Page 1 — SYSTEM DRIVES PCS6000 Service manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL System Drives, ABB Switzerland Ltd. 2023-03-15 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE Service manual 3BHS600000 E80 1/272 © Copyright 2012 ABB All rights reserved.
Page 2 This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document include all the features of the described or referenced standard.
Page 3: Table Of Contents
Polishing kit for fiber optics..................37 3.3. Commissioning tools ......................38 3.3.1. RCI-Box XU D194......................38 3.3.2. PCS6000 HMI......................... 39 3.3.3. Filling kit for PCS6000 water cooling ..............40 3.3.4. Filling kit extension tube....................41 3.4. Replacement tools ........................41 3.4.1. Reactor replacement kit....................41 3.4.2.
Page 4 Overview of replaceable control components ..............86 8.3.1. Replaceable control components in CCU ............... 87 8.3.2. Replaceable control components in POU............... 88 8.3.3. Replaceable control components in FIU ..............88 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 4/272...
Page 5 Checking neutral point (NP) diodes................ 131 9.10. Checking IPS ..........................132 10. Replacing power and cooling components..............133 10.1. Overview ............................133 10.2. Safety information ........................133 10.3. Overview of serialized power components ..............135 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 5/272...
Page 6 Training for maintenance and repair personnel ..........136 10.4.2.1. Service training....................136 10.4.3. List of PCS6000 components > 25 kg ..............136 10.5. Preparation of cooling liquid circuit before replacing components ......138 10.5.1. Releasing the over pressure from the cooling liquid circuit ..........................
Page 7 10.13.5. Replacing fan of GBU fan drawer................265 10.14. Replacing fans in miscellaneous units ................268 10.14.1. Replacing door fan with heater................268 10.14.2. Replacing roof fan and air filter mats..............269 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 7/272...
Page 9 Figure 4–1 Bolt connections, checking the tightening torque markings ....52 Figure 4–2 ASM10 ......................58 Figure 4–3 Insulation measurements PCS6000 Converter 1CL with PCM ....64 Figure 4–4 Insulation measurements PCS6000 Converter 1CL without PCM ... 64 Figure 4–5 Insulation measurements PCS6000 Converter 2CL ........66 Figure 5–1 Key switch .......................
Page 10 Figure 9–16 Clamp resistor connections ..............130 Figure 9–17 IGCT power supply (IPS) ................132 Figure 10–1 ESD precautions ..................134 Figure 10–2 Clamping components ................140 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 10/272...
Page 11 Figure 10–33 Pressure loading gauges storage place ..........167 Figure 10–34 Gate unit fixation .................. 168 Figure 10–35 Clamp capacitors ..................169 Figure 10–36 Symmetry resistor ................... 170 Figure 10–37 Clamp resistor ................... 172 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 11/272...
Page 12 Figure 10–70 Pressure gauge and transmitter ............223 Figure 10–71 Deionizer flow meter ................224 Figure 10–72 Ion exchange vessel (right side: old version) ........225 Figure 10–73 Ion exchange vessel ................. 226 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 12/272...
Page 13 Figure 10–106 Drawer mounting screws ..............252 Figure 10–107 Corner braces ..................252 Figure 10–108 GBM push button locking device ............252 Figure 10–109 Lower front beam mounting screws ........... 253 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 13/272...
Page 14 Figure 10–140 Flap open and engaged ................ 267 Figure 10–141 Door fan with heater ................268 Figure 10–142 Roof fan ....................269 Figure 10–143 Filter fan replacement ................270 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 14/272...
Page 15 Table 9–3 Input and output voltages of IPS ..................132 Table 9–4 IPS analysis..........................132 Table 10–1 Serialized power components ...................135 Table 10–2 Standard tightening torques for bolted connections..........136 Table 10–3 List of components > 25kg of PCS6000 product family ..........137 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 17: About This Manual
(eg, layout drawings, wiring diagrams, technical data, and engineering notes) in the appendices. If information is required beyond the instructions in this manual, refer the matter to ABB. 1.2. Overview This manual covers the standard PCS6000 equipment and provides information for service work.
Page 18: Contents Of This Manual
PCS6000. – Chapter 7, Checking control components, page 81 provides instructions on checking the electronic devices of the PCS6000 and an overview on the meaning of LEDs of the main circuit boards and I/O devices.
Page 19: Related Documents
3BHS600000 E87 PCS6000 Pilot commissioning report PF: review 3BHS600000 E89 PCS6000 Lockout/tagout procedure 3BHS600000 E22 PCS6000 product family WCU30 - WCU82 water cooling unit operating 3BHS317637 E40 and maintenance manual PCS6000: WCU81A IEC water cooling unit, operations and maintenance 3BHE054718 E40 manual Assemblies &...
Page 20: Target Groups And Required Qualification
IMPORTANT! Commissioning of the drive must only be performed by qualified and certified ABB personnel. 1.5.1. Handling Personnel must be skilled and experienced in unpacking and transporting heavy equipment.
Page 21: User's Responsibilities
Use of the drive outside the scope of the specifications is not permitted. Intended equipment use also implies that only spare parts recommended and approved by ABB must be used. Unauthorized modifications and constructional changes of the drive are not permitted.
Page 22: Document Conventions
Represents blinking text on a screen Symbols Symbol Description These pictograms refer to the subject matter of the text. See section 2.1.2, Safety signs, page 23. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 22/272...
Page 23: Important Safety Information
2.1.2. Safety signs Sign Description Sign Description Refer to the instruction manual. Automatic start-up warning Hazardous voltage warning Corrosive substance warning Hot surface warning Electrostatic discharge susceptibility PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 23/272...
Page 24: Product Safety Labels
For the location of the labels, see the label placement document for the drive. Figure 2–1 Product warning label examples (label placement depends on the drive) 1) Danger label 3) Caution label 2) Warning label 4) Notice label PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 24/272...
Page 25: Electrical Safety
5) In case of fire in the drive room: • Observe the established rules and regulations for fire safety • Only allow firefighters with the appropriate PPE to enter the drive room PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 25/272...
Page 26: The 7 Steps That Save Lives
IMPORTANT SAFETY INFORMATION 2.3.2. The 7 steps that save lives ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. 1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash.
Page 27 Check the earths are properly applied • Answer specific questions from the working group • Ensure the work can proceed without danger • Complete and verify the “Permit to Work” PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 27/272...
Page 28: Possible Residual Risks
Support the door with your hand when opening the locks. • Weight per door: approximately < 20 kg. 7) Generator disconnector: risk of excessive arcing due to undetected arc. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 28/272...
Page 29 • Operation time in constricted mode and idling with open disconnector must be reduced as far as possible PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 29/272...
Page 31: Service Tools
The following sections describe the special tools that are required for carrying out service on a PCS6000 drive. 3.1. Overview The following tables indicate all converter service tools required for service work on the PCS6000 with their ABB order number (SAP number). 3.1.1. Converter service tools Table 3–1 Converter service tool list Designation...
Page 32: Converter Service Tools
6HEX PIN INSERT 1/2” 12 mm WMN 400007P0212 Double fork key C 21x23 WM 420039P0023 Extension 1/2”-130 GMN 744036P0028 RATCHET 1/2Z GMN 744036P0043 Spreader tool 3BHE041414R0001 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 32/272...
Page 33: Figure 3-2 Spreading Tool (Part Of Converter Service Toolbox)
The spreading tool (see Fig. 3–2) is used to release the stacks containing semiconductors to allow replacement of semiconductors. See also section 10.6.3, Using the spreading tool, page 145. Figure 3–2 Spreading tool (part of converter service toolbox) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 33/272...
Page 34: Figure 3-3 Stabilizer Plate (Part Of Converter Service Toolbox)
Figure 3–3 Stabilizer plate (part of converter service toolbox) The FADEC 3 is a test device to find defective semiconductor in the stack. See chapter 9, Checking diodes, IGCTs and IPS, page 115 and the “PCS6000 user manual”, 3BHS600000 E40.
