ABB DCS800 Service Manual
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ABB DCS800 Service Manual

20 to 5200 a
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DCS800
Service manual
DCS800 Drives (20 to 5200 A)
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com

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Summary of Contents for ABB DCS800

  • Page 1 DCS800 Service manual DCS800 Drives (20 to 5200 A) Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 2 3AFE63988235 DDCS Branching Units - User’s Manual 3BFE64285513 DCS800 Applications PLC Programming with CoDeSys CoDeSys_V23 61131 DCS800 target +tool description - Application Program 3ADW000199 DCS800 Crane Drive DCS800 Crane Drive Manual suppl. 3AST004143 DCS800 Crane Drive Product note PDC5 EN REVA...
  • Page 3 20 to 5200 A Service Manual Code: 3ADW000195R0501 Rev E DCS800 Service Manual e e.doc EFFECTIVE: 03.2011 SUPERSEDES: Rev D 09.2009 2011 ABB Automation Products GmbH. All rights reserved. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0101 DCS800 Service Manual e a...

  • Page 5: Safety Instructions

    To which products this chapter applies The information is valid for the whole range of the product DCS800, the converter modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the Rebuild Kit DCS800-R00-9xxx.

  • Page 6: Installation And Maintenance Work

    220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO). • DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply. Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 7: Grounding

    AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required. Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0101 DCS800 Service Manual e a...
  • Page 8 The minimum allowed bend radius is 35 mm (1.38 in.). Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 9: Mechanical Installation

    WARNING! • DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back.

  • Page 10: Operation

    (e.g. protection against contact by children or similar) - these additional safety measures for the installation must be provided by the customer during assembly. Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 11 To stop the drive using the control panel, press the LOC/REM key and then the stop key Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0101 DCS800 Service Manual e a...
  • Page 12 Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 13: Table Of Contents

    (20...1000 A) ..........................29 Required Tools ......................29 Find faulty thyristor modules ..................29 Remove faulty thyristor modules ...................30 Install new thyristor modules ..................34 Table of contents Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 14 Remove faulty OnBoard bridge (V1) ................36 Install new OnBoard bridge (V1) .................. 36 OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units..37 OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units..38 OnBoard bridge and thyristor module terminals ............39 Exchange of Thyristors for Size D5 Installation of "Disc Type"...
  • Page 15 3 years preventive maintenance .....................140 6 years preventive maintenance .....................141 9 years preventive maintenance .....................143 Appendix A - Spare Parts List Table of contents Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 16: Introduction

    DCS800 Drive Manuals. Here is a list of the most important ones:  The DCS800 Hardware Manual (3ADW000194) describes all hardware Introduction Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 17: Storage And Transport

    DCS800, their connections and settings (e.g. jumpers)  The DCS800 Firmware Description (3ADW000193) gives an overview of the DCS800 firmware, describes all parameters, describes the function of the DCS Control Panel, gives support in case of faults and alarms and gives information about communication.

  • Page 18: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. DCS800-S01- 2005). The optional selections are given thereafter, on the name plate by plus code. The main selections are described below. Not all selections are available for all types.

  • Page 19: Current And Voltage Ratings

    The technical data and specifications are valid as of going to press. ABB reserves the right to make subsequent alterations. If you have any questions concerning your drive system, please contact your local ABB agent. Current and voltage ratings Unit size...
  • Page 20 Introduction Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 21: Fault Tracing Thyristors

    Make sure that all equipment in use is suitable for the voltage level applied to the power part! Fault Tracing Thyristors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 22: Additionally For Service And Preventive Maintenance

    In case of parallel fuses: If one of the parallel fuses is blown, all parallel fuses have to be changed. The ‘undamaged’ fuses might be ‘half-blown’ and will blow with the next high current. Fault Tracing Thyristors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 23: Dc-Current Pulses Measured By An Oscilloscope

    DC-current pulses measured by an oscilloscope Connect an oscilloscope to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3) and check for the proper amount of current pulses: Six current pulses in positive direction There should be six current pulses in positive direction. In case of a 4-Q converter also the six current pulses for the negative direction have to be checked.

