VFM74 3BHE046084R0001 PCS 6000 system power distribution cabinet Replacing IGCTs
Date: Sept 10, 2025Views:
1. Release the stacks according to section 10.6.2, Releasing the stacks, page 141.
2. Disconnect the fiber optic and power supply cables of the faulty IGCT as well as the one directly above it.
3. Remove both gate unit fixations (left and right) of the faulty IGCT completely by loosening the mounting screws with a 3 mm Allen wrench. IMPORTANT! Do not drop the nut from the bottom side.
Figure 10–14 Removing the gate unit fixations of the IGCT
4. Insert the spreading tool completely into the slots of the heat sinks above and below the faulty IGCT and expand it according to section 10.6.3, Using the spreading tool, page 145.
5. Extract the IGCT.
NOTICE Hold the IGCT at the black plastic frame and support from underneath as shown in Fig. 10–16.Avoid touching the gate drive board or semiconductor.
6. Insert the new IGCT carefully in the guiding rail until it is snapped into position by the positioning and stop device.
NOTICE Incorrect insertion of the IGCT can damage the IGCT and misalign the stack. When the IGCT is correctly inserted it can be heard and felt when it snaps into position.
7. In case the new IGCT is not fitted with positioning and stop devices remove them from the faulty IGCT and use them on the new one (see Fig. 10–18). CAUTION! DO NOT use any grease or any electrical joint compound.
8. Clean the contact surfaces of the IGCT with a fluff-free cloth.
• Clean heavily polluted surfaces with a cleansing agent (eg, pure alcohol). The surfaces must be free from dust, fat and oil.
• Make sure not to scratch the surface.
9. Lower the stack and remove the spreading tool.
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10. Remove the stabilizer plate.
11. Remount the gate unit fixations to the new IGCT without tightening the clamping screws (see Fig. 10–14).
12. Reconnect the fiber optic and the power supply cables (see Fig. 10–13).
13. Check the stack alignment according to section 10.6.6, Checking stacks alignment, page 159.
14.Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166.
15. Re-check the IGCTs as described in section 9.8, Checking IGCTs with multimeter (if a
FADEC 3 is unavailable), page 127.
16. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Replacing freewheeling diodes
▶ Always verify the polarity with the corresponding wiring diagram.
▶ DO NOT use any grease or any electrical joint compound.
▶ Pay attention to the correct polarity when inserting the new diode.
1. Release the stacks according to section 10.6.2, Releasing the stacks, page 141.
2. Insert the spreading tool completely into the slots of the coolers above and below the faulty diode and expand it according to section 10.6.3, Using the spreading tool, page 145.
3. Replace the faulty diode with a new one.
4. Clean the diode contact surfaces with a fluff-free cloth. – Clean heavily polluted surfaces with a cleansing agent (eg, pure alcohol). The surfaces must be free from dust, fat and oil. – Make sure not to scratch the surface.
5. Use the centering ball on the lower heat sink (see Fig. 10–19) to position the diode.
The diode snaps in place when it has been centered correctly.
NOTICE Failure to center the diode correctly can damage the diode and cause stack misalignment.
6. Rotate the diode so that you can easily see the serial number (see Fig. 10–20).
7. Remove the spreading tool.
8. Check the stack alignment according to section 10.6.6, Checking stacks alignment, page 159.
9. Remove the stabilizer plate.
10. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166.
11. Re-check the diodes according to section 9.9.2, Checking freewheeling diodes, page 129.
12. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Replacing clamp diodes
The position of the clamp diodes is at the top and bottom of each phase stack (see Fig. 10–21).
Procedure:
1. Release the stacks according to section 10.6.2, Releasing the stacks, page 141.
2. Insert the spreading tool completely into the slots of the coolers above and below the faulty diode and expand it according to section 10.6.3, Using the spreading tool, page 145.
3. For a smooth replacement, position the replacement diode next to the faulty one.
IMPORTANT! The lower clamp diode is centered with a centering ball on the lower heat sink. The copper bar and the isolator is then centered on the diode. Great care must be taken not to lose the upper centering ball of the copper bar and the isolator while removing or replacing the diode. Ideally, get assistance of another person.
4. Remove the faulty diode and immediately insert the replacement diode.
5. Clean the diode contact surfaces with a fluff-free cloth.
• Clean heavily polluted surfaces with a cleansing agent (eg, pure alcohol). The surfaces must be free from dust, fat and oil.
• Make sure not to scratch the surface.
6. Use the centering ball to position the diode.
• Upper clamp diode: centering ball is below the diode
• Lower clamp diode: centering ball above and below the diode
The diode snaps in place when it has been centered correctly.
NOTICE Failure to center the diode correctly can damage the diode and cause stack misalignment.
7. Rotate the diode so that you can easily see the serial number (see Fig. 10–20).
8. Remove the spreading tool.
9. Remove the stabilizer plate.
10. Check the stack alignment according to section 10.6.6, Checking stacks alignment, page 159.
11. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166.
12. Re-check the diodes according to section 9.9.3, Checking clamp diodes, page 130.
13. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
Replacing neutral point (NP) diodes
The NP diodes are located above and below the copper busbar (see Fig. 10–23). Procedure:
1. Release the stacks according to section 10.6.2, Releasing the stacks, page 141.
2. Insert the spreading tool into the slots above and below both NP diodes as illustrated in Fig. 10–23.
Two diodes are in-between the spreading tool.
IMPORTANT! The spreading tool must not be spread too far; the gear wheels have to grip into each other
3. Expand the spreading tool according to section 10.6.3, Using the spreading tool, page 145.
4. Replace the faulty diode with a new one.
5. Clean the diode contact surfaces with a fluff-free cloth.
– Clean heavily polluted surfaces with a cleansing agent (eg, pure alcohol). The surfaces must be free from dust, fat and oil.
– Make sure not to scratch the surface.
6. Use the centering ball on the lower heat sink (see Fig. 10–24) to position the diode. The diode snaps in place when it has been centered correctly.
IMPORTANT! Failure to center the diode correctly can damage the diode and cause stack misalignment.
7. Remove the spreading tool.
8. Remove the stabilizer plate.
9. Check the stack alignment according to section 10.6.6, Checking stacks alignment, page 159.
10. Tighten the stacks according to section 10.6.7, Tightening the stacks, page 166.
11. Re-check the diodes according to section 9.9.4, Checking neutral point (NP) diodes, page 131.
12. Restart the PCS6000 according to section 5.4, Start-up after
maintenance or troubleshooting, page 70.
3BHS600000_E80_RevF_Service_Manual_PCS6000 Replacing IGCTs(1).pdf
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