ABB PCS 6000 System Distribution Cabinet, Emptying the Cooling Liquid Circuit VFM74 3BHE046084R0001

Date: Sept 11, 2025 Views: 4588

　　Emptying the cooling liquid circuit

　　Replacement of certain components connected to the cooling liquid circuit requires emptying the cooling liquid circuit.

　　1. Cut off the external cooling circuits to/from external heat exchanger and to/from the filter unit if they need not be emptied (external valves and valves V30 / V31 and V56).

　　2. 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.

　　3. Place a catching tray under the drain valve V82 to collect the escaping cooling liquid when opening the valves.

　　IMPORTANT! The volume of the cooling liquid can be more than 250 L.

　　4. Open valve V82 to drain the cooling liquid. Ensure that V51 is open.

　　5. Open the venting valve in the FCA.

　　6. Close valve V82 again if the cooling liquid circuit is empty.

　　7. Remove the catching tray from the converter cabinet.

　　8. Wipe up any remnants of leaked cooling liquid.

　　Replacing components in POU

　　After faulty semiconductors have been identified, they have to be ex-changed according to the procedures below.

　　Converter service tools from the toolbox (3BHB008753R0001) for standard converters are required to carry out these procedures eg, a spreading tool and a stabilizer plate (see chapter 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.

　　General procedure to replace power semiconductors

　　All stacks containing semiconductors must be released before using the spreading tool.

　　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.

　　3. Check all IGCTs according to section 9.8, Checking IGCTs with multimeter (if a FADEC 3 is unavailable), page 127.

　　4. Replace faulty IGCTs according to section 10.6.4, Replacing IGCTs, page 149.

　　5. Check all power diodes according to section 9.9, Checking power diodes with multimeter, page 129.

　　6. Replace faulty diodes according to section 10.6.5, Replacing power diodes, page 153.

　　7. After the replacement of the faulty diodes recheck all diodes in the corresponding module.

　　IMPORTANT! More than one semiconductor in the module may be faulty due to secondary failures after a short circuit in one phase module.

　　Releasing the stacks

　　Switch off MCB -Q401 to interrupt the 3AC 400 V input voltages of the AC/DC converter (24 V power supply).

　　On the UPS -G402 turn the selector switch “Bat.-Select” to “Service”, then back to “7.2 Ah” (Fig. 8–11 in section 8.8, Replacing PECINTM, page 97) to interrupt the 24 V battery supply voltage (the yellow LED “Bat.-Mode” must be dark).

　　NOTE – No IGCTs in the stack are powered anymore; all LEDs are dark.

　　Verify that all power supply cables to the IGCTs are voltage-free.

　　NOTICE The power supply to the IGCTs must be switched off before releasing the stack! Otherwise the IGCTs could be damaged.

　　IMPORTANT! Towards the back on top of each triple stack module you will find three Ushaped pressure loading gauges in their storage place (mounted with screw, use 19 mm wrench to loosen).

　　Take the three pressure loading gauges from their storage places and insert them completely under the tension jacks of the three stacks (see Fig. 10–3).

　　NOTICE The pressure loading gauges must be inserted completely before the stack can be released (see Fig. 10–4). Otherwise the tension jacks can break.

　　4. Loosen all 24 fixation screws of the gate unit fixations (see Fig. 10–5) using a 5 mm Allen wrench to make sure that the gate unit fixation can move freely in vertical direction.

　　5. Release all three stacks in the order given in Fig. 10–6 by loosening the clamping screws counter-clockwise using the socket wrench with 12 mm Allen socket.

　　NOTICE Stack misalignment can damage the semiconductors. Release the stacks in the

　　following sequence:

　　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).

　　6. Enter a stabilizer plate in the bottom of the stack where a semiconductor needs to be exchanged as shown in Fig. 10–7.

3BHS600000_E80_RevF_Service_Manual_PCS6000 Overview of serialized power components(2).pdf

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