ABB 3BHS600000 E80 RevF Service Manual PCS6000

ABB 3BHS600000 E80 RevF Service Manual PCS6000

Security and Tools

Safe Working Practice

Strictly follow the "Seven Step Life Saving Rule", including risk assessment, power outage lockout (LOTO), voltage detection, grounding short circuit and other processes, to ensure operational safety.

The equipment poses risks of high voltage, high temperature, and electromagnetic fields. Maintenance personnel need to wear protective equipment to avoid contact with live parts and high-temperature surfaces.

Residual risks include electromagnetic interference with pacemakers, accidental movement, contact voltage, etc. It is necessary to ensure that the equipment operates within the specified parameter range.

special tools

Converter service toolbox: includes expansion tools for disassembling semiconductor stacks, stabilizing boards, etc., used to release stack pressure and replace components.

Debugging tools: such as RCI Box XU D194 (signal monitoring), PCS6000 HMI (human-machine interface), FADEC 3 (semiconductor testing equipment).

Replacement tools: including foundation beam jacks, chain hoists, pump maintenance platform kits, etc., used for dismantling and installing heavy components.

Preventive maintenance

Maintenance cycle and tasks

Daily/quarterly: visually inspect for dust and signs of overheating, clean cabinets, check bolt tightness and cable wear.

Year: Test the tripping circuit, insulation resistance, and grounding resistance of the main circuit breaker (MCB), and replace aging components such as batteries and fans.

Specific inspection:

Semiconductor stacking: Use FADEC 3 to detect IGCT and diodes, check stack alignment and clamping force.

Cooling system: Check the conductivity of the coolant, replace the ion exchange resin and filter, and inspect the function of the pump and valve.

Filter components: measure resistance and capacitance values to verify filtering performance.

Maintain records

Use the Preventive Maintenance Report to record component replacements, parameter adjustments, and abnormal situations to ensure traceability.

Component replacement and repair

1. Replacement of control components

AC 800PEC controller: Replace after power failure, pay attention to firmware version matching, and verify LED status after reconnecting the cable.

UPS and battery: When replacing, power off and release residual voltage. Pay attention to matching battery polarity and model, and test the charging and discharging function.

Fiber optic cable: Cut and polish with specialized tools to ensure that the connection loss meets the standard and avoid contaminating the fiber optic end face.

2. Replacement of power and cooling components

IGCT and diode:

Release the stacking pressure, use the expansion tool to separate the heat sink, replace it, realign the stack and tighten it.

Check the polarity and clean the contact surface, avoid using grease, and ensure even clamping force.

Cooling system components:

Pump: Drain the coolant, remove the flange and electrical connections, replace with a dedicated bracket, pay attention to the direction and sealing of the impeller.

Ion exchanger and filter: After replacement, the system needs to be flushed to test flow rate and conductivity.

Valves and sensors: After replacement, pressure and temperature sensors need to be calibrated to ensure that the control system is functioning properly.

3. Module level replacement

Voltage Limiting Module (VLM): After power failure, remove the cables and cooling pipelines, replace them, and test the voltage relief function.

Grid Circuit Breaker Unit (GBU): Use a dedicated trolley to disassemble the circuit breaker, check the wear of the contacts, reinstall and test the opening and closing time.

Dv/dt filter: When replacing reactors, resistors, and capacitors, it is necessary to match the model and parameters to ensure EMI suppression performance.

4、 Troubleshooting process

diagnostic procedure

Read the fault code through HMI or debugging tools, analyze the first fault (FF) and related alarms, check the LED status and historical records.

Check the power supply, communication links, sensors, and semiconductor components, and use tools such as multimeters and oscilloscopes to measure voltage and resistance values.

Typical fault handling

IGCT fault: Conduct characteristic detection through FADEC 3, replace and recalibrate trigger signal.

Cooling system leakage: locate the leakage point, replace the seals or pipelines, and test whether the pressure and flow are normal.

Communication interruption: Check the fiber optic connection, module power supply, and address settings, and replace the faulty S800 I/O module or communication board.

5、 Special precautions

Static Electricity Protection (ESD)

When operating the control board and semiconductor, it is necessary to wear a grounding wristband and use anti-static pads to avoid direct contact with circuit contacts.

Heavy component operation

Components weighing over 25 kg, such as reactors and circuit breakers, require the use of lifting tools, with two people working together to avoid the risk of falling.

Documentation and Compliance

Replacing serialized components (such as IGCT and capacitors) requires updating the ABB database and recording the new serial number.

Follow environmental requirements, dispose of waste components (such as batteries and circuit boards) correctly, and avoid environmental pollution.

The relevant models and component models of ABB PCS6000 are as follows:

Main device model

PCS6000

The medium voltage frequency converter models covered by the core of the manual are suitable for industrial scenarios such as large wind turbines and tidal energy, and support 1CL (single conversion line) and 2CL (dual conversion line) configurations.

Core component model

1. Power Unit (POU)

IGCT model:

5SHY 3545L0016 (old generation)

5SHY 4045L0006 (new generation, can replace old models one-on-one)

DC capacitor:

DCMKP 2.6kV/2x1.5mF（3BHB006617R0013）

DCMKP 3.15kV/2x1.01mF（3BHB006617R0014）

2. DC Link Unit (DLU)

Neutral Connection Module (NCM):

Includes resistors - R461, - R462_1/- R462_2, and capacitor - C461.

Voltage Limiting Module (VLM):

VLM30 (weighing approximately 50kg), VLM70 (weighing approximately 60kg).

Dv/dt filtering module (VFM):

Reactors, resistors, and capacitors components (such as - R581 to - R586, - C581 to - C587).

3. Grid Circuit Breaker Unit (GBU)

Circuit breaker model:

GEB (Generator Circuit Breaker), GRI (Grid Circuit Breaker), weighing approximately 160kg, compatible with VD4 series.

Dv/dt filter component:

Reactors, resistors, capacitors (such as - R581 to - R586, - C581 in GBU).

4. Water cooling unit (WCU)

Pump model:

Sweden water series: such as 300l/min pump (3BHE038551R0001, weight 77kg), 565l/min pump (3BHE043674R0001, weight 90kg).

ARMATEC series: Please refer to the accompanying service manual (such as Appendix B06).

Ion exchanger: For resin model adaptation, please refer to Safety Data Sheet (SDS) 81000-193.

5. Filter Unit (FIU)

High pass filtering module (HFM):

Reactors (such as 3BHE035425R0001, weighing 25kg) and capacitors (- C541 to - C544, weighing 41kg).

Filter Reactor Module (FRM):

For FRM70 (weighing 900kg), a dedicated replacement kit (3BHE039651R0001) is required.

6. Braking resistor unit (BRU)

model:

BRU50 (200kg), BRU51 (235kg), BRU70 (400kg), etc., suitable for different power requirements.

Control and auxiliary components

AC 800PEC controller:

PP D113 B03-20-110110（3BHE023584R204Z）。

S800 I/O module:

DI811 (digital input), AI810 (analog input), DO820 (digital output).

Power module:

QUINT-PS/3AC/24DC/40 (AC/DC converter, 3BHE031065R0001)

QUINT-DC-UPS/24DC/40（UPS，3BHB056371P0