ABB PCS 6000 System Distribution Panel Releasing the Stacks PCD I01-01 3BHE031197R0001

Date: Sept 11, 2025 Views: 589

　　IMPORTANT! The clamping pressure of the stack must be released when diodes or thyristors of the rectifier are replaced. Do not release the pressure all at once, as otherwise all semiconductors in the stack will become mis-aligned. They must then be re-centered in a time consuming procedure. The misalignment results from the flexible busbar connectors at the rear of the stack. They are connected to the coolers and push them to the front, resulting in misalignment of the semiconductors. 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).

　　3. Insert the spreader tool (type 2, see Fig. 10–42) into the openings of the coolers above and below the diode or thyristor which is to be replaced (see Fig. 10–43).

　　NOTICE DO NOT use the extensions available for type 1 of the spreader tool. The extensions cause the cooler above the faulty semiconductor to be pushed down by the flexible connectors at the rear of the stack, thus clamping the semiconductor. When replacing a semiconductor which is next to a pulse transformer, pay attention to the transformer leads. The wires can be easily caught in the gears of the spreader tool.

　　4. Alternately release the clamping pressure and then spread the spreader tool to maintain the pressure in the stack above the semiconductor to be changed. Proceeding in this manner prevents the semiconductors from becoming misaligned.

　　5. Remove the semiconductor as soon as the clearance above the semiconductor is big enough.

　　6. Prepare the new semiconductor for reassembly. Check the contact surfaces of the new diode for any dirt. If necessary, clean the contact surfaces with an appropriate solvent (eg, alcohol). Using a fluff-free cloth wipe the surfaces paying attention not to scratch the surfaces.

　　IMPORTANT! DO NOT use any grease or any electrical joint compound.

　　7. Insert the new semiconductor into the stack and center it.

　　NOTICE Pay attention to the correct polarity. Always verify the polarity with the corresponding wiring diagram.

　　8. Alternately close the gap between the new semiconductor and the cooler and increasethe 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.

　　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. 10–44 Rearranging misaligned stacks.

　　The two horizontal bars are fixed to the frame of the cabinet. By means of the adjustment bolts, the wooden bar is pushed against the coolers thus pushing the coolers back into place and holding them there. The semi-conductors can be centered one by one starting at the bottom of the stack. The spreader tool is used to create the clearance for moving the semiconductors into place. 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.

　　Replacing components in DLU

　　Replacing grounding isolator

　　Service MTTR 0 - 2 h

　　Figure 10–45 Earth isolator mounting screws

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

　　2. Before remove the grounding isolation install an additional grounding kit to ground the DC-link.

　　3. Disconnect all electrical cables.

　　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.

　　Replacing resistor -R462_1, -R462_2

　　Service MTTR 0 - 2 h

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

　　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.

　　Replacing resistor -R751 to -R754 or capacitor -C751 to -C752

　　Service MTTR 2 - 4 h

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

　　2. Release the over pressure of the cooling system according to section 10.5.1, Releasing the over pressure from the cooling liquid circuit, page 138.

　　3. Place a catching tray in such a way that leaking cooling liquid from the faulty resistorassembly does not spill into the converter.

　　NOTICE Leakage of cooling liquid into the converter needs to be avoided; especially glycol causes severe pollution of the converter.

　　4. Remove hoses from the resistor, direct the leaking water into the catching tray and close the leaks with Legris plugs.

　　5. Unbolt the cable to the capacitor.

　　6. Unbolt the 5 Allen-key screws (3 above and 2 below) from the relevant resistorassembly (see Fig. 10–47).

　　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.

　　Replacing resistor -R461 Service MTTR 0 - 2 h

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

　　2. Release the over pressure of the cooling system according to section 10.5.1, Releasing the over pressure from the cooling liquid circuit, page 138.

　　3. Place a catching tray in such a way that leaking cooling liquid from the faulty resistor does not spill into the converter.

　　NOTICE Leakage of cooling liquid into the converter needs to be avoided; especially glycol causes severe pollution of the converter.

　　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.

3BHS600000_E80_RevF_Service_Manual_PCS6000 Parts Replacement Manual(3).pdf

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