Page 35: Grounding Kit
PE connection), a connection pole and a bag. The grounding kit is used to ground the converter before any service or maintenance work on the converter is done. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 35/272...
Page 36: Tube Cutter
2. Insert the tube into the Legris adapter as far as it will go. 3. Make sure that there is no mechanical stress on the tube, especially not from sideways. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 36/272...
Page 37: Polishing Kit For Fiber Optics
The polishing kit for fiber optics is used to prepare and polish plastic fiber optical cables from Avago. These fiber optic cables are used in the converter for the control system. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 37/272...
Page 38: Commissioning Tools
The digital internal signals are converted to analog signals and sent to the oscilloscope by the RCI-Box. The signals to be monitored can be freely selected in the PCS6000 HMI. A maximum of 8 channels can be monitored simultaneously with one RCI.Box.
Page 39: Pcs6000 Hmi
SERVICE TOOLS 3.3.2. PCS6000 HMI The PCS6000 HMI is used for monitoring/controlling of the converter during commissioning and service. It will be installed locally on the IPC (Industrial PC) in the converter. Access is obtained remotely using the remote desktop protocol.
Page 40: Filling Kit For Pcs6000 Water Cooling
– Input: 1x 220 - 240 V AC 50Hz The filling kit for PCS6000 water cooling is used to fill the water cooling system with cooling liquid. It consists of a pump with one hose to connect to the converter (with connection) and one to the water source.
Page 41: Filling Kit Extension Tube
– Weight: 0.25 kg/m – Outer diameter: 22 mm If the tube of the filling kit for PCS6000 water cooling is not sufficient, ie, if the distance between the converter and the water source is bigger than 2 meters, an extension tube is available.
Page 42: Base Beam Lifting Jack
The use of the base beam lifting jack is shown in Fig. 10–80 “Use of chain-block to lift out pump” on page 231. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 42/272...
Page 43: Chain-Block
It has to be used together with a base beam lifting jack (see section 3.4.2, Base beam lifting jack, page 42). The use of the chain-block is shown for example in Fig. 10–80. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 43/272...
Page 44: Pump Maintenance Table Kit (Only For Swedewater Wcu)
Please note that the pump maintenance table kit can only be used with converters delivered after 1st January 2013. For converters delivered before that date this table can only be used partly (if the corresponding mounting holes are available). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 44/272...
Page 45: Generator Breaker Replacement Kit
With the trolley the generator breaker can be pulled out of the cabinet. The trolley can also be used for transportation of material. The use of the generator breaker replacement kit is shown for example in Fig. 10–125. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 45/272...
Page 47: Preventive Maintenance
High voltage! The PCS6000 is a medium voltage high power device. ▶ High voltage in the PCS6000 can result in serious injury or DEATH and damage to the equipment. ▶ Parts replacement and other work on the PCS6000 must only be carried out by qualified personnel in compliance with local regulations.
Page 48: General Directives
▶ Observing the maintenance schedule can prevent system malfunctions. ABB is not liable for defects as a result of neglecting preventive maintenance work. ▶ To maintain safe and reliable operation of the PCS6000, ABB recommends taking out a service contract with the local ABB service organization. For more information contact your local service representative.
Page 49: Preventive Maintenance Schedule
2. Check the components listed in Table 4–1. While doing so, pay particular attention to deformations or discolorations, eg, due to thermal stress. 3. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 50: Table 4-1 Visual Inspection
– Condition of the screw connections (visual inspection of the tightening torque markings, see Fig. 4–1) – Fiber-optic connections not bent – Fit of screw joints Ground connections – Yellow/green markings (completeness) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 50/272...
Page 51 – Traces of water leakage Water cooling system, pumps – Vibration noises (pumps) – Water temperature and pressure in the system and in the expansion vessel PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 51/272...
Page 52: Checking Semiconductor Stack Tightness
10.6.7, Tightening the stacks, page 166. 4.4.2.2. Checking bolt connections Effort 0 - 2 h 1. If not already done for other inspection purposes, shut-down the PCS6000 according to “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Check tightness of power conductor bolt connections: •...
Page 53: Cleaning
3. If necessary, clean the components with a dry cloth. 4. Clean all air inlets and outlets of the cabinets. 5. Clean the air inlets and outlets on all door and roof fans. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 54: Replacing Components
PCS6000 according to “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22 Switch off the corresponding MCB (see electrical diagram) before replacing the component. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. Table 4–2 Replacement procedures...
Page 55 Unit Component Replacement procedure Door air filter mats Unclip filter mat holder and replace filter mat with original ABB filter mat. Roof fan and roof fan See section 10.14.2, Replacing roof fan and air filter filter mats mats, page 269.
Page 56: Dc-Link Performance Check
HMI. IMPORTANT! The measurement results are compared to the nominal values in the “PCS6000 Preventive maintenance report”, 3BHS600000 E84. The deviation of the measured values from the nominal values is grouped in 3 categories: – OK: The measurement result is in the expected range.
Page 57: Dc-Link Component Check
6. Record the discharge time in the Preventive Maintenance Report. 7. If the converter is a 2CL system, repeat the test with the second conversation line. 8. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 58: Figure 4-2 Asm10
NOTE – If the tightening torque is not specified on the capacitor, use tightening torque defined under section 10.4.1, Correct tightening torques of bolted connections, page 135. 9. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 59: Filter Components Performance Check
61) 4.4.7.1. Grid side filter components performance check 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Double check that the DC-link is grounded (ground switch) and the grid side is grounded (grounding kit).
Page 60 5. Measure the capacitance between -X541/2:3 and -X541/2:4 (12 capacitors parallel, when grid side grounded). 1) -X541/2:3 2) -X541/2:4 6. Reconnect the removed connection. 7. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 61: Neutral Point Performance Check
8. Measure the resistance of -R463 between -R464:1 and -R464:2 9. Reconnect the removed connections. 10. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 4.4.7.3. dv/dt filter components performance check 1.
Page 62: Functionality And Security Procedure
Maintenance Report. This test procedure is used to verify the proper functionality of the Uninterruptible Power Supply (UPS). 10. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 63: Grb Opening Time Verification
The response time of the Grid Breaker (GRB) has to be checked according to the manufacturer's specifications (responsibility of customer). For the ABB converter, the GRB opening time has to be less than the specified limit in the Preventive Maintenance Report.
Page 64: Figure 4-3 Insulation Measurements Pcs6000 Converter 1Cl With Pcm
7. Verify that the measured circuit is discharged 8. Close the ground switch 9. Reconnect all components 10. Remove all temporary bridges 11. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 65: Insulation Measurement 2Cl
5000) is required to perform the insulation measurements. The water conductivity must be lower than 0.5 µs/cm during the insulation measurements. 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Visually check that the LEM current transducer cables do not touch the medium voltage busbars.
Page 66: Gdm Performance Check
8. Close the ground switch. 9. Reconnect all components. 10. Remove all temporary bridges 11. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 4.4.12. GDM performance check Effort 0 - 2 h 1.
Page 67: Braking Resistor Performance Check
PREVENTIVE MAINTENANCE 9. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 4.4.13. Braking resistor performance check Effort 0 - 2 h The braking resistor check has be done as described below.
Page 68 6. Reconnect the wires/busbars from the converter with the marked tightening torque. If the tightening torque is not specified use tightening torque defined in section 10.4.1, Correct tightening torques of bolted connections, page 135. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 69: Energizing, Grounding And Start-Up
High voltage! The PCS6000 is a medium voltage high power device. ▶ High voltage in the PCS6000 can result in serious injury or DEATH and damage to the equipment. ▶ Parts replacement and other work on the PCS6000 must only be carried out by qualified personnel in compliance with local regulations.
