ABB PCS 6000 system distribution cabinet Preventive maintenance CCU14 3BHE056532R0001

Date: Sept 11, 2025 Views: 547

　　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.

　　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.

　　▶ Low voltage remains on the auxiliary energy distributor of the converter control system after the PCS6000 has been switched off.

　　▶ External auxiliary and control voltages (eg, of measuring circuits) can also remain even if the internal auxiliary power supply has been switched off.

　　▶ Before working on these circuits, verify that the corresponding external voltage sources have been switched off and secured according to the safety rules.

　　Cooling fans can start automatically!

　　The water cooling system and the cooling fans can start automatically as soon as the auxiliary voltage is switched on or when the EMERGENCY OFF button is released, even if the PCS6000 is de-energized.

　　Switch off the corresponding motor protection switches (see diagrams contained in the cabinet specific documentation) to shut down the cooling system.

　　General directives

　　▶ ABB strongly recommended to carry out all preventive maintenance work according to the maintenance schedule on time and at the stated intervals.

　　▶ 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.

　　▶ During the warranty period, any repair work must be carried out exclusively by trained personnel according to the ABB service and authorization concept.

　　▶ The executed repair work must be documented.

　　▶ The specified maintenance intervals according to the “PCS6000 Preventive maintenance schedule”, 3BHS600000 E88 and ambient conditions must be complied with and documented.

　　▶ ABB recommends periodical training for the maintenance and repair personnel.

　　Preventive Maintenance Report

　　The maintenance has to be done according to the following chapters and reported in the “PCS6000 Preventive maintenance schedule”, 3BHS600000 E88 In the report all changed components, deviations, modifications or service activities must be documented.

　　The completed report is to be sent to the Service organization of both, the customer and ABB.

　　Preventive maintenance schedule

　　Carry out all maintenance tasks on time and at the stated intervals according to the applicable service instructions and the “PCS6000 Preventive maintenance schedule”, 3BHS600000 E88.

　　Preventive maintenance tasks

　　The following sections describe how the different maintenance tasks listed in the preventive maintenance schedule must be carried out.

　　Inspection

　　Periodical inspections are required to:

　　– Recognize aging of components and replacement of components not pre-defined in maintenance schedule

　　– Avoid failures due to wear and tear on components connections caused by the operating stress factors, eg, vibration

　　Inspections cover mainly checking of power connections and visual checking:

　　– Dust built-up inside the converter room and inside the converter

　　– Signs for overheated components, wires, cables or busbars

　　• Electronic components with unusual brown or black spots

　　• Copper busbars with a bluish discoloration have been overheated

　　– Corrosion on circuit boards, connectors or busbars

　　– Appropriate fastening of plugs, cables, wires and their connections\

　　Procedure:

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　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.

　　Checking semiconductor stack tightness

　　Effort 0 - 2 h

　　It is recommended to check periodically the tightness of the semiconductor stack. This can be done as described undersection 10.6.7, Tightening the stacks, page 166.

　　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:

　　• Make visual checks of the torque markings on the bolts (Fig. 4–1).

　　• If the torque markings on a screw are out of alignment, check torque of screw connection. The required torque is listed in

　　Table 10–2 in section 10.4.1, Correct tightening torques of bolted connections, page 135.

　　• If a connection is loose, tighten the bolt using a torque wrench, then check also the torque of all other connections (the probability is high that if one connection is loose also other connections are loose).

　　• Torque markings of bolts that have been released and/or re-tightened must be cleaned and newly applied.

　　NOTICE The capacitors bushing will be damaged when excessive force is applied.

　　DO NOT exceed the maximum tightening torque when tightening the capacitor terminals. For the appropriate tightening torque of all screws and especially for the screws of the capacitors refer to section 10.4.1, Correct tightening torques of bolted connections, page 135.

　　After completing all work - if no further inspections have to be performed - restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

3BHS600000_E80_RevF_Service_Manual_PCS6000(1)Goods inspection(2).pdf

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