Chapter 04 - MM-FR-CT005-BE-2251-50-2004-00-C

Code:
User’s Manual
Text: Document no: 3BHS 130 197
ABB Schweiz AG / Switzerland
DIVISION ATD
Drives and Power Electronics
User's Manual
for
Cycloconverter Power Part
SAG MILL SOSSEGO 20000 KW

2251-MO-01
Plant: SOSSEGO
Product: VERITHYR WXM - Cycloconverter
Customer: Mineração, Serra do Sossego
ABB Schweiz AG
Order No.: 1-9 500 497
Issued: 18.07.01 / Frei Change: Off. resp.: ATDE Doc.-type Language Format Page No of
pages
Check. 1: 18.07.01 / Erne A Rec. off.: UM E A4 1 62
Check. 2: - B Der. from:
Released: 25.06.03 / Imboden C Replaces: 3BHS 130 197
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden.  ABB Schweiz AG
User’s Manual - SOSSSEGO - ABB Schweiz AG Order No. 1-9 500 497
Notice
Read this manual before energizing the converter!
In case of fire
High voltage!
Toxic Gases!
Overheating!
1. Press the emergency off button.

2. Put on a protection mask. Inflammable substances, toxic gases!
3. De-energize the converter.
4. Earth the de-energized converter module.
5. Don’t use water or any other chemical agent to extinguish the fire; use CO2.
Change Language Sheet Nr.
E 2 / 62 3BHS 130 197

Content
1. Introduction .......................................................................................................................................6
1.1 Why You Should Read this Manual ....................................................................................................6
1.2 How to Read The ‘User’s Manual’.......................................................................................................7
1.2.1 Safety Instructions ...........................................................................................................................7
1.2.2 Scope...............................................................................................................................................8
1.2.3 User Group of the ‘User’s Manual’...................................................................................................8
1.3 How to Use the ‘User’s Manual’ ..........................................................................................................8
1.3.1 All Information on Operation, Trouble Shooting, Maintenance, Technology, Quality and Safety in
One Manual ..................................................................................................................................................8
1.3.2 Copyright..........................................................................................................................................8
1.4 Quality .................................................................................................................................................9
1.4.1 ABB’s Quality Management Philosophy ..........................................................................................9
1.4.2 ABB Schweiz AG Switzerland Meets ISO 9001 and ISO 14001 Requirements ..............................9
1.4.3 National and International Certificates .............................................................................................9
1.4.4 European and International Standards ..........................................................................................10
1.4.5 International Standards for Design and Construction ....................................................................11
2. Transport, Storage, Erection..........................................................................................................12

2.1 Transport...........................................................................................................................................12
2.1.1 Safety.............................................................................................................................................12
2.1.2 Transport Conditions......................................................................................................................12
2.1.3 Packing ..........................................................................................................................................13
2.1.4 Loading and Unloading ..................................................................................................................13
2.2 Preservation and Storage .................................................................................................................14
2.2.1 Safety Instructions .........................................................................................................................14
2.2.2 Storage Conditions ........................................................................................................................14
2.2.3 Preservation...................................................................................................................................15
2.2.4 Periodical Inspections ....................................................................................................................15
2.3 Erection .............................................................................................................................................16
2.3.1 Safety Instructions .........................................................................................................................16
2.4 Preparatory Works ............................................................................................................................16
2.4.1 Foundation .....................................................................................................................................16
2.4.2 Cable Compartment.......................................................................................................................17
2.5 Converter Installation ........................................................................................................................17
2.6 Mounting the pipe connections .........................................................................................................18
2.6.1 Conditions of compatibility .............................................................................................................19
2.6.2 Flanged tube joints ........................................................................................................................19
2.6.3 Flanged Tube Joints ......................................................................................................................20
2.7 Final Control......................................................................................................................................21
3. Commissioning ...............................................................................................................................22
3.1 Safety Instructions.............................................................................................................................22
3.2 Why You Should Read this Chapter .................................................................................................24
E 3 / 62 3BHS 130 197

3.3 Converter Commissioning Phase 1 (Motor Disconnected) ...............................................................25

3.3.1 Preconditions .................................................................................................................................25
3.3.2 Mechanical and Visual Inspection .................................................................................................27
3.3.3 Performance Check .......................................................................................................................27
3.3.4 Operation Check with High Voltage Applied ..................................................................................27
3.4 Converter Commissioning Phase 2 - Power Part and Cooling Unit (Motor Connected) ..................28
3.4.1 Mechanical and Visual Inspection .................................................................................................28
3.4.2 Performance Check .......................................................................................................................28
3.4.3 Operation Check ............................................................................................................................28
4. Decommissioning ...........................................................................................................................29
4.2 Why You Should Read this Chapter .................................................................................................29
4.3 Converter Standstill...........................................................................................................................29
4.4 Converter Intermediate Storage........................................................................................................30
4.5 Dismantling the Converter and Separation of Materials....................................................................30
4.6 Disposal and Recycling.....................................................................................................................30
5. Operation .........................................................................................................................................31
5.2 Operation Instructions .......................................................................................................................31
5.2.1 General Configuration -VERITHYR WXM......................................................................................31
5.2.2 Field of Application and Main Features..........................................................................................32
5.2.3 Operation .......................................................................................................................................34
5.3 Trouble Shooting and Maintenance ..................................................................................................35
5.3.1 Trouble Shooting converter power part and cooling unit in general...............................................35
5.3.2 Trouble Shooting converter power part..........................................................................................36
5.3.3 Trouble Shooting Cooling Unit .......................................................................................................37
5.4 Care and Service ..............................................................................................................................40
5.5 Replacing of components of the converter power part......................................................................40
5.6 Replacement of Cooling Parts ..........................................................................................................41
5.6.1 Changing the Resin Filling in the Deionizing Devices KT001 or KT002 (if available) .....................42
5.6.2 Replacing the level sensor.............................................................................................................42
5.6.3 Replacing the pressure sensor CP001 or CP002 ..........................................................................43
5.6.4 Replacing the conductivity measuring device CD001 or CD002 ...................................................43
5.6.5 Replacing the temperature sensor CT001 or CT002 .....................................................................44
5.6.6 Replacing the flow transmitter ‘Bürkert’ Type 8025, CF001...........................................................44
5.6.7 Replacing and cleaning the strainer KT011 ...................................................................................45
5.6.8 Filling or refilling deionized water circuit ........................................................................................45
5.6.9 Replacing the pump .......................................................................................................................46
5.7 Maintenance Heat Exchanger...........................................................................................................46
5.7.1 Opening the heat exchanger..........................................................................................................46
5.7.2 Taking out the plates .....................................................................................................................47
5.7.3 Cleaning the plates ........................................................................................................................47
5.7.4 Gaskets..........................................................................................................................................48
E 4 / 62 3BHS 130 197

5.7.5 Adjusting the gaskets.....................................................................................................................48

5.7.6 Suitable gasket glue ......................................................................................................................48
5.7.7 Cleaning the gasket groove ...........................................................................................................49
5.7.8 Glueing the gaskets .......................................................................................................................49
5.7.9 Plates - Marking .............................................................................................................................49
5.7.10 Assembly ....................................................................................................................................50
5.7.11 Inserting the plates .....................................................................................................................50
5.7.12 Tightening the heat exchanger ...................................................................................................51
5.7.13 Lubrication ..................................................................................................................................52
6. Technology ......................................................................................................................................53
6.1 Technical Facts about the Converter ................................................................................................53
6.1.1 Identification...................................................................................................................................53
6.2 Dimensions and Specifications .........................................................................................................54
6.2.1 Power Converter Section ...............................................................................................................54
6.2.2 Cooling System..............................................................................................................................55
6.2.3 Identification Cooling Unit ..............................................................................................................56
6.3 Description of Essential Components ...............................................................................................57
6.3.1 Thyristors .......................................................................................................................................57
6.3.2 Thyristor Monitoring PCB (Printed-Circuit Board) ..........................................................................57
6.3.3 Pulse Transformers........................................................................................................................57
6.3.4 Snubber Circuit ..............................................................................................................................57
6.3.5 Overvoltage/Surge Protection........................................................................................................57
6.3.6 Base Load......................................................................................................................................58
6.3.7 Short-Circuiter................................................................................................................................58
6.3.8 Current and Potential Transformers...............................................................................................58
6.4 Inspection and Service Program for Converter and Water Cooling Unit ...........................................59
6.4.1 Overview ........................................................................................................................................59
6.4.2 Inspection Program for converter...................................................................................................59
6.4.3 Inspection Program for Cooling Unit ..............................................................................................60
6.4.4 Service Program Cooling Unit........................................................................................................61
6.5 Drawings ...........................................................................................................................................62
E 5 / 62 3BHS 130 197

1. Introduction
Notice
Keep this manual for future reference!
1.1 Why You Should Read this Manual

We ask you to please read this manual before starting the converter because
- you will see important safety and service information.