Page 70: Lockout/Tagout
Service MTTR 0 - 2 h DANGER High voltage! ▶ DO NOT access the power sections of the PCS6000 before the converter is completely disconnected and grounded. ▶ Before the internals of the PCS6000 are accessed for service purposes, the relevant components of the converter must be de-energized safely.
Page 71: Figure 5-1 Key Switch
Figure 5–2 DC-link grounding isolator in position “not grounded” 12. Check the status supervision signal lamps (GRB closed, DC-link grounding isolator closed/released) located at the front of the PCS6000. All three yellow signal lamps must be off to get the ready to start converter.(With old grounding isolator setup grounding isolator is still released) 13.
Page 72 16. The PCS6000 can only be started if all faults are eliminated. The PCS6000 is now in status OFF and ready to be started via the customer's HMI system (see application specific information in Appendix A04 Operation & Interface Documents, 01 Function Description and Control Interface).
Page 73: Troubleshooting
6.1. General The following sections provide instructions on how to replace control components and are intended for qualified personnel who are responsible for servicing a PCS6000 drive. 6.2. Safety information Before you begin, read and understand the material in chapter 2, Important safety information, page 23 and always follow the safety rules that are described in section 2.3.2, The 7 steps that save lives, page 26.
Page 74 ▶ Observing the maintenance schedule can prevent system malfunctions. ▶ ABB is not liable for defects as a result of neglecting preventive maintenance work. ▶ To maintain safe and reliable operation of the PCS6000, ABB recommends taking out a service contract with the local ABB service organization.
Page 75: Standard Procedure For Troubleshooting
TROUBLESHOOTING 6.3. Standard procedure for troubleshooting IMPORTANT! After a temporary blocking of IGCTs, the PCS6000 attempts to reset the fault and to restart. If the restart is successful, ie, the device does not trip again within a pre-set time, the fault will be cleared automatically.
Page 76: Figure 6-2 Standard Procedure For Troubleshooting (Overview)
3) Check states of power equipment (converter, cooling system, switchgear, etc). 4) Repair or replace faulty component. Fault eliminated? Call ABB service Restart Figure 6–2 Standard procedure for troubleshooting (overview) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG.
Page 77: Figure 6-3 Commissioning Tool (Optional), Typical Window
Measured quantities, such as voltage, current, temperature, pressure and quality, statuses of switchgear. 6. If appropriate, try to restart the PCS6000 (in case of over temperature wait for cooling down first) and check if the fault occurs again. NOTICE DO NOT try to restart if the fault is related to converter hardware (eg, short...
Page 78 PCS6000 components are precision devices. Incorrect handling can result in serious injuries or DEATH and damage to the equipment. ▶ DO NOT access the power sections of the PCS6000 before the converter is completely de-energized and grounded. ▶ All repair work inside the PCS6000 must be carried out exclusively by service personnel authorized by ABB.
Page 79 “PCS6000 Local control panel description”, 3BHS606571 E49. 10. Check if the fault occurs again. If the reason for the failure is unclear or the problem cannot be solved, contact the ABB service representative! For efficient troubleshooting, have the following data available when calling the ABB service representative: •...
Page 81: Checking Control Components
CHECKING CONTROL COMPONENTS 7. Checking control components 7.1. General The following sections provide instructions on checking the electronic devices of the PCS6000 and an overview on the meaning of LEDs of the main circuit boards and I/O devices. 7.2. Safety information DANGER...
Page 82: Leds On Ac 800Pec
LED on: normal state LED off: PowerLink not available LED 5 Yellow T(ransmission) LED flashing: PowerLink available LED off: watchdog error LED 6 Yellow A(ctivity) LED flashing: normal state PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 82/272...
Page 83: Leds On Pecintm
LED flashing: in test mode and only one LED 4 Green TOF (test offset) channel in offset test range LED on: in test mode and both channels in offset test range PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 83/272...
Page 84: Leds On Ups
LED on: output fed from battery Bat.-Charge LED flashing: battery charging LED off: power supply out of range LED 3 Green Power In LED on: power is on PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 84/272...
Page 85: Replacing Control Components
8.1. General The following sections provide instructions on how to replace control components and are intended for qualified personnel who are responsible for servicing a PCS6000 drive. 8.2. Safety information Before you begin, read and understand the material in chapter 2, Important safety information, page 23 and always follow the safety rules that are described in section 2.3.2, The 7 steps that save lives, page 26.
Page 86: Overview Of Replaceable Control Components
If the component was replaced in the field the serialization database should be updated, ie, the new serial number has to be reported to ABB by means of a warranty and failure report. For a complete list of serialized parts refer to the list of serialized assemblies and components (3BHE600000 E70).
Page 87: Replaceable Control Components In Ccu
QUINT-DC-UPS/24DC/ 3BHB056371P0040 Set time and battery dial according to electrical drawings Battery QUINT-BAT/24DC/3.4Ah 3BHB056372R0003 Voltage UUD148AE01 3BHE014185R0001 Set jumpers Transducer according to electrical drawings PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 87/272...
Page 88: Replaceable Control Components In Pou
Table 8–3 FIU control components replaceable by customer Component name Product number SAP number Serialized Special tasks in case of replacement AC/DC Converter QUINT-PS/1AC/ 3BHE016113R0110 Set voltage 24DC/10 according to electrical drawings PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 88/272...
Page 89: Replaceable Control Components In Dlu
Table 8–5 DRU control components replaceable by customer Component name Product number SAP number Serialized Special tasks in case of replacement 12-Pulse Firing DDC779BE02 3BHE037945R0001 Board UF C765 AE102 3BHE003604R0102 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 89/272...
Page 90: Replacing Ac 800Pec
Service MTTR 0 - 2 h Figure 8–1 AC 800PEC 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off MCB -Q306 to interrupt the 3AC 400 V input voltages of the AC/DC converter (24 V power supply).
Page 91: Figure 8-3 Removing A Ac 800Pec Module
Contact ABB Service for further instructions. 13. Check the LEDs for any possible errors according to section 7.4.1, LEDs on AC 800PEC, page 82. 14. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 92: Replacing Combi Io
8. Check the LEDs for any possible errors according to section 7.4.2, LEDs on Combi IO, page 82. 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. NOTE – Depending on the replaced board it might be necessary to update the software.
Page 93: Replacing S800 I/O Modules
5) DO820 3) Connection base TU810V1 6) Connection base TU811 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off MCB -Q306 to interrupt the 3AC 400 V input voltages of the AC/DC converter (24 V power supply).
Page 94: Figure 8-6 S800 I/O Module
2) I/O module 8. Engage the locking knob (see Fig. 8–6). 9. Switch on MCB -Q306. 10. Check the new module for correct functioning. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 95: Replacing Voltage (Ae01) And Current (Ae02) Transducer Boards
Figure 8–8 Voltage and current transducer boards UUD 148 AE01/2 1) Voltage board 2) Current transducer board 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off MCB -Q306 to interrupt the 3AC 400 V input voltages of the AC/DC converter (24 V power supply).
Page 96: Figure 8-9 Short-Circuit Of Current Transducer
9. Remove the short-circuits from the current measurement inputs on -X900. 10. Power up the transducer board by switching on MCB -Q306. 11. Check the new module for correct functioning. 12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 97: Replacing Pecintm
Service MTTR 2 - 4 h Figure 8–10 PECINTM PC D237 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off MCB -Q401 to interrupt the 3AC 400 V input voltages of the AC/DC converter (24 V power supply).
