Maintenance and Repair Instructions

Operating Instructions

Standard Converter - Cabinet

Type UNL133

No. of p.
Prep. 01-07-30 A.K.
Appr. 01- 08-23 T.G. Operating Instructions 32
Resp. REV. B 4.9.03 / Mo
ATPE
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 Maintenance and Repair Instructions

Important Notice
Our experience has shown that if the information and recommendations contained in
this " Operating Instructions" are observed, the best possible reliability of our products is
assured.
The data contained herein purports solely to describe the product and is not a warranty
of performance or characteristics. It is with the best interest of our customers in mind
that we constantly strive to improve our products and keep them abreast of advances in
technology. This may, however, lead to discrepancies between a product and its
"Technical Description" or " Operating Instructions".
This document has been carefully prepared and reviewed. However, should in spite of
this the reader find an error, he is requested to inform us at his earliest convenience.
It is scarcely possible for the operating instructions for technical equipment to cover
every eventuality which can occur in practice. We would therefore request you to notify
us or our agent in the case of all unusual behaviour, which does not appear to be
covered by these operating instructions.
It is pointed out that all local regulations must be observed when connecting and
commissioning this equipment in addition to these operating instructions.
Any work that has to be carried out inside the equipment, such as changing soldered
links or fitting or removing resistors, may only be performed by correspondingly qualified
personnel.
We cannot accept any responsibility for damage incurred as a result of mishandling the
equipment regardless of whether particular reference is made in these operating
instructions or not.
We lay particular stress on the fact that only genuine spare parts should be used for
replacements.
All rights with respect to this document, including applications for patent and registration
of other industrial property rights, are reserved. Unauthorized use, in particular
reproduction or making available to third parties, is prohibited.

ABB Switzerland Ltd.

Excitation Systems, Voltage Regulators
and Synchronizing Equipment
CH-5300 Turgi/Switzerland

Telephone: +41 58 589 24 86

Fax: +41 58 589 23 33
Email: [email protected]
Internet: http://www.abb.com/unitrol

24 h - Hot line for urgent service inquiries: +41 844 845 845

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Maintenance and Repair Instructions

Contents Page

1. Introduction 4
1.1. Using these Operating Instructions 4
1.2. Definition of symbols used in this document 4
1.3. Related documents 4

2. Description of equipment 5
2.1. Overview 5
2.2. Key to Types and Variants 6
2.3. Mechanical layout 7
2.3.1. General assembly of variant without isolator, forced ventilation 7
2.3.2. General assembly of variant with isolator, forced ventilation 8
2.3.3. General assembly of variants without isolator, natural ventilation 9
2.4. Description of individual units 10
2.4.1. Converter module G01 10
2.4.2. Snubber F01 11
2.4.3. Types of ventilation 12

3. Safety Regulations 14
3.1. Safety conditions 14
3.2. The results of non observation 14
3.3. Requirements for involved personnel 15

4. Maintenance 16
4.1. Introduction 16
4.2 Maintenance work 16
4.2.1. 3 monthly on the working equipment 16
4.2.2. Yearly with the equipment on shutdown 17

5. Repairs 18
5.1. Important points to be observed before work starts 18
5.1.1. Converter cabinets with isolators 18
5.1.2. Converter cabinets without isolators 20
5.2. Fault sources and fault elimination 20
5.2.1. Thyristor defect 21
5.2.2. Fault in the snubber 23
5.2.3. Faults in the ventilator box 26
5.2.4. Overheating through poor cabinet ventilation 27
5.3. Changing a thyristor 28
5.3.1. Tools and auxiliary materials 28
5.3.2. Replacement of thyristors UNS 4680 Var. 87,88,89,98 29
5.4. Function check 31

6. Spares 32

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 Maintenance and Repair Instructions

1. Introduction
1.1. Using these Operating Instructions

The contents of these instructions will provide you with all the information necessary for
the maintenance and repair of the electrical components of a Converter Cabinet Type
UNL 133

.

1.2. Definition of symbols used in this document

General Warning
This symbol in front of the text warns of situations or conditions which can
endanger life or cause potentially fatal injuries. The description indicates the
procedure to be followed in order to avoid risks.

