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ABB DCT880 Service Manual

Thyristor power controller
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DCT880
Service Manual
DCT880 Thyristor power controller (20 A ... 4160 A)
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Summary of Contents for ABB DCT880

  • Page 1 DCT880 Service Manual DCT880 Thyristor power controller (20 A … 4160 A) ...

  • Page 3: Safety Instructions

    − Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the thyristor power controller (e.g. XRO1 … XRO3). − DCT880 with enclosure extension: Before working on the thyristor power controller, isolate the whole thyristor power controller system from the supply.
  • Page 4 WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wristband when handling the boards. Touch the boards only when necessary. ABB order no.: 3ADV050035P0001 Safety Instructions 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 5 WARNING! − DCT880 sizes T4 and T5: The thyristor power controller is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units T4 and T5 only on its back. − Make sure that dust from drilling does not enter the thyristor power controller when installing.

  • Page 6: Table Of Contents

    Install new thyristor modules ........................26 Thyristor module terminals ........................27 Exchange thyristors size T5 Installation of thyristor modules in thyristor power controllers size T5 (890 A … 960 A) ......29 Table of contents 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 7 3 years preventive maintenance ........................79 6 years preventive maintenance ........................80 9 years preventive maintenance ........................81 Preventive maintenance Checklist DCT880 ....................82 Appendix A: Spare Parts List T1 (20 A … 125 A) ............................84 T2 (160 A … 245 A) ............................85 T3 (325 A …...

  • Page 8: Dct880 Manuals And Tools

    NETA-21 remote monitoring tool 3AUA00000969391 NETA-21 remote monitoring tool installation and 3AUA0000096881 startup guide DCT880 Service Manual 3ADW000449 x = existing p = planned Status 09.2015 DCT880 Manuals list f e.docx Manuals and Tools 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 9: Documentation

    4. Start-up and maintenance of the entire thyristor power controller. 5. Faults, warnings and information for trouble shooting. − The DCT880 Service Manual contains information for maintenance and repair of the thyristor power controller. − Additional information about technical accessories (e.g. hardware extension or fieldbus adapter) are handled by separate manuals –...

  • Page 10: Introduction

    This chapter describes the purpose, contents and the intended use of this manual. Before You Start The purpose of this service manual is to provide detailed information on how to service DCT880 thyristor power controllers. The at the beginning of this manual need to be studied before Safety instructions attempting any work on or with the thyristor power controller.

  • Page 11: Name Plate

    Rated input current Rated output power Rated fan voltage Type code The type code contains information on the specifications and configuration of the thyristor power controller: The thyristor power controller’s basic type code: DCT880-AAB-CCCC-DD-E Product family: DCT880 Type: = W0...

  • Page 12: 400 V / 525 V Units, Current And Power Ratings

    1.14 0.78 2.01 1.33 1064 3.50 ③ Power ratings for a 3-phase load in star configuration at 690 V 2.90 (e.g. √3 ∗ 20 A ∗ 690 V / 1000 = 23 kW) Introduction 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 13 690 V DCT880-W0x-0020-04/05 DCT880-W0x-0035-04/05 DCT880-W0x-0035-07 DCT880-W0x-0055-04/05 DCT880-W0x-0080-04/05 DCT880-W0x-0080-07 DCT880-W0x-0100-04/05 DCT880-W0x-0100-07 DCT880-W0x-0125-04/05 DCT880-W0x-0160-04/05 DCT880-W0x-0160-07 DCT880-W0x-0200-04/05 DCT880-W02-0200-07 DCT880-W0x-0245-04/05 DCT880-W0x-0325-04/05 DCT880-W0x-0360-04/05 DCT880-W0x-0360-07 DCT880-W0x-0420-04/05 DCT880-W0x-0550-04/05 DCT880-W0x-0630-07 DCT880-W0x-0675-04/05 DCT880-W0x-0740-04/05 DCT880-W03-0890-04/05 DCT880-W03-0890-07 DCT880-W02-0960-04/05 DCT880-W02-0960-07 Note: Input current = output current Introduction 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 14: Fault Tracing Thyristors

    1000 V probes and test leads. − An ESD-field service kit (ABB Service Finland code 0001ESD / MS-Antistatic). Make sure that all equipment in use is suitable for the voltage level applied to the power part! Fault Tracing Thyristors 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 15: Additionally For Service And Preventive Maintenance

    An external short circuit at the output terminals of the thyristor power controller without sufficient load. Output current measured by an oscilloscope Connect an oscilloscope to the output and check for the proper current (e.g. phase angle control): Fault Tracing Thyristors 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 16: Thyristor Diagnosis