Page 98 7. Power up the module by switching on MCB -Q401. 8. Check the LEDs for any possible errors according to section 7.4.3, LEDs on PECINTM, page 83. 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 99: Replacing Ips
6. Reconnect all plugs and power up the module by switching on MCB -Q401. 7. Check the new module for correct functioning according to section 9.10, Checking IPS, page 132. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 100: Replacing Hvd
5. Replace the detached board with a spare one. 6. Reconnect all cables and power up the board by switching on MCB -Q401. 7. Check the new module for correct functioning. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 101: Replacing Vlscd
8. Apply a variable DC-voltage (0 to 15 V) between B1 and B2. Below 12.9 V the LED must be dark and above 14.0 V the LED must be alight. 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 102: Replacing Ase
9. Power up the module by switching on MCB -Q401. 10. Check the LEDs for any possible errors according to section 7.4.4, LEDs on ASE2 board, page 83. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 103: Replacing Ac/Dc Converter
11. Make sure the LED “DC OK” is lit. 12. Measure the output voltage with a multimeter and adjust the voltage dial if it's not 24 V. 13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 104: Replacing Ac/Dc Converter -G501 In Fiu
9. Make sure the LED “DC OK” is lit. 10. Measure the output voltage with a multimeter and adjust the voltage dial if it's not 24 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 105: Replacing Dc/Dc Converter
11. Make sure the LED “DC OK” is lit. 12. Measure the output voltages with a multimeter and adjust the voltage dial if it's not 24 V and 48 V, respectively. 13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 106: Replacing Ups
MCB -Q306 (CCU) or -Q401 (POU). 11. Check the LEDs for any possible errors according to Table 7–5 in “section 7.4.5, LEDs on UPS, page 84. 12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 107: Replacing Ups -G502 In Fiu
7. Reconnect all plugs and power up the module by switching on MCB -Q503. 8. Check the LEDs for any possible errors according to section 7.4.5, LEDs on UPS, page 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 108: Replacing Batteries
IMPORTANT! Normally the PCS6000 should be shut-down for replacing the battery as described below. With special care the battery may be replaced while the PCS6000 is in operation (24 V power supply on). Then only carry out points 4 to 8.
Page 109: Replacing Battery -G403 In Pou
8. Mount new battery and reconnect the battery connection wires to the UPS (Battery +/- terminals). 9. Reinsert the car-fuse. 10. Switch on MCB -Q306. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 8.17.2. Replacing battery -G403 in POU Service MTTR 0 - 2 h The delivered replacement batteries are already charged.
Page 110: Replacing Battery In Ups -G502 In Fiu
8. Mount new battery and reconnect the battery connection wires to the UPS (Battery +/- terminals). 9. Reinsert the car-fuses. 10. Switch on MCB -Q401. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 8.17.3. Replacing battery in UPS -G502 in FIU Service MTTR 0 - 2 h The battery is built into the UPS -G502.
Page 111: Replacing Fiber Optic Cables
▶ ABB provides kits to prepare the fiber optic cables to correct length. These kits also contain a tool to polish the fiber optic cables (see section 3.2.4, Polishing kit for fiber optics, page 37).
Page 112 Replace the polishing fixture when any dot is no longer visible. 8. Place the 600 grit abrasive paper on a flat surface and press the polishing tool down on PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 112/272...
Page 113 12. Repeat this procedure for the other end of the fiber optic cable. 13. Replace the fiber optic cables with the newly assembled cables. 14. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 115: Checking Diodes, Igcts And Ips
2.3.2, The 7 steps that save lives, page 26. DANGER High voltage! Dangerous voltage inside the PCS6000 can lead to life-threatening situations, injury of the persons involved or damage to equipment. ▶ When planning and carrying out maintenance work, the operating condition of the whole system should be considered.
Page 116: Fault Identification In Triple Stack (Pom)
9.3. Fault Identification in triple stack (POM) DANGER High voltage! ▶ DO NOT access the power sections of the PCS6000 before the converter is completely disconnected and grounded. The service work described in the following chapter always has to be done after a firing through of the converter.
Page 117: Location Of Components
CHECKING DIODES, IGCTS AND IPS 9.4. Location of components -V34G -V33G -V32G -V31G -V24G -V23G -V22G -V21G -V14G -V13G -V12G -V11G Figure 9–1 IGCT stack PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 117/272...
Page 118: Freewheeling Diode Stack
CHECKING DIODES, IGCTS AND IPS 9.4.1. Freewheeling diode stack -V34D -V33D -V32D -V31D -V24D -V23D -V22D -V21D -V14D -V13D -V12D -V11D Figure 9–2 Freewheeling diode stack PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 118/272...
Page 119: Neutral Point And Clamp Diode Stack
9.4.2. Neutral point and clamp diode stack -V32C -V32N -V31N -V31C -V22C -V22N -V21N -V21C -V12C -V12N -V11N -V11C Figure 9–3 Neutral point and clamp diode stack PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 119/272...
Page 120: Clamp Capacitors And Symmetry Resistors
CHECKING DIODES, IGCTS AND IPS 9.4.3. Clamp capacitors and symmetry resistors -C32 -C31 -C22 -C21 -C12 -C11 Figure 9–4 Clamp capacitors and symmetry resistors PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 120/272...
Page 121: Semiconductor Checking Sequence
4. Measure IGCTs Figure 9–5 Semiconductor orientation (A) Module top view with phase (C) IGCT stack connections (D) Freewheeling diode stack (B) Neutral point and clamp diode stack PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 121/272...
Page 122: Checking Igcts With Fadec 3
This means, before checking the LEDs, the fault must be reset. IMPORTANT! Before resetting the alarm, “PCS6000 HMI” must be checked for any additional trips or alarms. Any trips or alarms need to be noted down before resetting The yellow LED indicates the state of the internal voltage controller (20 VDC) and the green LED gives information about the state of the gate-cathode circuit of the IGCT.
Page 123: Checking Power Diodes With Fadec 3
Figure 9–7 FADEC 3 Indication of defective semiconductor 9.7. Checking power diodes with FADEC 3 9.7.1. Preparation for checking power diodes 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. All semiconductor stacks are tightened.
Page 124: Checking Freewheeling Diodes
IMPORTANT! Pay attention to the correct polarity of the diode and the probes. The plus probe must always be connected to the anode (1) of the diode and not the cathode (2). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 124/272...
Page 125: Checking Clamp Diodes
IMPORTANT! Pay attention to the correct polarity of the diode and the probes. The plus probe must always be connected to the anode (1) of the diode and not the cathode (2). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 125/272...
Page 126: Checking Neutral Point (Np) Diodes
IMPORTANT! Pay attention to the correct polarity of the diode and the probes. The plus probe must always be connected to the anode (1) of the diode and not the cathode (2). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 126/272...
Page 127: Checking Igcts With Multimeter (If A Fadec 3 Is Unavailable)
This means, before checking the LEDs, the fault must be reset. IMPORTANT! Before resetting the alarm, “PCS6000 HMI” has to be checked for any additional trips or alarms. Any trips or alarms need to be noted down before resetting.
Page 128: Figure 9-14 Correct Measuring Between Gate And Cathode
7. If the voltage value is below 20 V (or different from the other IGCTs) the IGCT needs to be replaced according to section 10.6.4, Replacing IGCTs, page 149. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 128/272...
Page 129: Checking Power Diodes With Multimeter
9.9. Checking power diodes with multimeter A multimeter is used to locate faulty diodes. 9.9.1. Preparation for checking power diodes 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. All semiconductor stacks are tightened. 3. All broken IGCTs have been replaced.
Page 130: Checking Clamp Diodes
Normally, only one diode is defective and the voltage should be lower than across all others. If the multimeter shows a different value, the diode needs to be replaced according to section 10.6.5.2, Replacing clamp diodes, page 155. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 130/272...
Page 131: Checking Neutral Point (Np) Diodes
0.22 V, check and replace the diodes connected in parallel first, before doubting the quality of the new diode. In the worst case, all three diodes have to be replaced to find the faulty one. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 131/272...
Page 132: Checking Ips
Disconnect output plugs Dark < 20 VDC Disconnected Check power supply If the IPS is not OK, replace it according to section 8.9, Replacing IPS, page 99. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 132/272...