Dangerous Voltage
This symbol indicates that dangerous voltages are involved which can
endanger life or cause potentially fatal injuries.

Attention Attention is used to mark the parts of the text which contain information on
situations and conditions which, if they are not paid attention, can cause
material damage or equipment failure.

Note Note is used to mark the parts of the text which contain information on
situations and conditions which, if they are not paid attention, can lead to
undesirable operating conditions or automatic shutdown.

1.3. Related documents

- Data sheet ”Standard Converter Cabinet UNL 133

" (3BHS121826 E01)
- Operating Instructions for the complete equipment (Excitation system)

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2. Description of equipment
2.1. Overview

A converter cabinet of the UNL 133

type has a modular construction and consists of
the following units:

Converter Module (-G01)

The converter module UNS 4680 is a fully controlled 3-phase bridge with six thyristors
cooled on both sides. To protect the thyristors against overcurrents, which can result
from internal or external short-circuits, each thyristor branch has an ultra fast fuse with
defect indication switch.

Snubber (-F01)

The snubber (overvoltage protective circuit) UNS 4681 protects the six thyristors in the
converter module from undesirable overvoltages. The unit has a 3-phase protection on
the input side and the fuses are fitted with a defect indication switch.

Snubber resistor (-R01)

The external resistor is part of the snubber, however it must be ordered separately.

Types of ventilation (-E01)

A natural or forced ventilation is provided for the converter modules. Forced cooling can
consist of simple, redundant or reinforced ventilation.

Isolator 1600 A / 1000 V or 2000 A / 1000 V (-Q01)

The converter module is available with or without an isolator.

Coils for current flow monitoring (-T02, -T03)

At parallel operation (n-1 redundancy) the converter modules are equipped with current
seonsors at the positive and negative connections. Thus an automatic current balance
can be achieved and the functionality of each semiconductor can be observed. The
current sensors transfer the measured current values to the control board (COB) UNS
2880. Defective thyristors are indicated on the converter display (CDP) UNS 0885.

For technical performance data see data sheet 3BHS121826 E01.

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2.2. Key to Types and Variants

The type key UNL 133

defines the converter cabinet i.e. the parts which are built
into a cabinet of 1000 x 1000 x 2200 mm.

The last 2 digits in the type designation UNL 133

identify the type of thyristor being
used and the snubber.

The Variant Var. _ _ _ _ defines the ventilation and the degree of IP protection:

UNL 133 Var.  for UN 5000 applications with Gate Driver Interface (GDI)

Type of ventilation:
1 without (natural ventilation)
2 with 2 fans
3 with 2+2 fans (redundant ventilation)
4 with 4 fans (rectified ventilation)

Eintritts- / Austrittsöffnungen:
00 Specified by customer
03 4 grids with filter IP31/ roof grid IP30
08 2 grids with filter IP31/ roof hood w/o flaps IP31
09 2 grids with filter IP54/ roof hood with flaps IP54

Schutzart:
0 IP00 or specified by customer
3 IP30
4 IP31
5 IP54

Systeme mit forcierter Kühlung

Thyristor: Converter Module: Snubber: Resistor:
3BHB005885R00xx 3BHE004074R051x
87 3BHS126937 UNS4680 Var.87 UNS4681 Var.512 HIER465106P0001
88 3BHS126938 UNS4680 Var.88 UNS4681 Var.511 HIER465107P0001
89 3BHS126939 UNS4680 Var.89 UNS4681 Var.511 HIER465107P0003

Systeme mit Selbstkühlung

Thyristor: Converter Module: Snubber: Resistor:
3BHB005885R0098 3BHE004074R0511
98 3BHS126938 UNS4680 Var.98 UNS4681 Var.511 HIER465107P0001

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Maintenance and Repair Instructions

2.3. Mechanical layout

2.3.1. General assembly of variant without isolator, forced ventilation

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2.3.2. General assembly of variant with isolator, forced ventilation

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2.3.3. General assembly of variants without isolator, natural ventilation

The following diagram shows the side view of the cabinet. The arrows indicate the
airflow caused by natural convection.