    In this case, it is sufficient to know which thyristor module has a defective thyristor because the complete module must be replaced. − After a thyristor module is replaced, the above-mentioned measurement should be done another time to make sure that all faulty thyristors have been detected! Fault Tracing Thyristors 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 17: Standard Thyristor Power Controllers Size T5 (890 A

    Thyristor power controllers size T1 … T4 (20 A ... 740 A), with +S500 Thyristor power controllers, with +S500. Internal semiconductor fuses are included. − The thyristor power controller must be disconnected from the mains. Fault Tracing Thyristors 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 18: Blown Fuses

    The measurement, showing less resistance than 1 Ω should be made a second time with test leads applied to the terminals with opposite polarity; if this measurement shows the same result, one or two thyristors located in that path are faulty; they need to be replaced. Fault Tracing Thyristors 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 19: 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 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 20: Exchange Thyristors Sizes T1

    T4 (20 A ... 740 A) All DCT880 size T1 … T4 are equipped with 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 21: Remove Faulty Thyristor Modules

    Remove faulty thyristor modules 1. Remove control panel and design cover. 2. Remove all F-type extension modules. Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 22 3. Disconnect all I/O plugs from the SDCS- CON-H. 4. Remove the grounding / holding screws at the electronic tray. Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 23 (X14, XC12, XS13) and the cable connected to X38. 7. Remove following cables and plugs at the SDCS-PIN-H: − Auxiliary voltage input (X99). − External measurement channels (X54, X60, X65). Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 24 − Voltage measurement (X51, X52, X53 and X55, X56, X57). − Cooling fans (X41 … X44) if existing. − Snubber resistor (X30, X31). − Gate leads (X15, X17). Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 25 11. If a current transformer must be removed, mark its position, direction and the connections clearly. Note: 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 thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 26: Install New Thyristor Modules

    9. Reconnect all gate leads to the thyristor module. 10. Perform an OHM test to make sure the thyristor is ok. 11. Reinstall the SDCS-PIN-H board. 12. Reconnect all cables and plugs at the SDCS-PIN-H: Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 27: Thyristor Module Terminals

    For all firing pulse cables is valid: − Yellow is gate lead. − Red is cathode lead. SKKT27B, 42B, 57B, 106B MCC26, 44, 56, 140 SKKT162 MCC162, 200 Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 28 MCC255, 312 TT250 TT425, 570 SKKT250 MT3-540, 595 MCC501 Exchange thyristors sizes T1 … T4 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 29: Exchange Thyristors Size T5

    Find faulty thyristor modules Fault Tracing Thyristors of this publication. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 30: Remove Faulty Thyristor Modules

    Remove faulty thyristor modules 1. Remove control panel and design cover. 2. Remove all F-type extension modules. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 31 3. Disconnect all I/O plugs from the SDCS- CON-H. 4. Remove the grounding / holding screws at the electronic tray. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 32 (X14, XC12, XS13) and the cable connected to X38. 7. Remove following cables and plugs at the SDCS-PIN-H: − Auxiliary voltage input (X99). − External measurement channels (X54, X60, X65). Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 33 − Voltage measurement (X51, X52, X53 and X55, X56, X57). − Snubber resistor (X30, X31). − Gate leads (X15, X17). Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 34 − Temperature sensor (X22). − Current transformers (X3, X4, X5). 8. Remove the holding screws. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 35 9. Remove the plastic cover and the SDCS- PIN-H. 10. Remove the all 9 screws at the fuses and the U1, V1, W1 busbars. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 36 11. Remove the loose U1, V1 and W1 busbars. 12. Remove all fuses using a torque spanner (nut size 18). Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 37 13. To remove the U1, V1, W1 and U1, V2, W2 busbars loosen the 4 screws at the bottom plate. 14. Remove the screws holding the U2, V2 and W2 busbars. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 38 15. Remove the U2, V2 and W2 busbars including the busbar arrangement at the bottom. 16. Check the thyristors. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 39: Install New Thyristor Modules

    15. Reconnect the grounding / holding screws at the electronic tray. 16. Reconnect all I/O plugs at the SDCS-CON-H. Reinstall all plug in options (do not forget the screws), the design cover and the control panel. Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 40: Thyristor Module Location In T5 Units

    The next figures show the terminals of the used thyristor modules. The terminal description is also stamped or marked by a sticker on the thyristor modules. For all firing pulse cables is valid: − Yellow is gate lead. Red is cathode lead. − MT3-540, 595 Exchange thyristors size T5 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 41: Exchange Sdcs-Con-F General