Page 133: Replacing Power And Cooling Components
10.1. Overview The following sections provide instructions on how to repair defective parts and are intended for qualified personnel who are responsible for servicing a PCS6000 drive. 10.2. Safety information Before you begin, read and understand the material in chapter 2, Important safety information, page 23 and always follow the safety rules that are described in section 2.3.2, The 7 steps that save lives, page 26.
Page 134: Figure 10-1 Esd Precautions
▶ Hold a board only at the edge. ▶ Handle a faulty board as carefully as a new one ▶ ABB strongly recommended to install a cover (plastic, cardboard, etc.) below the components to be removed before starting replacement work. This cover will catch dropped parts as screws, washers, screw nuts, etc.
Page 135: Overview Of Serialized Power Components
If one of these components were replaced in the field the serialization database shall be updated, ie, the new serial number has to be reported to ABB. For a complete list of serialized parts, see “Assemblies & components PCS6000 product family with serialization profile”, 3BHE600000 E70.
Page 136: Capacitors
▶ ABB recommends periodical training for the maintenance and repair personnel. 10.4.2.1. Service training Maintenance and service training courses are offered by ABB on request. Customer staff having successfully attended such courses, will be certified to do maintenance and repair work on the PCS6000 after the warranty period.
Page 137: Table 10-3 List Of Components > 25Kg Of Pcs6000 Product Family
REPLACING POWER AND COOLING COMPONENTS Table 10–3 List of components > 25kg of PCS6000 product family Material Name of material Weight Dimensions (mm) (kg) 3BHE034815R0001 BRM Braking Resistor Module 74.00 1000 x 330 x 236 3R0 Widap 3BHE034908R0001 BRU50 Braking Resistor Unit 200.00...
Page 138: Preparation Of Cooling Liquid Circuit Before Replacing Components
REPLACING POWER AND COOLING COMPONENTS Table 10–3 List of components > 25kg of PCS6000 product family (continued) Material Name of material Weight Dimensions (mm) (kg) 3BHE045468R0001 Wilo Pump (Helix) 520l/min 3AC400V 84.00 320 x 296 x 1177 7.5kW 3BHE045481R0001 Wilo Pump (Helix) 580l/min 3AC400V 146.00...
Page 139: Emptying The Cooling Liquid Circuit
3, Service tools, page 31). To ensure sufficient cooling, each stack is clamped with a specified clamping force. To exchange semiconductors, the clamping force must be released. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 139/272...
Page 140: General Procedure To Replace Power Semiconductors
1. Discharge the DC-link, earth all power connections at the foreseen positions and check the converter for residual voltage before doing any other work on the converter. 2. Check the computer screen in “PCS6000 HMI” to find out which phase module has initiated the failure.
Page 141: Releasing The Stacks
(see Fig. 10–4). Otherwise the tension jacks can break. 50x50 L375 50x50 L375 Figure 10–3 Pressure loading gauges 1) Pressure loading gauge in storage place 2) Pressure loading gauges placed under tension jacks PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 141/272...
Page 142: Figure 10-4 Pressure Loading Gauges Inserted
Allen wrench to make sure that the gate unit fixation can move freely in vertical direction. Figure 10–5 Gate unit fixation 1) Gate unit fixation 2) Fixation screw PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 142/272...
Page 143: Figure 10-6 Order Of Loosening The Clamping Screws
1)Neutral point and clamp diode stack 2)Freewheeling diode stack 3)IGCT stack The clamping screws must be unbolted until they reach above the pressure plate (see Fig. 10–2). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 143/272...
Page 144: Figure 10-7 Stabilizer Plate Insertion
6. Enter a stabilizer plate in the bottom of the stack where a semiconductor needs to be exchanged as shown in Fig. 10–7. Figure 10–7 Stabilizer plate insertion 1) Stabilizer PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 144/272...
Page 145: Using The Spreading Tool
Procedure: 1. Insert the spreading tool completely into the slots of the coolers (heat sink) above and below the faulty semiconductor as shown in Fig. 10–9. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 145/272...
Page 146: Figure 10-9 Spreading Tool Insertion
Figure 10–10 Spreading tool expansion 1) Heat sink – For replacing the neutral point diodes the spreading tool must be applied over three heat sinks (see Fig. 10–11). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 146/272...
Page 147: Figure 10-11 Spreading Tool Applied Over Three Heat Sinks
Figure 10–11 Spreading tool applied over three heat sinks IMPORTANT! The spreading tool must not be spread too far; the gear wheels must grip into each other at least 3 mm. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 147/272...
Page 148: Figure 10-12 Spreading Tool Use Example
Fig. 10–12 shows an example of the use of the spreading tool, inserted in the IGCT stack. Turning the wrench clockwise would open the stack. Figure 10–12 Spreading tool use example PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 148/272...
Page 149: Replacing Igcts
Figure 10–14 Removing the gate unit fixations of the IGCT 1) Gate unit fixation 3) Mounting screw 2) Fixation screw (has been loosened prior to releasing stacks) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 149/272...
Page 150: Figure 10-15 Extracting The Igct
NOTICE Hold the IGCT at the black plastic frame and support from underneath as shown in Fig. 10–16.Avoid touching the gate drive board or semiconductor. Figure 10–16 Correct handling of IGCT PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 150/272...
Page 151: Figure 10-17 Inserting The Igct
When the IGCT is correctly inserted it can be heard and felt when it snaps into position. Figure 10–17 Inserting the IGCT 1) Guiding rail 2) Positioning and stop device PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 151/272...
Page 152: Figure 10-18 Igct Components
14. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166. 15. Re-check the IGCTs as described in section 9.8, Checking IGCTs with multimeter (if a FADEC 3 is unavailable), page 127. 16. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 153: Replacing Power Diodes
NOTICE Failure to center the diode correctly can damage the diode and cause stack misalignment. Figure 10–19 Centering freewheeling and neutral point diodes 1) Heat sink 2) Centering ball PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 153/272...
Page 154: Figure 10-20 Diode Marking
10. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166. 11. Re-check the diodes according to section 9.9.2, Checking freewheeling diodes, page 129. 12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 155: Replacing Clamp Diodes
Ideally, get assistance of another person. 4. Remove the faulty diode and immediately insert the replacement diode. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 155/272...
Page 156: Figure 10-22 Centering Upper (A) And Lower (B) Clamp Diodes
11. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166. 12. Re-check the diodes according to section 9.9.3, Checking clamp diodes, page 130. 13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Page 157: Replacing Neutral Point (Np) Diodes
5. Clean the diode contact surfaces with a fluff-free cloth. – Clean heavily polluted surfaces with a cleansing agent (eg, pure alcohol). The surfaces must be free from dust, fat and oil. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 157/272...
Page 158: Figure 10-24 Centering Freewheeling And Neutral Point Diodes
10. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166. 11. Re-check the diodes according to section 9.9.4, Checking neutral point (NP) diodes, page 131. 12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 159: Checking Stacks Alignment
Figure 10–25 Example of positioning and stop device not fully inserted yet 1) Positioning and stop device 2) Guiding rails IMPORTANT! If an IGCT has not been inserted correctly, use the following procedure: PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 159/272...
Page 160 4. Visually confirm that the positioning and stop device has reached the end position up against the guiding rails. 5. Lower the stack and remove the spreading tool. 6. Remove the stabilizer plate. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 160/272...
Page 161: Diode Stack (Freewheeling / Neutral Point And Clamping)
Neutral point and clamping diode stacks: clamping capacitor busbars. 2. Visually check the vertical alignment of the heat sink slots. If the slots are not aligned, you need to realign the stack. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 161/272...
Page 162: Figure 10-27 Heat Sink With Loosened Flexible Bus Bar
1) Freewheeling diode stack, bottom disk and 3) Neutral point stack, bottom disk and centering pin centering pin 2) IGCT stack, bottom disk and centering pins PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 162/272...
Page 163: Figure 10-29 Heat Sink Moved Back Into Position
8. Tighten the M12 bolts with two 19 mm wrenches to the heat sinks according to section 10.4.1, Correct tightening torques of bolted connections, page 135. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 163/272...
