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ABB ACS 6000 Service And Maintenance Manual

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

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Summary of Contents for ABB ACS 6000

  • Page 1 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 Switzerland Ltd. All Rights Reserved. ...
  • Page 2 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.

  • Page 3: Table Of Contents

    Installing a Phase Module Chapter 5 - Changing RC-IGCTs in 3/5 MVA Phase Modules Chapter 6 - Changing Clamp Diodes in 3/5 MVA Phase Modules Required Tools and Accessories Changing Procedure ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1 (4)
  • Page 4 9.4.3 Mounting a New Thyristor Deflection Diagram 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 2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 5 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 ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3 (4)
  • Page 6 4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 7: Chapter 1 - Introduction And Safety

    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.
  • Page 8 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 1-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 9: Safety

    The IGCT to be tested can stay in the phase module. The test is carried out in two steps: Step 1 Deenergize and ground the ACS 6000 but leave the power supply for the gate units on. Check the IGCT for burned components. In this case the whole IGCT must be replaced.

  • Page 10: Step 2

    INT board. • Inside ARU: connector A714 (see Figure 2-3 ) • Inside INU: connector A712 or A713 (see Figure 2-3 ) 2-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 11 Chapter 2 - Checking IGCTs and Diodes A714 A712 A713 Figure 2-3 INT Board ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-3 (6)

  • Page 12: Checking Diodes In 7/ 9 Mva Phase Modules

    The diodes can be accessed from the front of the phase module. Deenergize and ground the ACS 6000. Switch off the auxiliary power supply. Remove the two fastening bolts at the bottom on each side of the phase module.
  • Page 13 VR2, VR3, VN1, VN2 ~ 0.2..0.3 V ~ 2.2..2.3 V If uncertain, verify the result by checking another diode of the same phase module or of another phase module. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-5 (6)
  • Page 14 Chapter 2 - Checking IGCTs and Diodes 2-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 15: Chapter 3 - Changing Diodes And Thyristors In Lsu

    Chapter 3 - Changing Diodes and Thyristors in LSU Required Tools and Accessories The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • Spreader tool Figure 3-1 Spreader Tool • ½ " reversible ratchet •...

  • Page 16: Safety

    Stop the cooling water pumps and make sure that they cannot be switched on by accident. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.

  • Page 17: Replacing Diodes And Thyristors

    It is therefore highly recommended that the instructions below are followed. A Pressure adjusting bolts B Pressure loading spanner C Spreader tool Figure 3-2 LSU Rectifier ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-3 (6)
  • Page 18 Alternately close the gap between the new semiconductor and the cooler and increase the pressure in the stack until the pressure adjustment spanner can be removed. Reconnect any disconnected wires. 3-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 19 Since the space is very narrow it is recommended to use a piece of wire shaped into a half moon to move the semiconductors. Wooden bar Horizontal bar Adjustment bolts Vertical bar Horizontal bar Figure 3-3 Fixture ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-5 (6)
  • Page 20 Chapter 3 - Changing Diodes and Thyristors in LSU 3-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 21: Chapter 4 - Changing 3/5 Mva Phase Modules

    Required Tools and Accessories The tools listed below are part of the tool set (ident. No. 3BHS130246) delivered with the ACS 6000. • Lifting device (customer crane or ACS 6000 hoist), two rails Fastening bolts Figure 4-1 ACS 6000 Hoist and Rails •...

  • Page 22: Removing A Phase Module

    Stop the cooling water pumps and make sure that they cannot be switched on by accident. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.
  • Page 23 Disconnect the fiber optic cables (4) and the power supply leads (4) from the module to be changed (see arrows Figure 4-4 ). Figure 4-4 Disconnecting Fiber Optics and Power Supply Cables ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-3 (10)
  • Page 24 Figure 4-5 Mounting the Rails Secure the rails by inserting the safety pins at the front, one on each side of the phase module. Safety pin Figure 4-6 Safety Pin 4-4 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 25 Fastening Bolts 10 Extract the phase module from the cabinet. 11 Lift the phase module from the rails. 1 Continue with step 12 when using the ACS 6000 hoist. 2 Continue with step 16 when using a crane. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev.