    Exchange SDCS-CON-F General All DCT880 size T1 … T5 are equipped with the same controller board SDCS-CON-H, thus the exchange of the board is similar for all unit sizes. Required Tools Special tools or material needed in addition to standard tools for the exchange of the SDCS-CON-H: TX10, TX20, TX25 −...
  • Page 42 Do not remove or insert a memory unit when the thyristor power controller is powered. Replacing the memory unit Unscrew the memory unit and pull it out. Replace the memory unit in reverse order. Exchange SDCS-CON-H 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 43 3. Remove all F-type extension modules. 4. Disconnect all I/O plugs from the SDCS- CON-H. Exchange SDCS-CON-H 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 44 4. Reinstall all plug in options (do not forget the screws), the memory unit, the design cover and the control panel. 4. Set type code of the thyristor power controller Follow the instructions in chapter Set type code. Exchange SDCS-CON-H 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 45: Service

    Unit types DCT880-W0x-0035-07 and DCT880-W0x-0055-0x … DCT880-W0x-0125- 0x using two 24 V fans. Removing the converter fan 1. Remove the control panel and the design cover. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 46 2. Remove the two fan arrangement screws. 3. Move the fan arrangement forward and up. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 47 5. Remove the fan holding screws of the broken fan. 6. Attach the new fan, reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 48: Exchange Cooling Fans Size T3 (Four Fans)

    Unit types DCT880-W0x-0420-0x using four 24 V fans. Removing the converter fans 1. Remove the control panel and the design cover. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 49 2. Remove the two fan arrangement screws. 3. Move the fan arrangement forward and up. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 50 5. Remove the fan holding screws of the broken fan. 6. Attach the new fan, reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 51: Exchange Cooling Fans Size T4

    Unit types DCT880-W0x-0550-0x … DCT880- W0x-0740-0x using one 230 V fan. Removing the converter fan 1. Remove the control panel, the design cover and the fan connection plug X52 on the top of the converter housing. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 52 2. Remove the two fan arrangement screws. 3. Remove the holding plugs by pulling out the head (use a flat screwdriver). Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 53 4. Move the fan arrangement forward and up. 5. Remove the fan holding screws. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 54 6. Remove the Faston plugs from X52 and the broken fan. 7. Attach the new fan, reassemble everything and check for correct blow direction of each fan. The air should be sucked out of the module. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 55: Exchange Cooling Fans Size T5

    Unit types DCT880-W03-0890-0x … DCT880-W02- 0960-0x using one 230 V fan. 1. Remove both screws at the bottom of the fan arrangement. 2. Disconnect the plug. 3. Now the fan arrangement can be pulled out. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 56: Exchange Of Internal Semiconductor Fuses In Thyristor Power Controllers Size T1

    Exchange of internal semiconductor fuses in thyristor power controllers size T1 … T4 (20 A ... 740 A) Optional all DCT880 size T1 … T4 can be equipped with internal semiconductor fuses. Required tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules: TX10, TX20, TX25 −...
  • Page 57 2. Remove all F-type extension modules. 3. Disconnect all I/O plugs from the SDCS- CON-H. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 58 5. To unhinge the electronic tray including the SDCS-CON-H pull it up and then out. 6. Before removing the tray completely unplug the flat cables (X14, XC12, XS13) and the cable connected to X38. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 59 7. Remove following cables and plugs at the SDCS-PIN-H: − Auxiliary voltage input (X99). − External measurement channels (X54, X60, X65). − Voltage measurement (X51, X52, X53 and X55, X56, X57). − Cooling fans (X41 … X44) if existing. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 60 − Snubber resistor (X30, X31). − Gate leads (X15, X17). − Temperature sensor (X22). − Current transformers (X3, X4, X5). Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 61: Install New Semiconductor Fuse(S)

    7. Reconnect the grounding / holding screws at the electronic tray. 8. Reconnect all I/O plugs at the SDCS-CON-H. 9. Reinstall all plug in options (do not forget the screws), the design cover and the control panel. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 62: Exchange Of Internal Semiconductor Fuses In Thyristor Power Controllers Size T5 (890 A

    Exchange of internal semiconductor fuses in thyristor power controllers size T5 (890 A … 960 A) All DCT880 size T5 are equipped with internal semiconductor fuses. Required tools Special tools or material needed in addition to standard tools for the exchange of thyristor modules: TX10, TX20, TX25 −...
  • Page 63 2. Remove all F-type extension modules. 3. Disconnect all I/O plugs from the SDCS- CON-H. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 64 (X14, XC12, XS13) and the cable connected to X38. 7. Remove following cables and plugs at the SDCS-PIN-H: − Auxiliary voltage input (X99). − External measurement channels (X54, X60, X65). Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 65 − Voltage measurement (X51, X52, X53 and X55, X56, X57). − Snubber resistor (X30, X31). − Gate leads (X15, X17). Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 66 − Temperature sensor (X22). − Current transformers (X3, X4, X5). 8. Remove the holding screws. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 67 9. Remove the plastic cover and the SDCS- PIN-H. 10. Remove the screws of the busbars of the broken fuse(s). Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 68 11. Remove the busbar(s) of the broken fuse(s). 12. Remove the blown fuse(s) using a torque spanner (nut size 18). Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 69: Install New Semiconductor Fuse(S)