- you will learn about the many features of the converter and how to operate it properly.
- you will get top performance and longer life from the converter.
E 6 / 62 3BHS 130 197

1.2 How to Read The ‘User’s Manual’
1.2.1 Safety Instructions
The safety instructions always appear at the beginning of each chapter, paragraph and/or sub-paragraph.
The safety instructions are divided into five categories and emphasized by the use of the following safety
signs on the left side of the page:
Danger Herewith an imminent danger, which can lead to life

threatening injuries, is indicated.
! Attention Herewith a possibly dangerous situation, which could lead to bad

or life threatening injuries, is indicated.
! Caution Herewith a dangerous situation, which can lead to injuries,

is indicated.
Notice Herewith is indicated that something can damage the

converter.
! Important All important information is emphasized by the use of this

sign and text on the left side of the page.
E 7 / 62 3BHS 130 197

1.2.2 Scope
The 'User's Manual' is considered as an integral part of the delivery of the VERITHYR WXM. The 'User's
Manual' contains all information and instructions required for the safe and correct operation of the
VERITHYR WXM.
1.2.3 User Group of the ‘User’s Manual’
The 'User's Manual’ is directed primarily to the converter operator, the maintenance personnel and the
personnel in charge of transport, storage, erection and commissioning. They should have sufficient
electrotechnical or technical knowledge and experience.
1.3 How to Use the ‘User’s Manual’
1.3.1 All Information on Operation, Trouble Shooting, Maintenance, Technology,

Quality and Safety in One Manual
This manual provides all information and instructions for properly operating the converter. If you need
further information on a specific aspect, cross-references are given to easily find out the required
information. Always keep this manual at the operator's working place.
1.3.2 Copyright
ABB Schweiz AG reserves all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
E 8 / 62 3BHS 130 197

1.4 Quality
1.4.1 ABB’s Quality Management Philosophy
Customer satisfaction is one of the preconditions for ABB's continuous growth and success. For this
reason ABB's quality management philosophy focuses on fulfilling customer's needs to the highest extent.
ABB's quality management is based on
- the quality of products

- the quality of the processes
- the personnel education, training and development
- the cooperation and partnership with suppliers
- the time based management
- the corporate customer focus.
1.4.2 ABB Schweiz AG Switzerland Meets ISO 9001 and ISO 14001 Requirements
Total quality management, time based management and supply management are the basic elements for
the leading position ABB holds worldwide in quality aspects. Every two years ABB Schweiz AG,
Switzerland has to pass the Quality System Review done by an external group of experts in order to
assure the high quality standards. The quality management of ABB Schweiz AG, Switzerland meets all
requirements of ISO 9001and ISO 14001.
1.4.3 National and International Certificates
In accordance with ABB's quality management philosophy ABB Schweiz AG has been awarded the
following quality management certificates:
- SQS Certificate, category ISO 9001/ISO 14001

(Swiss Association for Quality and Management Systems)
- IQ Net Certificate ISO 9001 and ISO 14001

(The International Certification Network)
E 9 / 62 3BHS 130 197

1.4.4 European and International Standards
The converter's design corresponds to the relevant common security standards as defined in all member
states of the European community as precondition for exporting the products within the EEC.
The relevant EEC standards are:
- Council Directive of June 1989 on the approximation of the laws of the Member States relating to
machinery (89/392/EEC)
- Council Directive of June 1989 on the approximation of the laws of the Member States relating to
machinery (89/392/EEC) Annex 1: Essential health and safety requirements relating to the design
and construction of machinery
- Council Directive of 19 February 1973 on the harmonization of the laws of Member States
relating to electrical equipment designed for use within certain voltage limits (73/23/EEC)
- Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to
electromagnetic compatibility (89/336/EEC)
E 10 / 62 3BHS 130 197

1.4.5 International Standards for Design and Construction
The most important standards for the design, the construction and the test procedures of the ABB
Schweiz AG converters are:
- DIN/EN 60146 / IEC 146

Semiconductor converters; General requirements and line commutated converters
- DIN/EN 60204
Safety of machinery - Electrical equipment of machines;
Part 1: General requirements
- EN 60721 / IEC 721

Classification of groups of environmental parameters and their severities
- EN 292
Safety of machinery: Basic concepts, general principles for design
- IEC 439
Low voltage switchgear and control gear assemblies
- IEC 694
Common clauses for high-voltage switchgear and controlgear standards
- DIN/VDE 0110
Insulation co-ordination for equipment within low-voltage systems;
Fundamental requirements
- DIN 31000 / VDE 1000

General guide for designing of technical equipments to satisfy safety requirements
- DIN/VDE 40008
Electrical engineering; safety signs; survey
- DIN 55402
Marking for shipping of packages; directive for export packaging
- ISO 780
Packaging - Pictorial marking for handling of goods
E 11 / 62 3BHS 130 197

2. Transport, Storage, Erection
2.1 Transport
2.1.1 Safety
!
Do not step on the top side of the converter
You could be injured!
Notice
For transport and loading, the converter must always be in an upright position.
2.1.2 Transport Conditions
The transport conditions are defined on the basis of IEC 721-3-2 'Classification of environmental
conditions; Part 3: Classification of groups of environmental parameters and their severities;
Transportation'.
Classification: 2K1 / 2B1 / 2C1 / 2S2 / 2M1

Transport time: 1 month
Acceleration: max. 1g (m/sec2)
Microclimatic class: X2 / Y1
Pay attention to always fulfill the following environmental conditions inside the converter during transport:
Air temperature: +5 ... +40°C

Relative air humidity: max. 75% at 30°C
E 12 / 62 3BHS 130 197

2.1.3 Packing
Packing must be, so that the transport conditions according to IEC 721-3-2 can be conformed with.
2.1.4 Loading and Unloading
For loading and unloading the converter with the help of a lifting gear follow the instructions set out below.
See drawing 3BHS 126 277. Be sure to strictly observe the environmental conditions.
1. Always transport the converter in an upright position.

2. Always use the transport rails on the top with transport device.
3. The transport rails may only be removed if the converter is placed in its definite position. They
have to be remounted if the converter has to be transported again.
4. The material and diameter of the transport rope or chain has to correspond to the weight of the
converter module.
E 13 / 62 3BHS 130 197

2.2 Preservation and Storage

!
Do not step on the top side of the converter
You could be injured!
Notice
Always store the converter in an upright position.
2.2.2 Storage Conditions
The minimum requirements for storage are defined on the basis of IEC 721-3-1 'Classification of
environmental conditions; Part 3: Classification of groups of environmental parameters and their
severities; Storage'.
Classification: 1K2 */ 1B1 / 1C1 / 1S1 / 1M1

Storage time: 1 year
* max. allowed temperature: +55°C
Pay attention to always fulfill the following environmental conditions during the storage period:
Air temperature: +5 ... +55°C

Relative air humidity: 5% ... 85%
E 14 / 62 3BHS 130 197

2.2.3 Preservation
Take the following measures, if you want to store the converter module for one year. In case of a longer
storage period contact ABB service organization.
1. Install and fix the converter on a wooden frame or palette.