  • Page 24: How To Find A Faulty Thyristor

    Fault Tracing Thyristors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 25: Converters Size D5, D6, And D7 (900

    Converters size D5, D6, and D7 (900...5200 A) These converters are equipped with fuses in the branches of the power part.  The converter must be disconnected from the mains. Blown fuses  In case of a blown fuse, the faulty thyristor or the faulty pair of thyristors are already isolated at one side from the others and therefore the faulty branch is known (see picture Anti-parallel...
  • Page 26 Fault Tracing Thyristors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 27: Handling The Semiconductors

    1. Keep new semiconductors as long as possible in their original packages. 2. Use protective gloves if possible. 3. Clean work area and hands frequently. 4. Use good illumination. Handling the Semiconductors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 28 Handling the Semiconductors Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 29: Exchange Of Thyristors For Size D1 To D4

    D1 to D4 (20...1000 A) All DCS800 size D1 to D4 are equipped with an OnBoard bridge (excitation) and thyristor modules. In order to keep the operating temperature of the semiconductor module low, the joint between the heat sink and the module should have a good heat conducting ability.

  • Page 30: Remove Faulty Thyristor Modules

    Remove all options, so that the intermediate cover is empty Remove plug in options Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 31 5. Remove the grounding plug and the holding screw at the electronic tray: Remove the grounding plug and the holding screw Remove grounding and screws Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 32 D2 - D4: thread the wire 1 time through the hole in T100 (that equals no loops) Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 33 Remove only as many parts as needed around the faulty thyristor module. 12. Remove the faulty thyristor module and mark it clearly as defective. Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 34: Install New Thyristor Modules

    6. Tighten the screws to nominal torque according to table Nominal mounting torque for OnBoard bridge and thyristor modules page 35. Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 35 SDCS-DSL-4 (X51 to X54). 15. Reinstall the intermediate cover, all plug in options and the design cover. Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 36: Remove Faulty Onboard Bridge (V1)

    7. Reconnect all connectors to the OnBoard bridge. 8. Follow the instructions Install new thyristor modules beginning with step 10. Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 37: Onboard Bridge (V1) And Thyristor Module Location In Dcs800-S01 (2-Q) Units

    V16/V13 V12/V15 DCS800 loc of mod 1Q.dsf Location of the OnBoard bridge and thyristor modules in DCS800-S01 (2-Q) units Note: This drawing is only showing the location of the OnBoard bridge and thyristor modules, the actual converter module size is different! Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 38: Onboard Bridge (V1) And Thyristor Module Location In Dcs800-S02 (4-Q) Units

    V21/V14 V25/V12 DCS800 loc of mod 4Q.dsf Location of the OnBoard bridge and thyristor modules in DCS800-S02 (4-Q) units Note: This drawing is only showing the location of the OnBoard bridge and thyristor modules, the actual converter module size is different! Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 39: Onboard Bridge And Thyristor Module Terminals

    (AK) (AK) SKKT 27, 42, 57, 106 MCC26, 44, 56, 95 (AK) SKTT 162 MCC162 Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 40 TT 250, 330 TT 425, 570 Terminals of the OnBoard bridge and all thyristor modules Exchange of Thyristors for Size D1 to D4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 41: Exchange Of Thyristors For Size D5

    Exchange of Thyristors for Size D5 Installation of "Disc Type" thyristor in converters size D5 (900...2000 A) All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the "Disc type" semiconductor component is such that it requires a certain compression force to operate.

  • Page 42: Disk Type Thyristors

    Original thyristor type (900 A) Converter with original thyristor type T459Nxxx Id code: DCA0012007P0001 Original thyristor type Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 43 Original thyristor type (1200 A) Converter with original thyristor type T589Nxxx Id code: DCA0012015P0001 Original thyristor type Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 44 Round terminal D = 1.5 mm Cathode (5): Faston 4.8 x 0.5 mm Conductive plate: Diameter 36 mm Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 45: Find Faulty Thyristor

    Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 46: Remove Faulty Thyristor

    View from the right the left Disassembly tool mountcl_b.dsf Front view How to use the disassembly tool Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 47: Install New Thyristor

    6. Turn the thyristor so that the gate leads point in the right direction. Loose condition TORQUE INDICATING SPRING Insulating plate Heatsink Correct torque Aluminum spring with welded indicating spring Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 48 View from the left Front view View from the right Location of thyristors in frame D5 (4-Q bridge) Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 49 View from the left Front view View from the right Location of thyristors in frame D5 (2-Q bridge) Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 50 D1 (-) C1 (+) Location of branch fuses frame D5 Exchange of Thyristors for Size D5 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 51: Exchange Of Thyristors For Size D6

    Exchange of Thyristors for Size D6 Installation of "Disc Type" thyristor in converters size D6 (1900...3000 A) All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the "Disc type" semiconductor component is such that it requires a certain compression force to operate.

