ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993

Technical Description 00319539_B.DOC

Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 1 / 26

GENERAL
This document describes how to replace the Thyristor modules, DC-fuses, boards and the fan of the
ACS800-304/704 supply unit.

ACS800-304/704 MAINTENANCE INSTRUCTION

WARNING! All electrical installation and maintenance work on the ACS 800 should
be carried out by qualified electricians.

Do not attempt any work on a powered ACS 800. After switching off the mains,
always allow the intermediate circuit capacitors 5 minutes to discharge before
working on the frequency converter, the motor or the motor cable. The voltage
between each input terminal (U1, V1, W1) and earth must be measured with a
multimeter (impedance at least 1MΩ) to ensure that the frequency converter is
discharged before beginning work.

All insulation tests must be carried out with the ACS 800 disconnected from the
cabling.

The ACS 800 motor cable terminals are at a dangerously high voltage when input
power is applied, regardless of motor operation. No work on the motor cable should
be attemped with mains power applied.

There can be dangerous voltage inside the ACS 800 from external control circuits
when the ACS 800 input power is shut off. No work on the control cables should be
attempted when power is applied to the frequency converter or to the external
control circuits. Exercise appropiate care when working with the unit.

ESD (Electro Static Discharge) The printed circuit boards contain integrated
circuits that are extremely sensitive to electrostatic discharge. Exercise appropiate
care when working on the unit to avoid permanent damage to the circuits. Do not
touch the boards unnecessarily.

WARNING! Only qualified electrians are allowed to carry out work described in this
instruction. Before working with the ACS 800 or handling the IGBT modules, read
carefully the Safety Instruction on the ACS800 Hardware Manual. Ignoring the
safety instructions can cause injury or death.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Maintenance without opening the module

Supply module fan replacement

See ACS800-304 and -704 User's Manual chapter "Maintenance"

Changing the fan

• Read and repeat the steps in Safety Instructions.

• Open the cabinet doors.
• Loosen the screw tightening the fan frame against the module. (1)
• Disconnect the fan power cable plug. (2)
• Pull the fan out. (3)
• Install a new fan in reverce order.

Figure 1-1 Replacing DSU module cooling fan.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Opening the module

Remove the module from cabinet

See ACS800-304 and -704 User's Manual chapter "Electrical installation"

WARNING! DSU modules are heavy and the centre of gravity is high. Be
careful when removing or replacing the module.

• Turn the switch-disconnector handle to open position. (1)

• Release the door handle and open the doors. (2)
• Loosen the module fastening screws and the quick connector locking screw (5 mm
hexagonal head). (3)
• Place the module pull-out ramp firmly against the cabinet base. (4)
• Pull the module carefully out of the cabinet. (5)

Figure 2-1 Opening the cabinet and removing DSU module.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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Put module into horizontal position

Before opening the module it must be put into horizontal position. Be careful - the weight
of module is about 180kg. Note that modules left side must be against floor or table.

NOTE: Use a crane or other applicable lifting tool to assure personal safety.

Remove right side plate and top plate.

• Open 2pcs M6 nut for wheels. (1)

• Open 8pcs screws for handle. (2)
• Open ab. 16pcs screws for side plater and top plate. (3)
• Lift the side plate up. (4)
• Remove the top plate. (5)
1

2
3 4
5

Figure 2-2 Opening DSU module cover.

Replace the faulty components.

Figure 2-3 Opened DSU module.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Component locations