2. Cover all cable and air inlets and outlets with a wooden plate. Insert an impermeable plastic or
aluminum foil between the cover and the opening.
3. Add the desiccant of the appropriate quality: 1 unit desiccant (30g) absorbing 6g water vapor. You
need the following quantity with respect to the packaging material:
- PE foil: 10 units/sqm foil
- ALU foil: 8 units/sqm foil
4. Close the doors and lock them.
5. Use polyethylene or aluminum-combination foil as humidity barrier of the following quality:
- PE foil: 0,3g/sqm/24h water vapor diffusion
- ALU foil: 0,01g/sqm/24h water vapor diffusion
6. Add humidity indicators (e.g. mechanical hygrometers) within the packaging. Place them on the
converter front doors for example.
2.2.4 Periodical Inspections
During the storage period you should control the storage conditions and the condition of the converter
every month. For this reason check the condition of the packaging. Pay attention to damages caused by
mechanical forces, water/humidity and heat/fire.
If the packaging is damaged or you find damages caused by water/humidity or heat/fire you have to
unpack the converter and to check its condition outside and inside. Before storing the converter once
again all damages have to be removed. Preserve the converter as described above under paragraph
2.2.3.
E 15 / 62 3BHS 130 197

2.3 Erection
!
Erection
You could be injured and the converter could be damaged if you try to do Installation work
without knowing enough about it. Be sure you have sufficient knowledge, experience, and the
proper tools before you attempt any converter Installation task.
ABB Schweiz is well qualified to assist you in this work.
2.4 Preparatory Works

2.4.1 Foundation
The foundation for the converter has to be prepared as follows:
- horizontally adjusted +/- 0,5 %

- load capacity corresponding to the weight of the converter cabin
- protected against humidity diffusion
Note: For defining the exact location of the foundation and the minimum distances refer to the installation
plan 3BHS 126 278.
E 16 / 62 3BHS 130 197

2.4.2 Cable Compartment
The cable compartment has to be prepared as follows:
- non-abrasive
- protected against humidity, dust and entrance of animals
- protected against fire extension
! Important: All openings have to be well covered/sealed to prevent possible fire from extending
into the converter.
2.5 Converter Installation

Follow the instructions below to erect the converter cabin.
! Important: Be sure that all cable and water pipe inlets / outlets are protected against the
entrance of dust, humidity and animals.
1. Place the converter exactly on the prepared foundation and tighten all fixing screws.
2. If necessary support the converter with leveling shims.
3. Mark the location of the cable glands on the bottom shield. Be sure the cable glands diameter exactly
fits the cable diameters.
4. Remove the bottom shield, prepare the cable glands openings and mount the cable glands.
! Important: Be sure that there is no mechanical stress acting on the cables and the cable
terminals.
! Important: Observe the different torques for power cable connections as set out below
(specification of screws: ST-NR A2-70)
Size M10 M12 M16 M20 M24

Torque [Nm] 19.0 31.0 76.0 153.0 147.0
! Important: Pay attention to correct power and signal cable placing in order to prevent
interferences.
E 17 / 62 3BHS 130 197

Notice
Never use blank aluminum cable lugs in combination with copper bars.
This material mix could cause corrosion and damage the converter.
Use nickel-plated aluminum or copper cable lugs.
5. Always use the cable quality as described here.
a) HV and LV cables:
- temperature range from -55°C to +120°C
- halogen-free
- flame retardent
- cable cross section according to the operating current and installation conditions
- shielded cables for signal and control connections
b) Grounding cables/bars:
- cross section min. 2 x 150 sq. millimeters
c) Insulation level of all cables according applied voltages and regulations.
6. Fix the bottom shield and pull the cables through the cable glands. Tighten the gaskets.
7. Test the insulation (for all power and control cables) and fill out the test report (necessary for
commissioning). The insulation tests have to be performed with the following test voltages (IEC 146-
1-1):
Test Voltage / Low Voltage
UM / √2 Test Voltage
≤ 60 V 500 V
≤ 125 V 1000 V
≤ 250 V 1500 V
≤ 500 V 2000 V
Test Voltage / Medium Voltage
Line Voltage [kV] Impulse Voltage [kV peak] AC Voltage [kV rms]
(1,2 µs / 50 µs) (power frequency)
0,5 < ULN ≤ 1,1 not applicable 1 + 2 UM / √2
1,1 < ULN ≤ 3,6 not applicable 1 + 3 UM / √2
3,6 < ULN ≤ 38 15 + 3 UM / √2 1 + 1,8 UM / √2
8. Connect the power and earthing cables/bars according to diagram 3BHS 126 278.
9. Fix all information plates, safety signs and protection shields according to diagram
3BHS 126 276.
2.6 Mounting the pipe connections
E 18 / 62 3BHS 130 197

Location see drawing 3BHS 126 279.
2.6.1 Conditions of compatibility
Customer’s flange facings and bolting provisions must matched to the flange facings of the
Cycloconverter cooling circuit.
Customer’s tubing must not cause any mechanical stress on the Cycloconverter tubing.
Prior to connection to the Cycloconverter cooling circuit, customer’s tubing must be well cleaned and
flushed.
2.6.2 Flanged tube joints
Clean contact surfaces with white spirit.
Grease flange gasket slightly by means of a soft woolen cloth.
Insert flange gasket and tighten bolts crosswise.
! Important: Bolt threats must be well greased
E 19 / 62 3BHS 130 197

2.6.3 Flanged Tube Joints
Grease lubricant for flanged joints: Rhodorsil silicone lubricant No. 4

Grease lubricant for steel-bolt joints: Molikote lubricant
Supplier: Dow Corning, Munich, Germany
or a comparable lubricant
Insertion torques for flange-joint bolts with PN16. Bolt material quality: 4.6.
Nominal tube width [DN] 25 32 40 50 65 80 100 125

Bolt size [M] 12 12 16 16 16 16 16 16
Insertion torque [Nm] 25 30 45 55 52 50 48 52
smooth flange gaskets
E 20 / 62 3BHS 130 197

2.7 Final Control

1. Check all cable connections (position and torques).
2. Check the correct mounting and position of all cable shields.
3. Check the gaskets at the cable glands.
4. Check that the cooling connections inlet and outlet are properly installed.
5. Check the grounding cables/bars.
6. Check that the information plates, safety signs and protection shields are located at the right position
inside and outside the converter cabin.
7. Check position and fixing of all HV protection shields inside the converter block.
8. Do not forget to take all tools and materials with you when you leave the converter site.
! Important: Do not hesitate to inform the local ABB service organization about problems and
difficulties during erection work.
E 21 / 62 3BHS 130 197

3. Commissioning
3.1 Safety Instructions
High Voltage
Danger !
1. High voltage in the high voltage room!
2. Never remove the protecting shields.
3. Before you attempt any converter maintenance task:
- switch off the converter
- disconnect the converter from the main power supply (circuit breaker controlled by customer)
- take steps against unintentional energizing
- check that HV has disappeared
- be sure the converter is disconnected from all machine side power supplies.
4. Be sure there is no high voltage at the incoming bars (transformer side) and at
the outgoing bars (motor side) before you attempt any earth connection.
5. Connect the incoming bars (transformer side) to earth by operating the earthing isolators
according the diagram on the following page.
6. Connect the outgoing bars (motor side) to earth by operating the earthing isolators according the
diagram on the following page.
!
High temperature
Danger of burning
Always high temperature at bars, reactors and heaters.
E 22 / 62 3BHS 130 197

E 23 / 62 3BHS 130 197

!
Commissioning
Only specially trained ABB personnel is qualified to perform the commissioning work.
Do not try to do commissioning work on the converter. You could be hurt and the converter could
be damaged.
3.2 Why You Should Read this Chapter

This chapter describes in general terms the correct commissioning of the converter cabin. This includes all
preparatory work and helpful hints on avoiding damages. Be sure to follow all the instructions as
described below or you could cause a damage to the converter cabin. Pay special attention to all safety
instructions.
Note: The commissioning has to be performed by ABB Schweiz AG personnel only!
E 24 / 62 3BHS 130 197

3.3 Converter Commissioning Phase 1 (Motor Disconnected)
3.3.1 Preconditions
- the raw water circuit of the converter must be connected, checked and commissioned
- deionized water must be available for the converter-internal closed water-circuit (about 300 liters for
each converter)
Preparatory work:
! Important: All auxiliary tools to be used for the filling procedure (e.g. pump, hoses, tank for
the deionized water) must be thoroughly cleaned and rinsed with deionized
water. The water penetrating through openings and venting valves during the
filling procedure must not be used anymore.
a) Make available deionized water of a conductivity of less than 20 µS/cm in an appropriate vessel next
to the converter cubicle (for the quantity refer to the enclosed data sheet).
b) Rinse well the filling accessories - e.g. pump and hoses - with deionized water. Connect the hose to
the filler valve KA101 and prepare the tube connection to the vessel with the de-ionized water as well.
! Important: Proceed with extreme cleanness in order to prevent the deionized-water cooling
system from getting dirty.
Filling Procedure:
a) Open ball valves in the main circuit completely.
b) Close ball valves to and from the deionizer bottle.
c) By means of a pump, slowly fill-in water through the cock until the deionized water penetrates
from the expansion-tank overflow.
Note: If no pump is available, the deionized water can be filled into the cooling system at the vent
plug of the expansion tank.
Note: While filling, repeatedly vent the cooling system carefully by means of all venting devices in the
power converter cooling system (i.e. the screw plugs at the water-distributing resp. water-collecting
tubes) as well as at vent and fill ball valves.
d) Make pump KP001 run shortly (≤ 3 sec) to make the de-ionized-water flow within the cooling
system. Then continue to fill in.
E 25 / 62 3BHS 130 197

