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ABB ACS 6000, User Manual

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10 PREVENTIVE AND CORRECTIVE MAINTENANCE

3BHS212794 E01 REV M

ACS6000

 USER MANUAL

230/278

10.4 Maintenance tasks

The following sections describe the maintenance tasks and associated 
actions that you can perform on the drive.

10.4.1

Safety

 ▲ 

DANGER 

 ⚠ 

Hazardous voltages!

To avoid serious injury or death, read all instructions before performing 
the maintenance tasks.

• Before you work on the drive, verify that:

- Main and auxiliary power supply to the drive are switched off, 

locked out, and tagged out

- Drive is de-energized
- Grounding connections are in place
- Personal protective equipment is provided and used when 

required

- Everyone involved is informed

• Before energizing the drive, verify that:

- All foreign objects are removed from the drive
- All internal and external covers are securely fastened and all 

doors are closed, locked and / or secured (locking bar in locked 
position)

- Release dials of safety switches are in locked position

• Before you remove a phase module from a cabinet:

- Connect the grounding equipment at the appropriate locations.

• When the motor is spinning, a HAZARDOUS VOLTAGE appears at the 

output of the IOI switch in the RDC unit, even if the switch is open 
and the drive is grounded.
- See the local safety procedures on how to isolate and ground 

the equipment.

Summary of Contents for ACS 6000

Page 1: ... SYSTEM DRIVES ACS6000 User manual ...

Page 2: ...purpose without written permission from ABB Switzerland Ltd System Drives The hardware and software described in this document is provided under a license and may be used copied or disclosed only in accordance with the terms of such license Document owner ABB Switzerland Ltd System Drives CH 5300 Turgi Switzerland Document name ACS6000 user manual Document number 3BHS212794 E01 Rev M Release date ...

Page 3: ...ion 37 1 6 3 Electrical installation 37 1 6 4 Operation 37 1 6 5 Maintenance 37 1 7 User s responsibilities 38 1 8 Intended use of equipment 38 1 9 Cyber security disclaimer 38 1 10 Quality certificates and applicable standards 39 1 11 Identifying the delivery 40 1 12 Tools 40 2 Important safety information 41 2 1 Safety standards 41 2 2 Safety messages 41 2 3 Product safety labels 42 2 4 General ...

Page 4: ... 3 2 Standard cabinet units 53 3 2 1 Active rectifier unit ARU inverter unit INU 53 3 2 2 Line supply unit LSU 55 3 2 3 Capacitor bank unit CBU 58 3 2 4 Terminal unit TEU 59 3 2 5 Control unit COU 60 3 2 5 1 COU versions 60 3 2 5 2 Control system configuration 62 3 2 5 3 AMC circuit board 63 3 2 5 4 Main circuit breaker 64 3 2 5 5 Speed and torque control 65 3 2 5 6 Peripheral I O devices 65 3 2 5...

Page 5: ...sing switch 78 3 3 5 3 Output disconnector 78 3 3 6 Customer interface unit CIU 79 3 3 6 1 Arc detection with Arc Guard optional 80 3 4 Air cooling 80 3 4 1 Air to air heat exchangers 80 3 4 2 Auxiliary fan units 81 3 5 Cabinet design 82 3 6 Door locking system 83 3 7 Arc resistant design 83 3 7 1 Internal arc classification 83 3 8 Busbars and grounding 84 3 8 1 AC busbars 84 3 8 2 DC busbars 85 3...

Page 6: ...ents 94 5 Mechanical installation 95 5 1 Safety 95 5 2 Overview 95 5 3 General notes on installation 96 5 3 1 Dimensions and clearances 96 5 3 2 Access to the cabinets 96 5 3 3 Cabinet roof 96 5 3 4 Fire protection 96 5 3 5 Cable duct material 97 5 3 6 Installation material 97 5 3 7 Tools 97 5 3 8 Floor preparation 97 5 3 9 Floor fixation 97 5 3 10 Raw water circuit 97 5 4 Aligning transport units...

Page 7: ...tallation 113 5 8 2 Removing air to air heat exchangers 117 5 8 2 1 Removing an air to air heat exchanger 118 5 8 2 2 Reinstalling an air to air heat exchanger 119 5 8 3 Installing the transformers of air to air heat exchangers 120 5 9 Installing the pressure relief vents 121 5 10 Attaching the sealing tapes 123 5 11 Installing the roof joints and the roof attachments 124 5 11 1 Installing roof jo...

Page 8: ... with type 2 sealing modules 137 6 5 3 Plates with cable glands 137 6 5 4 EMC plates with sealing grommets 138 6 6 Preparing cable entry systems for TEU ARU and EXU cabinets 138 6 6 1 TEU cable entry frames with type 1 sealing modules 139 6 6 2 ARU cable entry frames with type 1 sealing modules 140 6 6 3 EXU cable entry with EMC plate and sealing grommets 141 6 7 Power ground and equipotential bon...

Page 9: ... cabinet 153 6 8 6 1 Top cable entry 154 6 8 6 2 Bottom cable entry 155 6 8 6 3 Connecting the cables 156 6 8 7 Routing cables in an EXU cabinet 157 6 8 7 1 Auxiliary power and control cables 157 6 8 7 2 Optical fiber cables 159 6 8 7 3 Routing optical fiber cables in an EXU cabinet with an ED5V EB5R EB5S EB7P or EB7Q type DCS800 converter 160 6 8 7 4 Routing cables in an EXU cabinet with an ED7Y ...

Page 10: ...list 172 7 6 6 Insulation tests checklist 172 7 6 7 Power checklist 172 7 6 8 Miscellaneous checklist 172 8 Operation 173 8 1 Overview 173 8 2 Operating conditions 173 8 3 Safety 173 8 4 1 ARU control panel 174 8 4 2 INU control panels 175 8 4 2 1 Lamp test 176 8 4 3 Semi redundant drive control panel drive backup control 176 8 4 3 1 Operating modes 177 8 4 3 2 Semi redundant drive control panel 1...

Page 11: ...rtup sequence 188 8 9 Starting the drive 189 8 9 1 Checks before starting the drive 189 8 9 2 Starting the drive remotely 190 8 9 3 Starting the drive locally 190 8 10 Stopping the drive 193 8 10 1 Stopping the drive locally 193 8 10 2 Stopping the drive with the emergency off function 195 8 10 3 Initiating an emergency off 195 8 10 4 Starting the drive system after an emergency off 196 8 11 Arc d...

Page 12: ... fault 208 9 2 3 Parameters mode 209 9 2 3 1 Overview 210 9 2 3 2 Changing a parameter setting 211 9 2 3 3 Enabling unlocking a parameter lock 213 9 2 3 4 User lock 213 9 2 4 Functions mode 214 9 2 4 1 Adjusting the display contrast 214 9 2 5 Local and remote control mode 216 9 2 5 1 Local control 216 9 2 5 2 Disabling enabling local lock function 216 9 2 5 3 Enabling the local lock 217 9 2 5 4 Re...

Page 13: ... handling 224 10 3 2 3 Standard troubleshooting procedure 225 10 3 3 LEDs and switches on circuit boards and I O devices 225 10 3 3 1 AMC circuit board 226 10 3 3 2 S800 I O bus modem TB820 227 10 3 3 3 S800 I O modules 227 10 3 3 4 Serial communication interfaces 228 10 3 3 5 LEDs on optional heat exchangers 229 10 4 Maintenance tasks 230 10 4 1 Safety 230 10 4 2 De energizing and grounding the d...

Page 14: ...a phase module 253 10 4 10 2 Installing a phase module 255 10 4 11 Visual checks on the drive 256 10 4 12 Cleaning 256 10 4 12 1 Cleaning the drive cabinet 256 10 4 13 Checking wire and cable connections 257 10 4 14 Checking and replacing filter mats 257 10 4 15 Testing and replacing auxiliary fan units 259 10 4 15 1 Testing auxiliary fan units 259 10 4 15 2 Replacing auxiliary fan units 260 10 4 ...

Page 15: ...nt fans 269 10 4 17 Replacing the fan unit in an EXU with a DCS800 D4 size controller 270 10 4 18 Replacing the fan unit in an EXU with DCS800 size D5 controller 272 10 4 19 Replacing the air to water heat exchanger of the EXU 274 ...

Page 16: ......

Page 17: ... with IGCTs B 55 Figure 3 6 LSU block diagram 56 Figure 3 7 LSU 12 pulse circuit diagram 56 Figure 3 8 LSU 12 pulse 57 Figure 3 9 CBU 58 Figure 3 10 TEU 1000 mm 59 Figure 3 11 Control units 1000 mm COU A and 600 mm COU B 61 Figure 3 12 Block diagram of control system 62 Figure 3 13 Examples of AMC circuit boards in 1000 mm COU A and 600 mm COU B 63 Figure 3 14 AMC circuit board example 64 Figure 3...

Page 18: ... A and WCU800 cabinet B 79 Figure 3 32 ACS6000 example drive with air to air heat exchanger 80 Figure 3 33 Auxiliary fan unit 81 Figure 3 34 Air circulation through ventilation grids in 600 mm COU A 1000 mm COU B and WCU800 C 81 Figure 3 35 Basic cabinet design 82 Figure 3 36 IAC label example 84 Figure 3 37 Busbars 84 Figure 4 1 Lifting bracket 1 on base frame of a drive safety hook 2 secured to ...

Page 19: ...eat exchangers type LT 5 5165 UL 117 Figure 5 15 Tools for removing an air to air heat exchanger 118 Figure 5 16 Installation example of transformers in an air to air heat exchanger 120 Figure 5 17 Connect wires to terminal block 121 Figure 5 18 Pressure relief vents 121 Figure 5 19 Tools required to fasten the pressure relief vent to the roof 122 Figure 5 20 Installation example of pressure relie...

Page 20: ...with top 1 and bottom 2 cable entries 139 Figure 6 15 Short busbar removal in ARU 140 Figure 6 16 EXU with top cable entry A and EXU with bottom cable entry B 141 Figure 6 17 EXU cabinet 141 Figure 6 18 Preparing power cables for sealing modules 143 Figure 6 19 Prepare power cables for cable glands 144 Figure 6 20 Preparing cables for EMC plates A cables with an outer screen or shield B cables wit...

Page 21: ...TAC pulse encoder A and synchronous serial interface B 157 Figure 6 36 Cable routing examples in an EXU cabinet with an ED5V EB5R EB5S EB7P and EB7Q type DCS800 converter A and in an EXU cabinet with an ED7Y type DCS800 converter 158 Figure 6 37 DCS800 converter ED5V EB5R EB5S EB7P and EB7Q types 160 Figure 6 38 COM 8x circuit board A in a DCS800 converter ED5V EB5R and EB5S types and a detail of ...

Page 22: ...d position 189 Figure 8 9 Arc Guard System in a WCU REB 197 Figure 8 10 HMI panel 197 Figure 9 1 CDP control panel 199 Figure 9 2 Control panel functions for Actual signals mode 202 Figure 9 3 Control panel functions for Parameters mode 209 Figure 9 4 Control panel functions for Functions mode 214 Figure 10 1 Device identification 222 Figure 10 2 Cable and wire designation 222 Figure 10 3 LEDs of ...