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2.4. Description of individual units

2.4.1. Converter module G01

The converter module (UNS4680) consists of an assembly plate on which 6 thyristors

are mounted (-V1 to -V6). Each thyristor is located between two heat sinks. The branch
fuses (-F1 to -F6) are fixed to the front heat sinks. Each set of three are attached to a
connecting rail, the upper being the minus rail and the lower being the plus rail. The
alternating current connections (AK1, AK2, AK3) are arranged at the top. On the left-
hand side of the assembly plate, the converter interface CIN (UNS 0880) and the gate
driver interface GDI (UNS 0881) are fixed which are necessary for firing of the thyristors.
The elements of the rectifier bridge are numbered so that those belonging to individual
branches have equal numbers. Thus V1, F1 or V2, F2 etc., create each of the six
branches.

To identify the module a type plate (1) is provided on the right-hand side. The type plate
contains all the information necessary for the ordering of spare parts.

CIN

(1)

GDI

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2.4.2. Snubber F01

The snubber (UNS4681) consists of the following parts:

(1) Assembly plate with the diodes (-V1 to -V6), capacitor (-C1) and fuse holder (-F02)
with three fuses.

(2) Resistor (-R1). The resistor is part of the snubber, however it must be ordered
separately.

UNS4681 Var 511 (-V1 to -V6)

UNS4681 Var 512 (-V1 to -V3)

-R1

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2.4.3. Types of ventilation

Basically the following variants are available:

Natural ventilation of the converter module

The heat produced by the thyristor losses is

carried away by the natural air flow which is
established by the chimney effect of the heat
sinks. No fans are required.

To prevent the thyristor modules from mutually (1)

heating each other a baffle plate (1) is directing
the warm air from the lower module towards the
rear.

Natural ventilation is only possible in cabinets with

a roof grid according to standard IP30. Cabinets
according to higher protection standards are not
available, because a closed roof makes natural air
circulation impossible.

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Maintenance and Repair Instructions

Forced ventilation of the converter module

Variant 1: simple ventilation

This consists of a six part channelling kit

(2) which directs the air through the
converter module and a ventilator box (3)
with two fans.

Variant 2: redundant ventilation

Like Variant 1, but with four fans. Only two (2)

of the fans are in operation at the same
(2)
time.

Variant 3: reinforced ventilation

Like Variant 1, but with four fans. All four

fans are always in operation.

(2)
(2)

(3)

M1 M3
Arrangement of the fans and switches with S1 S3
full set.

(Viewed from above)

Air entry
M2 M4
S2 S4

-E01

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3. Safety Regulations

3.1. Safety conditions

Warning signs are fitted to all cabinet doors to warn of the operating voltages present in
the control cabinets (over 50 volts), but in particular to warn of the voltages occurring in
the power section (over 1000 volts possible) and the enormous short-circuit currents
which may occur. These signs warn personnel against opening the doors during
operation.

Symbol Meaning

Danger, High Voltage !

Work on the electrical equipment can only take place if the affected voltage carrying
parts are switched off on all sides and earthed. Should this not be possible, the following
special procedures must be taken:

The work area must be fenced off and a yellow warning notice ”Danger - High Voltage”
is to be provided.

Precautions are to be taken to prevent any switched off equipment being switched on
again through a control fault or a third person, e.g. by using a locked off key switch to
prevent a switch on.

3.2. The results of non observation

Non observation of the safety regulations can result in the danger of electrocution for
the personnel involved and extensive damage to the equipment.

Should any cover which provides isolation to the live parts, be

removed there will be a great danger of electrocution, not only for
the personnel working on it, but also for a third person
approaching the equipment.

If the intended maintenance work is not or only partially carried out, damage can result
leading to high repair costs. In particular dirt and dust layers can build up in the
converter with a great risk of flashover which can cause enormous damage.

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3.3. Requirements for involved personnel

The maintenance personnel are familiar with this document.

The maintenance personnel are trained for carrying out the mechanical as well as the
electrical installation work e.g. as necessary for fan replacement.

The maintenance personnel are familiar with the accident prevention procedures at their
working place and trained in first aid and fire extinguishing procedures .

They or a supervisor are familiar with the operation of control elements, operating and
alarm indicators of the excitation unit both on the excitation unit itself (Local Operation)
and in the Control Room (Remote Operation).

They or a supervisor are aware of the power supply concept for the excitation unit as
well as the emergency stop procedures and, in the event of an emergency, could switch
off the power.