  • Page 26: Using The Hoist

    Figure 4-8 ). Figure 4-8 Attaching the Hoist 13 Attach the lifting bar to the phase module using two M12 bolts. Fastening bolts Figure 4-9 Lifting Attachments 4-6 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 27: Using A Crane

    16 Screw the two eyebolts into the tapped holes of the lifting bar, attach Using a Crane the phase module to the crane and lift it from the rails. Fastening bolts Figure 4-11 Phase Module Attached to Crane ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-7 (10)

  • Page 28: Installing A Phase Module

    RHODORSIL or SILICONPASTE 4. See arrows in Figure 4-13 . Figure 4-13 Greasing Busbar Stubs Lift the phase module onto the rails by means of the ACS 6000 hoist 4-8 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 29 12 Power up the drive and confirm its proper functioning. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-9 (10)
  • Page 30 Chapter 4 - Changing 3/5 MVA Phase Modules 4-10 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 31: Chapter 5 - Changing Rc-Igcts In 3/5 Mva Phase Modules

    Pull out the faulty RC-IGCT. In case the new IGCT is not fitted with retaining clamps and guides (see Figure 5-3 ) remove these parts from the faulty IGCT and mount ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 5-1 (2)
  • Page 32 10 Remount the retaining rods and fasten the RC-IGCTs. 11 Push the phase module back into the cabinet following the instructions in section 4.3 Installing a Phase Module . 5-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 33: Chapter 6 - Changing Clamp Diodes In 3/5 Mva Phase Modules

    (see Figure 6-2 ) to prevent damaging the brackets. Figure 6-1 Phase Module with Fastening Bolts Removed ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 6-1 (4)
  • Page 34 (see Figure 6-3 ). Clamp pressure loading gauge Clamp ring Figure 6-3 Releasing the Clamp Pressure Remove the isolator disc at the top of the stack. Figure 6-4 Removing Isolator Disk 6-2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 35 13 Reconnect the mounting brackets with the fastening bolts. 14 Lift the module onto the rails and install the phase module following section 4.3 Installing a Phase Module . ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 6-3 (4)
  • Page 36 Chapter 6 - Changing Clamp Diodes in 3/5 MVA Phase Modules 6-4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 37: Chapter 7 - Changing 7/9 Mva Phase Modules

    Chapter 7 - Changing 7/9 MVA Phase Modules Required Tools and Accessories The tools and accessories listed below are part of the tool set (Ident. no. 3BHS130246) delivered with the ACS 6000. • ACS 6000 lifting table Figure 7-1 ACS 6000 Lifting Table •...

  • Page 38: Removing A Phase Module

    Stop the cooling water pumps and make sure that they cannot be switched on by accident. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.
  • Page 39 (see arrow in Figure 7-4 ). Figure 7-4 Diconnecting a Water Hose Wipe off any spilled water immediately. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 7-3 (6)
  • Page 40 Remove the two fastening bolts at the bottom of each side of the phase module. See arrows in Figure 7-6 . Right side Left side Figure 7-6 Removing the Fastening Bolts 7-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 41: Installing A Phase Module

    Screw in the fastening bolts (two bolts on each side) and tighten them. Cover the equipment below a coupling by a plastic sheet (see Figure 7-3 ) or hold a towel or cloth underneath the coupling before connecting the water hoses. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 7-5 (6)
  • Page 42 Fasten the cables with cable ties (see circles in Figure 7-5 ). 10 Power up the drive and confirm its proper functioning. 11 If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).

  • Page 43: Chapter 8 - Changing Diodes And Igcts In 7/9 Mva Phase Modules

    Chapter 8 - Changing Diodes and IGCTs in 7/9 MVA Phase Modules Required Tools and Accessories The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • Spreader tool Figure 8-1 Spreader Tool •...

  • Page 44: Overview

    Refer to Figure 8-3 to locate the semiconductors. Storage place of pressure loading gauge Pressure adjusting bolts for: Free wheeling diodes Clamp and NP diodes IGCTs Figure 8-2 Phase Module 8-2 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 45 Chapter 8 - Changing Diodes and IGCTs in 7/9 MVA Phase Modules Clamp diode NP diode NP diode Clamp diode IGCTs Free wheeling diodes Figure 8-3 Phase Module ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-3 (18)

  • Page 46: Safety

    Before starting any work on the phase module do the following: Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.