V11…V13 3 pcs 3AFE64607701 THYRISTOR/DIODE MODULE SKKH 210/20 E

V21…V23 3 pcs 3AFE64607701 THYRISTOR/DIODE MODULE SKKH 210/20 E
Q1 1 pcs 3AFE64607201 DISCONNECTOR OETL400KML33-2
1 pcs 3AFE10000432 AUXILIARY CONTACT OZXK 1
K1, K2 2 pcs 3AFE64607821 CONTACTOR A300-30-11-80
L1, L2 1 pcs 3AFE64610813 AC CHOKE DCHO-7D-400
A12 1 pcs 3AFE64630199 ACCESSORY BOARD DSAB-01C
A13 1 pcs 3AFE64637029 PLUG CONNECTOR BOARD DSCB-01C
A43 1 pcs 3AFE64691929 POWER SUPPLY BOARD DSMB-01C
A45 1 pcs 3AFE64666606 CONTROL BOARD DSMB-02C
C11…C23 1 pcs 3AFE64705563 SNUBBER BOARD DSSC-01C
R2 1 pcs 3AFE64674617 THERMAL SWITCH
F1, F3 2 pcs 3AFE64720066 SCREWFUSE 170M4467
2 pcs 3AFE58063690 ALARM CONTACT 170H0069
F2, F4 2 pcs 3AFE64607383 SCREWFUSE 170M4417
M1 1 pcs 3AFE64650114 COOLING FAN D2D146-AA02-22
T31…T33 1 pcs 3AFE64697811 CURRENT TRANSFORMER VM5000K DIA0.14CU, SET 3PCS
T34…T36 1 pcs 3AFE64697811 CURRENT TRANSFORMER VM5000K DIA0.14CU, SET 3PCS

Figure 3-1 DSU module component locations.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Replacing boards

DSAB-01C

NOTE! When updating DSAB-01C board from revision D (or older) to F (or
newer), read document 3AFE 6825 5601 “Updating Instruction”. Board
support and cable set are needed to be updated by the replace of old revision
of DSAB board.

• Undo connectors, 9 pcs.

• Open fixing screws, 13 pcs M4.
• Open fixing clips, 3pcs.
• Replace DSAB-01C board.
• Fasten M4 fixing screws to 1.5 Nm torque.
• Fasten connectors.

Figure 4-1 DSAB-01C board, cables and fixing screws.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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DSMB-01C and/or DSMB-02C

• Undo connectors
• Remove cable ties and the screws (2 pcs M4, fastened to DC bus bar) holding the ferrite
ring.
• Remove metallic support for lower plastic board support (3 pcs screws).
• Replace DSMB-01C and/or DSMB-02C board.
• Fasten Connectors.
• Fasten ferrite ring.
• Use the orginal number of cable ties.

Figure 4-2 DSMB-01C and -02C boards, cables and board supports.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Replacing DC fuses

• Remove Auxiliary contacts. (1)

1
1

Figure 5-1 Auxiliary contacts of the DC fuses.

• Remove flat DC busbars. (2)

• Note! Also ferrite support screws (2 pcs) must be removed from DC minus bar.

Figure 5-2 DSU module open, removing DC busbars.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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• Open M8 screws for DC busbars. (3)

3 3

Figure 5-3 DC busbar assembly screws.

• Remove DC busbars together with fuses

Figure 5-4 DC busbars with fuses.

• Replace fuses. Note! Ensure correct fuse orientation (see figure 5-4 above). Fixing torque
is 10 Nm.
• Reassemble module. Torque for M8 electrical contacts is 10 Nm
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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Replacing Thyristor/diode modules

NOTE! When replacing Thyristor/Diode modules to DSU modules
manufactured before week 05 year 2005, read document 3AFE 6859 0671
“Instruction of Thyristor/diode maintenance”. Thyristor/Diode module type has
changed and extra components are needed for the changing.

Accessing the Thyristor/Diode module

• Remove the DC busbars and the thermostat plate to gain access to the Thyristor/Diode
modules.
• Remove wiring.
• Remove the faulty Thyristor/Diode modules.
• Clean the contact surface of the heatsink with an appropriate solvent and a soft cloth from
excessive thermal compound and particles.

Thyristor/Diode module assembly

• Clean the contact surface and terminals of the Thyristor/Diode module. Check that the
contact surface is not damaged.
• Apply a thin and uniform layer of thermal grease (typ. thickness 50 –100 µm) to whole
contact area of the Thyristor/Diode modules with a roller or a rubber spatula. The Amount
of grease is sufficient when bright contact surface of Thyristor/Diode module is not visible
through the grease. Check visually that there are no foreign particles among the spread
grease.
• Place the module to heatsink by hand and press it about 5 sec. Repeat phases above to
every Thyristor/Diode module before the next phase.
• Place the thermostat plate according to Figure 6-1.