Page 164: Effects Of Stack Misalignment On Semiconductors Pole Pieces
If repetitive semiconductor failures happen in a stack where similar observations as marked are made, the necessity of replacing of all semiconductors in the stack should be evaluated with ABB technical support. – Observation: All imprints of the above heat sink are centered on the pole piece of the semiconductor.
Page 165 – Possible cause: Semiconductor tighten inside an already misaligned stack (pressure distribution not nominal). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 165/272...
Page 166: Tightening The Stacks
Figure 10–31 Tightening the clamping screw 1) Tension jack 4) Pressure plate 2) Clamping screw 5) Tension jack 3) Pressure loading gauge PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 166/272...
Page 167: Figure 10-32 Adjusting Clamp Pressure Of Stack
19 mm wrench. 50x50 L375 Figure 10–33 Pressure loading gauges storage place 1) Pressure loading gauges in storage location 2) M12 fastening screw and washer PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 167/272...
Page 168: Figure 10-34 Gate Unit Fixation
4. Tighten the 24 fixation screws of the IGCT gate unit fixations using a 5 mm Allen wrench. Figure 10–34 Gate unit fixation 1) Gate unit fixation 2) Fixation screw PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 168/272...
Page 169: Replacing Clamp Capacitor
23 mm flat wrench (contained in converter service toolbox). 2. Use flat wrench from ABB toolbox to access the capacitor nut and loosen the capacitor(s). WARNING! Discharge the capacitor before touching! Make sure the replacement capacitor is not pre-charged.
Page 170: Replacing Symmetry Resistor
NOTICE Leakage of cooling liquid into the converter needs to be avoided, especially glycol, which causes severe pollution of the converter. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 170/272...
Page 171 5. Check that no hose is touching busbars or other voltage carrying parts. 6. Remove catching tray and all tools from the converter cabinet. 7. Wipe up any remnants of leaked cooling liquid. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 172: Replacing Clamp Resistor
6 small resistors (see Fig. 10–37). The replacement procedure is similar for both versions. Figure 10–37 Clamp resistor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty the water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139 (recommended since access to the hoses is quite difficult).
Page 173: Replacing Clamp Reactor
REPLACING POWER AND COOLING COMPONENTS 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 10.6.11. Replacing clamp reactor Service MTTR 2 - 4 h 1. Shut-down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.
Page 174 REPLACING POWER AND COOLING COMPONENTS 10. Reconnect all plugs. For instructions to connect the cooling tubes, see section 3.2.3, Tube cutter, page 36. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 175: Replacing Lem Current Transducer
7. Bolt the cooper bars again (40 Nm). 8. Reconnect all cables. Make sure no wire was interchanged, compare to the remaining LEM current transducers. 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 176: Replacing Dc Capacitor
10.6.13. Replacing DC capacitor Service MTTR 2 - 4 h Figure 10–40 Mounting screws of ASM in front of DC capacitor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Disconnect all system cables from ASM.
Page 177: Figure 10-41 Dc Capacitor
19 mm spanner. For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 8. Reconnect the cable. 9. Install the ASM again. 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 178: Replacing Components In Dru
2) Type 2 spreader tool To ensure sufficient cooling, each stack is clamped with a specified clamping force. To exchange semiconductors, the clamping force must be released. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 178/272...
Page 179: Releasing The Stacks
It is therefore essential that the instructions below are followed. Procedure: 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Insert the clamp pressure loading spanner (see B in Fig. 10–43).
Page 180: Centering Misaligned Stacks
8. 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. 9. Reconnect any disconnected wires. 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 10.7.3. Centering misaligned stacks In case a stack becomes misaligned, the coolers can be pushed back into place and the semiconductors can be centered using a fixture as illustrated in Fig.
Page 181: Figure 10-44 Rearranging Misaligned Stacks
Since the space is very narrow it is recommended to use a piece of wire shaped into a half moon to move the semi-conductors. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 181/272...
Page 182: Replacing Components In Dlu
4. Unbolt the 4 screws (see Fig. 10–45). 5. Replace the earth connector (weight approximately 10 kg). 6. Remove the additional grounding kit 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 183: Replacing Resistor -R462_1, -R462_2
2. Disconnect all electrical cables. 3. Unbolt the Torx screws for the resistor, which have to be replaced. 4. Replace the faulty resistor. 5. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 184: Replacing Resistor -R751 To -R754 Or Capacitor -C751 To -C752
7. Unbolt the cable between the resistor and the copper bar. 8. Remove the whole resistor-assembly and replace the faulty component. 9. Install the resistor-assembly again and reconnect all cables and hoses. 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 185: Replacing Resistor -R461
4. Remove hoses from the resistor, direct the leaking water into the catching tray and close the leak with a Legris plug. 5. Disconnect the electrical connection. 6. Replace the resistor. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 186: Replacing Capacitor -C461
23 mm flat wrench (contained in converter service toolbox). For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 3. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 187: Replacing Igcts And Diodes
5. Release the stack by loosening the clamping screw counter-clockwise using the socket wrench with 12 mm Allen socket. 6. Enter a stabilizer plate in the bottom of the stack. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 187/272...
Page 188 19 mm wrench. 13. f an IGCT has been changed, tighten all 4 fixation screws of the IGCT gate unit fixations using a 5 mm Allen wrench. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 188/272...
Page 189: Replacing Vlm
CAUTION! The VLM weights approximately 60 kg. Single person lift could cause injury. Use assistance when lifting and moving. 8. Unbolt the VLM with the four screws (see Fig. 10–51) from the frame. 9. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 190: Replacing Pre-Charging Transformer
(see Fig. 10–52). 6. Rebuild the DLU in reverse order. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 191: Replacing Dv/Dt Filter Reactor In Dlu
10.8.9. Replacing dv/dt filter reactor in DLU Service MTTR 4 - 8 h Figure 10–53 dv/dt filter reactor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 192: Figure 10-54 Dv/Dt Filter Reactor Mounting Bolts (Different Vfm Variants)
Figure 10–54 dv/dt filter reactor mounting bolts (different VFM variants) NOTE – 2 bolts in front and 2 bolts on back of the reactor. 5. Replace the faulty dv/dt filter reactor. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 193: Replacing Dv/Dt Filter Resistor In Dlu
4. Disconnect water pipes and cables. 5. Remove the cable ties. 6. Replace the dv/dt filter resistor. 7. Reconnect water pipes and cables. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 194: Replacing Dv/Dt Filter Capacitor In Dlu
NOTE – For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 5. Reconnect cables. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 195: Replacing Grid/Generator Disconnector Module In Dlu
1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Disconnect all electrical cables.
Page 196 REPLACING POWER AND COOLING COMPONENTS 4. Remove the upper aluminum bracket above the capacitors. 5. Loosen the electrical connection between the resistors and capacitor. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 196/272...
Page 197 REPLACING POWER AND COOLING COMPONENTS PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 197/272...
Page 198 CAUTION! The capacitor bank weighs approximately 30 kg. 7. Remove the HV cables on the right side of the converter which are connected to the Pfisterer plugs. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 198/272...
Page 199 11. Disconnect the ground (1) in front of the GDM and remove the insulated bar by loosening the mounting screws on the left (2) and the right (3) side of the GDM. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 199/272...
Page 200 13. Disconnect the cables between the dv/dt filter and the main copper bars (on busbar side). 14. Disconnect the ground cable positioned in the left corner at the back of the DLU. 15. Unscrew the roof part above the GDM. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 200/272...
Page 201 NOTICE Ensure that the position of the tension belt matches with the center of gravity so that the GDM can be craned straight up and down. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 201/272...
Page 202 20. Crane the GDM carefully through the door. NOTICE ABB recommends that two people lift the GDM. Be careful that it doesn't hit the water cooled resistors. Also be careful with the relays on the left side of the GDM.