Page 23: ...down B Numbers indicate the connection sequence 248 Figure 10 20 Connect the grounding sets in COU1 A and C TEU1 B INU1 D and INU2 E 249 Figure 10 21 Busbar connector removal sequence in TEU1 or COU1 250 Figure 10 22 Fitting sequence for busbar connectors 251 Figure 10 23 Phase module removal 254 Figure 10 24 COU filter 258 Figure 10 25 Accessing the fan units in the WCU roof box 260 Figure 10 26 ...

Page 24: ......

Page 25: ...LSU cabinet 56 Table 3 3 Main components in a CBU cabinet 58 Table 3 4 Main components in a WCU cabinet 67 Table 3 5 BCU braking power 74 Table 3 6 RBU braking power 74 Table 3 7 ABB arc resistant classes 83 Table 5 1 Installation material for AC busbars COU TEU ARU INU 109 Table 5 2 Installation material for roof joints 124 Table 6 1 Cable entry frames for type 1 sealing modules 136 Table 8 1 Med...

Page 26: ......

Page 27: ...x A Additional manuals provides manuals about additional equipment delivered with the drive such as project specific options such as pulse encoder or fieldbus interfaces or information on modifications of the standard drive Appendix B Technical data contains the technical data sheets of the drive Appendix C Mechanical drawings provides the outline drawings of the drive The drawings are generated a...

Page 28: ...OS Application and Motor Controller Operating System ANSI American National Standards Institute AO Analog Output APU Auxiliary Pump Unit ARU Active Rectifier Unit The ARU rectifies the voltage of the supply network to the DC voltage and maintains the DC link voltage at a constant level irrespective of changes in the supply network The unit is designed as a self commutated 3 level voltage source in...

Page 29: ...Direct Current DC_NP DC Neutral Point Neutral point of the DC link of the drive DCS Acronym for the AC to DC converter or the three phase AC power controller of an excitation unit DDCS Distributed drive control system DDCS is an acronym for a serial communications protocol designed for data transfer via optical fibers DI Digital Input DIN Deutsches Institut für Normung DIU Discharging Unit DO Digi...

Page 30: ...ynchronous motor FBA Fieldbus Adapter FCB Function Chart Builder FCI Fieldbus Communication Interface FFU Fin Fan Unit FIR filter Fast Impulse Response filter FIS Flow meter FT Firing Through Synonym for protective firing Meaning simultaneous gating of the power semiconductors of the inverter unit to effectively protect the semiconductors against overvoltage and overcurrent FSCD Fast Short Circuit...

Page 31: ...dule I O module Term of ABB s S800 I O system The I O module is an active input or output device for digital or analog signals I O station Term of ABB s S800 I O system The I O station typically consists of a bus modem and several input and output devices IOI Inverter Output Isolator The IOI is a switching device that disconnects the inverter from the motor IP Ingress Protection The IP code specif...

Page 32: ...embly of wired components including the power semiconductors that serves as a standardized building block for the ARU LSU and INU of the drive PINT Pulse Interface Circuit Board POM Power Operation Mode PPCC Power Plate Communication Circuit PPCS Power plate communication system PPCS is an acronym for a serial communication protocol designed for data transfer via optical fibers between AMC circuit...

Page 33: ...transformer and motor cables the ground frame for the cable screens and the ground cable and the grounding accessories THD Total Harmonic Distortion TT Temperature Transmitter UPS Uninterruptible Power Supply USB Universal Serial Bus VLSCD Voltage Limiting Short Circuit Detection VLU Voltage Limiter Unit VSD Variable Speed Drive VSI Voltage Source Inverter WCU Water Cooling Unit The WCU dissipates...

Page 34: ...ark of ABB Arc Guard System Registered trademark of ABB Carboweld Registered trademark of ABB DriveWare Registered trademark of ABB Ethernet Registered trademark of Xerox Corporation Industrial IT Trademark of ABB Modbus Registered trademark of the Modbus Organization Inc Profibus Registered trademark of Profibus International PI Windows Registered trademark of Microsoft Corporation Table 1 3 Main...

Page 35: ...nsformer requirement specification 3BHS125393 E01 16 Emergency off and stop modes and prevention of operation 3BHS196243 E01 17 Recycling instructions 3BHS122085 E01 18 Environmental information material declaration 3BHS360175 E01 19 Roxtec CF16EMC installation instructions 3BHS820829 E01 20 ACS6000 ACS6080 label placement 3BHS544773 E01 21 Painting specification for ACS1000 ACS2000 ACS5000 and AC...

Page 36: ...llation and startup guide 3BFE64341588 31 S800 I O Getting started 3BSE020923 32 S800 I O Modules and Termination Units 3BSE020924 Table 1 9 User manuals related to drive units Title Document number 33 ACS5000 ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 34 ACS5000 ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 Table 1 8 Communication interfac...

Page 37: ...d in unpacking and transporting heavy equipment 1 6 2 Mechanical installation The personnel must be qualified to prepare the installation site according to the site and equipment requirements and to perform the installation accordingly 1 6 3 Electrical installation Personnel must have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment be...

Page 38: ...cations is not permitted Intended equipment use also implies that only spare parts recommended and approved by ABB must be used Unauthorized modifications and constructional changes of the drive are not permitted 1 9 Cyber security disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is the customer s sole responsibility to provi...

Page 39: ... related parts of control systems Part 1 General principles for design section 6 2 6 Category 3 40 IEC 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements 41 IEC 60721 3 1 Classification of environmental conditions Classification of groups of environmental parameters and their severities Storage 42 IEC 60721 3 2 Classification of environmental conditions Classi...

Page 40: ...ated on the back of the control compartment door The label provides information on the type of drive the rated voltage the frequency and the current of the main and the auxiliary power supply 1 12 Tools ABB offers various tool sets containing all necessary tools and equipment for installation commissioning and maintenance of the drive The content of the tool sets is described in the Service Equipm...

Page 41: ... do so can result in serious Injury or DEATH Keep for future reference This is the safety alert symbol It is used to alert you to potential physical injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not a...

Page 42: ... sign can also have additional text below it eg High voltage Hot surface Crushing of hands No access for people with active implanted cardiac device The magnetic field of the drive can influence the functioning of pacemakers The pacemaker sign should be installed at the entrance to the drive room or at a minimum distance of 6 m from the drive to stop personnel with pacemakers approaching the drive...

Page 43: ...earing protection when a drive is running 4 While working on the drive Do not step on the roof Do not install foreign objects on the roof 5 Before working on a water cooling unit WCU In addition to the safety instructions for working on a drive always read the WCU safety data sheet for relevant safety information eg the type of ion exchange resin and glycol 6 Before working simultaneously on the d...

Page 44: ...e Permit To Work PTW process For an example Permit to Work see Permission for working and permit to work for test work at test stations 3BHS817511 E30 2 Clearly identify the work location and equipment Use your senses sight hearing and smell to identify problem areas Define the work area via barriers and barricading and label equipment Avoid distractions such as talking or texting on the phone 3a ...

Page 45: ... this is carried out by the customer then the PICW must ensure that this equipment is properly earthed as a part of the integration verification and during step 7 when the PICW walks the PTW 6 Protect against adjacent live parts and take special precautions when close to bare conductors Determine minimum approach distances apply screening or shrouding and when applicable padlock both cable and bus...

Page 46: ...installed equipment Wrongly connected cables External influence on or damage of the equipment Wrong parameter settings Software errors Faulty hardware 3 Hazardous touch voltages can be present on drive system components which can be caused by Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltages by external equipment Co...

Page 47: ...equipment The MCB is located on the primary side of the converter transformer Figure 2 2 Drive system overview Note MCBs and protection relays are not included in the drive supply Typical MCBs devices Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor control centers Dedicated protection relay Transformer or drive primary cable protection DTL Transformer protection if applicabl...

Page 48: ...he MCB at any time It is not permitted to interrupt the open and or trip command eg with a local remote switch in the MCB Closing control of the MCB when the MCB is in service position the drive must have exclusive control over closing the MCB ie local closing of the MCB is not permitted MCB maximum opening time cannot exceed the maximum time that is defined in the product or project specific MCB ...

Page 49: ...m protection coordination scheme is provided which uses the breaker failure ANSI 50BF signal to automatically trip the upstream breaker in case the MCB does not open IMPORTANT The upstream breaker must open within the maximum safety trip time after a failure has occurred 2 8 Maintenance recommendation The MCB trip circuits should be checked annually 1 Short circuit occurs 2 Open and or trip comman...

Page 50: ......

Page 51: ...ired if the line voltage must be adapted to the motor voltage For more information see the Main transformer specification Drive Motor 3 1 1 Drive The ACS6000 is a voltage source frequency converter for high power induction and synchronous motors The drive features a common DC bus permitting the configuration of single motor or multi motor solutions Figure 3 1 Common DC bus principle for single mot...

Page 52: ...e source inverter with IGCT technology 2 Drive control panel for local operation Keypad with multi language display main supply on off pushbuttons and emergency off push button 3 Inverter unit INU Self commutated 6 pulse 3 level voltage source inverter with IGCT technology 4 Capacitor bank unit CBU DC capacitors for smoothing the intermediate DC voltage 5 Water cooling unit WCU Supplies deionized ...

Page 53: ...a 6 pulse self commutated voltage source inverter that rectifies the line voltage of the supply network and maintains the DC link voltage at a constant level irrespective of changes in the supply network The active 6 pulse rectifier allows for regenerative braking INU The INU controls the 3 phase motor voltage and converts the DC link voltage to the required AC motor voltage and frequency The INU ...

Page 54: ... gate commutated thyristors IGCTs diodes and clamp capacitors The phase modules are identical in construction for all power ratings However the types of semiconductors vary depending on the power rating For this reason it is not possible to mix phase modules for different power ratings in one unit Clamping circuit Protects the circuit from excessive rises in current with di dt reactors and freewhe...

Page 55: ...nergy An LSU is used with input transformers and is available in various power ratings The LSU allows two quadrant operation and maintains the power factor at 0 95 in the whole operating range To achieve 24 pulse rectification or to increase the drive power units with the same power rating can be operated in parallel 1 EMC filter 2 Control interface 3 Gate unit power supply 4 Phase module 5 Diode ...

Page 56: ...2 pulse LSU cabinet Component Description 12 pulse diode rectifier Snubber circuit Limits the rate of the voltage rise dv dt across the diodes and the crowbar thyristors di dt limiting reactors Define the current rise in the thyristor crowbar Thyristor crowbar Protection circuit that activates when a short circuit occurs By applying protection firing the thyristor crowbar short circuits the rectif...

Page 57: ... M ACS6000 USER MANUAL 57 278 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3 8 LSU 12 pulse 1 Snubber resistor 2 Snubber capacitor 3 Rectifier monitoring unit 4 di dt limiting reactors 5 Diode stacks 1 2 3 4 5 5 5 5 ...

Page 58: ... 9 CBU Table 3 3 Main components in a CBU cabinet Component Description Liquid cooled DC link capacitors Charging unit To avoid excessive inrush currents after the main circuit breaker has been closed the capacitors are charged before the drive is connected to the main power source Discharging unit This optional unit discharges the DC link capacitors if the drive is not equipped with a voltage lim...