Figure 6-1 Assembly of thyristors and the thermostat plate.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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• Tighten the M5 screws to a pre-torque according to Table 6-1 and in sequence 1-2-3-4
according to Figure 6-2.

2 3

4 1

Figure 6-2 Screw numbers for Thyristor/Diode module.

• Tighten the M5 screws to the final torque according to Table 6-1 in sequence 1-2-3-4
according to Figure 6-2.
• After the tightening a small rim (1 – 4 mm) of grease must be seen around the mounted
module. This shows that the amount of grease is sufficient. Wipe off the excess grease.
• Connect the DC busbars to the thyristor modules by M8 screws to 10Nm torque.

Figure 6-3 Connecting DC busbars.

• Connect gate control cables from DSMB-02C to Thyristor/Diode modules.

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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Check after the assembly

• It is important to check that the cables (6 pcs) from DSMB-02C board connectors -X111 to
-X161 are properly connected to Thyristor/Diode modules pins 4 and 5. By these wires are
the gates of the Thyristor/Diode modules controlled by DSMB-02C board.
• Ensure that the thermistor switch cable is connected to DSMB-01C connector -X173.

Table 6-1 Torque for the installation and the connection screws.

Terminal Torque
Pre-Torque Final torque
Module assembling screws
M5 (Ø 5 mm) 2.5 Nm 5.0 Nm
Main circuit terminals
M8 (Ø 8 mm) 10 Nm
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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FAULT TRACING
This chapter instructs how to interpret the fault indications of the Diode Supply Unit. The
information is valid for cabinet-installed DSU types ACS800-307 and -507, and for modules
ACS800-304 and -704 when equipped with similar auxiliary devices.

Fault diagnostics by DSSB-01C fault LEDs

LED Cause What to do

LEDs on the control board DSSB-01
FAN FAILURE The module cooling fan has over Check fan operation. The fan is rotating
heated and the thermistor switch of freely. Broken fan bearing causes noise
the fan motor has opened. This may and sticky bearing may be noticed by
be caused by jammed fan bearing or rotating the fan rotor by hand. See the
the fan has been running by full fan production week from the fan label.
speed too long. Problems have been with bearing of the
fans produced before week 42/04.
Damaged cooling fan supply cabel. Check cooling fan supply cable from
DSMB-01 board to fan motor or change
the fan.
Thermistor switch of the cooling fan Change cooling fan.
motor is defective.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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LED Cause What to do

OVER TEMP DSU module has exceeded Check ambient temperature. Check
FAILURE temperature fault limit and thermistor cooling air flows freely and cooling fan
switch of the DSU module has operation. Check inlet and outlet
opened by module over heating. airfilters. Check heatsink for dust pick-up.
Thermistor switch of the DSMB-01C See instructions above.
board (DSU module auxiliary power
supply board) has opened by over
heating.
OVER TEMP DSU module or DSMB-01C boards Change the module thermistor or change
FAILURE thermistor switches are defective DSMB-01C board.
There is some failure in the cabeling Check the DSU module internal wiring
of the above mentioned thermistor for loose connectors or wiring failures.
switches. Measure wiring by multimeter.
EXTERNAL FAULT External swiches or auxiliary Check wiring and external switches
contacts wired to digital input (DI) 4 connected to DI4 of DSSB board.
of the DSSB-01C board are
activating the External Fault.
EARTH FAULT Earth fault supervision is active even Switch off the earth fault supervision
the supply net type is floating. from DSSB board. Earth fault supervision
works properly only in earthed supply
net.
Load unbalance due to earth Check supply cables.
(ground) fault leakage current inside Ensure the function is not set too
the DSU module or supply cable. sensitive.
Control board DSSB-01C is distorted Check earth fault settings on the board.
on some reason, but the earth fault is Change the DSSB-01C board.
not actual.
Heavy unbalance of the supply net. Measure mains.
SUPPLY MISSING LED blinks and Phase L_._ Missing LED on module cover blinks:
Main circuit AC fuse has blown. Check the DSU modules which ones are
indicating Supply Missing failure by
binking leds. Change main circuit AC
fuse. Measure also thyristor diode
modules and circuit boards of the DSU
module. Blown AC fuses are signal from
major failure.
3A cardridge fuse on DSAB-01C Check DSAB board fuses and change
board has blown. blown fuse. Measure DSMB-01C board.
Short-circuit on DSMB-01C will blow
DSAB board fuses.