! Important: Prior to the first pump start, the pumps shall be vented at their vent plugs (if
existing)
Repeat this procedure until the liquid level in the expansion tank remains constant and no more
big air bubbles appear (can be heard by the sound the pump makes).
e) Repeat same procedure as d) with pump KP002 (if installed).
f) Make the deionized water circulate for approx. 24 hours, then turn-off the pump and pump out
the first water filling.
Note: The first water-filling procedure serves to clean the cooling system and to remove any dust
deposits within the tubes.
g) Remove the strainer KT011 for cleaning, then mount it again.
h) Slowly fill-in water a second time. Proceed as described under c), d) and e).
i) Open the ball valves to and from the deionizer bottle
k) Leave this position until there is no more air in the bypass circuit (observe floating-body flow
meters). Fill in more water if necessary.
l) With the pump operating adjust the cock valves KA050 in such a manner that the flow rate
according to the enclosed list of set points is reached.
m) Check the water level in the expansion tank after the air has been completely eliminated (after
approx. 24 hours)., Fill in more water if necessary.
E 26 / 62 3BHS 130 197

3.3.2 Mechanical and Visual Inspection
! Important: Be sure the preconditions have been fulfilled.
1. Check the condition of the converter with regard to transport or erection damages.
2. Check the external cable connections according the converter installation diagram 3BHS 126 278
and the erection instructions with regard to
- position;
- shielding incl. earthing;
- earthing;
- polarity;
- tightness of water cooling system.
3. Check that all terminals are properly tightened, completely and properly mounted.
4. Check that the space between the cable bundles and the cable glands is well sealed.
3.3.3 Performance Check
The performance check has to be performed by ABB Schweiz AG personnel only!
3.3.4 Operation Check with High Voltage Applied
The operation check with high voltage applied, has to be performed by ABB Schweiz AG personnel only!
E 27 / 62 3BHS 130 197

3.4 Converter Commissioning Phase 2 - Power Part and Cooling Unit

(Motor Connected)
3.4.1 Mechanical and Visual Inspection
! Important: Be sure the preconditions have been fulfilled.
1. Check the condition of the converter with regard to transport or erection damages.
2. Check the external cable connections according the converter installation diagram 3BHS 126 278
and the erection instructions with regard to
- position;
- shielding incl. earthing;
- earthing;
- polarity;
- tightness of water cooling system.
3. Check that all terminals are properly tightened, completely and properly mounted.
4. Check that the space between the cable bundles and the cable glands is well sealed.
3.4.2 Performance Check
Check the motor/converter interface: HV cables and excitation cables connected properly according to the
diagram 3BHS 126 278.
3.4.3 Operation Check
The operation check has to be performed by ABB Schweiz AG, personnel only!
E 28 / 62 3BHS 130 197

4. Decommissioning
!
Decommissioning
You can be injured if you try to do decommissioning work on the converter without knowing
enough about it. Be sure you have sufficient knowledge, experience, and the proper tools before
you attempt any converter decommissioning task.
4.2 Why You Should Read this Chapter

This chapter tells you about the correct decommissioning of the converter. This includes all preparatory
work and helpful hints on avoiding damages and environmental compatible procedures. Be sure to follow
all the instructions as described below or you can be injured. Pay special attention to all safety
instructions.
4.3 Converter Standstill

In case of a short time converter standstill (less than 6 months) please observe the following instruction in
order to avoid damages.
! Important: Pay attention to the preservation and storage instructions
1. Disconnect all power supplies and connect to earth.
2. Protect the converter against dust, humidity, dirt, and other detrimental influences.
3. Inspect periodically the condition of the converter cabin.
4. Do not drain the cooling system. Ensure that the water will be circulated through the pumps every
2 (two) weeks for 2 (two) hours.
E 29 / 62 3BHS 130 197

4.4 Converter Intermediate Storage
! Important: Before removing the external cable connections switch off all power supplies.
1. Disconnect all power supplies and connect to earth.
2. Observe the following cable connection dismounting sequence:

1. Mark all cable connections.
2. Dismount the power cables.
3. Dismount the control cables.
4. Dismount the earthing cables/bars.
5. Drain the cooling system (pump out the water at the lowest point of the cooling system) and
blow out with oilfree compressed air until it is definite that water is no longer contained in the
piping system.
6. When restarting the converter replace the resin in the resin bottle.
4.5 Dismantling the Converter and Separation of Materials

Do not forget that used materials can serve as raw materials for another purpose. For environmentally
compatible waste handling please contact your community or the local waste disposal company.
4.6 Disposal and Recycling

Contact your local authorities for more detailed information about disposal and recycling of materials and
components. Note that the future quality of our environment depends on what we are doing today for
environmental protection.
E 30 / 62 3BHS 130 197

5. Operation
High Voltage
Danger
Always close the doors at normal operation!
5.2 Operation Instructions

5.2.1 General Configuration -VERITHYR WXM
Control and
Monitoring
Excitation
Cooling
M
3
ABB, Dept. IAA scope of supply
E 31 / 62 3BHS 130 197

5.2.2 Field of Application and Main Features
ABB VERITHYR WXM converter units are water-cooled.
They are mainly used in electric drive technique for supplying variable-speed three-phase motor drives
and, in general, for those plants, which require conversion from a.c. to d.c. current or vice versa within a
certain current/voltage range.
Besides current conversion, with VERITHYR WXM also a.c. power regulators and several other functions
can be realized (with appropriate constructive matching).
One of the main features of VERITHYR WXM series is the possibility of connecting 1 to 6 thyristors in
series per branch. A direct parallel connection of thyristors is not envisaged (for this, the air-cooled ABB-
series THYRIBLOC L is specially suited). However, two or more VERITHYR WXM can be connected in
parallel, if current ratings require.
Another appreciable feature of the VERITHYR WXM series is the application of the ABB high-capacity air
coolers for thyristors, which even for the largest thyristors will ensure sufficient cooling and hence -
compared with conventional coolers available on the market - will effect less temperature rise and thus
higher operational reliability for the same current loading.
This ‘User’s Manual’ deals with the VERITHYR WXM power converter.
Automatic electrical control is treated in a separate ‘User’s Manual’.
E 32 / 62 3BHS 130 197

Expected life time: 10 years

Operation cycle: continuous
Note: The expected lifetime of theVERITHYR WXM is defined as the time during which the converter will
remain suitable for the application for which it was made, provided that it is used, regularly inspected and
serviced in accordance with the manufacturer’s instructions, and provided that lubricants and parts, which
are subject to mechanical wear, are replaced regularly.
The converter is installed in a container cabin for outdoor installation. Access shall only be allowed to
authorized personnel.
Be sure that all converter doors are accessible. Never install anything inside or outside to the converter
block. Never cover it for protection grids.
Pay attention to always fulfill the following environmental conditions for properly operating the converter:
Air temperature: +5°C... +40°C

Cooling air quality: free of particles (e.g. coal, iron, sand ...)
Relative air humidity: 5 ... 85 % (without condensation)
Raw water temperature and quality: min 20 °C, max. 35 °C, drinking water, ph-neutral
The minimum requirements for stationary use are defined on the basis of IEC 721-3-3 'Classification of
environmental conditions; Part 3: Classification of groups of environmental parameters and their
severities; stationary use at weather protected locations'.
Classification: 3K3 / 3Z2 / 3B1 / 3C1R / 3S1 / 3M1

!
Heart Pacemaker
The converter can influence the working of heart pacemakers. Be sure you have installed the
safety sign (part of the delivery) at a minimum distance of 6000 mm / 20 feet!
E 33 / 62 3BHS 130 197

5.2.3 Operation
Perfect operation of the ABB inverter power section will be guaranteed as long as the data specified on
the rating plate as well as in the data sheet are observed.
! Important: Correct working of control electronics and cooling is a prerequisite for trouble-
free operation.
Remedial Measures in Case of Trouble, Trouble-Recording
The powering up and the powering down (switching ON and OFF) procedures as well as various
annunciations, their consequences and the application of the disturbance recording are outlined in the
control system "operation manual".
E 34 / 62 3BHS 130 197