  • Page 52: Disk Type Thyristors

    Attention: Use always the correct spare thyristor! Original thyristor type Thyristor T 1329Nxxx with Id code 3ADC340081P0001 Original thyristor type Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 53: Bct Thyristors

    Faston 4.8 x 0.5 Gate A Gate A Faston 6.3 x 0.8 Gate B Gate B BCT.dsf Gates of BCT Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 54: Find Faulty Thyristor

    Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 55: Remove Faulty Thyristor

    Note: It depends on the location of the defective thyristor which DC-busbar plates have to be disconnected. Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 56 Do not remove the nuts totally, otherwise the treaded rods will fall down! 6. Pull out both DC-busbar plates. busbar plates DC-busbar plates Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 57 Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor! Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 58: Install New Thyristor

    6. Connect the gate leads if possible. 7. Insert first the top DC-busbar plate and then the bottom one. Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 59 10. Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further. Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 60 13. Perform an OHM test between U1, V1, W1 and C1, D1 to make sure the power part is ok. Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 61 D1(-) View from the right A6_thyr_locat.dsf Location of thyristors in frame D6 (4-Q bridge with single thyristors) Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 62 V12 / V25 D1(-) View from the right A6_thyr_locat.dsf Location of thyristors in frame D6 (4-Q bridge with BCT’s) Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 63 D1(-) View from the right A6_thyr_locat.dsf Location of thyristors in frame D6 (2-Q bridge with single thyristors) Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 64 C1(+) D1(-) C1(+) D1(-) C1(+) D1(-) A6_branch_fuse_locat.dsf Location of parallel branch fuses frame D6 Exchange of Thyristors for Size D6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 65: Exchange Of Thyristors For Size D7

    Exchange of Thyristors for Size D7 Installation of "Disc Type" thyristor in converters size D7 (2050...5200 A) All DCS800 converters sizes D5/D6/D7 are equipped with disk type thyristors. The structure of the "Disc type" semiconductor component is such that it requires a certain compression force to operate.

  • Page 66: Find Faulty Thyristor

    2 - quadrant converter: 3. Find the defective thyristors by performing an OHM test (both polarities) over their heat sinks. Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 67 5. Loosen the mounting clamp at the top of the thyristor stack. mounting clamp indicating spring Handling of indicating spring and mounting clamp Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 68 Open the gap wide enough that the thyristor and the pins are not damaged while removing the thyristor! Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 69: Install New Thyristor

    7. Tighten the nuts of the mounting clamp by hand so that the clamp is in parallel with the contact surface of the heat sinks. Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 70 8. Tighten each nut in turn, half a turn at a time with the help of a ring spanner until the indicating spring clicks into position “correct torque”. Do not tighten the screws any further. Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 71 11. Perform an OHM test between U1, V1, W1 and C1, D1 to make sure the power part is ok. Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 72 Busba rs o n th e left; view from the front view from the front Location of thyristors in frame D7 (2-Q bridge) Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 73 AC-busbar AC-busbar D1(-) DC-busbar A7_branch_fuse_lopcat.dsf C1(+) DC-busbar Location of branch fuses frame D7 (busbars on the right) Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 74 AC-busbar AC-busbar C1(+) DC-busbar A7_branch_fuse_lopcat.dsf D1(-) DC-busbar Location of branch fuses frame D7 (busbars on the left) Exchange of Thyristors for Size D7 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 75: Exchange Of Sdcs-Con-4