Page 203: Replacing Components In Vfu
2) Framework for chain block 5) Front door location 3) GDM2 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Remove grounding cables shown in the figure below. 3. Remove the insulated bar in front of the GDM1 by loosening the four mounting bolts positioned on the left and right side of the GDM1 aluminum frame.
Page 204 5. Remove the screws which connect the GDM1 to the copper bars. 6. Remove the HV-cables on the dv/dt reactors and position them in a way that the GDM1 can be pulled out easily. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 204/272...
Page 205 NOTICE While removing this roof segment, do not pull on the roof fan itself. 13. Remove the screws and afterwards the cover plate above GDM1 14. Unscrew the overlapping plate between VFU and WCU. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 205/272...
Page 206 17. Remove the roof cover above GDM2. 18. Remove grounding cables on the copper bar between GDM1 and GDM2 as well as the insulated bar by loosening the mounting bolts. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 206/272...
Page 207: Figure 10-58 Gdm1 Mounting Screws And Aluminum Plate
20. Remove the grounding cable from the Insulated bar which is located between GDM1 and GDM2. 21. Pull the GMD1 with the Plexiglas housing to the front. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 207/272...
Page 208: Figure 10-59 Gdm1 With Framework For Chain Block
22. Remove the Plexiglas housing. 23. Install the framework and the chain block above the GMD1. Figure 10–59 GDM1 with framework for chain block 1) Chain block 2) Framework PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 208/272...
Page 209 CAUTION! Two people are required, one to operate the chain block and one to move the GDM1. 27. Replace the GDM1. 28. Rebuild the DLU in reverse order. 29. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 210: Replacing Grid/Generator Disconnector Module (Gdm2) At The Back Of The Vfu
2) Framework for chain block 5) Front door location 3) GDM2 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Follow the procedure of section 10.9.1, Replacing grid/generator disconnector module (GDM1) at the front of the VFU, page 203.
Page 211 4. Remove the HV cables and position them in a way that the GDM can easily be pulled out and open the green cable holder on the left side. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 211/272...
Page 212 (GDM1) at the front of the VFU, page 203. 8. Replace the GDM2. 9. Rebuild the VFU in reverse order. 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 213: Replacing Dv/Dt Filter Reactor At The Front Of The Vfu (Vfm1)
1) VFM2 3) Front (door location) 2) VFM1 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 214: Figure 10-62 Dv/Dt Filter Reactor Mounting Screws (Different Vfm Variants)
(See section 10.4.1, Correct tightening torques of bolted connections, page 135). It also has to be ensured that the washer rest flat on the copper busbars. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 215: Replacing Dv/Dt Filter Reactor At The Back Of The Vfu (Vfm2)
1) VFM2 3) Front (door location) 2) VFM1 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 216 Note: 2 screws in front and 2 screws on back of the reactor. 7. Replace the faulty dv/dt filter reactor. 8. Reconnect pipes, busbars and power cables. 9. Reassemble the dv/dt filter in the front. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 216/272...
Page 217: Replacing Dv/Dt Filter Resistor In Vfu
10.9.5. Replacing dv/dt filter resistor in VFU Service MTTR 0 - 2 h Figure 10–64 dv/dt filter resistors 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 218: Figure 10-65 Position Of Mounting Screws Dv/Dt Filter Resistors
7. Replace the dv/dt filter resistor. 8. Add new cable ties. 9. Mount the resistor together with its backplane. 10. Reconnect water pipes and cables. 11. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 219: Replacing Dv/Dt Filter Capacitor In Vfu
(contained in converter service toolbox). For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 5. Reconnect cables. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 220: Replacing Components In Wcu (Swedewater)
Service MTTR 4 - 8 h Figure 10–67 Conductivity meter 1) Coupling ring 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 221: Figure 10-68 Conductivity Meter
4. Turn coupling ring below the meter clockwise (looking from top) to open. Figure 10–68 Conductivity meter 5. Replace the conductivity meter. 6. Tighten coupling ring below the meter in anti-clockwise direction. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 222: Replacing Inlet Water Temperature Meter
IMPORTANT! Pocket type sensor, water circuit has not been touched. 2. Remove 2 radial screws. 3. Replace measuring head and check that the sensor wires are covered with heat conducting paste. 4. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 223: Replacing Pressure Gauge And Pressure Transmitter
Use a sealing paste (Loctite 278 or similar product) and apply according to the manufacturer's technical information. 4. Open the valve again. 5. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 224: Replacing Deionizer Flow Meter
3. Close valve V59. 4. Replace the deionizer flow meter. 5. Open valve V59 again. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 7. Adjust the flow valve to a flow indication of approximately 8 l/min...
Page 225: Replacing The Ion Exchange Vessel
▶ Wear protective clothing, including rubber gloves and safety goggles Figure 10–72 Ion exchange vessel (right side: old version) 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Close flow meter FI10 before and valve V59 after the ion exchange vessel.
Page 226: Figure 10-73 Ion Exchange Vessel
13. Run pump for approximately 30 minutes to flush loosen resin into the (old) water filter. 14. Replace the water filter according section 10.10.6, Replacing the water filter, page 227. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 226/272...
Page 227: Replacing The Water Filter
If you have replaced the resin vessel it is possible to flush any new resin out of the vessel. Therefore, first run the pump for 30 minutes with the new vessel before replacing the old filter. 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Close flow meter FI10 and valve V59.
Page 228: Replacing Pump
11. Turn on water supply (flow meter FI10) slowly to fill the cooling system with water. 12. Open valve V59. 13. Check for leaks before leaving installation. 14. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. 10.10.7. Replacing pump...
Page 229: Figure 10-75 Pump Support
8. Remove the 3 support bolts (see Fig. 10–75). 9. Loosen both flanges of the pump and remove bolts. Figure 10–76 Pump flange 1) Pump flange bolt PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 229/272...
Page 230: Figure 10-77 Connecting Pipes Turned Aside
January 1, 2013), the pump maintenance table can only be used after drilling these holes according to the drilling plan shown in Fig. 10–78. 26 mm 26 mm 100 mm 100 mm Figure 10–78 Drilling plan PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 230/272...
Page 231: Figure 10-79 Pump Maintenance Table With Long Legs (For Upper Pump)
17. Lift pump out of the cabinet. Figure 10–80 Use of chain-block to lift out pump 18. Replace pump and fit all back in opposite order. 19. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 232: Replacing Pump Slip Ring Sealing
1. Follow instruction in section 10.10.7, Replacing pump, page 228 (steps 1 to 10). 2. Open pump case (see Fig. 10–82). Figure 10–82 Opening pump case 3. Remove pump wheel with impact wrenches. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 232/272...
Page 233: Figure 10-83 Pump Shaft
7. Rotate pump by hand to ensure correct centering. 8. Fit all back in opposite order. 9. Pump wheel torque is 45 Nm. 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 234: Replacing The 3-Way Valve
5. Loosen the actuator and move it out of the way. 6. Open all 3 “Grinnell” flanges. 7. Replace valve and fit all back in opposite order. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 235: Replacing Expansion Vessel
10.10.10. Replacing expansion vessel Service MTTR 0 - 2 h Figure 10–86 Expansion vessel 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off 24 V DC auxiliary power. 3. Release the over pressure of the cooling system as described in section 10.5.1, Releasing the over pressure from the cooling liquid circuit, page 138.
Page 236: Figure 10-87 Expansion Vessel
9. Equalize the air pressure to zero by pressing the car tube valve on the vessel. 10. Open valve V56 and secure against closing with padlock. 11. Switch on 24 V DC auxiliary power. 12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 237: Replacing Automatic Deaeration Valve
WCU frame without removing the cables (see Fig. 10–86). 4. Open valve V51. 5. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 238: Replacing (Checking) Ball Valve ¾
1) Mounting nut 2. Tight the gland with a 14 size spanner with approximately 20 Nm. Figure 10–90 Gland from the Ball valve ¾” 1) Gland PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 238/272...