5.3 Trouble Shooting and Maintenance

5.3.1 Trouble Shooting converter power part and cooling unit in general
! Important: Prior to commencing any works on the converter, ensure that the plant is switched
OFF and the converter is grounded.
! Important: 1. The converter power part as well as the cooling unit faults and malfunctions
and the result (T = trip / A = alarm) are indicated at the converter control
display.
2. For more information about dealing with faults and the RESET function and in
case of troubles, refer to the separate operating and trouble shooting manual of
the control electronic.
E 35 / 62 3BHS 130 197

5.3.2 Trouble Shooting converter power part
Trouble Possible Cause Check Elimination
Drive switch OFF Defective semiconductor. Check of blocking Replace all thyristor of a stack.
caused by an resp. barrier capability For detail ionformation see
overcurrent in the in order to localize sep. manual in the replace
converter. defective thyristor. tool box.
Defective overvoltage Check thyristors and Replace thyristors and

protection or snubber- verify the data of the defective elements of the
circuit. snubber-circuit snubber circuit or the
components: overvoltage protection.
(Compare with data
sheets.)
R: resistance
C: capacitance
V: thyristor
blocking-voltage.
Defective pulse Verify firing pulse on Replace pulse amplifier.

transformer. pulse-amplifier output
of Control.
Overvoltage- Fuse defective. Optical display on Replacement of fuse and of

protection fuse micro-switch. further defective elements of
defective. overvoltage protection, if
necessary.
Detailed converter fault finding and trouble shooting,, refer also to the "operation manual" of the control
electronics.
E 36 / 62 3BHS 130 197

5.3.3 Trouble Shooting Cooling Unit
Signals from cooling-unit transmitters
ABB Code Measurement Range Transmitter Alarm Trip

Analog-
Signals
CT001 Converter inlet temperature 0…100 °C 4…20 mA - -
CT002 Converter outlet temperature 0…100 °C 4…20 mA TAH TAHH
CF001 Flow (converter) 0…252 l/min 0…300 l/min 4…20 mA FAL FALL
CD001 Conductivity 0…10 µS 4…20 mA QAH QAHH
CL001 Water level expansion tank full = 4…20 mA LAL LALL
100 %
CP001 Pressure 0…600 kPa 4…20 mA
Signal for pump change-over 200 kPa PAL
CL011 Leakage water detection yes/no - LAL -
E 37 / 62 3BHS 130 197

A = Alarm
T = Trip
Fault Function Fault Possible Cause Action Remarks

number
TAHH T Cool Unit: the internal cooling a) the external raw a) check external raw If the values indicated
Overtemp water temperature is water does not flow water circuit on the value from
Converter higher too high b) the heat exchanger b) clean the heat CT001 (converter inlet
than 10 °C from the is not clean exchanger temperature) are
nominal value higher 5 °C than the
admissible temperature
acc. the data sheet.
FAL T Cool Unit: water flow in converter a) pump fault (+F15) a) mechanical and
Converter Flow not sufficient electrical check of the
lower than 90 % pump; replace if
from nominal value b) faulty flow sensor necessary
(+F15) b) check/replace flow
sensor
FAHH T Cool Unit: water flow in converter a) pump fault (+F15) a) mechanical and
Converter Flow not sufficient electrical check of the
lower than 80 % pump; replace if
from nominal value b) faulty flow sensor necessary
(+F15) b) check/replace flow
sensor
LALL T Cool Unit: Deionized water a ) water leakage a) check internal Replacement
Water Level lower quantity not sufficient cooling circuit Instructions together
than 20 % in the b) leakage by the b) replace the sealing with spare sealing.
expansion tank pump sealing
c) refill deionized water
QAHH T Cool Unit: Water the conductivity of the a) long standstill-time a) start the pump and
Conductivity higher internal cooling water b) deionizer not observe the cond.
than 2 µS is too high effective value
b) if sufficient water
flows through the
deionizer (check acc.
flow meter) and the
cond. value does not
decrease then replace
the deionizing unit
E 38 / 62 3BHS 130 197

Fault Function Fault Possible Cause Action Remarks

number
TAH A Cool Unit: the internal cooling a) the external raw a) check external raw If the values indicated
Overtemp water temperature is water does not flow water circuit on the value from
Converter higher too high b) the heat exchanger b) clean the heat CT001 (converter inlet
than 5 °C from the is not clean exchanger temperature) are
nominal value higher 5 °C than the
admissible temperature
acc. the data sheet.
PAL A Cool Unit: Water internal water cooling a) cooling pump works a) check coolwater
Pressure lower circuit pressure not not properly pump
than 200 kPa sufficient b) faulty pressure b) check the by-pass
sensor flow
b) check pressure
sensor
LAL A Cool Unit: Deionized water a ) water leakage a) check internal Replacement
Water Level lower quantity not sufficient cooling circuit Instructions together
than 50 % in the b) leakage by the b) replace the sealing with spare sealing.
expansion tank pump sealing
c) refill deionized water
QAH A Cool Unit: Water the conductivity of the a) long standstill-time a) start the pump and
Conductivity higher internal cooling water b) deionizer not observe the cond.
than 1µS is too high effective value
b) if sufficient water
flows through the
deionizer (check acc.
flow meter) and the
cond. value does not
decrease then replace
the deionizing unit
E 39 / 62 3BHS 130 197

5.4 Care and Service

During maintenance of the entire plant the following work have to be carried out on the converter:
- Clean dirty components. Do not clean plastic parts with solvents. Remove dust and dirt gathered of
the semiconductor parts by means of a vacuum cleaner.
- Check all bolted joints for firm seats.
- Check all faston plug terminals for firm seats (they must be latched).
5.5 Replacing of components of the converter power part

For replacing components, neither special tools, nor specific procedures are necessary. Pay attention to
the following aspects in order to avoid damages.
1. Disconnect all power supplies before replacing a component.
2. Mark all electrical and mechanical connections before disassembly for proper installation of the
spare part.
3. Always check if the type/identification/modification numbers or other identification devices (dip

switches, code switches etc.) on the original and on the spare part are identical.
4. For replacing a thyristor please use the special tool set (‘User’s Information’ included).
E 40 / 62 3BHS 130 197

5.6 Replacement of Cooling Parts

For replacing components, neither special tools, nor specific procedures are necessary. Pay attention to
the following aspects in order to avoid damages.
1. Disconnect all power supplies before replacing a component.
2. Mark all electrical and mechanical connections before disassembly for proper installation of the
spare part.
3. Always check if the type/identification/modification numbers or other identification devices (dip

switches, code switches etc.) on the original and on the spare part are identical.
E 41 / 62 3BHS 130 197

5.6.1 Changing the Resin Filling in the Deionizing Devices KT001 or KT002 (if available)
Note: The resin filling can be change with the cooling system in operation.
1. Close the ball valve KA050 slowly.
2. Switch out the exhausted deionizer-bottle and switch on the other. Coupling to resin-bottle with
bayonet-coupling, both male and female are close on decoupling.
3. Open the valves KA050 slowly. Control the vent drains. Control the waterlevel in the expansion
tank.
4. Open the exhausted bottle and replace the resin.
5. Replace the complete bottle or open the exhausted bottle and replace the resin.
! Important: z The resin bottle has a capacity of 8,7 litters.

z It has an opening screw on its bottom.
z Always use deionizer resin of the following specification:
Amberlite ARM 9381
z Never use an other type of resin!

z When the bottle refilled with resin, fill it with deionized water before closing.
z Pay attention that no resin grains or particles remain in thread of the bottle,
when the bottle is closed and screwed down.
Note: Pay attention to the tube joints, so that the input and the output tube joints of the deionizer bottle are
not mixed up.
6. Restart the converter cooling pump.
7. Check after 1 to 3 hours, whether the water conductivity has improved visibly.
5.6.2 Replacing the level sensor
With the points 1, 2 and 3 fulfilled, no special procedures are to be considered during the replacement.
Take care that no tools or objects can fall through the sensor opening into the expansion tank.
E 42 / 62 3BHS 130 197