Note! If fuse blown on revision J or K

DSAB board, change the whole board.
Charging resistors may be blown.
Input power terminal is loose. Check and tighten input power terminals.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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LED Cause What to do

SUPPLY MISSING LED blinks but no Phase L_._ Missing LED on module cover blinks:
Auxiliary circuit AC fuse of Diode Change blown auxiliary circuit AC fuse.
supply Unit has blown.
Main circuit AC fuse of brances L1.1, Change blown main circuit AC fuse.
L2.1 or L3.1 of the first DSU module
has blown.
Input power terminal is loose. Check and tighten input power terminals.

LED on:
DSU overload. Constantly lighted Check load. Are all palallel-connected
LED is indicating that overload supply modules in place? Is the
supervision of the DSU has tripped. aircirculation cover plate (code:
(New function on revision K and 68395721) used if DSU module
newer DSSB boards). removed? Decrease load or replace
missing module.
Faulty DSSB board. Change faulty DSSB board.
DC FUSE DC Fuse(s) blown. Change DSU module DC fuses. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown DC
fuses are signal from major failure.
DC fuse auxiliary contact wiring is Check DC fuse auxiliary contacts and
faulty. DC fuse auxiliary contact is wiring between DSAB board and
faulty or loose. auxiliary contacts.
Connector -X411 or -X412 loose or Check DSAB board connectors.
uncoupled on DSAB board.
EMERGENCY STOP / Appears immediately after connecting supply:
OTHER FAULT
Emergency stop circuit is open, or Release emergency stop button. Check
nor connected correctly. connections of emergency stop circuit.
Loose connectors -X4 or -X8 on Check connectors -X4 and -X8 are
DSSB board. properly fastened.
4A fuse blown on DSSB board and + Measure +/-24VDC from DSSB board
or -24VDC is missing from connectors -X4 and -X8. Change the 4A
emergency stop circuit. circuit board fuses F1 and F2 of DSSB
board.
Short-circuit on DSSB board If the fuses are blown again after
emergency stop circuit (rev. F and changing for new ones, change the
older boards). DSSB board. Rev. F DSSB (and older)
boards diodes may be blown to short-
circuit.
DSMB-01 board is defective and is Change DSMB-01C board.
not supplying -24V auxiliary voltage.
Defective flat ribbon cable between Check flat ribbon cable X500
DSSB board and DSU modules.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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LED Cause What to do

EMERGENCY STOP / Appears after trying to charge the DC voltage
OTHER FAULT (START command given for DSU and after 5 seconds DSU trips):
2A fuse blown on DSMB-02 board. Change 2A fuses to DSMB-02 board.
DC voltage supply connector -X104 Check connector -X104 is properly
loose on DSMB-02 board. fasten to DSMB-02C board.
+16V auxiliary supply voltage cable Check connector -X192 from DSMB-01C
loose between DSMB-01C and -02C and -X102 from DSMB-02C board.
boards.
Charging control signal cable is not Check connector -X193 from DSMB-01C
connected between DSMB-01C and and -X103 from DSMB-02C board.
-02C boards.
Loose or defective flat ribbon cable Check flat ribbon cable between DSMB-
between DSMB-01C and DSCB-01C 01C and DSCB-01C boards. Also check
boards. the flat ribbon cable connectors -X302
from DSCB and -X100 from DSMB-01C
boards. Change flat ribbon cable if
needed.
DSAB-01C board do not close the Check DSAB board connectors -X402
main contactors K1 and K2. and -X404 for main contactor supply.
Replace DSAB board if main contactors
cannot be closed.
Auxiliary contact of the main Check the auxiliary contacts of the main
contactor K1 or K2 is not working or contactors K1 & K2. The function of the
loose. auxiliary contacts may be tested by
manually pressing the main contactors
closed and the auxiliary contacts should
be short-circuited (ohmic measured).
Defective DSCB-01 connector board. Change DSCB-01C board.
Supply net is too weak for charging If the operation of the DSU unit is tested
the DC voltage. DSU takes and the supply net is too weak to give
remarkable charging current for the charging current for DSU, must the
charging the intermediate circuit INU modules be removed or
capacitors of INU modules. Supply disconnected.
net must be rated for the DSU unit.
OVER TEMP Cooling fan rotates at maximum Check ambient temperature.
WARNING speed and the DSU module has Check cooling air flows freely.
exceeded temperature warning limit.
Check cooling fan operation.
Check inlet and outlet airfilters.
Check heatsink for dust pick-up.
Check load. Are all palallel-connected
supply modules in place? Is the air
circulation blocking plate used if supply
module is removed? Reduce load or
replace missing module.
NTC resistor resistace of the cooling Replace the DSU module NTC-resistor
fan is too low ohmic and this drives that is connected to connector X173 of
the cooling fan to full speed (even the DSMB-01 board.
the DSU module is cold).
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
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LED Cause What to do