    Exchange of SDCS-CON-4 General All DCS800 size D1 to D7 are equipped with the same controller board SDCS- CON-4, thus the exchange of the board is similar for all module sizes. Required Tools Special tools or material needed in addition to standard tools for the exchange of the SDCS-CON-4: ...
  • Page 76  DriveWindow Click File then Save As… Light  Click Save:  DriveWindow Click File then Parameters and Save As… Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 77 Remove design cover 2. Remove all plug in options on the intermediate cover e.g.:  serial communication modules (R-type), Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 78 4. Disconnect all I/O plugs (X3 to X7) at the SDCS-CON-4 and the plugs at the SDCS-DSL-4 board, if used (X51 to X54): Disconnect all plugs from SDCS- CON-4 and SDCS-DSL-4 boards Disconnect all plugs Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 79 Remove screws and studs 6. Unplug the flat cables (X12, X13, X37): Remove flat Remove flat cables cables Unplug the flat cables Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 80 The actual parameter set is now downloaded into the new SDCS-CON-4.  DriveWindow Click File then Open… Light  Choose correct parameter file and click Open: Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 81 To check if the parameter download was successful connect the drive with DriveWindow Light and compare drive memory the downloaded parameter set. Click Drive then Parameters & Signals and Compare… Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 82 To check if the parameter download was successful connect the drive with DriveWindow and compare drive memory the downloaded parameter set. Click File then Parameters and Compare… Exchange of SDCS-CON-4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 83: Service

    Service How to remove the converter fans in frames D1 to D3 (two fans) Converters types DCS800-S01-0045-0x to DCS800-S02-0350-0x using two 115 VAC fans. Depending on the supply voltage they are either connected in series, for 230 VAC. or in parallel, for 115 VAC: Fan configuration D1 to D3 In case a fan fails there are different approaches due to the incoming voltage.
  • Page 84 1. Remove the DCS Control Panel, the design cover and the fan connection plug X2 on the top of the converter housing: Remove DCS Control Panel Design cover Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 85 2. Remove the two fan arrangement screws: Fan arrangement 3. Move the fan arrangement forward: Move fan arrangement Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 86 Faston plugs 6. Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 87: How To Remove The Converter Fans In A Frame D3 (Four Fans)

    How to remove the converter fans in a frame D3 (four fans) Converters types DCS800-S01-0405-0x to DCS800-S02-0520-0x using four 115 VAC fans. Depending on the supply voltage they are either connected in series, for 230 VAC. or in parallel, for 115 VAC: Fan configuration D3 In case a fan fails there are different approaches due to the incoming voltage.
  • Page 88 1. Remove the DCS Control Panel, the design cover and the fan connection plug X2 on the top of the converter housing: Remove DCS Control Panel Design cover Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 89 2. Remove the two fan arrangement screws: Fan arrangement 3. Move the fan arrangement forward: Move fan arrangement Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 90 4. Remove the fan holding screws: Fan holding screws Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 91 Faston plugs 6. Reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 92: How To Remove The Converter Fan In A Frame D6

    1. Remove the three screws at the top of the fan. 2. Disconnect the cables. 3. Lift the fan up and pull it out. screws cables Converter fan in frame D6 Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 93: How To Remove The Converter Fan In A Frame D7

    1. Remove the three screws at the bottom of the fan. 2. Disconnect the cables. 3. Pull the fan out. cables screws Converter fan in frame D7 Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 94: Dcs800 Firmware Download