Page 59: ...are designed for top or bottom cable entry The terminal units are available either as individual units or are integrated into a master COU or ARU The width of the unit 600 mm or 1000 mm depends of the number of line supply units or active rectifier units and or the motors supplied via one terminal unit Figure 3 10 TEU 1000 mm 1 DC busbars 2 AC busbars 3 Cable entry frame 4 PE ground busbars 1 2 3 ...

Page 60: ...first INU Depending on the selected options and the configuration of the drive a separate control unit is used for the ARU If an LSU is part of the drive all rectifier and line related functions are implemented in the control unit of the INU A separate control unit is assigned to each INU that supplies a single motor If several INUs supply one motor they share one control unit Note For information...

Page 61: ...3BHS212794 E01 REV M ACS6000 USER MANUAL 61 278 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3 11 Control units 1000 mm COU A and 600 mm COU B A B ...

Page 62: ... used for control monitoring measurement and protection on both throughout the drive However circuit boards of the same type can be equipped with different software depending on the function the circuit board fulfills Figure 3 12 Block diagram of control system 1 Higher level control system 2 External devices 3 DriveWare 4 Cloud connectivity 5 CDP control panel 6 RS485 7 Fieldbus adapter 8 S800 I ...

Page 63: ...ment Note For more information on the parameters see the Appendix G Signal and parameter table 3 2 5 3 AMC circuit board The AMC circuit board is the major component of the control system and performs general drive motor control and closed loop functions The main internal control hardware and the peripheral input and output interfaces to the customer communicate with the AMC circuit board via opti...

Page 64: ...ternal functions are not programmable by the user Optionally the drive offers monitoring of signals from external equipment These can be activated and set with parameters Other general control protection and monitoring tasks regarding the whole drive include control and monitoring of Main circuit breaker Grounding switch Door locking system Cooling system Note For more information on control prote...

Page 65: ...e inputs to an adaptive motor model The model produces exact values of torque and flux every 25 microseconds Motor torque and flux comparators compare the actual values to reference values produced by the torque and flux reference controllers Depending on the outputs from the hysteresis controllers the switching logic directly determines the optimum switch positions every 50 microseconds and initi...

Page 66: ...ce for monitoring control and operation of the drive and setting of parameters Figure 3 16 Local control panels on 1000 mm COU A and 600 mm COU B Note For more information see 8 Operation on page 173 9 CDP control panel on page 199 3 2 5 8 S800 I O system Standard S800 I O modules connect the internal and external I O signals to the control system External I O signals connect to the terminals insi...

Page 67: ...e water to water heat exchanger The water cooling units are accessible for maintenance even when the drive is in operation Note For more information see ACS5000 ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 and ACS5000 ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 1 TB 820 bus modem 2 I O modules 3 Module termination unit 1 2 3 Table 3 4 Main ...

Page 68: ...ump is also available Water to water heat exchanger Transfers the heat from the internal cooling circuit to the external cooling circuit Expansion vessel Used for pressure compensations Ion exchange vessel The ion exchange vessel in the water treatment circuit deionizes the coolant of the internal cooling circuit and maintains the conductivity 3 way valve The three way valve controls the flow of t...

Page 69: ... A and WCU800 B cabinet and system components 1 Control equipment mounted on a swing frame 2 Pump circuit breakers 3 Warm water 4 Expansion vessel 5 Pump 1 6 Pump 2 7 Cool water 8 Expansion vessel 9 Three way valve 10 Water to water heat exchanger 11 Deionizer A 1 2 3 4 5 6 7 8 9 10 11 B 1 3 4 5 6 8 10 2 7 11 ...

Page 70: ... to keep conductivity at a low level External cooling circuit transfers the heat losses from the water to water heat exchanger to the exterior The water cooling units are pressurized and not open to atmospheric pressure Figure 3 19 Cooling circuit in an ACS6000 drive 3 2 6 2 External cooling connection Two flanges connect the external cooling circuit water pipes to the cooling unit They are part o...

Page 71: ... 1 Input reactor unit IRU The IRU is used with the 6 pulse LSU for applications without an input transformer The IRU limits the input current and improves the total harmonic distortion THD of the supply voltage Figure 3 20 IRU circuit diagram Figure 3 21 IRU cabinet 1 IRU 2 LSU 3 Thyristor crowbar 4 Diode rectifier 5 Snubber circuit 6 di dt choke 1 Three phase reactor DC DC 1L1 1L2 1L3 1 2 3 4 5 6...

Page 72: ...ion with 6 pulse active rectifier units connected to a weak supply network The tuned filter is located between the input transformer and the ARU and reduces harmonic voltages injected to the supply network Figure 3 22 IFU circuit diagram Figure 3 23 IFU cabinet 1 TEU 2 IFU 3 ARU 1 Resistor 2 Capacitor 3 Reactor L1 L2 L3 L1 L2 L3 1 2 3 1 2 1 2 3 ...

Page 73: ...sed for applications that require dynamic changes between driving and braking mode During braking the energy is dissipated in liquid cooled resistors The resistors are controlled by IGCT semiconductors and protected against overload Figure 3 24 VLU circuit diagram Figure 3 25 VLU cabinet 1 Air cooled resistors 2 IGCT DC DC NP DC 1 2 ...

Page 74: ...ctive motor braking However BCUs and RBUs can also be used in combination with ARUs eg mine hoists and other special applications that require emergency braking in the event of a power outage During braking the BCU limits the DC link voltage and converts the braking energy into heat that is dissipated in resistors IGCT semiconductors switch the braking energy to the resistors Table 3 5 BCU braking...

Page 75: ...per unit A BCU is used when the braking scenario requires consistent energy dissipation The energy generated during braking is dissipated in external water cooled resistors which are not part of the drive Figure 3 26 BCU circuit diagram Figure 3 27 BCU cabinet 1 Resistor external 2 BCU 1 IGCT DC DC NP DC 1 2 1 ...

Page 76: ...12794 E01 REV M ACS6000 USER MANUAL 76 278 3 3 4 2 Resistor braking unit An RBU with integrated resistors is used for smaller braking capabilities Figure 3 28 RBU circuit diagram Figure 3 29 RBU cabinet 1 IGCT 2 Water cooled resistor DC DC NP DC 1 2 ...

Page 77: ... excitation AC excitation Uses a three phase DCS800 AC power controller The power controller feeds an exciter which is mounted on the shaft of the main motor The rotating armature of the exciter supplies a rectifier which generates the DC current for producing the magnetic field in the synchronous motor Note For more information see Air cooled excitation units brush brushless excitation technical ...

Page 78: ... another DCS800 Note For more information see 8 5 EXU control panel on page 178 3 3 5 2 Reversing switch The EXU for brushless excitation is equipped with a reversing switch for changing the sense of rotation The switch is actuated by the drive The switch changes the sense of rotation via the optical communication link When the drive is in state ReadyOn or NotReadyOn the switch is opened 3 3 5 3 O...

Page 79: ...ing the auxiliaries of motors and the transformers The I O module modules are connected to the drive controller CIUe provides engineered project specific interfaces and an application controller with customer specific software As an option for single motor drives it is possible to integrate the predefined I O modules maximum 4 modules in the rooftop extension box REB of the water cooling unit For ...

Page 80: ...1 Air to air heat exchangers Drives for high power applications are equipped with air to air heat exchangers They ensure a constant air flow through the medium voltage units and transfer the heat losses of non water cooled components to the exterior The fans of the air to air heat exchangers are controlled by the drive The auxiliary power for the heat exchangers is supplied by an additional transf...

Page 81: ...units circulate the air in the control unit cabinet s and in the WCU cabinet If installed additional fan units are available in the optional WCU roof box Figure 3 33 Auxiliary fan unit Figure 3 34 Air circulation through ventilation grids in 600 mm COU A 1000 mm COU B and WCU800 C Note The number of fans varies depending on the cabinet A B C ...

Page 82: ... The inside panels of the compartments are not painted because paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC The joining surfaces of two transport units are equipped with EMC sealing strips The cabinet doors and the internal cable ducts are also equipped with EMC sealing Degree of protection The standard cabinets are rated for IP 32 Ratings for IP...

Page 83: ...ormation on the door locking system including grounding switches locking bars and safety switches see 8 5 EXU control panel on page 178 3 7 Arc resistant design The optional Arc Resistant Design provides the drive with arc fault protection see Table 3 7 in accordance with IEC 62477 2 3 7 1 Internal arc classification The arc fault rating which is based on arc fault tests is on the label underneath...

Page 84: ...ns busbars for various types of connections Figure 3 37 Busbars 3 8 1 AC busbars The incoming feeder and motor cables are connected to their corresponding busbars inside a TEU In multi motor drives several TEUs are part of the drive lineup Depending on drive configuration the incoming busbars are interconnected with the ARU or the LSU The outgoing busbars are interconnected with the inverter unit ...

Page 85: ... safety and to ensure smooth functioning of the equipment it is important to ground the drive properly For this reason the ground cable of the drive is connected to the grounding system of the installation site The drive is equipped with a continuous PE ground busbar that stretches across the bottom part of the entire cabinet 3 8 4 PG busbar To ensure proper operation cable shields are connected t...

Page 86: ......

Page 87: ... It is recommended to photograph the damages and send the photographs to ABB 4 4 Identifying transport units A delivery can consist of transport units for several drives To identify the transport units and assign them to a particular drive see the following accompanying papers for information Packing list that is attached to the packaging of each transport unit Packing label on the back wall of ea...

Page 88: ...and Ltd Drives Mailing address CH 5401 Baden Switzerland Phone 41 58 589 27 95 Telex 755749 abb ch Facsimile 41 58 580 20 84 Bank Credit Suisse CH 8070 Zurich Switzerland ABB item Customer item Qty Unit Identnumber Commodity description 001221 1 1 The third digit from the right identifies the drive that the accessories belong to ie drive 1 1 PC cross wiring 001222 1 PC WCU accessory 001223 1 PC cr...

Page 89: ... NOT lift and move them with a crane Use appropriate transport means such as heavy load hydraulics rollers or air cushions If in doubt contact ABB for instructions To prevent damage to drive components transport and move the drive or a transport unit only in upright position To prevent dirt from entering the drive keep the doors of the drive or a transport unit closed Metallic dust in particular c...

Page 90: ...s of the cabinet roof Use appropriate safety hooks or shackles to attach a sling DO NOT pass a sling through the hole of the bracket Protect the edges and the door handles if the slings are too close to the cabinet If a lift frame or lift spreader is not available make sure that the slope angle is a maximum of 15 see Fig 4 2 Observe the center of gravity Lift the drive or a transport unit slowly a...

Page 91: ...ON STORAGE AND DISPOSAL Figure 4 2 Lift frame A and lift spreader B 1 Safety hook 2 Lift frame 3 Strap 4 Protect the edges door handles and levers 5 Safety hook or shackle 6 Lifting bracket 7 Slope angle maximum 15 8 Lift spreader A 1 2 2 3 4 5 6 B 1 3 4 5 6 7 8 8 ...

Page 92: ... C Note For information about draining and frost proofing see the manual of the water cooling unit in Appendix A Additional manuals 2 Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil and a wooden panel 3 Add a desiccant of the appropriate quality 4 1 unit desiccant 30 g absorbs 6 g water vapor IMPORTANT If you use polyethylene foil to cover the cabinets use...