READY Off: Input terminals are not live and Close switch-disconnectors and check
module switch-disconnectors are that the cooling fan starts to rotate. If the
switched off. Or DSMB-01C board is cooling fan is not rotating even the
not supplying the auxiliary voltage. supply voltage is switched is the DSMB-
01C board damaged or input fuses
blown.
Blinking: DSU module contactor is Contactors off: Close contactors by
off or DSU is charging intermediate giving start command for DSU.
circuit (charging mode). Input Contactors on: Wait until DSU has
terminals are live and module switch- charged intermediate circuit (i.e LED
disconnectors are switched on. illuminates steadily) and start to load the
unit.
Fast blinking: DSU has changed -
from diode mode to charging mode
because intermediate circuit voltage
has dropped more than 30% from the
actual voltage level. If the
intermediate voltage drops below
400VDC turns the DSU to off/ride
through function.
On: DSU is in operation (diode Load/control DSU.
mode) and can be loaded; Input
terminals are live, module switch-
disconnectors and contactors are on,
intermediate circuit capacitors have
been charged.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
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Fault diagnostics by DSU module fault LEDs

LED Cause What to do

LEDs on the DSU module (on DSAB board)
DC FUSE FAILURE DC Fuse(s) blown. Change DSU module DC fuses. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown DC
fuses are signal from major failure.
DC fuse auxiliary contact wiring is Check DC fuse auxiliary contacts and
faulty. DC fuse auxiliary contact is wiring between DSAB board and
faulty or loose. auxiliary contacts.
Connector -X411 or -X412 loose or Check DSAB board connectors.
uncoupled on DSAB board.
FAN FAILURE The module cooling fan has over Check fan operation. The fan is rotating
heated and the thermistor switch of freely. Broken fan bearing causes noise
the fan motor has opened. This may and sticky bearing may be noticed by
be caused by jammed fan bearing or rotating the fan rotor by hand. See the
the fan has been running by full fan production week from the fan label.
speed too long. Problems have been with bearing of the
fans produced before week 42/04.
Damaged cooling fan supply cabel. Check cooling fan supply cable from
DSMB-01 board to fan motor or change
the fan.
Thermistor switch of the cooling fan Change cooling fan.
motor is defective.
OVER TEMP DSU module has exceeded Check ambient temperature. Check
FAILURE temperature fault limit. Thermistor cooling air flows freely. Check cooling
switch of the DSU module has fan operation. Check inlet and outlet
opened by module over heating. airfilters. Check heatsink for dust pick-up.
Thermistor switch of the DSMB-01C See instructions above.
board (DSU module auxiliary power
supply board) has opened by over
heating.
DSU module or DSMB-01C boards Change the DSU module thermistor or
thermistor switches are defective change DSMB-01C board.
Damaged wiring of the DSU module Check the DSU module internal wiring
or DSMB-01C boards thermistor for loose connectors or wiring failures.
switches. Measure wiring by multimeter. When the
thermistor switch is cold should the
short-circuit be measured from the switch
pins.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
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LED Cause What to do

PHASE L_._ MISSING Main circuit AC fuse has blown. Change main circuit AC fuse. Measure
also thyristor diode modules and circuit
boards of the DSU module. Blown AC
fuses are signal from major failure.
3A cardridge fuse on DSAB-01C Check DSAB board fuses and change
board has blown. blown fuse. Measure DSMB-01C board.
Short-circuit on DSMB-01C will blow
DSAB board fuses.