     A recent workspace including firmware file and text file should be saved on the Workspaces ABB provides workspaces called DCS800.fdt. New workspaces have to be saved C:\ABB\DCS800\Firmware\CON-4\Ver x.x Firmware / text file The firmware consists of two parts. The firmware file itself and the text file. New firmware files (*.rec) have to be saved in:...
  • Page 95 New text files (*.cde) have to be saved in: C:\ABB\DCS800\Firmware\ CON-4\Ver x.x\Text Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 96 De-energize the DCS800 electronics  Set jumper S5 on SCDS-CON-4 from position 3-4 to position 1-2  Connect a RS232 cable between a PC COM Port and DCS800 X34  Energize the DCS800 electronics, the 7-segment display shows: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 97 Start the Hitachi Flash Development Toolkit 2.2 by means of Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development Toolkit 2.2 Choose workspace:  Mark Open an existing Workspace,  Confirm with OK Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 98 Activate firmware download:  Select Firmware with a right mouse click and choose Set as Active Project from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 99 Select the Communications tap, choose the desired COM Port, un-tick the box Use default baud from the pop up menu and set the Target Baud Rate to 38400. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 100 Download firmware file to device:  Select desired firmware with a right mouse click and choose Download File to Device from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 101 After the download is complete the FDT2.2 has to be disconnected. Select Firmware with a right mouse click and choose Disconnect from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 102 Set jumper S5 on SCDS-CON-4 from position 1-2 to position 3-4  Energize the DCS800 electronics. In case the 7-segment display shows a the firmware’s corresponding text file has to be downloaded from the workspace. If the 7-segment display shows something else, it is not necessary to download the text file and the download is complete.
  • Page 103 Use default baud from the pop up menu and set the Target Baud Rate. Attention:  For firmware version 80x130/80x130Demo and higher set the Target Baud Rate to 38400. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 104 Do not de-energize the drive or disconnect the tool while the seven segment display shows the u.  Wait until the 7-segment display shows: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 105  Now FDT2.2 has to be disconnected. Select Text with a right mouse click and choose Disconnect from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 106 When closing the FDT2.2 save the workspace only if firmware files or text files have been added. The firmware download is complete now. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 107: Add Firmware Or Text Files

    Start the Hitachi Flash Development Toolkit 2.2 by means of Start/Programs/Hitachi/Flash Development Toolkit 2.2/Flash Development Toolkit 2.2 Choose workspace:  Mark Open an existing Workspace,  Confirm with OK Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 108  Select the workspace in directory: C:\ABB\DCS800\Firmware\CON-4\Ver x.x  Confirm with Open Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 109  Select Firmware with a right mouse click and choose Add Files to Project… from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 110  Go to the directory containing the desired firmware file e.g.  Choose the desired firmware file and press Open: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 111 If the text file to be downloaded is not shown under Target files the text file has to be added  Select Text with a right mouse click and choose Add Files to Project… from the pop up menu Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 112 Go to the directory containing the desired text file e.g.  To display the desired text file write in File name and press Open: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 113 Choose the desired text file and press Open: Close download tool:  When closing the FDT2.2 confirm with Yes Adding of files is complete now. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 114: Create A Workspace

    In case the Hitachi Flash Development Toolkit 2.2 is not installed at its default location (e.g. using Windows in an different language than English): C:\Program Files\Hitachi\FDT2.2 it is not possible to use the standard ABB workspace called DCS800.fdt. Thus the user has to create a new workspace. Start download tool: ...
  • Page 115 Name new workspace:  Name the new workspace,  choose its location and  confirm with OK  Choose Yes Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 116 Create the project for the firmware file:  Name the new project and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 117 Choose Device And Kernel:  Select Device: H8S/2633F and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 118  Select the proper COM port,  Select Baud Rate: 38400,  un-tick Use Default Baud Rate and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 119 Enter the CPU crystal frequency for the selected device: 6.25 MHz,  Select the multiplier for the main clock frequency (CKM): 4 and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 120 Connection Type:  Select connection: BOOT Mode,  Select Interface: Direct Connection,  un-tick Kernel already resident and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 121 Programming Options:  Protection: Automatic and  Messaging: Advanced,  confirm with Finish Now the project for the firmware file is finished: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 122  Select Workspace with a right mouse click and choose New Project…  Name the new project and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 123 Choose Device And Kernel:  Select Device: H8S/2633F and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 124  Select the proper COM port,  Select Baud Rate: 38400,  un-tick Use Default Baud Rate and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 125 Enter the CPU crystal frequency for the selected device: 6.25 MHz,  Select the multiplier for the main clock frequency (CKM): 4 and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 126 Connection Type:  Select connection: BOOT Mode,  Select Interface: Direct Connection,  tick Kernel already resident and  confirm with Next Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 127 Programming Options:  Protection: Automatic and  Messaging: Advanced,  confirm with Finish Now the project for the text file is finished: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 128 Close download tool:  When closing the FDT2.2 confirm with Yes Creating of projects is complete now. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 129: Download Sdcs-Com-8 Firmware

    Unzip the SDCS-COM-8 firmware (file COM-8 88xxxx.zip) by right click on the zip file:  Following files and folders will be created: Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 130  Connect the DCS800 directly with the PC, fiber optic cable from SDCS-COM-8 channel 3 to: 1. PCMCIA adapter NDPA-02 with NDPC-12 or 2. USB adapter RUSB-02  Switch on the DCS800  Set Ch3 HW Config (70.21) = Ring ...

