Medium voltage high-power water-cooled inverter for ABB PCS6000 IGCT device

Medium voltage high-power water-cooled inverter for ABB PCS6000 IGCT device

Service specific tools

Divided into three categories: maintenance tools, debugging tools, and replacement special tools, provide ABB material ordering numbers.

Converter service toolbox: includes hexagonal socket, ratchet wrench, spreading tool (disassembling IGCT/diode press fit stack), stabilizer board, FADEC 3 semiconductor tester, used for power stack disassembly and inspection.

Grounding kit: Multi branch grounding short wire, forcibly ground the high-voltage power circuit before maintenance.

Other maintenance tools: tube cutter, fiber polishing kit (for processing plastic fibers).

debugging tool

RCI-Box XU D194: Convert internal digital measurement data to analog output and connect it to an oscilloscope to collect up to 8 channels simultaneously;

PCS6000 HMI human-machine interface: single line diagram, status monitoring, alarm fault, IO viewing, RCI-Box control;

Water cooling filling kit and extension tube, used for refilling the water cooling system.

Large replacement tools: reactor replacement kit, bottom beam lifting lug, chain block, pump maintenance workbench, generator circuit breaker replacement trolley.

Preventive maintenance

After the maintenance work is completed, a preventive maintenance report must be filled out, retained, and copied to the ABB service department. All high-pressure operations must follow a 7-step safety process.

Main maintenance tasks

Visual inspection: cabinets, circuit boards, busbars, cables, optical fibers, water-cooled pipelines, fans, with a focus on checking for discoloration, erosion, dust, corrosion, and torque markings on fasteners.

Semiconductor stack compression force inspection; Bolt connection torque review (key power busbar, capacitor terminals must not exceed torque).

Cleaning: must be anti-static; Only use anti-static brushes and vacuum cleaners; It is strictly prohibited to use compressed air for blowing, as it may spread dust; Prohibit cleaning circuit boards with alcohol solvents.

Components are regularly replaced according to the maintenance schedule, including fans, filters, UPS batteries, water-cooled filters, pump seals, etc.

DC link performance test: HMI testing module charges the DC bus and records the discharge time; Deviation greater than 10%, further disassembly and measurement of the individual capacitance of the capacitor.

Disassembly and testing of DC link components: disconnect and measure the actual capacity of each capacitor, and compare it with the nominal value.

Filter performance testing: grid side filter, neutral point component, dv/dt filter, measure resistance and capacitance values, and the results are divided into OK/Monitor observation/Action. It is recommended to replace the three levels.

Safety function verification: local emergency stop, cabinet door interlock, grounding isolation switch interlock, UPS power supply integrity; Verify the opening time of the GRB circuit breaker in the power grid.

Insulation withstand voltage test: 1CL/2CL converter, using a 2500VDC insulation tester; The conductivity of water-cooled water must be less than 0.5 µ S/cm in order to perform insulation testing.

GDM generator isolation switch inspection and brake resistance performance measurement.

After all maintenance tasks, record all measurement data and write it into the maintenance report.

Power outage, grounding, and re operation

Shutdown must follow the official LOTO tagging and locking procedure.

Pay attention to the risk: even if the inverter is powered off, the auxiliary circuit will still be live; The cooling system can start automatically.

Maintenance completed, restart inspection items:

Water cooling system pressure 1.3-1.7 bar;

Remove all temporary grounding short circuits; There are no tools or debris left in the cabinet;

The UPS battery mode dip switch is in the correct position;

All high-voltage compartment cabinet doors are completely closed (cabinet door interlock prevents startup);

Switch the DC link grounding isolation switch to the "ungrounded" position;

Confirm the status of the power grid isolation switch; Clear the fault alarm;

After replacing serialized components with serial numbers, a warranty fault report must be submitted to ABB to update the serial number database.

Troubleshooting

Standard fault handling process:

Prioritize reading fault records on the HMI, confirm the first fault source FF (First Failure), and prohibit immediate clearing of fault and transient record TR files (IPC automatically saves records every 10 minutes).

Remote analysis: Refer to the fault manual, view transient waveform recording, check the status of each subsystem (cooling, S800IO, control power), and attempt to reproduce the fault.