Note! If fuse blown on revision J or K

DSAB board, change the whole board.
Charging resistors may be blown.
Input power terminal is loose. Check and tighten input power terminals.
FAN FULL SPEED By the switch on of mains Fan Full This is not a fault. Revision K and newer
Speed LED is lighted and cooling fan DSSB boards are forcing the cooling fan
rotates at maximum speed for about to maximum speed when the supply
5 seconds. voltage is switched on. After 5 seconds
the fan returns to normal speed.
Cooling fan rotates constantly at See Over Temp Warning below.
maximum speed and the DSU
module is overheating.
NTC resistor (that controls cooling Check NTC-resistor wires and coupling.
fan rotating speed) resistace is too Change the NTC-resistor.
low ohmic and this forces the cooling
fan to full speed (even the DSU
module is cold).
OVER TEMP Cooling fan rotates at maximum Check ambient temperature.
WARNING speed and the DSU module has Check cooling air flows freely.
exceeded temperature warning limit.
Check cooling fan operation.
Check inlet and outlet airfilters.
Check heatsink for dust pick-up.
Check load. Are all palallel-connected
supply modules in place? Is the air
circulation blocking plate used if supply
module is removed? Reduce load or
replace missing module.
NTC resistor resistace of the cooling Replace the DSU module NTC-resistor
fan is too low ohmic and this drives that is connected to connector X173 of
the cooling fan to full speed (even the DSMB-01 board.
the DSU module is cold).
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
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LED Cause What to do

POWER Off: Input terminals are not live and Close switch-disconnectors and check
module switch-disconnectors are that the cooling fan starts to rotate. If the
switched off. Or DSMB-01C board is cooling fan is not rotating even the
not supplying the auxiliary voltage. supply voltage is switched is the DSMB-
01C board damaged or input fuses
blown.
Blinking: DSU module contactor is Contactors off: Close contactors by
off or DSU is charging intermediate giving start command for DSU.
circuit (charging mode). Input Contactors on: Wait until DSU has
terminals are live and module switch- charged intermediate circuit (i.e LED
disconnectors are switched on. illuminates steadily) and start to load the
unit.
On: DSU is in operation (diode Load/control DSU.
mode) and can be loaded; Input
terminals are live, module switch-
disconnectors and contactors are on,
intermediate circuit capacitors have
been charged.

Other indication of fault

Indication Cause What to do

DSSB panel display +/- 24VDC auxiliary voltage is Ckeck that flat ribbon cable connector
and LEDs are dark missing. X500 is properly fastened.
Check DSU modules, are the cooling
fans rotating and power LEDs lighted?
Auxiliary power supply board DSMB-01C
is most propably broken if the fan is not
rotating and power LED not lighted.
Change DSMB-01C board.

If DSMB-01C board has short-circuited

check also DSAB-01C board 3A fuses
and charging resistors.
DSSB board software has jammed. Switch supply voltage off for about 5
minutes and restart the DSU unit. If this
do not help, change the DSSB board.
DSSB boards processor is not Change DSSB board.
working or some other fault on board.
DSSB panel display DSSB board software has jammed or Change DSSB board.
and / or all LEDs are processor has broken.
continuosly lighted
Displayed AC DSSB displays much higher phase Ckeck and measure that DSU module
currents are not currents than the actual currents are. current transformers are properly wired.
correct on DSSB Current transformer(s) is faulty on Change faulty current transformer (code
panel DSU module. 64697811).

If DSU unit contains more than one DSU

module, test the modules assembling
one by one to DSU unit. Charge
intermediate voltage and load the DSU
module. Faulty module will be detected
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 21 / 26

by displayed phase currents of DSSB.