  • Page 131: Set Type Code

    To change the type code as whole follow the instructions below:  un-protect the type code by means of ServiceMode (99.06) = SetTypeCode  set TypeCode (97.01) = S01-0020-04 to S02-5200-05 (details, see table below) The drive’s basic type code: DCS800-AAX-YYYY-ZZB Product family: DCS800 Type: = S0 Modules...
  • Page 132 (99.06) has to be set back to NormalMode by the user  the new values can be seen in group 4 ConvNomCur (4.05), ConvNomVolt (4.04), MaxBridgeTemp (4.17) and QuadrantType (4.15) Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 133: Type Code Table

    S01-2050-06 S02-0450-04 S02-4000-10 S01-2050-07 S02-0450-05 S02-4800-06 S01-2500-04 S02-0520-04 S02-4800-07 S01-2500-05 S02-0520-05 S02-4800-08 S01-2500-06 S02-0650-06 S02-5200-04 S01-2500-07 S02-0680-04 S02-5200-05 S01-2500-08 S02-0680-05 S01-4000-12 S02-4000-12 Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 134: Dc-Motor Neutral Zone Adjustment

    Sometimes you have to do a little offset to compensate for movements during tightening.  Finally, mark the correct neutral zone position in case the motor will be taken apart in the future. Service Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 135: Preventive Maintenance

    It is easiest to use the spare parts ESD package. Place the protective package on the ESD mat before opening. Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 136: Recommended Regular Maintenance

    A harsh environment, such as high ambient temperature, humidity, dust and cyclic heavy load, not only shortens the components lifetime but also the preventive maintenance and replacement intervals. Maintenance schedule Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 137: Annual Preventive Maintenance

    Open the cabinet’s and module’s door; if needed secure them.  Set a latching torque spanner to 25 Nm (18 lb-ft). A 17 mm nut is needed too. Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 138 Don’t loosen the screws by a left hand turn! Put on a new marking, if appropriate. Power part of a converter module type D7 Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 139 Any signs of corrosion, especially at ground components, must be removed. Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 140: Years Preventive Maintenance

    30,000 hours at 40°C (D7) The mayor problem is the failure of the bearings. Typical lifetime of the cooling fan versus ambient temperature Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 141: Years Preventive Maintenance

    CN2B2: 40,000 hours at 60°C  W2E200: 45,000 hours at 60°C  W2E250: 40,000 hours  D2E160: 30,000 hours at 40°C Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 142 1. Increased vibration due to the imbalance of the cooling fan (can last for several months) 2. Increased temperature due to the stopped cooling fan (drive trips with overtemperature) Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 143: Years Preventive Maintenance

    Aging of the electronic card result in: 1. Damage other devices 2. Trip the drive and cause break-down time  Replace the power supply board SDCS-POW-4 of units D5 to D7 and DCS800- R (Rebuild- and Upgrade Kits). SDCS-POW-4 Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 144 Aging of the electronic card result in: 1. Damage other devices 2. Trip the drive and cause break-down time  Check the flat cables and their connections. Preventive Maintainance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...