Page 93: ... boards in antistatic bags or boxes Storage temperature range 5 C to 55 C Storage place requirements Free of vibration and shock Protected against dust sand vermin and insects Free of corrosive gases salt or other impurities that could damage electronic equipment Dry no condensation Relative humidity 5 85 DO NOT touch a circuit board without wearing a wrist grounding strap Put the component on a g...

Page 94: ...8 4 8 Disposing package materials and components Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations Note For more information on the disposal of packaging materials and drive components see the recycling instructions ...

Page 95: ...its on page 98 5 5 Joining transport units on page 100 5 6 Joining water pipes on page 101 Joining the busbars 5 11 Installing the roof joints and the roof attachments on page 124 Only for optional components 5 8 Installing and removing air to air heat exchangers on page 112 5 9 Installing the pressure relief vents on page 121 5 10 Attaching the sealing tapes on page 123 All installation work must...

Page 96: ...k is discontinued and completely cover openings Metallic dust in particular could cause failures when the drive is powered up and cause damage When joining two transport units do not damage or dislocate the EMC sealing strip that is glued onto the outer joining surfaces of the cabinet frame If the transport units are joined but not yet on the base frame do not lift and move them with a crane Inste...

Page 97: ...ter circuit The incoming and outgoing raw water pipes are connected to the flanges of the WCU Installation material such as counter flanges bolts nuts and seals are supplied For information on dimensions of the raw water entry and the flanges see Appendix C Mechanical drawings NOTICE Risk of component damage Use cable ducts of non flammable material with non abrasive surface To prevent dust humidi...

Page 98: ...ral transport units 1 If a transport unit has water pipes remove the protective covers from the water pipe ends on both sides 2 Check that a pipe joint 1 has been slid on one pipe end of two adjoining water pipes 3 Line up the transport units as shown in Appendix C Mechanical drawings Note The units can be lined up either beginning from the left or the right 1 ...

Page 99: ...and the angular deflection of two adjoining water pipes are not exceeded Axial misalignment 3 mm Axial deflection 5 Bolt holes are aligned where transport units are joined see the connection points on Fig 5 1 Cabinet doors are not misaligned and that there are no gaps between cabinet walls and cabinet frame Adjoining surfaces of transport units meet perfectly all around ...

Page 100: ...ote Some of the connection points might not be accessible in certain configurations In such cases you only need to join the connection points that you can access Figure 5 1 Connection point locations on transport units NOTICE Risk of component damage DO NOT move joined transport units with a crane Use transport means such as heavy load hydraulics rollers or air cushions instead 1 Connection point ...

Page 101: ...of a pipe joint on one end of a water pipe as a fitting guide 2 Slide the pipe joint over the two adjoining pipe ends 3 Center the pipe joint 4 Orientate the locking bolts of the pipe joint for the return water pipes Fig 5 2 Figure 5 2 Minimum distances and locking bolt orientation A front WARNING Flashover hazard The locking bolts maintain the required minimum distances between pipe joint and bus...

Page 102: ...n the bolts to the torque indicated on the pipe joint 5 6 1 Removing a pipe joint 1 Loosen the bolts alternately but do not remove them completely 2 Slide the pipe joint to the side Note The sealing lip can touch the pipe end 3 Turn and move the pipe joint smoothly 4 Clean the pipe joint and treat the bolts with an appropriate lubricant before refitting ...

Page 103: ...se a conical spring washer on each side of a connection Figure 5 3 Bolted busbar connection CAUTION Flashover hazard Incorrect orientation of the busbar bolts can cause flashover when the drive is energized Orientate the bolts and the nuts of each connection as shown in this section to maintain the required minimal distances between busbars of different polarity NOTICE Risk of component damage Tig...

Page 104: ... configuration of the drive DC busbar configuration 1 Fig 5 4 DC busbar configuration 2 A in Fig 5 5 DC busbar configuration 3 B in Fig 5 5 DC busbar configuration 4 C in Fig 5 5 Figure 5 4 Top view of DC busbar configuration 1 Item Quantity Technical parameters Identification 1 Connecting plate 3 Flex 3BHB010246R0001 R0051 2 Hex head bolt 6 M12 x 35 A2 NB 312350P8118 3 Hex head nut 6 M12 A2 70 co...

Page 105: ...78 05 MECHANICAL INSTALLATION Figure 5 5 Top view DC busbar configurations 2 A 3 B and 4 C 1 Busbar with negative potential 2 Busbar with neutral potential 3 Busbar with positive potential 4 Front of cabinet A B C NP NP NP NP NP NP NP NP NP 1 2 3 4 ...

Page 106: ...und busbar joints Item Quantity Technical parameters Identification 1 Connecting plate 2 Flex 3BHB010246R0001 R0051 2 Hex head bolt 4 M12 x 40 A2 NB 312350P8119 3 Hex head nut 4 M12 A2 70 coated HZN 452198P1022 4 Conical spring washer 8 13 x 29 x 3 HAQN400344P0111 5 Water pipe 6 Cabinet front PG PE 1 1 2 3 4 4 5 ...

Page 107: ...een the COU TEU and LSU 5 7 9 MVA Item Quantity Technical parameters Identification 1 Connection bus bar 1 LSU TEU 1b 3BHB045554R0001 2 Connection bus bar 1 LSU TEU 2b 3BHB045556R0001 3 Connection bus bar 4 LSU TEU 3b 3BHB045558R0001 4 Bus bar spacer 4 80 mm spacer 10 mm 3BHB031095R0001 5 Hex head bolt 32 M12 x 45 A2 70 NB 312450P8120 6 Hex head bolt 16 M12 x 50 A2 70 NB 312450P8121 7 Conical spri...

Page 108: ...of this figure Figure 5 8 AC busbar joints between the COU TEU and LSU 14 MVA Item Quantity Technical parameters Identification 1 Connection bus bar 1 LSU TEU 1a 3BHB045554R0001 2 Connection bus bar 1 LSU TEU 2a 3BHB045556R0001 3 Connection bu bar 4 LSU TEU 3a 3BHB045558R0001 4 Hex head bolt 32 M12 x 45 A2 70 NB 312450P8120 5 Hex head bolt 16 M12 x 65 A2 70 NB 312450P8124 6 Conical spring washer 9...

Page 109: ... M12 x 40 A2 70 NB 312350P8119 Single busbar Hex head bolt M12 x 60 A2 70 NB 312450P8123 Double busbars Hex head bolt M12 x 80 A2 70 NB 312450P8127 Triple busbars Conical spring washer 13 x 29 x 3 HAQN400344P0111 Hex head nut M12 A2 70 coated HZN 452198P1022 Modules Busbar joints ARU INU COU TEU ARU INU 5 MVA without MOI COU TEU 600 mm 1000 mm COU TEU ARU INU ARU INU 5 MVA without MOI COU TEU 600 ...

Page 110: ...with motorized disconnector COU TEU ARU INU ARU INU 7 9 13 peak MVA 5 MVA with MOI COU TEU 600 mm 1000 mm ARU INU COU TEU ARU INU 12 MVA COU TEU 1000 mm COU TEU ARU INU ARU INU 12 MVA COU TEU 1000 mm Module Busbar joints ARU INU COU TEU ARU INU 5 7 9 13 peak MVA COU TEU 1000 mm Modules Busbar joints ...

Page 111: ...S6000 USER MANUAL 111 278 05 MECHANICAL INSTALLATION COU TEU ARU INU ARU INU 5 7 9 13 peak MVA COU TEU 1000 mm ARU INU COU TEU ARU INU 12 MVA COU TEU 1000 mm COU TEU ARU INU ARU INU 12 MVA COU TEU 1000 mm Module Busbar joints ...

Page 112: ...lling air to air heat exchangers For information on the number of air to air heat exchangers to be installed and their fitting position see Appendix C Mechanical drawings Figure 5 9 Air to air heat exchanger type LT 5 5165 UL Figure 5 10 Tools for installing an air to air heat exchanger Weight 65 kg Length 1025 mm Width 750 mm Height 316 mm 1 Cordless drill 2 Wire cutter 3 Torx drill bit 4 M6 x 12...

Page 113: ...fore lifting the heat exchanger onto the roof cut off the cable ties 2 Loop the cables as illustrated and fasten them to the cable tie mounts circles NOTICE Risk of damage Incorrect installation of the heat exchanger cables can cause Ground fault Unexpected shutdown of the drive Damage to the heat exchanger 2 x ...

Page 114: ... cover on the roof where the heat exchanger is installed 5 Lift the heat exchanger above the opening in the roof and orientate the heat exchanger with the LEDs circle pointing to the front of the cabinet CAUTION Hazardous voltage Make sure that the heat exchanger cables do not touch the high voltage carrying DC busbars 2 in Fig 5 11 1 Correct cable installation 2 DC busbar 3 Incorrect cable instal...

Page 115: ...S6000 USER MANUAL 115 278 05 MECHANICAL INSTALLATION 6 Route the cables through the designated openings circle at the front of the cabinet 7 While lowering the heat exchanger onto the roof pull the cables through the openings ...

Page 116: ...RU INU IFU 9 MVA and LSU Figure 5 12 ARU INU IFU cable routing Figure 5 13 LSU cable routing 9 Connect each wire to terminal block X1 according to the terminal numbers printed on the marker sleeves white 10 In the upper part of the cable duct 1 fasten the cables to the cabinet frame 11 In the lower part 2 tie the cables together at regular distances 1 1 2 1 2 15 x 1 1 2 ...

Page 117: ...lies to drives that are delivered in several transport units Figure 5 14 Air to air heat exchangers type LT 5 5165 UL Air to air heat exchangers must be removed and refitted where two transport units are joined CAUTION Heavy object An air air height exchanger weighs approximately 65 kg Observe the installation height of the heat exchanger as well as the dimensions and weight of the heat exchanger ...

Page 118: ... for joining the DC busbars of two adjacent transport units Figure 5 15 Tools for removing an air to air heat exchanger 5 8 2 1 Removing an air to air heat exchanger 1 Loosen the 4 self tapping M6x12 screws HAQN401205P0257 that fasten the heat exchanger to the roof 2 Remove the cable ties 1 Cordless drill 2 Wire cutter 3 Torx drill bit 4 Cable tie 1 2 3 4 ...

Page 119: ... exchanger and place the removed heat exchanger on the timber 6 Join the DC busbars with the supplied installation material 5 8 2 2 Reinstalling an air to air heat exchanger 1 Move the heat exchanger to its original position 2 Pull the cables down towards the terminal box 3 Move the heat exchanger to its exact position 4 Fix the cables with cable ties at regular distances of approximately 20 cm 5 ...

Page 120: ...r of transformers to be installed and their fitting position see Appendix C Mechanical drawings 1 Install the transformer and hood as illustrated Figure 5 16 Installation example of transformers in an air to air heat exchanger 1 8 x M6x12 HAQN401205P0257 2 Transformer hood 3 4 x M8x20 9ABA450093R0310 4 Transformer connection plate 5 1 5 kVA transformer 17 kg 6 2 8 kVA transformer 49 kg 7 3 5 kVA t...

Page 121: ...rs printed on the marker sleeves Figure 5 17 Connect wires to terminal block 5 9 Installing the pressure relief vents This section applies to drives with separately delivered pressure relief vents Pressure relief vents are installed on the roofs of TEUs and COUs Figure 5 18 Pressure relief vents Weight 26 kg Length 840 mm Width 520 mm Height 210 mm ...