DSU module cooling Broken DSMB-01C board. Change DSMB-01C board.

fan is not rotating Jammed fan bearing. Change cooling fan.
Fan inverter of DSMB-01C in failure Try to restart DSU by switching mains
state (only revision G and older supply OFF and after few seconds ON.
DSMB-01C boards).
Change DSMB-01C board.
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 22 / 26

Measuring the rectifier diodes of DSMB-02C board

The measurement is done with multimeter in the diode position.

• The measurement is done between diodes anode(+) and catode(-) and measured
from circuit board connector pins, see Figure 7-1 on next page.
• Diodes are coupled in series on the circuit board and because the measurement is
done via connector pins are two or three diodes measured simultaneously, as
Figure 7-1 shows.
• When the measurement with the multimeter displays infinite (OL Over Limit) in one
direction and the forvard voltage of diode (e.g. 500 mV) in the opposite direction the
junction is OK. Note that the values shown by the multimeter depends on its brand
and type. Different multimeters with different output voltages show different forfard
voltages when measuring semiconductor components.
• If the multimeter indicates a short-circuit, the diode in question is faulty and the
board must be replaced.
• If the forward voltage of some of the diodes is different from the others, the diode is
most propably broken.
• Tolerance of the measurements is about 0.2V.

Note: If 2A cardridge fuses of DSMB-02C board are blown, must the measurement
done from fuse holders.

Table 7-1 Measurements in the forward direction of the rectifier diodes of DSMB-02C board.

+ probe - probe Display

-X104: 3 (DC+) -X101: 1 (AUX+) ≈ 1.1 V
-X101: 5 (AUX-) -X104: 1 (DC-) ≈ 1.1 V
DSMB-02C connector

-X101: 5 (AUX-) -X150: 1 (Phase U1 ) ≈ 1.1 V

-X101: 5 (AUX-) -X150: 3 (Phase V1) ≈ 1.1 V
-X101: 5 (AUX-) -X130: 1 (Phase W1 ) ≈ 1.1 V
-X101: 5 (AUX-) -X130: 3 (Phase U2) ≈ 1.1 V
-X101: 5 (AUX-) -X110: 1 (Phase V2 ) ≈ 1.1 V
-X101: 5 (AUX-) -X110: 3 (Phase W2) ≈ 1.1 V

-X150: 1 (Phase U1 ) -X101: 1 (AUX+) ≈ 1.6 V

-X150: 3 (Phase V1) -X101: 1 (AUX+) ≈ 1.6 V
-X130: 1 (Phase W1 ) -X101: 1 (AUX+) ≈ 1.6 V
-X130: 3 (Phase U2) -X101: 1 (AUX+) ≈ 1.6 V
-X110: 1 (Phase V2 ) -X101: 1 (AUX+) ≈ 1.6 V
-X110: 3 (Phase W2) -X101: 1 (AUX+) ≈ 1.6 V
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 23 / 26

Table 7-2 Measurements in the reverce direction of the rectifier diodes of DSMB-02C board.

+ probe - probe Display

-X101: 1 (AUX+) -X104: 3 (DC+) OL
-X104: 1 (DC-) -X101: 5 (AUX-) OL
DSMB-02C connector

-X150: 1 (Phase U1 ) -X101: 5 (AUX-) OL

-X150: 3 (Phase V1) -X101: 5 (AUX-) OL
-X130: 1 (Phase W1 ) -X101: 5 (AUX-) OL
-X130: 3 (Phase U2) -X101: 5 (AUX-) OL
-X110: 1 (Phase V2 ) -X101: 5 (AUX-) OL
-X110: 3 (Phase W2) -X101: 5 (AUX-) OL

-X101: 1 (AUX+) -X150: 1 (Phase U1 ) OL

-X101: 1 (AUX+) -X150: 3 (Phase V1) OL
-X101: 1 (AUX+) -X130: 1 (Phase W1 ) OL
-X101: 1 (AUX+) -X130: 3 (Phase U2) OL
-X101: 1 (AUX+) -X110: 1 (Phase V2 ) OL
-X101: 1 (AUX+) -X110: 3 (Phase W2) OL