5.6.3 Replacing the pressure sensor CP001 or CP002
Disconnect electrical wiring with plug. Close the stop valve KA015 before the pressure sensor. Screw the
pressure sensor off (note: left-hand thread).
Together with the new pressure sensor, a new sealing washer shall be mounted. Grease the thread of the
sensor slightly with silicone grease. When the new pressure sensor is mounted, open the stop valve
slowly and vent the sensor socket.
5.6.4 Replacing the conductivity measuring device CD001 or CD002
Disconnect electrical wiring with plug. Close the ball valve KA050 slowly and switch out bayonet-coupling
from resin-bottle KT001 (both male and female are closed on decoupling).
Note: Before closing, mark the aperture angle setting.
! Important: When transmitter screw out, the water between the pipe parts KA050 resin bottle
flows out.
Replace the conductivity transmitter as follows: Then connect it to the power supply.
- The fitting ❹ must be installed into the pipe

according to the installation specifications.
- Insert plastic nut ❸ into fitting and let plastic ring
❷ snap into guide bush ➎.
- Carefully insert transmitter ❶ into fitting. If
installed properly, the transmitter cannot be
rotated.
- Tighten transmitter housing to fitting with plastic
nut ❸.
! Important: Plastic nut must only be

tightened by hand!
Coupling the resin-bottle KT001

Open the ball valve KA050 slowly and fix it in the previously marked locking hole.
Refilling and open the vent drain.
For the adjustment of the new conductivity measuring device refer to the supplier’s specific manual.
E 43 / 62 3BHS 130 197

5.6.5 Replacing the temperature sensor CT001 or CT002
Disconnect electrical wiring. Remove the temperature sensor from the immersion.
! Important: Do not screw off the immersion tube!
Note: For the replacement of temperature sensors, the water system must not be opened.
Connect the electrically wiring.
5.6.6 Replacing the flow transmitter ‘Bürkert’ Type 8025, CF001
- Stop the pumps

- Empty the pipe parts and expansion tank through KA101 and KA102
- Close the valves KA010, KA012 and KA018
! Important: When transmitter screw out, the water flow out.
Replace the flow transmitter as follows: Then connect it to the power supply.
- The fitting ❹ must be installed into the pipe

according to the installation specifications.
- Insert plastic nut ❸ into fitting and let plastic
ring ❷ snap into guide bush ➎.
- Carefully insert transmitter ❶ into fitting. If
installed properly, the transmitter cannot be
rotated.
- Tighten transmitter housing to fitting with plastic
nut ❸.
! Important: Plastic nut must only be

tightened by hand!
- Open the valves KA010, 012, 018

- Close the valves KA101 and 102
- Refill deionized water
- Start-up the pump
- Control the watertight and screw the vent drains
E 44 / 62 3BHS 130 197

5.6.7 Replacing and cleaning the strainer KT011

(pump can be in operation)
- Close valve KA017, 023, 050

- Empty the pipe part with the drain-valve KA100
- Screw out the strainer-inset
- Clean the strainer-inset and replace it, or change to the spare strainer inset
5.6.8 Filling or refilling deionized water circuit
- Deionized water volume in the system 300 l

- With a auxiliary pump suck the deionized water from the depot into the system.
- Fill the pipe system from the bottom through valve KA102 or directly in the expansion tank.
From bottom, the air in the system will be pressed automatically out.
- Under refilling it is quickly to fill water in the expansion tank.

- Observe the level signal from expansion tank and check the level in the expansion tank visual.
E 45 / 62 3BHS 130 197

5.6.9 Replacing the pump
With the points 1, 2 and 3 fulfilled, close both the ball valves before and behind the pump. Loosen the
flanged joint (note: collect the several litters of draining water in an vessel).
Note: Since a pump weights more than 20 kg, use a lifting device to remove and replace it.
• Installation of a new pump: For the installation of a new pump follow the description.
• Open the ball valve behind the installed pump slowly.
• Open the ball valve before the pump slowly.
• If the pump has a vent plug, vent the pump,
Connect power supplies.
Check the direction of rotation of the pump by starting the pump shortly. If necessary, change the
electrical connections of the phases S and T. Caution: Disconnect power supply first!
5.7 Maintenance Heat Exchanger
5.7.1 Opening the heat exchanger
- Cool the heat exchanger. If possible allow the

heat exchanger to stand and cool overnight.
- Disconnect any connections to the movable
cover plate.
- Remove bolts ❶
- Slacken nuts ❷, ❸ and ❹ alternately, so that
the movable cover plate can move parallel with
the frame plate.
- Remove bolts ❷.
- Slacken nuts ❸ and ❹ alternately.
- Remove bolts ❸.
- Slacken nuts ❹ alternately.
- Remove bolts ❹.
E 46 / 62 3BHS 130 197

5.7.2 Taking out the plates
!
The plate edges are sharp!
Use gloves!
If two or more plates have stuck together they must be separated carefully so that the gaskets are kept on
the correct plate.
The plates support each other in pairs. If a plate has been so damaged that it must be taken out and
cannot be repaired or replaced with an identical one, its adjacent plate must also be taken out of the
exchanger.
If the number of plates are changed, so is the thickness of the clamped plate pack, A.
Special plates, such as the first and last plates, and turning plates in multipass heat exchangers, must be
replaced with identical plates.
5.7.3 Cleaning the plates
!
Sodium Hydroxide / Concentrated Nitric Acid
Sodium Hydroxide and concentrated Nitric Acid can seriously harm the skin and mucous
membranes!
The solution must be handled with the greatest care!
Always wear protective goggles and protect hands with rubber gloves!
Fouling of the plate heat exchanger often depends on the flow velocity through the heat exchanger being
too low. Where the possibility exists to increase the flow, this should be tried out if the heat exchanger
shows signs of reduced capacity or increased pressure drop.
E 47 / 62 3BHS 130 197

However, with products that crystallize of heavily foul the plates or if the heat transfer surfaces have been
scorched, opening and cleaning the heat exchanger is necessary.
- The heat exchanger according to Opening the heat exchanger.

- Steel wool or brushes of carbon steel must not be used, nor may stainless steel be used on titanium
plates.
- In the first place the heat transfer surface is cleaned by rinsing with a powerful jet of water and
scrubbing with a nylon or similar brush.
- Take care not to damage the gasket.
- Oxide or chalk deposits are removed with a soft brush and 2…5 % nitric acid solution. (Hydrochloric or
sulfuric acid may not be used.) Organic deposits containing proteins are removed with a soft brush and
2 % solution of sodium hydroxide solution at 50 °C.
- Surfaces with greasy deposits are cleaned with kerosene and a soft brush. After cleaning, rinse
thoroughly with water.
5.7.4 Gaskets
Ultra Flex heat exchange plates differ from

Alway to conventional plates. Because the gasket groove
the right lies in the plate’s neutral plane, alternate plates
have gaskets on both their sides, while the
interleaving alternate plates have no gaskets at all.
The gaskets used between the first plate and the
movable cover plate are 1/2 thickness.
The double ‘ring’ sections of the gasket are always
placed at the top right and the bottom left of the
plate.
5.7.5 Adjusting the gaskets
A gasket that has come loose, either partly or entirely, must be glued in place. If only a short length has
become detached, glueing can be carried out immediately before clamping, with the plate still sitting in the
frame. If the entire gasket has become detached, the plate should be taken out to the heat exchanger.
5.7.6 Suitable gasket glue
Only certain glues may be used for glueing gaskets, namely Bostik 1782, 3M EC 1099. Bond Spray 77 or
Pliobond 20/30 Synthetic glue. Do not use other types of glue, they may contain chlorine or other
substances that attack the plate material. To facilitate application with a brush, The glue should be diluted
with acetone. Maximum dilution 1:1.
E 48 / 62 3BHS 130 197

5.7.7 Cleaning the gasket groove
The solvent must not contain chlorine.
Clean the plates from residues of old gaskets. Small patches of glue, hard to remove, that are securely
stuck to the gasket groove may remain there. They provide an excellent foundation for the new gasket.
Wash the gasket groove so that it is completely free of oil and other greasy substances, using a rag and
acetone or other solvent not containing chlorine compounds. Then let the plate dry off.
5.7.8 Glueing the gaskets
The glue is applied with a small flat brush to those

parts of the plate’s groove in which the gasket shall
lie. These parts of the gasket groove are easily
recognized as they differ in color arising from
previous residues of glue. The gasket is then
placed into position on the plate. After drying for ca.
30 seconds (the time depends on the thickness of
the glue film and how much the glue has been
diluted), the glue holds the rubber gasket firmly in
place in the gasket groove, thus facilitating
mounting. The plate must then be held under light
pressure with the aid of other plates or a stiff sheet
of other material of suitable weight for ca. 1/2 hour.
When the glue joint has dried the gasket should be

coated with talc to prevent the plates are then
ready to assemble into the frame.
5.7.9 Plates - Marking
An Ultra Flex plate is identified by means of an

embossed code letter. This letter can be found to
the RIGHT of the UPPER carrying bar cut-out when
the plate is facing TOWARDS the frame plate.
E 49 / 62 3BHS 130 197

