100.

6000

RECTIFIER UNIT
-Liquid cooled-

Basic instruction manual

Date : 12-12-2012
Version : 1.2
Doc.no. : 100.6000-003
 PROJECTDOCUMENT
Project : RECTIFIER UNIT Doc.no. : 100.6000-003
Projectno. : 100.6000 Version : 1.2 Pag: 2/14

Sub Project : Date : 12-12-2012

Subject : Basic instruction manual Written by : R. Vlielander

TABLE OF CONTENTS Page

1. GENERAL .................................................................................................................................................... 4
1.1. TERMS AND ABBREVIATIONS .................................................................................................................. 4
1.2. ADDRESS ................................................................................................................................................ 5
2. BASIC MAINTENANCE & REPAIR ........................................................................................................ 6
2.1. TIGHTENING TORQUE .............................................................................................................................. 6
2.2. MAINTENANCE INTERVALS ..................................................................................................................... 6
2.3. VISUAL INSPECTION ................................................................................................................................ 6
2.4. REMOVING AND INSERTING RECTIFIER UNITS ......................................................................................... 7
2.4.1. Rectifier unit B6U 600A / 1100A / 1300A DC ............................................................................... 7
2.4.2. Rectifier unit B6U 2500A DC........................................................................................................ 8
2.5. REMOVING AND REPLACING DIODES OF RECTIFIER UNITS ..................................................................... 10
2.5.1. Removing the diode of B6U 600A / 1100A DC ........................................................................... 10
2.5.2. Placing the diode of B6U 600A / 1100A DC ............................................................................... 10
2.5.3. Removing the diode of B6U 1300A DC ....................................................................................... 10
2.5.4. Placing the diode of B6U 1300A DC .......................................................................................... 11
2.5.5. Removing the diode of B6U 2500A DC ....................................................................................... 11
2.5.6. Placing the diode of B6U 2500A DC .......................................................................................... 11
2.5.7. Replacing a cooler / nozzle of B6U 2500A DC ........................................................................... 12
2.6. REPLACING THE DC-FUSES ................................................................................................................... 12
2.7. REMOVING AND INSERTING OF THE FAN ............................................................................................... 13
2.8. REPLACING CAPACITORS ...................................................................................................................... 14
2.9. REPLACING RESISTORS ......................................................................................................................... 14
2.10. WATER-COOLING UNIT ......................................................................................................................... 14

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 Version Date Chapter Description
1.0 20-03-2009 ALL First version
1.1 29-07-2009 1, 1.1, 2 Textual changes
1.2 12-12-2012 2.1, 2.8 Tightening table and life span capacitors

APPROVAL

Bakker Sliedrecht Electro Industrie BV Principal

Name : Name :

Date : Date :
Signed: Signed:

DISTRIBUTION

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
1. GENERAL

This manual provides a short description of the Bakker liquid cooled rectifier unit.

Read document “General Safety and Instruction Manual” of Bakker Sliedrecht before
starting any work on the rectifier unit

It can be useful for mechanical/electrical installation and basic maintenance/repair of the

drive.

The manual gives information about installing the unit in a proper way and to work safely at
the cabinet in case of maintenance and reparation. It describes the working of the rectifier
unit and how to replace components.

The liquid cooled rectifier unit can be built for the ranges 0 – 4000A, but in the special cases
the range can be extended from 4000 – 8000A.

This manual will only discuss the drive in general, not the different type of drives. As a result
it is possible that the drive description will differ a little. The photos used in this document are
only an impression of the situation.

1.1. Terms and abbreviations

Term/abbreviation Explanation
AC Alternated Current
Cabinet Could exist of a control panel, Rectifier unit, Frequency unit, Brake
chopper and Water cooling unit
DC Direct Current
EMC ElectroMagnetic Compatibility
I/O Input/Output
LED Light Emitting Diode
PE Protective Earth
PLC Programmable Logic Controller

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
1.2. Address

Bakker Sliedrecht electro industrie B.V.

P.O. Box 25
3360 AA SLIEDRECHT
Netherlands

Phone : +31 184 436 666

Fax : +31 184 436 677
E-mail : [email protected]
Internet : www.bakkersliedrecht.com

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
2. BASIC MAINTENANCE & REPAIR

These instructions handle generally how to maintain and repair the rectifier unit in a manner
that it is safe for personnel and for the system.