Page 122: ...ows pointing to the center of the drive Note The orientation of the baffle blades can be seen through the grille on the underside Figure 5 20 Installation example of pressure relief vents 2 Fasten the pressure relief vent to the roof with the supplied screws Fig 5 20 1 Cordless drill 2 Torx bit 3 24 x M6x20 Self tapping HAQN40105P0260 1 Orientation of baffle blades 2 Center of drive 3 Pressure rel...

Page 123: ...it prevents water entering the gap between two adjoining roof plates The tape is installed where two transport units have been joined Gaps within a transport unit have been sealed with a tape in the factory Procedure 1 Remove the roof plates of two adjoining transport units 2 Cut the sealing tape to the required length 3 Attach the tape on the whole length of the joining crossbars 1 Figure 5 21 At...

Page 124: ...tion see Appendix C Mechanical drawings Install the joints at the front and the back of the roof of two adjoining transport units using the supplied installation material Note The joints 1 within a transport unit are factory installed Figure 5 22 Roof joints 1 Table 5 2 Installation material for roof joints Item Technical parameter Identification Connecting plate 8 x 80 x 220 mm 3BHB011552R0001 He...

Page 125: ...ppendix C Mechanical drawings Figure 5 23 Roof attachment parts Item Details ID number 1 2 x nuts M12 HZN 452198P1022 2 2 x washers 13 29 ST ZN 9ABA450078P0007 3 2 x washers 17 x 30 x 3 9ABA450078P0008 4 2 x hex head bolts M16 x 40 NB 312350P0464 5 1 x bracket 3BHB035997R0002 6 2 x spacers 3BHB032466R0001 7 1 x damping pad 3BHB035998R0001 8 1 x bracket 3BHB035997R0001 9 2 x damping connectors 3BHB...

Page 126: ...ot supplied WARNING Do not install the struts at a 90 angle to the cabinet roof Fig 5 24 4 If you fix the drive to the ceiling use two struts per roof attachment 1 in Fig 5 24 5 If you fix the drive to the back wall install one strut in a 90 angle to the drive 2 in Fig 5 24 Figure 5 24 Recommended ceiling and wall fixings 1 Two struts at 45 to ceiling 2 One strut at 90 to wall 3 Do not install the...

Page 127: ... 6 1 Phase module on lift table DANGER Hazardous voltage Improper work could lead to life threatening injury or death The electrical installation must be carried out by qualified personnel according to the site and equipment requirements and the relevant electrical codes When the electrical installation is completed the main and auxiliary power supply to the drive must not be switched on without t...

Page 128: ...te For information on the requirements for the auxiliary power cable and the control cables see Auxiliary power and control cables guideline 3BHS813742 E01 6 2 3 Synchronization cables Synchronization cables are used in drives with an ARU A shielded 3 phase cable without neutral wire is required for the supply voltage of the synchronization transformer NOTICE Risk of false signals DO NOT lay contr...

Page 129: ...e B of the drive system 1 Transformer or busbar 2 System ground 3 Cable shield 4 Cable armor 5 Equipotential bonding conductor 6 Ground cable 7 TEU 8 ARU 9 Transformer 10 LSU 11 INU 12 Motor L1 L2 L3 PE U1 V1 W1 PG PE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 L1 L2 L3 PE 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 L1 L2 L3 PG PE L1 L2 L3 2L1 2L2 2L3 PG PE U1 V1 W1 PE U2 V2 W2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3...

Page 130: ... ground busbar is fitted below the roof Figure 6 3 System ground connection 1 in a 600 mm TEU Note For project specific information see Appendix D Wiring diagrams For information on busbar thickness and fastening hole diameter see Appendix C Mechanical drawings 6 3 3 Cable shield ground connection Cable shields are connected to the separate PG ground busbar The connection between the PE and PG gro...

Page 131: ...a cable At the EXU ground the cable screen via the conductive sleeve of the entry plate Figure 6 4 Grounding the EXU 6 4 Internal wiring This section applies to a drive that is delivered as multiple transport units Cables for internal wiring are delivered separately The pre assembled cables are fitted with terminal identifications at each end All necessary data for each individual connection are s...

Page 132: ... minimum distance of 5 mm from the closest metal part 3 Connect all cables and wires according to the Converter Hardware diagram NOTICE Risk of equipment failure Handle optical fibers with care DO NOT touch the ends of the fibers they are sensitive to dirt When unplugging hold the connector and not the fiber If an optical fiber is damaged or improperly installed data transmission can be affected a...

Page 133: ...ed for arc faults by the Arc Guard System with optical detectors 2 detectors in COU TEU 2 detectors in ARU with bottom cable entry option 1 detector in BCU Figure 6 6 Arc Guard System in an optional roof extension box REB The Arc Guard System consists of the following Arc Guard unit TVOC 2 with HMI panel Optical fiber detectors The detectors are pre installed in the relevant cabinets with the corr...

Page 134: ...through the cable duct 3 in Fig 6 8 at the top of the cabinets Note Cut outs in the ducts provide entry into the cabinets Figure 6 8 Cable tray and cable ducts in an LSU A front 2 Lay the cables into their designated trays and cable ducts as illustrated in Fig 6 8 3 Connect the cables to the arc monitor located in the REB according to the drawings 1 Cable tray for auxiliary power supply cable 2 Ca...

Page 135: ...top and or bottom cable entry 6 5 1 Frames with type 1 sealing modules on page 135 6 5 2 Frame with type 2 sealing modules on page 137 6 5 3 Plates with cable glands on page 137 6 5 4 EMC plates with sealing grommets on page 138 Note For information on the location and the dimensions of the cable entry see Appendix C Mechanical drawings 6 5 1 Frames with type 1 sealing modules Figure 6 9 Cable ent...

Page 136: ...ngle core cable Table 6 1 Cable entry frames for type 1 sealing modules Cabinet entry frame Cabinet Maximum number of sealing modules openings Maximum number of cables openings RM12 0 RM9 0 RM6 0 Single core Ø28 50 mm Three core Ø68 99 mm Single core Ø48 71 mm 1 TEU 1000 mm 1 2 6 6 1 2 2 TEU 600 mm 1 2 6 6 1 2 3 ARU 1 2 6 6 1 2 4 BCU 1 1 4 3 1 1 5 EXU 1 2 6 6 1 2 L1 L2 L3 L1 L2 L3 L1 L2 L3 L3 L1 L...

Page 137: ...land 1 EMC sealing modules 2 Frame Usage Auxiliary power cables Control cables Included in delivery Cable entry frame Supplier Roxtec AB www roxtec com Not included in delivery EMC sealing inserts Installation tools Accessories 1 2 Usage Power cables ground cables bonding conductors Auxiliary power cables control cables Included in delivery Undrilled gland plate Not included in delivery Cable glan...

Page 138: ...ble entry systems for TEU ARU and EXU cabinets This section describes how to prepare cable entry systems for the following cabinets TEU ARU EXU 1 EMC sleeves 2 Sealing grommets 3 45 mm 4 1 5 mm Usage Power cables Ground cables Bonding conductors Auxiliary power cables Control cables Included in delivery Galvanized plate with net like EMC sleeves Sealing grommets 1 2 3 4 ...

Page 139: ...ompression wedge 4 between the frame 1 and the sealing module 5 This ensures that the minimum distance to the high voltage busbars is maintained Figure 6 14 TEU 1000 mm cabinet A back with top 1 and bottom 2 cable entries 1 Top cable entry frame 2 Bottom cable entry 3 High voltage busbars 4 Compression wedge 5 RM90 sealing module with 3 core cable L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2...

Page 140: ...s well 6 6 2 0 1 Removing the short busbars on page 140 6 6 2 0 1 Removing the short busbars 1 Remove the phase module according to 10 4 10 Removing and installing a phase module on page 253 2 If necessary remove the short busbars boxes to facilitate entering the cables 3 To remove a busbar unscrew the bottom bracket and the bolts and then move the busbar downward and away from the cabinet Figure ...

Page 141: ... 6 16 EXU with top cable entry A and EXU with bottom cable entry B If the cabinet is only accessible from the front and the cables are entered through the bottom proceed as follows 1 Remove the front cover and if present unplug the heating cable and remove the cross brace with the heating cable 2 Remove the cover above the fan unit 3 Remove the fan unit as explained in 10 4 17 Replacing the fan un...

Page 142: ...point of cable entry and terminals or busbars Busbar and fastening hole dimensions Busbar designations See Appendix D Wiring diagrams for information on Conventions for cross reference and device identification 6 7 1 Determining the cable length 1 Determine the required length of a cable between the point of entry and the connection point inside the cabinet 2 Cut the cable to the required length b...

Page 143: ...dules 2 Install the sealing modules according to the instructions of the sealing module supplier 1 Sealing module 2 Frame 3 Conductive foil of sealing module 4 Cable clamp 5 Shrinkable sheath seal 6 Heat shrinkable termination 7 Outer cable sheath 8 Cable sheath removed to expose cable shield 9 Shield extension to connect to PG busbar 10 Cable screen extension to connect to the PG busbar 11 Cable ...

Page 144: ...le glands 6 7 4 Preparing cables for EMC plates This section describes how to prepare standard cables for EMC plates as well as cables for an EXU 1 Remove the grommets from the entry plate 2 To ensure proper sealing cut along the marking that corresponds to the cable diameter 1 Cable gland 2 Plate 3 Heat shrinkable termination 4 Outer cable sheath 5 Conductor insulation removed to expose cable shi...

Page 145: ... Fig 6 20 6 Prepare EXU cables according to Fig 6 20 The orientation of the EMC plates in both scenarios is the same for top and bottom cable entries ie the sealing grommets face upwards Figure 6 20 Preparing cables for EMC plates A cables with an outer screen or shield B cables without an outer screen or shield or C cables in an EXU cabinet 1 Grommet 2 EMC sleeve 3 Cable tie 4 Heat shrinkable ter...

Page 146: ...are connected to a busbar attach the cable lugs of the cables on each side of the busbar 2 Fasten the cables to the strain relief rails with suitable cable clamps Figure 6 21 Cable connections in an EXU cabinet WARNING Risk of flashover High voltages will be present in the terminal compartment High voltages can cause flashover between the electric potential of different conductors and the electric...

Page 147: ...m distance between bolted joints of different phases in an EXU 6 7 5 3 Bolted busbar connections marine drives The following bolts washers and nuts are supplied and fixed to the busbars in marine drives Figure 6 23 Bolted busbar connection marine drives 1 25 mm 1 Part Quantity Identification Hex head bolt M12x40 A2 NB 312350P8119 Coated hex head nut M12 A2 70 HZN 452198P1022 Conical spring washer ...

Page 148: ...o a busbar Spring washer and flat washer on each side of the busbar The spring washer and flat washer can be replaced by a conical spring washer Fig 6 23 Other washers can be used provided they maintain the required contact pressure Use cable lugs suitable for M12 bolts 6 7 5 4 3 Lubrication If stainless steel bolts and nuts are used lubricate the thread and head contact surface of the bolt using ...