  • Page 47: Replacing Clamp And Np Diodes

    (see circles in Figure 8-5 ) and the connection in the middle loosened (see arrow in Figure 8-5 ). Figure 8-5 Removing Clamp Capacitors ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-5 (18)
  • Page 48 Figure 8-7 Loosening the Middle Connection Remove the capacitors. 8-6 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 49 Figure 8-9 Removing Fastening Bolts of Perforated Busbar Continue with section 8.4.2 if clamp diodes have to be replaced. Continue with section 8.4.3 if NP diodes have to be replaced. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-7 (18)

  • Page 50: Replacing Clamp Diodes

    Continue with section Lower Clamp Diode if the lower diode has to replaced. Continue with section 8.4.4 Finishing Steps to remount the capacitors, adjusting the clamp pressure and installing the phase module. 8-8 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 51: Lower Clamp Diode

    Figure 8-11 Perforated Busbar Turned Aside Insert the spreader tool into the openings of the cooler. Figure 8-12 Spreader Tool Inserted ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-9 (18)
  • Page 52 Always verify the polarity with the corresponding wiring diagram. When inserting the components be careful to keep them centered. Figure 8-14 Inserting the Diode 11 Continue with section 8.4.4 Finishing Steps . 8-10 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 53: Replacing Np Diodes

    Lift the cooler above the diode with one hand and extract the diode from the stack with the other. Upper NP Diode removed Figure 8-16 Upper NP Diodes Removed ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-11 (18)

  • Page 54: Assembling The Stack

    Pay attention to the correct polarity particularly when exchanging diodes from different suppliers. Always verify the polarity with the corresponding wiring diagram. Turn the u-shaped busbar back into place and connect it to the top perforated busbar. 8-12 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 55: Finishing Steps

    Check the blocking/unblocking behaviour of the new diode. Refer to Chapter 2 - Checking IGCTs and Diodes . Remount the phase module in the cabinet following section 7.3 Installing a Phase Module . ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-13 (18)

  • Page 56: Replacing Free Wheeling Diodes

    12 mm ½" hex socket from the tool box. Pressure adjusting bolt Figure 8-18 Pressure Adjusting Bolt Remove the top isolator disc from the stack. Top isolator disk removed Figure 8-19 Removing Top Isolator Disk 8-14 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 57 10 Refit the clamp pressure loading gauge in its storage place. 11 Check the blocking/unblocking behaviour of the new diode. Refer to Chapter 2 - Checking IGCTs and Diodes . ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-15 (18)

  • Page 58: Replacing Igcts

    12 Remount the phase module in the cabinet following section 7.3 Installing a Phase Module . 13 If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).
  • Page 59 In case the new IGCT is not fitted with retaining clamps and guides (see Figure 8-23 ) remove these parts from the faulty IGCT and mount them on the new IGCT. Retaining clamps Guides Figure 8-23 IGCT ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-17 (18)
  • Page 60 14 Fasten the gauge in its storage place. 15 Power up the drive and confirm its proper functioning. 16 If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).

  • Page 61: Chapter 9 - Changing Thyristors In Exu

    Before starting any work on the EXU do the following: Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.

  • Page 62: Replacing Thyristors In Exus For Brushless Excitation

    Loosen the clamp bolts alternately until they can be turned by hand and loosen the thyristor (see Figure 9-2 ). At first, do not open the bolts completely to prevent the clamp from dropping. Clamp Figure 9-2 Loosening the Bolts 9-2 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 63: Treating A New Thyristor Before Installation

    Using a sliding caliper, verify that the distance between the clamp and the outer cooling element is equal on both sides (see Figure 9-4 ). Top view! a = b Figure 9-4 Checking the Distances ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-3 (8)
  • Page 64 Connect the gate wires to the pulse transformer. Fasten the gate wires with a cable tie. If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).

  • Page 65: Replacing Thyristors In Exus For Direct Excitation

    Loosen the clamp bolts alternately until they can be turned by hand and loosen the thyristor (see Figure 9-7 ). To prevent the clamp from dropping, do not open the bolts completely. Clamp Figure 9-7 Loosening the Bolts ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-5 (8)

  • Page 66: Treating A New Thyristor Before Installation

    Figure 9-9 for the correct value). Connect the gate wire to the pulse transformer. Fasten the gate wires with a cable tie. If a defective part has to be returned to ABB, particularly if it is still 9-6 (8) 3BHS202077 ZAB E01 Rev. C...