Before any maintenances or repair procedures, read carefully document “General

Safety and Instruction Manual” of Bakker Sliedrecht.

The rectifier unit is a device of dangerous voltage and when misused can cause damage to
personnel and property. Therefore it is absolutely important, that special care is taken before
the panel doors are opened and maintenance work is done.
Before opening the panel doors, it is essential to make sure, that the rectifier unit does not
contain lethal voltages.

Generally the supply must be isolated and the DC-circuit discharged, before panel
doors are opened. Also the auxiliary voltage must be switched off, before any
components are disconnected.

The person responsible for the rectifier unit service must be an authorised electrical
professional who is fully acquainted with the rectifier unit.

In the next paragraphs will be explained the maintenance and repair instructions for the
rectifier unit.

2.1. Tightening torque

For screw and bolt connection of components see documentation of the concerning
manufacturer.
For screw and bolt connection between cable-copper or copper-copper contact Bakker
Sliedrecht.

2.2. Maintenance intervals

Interval Maintenance Instructions
Every 2 years Addition of corrosion inhibitor to coolant See §2.10
Every 6 years Cooling fan change See §2.7
Still unknown Resistors See §2.9
Every 9 years Capacitor renewal See §2.8

2.3. Visual inspection

Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht.

It is advisable to have a through visible inspection of the cabinets and cable connections
every year. Check for loose connections in control wiring and for overheated main
connections.
Check on a regular basis (every month) the mechanical running conditions of fans.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
2.4. Removing and inserting rectifier units

For B6U 600A DC, B6U 1100A DC and B6U 1300A DC, for each of them is a single version:

B6U 1300A DC
and an double version:

B6U 1100A DC
2.4.1. Rectifier unit B6U 600A / 1100A / 1300A DC
Contact with Bakker Sliedrecht.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 2.4.2. Rectifier unit B6U 2500A DC
• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Remove the shroud covering the cabinet;

• Close shut off valve’s

• Drain the unit of all coolant. Lead the bleed and drain hoses to buckets or other suitable
containers. Extend the standard hoses if necessary;
• Detach the coolant inlet and outlet pipes;

• If present open service hatch on top of cabinet, otherwise use special tools for reaching
the screws;

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 • Remove the screws of the connection at top of the unit (total of 12);

• Remove the screws of the connection at bottom of the unit (total of 12);

• Remove the screws which holding the unit (total of 4);

• Remove the rectifier unit;

• Install (new) rectifier unit in reverse order.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
2.5. Removing and replacing diodes of rectifier units

2.5.1. Removing the diode of B6U 600A / 1100A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Remove the shroud covering the cabinet;
• Disconnect the copper DC strips of the DC + and – bar;
• Remove the screws which connects the copper DC strips to the diodes and remove the
copper DC strips;
• Remove the plastic shield;
• Disconnect the AC connection with the diode;
• Remove the screws which holding the diode on the cooling water plate (total of 4);
• Remove the diode from the cooling water plate.

2.5.2. Placing the diode of B6U 600A / 1100A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Clean the (new) diode, copper DC strips, AC connection and cooling water plate contact
surfaces using a clean rag or tissue. It is permissible to use a scouring pad such as
‘Scotchbrite’ to remove persistent dirt;
• Apply a thin film of jet lube SCX13 mounting grease with a 10mm bristle brush to the
cooling surface of the diode;
• Screw the diode on the cooling water plate. Check also that the polarity is correct;
• Reconnect the AC connection to the diode;
• Place the plastic shield;
• Connects the copper DC strips to the diodes;
• Reconnect copper DC strips to the DC + and – bar;
• Replace shroud covering the cabinet.