  • Page 145: Appendix A - Spare Parts List

    Control Panels and plug-in options D1 - D7 8.04 - 8.05 Field exciters FEX-425-Int, DCF803-0035 and DCF503/4B 8.06 Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A 8.07 Common parts for DCS800-A0 Enclosed Converters 8.08 Parts for DCS800-R0 Rebuild Kit 8.09...
  • Page 146 Fan for DCF50xB0060 GHSN700002P0001 AC220V 8556V Fan M55/M56 for DCF50xB0060 Item 8.06 Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A 8.06 Overvoltage protection DCF506-... for fieldexciter DCS800-S0x-0020, …, 0520, 20 A - 520 A DESCRIPTION CODE...
  • Page 147 20 A - 260 A, cable 250 mm Temperatur Sensor (D3 and D4) 3ADT710005P0002 KTY10-6-M4/400mm 315 A - 1000 A, cable 400 mm Module contains: 11.00 DCS800-S01-0020-04/05 & DCS800-S02-0025-04/05 (400 V - 525 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor modules 3ADC340063P0001...
  • Page 148 Module contains: 14.00 DCS800-S01-0090-04/05 & DCS800-S02-0100-04/05 (400 V - 525 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor modules 3ADC340068P0001 SKKT57B/xxx MCC 56 -16 xxx Semiconductor fuses 3ADT730004R0007 UR 125 A / 660 V Blade- or knife fuse Cooling fan 115V, 50/60Hz...
  • Page 149 Module contains: 20.00 DCS800-S01-0405-04/05 & DCS800-S02-0450-04/05 (400 V - 525 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor modules GHSN610089P0002 TT250 Nxxx MCC 255 - xxx Semiconductor fuses 3ADT730004R0013 UR 700 A / 660 V Blade- or knife fuse Cooling fan 115 V, 50/60 Hz...
  • Page 150 3ADT754017P0001 W2E250-HL06-10 Fuses as Enclosed Converter 3ADV050092P0020 170M6016 Fuses as Enclosed Converter with OESA Module contains: 27.00 DCS800-S01-0610-04/05 & DCS800-S02-0680-04/05 +S171 (400 V - 525 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor modules 3ADC340032P0001 TT 425 Nxxx MCC 501 - xxx...
  • Page 151 Module contains: 31.00 DCS800-S01-0900-06/07 & DCS800-S02-0900-06/07 (600 V - 690 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor DCA0012007P0001 T459Nxxx original thyristor type Semiconductor fuses 3ADC770009P0007 UR 630 A / 1250 V Screw type fuse Module contains: 31.00a DCS800-S01-0900-06a/07a & DCS800-S02-0900-06a/07a (600 V - 690 V)
  • Page 152 UR 1500 A / 660 V Screw type fuse Cooling fan 3ADT754008P0001 GR31M-..(500V) 400 V - 500 V / 50/60 Hz Appendix A - Spare Parts List Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 153 Module contains: 43.00 DCS800-S01-2050-06/07 & DCS800-S02-2050-06/07 (600 V - 690 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor 3ADC340081P0001 T 1329Nxxx original thyristor type Puls transformer board 3ADT220090R0043 SDCS-PIN-48 SDCS-PIN-48 replaces SDCS-PIN-41 Semiconductor fuses 3ADC770009P0008 UR 700 A / 1250 V Screw type fuse (double fuses)
  • Page 154 Module contains: 47.00 DCS800-S01-3000-04/05 & DCS800-S02-3000-04/05 (400 V - 500 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor for DCS800-S01, 2-Q 3ADC340088P0001 T 989-3300xxx B idirectional- C ontrolled- T hyristor (BCT) Thyristor for DCS800-S02, 4-Q 3ADC340079P0001 5 STB 24-Qxxx Puls transformer board...
  • Page 155 3ADT780007R0002 SDCS-PIN-5x-1190 meas. Prepared for galvanic isolation (A92) Semiconductor fuses 3ADC770025P0001 UR 1700 A / 1500 V Flush-end contact fuse Module contains: 54.00 DCS800-S01-3300-04/05 & DCS800-S02-3300-04/05 (400 V - 500 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor 3ADC340089P0001 T 989-3030xxx Semiconductor fuses...
  • Page 156 Module contains: 60.00 DCS800-S01-4000-06/07 & DCS800-S02-4000-06/07 (600 V - 690 V) DESCRIPTION CODE TYPE/DATA NOTES Thyristor 3ADC340046P0002 5 STP 3328 Lxxx Semiconductor fuses 3ADC770030P0002 UR 3000 A / 1000 V Flush-end contact fuse Module contains: 61.00 DCS800-S01-4000-08 & DCS800-S02-4000-08 (800 V)
  • Page 157 Appendix A - Spare Parts List Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com 3ADW000195R0501 DCS800 Service Manual e e...
  • Page 158 *195R0401A9370000* *195R0401A9370000* Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

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