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4. Maintenance
4.1. Introduction

Although the electronic components display no signs of wear, and only slight signs of
ageing, the converter cabinet includes a range of conventional electromechanical
components, e.g. fans, which are subject to a certain degree of wear.

Due to air circulation dirt can build up in the converter. Faston plug connections can
become loose through vibration.

Therefore periodic attention is necessary to guarantee operation without any

interruption.

Attention: During maintenance and repair work only original replacement parts
are to be used. In order to ensure, in the event of a breakdown, a rapid
and problem free replacement, the important components are to be
procured and held ready in the stores. (For recommended spares see
section 6).

4.2 Maintenance work

The maintenance work is divided into 3-monthly checks on the working equipment and
more substantial works are to be performed on the occasion of planned revisions during
an equipment shutdown, normally on a yearly cycle. Normally the maintenance work is
limited to checking. Routine maintenance work such as lubricating bearings is not
necessary.

Checking work can be carried out while the converter is still in operation. For all repair
work, such as fan changing, cleaning the converter module, etc., the equipment must be
switched off and the safety regulations and preparation procedures of section 5 strictly
observed.

4.2.1. 3 monthly on the working equipment

Checking of the fans (ventilator box or door fans) for abnormal noises. Lubricating the
bearings is not possible. The fans are to be replaced after ca. 25,000 working hours.

The step-by-step procedure for exchanging fans is described in sections 5.2.3 and
5.2.4.
If the converter is provided with standby fans the working fans are to be switched over
periodically. The switching can be carried out while the equipment is working.

Checking of the filter mats for dirt. The mats can be changed with the doors closed (see
section 5.2.4.).

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4.2.2. Yearly with the equipment on shutdown

In order to carry out the yearly maintenance work it is necessary

to open the cabinet doors and remove the contact protection
covers.
Work may only be carried out on the converter cabinet if the
voltage carrying parts have been switched off on all sides
and earthed.
For this, the personnel involved are responsible and must adopt
the safety procedures described in sections 3 and 5.1.

Checking of the dust situation in the converter. With the heavier layers especially on the
heat sinks, cleaning should be with oil free, dry, compressed air.

If an isolator is fitted: Visually check the isolator for dirt and burning off on the contacts.

Checking of the Faston plug connections for grip (the Faston plugs must be positively
engaged).

For equipment without current monitoring it is recommended that the firing of the
thyristors is checked together with the pulse generation of the control electronics (see
operation and maintenance manual of the excitation equipment). If this is not possible, a
simple check can be carried out with the help of a continuity tester. (see section 5.2.1).

After cleaning work on the converter module, the function checks are to be carried out
according to section 5.2.1.

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5. Repairs
5.1. Important points to be observed before work starts

In order to carry out the majority of repair work, the affected cabinet must be switched
off and the converter module earthed. In general the whole equipment must be
completely switched off.

Work on the cabinet door e.g. changing the filter mat can be carried out while in
operation.

Certain work can be carried out with the isolator open on variants which have isolators
on each converter cabinet while the remaining equipment is in operation.

Before commencing any repair work the following procedures are

to be carried out. The safety procedures of section 3 are to be
strictly observed.
Work on the converter cubicle can only be carried out if the
voltage carrying parts in the cabinet have been switched off
and earthed.

5.1.1. Converter cabinets with isolators

Once the isolator has been opened the majority of repair work can be carried out while
the remaining equipment is in operation. Exceptions are works on the snubber circuit
which is located close to the primary side of the isolator connections, which are under
voltage even with the isolator open. Care is also to be taken as the auxiliary voltage for
the fuse monitoring is not interrupted by the isolator.

The following works relate only to parts which are located in the
areas switched off by the isolator. For work on the snubber cicuit,
the preparation procedures must be carried out according to
section 5.1.2.
Despite the isolator, extreme care is to be taken when
carrying out repair work, since the neighbouring cabinets
are not free of voltage. Short-circuit currents can lead to
potentially fatal injuries and major material damage.

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Maintenance and Repair Instructions

Preparation procedures:

1. Open the isolator.

2. Remove auxiliary voltage for the fuse monitoring (see equipment circuit diagram).

3 Earth AC and DC rails.

(AC and DC main leads of the excitation).