Page 149: ...U and EXU cabinets on page 138 See Appendix C Mechanical drawings for information on Project specific cable entry Dimensions between point of cable entry and terminals See Appendix D Wiring diagrams for information on Conventions for cross references and device identification Terminal designations 6 8 1 Determining the cable length 1 Determine the required length of a cable between the point of en...

Page 150: ...A Additional manuals Figure 6 25 Cable entry with sealing modules 1 Unscrew the frame 2 Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig 6 26 Figure 6 26 Preparing control cables for sealing modules 1 Sealing modules 2 Compression wedge 1 Sealing module 2 Conductive foil 3 Cable sheath removed to expose cable shield 4 Condu...

Page 151: ...he grommets from the entry plate 2 To ensure proper sealing cut along the marking that corresponds to the cable diameter 3 Slide the grommet onto the cable and ensure that the grommet fits tightly to prevent water from entering the cabinet Note If cables are routed through the cabinet floor the grommets can be discarded 4 If necessary remove the entry plate and pull the cable through the entry hol...

Page 152: ... is non conductive 1 Cut open the cable screen in the middle of the stripped area 1 in Fig 6 28 2 Pull the cable screen ends over the cable insulation to turn the conductive side inside out 2 in Fig 6 28 3 Connect the screens ends with a continuous conducting foil 3 in Fig 6 28 Figure 6 28 Preparing the screens of control cables for EMC plates 1 Cable screen 2 Cable screen ends 3 Conductive foil 1...

Page 153: ...try see Appendix C Mechanical drawings 6 8 6 Routing cables in a COU cabinet The serial communications and encoder cables are connected inside a COU Top and bottom cable entries are covered with blanking plates Materials for cable fitting EMC requirements and sealing are not supplied 1 Outer cable sheath 2 Grommet 3 EMC sleeve 4 Plate 5 Cable sheath removed to expose cable shield 6 Conductor scree...

Page 154: ... cable entry of 600 mm COU 2 On the length of cable that passes through the cable transit prepare the cable according to 6 8 3 Preparing cables for cable glands on page 151 3 Route the cable to its destination as illustrated in Fig 6 31 COU 600 mm Fig 6 32 COU 1000 mm Figure 6 31 Cable route in COU 600 mm top cable entry 1 Top cable entry 1 ...

Page 155: ...STALLATION Figure 6 32 Cable route in COU 1000 mm top cable entry 6 8 6 2 Bottom cable entry 1 Insert and route the cables as illustrated in Fig 6 33 and Fig 6 34 Figure 6 33 Cable route in COU 600 mm bottom cable entry 1 Cable entry bottom 2 Side view 3 Detail 1 2 3 ...

Page 156: ...ed until they reach the terminals Leave unshielded conductor ends as short as possible not longer than 50 mm Cable shields Connect the shield of serial communications cables to the fieldbus adapter Connect the individual shields and the overall shield if present of encoder cables to the separate shield grounding point IMPORTANT DO NOT connect the shields to the terminals of the interface Different...

Page 157: ...es 1 Enter the cables through a free hole of the EMC plate 2 On the length of cable that passes through the cable transit prepare the cable according to the following instructions Cable entries with EMC plates 6 8 4 Preparing cables for EMC plates on page 151 Cable entries with cable glands 6 8 3 Preparing cables for cable glands on page 151 Note Materials for cable fitting EMC requirements and se...

Page 158: ... EB5S EB7P and EB7Q type DCS800 converter A and in an EXU cabinet with an ED7Y type DCS800 converter 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Terminal for optical fibers behind cover 7 Optical fibers to DCS800 D4 converter 8 Optical fibers to DCS800 D5 converter A B 1 1 2 2 3 3...

Page 159: ...y used for the encoder cables The conduit starts at the drive and ends inside the EXU At the drive the conduit enters through the entry plate with about 10 20 mm of conduit extending from the entry plate To protect the tip of the optical fiber against scratches cover the cable end with a cap before pulling the cable through the conduit DO NOT exceed the specified maximum tensile load and the minim...

Page 160: ... bottom of the removable cover 4 Gently press down the latch tab with the tip of the screwdriver and pull the corner of the cover forward and repeat for the other side 5 Slide the removable cover up and then remove the cover 6 Connect the 2 optical fibers to the receptacles of channel CH0 B on the COM 8x circuit board A according to the terminal numbers printed on the marker sleeves Figure 6 38 CO...

Page 161: ...routing example in an EXU cabinet with an ED5V EB5R EB5S EB7P or EB7Q type DCS800 converter 8 Reattach the DCS800 cover 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Terminal for optical fibers behind cover 7 Optical fibers to DCS800 D4 converter 1 2 3 4 5 6 7 ...

Page 162: ...cover from the DCS800 unit Figure 6 40 DCS800 converter ED7Y 2 Connect the two optical fibers to the receptacles of channel CH0 B on the COM 8x circuit board A according to the terminal numbers printed on the marker sleeves Figure 6 41 COM 8x circuit board A in a DCS800 converter ED7Y type and a detail of channel CH0 B on the board 1 Control panel 2 Removable cover 1 2 CH0 A B ...

Page 163: ...able routing example in an EXU cabinet with an ED5V EB5R or EB5S type DCS800 converter 4 Reattach the DCS800 cover 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Terminal for optical fibers behind cover 7 Optical fibers to DCS800 D4 converter 1 2 3 4 5 6 7 ...

Page 164: ...erly installed data transmission can be affected and the equipment can fail To prevent such problems follow the handling and installation guidelines To protect the optical fibers against damages lay them in a steel or plastic conduit that is only used for the encoder cables The conduit starts at the drive and ends inside the EXU At the drive the conduit enters through the entry plate with about 10...

Page 165: ...arded or used as an entry plate 2 Route the cable along the WCU side wall through the cable transit and to the receiver 3 To fix the cables to the rails on the side wall use a screw base with a cable tie or cable clamps appropriate for fiber optics 4 To seal the cable entry use appropriate sealing inserts for the cable entry frames Figure 6 43 REB cable entry 1 Blanking plate removed 1 ...

Page 166: ...ith a heating cable Procedure 1 Connect the power supply of the heating cable Note For more information on power supply connections see the converter hardware diagram in Appendix D Wiring diagrams 2 Connect the heating cables of two adjoining transport units with each other 3 Fasten the connectors with cable ties Figure 6 44 Heating cable connection 1 Heating cable plug 2 Cable tie 1 1 2 2 ...

Page 167: ... ELECTRICAL INSTALLATION 6 10 Final checks Check that the entry plates are properly fastened If EMC entry plates with grommets are used check that the grommets fit tightly arrows to prevent water entering the cabinet If necessary seal gaps with silicone ...

Page 168: ......

Page 169: ... completing the items in the commissioning checklist before the commissioning personnel arrive on site will help to achieve this During the commissioning period the customer is requested to provide qualified personnel for assistance who are Experienced with medium and low voltage equipment and with the local safety regulations Familiar with the driven process Authorized to operate associated mediu...

Page 170: ...Raw water supply is ready 9 Visual inspection No badly affixed or damaged components No foreign objects left in the cabinet No dirt dust or moisture in the cabinet 7 6 2 Electrical installation checklist 1 Types and cross sections of control cables suitable for the signal type and signal level 2 Types and cross sections of power cables selected according to the ABB power cable specification 3 Puls...

Page 171: ... connection 7 6 3 Main circuit breaker MCB 1 MCB selected as per Main circuit breaker specification 1 2 High voltage power connections completed 3 MCB is ready to be tested with drive 4 MCB protection relay settings are tested 5 Protection devices eg door locks are tested and in operation 6 Local operation of MCB is disabled 7 Emergency off loop is tested 1 Pay attention to MCB opening time and in...

Page 172: ...ithin required limits 2 Test report is available If the commissioning personnel carry out the test an additional day per drive motor combination must be reserved After the test the mains cables can be connected except at the drive end Test must comply with the specification 7 6 7 Power checklist 1 Medium voltage available for startup of drive 2 Low voltage is available for startup of drive 7 6 8 M...

Page 173: ...essages and parameter settings used in this chapter are typical examples to illustrate the related instructions and display functions and may therefore differ from the actual status messages and parameter settings in the drive 8 2 Operating conditions The operating conditions for the drive are according to IEC 60721 3 3 Classification 3K22 3B1 3S6 3M11 8 3 Safety The drive system must only be oper...

Page 174: ...l panel is present in drives with an ARU The control panel is installed on the door of control unit COU1 Figure 8 1 ARU control panel Main functions Starts and stops the motor Displays status messages of the INU Displays alarm and fault messages of the drive and monitored foreign equipment Resets alarm and fault messages ...

Page 175: ... messages of the drive and monitored foreign equipment Resets alarm and fault messages 2 Main power supply off Illuminated pushbutton opens the main circuit breaker 3 Main power supply on Illuminated pushbutton charges the DC link and closes the main circuit breaker 4 Alarm fault lamp Alarm flashing light Fault permanent light 5 EMERGENCY OFF RESET pushbutton Resets the emergency off relay in the ...

Page 176: ...One single motor drive with double or quadruple inverter units for one common motor One common control unit for the whole drive system Transfer between full and half power is not bumpless Line disconnectors are provided in the inverter units to separate the inverters from the motor Note The configurations shown here are typical examples Different configurations are possible The optional ISU can be...

Page 177: ...orresponding application note Fig 8 4 shows typical full and half power modes For further variants refer to the Signal and Parameter Table document Figure 8 4 Typical full power A and half power B drive modes 8 4 3 2 Semi redundant drive control panel The semi redundant drive control panel can be operated in both local and remote mode For more information see the appropriate application note 1 MCB...

Page 178: ...t any time Context sensitive help menu Fault and alarm text messages including fault history Note For more information see DCS800 drives firmware manual 3ADW000193R0801 1 LED Steady green light normal operation Flashing green light alarm Steady red light fault 2 Soft keys function changes with the text that is displayed above the soft key 3 Local remote key changes between local and remote control...

Page 179: ...by pressing the reset soft key The alarm resets automatically as soon as the reason causing the alarm has been resolved Fault messages must be reset manually after the reason causing the fault has been resolved The message on the display can be reset either by pressing the reset soft key on the EXU control panel or by pressing the reset button on the control panel of the drive 8 5 3 Parameter sett...

Page 180: ... below 50 V DC When the grounding switch is in position grounded the door safety switches of the medium voltage units are released and the doors can be opened 1 Grounding switch in ungrounded position A 2 Grounding switch in grounded position B When the switch is in grounded position the DC link of the drive is connected to the ground busbar of the drive 3 White illuminated pushbutton DC link is g...

Page 181: ... EXU and WCU are not part of the interlocking circuit and can be opened when the drive is energized Note For more information see 10 4 4 Unlocking and opening the doors on page 236 Figure 8 7 Location on the safety switches The safety switches are part of an interlocking circuit that prevents the doors being opened as long as the DC link is charged The interlocking circuit ensures that the Table 8...

Page 182: ... grounding switch is in position not grounded and the safety switches are in position locked Doors can only be opened when the main power has been disconnected the DC link capacitors have been discharged and the grounding switch is in position grounded The locking bar locks and unlocks the locking mechanism of the door of a medium voltage unit ...

Page 183: ...s for actuating the manual output switches are installed inside the drive cabinets The location depends on the configuration of the drive The switches are accessible after the DC link has been discharged and the doors have been opened The open and closed position of the switches is monitored by the drive Depending on the operating state of the drive and the settings of the parameters for this func...