Figure 7-1 Simplified circuit diagram of the rectifier diodes of DSMB-02C board
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 24 / 26

Measuring of a Thyristor/Diode module

The following action should be done and results verified before the measurement of the
Thyristor/Diode module is started:

• Before starting any individual Thyristor/Diode module measurement described below the
bkoken component can be located by measuring between the (+) busbar and input phases
and similarly (-) busbar and input phases if an input phase is short-circuited.
• Check Thyristor/Diode modules also visually. Sometimes the case of the Thyristor/Diode
module may be broken or burned by for example an arc caused by a short-circuit inside the
Thyristor/Diode module.
• The Thyristor/Diode modules can be measured when they are still mounted on the heat
sink, if the DC busbars are removed on top of them.
• Undo also Thyristor cate control cables (between Thyristors and DSMB-02C board).
• When the measurement with the multimeter displays infinite (OL Over Limit) in one
direction and the forvard voltage of diode (e.g. 380 mV) in the opposite direction the
junction is OK. Note that the values shown by the multimeter depends on its brand and
type. Different multimeters with different output voltages show different forfard voltages
when measuring semiconductor components.
• If the multimeter indicates a short-circuit, the Thyristor or Diode in question is faulty and the
Thyristor/Diode module must be replaced.
• If the forward voltage of some of the diodes is different from the others, the diode is most
propably broken.

The names of the terminals of the Thyristor/Diode module are presented in Table 7-3.

The measurement is done with multimeter in the diode position.

Table 7-3 Terminal names of the Thyristor/Diode module

Terminal Name
1 Thyristor anode / Diode catode
2, 4 Thyristor catode
3 Diode anode
5 Thyristor gate

Figure 7-2 Terminals of the Thyristor/Diode module

ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 25 / 26

Figure 7-3 Circuit diagram of the Thyristor/Diode module

Table 7-4 Measurements in the A-C direction

+ probe - probe Display

1 2 OL
Thyristor/Diode
1 5 OL
module terminal 3 1 ≈ 0.38 V

Table 7-5 Measurements in the C-A direction

+ probe - probe Display

1 3 OL
Thyristor/Diode 2 1 OL
module terminal 5 1 OL
2 5 OL

Measure also the gate resistance of each Thysristor. Measurement is done in the resistance
mode between Thyristor gate and catode.

Table 7-6 Thyristor gate resistance measurement

+ probe - probe Display

Thyristor/Diode
module terminal 5 2 ≈ 20 Ohm
ABB Drives MAINTENANCE INSTRUCTION 3AFE 6829 9993
Technical Description 00319539_B.DOC
Dept. Project Status Date Author Status Revision Page
APPROVED/KOSOLA JUHA
BANANA 19.Oct 2005 HAUVONEN URPO B 26 / 26

Measuring of the charging resistors of DSAB-01C board

The measurement is done with multimeter in the resistance position.

• Revision F and newer DSAB boards have charging resistors. The charging resistors have
to be measured in auxiliary power supply board DSMB-01C failure or short-circuit.
• The charging resistors of the DSAB-01C board can be measured when the board is still
mounted on the DSU module.
• Undo DSAB cable connectors X401A and X401B.
• Measure the 3A cardridge fuses of DSAB board. If the fuses are ok, measure the charging
resistors according the Table 7-7. If the fuse(s) is blown, measure the resistace through the
upper fuse holder (not from connectors X404A…F).
• Correct resistance measured between board connector pins is 7 ± 0.5 ohm.
• If the multimeter indicates OL or higher resistance than 8 ohm, the charging resistor(s) in
question is faulty and the DSAB board must be replaced.

The names of the DSAB-01C board terminals are presented in Table 7-7 and in Figure 7-4.

Table 7-7 DSAB-01C board charging resistor measurements

+ probe - probe Display

X401A: 1 X404A 7
X401A: 3 X404B 7
DSAB-01C board X401A: 5 X404C 7
connector X401B: 1 X404D 7
X401B: 3 X404E 7
X401B: 5 X404F 7

Figure 7-4 DSAB-01C charging resistor circuit.