R01

-Q01

AK1 + AK2 - AK3

T31 T32 T33

-G01

-E01

Earthing cable

4. Remove contact protection (Plexiglas).

5. In variants with forced ventilation remove the front part of the channelling.

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 Maintenance and Repair Instructions

5.1.2. Converter cabinets without isolators

For all works inside the converter cabinet, the equipment must be switched off and the
voltage carrying parts must be earthed.

Preparation procedures:

1. Switch off the whole equipment.

2. Remove auxiliary voltage for the fuse monitoring (see equipment circuit diagram).

3. Earth AC and DC rails.

(AC and DC main leads of the excitation).

4. Remove contact protection (Plexiglass).

5. In variants with forced ventilation remove the front part of the channelling.

5.2. Fault sources and fault elimination

The converters described here are always part of an excitation unit and consist of
control and power components. Breakdowns in a converter cabinet will be reported
through a monitoring contact (e.g. fuse auxiliary contacts) to the control system and the
source can then be localised with the help of the alarm indicator on the control cabinet
as well as the operating instructions on the excitation unit.

The possible sources of faults as well as the procedures for the elimination of the
internal faults within the converter cabinet are listed below:

Thyristor defect: section 5.2.1

Carrying out the thyristor test.

Replacing a thyristor.
Replacing a branch fuse.
Function check.

Fault in the snubber: section 5.2.2

Carry out snubber test.

Changing of fuses.
Repairing the snubber.
Function check.

Fault in the ventilator box (with forced ventilation): section 5.2.3

Removal of the ventilator box.

Changing a fan.
Function check.

Overheating through poor cabinet ventilation: section 5.2.4

Changing the filter mats.

Function check.

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5.2.1. Thyristor defect

For more accurate fault diagnosis and its elimination the affected
converter cabinet must be switched off. Then the preparation
procedures of section 5.1 are to be essentially carried out.

Carrying out the thyristor test

1. Identify the defective thyristor branch:

For equipment with current flow monitoring the defective semiconductor will be indicated
by an LED on the UNS 0674 operating panel. This also applies to loss of blocking
capabilities and a failure to fire.

For equipment without current monitoring the auxiliary contact on the branch fuses must
be checked:

The loss of blocking capability of a thyristor

always leads to a response of the
associated branch fuse. The fuses are
equipped with signalling contacts i.e. the
affected converter branch is identifiable (1) (2)
through the protruding red plastic part of
the signalling contact.
(1) = response
(2) = no response

2. Remove defective fuses

In section 5.3 the step-by-step procedure for the removal of a semiconductor is

described. To remove a fuse steps D1 and D2 of these instructions are to be followed.

3. Testing the blocking ability of the thyristor:

The blocking ability of a thyristor must be tested before its removal. In the unmounted
position thyristors basically do not work since the silicon layer only makes contact within
the thyristor by pressure. A simple test can be made with a continuity tester (torch, test
buzzer) with a DC voltage of 3V to 10V.

Apply the voltage of the continuity tester in

the forward direction of the thyristor: for the - +
upper half of the bridge (+) to the front heat
sink, (-) to the rear one. The tester must
not indicate continuity.

For the lower bridge half, reverse the GDI

polarities: (+) to the back heat sink, (-) to
the front one.
- V4

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If the tester shows continuity, there is a short circuit in the semiconductor. The element
must be replaced and returned to the manufacturer for a more precise fault diagnosis,
with a brief explanation of the origin of the fault.

4. Testing the firing ability of the thyristor.

If the thyristor blocks in the forward direction the firing can be tested.

Remove the gate wire (white) from the

- +
belonging connection on the gate driver
interface (GDI). Now fire the thyristor by briefly
contacting the (+) potential with the gate wire.
After being fired it must remain conducting
until the voltage is cut off. GDI

- V4

Should the tester show no continuity even when the gate wire is in contact, then either
the cable or the thyristor is defective and the semiconductor must be removed.

Should the tester only show continuity while the gate wire is in contact, it is possible that
the latching current is not reached. According to the size of the layers a current of 100
to 300 mA is required for the thyristor to continue conducting once fired. If this current
cannot be delivered by the continuity tester, the test must be carried out with a stronger
source (a power supply or similar). The voltage must not however be permitted to
exceed 10 V. If the thyristor is supplied with a higher current and still does not fire, it
can be considered to be defective and must be replaced.