Page 184: ...nding switch of the drive is in the grounded position or the motor starter of the fan unit is switched off The drive is healthy and ready for the ON command The ON command initiates charging of the DC link and the closing of the main circuit breaker of the drive Depending on the control place the command can either be sent from the higher level control system to the drive or be initiated by pressi...

Page 185: ...age changes to ReadyRun when the zero speed threshold is reached When a start command is given while the drive is stopping the drive resumes operation and the status message changes to ReadyRef again Indicates that a fault condition has occurred that requires a shutdown of the drive The status message always alternates with the specific fault message The type of shutdown depends on the fault class...

Page 186: ...ons 3 ReadyOn Auxiliary power supply on Doors of medium voltage units closed and locked Drive is not grounded No emergency off No fault WCU ready 4 On command 5 Charging DC link charges MCB closes Cooling system switches on 6 ARU ReadyRef Only in drives with an ARU 7 ReadyRun INU starts magnetizing only in drives with an ARU INU starts to modulate 8 Start command 9 ReadyRef 10 Operation ...

Page 187: ...d ramps down INU stops modulating 5 Off command Stop command to ARU only in drives with an ARU MCB opens DC link discharges Cooling system switches off after a delay 6 ReadyRun 7 ARU ReadyOn Only in drives with an ARU 8 ReadyOn Drive is grounded Doors in medium voltage units are released for opening Auxiliary power supply switched off 9 NotReadyOn ...

Page 188: ...off command Stop command to ARU only in drives with an ARU MCB opens INU stops modulating Speed coasts down 4 Emergency off 1 Operation 2 ReadyRef 3 Prevention of unexpected startup command Drives stops according to Ramp Torque and Ramp stop modes Open disconnector Prevention of unexpected startup complete Drive remains charged MCB closed 4 INU operation prevention feedback ...

Page 189: ...closed All covers are fitted All locking screws have been removed from the locking bars on the inside of the doors of medium voltage compartments Doors are closed and locked or bolted Grounding switch is in position not grounded Figure 8 8 Grounding switch in ungrounded position MCB is in operating position DANGER Hazardous voltages To prevent unintentional contact with energized components all co...

Page 190: ...ff safety relay of the drive is actuated and lets the EMERGENCY OFF RESET pushbutton flash The EMERGENCY OFF RESET push button also flashes if the EMERGENCY OFF push button on the control compartment door or any other EMERGENCY OFF push button linked to the drive is pressed If the EMERGENCY OFF RESET push button continuous flashing verify that there is no emergency off command active See 8 10 2 St...

Page 191: ...alternates between Charging and AuxiliaryOn Note After charging has been finished the following takes place Main circuit breaker closes automatically SUPPLY ON push button lights up permanently Drives with an ARU The ARU is now ReadyRun 1 L 0 0 rpm StateINU ReadyOn DC VOLT 0 00 rpm PRI VOLT 0 kW 1 L 0 0 rpm StateINU Charging MOTOR SP 0 00 rpm POWER 0 0 kW Alternating display message Charging Auxil...

Page 192: ...he other INUs change to ReadyRun 6 Enter the reference value 7 Start the motor with the INU control panels After the motor has been magnetized the motor speed ramps up to the reference value While the motor is magnetizing the run status message on the display blinks When the motor has finished magnetizing the run status message lights up permanently 1 L 0 0 rpm 0 StateINU ARU NotRun MOTOR SP 0 00 ...

Page 193: ...cording to the preset stop function While the motor stops the status line of the display shows ReadyRef and the run status message blinks Note During the stop sequence you can restart the drive by pressing the START key The drive is now in stopping mode 1 L 600 0 rpm I StateINU ReadyRef MOTOR SP 0 00 rpm POWER 1000 0 kW I 0 1 L 600 0 rpm I StateINU ReadyRef MOTOR SP 300 00 rpm POWER 20 0 kW LOC RE...

Page 194: ...M ACS6000 USER MANUAL 194 278 2 When the motor has reached zero speed the drive is ReadyRun As long as the MCB has not been opened you can restart the motor at any time 1 L 600 0 rpm 0 StateINU ReadyRun MOTOR SP 0 00 rpm POWER 0 0 kW ...

Page 195: ...CY OFF push button does not disconnect the auxiliary power supply from the drive Note For more information see Emergency off stop modes and prevention of operation safe torque off 3BHS196243 8 10 3 Initiating an emergency off When an emergency off is initiated during operation the following sequence of events occurs 1 MCB opens 2 Drive system coasts down 3 DC link of the drive discharges 4 Status ...

Page 196: ...tton 2 Press the EMERGENCY OFF RESET button to reset the emergency off safety relay of the drive The drive remains in emergency off state until the DC link voltage has dropped to 50 V discharged After resetting the status message of the drive changes to ReadyOn The status line of the CDP control panel shows the following 3 The main power supply can be connected to the drive again and the drive sys...

Page 197: ...g and immediately opens the main circuit breaker Figure 8 9 Arc Guard System in a WCU REB 8 11 1 Action after the Arc Guard System has been triggered 1 De energize and ground the drive according to 10 4 2 De energizing and grounding the drive on page 231 2 Search for the location where the arc has been detected 3 Check the Arc Guard HMI panel messages and use the circuit diagrams Figure 8 10 HMI p...

Page 198: ...e power units and localize the defect 5 Repair the defect or contact support line if needed 6 Reset the fault on Arc Guard HMI panel 7 Acknowledge the firing through with parameter 16 26 on the control panel only when fault was understood and corrected 8 Restart the drive ...

Page 199: ...tatus line 3 Actual signal names and values 4 Keypad 5 Mode selection keys 6 Fast navigation key for selecting the actual signals display or the fault memory display 7 Local remote selection key 8 Reset key 9 Forward key 10 Backward key 11 Slow navigation key for selecting signals or fault messages 12 Enter key terminates a procedure 13 Reference key 14 Start key 15 Stop key 1 2 3 4 5 6 7 8 9 10 1...

Page 200: ...n the most recent 64 fault events 9 2 Modes The CDP control panel provides the following modes 9 2 1 Identification mode on page 200 9 2 2 Actual signals mode on page 202 9 2 3 Parameters mode on page 209 9 2 4 Functions mode on page 214 Drive mode not used 9 2 1 Identification mode The identification mode informs the user about the CDP control panel version and the ID number of the drive The info...

Page 201: ...anges to the actual signals display The status line of the display alternates between DCGndNOpen and NotReadyOn ACS6000 xxxx Device Name LXHH44xx ID NUMBER 1 1 2 3 4 1 L 0 0 rpm StateINU InitSeq MOTOR SP 0 00 rpm POWER 0 0 kW 1 L 0 0 rpm StateINU DCGndNopen MOTOR SP 0 00 rpm POWER 0 0 kW Alternating display message DCGndNopen NotReadyOn ...

Page 202: ...rive is in a fault condition the fault memory display appears instead The actual signals display is used to monitor the drive without interfering with its operation It continuously displays three selectable actual values 1 Display 2 Actual signal names and values 3 Selection key for actual signals mode 4 Fast navigation key for selecting the actual signals display or the fault memory display 5 Slo...

Page 203: ...ng an active fault on page 208 When the drive generates a fault or alarm the corresponding message displays immediately Changing from the fault memory display to other modes is possible without resetting the fault first If no key is actuated the fault or alarm message displays as long as the fault is active 9 2 2 2 Selecting the actual signals display To select the actual signals display press the...

Page 204: ...ree actual signals press and hold the ACT key 2 To return to the actual signals display release the ACT key 9 2 2 5 Selecting actual signals 1 To select the actual signals display press the ACT key 1 L 600 0 rpm 1 LAST FAULT Overspeed 070730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU MOTOR SPEED POWER ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0...

Page 205: ...er group press a fast navigation keys 5 To select an actual signal press a slow navigation keys 1 L 600 0 rpm StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 ACTUAL SIGNALS 15 POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 ACTUAL SIGNALS 01 DC VOLTAGE 1000 V ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER RE...

Page 206: ...6 Displaying a fault and resetting the fault memory 1 To open the actual signals display press the ACT key 2 To change to the fault memory display press a fast navigation key 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm NP VOLT 0 V ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 ...

Page 207: ...he actual signals display press a fast navigation key 1 L 600 0 rpm 1 LAST FAULT PANEL LOST 070730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 2 LAST FAULT AMC Fault Class 1 9H 38 MIN 48 s ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 LAST FAULT H MIN S ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm PO...

Page 208: ...an active fault 1 To display an active fault press the ACT key 2 To reset the fault press the RESET key 1 L 600 0 rpm ACS5000 FAULT MCB CloseControl ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 209: ...y be set by qualified personnel DO NOT change any parameter if the meaning of the parameter and the effects of the change are not fully understood 1 Status line 2 Group number and name 3 Parameter number and name 4 Parameter value 5 Selection key for parameters mode 6 Fast navigation key for selecting a parameter group and a parameter value 7 Slow navigation key for selecting a parameter and a par...

Page 210: ...ameter group 11 The next time the parameters mode is entered the previously selected parameter displays Some parameter settings cannot be changed while the drive is running If tried the following warning displays Group Description Paramet er Description Group 07 Control words 21 01 Start function Group 08 Status words 21 02 Start function Group 09 Fault and alarm words 21 03 Off1 stop mode Group 1...

Page 211: ...parameter setting function press the ENTER key 1 L 600 0 rpm 77 SYSTEM CONFIG 01 INU IdentifySel INU1 MASTER ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 06 C3P1 AI820 Module DISABLED ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DISABLED ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MO...

Page 212: ... the ENTER key 9 To cancel the setting and keep the original setting press any of the mode selection keys The selected keypad mode is entered 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DI810 24VDC ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DI810 24 VDC ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 0...

Page 213: ...on see Appendix G Signal and parameter table 9 2 3 4 User lock NOTICE ABB is not be liable for damages or losses caused by the failure to activate the user lock with a new pass code For more information see 1 9 Cyber security disclaimer on page 38 For better cyber security it is highly recommended that you set a master pass code for the control panel to prevent the parameter values from being chan...

Page 214: ...e 9 2 4 1 Adjusting the display contrast 1 To enter the functions mode press the FUNC key 1 Status line 2 Selectable functions 3 Selection key for functions mode 4 Slow navigation key for selecting a line and adjusting the contrast 5 Enter key for confirming the selection 1 2 3 4 5 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF EN...

Page 215: ...ontrast press the slow navigation keys 5 To confirm the setting and to return to the actual signals display press the ENTER key 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm CONTRAST 6 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 6 ACT PAR...

Page 216: ...n page 217 9 2 5 1 Local control In local control mode full operational control of the drive is enabled from the local operator panel Commands from remote have no effect To enter the local control mode press the LOC REM key Local control is indicated by the letter L 9 2 5 2 Disabling enabling local lock function Accidental switching from remote control to local control can be prevented with the lo...

Page 217: ...ol is enabled 9 2 5 4 Remote control In remote control mode operational commands or reference values usually come from a higher level control system via fieldbus or remote I O However with the following parameter settings it is possible to start and stop the drive to set the direction of rotation and to enter reference values from the CDP control panel 11 01 EXT1 START STOP DIR 10 KEYPAD or 12 03 ...

