ABB ACS 6000 Installation and user guide

ACS 6000

Medium Voltage Drives

3 to 27 MVA

Service and Maintenance Manual

Document No.: 3BHS202077 ZAB E01 Rev. C

Issued: 21-01-2005

ABB

2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

ABB reserves all rights to this document, also in the event of patent issue

or registration of any other industrial property protection right. Misuse, in

particular duplication and forwarding to third parties, is not permitted.

This document has been checked with due care and attention. However,

should the user find any errors, these should be reported to ABB.

ABB aims to maintain the most modern standard, therefore, entries in this

manual may differ from the actual product.

ABB

ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1 (4)

Table of Contents

Chapter 1 - Introduction and Safety 1-1

1.1 Introduction 1-1

1.2 Safety 1-1

Chapter 2 - Checking IGCTs and Diodes 2-1

2.1 Safety 2-1

2.2 Checking IGCTs 2-1

2.2.1 Required Tools and Accessories 2-1

2.2.2 Test Procedure 2-1

Step 1 2-1

Step 2 2-2

2.3 Checking Diodes in 7/ 9 MVA Phase Modules 2-4

Chapter 3 - Changing Diodes and Thyristors in LSU 3-1

3.1 Required Tools and Accessories 3-1

3.2 Safety 3-2

3.3 Replacing Diodes and Thyristors 3-3

Chapter 4 - Changing 3/5 MVA Phase Modules 4-1

4.1 Required Tools and Accessories 4-1

4.2 Removing a Phase Module 4-2

Using the Hoist 4-6

Using a Crane 4-7

4.3 Installing a Phase Module 4-8

Chapter 5 - Changing RC-IGCTs

in 3/5 MVA Phase Modules 5-1

Chapter 6 - Changing Clamp Diodes

in 3/5 MVA Phase Modules 6-1

6.1 Required Tools and Accessories 6-1

6.2 Changing Procedure 6-1

ABB

2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

Chapter 7 - Changing 7/9 MVA Phase Modules 7-1

7.1 Required Tools and Accessories 7-1

7.2 Removing a Phase Module 7-2

7.3 Installing a Phase Module 7-5

Chapter 8 - Changing Diodes and IGCTs

in 7/9 MVA Phase Modules 8-1

8.1 Required Tools and Accessories 8-1

8.2 Overview 8-2

8.3 Safety 8-4

8.4 Replacing Clamp and NP Diodes 8-5

8.4.1 Preparatory Steps 8-5

8.4.2 Replacing Clamp Diodes 8-8

Upper Clamp Diode 8-8

Lower Clamp Diode 8-9

8.4.3 Replacing NP Diodes 8-11

Removing Upper NP Diode 8-11

Removing Lower NP Diode 8-12

Assembling the Stack 8-12

8.4.4 Finishing Steps 8-13

8.5 Replacing Free Wheeling Diodes 8-14

8.6 Replacing IGCTs 8-16

Chapter 9 - Changing Thyristors in EXU 9-1

9.1 Required Tools and Accessories 9-1

9.2 Safety 9-1

9.3 Replacing Thyristors in EXUs for Brushless Excitation 9-2

9.3.1 Preparatory Steps 9-2

9.3.2 Treating a New Thyristor before Installation 9-3

9.3.3 Mounting a New Thyristor 9-3

9.4 Replacing Thyristors in EXUs for Direct Excitation 9-5

9.4.1 Preparatory Steps 9-5

9.4.2 Treating a New Thyristor before Installation 9-6

9.4.3 Mounting a New Thyristor 9-6

9.5 Deflection Diagram 9-7

Chapter 10 - Changing Semiconductors in VLU 10-1

10.1 Required Tools and Accessories 10-1

10.2 Safety 10-1

10.3 Replacing the Semiconductors 10-2

ABB

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

10.3.1 Preperatory Steps 10-2

10.3.2 Replacing Upper Diode 10-2

10.3.3 Replacing IGCTs 10-3

10.3.4 Replacing Lower Diode 10-5

10.3.5 Finishing Steps 10-5

Chapter 11 - Changing IGCTs in DIU 11-1

11.1 Required Tools and Accessories 11-1

11.2 Safety 11-1

11.3 Removing an IGCT 11-2

11.4 Installing an IGCT 11-5

Chapter 12 - Replacing Printed Circuit Boards 12-1

12.1 Safety 12-1

12.2 Replacing an AMC3 Board 12-2

12.3 Changing the AMC3 Flash Memory 12-4

12.4 Replacing an INT Board 12-7

Transferring the EPLD Chips 12-10

Transferring the Pulse Pattern Flash 12-10

12.5 Replacing a CVMI Board 12-12

Chapter 13 - Function of LEDs 13-1

13.1 AMC Board 13-1

13.2 INT Board 13-3

13.3 GUSP 13-5

13.4 IGCT 13-6

Chapter 14 - Tightening Torques and

Threaded Connections 14-1

14.1 Water Cooling Unit 14-1

14.1.1 Tightening Torque for Pipe Coupling

(WCU Type 29 and 52) 14-1

14.1.2 Tightening Torque for Pumps

(WCU Type 29 and 52) 14-1

14.1.3 Tightening Torque for Flanges

(WCU Types 29, 52, 80, 106, 120) 14-3

14.2 Pipe Joints and Busbar Connections 14-3

ABB

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

ABB

ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1-1 (2)

Chapter 1 - Introduction and Safety

The manual mustbe thoroughly read andunderstoodbefore maintenance

work on the ACS 6000 is started.

The manual is addressed to qualified persons who are responsible for

maintaining and servicing the ACS 6000. Hence all general and safety

instructions given in the ACS 6000 User's Manual must be complied with.

Danger: The ACS 6000 is a high voltage device.

High voltage can cause physical injury and death.

Maintenance, parts replacement and other work on the ACS 6000 must

only be carried out by qualified personnel in compliance with local regula-

tions.

Danger: Do not access the ACS 6000 or work on the motor or the power

cables, if the drive system is energized and not properly grounded!

After switching off the mains and after the motor has come to a stop, wait

approximately 5 minutes for the DC link capacitors to discharge. The light

GND.- SWITCH UNLOCKED

must be on before grounding the ACS 6000.

Danger: Make sure that the main power cannot be applied by accident.

Rack out the main circuit breaker and lock it.

Danger: Some loads can cause the motor to rotate!

Therefore, always disconnect, short-circuit or block the motor before work

is started.

1.1 Introduction

1.2 Safety

Chapter 1 - Introduction and Safety ABB

1-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

Danger: Before power is applied to the drive, check that:

• Mains and motor connections are ok

• Auxiliary power and control cable connections are ok

• No tools or other foreign objects are left in the cabinet

• All doors including the door of the power cable section are closed

ABB

ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-1 (6)

Chapter 2 - Checking IGCTs and Diodes

IGCTsanddiodes ofphasemodulescan onlybetestedaftertheconverter

has been deenergized and grounded.

Danger: The ACS 6000 is a high violtage device.

Make sure that the drivehas been completely deenergized andthat power

cannot be applied by accident.

Failure to do so may result in injury or death.

2.2.1 Required Tools and Accessories

To test IGCTs the following is needed:

• Fiber optic cable (approx. 2 m long)

• Multimeter

2.2.2 Test Procedure

The IGCT to be tested can stay in the phase module. The test is carried

out in two steps:

Step 1

1Deenergize and ground the ACS 6000 but leave the power supply for

the gate units on.

2Check the IGCT for burned components. In this casethe whole IGCT

must be replaced. Check that both LEDs are on. See

Figure 2-1

(

Figure 2-1

depicts the horizontal fitting position of IGCTs as applied

in 7/9 MVA phase modules).

Figure 2-1 IGCT

2.1 Safety

2.2 Checking IGCTs

LEDs Fiber optic cable

Chapter 2 - Checking IGCTs and Diodes ABB

2-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual

Note: When checking be careful not to disconnect the fiber optic cable

while the IGCT is energized to prevent an undefined control state.

3Test the IGCT by measuring the voltage between gate and cathode.

Note: Whenmeasuring be carefulnot toshorten gate and cathode/anode

of the IGCT. A short circuit will destroy the semiconductor.

Figure 2-2 Testing IGCTs

To avoid shortening gate and cathode:

• Use short tipped probes

• Hold one probe against the cooler on the cathode

side and the otherprobe against ascrew head on the

gate side (see

Figure 2-2

Result of the measurement: approx. -20 VDC (see

Figure 2-2

4Disconnect the power supply of the gate unit (one of the following

circuit breakers in COU: -Q1041, -Q1042, -Q1043, see wiring dia-

gram).

5Wait approx. 20 sec. for the capacitors of the gate unit to discharge.

Step 2

1Verify that the power supply of the gate unit is off.

2Switch off the auxiliary power supply pertaining to the INT board in

the cabinet.

3Connect a temporary fiber optic cable at one end to the gate unit and

at the other end to a permanent light transmitter of the INT board.

• Inside ARU: connector A714 (see

Figure 2-3

)

• Inside INU: connector A712 or A713 (see

Figure 2-3

)

Cathode

Gate

Measuring results:

Step 1: -20 VDC

Step 2: +0.7 VDC

Side view

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