The gate wire is to be reconnected after the test.

5. Testing with an unmounted thyristor.

In the unmounted condition the gate wire can be tested. If broken, the wire can be
replaced and the thyristor reinstalled. It is important however that the correct quality of
cable and a suitable connection plug is used. If in doubt replace the whole thyristor and
order a gate wire set from the manufacturer.

Note: On changing the gate wire ensure that the plug unit (Faston, etc.) is
tight. This connection can no longer be checked once the thyristor is
mounted.

The gate connection should never be soldered. This can damage the element.

To test the firing directly on the gate when unmounted, the thyristor housing must be
weighted down e.g. with the removed heat sink half. If the thyristor is defective it must
be returned to the manufacturer with a short explanation of the fault situation.

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Replacing a thyristor

The step-by-step procedure for changing a semiconductor is described in section 5.3

Replacing a branch fuse

This is achieved following the step-by-step instructions in section 5.3. Removal is as

steps D1 and D2, reinstalling is as described in M5 and M6.

Function check

1. After changing a fuse the functioning of the fuse monitoring is checked by withdrawing
the red plastic part of the indicating switch until it latches. This simulates the operation
of the fuse. Correct signalling by the control system can now be checked. Finally the
indicating switch can be reset.

2. After cleaning and repair works on the main circuit a visual check and an insulation
check are to be carried out before returning the unit into operation. First check visually
whether all tools have been removed and no loose parts remain in the cabinet. On
completion of repair work remove the earthing from the main circuits and connect
together the five main leads AK1, AK2, AK3, (+) and (-) of the converter module and test
to earth. In this way, the pulse cables are also tested up to the pulse transformer. The
insulation resistance must not be less than 1 MOhm.

3. As a further test the insulation resistance between the heat sinks can also be checked.
For this it is essential that the maximum permitted blocking voltage of the thyristor is
taken into account. The type of converter module is to be noted from the type plate,
then the thyristor type and blocking voltage can be found in the 3BHS121826 E01 data
sheet.

Attention: The maximum blocking voltage of the thyristor must not be exceeded
during testing, otherwise there is a danger of destroying the
component.

5.2.2. Fault in the snubber

For an accurate diagnosis and fault elimination all the power

components of the equipment must be switched off. Even on
variants with an isolator, work on the snubber is not possible with
the equipment in operation as there is a danger of contact with
the primary side of the isolator. It is essential that the preparation
procedures in section 5.1.2 are carried out.

Procedure for testing the snubber

1. Measure the capacitor voltage. The capacitor must be discharged, if not, discharge it
with a wire bridge.

2. Open the fuse holders. Defective fuses are indicated by the protrusion of the set stud.
This may either indicate a short circuited diode or a flashover of the capacitor. The fuse
holder can be left open for further measurements.

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3. Test the diodes with a continuity tester. The forward direction is presented below.
Depending on the sensitivity of the tester, the resistor must be disconnected first.
(Resistor -R01 ca. 1.2 kOhm).

UNS 4681, Var. 51x

AK K A
1 2 3

AK K A
1 2 3
6
7

4
5

4. Test the resistor and capacitor with an Ohmmeter. To clearly identify a defective
element it may be necessary to remove the wiring between the components.

Changing of fuses

Only original spare parts should be used when replacing defective fuses. Ensure that
the contact surfaces are clean and insert the fuses with the set stud upwards.

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Maintenance and Repair Instructions

Repairing the snubber

Only original spare parts should be used when replacing defective components. After
replacements, the wiring must be returned to its original state as shown in the following
diagrams:

UNS 4681, Var. 511

UNS 4681, Var. 512 (only one diode in serie)

Part of
plant-wiring

Variant with MDD44-18N1-B

test voltage 5 kV

Function check

In order to carry out the function checks, a fused single-phase auxiliary power supply is
required e.g. for fan supply, heating, etc., maximum voltage 440 VAC.