2.5.3. Removing the diode of B6U 1300A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Remove the shroud covering the cabinet;
• Disconnect the AC / DC connection;

• Remove the screws which holding the diode on the cooling water plate (total of 4);

• Remove the diode from the cooling water plate.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 2.5.4. Placing the diode of B6U 1300A DC
• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Clean the (new) diode, AC / DC connection and cooling water plate contact surfaces
using a clean rag or tissue. It is permissible to use a scouring pad such as ‘Scotchbrite’ to
remove persistent dirt;
• Apply a thin film of jet lube SCX13 mounting grease with a 10mm bristle brush to the
cooling surface of the diode;
• Screw the diode on the cooling water plate. Check also that the polarity is correct;
• Replace shroud covering the cabinet.

2.5.5. Removing the diode of B6U 2500A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• After the rectifier unit B6U 2500A DC is removed from cabinet (see §2.4.2);
• Unscrew the lock nuts and full nuts from the rods holding the reaction plate and remove it
together with the plate insulator to allow access to the diodes (total of 4);

• Slacken the 2 clamp nuts alternately a ¼ turn at a time until they loose;

• The diode is held with locators and can be slid out of assemble.

2.5.6. Placing the diode of B6U 2500A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Clean the (new) diode and bus bar contact surfaces using a clean rag or tissue. It is
permissible to use a scouring pad such as ‘Scotchbrite’ to remove persistent dirt;
• Apply a thin film of jet lube SCX13 mounting grease with a 10mm bristle brush to the pole
faces of the diode;
• Replace the diode into the locator and slide it into place making sure that all components
are correctly positioned. Check also that the polarity is correct;
• Screw the 2 clamps nuts finger tight to the washer/ bar spring and check that the bar is
parallel. Ensure all components are correctly located;
• Tighten the clamp nuts alternately a ¼ turn at a time until the indicators next to the spring
are just trapped. Release the clamp nuts 1/8 turn (45°C) on each nut and check that the

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 additional gap between 0,1 and 0,15mm, adjust if necessary. At this point the correct
force is applied to the diodes;
• Replace the plate isolator and reaction plate. Screw the full nuts on the rod finger tight so
that the plate isolator is touching the maximum area of the heat sink side. Tighten evenly
to approximately 1Nm and then fix the lock nuts to approximately 6Nm whilst holding the
full nuts.

2.5.7. Replacing a cooler / nozzle of B6U 2500A DC

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• For replacing a cooler / nozzle it is necessary to remove the 2 diodes adjacent to the
cooler see §2.5.5;
• The cooler / nozzle can then be removed past the location pins in the bus bars and
replace;
• The diodes can then be replaced, see §2.5.6.

2.6. Replacing the DC-fuses

The DC intermediate circuit is charged from the auxiliary voltage network before the main
circuit breaker is closed. Charging lasts less than 4 seconds and after this the main circuit
breaker closes automatically and the frequency converter is ready for operation.
If the DC-voltage doesn’t increase quickly enough in the pre-set time, the circuit breaker will
not be closed and charging will be stopped. If charging of DC-intermediate circuit has not
succeeded, one possible reason can be a blown charging fuse.

Replacement of the charging fuses can be done as follow:

• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Remove the shroud covering the cabinet;

• At the fuse is a red pin, which springs up if the fuse blows;

B6U 1100A DC B6U 1300A DC

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
 • Locate the short circuit and remove the cause of short circuit and renew possibly
damaged parts;
• Measure the resistance of the charging circuit to check for short circuit;
• Replace the blown fuses by a new fuse.

2.7. Removing and inserting of the fan

Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise.
• Read carefully document “General Safety and Instruction Manual” of Bakker Sliedrecht;
• Disconnect the fan wiring plug and remove the ty-raps;

• Remove the four locking screws;

• Install new fan in reverse order.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
2.8. Replacing capacitors
Their life span is 45.000 - 90.000 hours depending on the operating time of the drive, loading
and ambient temperature.

It is not possible to predict capacitor failure. Capacitor failure is usually followed by damage
to the unit, input cable fuse failure, or a fault trip.

When capacitor failure is suspected or for replacing the capacitor contact Bakker Sliedrecht.

2.9. Replacing resistors

Underconstruction

2.10. Water-cooling unit

See document “Installing, Operation and Maintenance Manual ACS800 Liquid Cooling
System” of Bakker Sliedrecht.

Copyright Bakker Sliedrecht Electro Industrie B.V.

The contents of this specification are property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.