5.7.10 Assembly
Before the heat exchanger is assembled, inspect all gaskets and surfaces that lie against the gaskets.
Particles that may jeopardize the integrity of the seals or damage the gaskets or sealing surfaces must be
removed. Note that contaminants usually collect at the lower part of the plates.
Plates that have been provided with new gaskets must be checked to make sure that the gaskets are in
the correct gasket groove. The correct gasket groove in used plates usually has a different color from the
rest of the plate due to residues of old glue. Also check the 1/2 thickness gaskets on the fist and last
plates.
5.7.11 Inserting the plates
Every delivery is accompanied by a computer

printout of the grouping scheme, giving plate’s code
letter together with the plate’s position in the heat
exchanger.
When the plates are correctly positioned the

flanged cut-outs at the upper carrying bar should
point towards each other.
The plate edges from a regular honeycomb pattern
E 50 / 62 3BHS 130 197

5.7.12 Tightening the heat exchanger
Notice
Never tighten the exchanger while it is under pressure!
The plate pack must be compressed to a specific

thickness - the A-dimension. The A-dimension ±
3 % gives the inside length in millimeters between
the fixed cover plate and the movable cover plate.
The A-dimension is: (Plate thickness 0,5 mm)

UFX-6 2.9 x number of plates
UFX-12/18 3.4 x number of plates
UFX-26/42 3.8 x number of plates
UFX-51 3.8 x number of plates
Example:
A plate heat exchanger UFX-12 has a total of 51
plates in the pack. The tightening length of the pack
is: 51 x 3.4=173.4 ± 3 %.
Note:
With large plate packs the A-dimension, due to
tolerance in the plate thickness and depth of
pressing, can deviate somewhat from that given
above ± 3 %. With the correct a-dimension the
plates lie in metallic contact with each other. Check
this by examining the plate edges around the heat
exchanger. Further compression can deform the
plates.
The nuts must be tightened alternately. The

movable cover plate must always be moved parallel
to the frame at all times, and never drawn out of
alignment.
- Tighten bolts ❶ alternately.
- As the resistance increases also tighten bolts
❷ and ❸ - always alternately.
- Tighten bolts ❹.
- Check the A-dimension along the heat
exchanger.
E 51 / 62 3BHS 130 197

5.7.13 Lubrication
The tighten bolts must be kept lubricated with molybdenum disulfide or its equivalent, particularly on the
sections of thread used for opening and closing the equipment.
E 52 / 62 3BHS 130 197

6. Technology
6.1 Technical Facts about the Converter

6.1.1 Identification
Manufacturer ABB Schweiz AG, 5400 Baden/Switzerland

Year 2002
Type MEGADRIVE-CYCLO
Internal Order No. HI 19500497-1000/1
Block Serial No. 40
Total Weight 10 000 kg
Design Data
Degree of Protection indoor (power part room)

Cooling Medium Fresh water / Deionized water
Duty Class S1; continuous running duty
Cooling Air Quality free of particles
Altitude above Sea Level max. 1000 m
Standards for Design IEC289/IEC146, IEC76
Technical Data
Cyclo Input
Phases 6 x 3-phase
Apparent Power 6 x 6070 kVA
Voltage (per phase) 1620 V
Current (rms) 2163 A
Frequency 60 Hz
Cyclo Output
Apparent Power 21 005 kVA
Voltage 0…4950…4950 V
Current (rms) 2450 A
Frequency 0 ... 5.574…6.18 Hz
Phases 3-phase
Excitation Input (AC)
Voltage 600 V
Current 441 A
Frequency 60 Hz
Excitation Output (DC)

Voltage 465 V
Current 540 A
E 53 / 62 3BHS 130 197

6.2 Dimensions and Specifications

See 'Converter ; Location Diagrams' 3BHS 126 279 and 3BHS 126 278 .
6.2.1 Power Converter Section
The principal element of the converter, the thyristor, is clamped between coolers each. The coolers and
the thyristors are mounted one upon the other in order to form stacks. A spring package mounted topmost
of each stack determines the clamping force exerted on the thyristors within the stack.
The stacks are mounted side by side in the center of the cubicle, dividing it into a front section and a rear
section.
The cooling-water distribution piping: It serves for distributing the cooling water (inflow and return) and for
connecting the deionized cooling-water circuit.
Electro-magnetic pulse transformers as well as are fitted each to the right and left of its corresponding
thyristor.
Components of snubber circuits: A snubber circuit comprises a capacitor and a water-cooled resistor.
The components of the semiconductor overvoltage protection (protection against commutation and
switching-voltage surges) are arranged partly on separate plates.
The power terminals as well as the voltage and current transformers, if applied, are situated in the rear of
the cabinet.
Shielded cables connect the separate terminals of the VERITHYR WXM thyristor-firing system directly
with the corresponding terminals of thyristor control electronics.
E 54 / 62 3BHS 130 197

6.2.2 Cooling System
The cooling unit serves to remove the heat losses produced in the power section. The heat losses are
dissipated by means of a water-to-water heat exchanger from the deionized-water cooling system to a
raw-water cooling system.
The enclosed cooling diagram shows the deionized-water cooling system of the power converter and
‘Datasheet Cooling Unit’ (see next page) gives the main data about the cooling system. The installed
pump KP001 makes the deionized water circulate in the cooling system.
The deionizer facilities KT001 ensure a constantly low water conductivity of the deionized water. The
water conductivity is measured by the conductivity probes CD001.
The flow-monitoring and -indication devices as well as the temperature-monitoring devices are installed in
the deionized-water system in order to protect the power converter from overheating due to too warm
cooling water or a too low cooling-water flow.
For protection, commissioning and periodical checks of the cooling system the actual valve (water in- and
outlet temperature, water flow main circuit, pressure after pumps, water conductivity and water level in the
expansion tank) are transmitted to the converter control system.
The expansion tank QS001 containing deionized water under atmospheric pressure is located on the
highest point of the cooling system. Any decrease in the water level in the expansion tank QS001 caused
by a leakage or by electrolysis is signaled to the control system by the level monitoring devices which are
installed in the expansion tank. The expansion tank QS001 regulates the heat expansion and the de-
gassing of the deionized water.
To prevent the cooling circuits of the power converter from pollution during commissioning the deionized
cooling circuit is equipped with a strainer, KT011, which is removable for cleaning purpose.
E 55 / 62 3BHS 130 197

6.2.3 Identification Cooling Unit
Type C3N212
Cooling Capacity 140 kW
Raw Water Pure Water

Medium Fresh Water Deionized Water
Capacity of Water System - ≈ 300 l
Water Flow, incl. AC 0…286.6 l/min ≥ 300 l/min
Inlet Temp. Cooler ≤34 °C ≤49 °C
Outlet Temp. Cooler ≤42 °C ≤42 °C
Pressure Drop
Cooler 38.58 kPa 38.36 kPa
Converter - 175 kPa
Rated Pressure 1000 kPa 400 kPa

Testing Pressure 1500 kPa 800 kPa
Pump Data
Motor Power - 5.5 kW
Electrical Data - 3 ∗ 480 V ± 10 %, 60 Hz, 9 A
E 56 / 62 3BHS 130 197

6.3 Description of Essential Components

6.3.1 Thyristors
The main elements of the converter are the disc-type thyristors, which have four terminals:
- The anode and the cathode as power terminals.