With the fuse holder open, connect the auxiliary power supply to two AC connections of
the snubber, then measure the voltage across the capacitor. If functioning correctly, the
voltage should amount to 1.25 x the effective value of the applied AC with tolerance of
+/- 5%. Now a lead from the auxiliary power supply is moved to the third AC connection
and the measurement is repeated. Finally the fuse holder is closed.

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 Maintenance and Repair Instructions

5.2.3. Faults in the ventilator box

For more accurate fault diagnosis and its elimination the affected
converter cabinet must be switched off. Then the preparation
procedures of section 5.1 are to be essentially carried out.

Removal of the ventilator box

(1) 1. The fans should be switched off by
opening the appropriate protection
switches (see equipment circuit
-F1 -F3 -F5 diagram)
2. Release wire binders and pull out
(2) (3) the plug (1).
3. Release fixing screws in positions
(2) and (3).
-E01
4. Withdraw the ventilator box (-E01)
from the front (4).
5. Insert new ventilator box and refit all
screws.
(4) 6. Re-insert plug (1) and fix the wire
binders.
7. Reclose protection switches.

Changing a fan

The fan can only be replaced with the

ventilator box removed.
1.The cable duct within the box must
(1)
be opened and the cable released
from its terminal.
2. The airflap (1) on the defective fan
must be carefully raised (taking
care not to bend the operating flags
for the auxiliary contact !).
(2)
3. The four screws (2) are to be
released and the fan lifted out.
4. Install the new fan.
5. Check the operation of the air flap
(easy movement, the switch will
operate).
6. Reinstall the ventilator box.

Function check

Switch on the fan supply, check for flow direction and quiet working. Check the
operation of the flap and the signalling contact.

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Maintenance and Repair Instructions

5.2.4. Overheating through poor cabinet ventilation

Changing the filter mats

Withdraw the air grid from the front. Now the filter mat can be changed. Finally, fix the
air grid back into position.

During installation note the direction of the slats, they have to point downwards.

(1)

(2)

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 Maintenance and Repair Instructions

5.3. Changing a thyristor

In the next section, the removal of a defective thyristor and the installation of its
replacement is presented in illustrated steps with comments.

For simplification purposes, in the diagram only the upper bridge half is represented. On
the lower bridge half the fuses are mounted under the heat sink. Apart from the
thyristors being the other way round (Anodes and Cathodes are reversed !) the
procedure remains the same.

Different clamping fixtures are used for the 3” thyristors to those used for the smaller
types. Attention should therefore be paid to the converter type when replacing a thyristor
(check with type plates for G01 converter modules). section 5.3.2 applies to 2” and 2.5”
thyristors - section 5.3.3 for 3” thyristors.

The affected converter cabinet must be switched off when

carrying out the following work. For this purpose it is essential
that the preparation procedures described in section 5.1 are to
be carried out.

5.3.1. Tools and auxiliary materials

No special tools are required to carry out a thyristor change. In addition to the normal
tools like screwdrivers, allen keys, spanners, etc., the following tools and materials are
to be available:

Tools:

Torque spanner 30 Nm
Straightedge
A rustfree steel wire brush
Clamping tool for cable end connectors
Faston cable end connectors 6.3 x 0.8 mm

Auxiliary materials:

Silicon grease:
Temperature resistant silicon grease (Melt temperature > 180o C)
(ABB Identification No. NBT 400 725 P1)

Contact grease for rail connections:

Acid free Vaseline grease without abrasive contents
(ABB Identification No. NBT 400 055 P2)

Industrial alcohol (denatured light spirit)

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Maintenance and Repair Instructions

5.3.2. Replacement of thyristors UNS 4680 Var. 87,88,89,98

Removal of a thyristor see steps D1 to D6

Installation of a thyristor see steps M1 to M6

(1) D1 Release nut (2), withdraw threaded

(2) bolt (1).

M6 Screw in threaded bolt (1) by hand and tighten nut

(2) with a 22 Nm torque.

Note: Always screw in the threaded bolt by hand up to

stop.

D2 Remove the auxiliary contact from the fuse. Release

(5) nut (3). Withdraw threaded bolt (4). Remove fuse (5).

(3)
M5 Install fuse (5) and threaded bolt (4). Tighten nut (3)
(4) with a torque of 22 Nm. Attach auxiliary contact to
fuse.

