ABB DCS800 Drives (20 to 5200 A) Service manual

ABB DCS800 Drives (20 to 5200 A) Service manual

Safety instructions

INSTALLATION AND MAINTENANCE WORK: Only qualified electricians are permitted to carry out installation and maintenance of the drive, motor cables or motor. The mains power supply must be disconnected before operation, measured with a multimeter to ensure that there are no dangerous voltages, and must not work on control cables while energised, avoiding insulation resistance or voltage withstand tests.

Grounding: Drives, motors and neighbouring equipment must be grounded, and the grounding conductor must comply with the safety regulations, and should be grounded separately for multi-drive installations.

Other safety precautions: wear a grounding wrist strap when handling printed circuit boards, handle fibre-optic cables with care, take care to avoid damage when handling drives, and follow relevant safety standards when operating.

Fault Tracing Thyristors

Tools: Software tools such as DriveWindow Light and hardware tools such as oscilloscopes, current probes, voltmeters, etc. are required for debugging and troubleshooting; an ESD-safe hair dryer or hoover is required for maintenance and preventive maintenance.

Detection Methods: Faults can be detected by blown fuses, oscilloscope measurements of DC current pulses, thyristor diagnostic functions, and ripple monitors. When determining a faulty thyristor, the detection method varies between converter sizes, with D1 - D4 models measuring AC and DC terminal resistance, and D5 - D7 models identifying the faulty branch when the fuse is blown and then performing the relevant tests.

Key Questions

How can I tell if the DCS800 drive thyristor is faulty?

You can observe whether the fuse is blown, if it is blown, it may be due to thyristor failure, internal short circuit, and so on. You can also use an oscilloscope to connect to a specific port to check whether the number of DC current pulses is normal; use the firmware thyristor diagnostic function to start the diagnosis in local mode and view the results; through the ripple monitor, if the DC current ripple is abnormally high, there may be a thyristor does not work.

What are the preventive maintenance intervals and main tasks for DCS800 drives?

Preventive maintenance intervals are annual, 3 years, 6 years and 9 years. Annually, the cooling fans, cooling air pressure switches, heatsink terminal tightness, cleaning of the door air filters, checking the internal environment of the module and the quality of the supply voltage are to be checked; in 3 years, the cooling fans of D6 and D7 are to be replaced, checking the tightness of all the terminals, the condition of the contactors and relays, the fibre-optic cables and their connections; in 6 years, the cooling fans of D1-D5 are to be replaced; and in 9 years, the SDCS PIN-4 boards of D1-D4 are to be replaced. PIN - 4 boards for D1 - D4 and SDCS - POW - 4 boards for D5 - D7 and DCS800R, check the flat cables and their connections.

Detailed specifications:

Basic Configuration and Type Codes: DCS800 drive type codes contain a wealth of information, from left to right, the beginning of the ‘DCS800’ represents the product family . ‘AA’ indicates the type, e.g. “S0” is a standard converter module, “A0” is a closed converter. ‘X’ stands for the bridge type, “2” for 2 anti-parallel bridges (4-Q). ‘YYYY’ stands for rated DC current, like “0025” means 25A DC. ‘ZZ’ stands for rated AC voltage. ‘B’ is for power connections etc. In addition, there are a number of optional configurations available via the ‘plus code’, e.g. settings related to internal excitation configuration, fan voltage, current measurement, voltage measurement, control panel, fieldbus, I/O and DDCS communication.

Current and Voltage Ratings: Drive current and voltage ratings vary by unit size. The current ratings of 2-Q and 4-Q vary at different rated AC voltages. Taking D1 unit as an example, under 400V and 525V AC voltage, 2-Q current ratings can be 20A, 45A, etc., and 4-Q current ratings can be 25A, etc.; D7 unit can be rated up to 5200A for 2-Q and 4-Q under 800V, 990V, and 1200V AC voltage. See the current and voltage ratings tables in the text for detailed ratings for each unit size.