On site investigation (power outage and grounding must be completed)

Visually inspect the hardware, board LED status, and whether there is overheating, erosion, or water leakage;

Detecting auxiliary power supply and fiber optic links;

Use FADEC3 to detect IGCT and diodes for power faults;

Locate the faulty component and replace it according to the corresponding chapter in the manual;

Hardware short circuit faults, direct restart of the inverter is prohibited, and the fault point must be identified; Reset after troubleshooting ordinary non hardware faults.

To contact ABB service, information is required: equipment serial number, fault time, power grid conditions, load conditions, water cooling parameters, and alarm codes.

Control component inspection

Power outage grounding safety process; Anti static requirements.

Preliminary diagnosis is conducted through the LED indicator lights of each board, and the manual provides a complete LED table:

AC800PEC controller: Fault, Run, Power, Supervisor, Communication transceiver light;

LED definitions for Combi IO, PECINTM, ASE2 measurement boards, and UPS power modules.

Key points for inspection: power supply, fiber optic cables, wiring, and burn marks on the appearance of the board.

Control component replacement

List the on-site replaceable control components inside the CCU control cabinet, POU power unit, FIU filtering unit, DLU DC link unit, and DRU drive unit; Distinguish components with serial numbers (after replacement, ABB needs to update the serial number). Replaceable components: AC800PEC controller, Combi IO, S800 IO module, voltage/current measurement board, PECINTM, IPS gate power supply, HVD, VLSCD, ASE2 board, various AC/DC, DC/DC power supplies UPS、 Battery, fiber optic.

General replacement points

Perform LOTO power outage, switch UPS to Service maintenance mode to cut off battery output;

Static protection: anti-static wristbands, anti-static pads; Board only takes edges;

Before replacing the current transformer board, the CT secondary circuit must be short circuited to prevent open circuit high voltage from injuring people;

Fiber optic processing: Do not touch the end face; Plastic optical fibers can be cut and polished using a kit;

After replacement, check the dialing and jumper, verify the LED status, and complete the system restart.

IGCT、 Detection of diode and IPS gate power supply

Power stacking is divided into IGCT stacking, freewheeling diode stacking, and neutral/clamp diode stacking; Comes with clamp capacitors and symmetrical resistors.

Two detection methods: prioritizing the use of FADEC3 semiconductor tester; Use a multimeter as an alternative when FADEC3 is not available.

Detection sequence: IGCT gate unit LED inspection → freewheeling diode → neutral point/clamp diode → IGCT body.

FADEC3 can directly determine semiconductor short-circuit damage; Different combinations of red/yellow/green LEDs in the gate unit correspond to IGCT gate faults, power outages, and gate cathode short circuits.

Measurement and judgment of input and output voltage of IPS (IGCT gate drive power supply).

Power and water cooling component replacement

High voltage risk, all operations must follow a 7-step safety process; Release pressure and drain coolant before repairing water-cooled components; Use lifting tools for components weighing more than 25 kg.

Bolt tightening torque table: capacitor terminals are strictly prohibited from exceeding torque.

POU power unit power semiconductor replacement process (IGCT, various diodes)

Use the spreading tool to loosen the compression stack and install the stable support plate;

Remove the damaged component and confirm the model and polarity of the new component;

Align and stack the components, remove the tooling, and tighten the clamping bolts in the prescribed order;

Stacking misalignment can directly damage semiconductor devices; Replace and retest the device.

Replacement of other power components in POU: clamp capacitor, symmetrical resistor, clamp reactor, LEM current sensor, DC bus capacitor.

Replacement of DLU DC link unit components: grounding isolators, various power resistors and capacitors, pre charging transformers, dv/dt filter components.

VFU filtering unit: GDM generator isolation switch module, dv/dt filtering reactor, resistor, capacitor.

WCU water cooling unit (Swedish/ARMATEC two types of water cooling systems): conductivity meter, temperature transmitter, pressure sensor, deionizer, water filter, circulation pump, pump seal, three-way valve, expansion tank, automatic exhaust valve, ball valve. Use a dedicated maintenance workbench and chain block for pump disassembly.

FIU filtering unit: HFM filtering reactor, capacitor, resistor.

GBU cabinet: Generator circuit breaker GEB/grid circuit breaker GRI, disassembled and assembled using a dedicated replacement trolley; Dv/dt filter; Drawer style fan.

Replacement of various types of fans, door fans, roof fans, and filters.