PCS 6000 system power distribution cabinet Preventive maintenance POU72 3BHE051398R0102

　　4.3. 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.

　　4.4.2.2. 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.

　　Figure 4–1 Bolt connections, checking the tightening torque markings

　　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.

　　Cleaning

　　Risk of component damage!

　　The PCS6000 contains components which are sensitive to electrostatic discharge. Electrostatic-sensitive precautions must be applied and suitable tools must be used when cleaning boards and assemblies:

　　▶ Clean with special care using anti-static brushes and a vacuum cleaner.

　　▶ Dirt and dust on the electrical components can cause malfunctions and component failures!

　　▶ DO NOT use compressed air to clean the control system cabinets or converter under any circumstances.

　　▶ Dirt can be spread uncontrollably this way, which could lead to the corresponding malfunctions.

　　▶ DO NOT use alcohol or solvents when cleaning inside the cabinets or any electrical components.

　　Cleaning is necessary if dirt or dust accumulation (also called fouling) occurs within the converter. This could lead to thermally activated accelerated aging, which can be prevented by periodically cleaning.

　　Procedure:

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

　　2. Clean the room carefully with a vacuum cleaner. In the area around the converter, use a soft nozzle tube in order not to damage any components.

　　3. If necessary, clean the components with a dry cloth.

　　4. Clean all air inlets and outlets of the cabinets.

　　5. Clean the air inlets and outlets on all door and roof fans.

　　6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Replacing components

　　Effort 2 - 4 h

　　Replacement means exchange of components as part of the maintenance schedule or as a consequence of performed visual inspection or performance checks.

　　The procedures to replace components are described in chapter 7, Checking control components, page 81 or in chapter 10, Replacing power and cooling components, page 133. The corresponding sections are depicted in the following table.

　　For replacement tasks without a description of the replacement procedure in this service manual, always shut-down the PCS6000 according to “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22 Switch off the corresponding MCB (see electrical diagram) before replacing the component. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70

3BHS600000_E80_RevF_Service_Manual_PCS6000 Checking diodes, IGCTs and IPS (1).pdf

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