  • Page 67: Deflection Diagram

    Clamp type SLZF 117 Force 22 kN Deflection 0.121 mm Meas. device code 57269324 0.07 0.08 0.09 0.11 0.12 0.13 Deflection of clamp (SLZD or SLZF) in mm Figure 9-9 Deflection Diagram ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-7 (8)
  • Page 68 Chapter 9 - Changing Thyristors in EXU 9-8 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 69: Chapter 10 - Changing Semiconductors In Vlu

    Before starting any work on the VLU do the following: Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.

  • Page 70: Replacing The Semiconductors

    In order to replace the upper diode only the clamp pressure of the stack must be released. The retaining rods of the IGCTs (see Figure 10-4 ) can stay in place. Isolator disk Upper diode Figure 10-2 Upper Diode 10-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 71: 10.3.3 Replacing Igcts

    Disconnect fiber optic cable and the power supply lead of the IGCT to be replaced (see arrows in Figure 10-3 ). Figure 10-3 Loosen the hexagon fastening bolts of the IGCTs (see arrows in Figure 10-4 ). Retaining rods Figure 10-4 ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 10-3 (6)
  • Page 72 (see Figure 10-6 ) remove these parts from the faulty IGCT and mount them on the new IGCT. Retaining clamps Guides Figure 10-6 IGCT Continue with section 10.3.5 Finishing Steps , step 1 . 10-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 73: 10.3.4 Replacing Lower Diode

    When starting to tighten the pressure adjusting bolt make sure that it inserts properly into the center hole of the upper clamping disk. Pressure adjusting bolt Clamping disk Figure 10-7 Upper Part of VLU Stack ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 10-5 (6)
  • Page 74 Refit the clamp loading gauge in its storage place. If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).

  • Page 75: Chapter 11 - Changing Igcts In Diu

    Before starting any work on the DIU do the following: Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident.

  • Page 76: Removing An Igct

    Disconnect the fiber optic cable (see Figure 11-1 ) and the power supply lead (not shown in Figure 11-1 ) of the IGCT to be replaced. Clamp bar Isolators IGCTs Fiber optic cable Figure 11-1 Front View of DIU 11-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 77 The fixing bolts (see arrows in Figure 11-3 ) of the clamp bar require a 24 mm socket. Clamp head seen from the side. This view is not possible in a line-up. Figure 11-3 Fastening Bolts ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 11-3 (6)
  • Page 78 Remove the fastening bolts of the IGCT. The bolts require a 10 mm socket. Fastening bolts Figure 11-4 Fastening Bolts Remove the faulty IGCT. Pins Mounting bracket Figure 11-5 IGCT Removed 11-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 79: Installing An Igct

    Figure 11-6 Adjusting the Clamping Pressure If a defective part has to be returned to ABB, particularly if it is still under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired).
  • Page 80 Chapter 11 - Changing IGCTs in DIU 11-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 81: Chapter 12 - Replacing Printed Circuit Boards

    12.1 Safety Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely deenergized and that power cannot be applied by accident. Failure to do so may result in injury or death.

  • Page 82: Replacing An Amc3 Board

    Chapter 12 - Replacing Printed Circuit Boards 12.2 Replacing an AMC3 Board Figure 12-1 AMC Board 12-2 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 83 Before touching the AMC3 board ground yourself at the converter frame with a wrist strap. Remove the power and ground the ACS 6000 according to section Chapter 1 - Introduction and Safety Unplug the fiber optic cables, the power supply connector and the control panel connector.

  • Page 84: Changing The Amc3 Flash Memory

    10 Put the defective board in an antistatic bag. 11 Power up the drive and confirm its proper functioning. 12 If the defective board has to be returned to ABB, particularly if the component is still under warranty, follow the procedures as stated in the Warranty Directives (this is recommended even if the warranty has expired).
  • Page 85 PCB will be damaged immediately when the auxiliary power is switched on. Figure 12-5 Attaching the Flash Memory PCB Press the PCB firmly down making sure that all pins are inserted properly. ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-5 (14)
  • Page 86 Put the defective board into an antistatic bag. Power up the drive and confirm its proper functioning. If the defective board has to be returned to ABB, particularly if the component is still under warranty, follow the procedures as stated in the Warranty Directives (this is recommended even if the warranty period has expired).