    8. Reconnect the grounding / holding screws at the electronic tray. 9. Reconnect all I/O plugs at the SDCS-CON-H. 10. Reinstall all plug in options (do not forget the screws), the design cover and the control panel. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 70: Dct880 Firmware Download

    Firmware download Make sure: − The drive composer is closed. − The DCT880 is done with booting (energized, auxiliary voltage is on). − The control panel is only connected to one DCT880. − Open the Drive loader 2.x by double click.
  • Page 71 Mark the desired firmware file and click Open. − Mark ACS880 and click Select. − Choose the proper COM port, in this case COM5. − How to find the proper COM port see below. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 72 − Click Control Panel. − Click Devices and Printers. − Double click ABB Drives Assistant control panel. − Choose Hardware. − The COM port can be found under Device Functions. − Here COM5. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 73 Make sure the proper COM port (here − COM5) is chosen. − Click Download. − Click OK. − Please wait and go for lunch! − The firmware download is complete now. − Click OK. Service 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 74 − Close the Drive loader 2.x. − Check for proper firmware version in 07.05 Firmware ver. Service 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 75: Set Type Code

    Un-protect the type code by means of 99.07 Service Mode = Set Type Code. − Set 95.16 Set: Unit type code = W00-0000-00 … W03-0890-07 (details, see table below). The thyristor power controller’s basic type code: DCT880-AAB-CCCC-DD-E Product family: DCT880...

  • Page 76: Preventive Maintenance

    Handle unprotected ESD sensitive boards only when connected to the system and always place them in a protective package that is sealed. It is easiest to use the spare parts ESD package. Place the protective package on the ESD mat before opening. Using the control panel 3ADW000431R0201 DCT880 Manual e b...

  • Page 77: Recommended Regular Maintenance

    The environmental and operating conditions of the thyristor power controller are also to be considered. 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 Maintenance 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 78: Annual Preventive Maintenance

    − Any signs of corrosion, especially at ground components, must be removed. − Check the quality of the supply voltage (e.g. deviation from nominal voltage value, …). Preventive Maintenance 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 79: Years Preventive Maintenance

    Check the tightness of all terminals. All connections should be inspected and checked for tightness. − Check the condition of the contactors and relays. Contactors and relays should be checked for proper function. Preventive Maintenance 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 80: Years Preventive Maintenance

    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). − Check the flat cables and their connections. Preventive Maintenance 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 81: Years Preventive Maintenance

    9 years preventive maintenance Following additional actions have to take place: − Replace the power interface board SDCS- PIN-H of units T1 … T5 (DCT880-W0x- 0020-0x … DCT880-W02-0960-0x). The SDCS-PIN-H is located between the heat sink and the electronic tray. It operates continuously, because it supplies the unit’s electronics even when the load...

  • Page 82: Preventive Maintenance Checklist Dct880

    Inspect connection of flat cables 6 years 3. Maintenance with main supply voltage applied Create parameter backup yearly Check level of all connected voltages yearly Inspect condition of fans (check that all fans are operational) yearly Preventive Maintenance 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 83 SDCS-PIN-H 9 years 4.3 Fan Cooling fan frame size T1 … T5 6 years Inspect = visual inspection, correction and replacement if needed Remarks: Date of inspection: Name of field service engineer: Preventive Maintenance 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 84: Appendix A: Spare Parts List

    Appendix A: Spare Parts List T1 (20 A … 125 A) Appendix A: Spare Parts List 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 85: T2 (160 A

    T2 (160 A … 245 A) Appendix A: Spare Parts List 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 86: T3 (325 A

    T3 (325 A … 420 A) Appendix A: Spare Parts List 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 87: T4 (550 A

    T4 (550 A … 740 A) Appendix A: Spare Parts List 3ADW000449R0101 DCT880 Service Manual e a...

  • Page 88: T5 (890 A

    T5 (890 A … 960 A) Appendix A: Spare Parts List 3ADW000449R0101 DCT880 Service Manual e a...
  • Page 90   ABB Automation Products Wallstadter-Straße 59 *449R0101A5390000* 68526 Ladenburg • Germany *449R0101A5390000* Tel: +49 (0) 6203-71-0 Fax: +49 (0) 6203-71-7609 www.abb.com/drives...

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