instructions in this manual refer the matter to ABB.

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1.3. Contents of this manual
– Chapter 2, Important safety information, page 23 explains the various safety
instruction levels and provides general instructions on safety, which need to be strictly
observed.
– Chapter 3, Service tools, page 31 introduces the special tools used for service work as
described in this document.
– Chapter 4, Preventive maintenance, page 47 contains an overview about periodically
required preventive maintenance tasks to ensure reliable operation.
– Chapter 5, De-energizing, grounding and start-up, page 69 provides instructions on
how to shut-down the PCS6000 for service purposes and on how to start-up again after
the work is done.
– Chapter 6, Troubleshooting, page 73 provides instructions on how to proceed when
encountering a problem with the PCS6000.
– Chapter 7, Checking control components, page 81 provides instructions on checking
the electronic devices of the PCS6000 and an overview on the meaning of LEDs of the
main circuit boards and I/O devices.
– Chapter 8, Replacing control components, page 85 provides instructions on how to
replace defective control components.
– Chapter 9, Checking diodes, IGCTs and IPS, page 115 provides instructions on how to
check power semiconductors and IPS.
– Chapter 10, Replacing power and cooling components, page 133 provides instructions
on how to repair defective parts.
ABB is constantly striving for the best product and service offerings for our customers.
Therefore ABB appreciates your valuable feedback or suggestions for improvements of
PCS6000 products.

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1.4. Related documents
Table 1–1 Product-specific documentation
Title Document number
Service training and authorization concept 3BHS393721 E01
PCS6000 user manual 3BHS600000 E40
PCS6000 Local control panel description(1)
(1) Only shore to ship application
3BHS606571 E49
FADEC 3 User manual 3BHS537463 E72
PCS6000 Fault handbook 3BHS846120 E90
PCS6000 Preventive maintenance schedule 3BHS600000 E88
PCS6000 Service software manual 3BHS600000 E81
PCS6000 Preconditions for commissioning 3BHS600000 E83
PCS6000 Preventive maintenance report 3BHS600000 E84(2)
(2) This document is only a template. The report for your drive will have a different number.
PCS6000 Commissioning test instruction 3BHS600000 E85
PCS6000 Commissioning test report 3BHS600000 E86
PCS6000 Quality checklist for commissioning 3BHS600000 E87
PCS6000 Pilot commissioning report PF: review 3BHS600000 E89
PCS6000 Lockout/tagout procedure(2) 3BHS600000 E22
PCS6000 product family WCU30 - WCU82 water cooling unit operating
and maintenance manual
3BHS317637 E40
PCS6000: WCU81A IEC water cooling unit, operations and maintenance
manual
3BHE054718 E40
Assemblies & components PCS6000 product family with serialization
profile
3BHE600000 E70
Permission for working and permit to work for test work at test stations 3BHS817511 E30
Table 1–2 Standards
Standard Title
ANSI Z535.6 American national standard for product safety information in product manuals,
instructions, and other collateral materials
ISO 7010 2011 (E) - Graphical symbols - Safety colours and safety signs - Registered safety
signs
ISO 3864-2 2004 (E) - Graphical symbols – Safety colours and safety signs – Part 2: Design
principles for product safety labels
EN 50110 European standard code for electrical work safety

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1.5. Target groups and required qualification
The drive presented in this manual is part of an industrial environment where voltages are
present that contain a potential hazard of electric shock and / or burn. For this reason, only
personnel who have a thorough knowledge of the drive and the industrial environment and
have obtained the required qualification should handle, install, operate, or maintain
the drive.
The manual addresses personnel who are responsible for unpacking, transportation,
installation, operation and maintenance of the drive. The personnel must carry out the
below listed tasks in a manner that does not cause physical harm or danger, and ensures
the safe and reliable functioning of the drive.
IMPORTANT! Commissioning of the drive must only be performed by qualified and
certified ABB personnel.
1.5.1. Handling
Personnel must be skilled and experienced in unpacking and transporting heavy equipment.
1.5.2. Mechanical installation
The personnel must be qualified to prepare the installation site according to the site and
equipment requirements and to perform the installation accordingly.
1.5.3. Electrical installation
Personnel must have a sound knowledge of the relevant electrical codes and specifications
covering low and medium voltage equipment, be experienced with electrical wiring
principles and know the electrical symbols typically used in wiring diagrams.
1.5.4. Operation
The personnel include all persons who operate the drive from the local operator panel of the
drive. The personnel must know the functions of the operator panel, be adequately trained
for the drive, and know the driven process. Special knowledge of frequency converter
technology is not required.
1.5.5. Maintenance
The personnel include all persons who:
– Are qualified to carry out preventive and corrective maintenance on drive as described
in this manual
– Are thoroughly familiar with the drive
– Have a sound knowledge of the relevant electrical codes and specifications covering low
and medium voltage equipment
– Are able to assess the hazards associated with the energy sources of the drive and act
correspondingly
– Know the safe shutdown and grounding procedures for the drive system