Page 239: Replacing (Checking) Ball Valve ½
A leaking valve might be fixed by following the steps below. However, if it's still dripping after tightening, then the whole valve should be replaced. 1. Turn the crank approximately 10 times ON and OFF. Figure 10–91 Ball valve ½” PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 239/272...
Page 240: Replacing Components In Wcu (Armatec)
REPLACING POWER AND COOLING COMPONENTS 10.11. Replacing components in WCU (ARMATEC) WARNING High voltage! ▶ Before the internals of the PCS6000 are accessed for service purposes, the relevant components of the converter must be de-energized safely. Service MTTR MTTR (hours)
Page 241: Replacing Components In Fiu
The FIU with FCM is the previous generation. From 2015 onward, the FIU is assembled with the FIM. Figure 10–92 FIU with FCM (left) and with FIM (right) 1) FIU with FCM 2) FIU with FIM PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 241/272...
Page 242: Replacing Hfm Filter Reactor
5. Replace the new reactor in the same position (marks), fix the mounting screws and connect all cables. 6. Install the middle beam as it was before. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 243: Replacing Hfm Filter Capacitor
–C542 –C544 Figure 10–94 HFM filter capacitor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. For -C541, first remove -C542. Likewise, for -C544 first remove -C543. 3. For -C541 and -C542. If applicable, remove the FCM.
Page 244: Figure 10-95 Fcm Removal (Circles Show Bolt Locations)
6. Remove the plate top of the capacitors. Figure 10–96 Top and bottom views of capacitor 7. Unbolt the capacitor (bottom long bolts and top short bolts). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 244/272...
Page 245: Figure 10-97 Lifting Out Capacitor
For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 12. Rebuild the filter unit by reconnecting all electrical connections and assembly all components at original position. 13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 246: Replacing Hfm Filter Resistor
4. Remove the 4 mounting screws of the base plate and remove the resistor with base plate. 5. Install new resistor with base plate and reconnect cooling hoses and cables. 6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 247: Replacing Filter Reactor
– Chain-block minimum 150 kg (3BHB032083R0001) See chapter 3, Service tools, page 31. Figure 10–99 Filter reactor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139circuit.
Page 248: Figure 10-100 Removed Filter Reactor
12. Reinstall all mechanical and electrical components in reverse order. IMPORTANT! DO NOT forget the ground connection in the back. Figure 10–101 Ground connection 13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 249: Replacing Pressure Transmitter
5. Clean any remaining Loctite from the thread and let it dry completely. 6. Install new pressure transmitter. The new part must be sealed again with “Loctite 620” or a similar product. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 250: Replacing Components In Gbu
– GEB replacement trolley GBU50/70 (3BHE040630R0001) (see chapter 3, Service tools, page 31). Procedure: 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Isolate and earth the power cable connection to the GEB/GRI. 3. Discharge GEB/GRI spring.
Page 251: Figure 10-104 Generator Breaker (Geb)
Figure 10–104 Generator breaker (GEB) Figure 10–105 Grid breaker (GRI) 1) DMC3 3) GRI plug breaker 2) -X561 rail 4) External rail -X561, fan MCB and temperature monitoring PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 251/272...
Page 252: Figure 10-106 Drawer Mounting Screws
Figure 10–108 GBM push button locking device 11. Unbolt the lower front beam mounting screws (one on each side) to allow the fan drawer to be pulled out. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 252/272...
Page 253: Figure 10-109 Lower Front Beam Mounting Screws
14. If access from the back side is possible, remove the back wall of the cabinet, if not, access to the GEB main power cable is possible underneath the GEB. If available, use a cushion to protect your head from the edges. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 253/272...
Page 254: Figure 10-112 Protection Cushion
17. Disconnect the protection earth cable on the back of the GEB base plate. NOTE – For better accessibility, you might need to remove the DMC3 / -X561 rail plate. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 254/272...
Page 255: Figure 10-115 Breaker's Protecting Earth Connection
REPLACING POWER AND COOLING COMPONENTS Figure 10–115 Breaker's protecting earth connection 18. Remove the fiber optic cable from the copper bar. Figure 10–116 Fiber optic cable PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 255/272...
Page 256: Figure 10-117 Breaker's Protecting Earth Connection
20. Install the two trolley track beam on the cabinet bottom and support the track beam outside of the cabinet securely (height ~210 mm). Figure 10–118 Trolley track beams PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 256/272...
Page 257: Figure 10-119 Support By Reactor Replacement Kit
23. Loosen the two wing nuts under the trolley and leave at least 25 mm space for adjusting the lever. Figure 10–121 Trolley with loose wing nuts PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 257/272...
Page 258: Figure 10-122 Fixing The Geb To The Lever
27. Pull the GEB out of the cabinet (take special care for the cooling hoses above the GEB!). The GEB can then be lifted by crane (with or without the trolley). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 258/272...
Page 259: Figure 10-125 Geb Pulled Out Of The Cabinet
REPLACING POWER AND COOLING COMPONENTS Figure 10–125 GEB pulled out of the cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 259/272...
Page 260: Figure 10-126 Releasing The Retaining Spring (Flap Closed)
Figure 10–126 Releasing the retaining spring (flap closed) Figure 10–127 Releasing the retaining spring (flap open) Figure 10–128 Flap open and engaged 29. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 261: Replacing Dv/Dt Filter Reactor In Gbu
▶ Use lifting aids and proper lifting technique when lifting and moving. Figure 10–129 dv/dt filter reactor 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Empty water circuit of the cooling system according to section 10.5.2, Emptying the cooling liquid circuit, page 139.
Page 262: Figure 10-130 Dv/Dt Filter Reactor Mounting Bolts
NOTE – 2 screws in front and 2 screws on back of the reactor. 6. Replace the faulty dv/dt filter reactor. 7. Remove the wooden beams. 8. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 263: Replacing Dv/Dt Filter Resistor In Gbu
3. Disconnect water pipes and cables. 4. Remove the cable ties. 5. Replace the dv/dt filter resistor. 6. Reconnect water pipes and cables. 7. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 264: Replacing Dv/Dt Filter Capacitor In Gbu
(contained in converter service toolbox). For maximum tightening torques refer to section 10.4.1, Correct tightening torques of bolted connections, page 135. 4. Reconnect cables. 5. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 265: Replacing Fan Of Gbu Fan Drawer
10.13.5. Replacing fan of GBU fan drawer Service MTTR 0 - 2 h Figure 10–133 Fan of GBU fan drawer 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Disconnect the fan power supply plugs from the generator breaker (GEB).
Page 266: Figure 10-135 Lower Front Beam Mounting Screws
8. Reassemble in reverse order. IMPORTANT! The explosion protection flap of the fan drawer must be open and held by the retention spring after the drawer has been reinserted. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 Service manual 3BHS600000 E80 266/272...
Page 267: Figure 10-138 Releasing The Retaining Spring (Flap Closed)
(see Fig. 10–128). Figure 10–139 Releasing the retaining spring (flap open) Figure 10–140 Flap open and engaged 10. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 268: Replacing Fans In Miscellaneous Units
10.14.1. Replacing door fan with heater Service MTTR 0 - 2 h Figure 10–141 Door fan with heater 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off corresponding MCB (see electrical circuit diagram) to interrupt the 3AC 400 V fan supply voltages.
Page 269: Replacing Roof Fan And Air Filter Mats
Service MTTR 0 - 2 h Figure 10–142 Roof fan Replacing the roof fan 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off corresponding MCB (see electrical circuit diagram) to interrupt the 3AC 400 V fan supply voltages.
Page 270: Figure 10-143 Filter Fan Replacement
REPLACING POWER AND COOLING COMPONENTS Replacing the roof fan filter Figure 10–143 Filter fan replacement 1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22. 2. Switch off corresponding MCB (see electrical circuit diagram) to interrupt the 3AC 400 V fan supply voltages.
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