  • Page 87: Replacing An Int Board

    Chapter 12 - Replacing Printed Circuit Boards 12.4 Replacing an INT Board b EPLDs c Pulse Pattern Flash Figure 12-7 INT Board ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-7 (14)
  • Page 88 Chapter 12 - Replacing Printed Circuit Boards Depending on the configuration of the ACS 6000, INT boards are located in the following cabinets: • The INT board is mounted on the back side of the hinged cover in the top section of the ARU cabinet. To access the board the cover needs to be opened.
  • Page 89 Figure 12-9 shows the INT board installed on the back side of the right front door. Depending on the layout of the cabinet and the configuration of the ACS 6000 the board can be mounted in a different position. Figure 12-9 Location of INT Board in COU Before touching the INT Board ground yourself at the converter frame with a wrist strap.

  • Page 90: Transferring The Epld Chips

    Note: Correct orientation of the Pulse Pattern Flash is important to ensure proper functioning of the drive. In case the EPLDs have been updated with new software, the labels on the chips have to be changed accordingly. 12-10 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 91 Drive Windows. 14 Confirm the proper functioning of the drive. 15 If the defective board has to be returned to ABB, particularly if the component is still under warranty, follow the procedures as stated in the Warranty Directives (this is recommended even if the warranty period has expired).

  • Page 92: Replacing A Cvmi Board

    Chapter 12 - Replacing Printed Circuit Boards 12.5 Replacing a CVMI Board Figure 12-11 CVMI Board 12-12 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...
  • Page 93 Figure 12-12 Location of CVMI Board in 3/5 MVA Concerters Before touching the CVMI board ground yourself at the converter frame with a wrist strap. Remove the power and ground the ACS 6000 according to section 12.1 Safety . Unplug the fiber optic cables and all other connectors.
  • Page 94 10 Put the defective board into an antistatic bag. 11 Power up the drive and confirm its proper functioning. 12 If the defective board has to be returned to ABB, particularly if the component is still under warranty, follow the procedures as stated in the Warranty Directives (this is recommended even if the warranty period has expired).

  • Page 95: Chapter 13 - Function Of Leds

    Chapter 13 - Function of LEDs 13.1 AMC Board Figure 13-1 AMC3 Board ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-1 (6)
  • Page 96 ON = receiving data on DDCS channel 0 yellow ON = receiving data on DDCS channel 3 yellow Always OFF yellow Always OFF yellow Always OFF yellow Always OFF 13-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 97: Int Board

    Chapter 13 - Function of LEDs 13.2 INT Board V568 V567 V566 V565 V564 V563 V562 V561 Figure 13-2 INT Board ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-3 (6)
  • Page 98 Y566 yellow ON = INT 2 PFF link OK Y567 yellow ON = ARU or INT 5 PFF link OK Y568 yellow ON = INT 1 PFF link OK 13-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 99: Gusp

    Table 13-5 is applicable for GUSP units with the following ID numbers: • 3BHB005243R0105 (GUSP type KU C755AE105) • 3BHB005243R0106 (GUSP type KU C755AE106) • 3BHB005243R0107 (GUSP type KU C755AE107) ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-5 (6)

  • Page 100: Igct

    - Output voltage < 17 V decreases - Regulating board repeatedly attempts to connect below 10 V) Yellow LED or its actuation is defective No supply voltage Regulating board defective 13-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 101: Chapter 14 - Tightening Torques And Threaded Connections

    30 - 35 Nm Hex. nut 920.1 30 - 35 Nm Hex. nut 920.4 M12x15 45 - 55 Nm 1) see Figure 14-2 to locate the parts 2) for lubricated threads ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 14-1 (4)
  • Page 102 Hex. nut 412.1 O-ring 930.1 Spring washer Mechanical seal 940.2 502.1/.2 Casing wear ring Casing drain Taper lock ring 1) not fitted on Etachrom 25-160/..., 32-160/... 2) not fitted 14-2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

  • Page 103: Tightening Torque For Flanges

    Figure 14-3 Flange Connection 14.2 Pipe Joints and Busbar Connections Table 14-5 Tightening Torque Tightening Item Torque Pipe joints 7.5 Nm Bolted busbar connections 30 Nm - DC busbars - AC busbars ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 14-3 (4)
  • Page 104 Chapter 14 - Tightening Torques and Threaded Connections 14-4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual...

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