D3 Release the pressure on the clamping fixture by

D3 loosening the nuts (6) and (7) alternately with ¼
turns. Remove the nuts. Remove the yoke (8) along
with its spring set.
(6)
(9)
(14) M4 Push yoke (8) over the bolts. First tighten nuts (6)
(10) and (7) by hand. Then with a spanner alternately
M4 tighten with ¼ turns until the yoke no longer displays
(7) any curvature (check with straightedge (9)).

(8)

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 Maintenance and Repair Instructions

D4 Remove the front half of the heat sink (11).

M3 Push front heat sink half (11) over bolts (12).

(10)

(11)

D5 Remove gate connections to thyristor. (In the event

of a defective gate wire: remove the connections
from the pulse transformer and cut away the wire
(12) binder on the gate wire). Remove the thyristor (13)
with holder.

(13) M2 Push the new thyristor (13) with its holder over the
bolts (12). Connect the gate lead to the thyristor. (In
the event of a defective gate wire: lay out a new wire
(12) and fix with a wire binder. Insert the gate lead into
the pulse transformer: white to connection 6, red to
7).
Note: Before inserting the new gate wire, cut it to the
required length and fit with suitable AMP wire end
terminals.

Minus-Schiene
negative lead D6 State before mounting of new thyristor.

M1 Clean the contact surfaces of both heat sink halves

thoroughly with alcohol. Then apply some silicon
grease to a steel wire brush and roughen the contact
surfaces by brushing them (crosswise). This
removes the aluminium oxide layer. Wipe away the
resultant black material. Finally with clean, non
fibrous cloth deposit a little silicon grease on the heat
sinks’ contact surfaces.
Note: The contact surfaces must only be provided with a
thin film of grease ! Once the grease is
applied mount the thyristor immediately.

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Maintenance and Repair Instructions

5.4. Function check

The function checks are described in each section, however in general the following
applies:

After all work on the main circuit before returning the unit into operation, a visual check
is to be carried out along with an insulation check. First check visually whether all tools
have been removed and no loose parts remain in the cabinet. On completion of repair
work remove the earthing from the main circuits and connect together the five main
leads AK1, AK2, AK3, (+) and (-) of the converter module and test to earth. In this way,
the pulse cables are also tested up to the pulse transformer. The insulation resistance
must not be less than 1 MOhm.

After the checks all tools, measuring instruments and test cables are to be taken away.
All covers (contact protection, channelling front cover) are to be put back in position.

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 Maintenance and Repair Instructions

6. Spares
When changing assemblies or components only original spare parts are to be used.

In order to be able to carry out the necessary repairs as quickly as possible in the event
of a breakdown, we recommend that you keep certain spare parts in store. The
numbers of these parts is dependent on:

The number of converters per equipment.

The number of equipments in the power station.
The number of redundant systems.

ABB will prepare for you an individual spare parts quotation which takes all of the above
mentioned points into consideration.

Note: On follow-up orders the delivery time e.g. for thyristors can be up to 12 weeks.

Order Numbers for Spare Parts:

Description Component Order No. Data

Thyristor -V1 to -V6 3BHS 126937 1800 V / 75 mm Si ∅
3BHS 126938 2800 V / 75 mm Si ∅
3BHS 126939 4200 V / 75 mm Si ∅
Branch Fuses -F1 to -F6 HIER 465095 P0003 1400 A / 1100 V
Fuse holder -F02 3BHE 002966 R0003
Fuse (3 pcs) HETT 401476 P0014 50 A / 1500V
Fuse holder -F02 HIER 319862 R0001
Fuse (3 pcs) HETT 401475 P0109 40 A / 660V
Diode module (3 or 6 pcs) -V1 to -V6 LGV 452578 P4418
Capacitor -C1 HEIS 413794 P0002 32uF / 2800 V
HIER 464918 P0001 32uF / 1800 V
Resistor -R01 HIER 465106 P0001 1240 Ohm / 800 W
HIER 465107 P0001 1133 Ohm / 2400 W
HIER 465107 P0003 1500 Ohm / 2400 W
Fan (-E01) HIER 465117 P0001
Mesh IP31 -- 3BHB 001490 R0001
Filter Mats IP54 HIER 467078 P0001

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