- The gate and the auxiliary cathode as control terminals.
To ensure optimum utilization of thyristors, the heat-loss power originating from the current through and
the voltage drop across the thyristors must be dissipated.
To achieve a sufficient heat dissipation, disc-type thyristors are clamped with a defined force between two
coolers each.
6.3.2 Thyristor Monitoring PCB (Printed-Circuit Board)
A thyristor monitoring PCB continuously checks the voltage over a pair of anti-parallel connected
thyristors. As long as a thyristor is able to block the voltage, the thyristor monitoring PCB generates a
signal, which is sent via an opticle-fibre cable to the valve-base electronics, which is located in the control
part.
In the case that one thyristor looses the blocking ability, the monitoring PCB stops signaling, which is
realized and indicated by the valve-base electronics.
6.3.3 Pulse Transformers
The pulse transformers serve for galvanic isolation of the power circuits from the control circuits. The
pulse transformers are connected with the output stages in the control section by shielded cables.
6.3.4 Snubber Circuit
The snubber circuits are RC circuits connected in parallel to each anti-parallel connection of two
thyristors. They damp the overvoltage generated during thyristor turn-off. The resistors of the RC
snubber-circuit are water-cooled.
6.3.5 Overvoltage/Surge Protection
The overvoltage protection protects the thyristors against overvoltages from the a.c. side (originating from
the hole-storage effect).
E 57 / 62 3BHS 130 197

6.3.6 Base Load
The base load consists of a number of capacitors and resistors, which, depending on the rating and the
required capacitance and resistance respectively, are suitably connected in parallel and/or in series.
These elements are mounted in the rear part of the cubicle, partly under the roof and partly to the rear
panel.
The base load ensure thyristor firing during start-up of the synchronous machine and prevents the
thyristors from overvoltages. It consists of a resistor in series with a capacitor, which are connected in
parallel to the load inductance.
6.3.7 Short-Circuiter
The short-circuiter is made of two antiparallel-connected BOD-protected thyristors in series with a resistor
pack. The components of the short-circuiter are mounted to the rear panel of the cubicle.
The short-circuiter is a protection against overvoltages occurring during switch-off of the synchronous
machine under load, at which the machine phases are shorted by means of the voltage-controlled short-
circuited in order to dissipate the magnetic energy of the machine windings into the resistor of the short-
circuiter.
6.3.8 Current and Potential Transformers
For measuring purposes it is possible to install current transformers and/or potential transformers with
their associated automatic circuit breakers in the VERITHYR WXM.
E 58 / 62 3BHS 130 197

6.4 Inspection and Service Program for Converter and Water Cooling Unit
6.4.1 Overview
Time interval Visual and Visual and Replacing the Replacing the Replacing the Changing all
mechanical mechanical resin filling of shaft seals of fans tubes in the
check Water check deionizer bottle pump cooling unit
cooling converter
Estimated time Estimated time Estimated time Estimated time Estimated time Estimated time
Every week 0.5 h
Every year approx.3 days
Every 2 years approx. 2 h
Every 4 years approx. 4 h approx. 4 h
Every 10 years approx. 2 days
6.4.2 Inspection Program for converter
Interval: Once a year

Responsible: ABB Schweiz AG or authorized service organization in cooperation with customer
! Important: The converter is designed for operation under specific environmental conditions. If
the actual environmental conditions differ from the defined conditions contact your
local ABB service organisation.
! Important: Never change the sequence of inspection steps as set out below.
Step What To Do Remarks
1 Visual and mechanical inspection
High Voltage
Danger
Follow the safety instructions!
1.1 Remove all dust carefully by the use of a vacuum cleaner. Never Notice
use the vacuum cleaner for PCB’s. Never use hot steam, compressed
Note: PCB's handle with care. Do not touch the printed circuits. Do air or chemical agents! This could
not use a vacuum cleaner. Remove dust with a smooth paint brush. cause a damage to the converter!
E 59 / 62 3BHS 130 197

1.2 Check environmental conditions for operation, if you find Notice

- dust containing grease and/or metallic particles; Greasy dust, metallic
- humidity. particles and humidity could damage
Remove all greasy, metallic dust and humidity immediately. the converter! Adjust the
environmental conditions!
1.3 Check the cover grid (bottom and on the roof). If necessary clean it.
1.4 Check tightness from the pipe and tube system.
1.5 Check
- tightness of all 'Faston' connections
- tightness of all connections of terminal blocks
1.6 Check number and position of all safety instructions/signs mounted Ref. to diagram in the 'User's
inside the converter and outside the converter block; replace the Manual'
missing instructions/signs.
6.4.3 Inspection Program for Cooling Unit
! Important: The converter is designed for operation under specific environmental conditions. If
the actual environmental conditions differ from the defined conditions contact your
local ABB service organisation.
! Important: Never change the sequence of inspection steps as set out below.
Interval: Every week

1 Visual and mechanical check of the cooling water pumps
! Important : Switch on the low voltage power supply for the High Voltage
mechanical checks. Danger
Follow the safety instructions!
1.1 Check general conditions (leakage, corrosion etc.)
1.2 Check if abnormal noise (creaking, friction) of the pump is existing
E 60 / 62 3BHS 130 197

6.4.4 Service Program Cooling Unit
Interval: Every 24 months

Replace the resin filling of the deionizer bottle according chapter 5.6 in this part of ‘User’ Manual)

Replace the shaft seals when installed a in-line centrifugal pump with shaft seals. Connected motor
pumps are maintenance-free.

Change all tubes in the cooling unit.
E 61 / 62 3BHS 130 197

6.5 Drawings
Transport 3BHS 126 277

Safety Earthing 3BHS 126 276
Location Diagram 3BHS 126 279
Location Diagram Power Part 3BHS 126 274
Cooling Diagram Converter 3BHS 126 273
Instrumentlist 3BHS 126 272
Power Part and Cooling Unit Layout 3BHS 126 278
Layout Powerpart and Cooling Unit 3BHS 126 281
P + I Legend 3BHS 126 281
Diagram 3BHS 126 281
Accessories and Equipment List 3BHS 126 271
Power Part Accessories and
Equipment List 3BHS 126 275
E 62 / 62 3BHS 130 197

Chapter 04 - MM-FR-CT005-BE-2251-50-2004-00-C

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chapter 04 - MM-FR-CT005-BE-2251-50-2004-00-C

Uploaded by

Copyright:

Available Formats

Code:

Text: Document no: 3BHS 130 197

ABB Schweiz AG / Switzerland

Drives and Power Electronics

SAG MILL SOSSEGO 20000 KW

Product: VERITHYR WXM - Cycloconverter

Customer: Mineração, Serra do Sossego

Read this manual before energizing the converter!

1. Press the emergency off button.

Change Language Sheet Nr.

E 2 / 62 3BHS 130 197

2. Transport, Storage, Erection..........................................................................................................12

Change Language Sheet Nr.

E 3 / 62 3BHS 130 197

3.3 Converter Commissioning Phase 1 (Motor Disconnected) ...............................................................25

Change Language Sheet Nr.

E 4 / 62 3BHS 130 197

5.7.5 Adjusting the gaskets.....................................................................................................................48

Change Language Sheet Nr.

E 5 / 62 3BHS 130 197

Keep this manual for future reference!

1.1 Why You Should Read this Manual

- you will see important safety and service information.

Change Language Sheet Nr.

E 6 / 62 3BHS 130 197

1.2 How to Read The ‘User’s Manual’

1.2.1 Safety Instructions

Danger Herewith an imminent danger, which can lead to life

! Attention Herewith a possibly dangerous situation, which could lead to bad

! Caution Herewith a dangerous situation, which can lead to injuries,

Notice Herewith is indicated that something can damage the

! Important All important information is emphasized by the use of this

Change Language Sheet Nr.

E 7 / 62 3BHS 130 197

1.2.3 User Group of the ‘User’s Manual’

1.3 How to Use the ‘User’s Manual’

1.3.1 All Information on Operation, Trouble Shooting, Maintenance, Technology,

Change Language Sheet Nr.

E 8 / 62 3BHS 130 197

1.4.1 ABB’s Quality Management Philosophy

- the quality of products

1.4.3 National and International Certificates

- SQS Certificate, category ISO 9001/ISO 14001

- IQ Net Certificate ISO 9001 and ISO 14001

Change Language Sheet Nr.

E 9 / 62 3BHS 130 197

1.4.4 European and International Standards

The relevant EEC standards are:

Change Language Sheet Nr.

E 10 / 62 3BHS 130 197

1.4.5 International Standards for Design and Construction

- DIN/EN 60146 / IEC 146

- EN 60721 / IEC 721

- DIN 31000 / VDE 1000

Change Language Sheet Nr.

E 11 / 62 3BHS 130 197

2. Transport, Storage, Erection

You could be injured!

2.1.2 Transport Conditions

Classification: 2K1 / 2B1 / 2C1 / 2S2 / 2M1

Air temperature: +5 ... +40°C

Change Language Sheet Nr.

E 12 / 62 3BHS 130 197

2.1.4 Loading and Unloading