Page 218: ...Setting the direction of rotation Setting the direction of rotation from the CDP control panel is possible in Local control mode L Remote control mode R The arrow on the display indicates the direction of rotation When the motor is running the arrow indicates the actual direction When the motor is not running the arrow indicates the preselected direction To set the direction of rotation press the ...

Page 219: ...e value from the CDP control panel is possible in Local control mode L Remote control mode R 1 Press a mode selection key 2 To enter the reference value input mode press the REF key 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF E...

Page 220: ... corresponding fast or slow navigation key 4 To exit the mode press a mode selection key 1 L 550 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 550 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 221: ...the ABB service organization 10 1 2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule on time and at the stated intervals in the ACS6000 preventive maintenance schedule 3BHS855273 E01 10 1 3 Logbook ABB recommends recording all troubleshooting and maintenance work in a logbook including Date and time Detailed description 10 1 4 Spare parts To ensure safe an...

Page 222: ... diagrams and parts lists all devices are labeled in accordance with IEC 81346 1 Figure 10 1 Device identification 10 2 2 Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams Figure 10 2 Cable and wire designation A1421 PP C907AE 275MHz AMC34 BOARD CDP312_ARU 141 F2 X17 R P T2 S1 S0 RX TX INTO F M T1 S3 S2 ...

Page 223: ...ng light Fault permanent light The message can be saved and viewed in the fault logger of the drive when a PC with Drive Composer is connected to the drive The fault history can also be called up on the control panel 10 3 2 Error message levels Two error message levels are used in the drive Alarm An alarm does not shut down the drive If the condition causing the alarm is not corrected a persisting...

Page 224: ...ault buffer as they occur and are numbered The last fault entered has number 1 The first fault entered has the highest number Information of the fault classification eg FC 1 or FC 2 is also saved when the first fault of the fault class is active Date and time stamps facilitate fault tracing especially when a fault leads to several subsequent faults Example In the above example Fault DC Undervoltag...

Page 225: ... supply voltage or try to reset a fault message before all information at the time of the occurrence of the fault condition has been saved 2 Select the fault history display on the control panel but do not clear the buffer now See 8 Operation on page 173 3 Identify the fault and make a logbook entry 4 Save the content of the data logger when a PC is available which has the Drive Composer Startup t...

Page 226: ...oaded Booting ON Booting ON F Red Fault ON OFF ON ON R Green Run OFF OFF OFF OFF M Green ON OFF ON ON P Green Supply OK ON ON ON ON T1 Yellow Receiving data on DDCS channel 0 Flashing ON OFF Flashing ON OFF T2 Yellow Receiving data on DDCS channel 3 Flashing ON OFF Flashing ON OFF S3 Yellow OFF OFF OFF OFF S1 Yellow Flashing OFF Flashing OFF S2 Yellow Flashing OFF Flashing OFF S0 Yellow Flashing O...

Page 227: ... The factory set value must not be changed 10 3 3 3 S800 I O modules LEDs on I O modules having the same meaning on all types of I O modules are always at the same position The LEDs are always at the topmost position on each module Fig 10 5 1 and are identified as follows F fault R run W warning O or OSP only output modules LED Color Indication F Red Fault in module R Green Device in operation P G...

Page 228: ...Appendix D Wiring diagrams For more information on the device select the appropriate manual AF 100 fieldbus NAFA 01 installation and start up guide 3BFE58919837 Modbus TCP NETA 21 remote monitoring tool user manual 3AUA0000096939 Modbus RTU NMBA 01 installation and startup guide 3AFY58919772 Profibus NPBA 12 installation and startup guide 3BFE64341588 LED Color Indication F Red Indicates failure R...

Page 229: ...e heat exchanger indicate the status of the unit Alarm signals are also shown on the CDP control panel Figure 10 6 Status LEDs on optional air to air heat exchangers 1 Red LED off A and Green LED on B Heat exchanger is healthy 2 Red LED on A and Green LED off B Alarm conditions 3 Red LED off A and Green LED off B Auxiliary voltage is missing B A B A B A 1 2 3 ...

Page 230: ...ions are in place Personal protective equipment is provided and used when required Everyone involved is informed Before energizing the drive verify that All foreign objects are removed from the drive All internal and external covers are securely fastened and all doors are closed locked and or secured locking bar in locked position Release dials of safety switches are in locked position Before you ...

Page 231: ...un WARNING Hazardous DC voltage Depending on the type of auxiliary supply the drive can be equipped with buffer capacitors inside the control unit During operation the capacitor voltage is 300 V DC over ground Wait 5 minutes for the capacitors to discharge Before touching a capacitor verify that the capacitors are discharged NOTICE Risk of component damage Foreign matter and particularly metallic ...

Page 232: ...k discharges the CDP control panel shows the following SUPPLY OFF push button flashes and changes to a permanent light when the DC link is discharged When the DC link is discharged the drive is ReadyOn 4 Rack out lock out ground and tag out the main power feeder 1 L 600 0 rpm StateINU OffSeqOn MOTOR SP 0 00 rpm POWER 0 0 kW Alternating display message OffSeqOn Discharging AuxiliaryOn 1 L 600 0 rpm...

Page 233: ... is on keep the yellow lamp cap pressed while you turn the grounding switch to the grounded position CAUTION If the lamp does not light up DO NOT force the grounding switch in any direction before you know the reason why the lamp has not lit up If you try the following can happen The switch closes when the DC link is still energized and short circuits the DC link capacitors The short circuit manif...

Page 234: ...xternal sources 9 To connect a grounding set continue with 10 4 8 Connecting a grounding set on page 242 10 4 3 Grounding the drive when the grounding switch is not released When the DC link of the drive has been discharged the lamp GROUNDING SWITCH UNLOCKED lights up to indicate that the grounding switch is released and can be turned to the grounded position If the lamp does not light up take the...

Page 235: ...back signal MCB is open is present 4 Verify that hazardous voltages from the motor cannot be fed into the drive 5 Check if the LED of digital output DO07 output module A2541 in COU1 is lit If the LED is lit the grounding switch is released 6 Check the discharging level of the DC link If the value of the parameter 2 01 DC VOLTAGE is below 50 V the DC link is discharged If the DC link is discharged ...

Page 236: ...g circuit and or the grounding circuit see Wiring diagram of COU1 Wiring diagram of CBU 10 4 4 Unlocking and opening the doors 1 Check that the auxiliary voltage is on and wait for the white lamp on the CBU to turn on The white lamp indicates that the drive is grounded and that the locking bars are released Note If the white lamp does not turn on continue with 10 4 6 Testing the white lamp on page...

Page 237: ...the door turn the door handle to the right if the door is hinged on the right or to the left if the door is hinged on the left 5 If you cannot open the door continue with 10 4 7 Emergency release of a door safety switch on page 240 10 4 5 Closing and locking the doors 1 Close the doors 2 To lock the door bring the door handle in line with the door plate 1 and press the handle down 2 until it click...

Page 238: ...ked properly you cannot start the drive 10 4 6 Testing the white lamp If the lamp does not turn on proceed as follows 1 To test the lamp press its lamp cap 1 in Fig 10 10 Lamp does not turn on Lamp is burnt out Lamp test circuit is faulty The lamp test circuit and the door releasing circuit are independent of each other From the lamp not lighting up it cannot be concluded that the door releasing c...

Page 239: ... is closed but the control system has not released the doors If the LED is not lit the feedback signal is missing 3 To open the door continue with 10 4 7 Emergency release of a door safety switch on page 240 Note For information on the wiring of the control circuit see Converter hardware diagram Wiring diagram of COU1 For information on the wiring of the discharging circuit and or the grounding ci...

Page 240: ...BCU RBU VLU TEU and ISU are equipped with safety switches Figure 10 11 Safety switch on an ARU INU cabinet door DANGER Hazardous voltages Touching energized components can be fatal Before you unlock a safety switch verify that the drive is de energized DO NOT unlock the safety switches permanently 1 Screw cap on door 2 Safety switch location behind door 3 Safety switch 4 Unlocked position 5 Locked...

Page 241: ...n the release dial from the locked to the unlocked position You can now actuate the locking bar and open the doors Location Setting Description 1 Unlocked Enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off 2 Release dial Direction of arrow indicates safety switch status ie locked or unlocked 3 Locked Normal operating setting To open the door of a ...

Page 242: ...cting a grounding set Figure 10 13 Four way grounding set Depending on the type of line side rectifier continue with 10 4 8 1 Drives with LSU on page 243 10 4 8 2 Drives with ARU on page 244 DANGER Hazardous voltages Grounding equipment ensures that FATAL voltages cannot be fed into the drive from the main power supply or the motor during maintenance work eg the removal of phase modules Connect gr...

Page 243: ...round busbar inside TEU Fig 10 14 2 Use the telescopic insulating pole to connect and tighten the busbar ground clamps to the ground ball studs 1 of the following busbars Inside TEU 1L1 1L2 1L3 2L1 2L2 and 2L3 in Fig 10 14 Inside INU L1 L2 and L3 in Fig 10 15 Figure 10 14 TEU ground ball stud locations 1 Ground ball stud example 2 2L2 3 1L1 4 1L3 5 2L3 6 2L1 7 1L2 8 PE 1 2 3 4 5 6 7 8 8 ...

Page 244: ...nd L3 in Fig 10 15 Figure 10 15 ARU INU ground ball stud locations 10 4 9 Drives with the manual output isolation optional The manual output isolation disconnects the output of the drive INU1 or INU2 from the motor and creates a visible isolating distance in the supply line to the motor The option includes the following items Busbar connectors in TEU1 and COU1 Busbar connectors for INU1 are locate...

Page 245: ...AINTENANCE Figure 10 16 Manual output isolation overview 1 LSU1 2 TEU1 3 INU1 4 CBU1 5 BCU1 6 INU2 7 COU1 8 LSU2 9 WCU1 10 Motor 11 Busbar connectors 3 x in TEU 12 Busbar connectors 3 x in COU1 13 Lever for removing and fitting the busbar connections 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 246: ... 2 COU1 LED LED Description 6 7 ON OFF The three busbar connectors are fitted in COU1 The motor is connected to INU2 OFF ON The three busbar connectors are not fitted in COU1 The motor is disconnected from INU2 OFF OFF Invalid configuration Drive will not start 8 9 ON OFF The three busbar connectors are fitted in TEU1 The motor is connected to INU1 OFF ON The three busbar connectors are not fitted...

Page 247: ...ing sets at the locations indicated in Fig 10 20 Be aware of arcing between ground clamp and busbar ground studs when connecting a grounding set to the busbars for the motor cables Arcing can be caused by voltages being fed into the drive when the motor is driven by the propeller of the ship Follow local safety procedures 1 Orientation of lever for removing busbar connectors 2 Orientation of lever...

Page 248: ...e Fig 10 18 to connect and tighten the enclosure ground clamp to the ground ball stud of the PE ground busbar 3 Connect the busbar ground clamps to the ground ball studs of the phase busbars in the following sequence Busbars for the cables to the secondary transformer windings 1 in Fig 10 20 Busbars for the motor cables 2 in Fig 10 20 Busbars in the INU 3 in Fig 10 20 Figure 10 19 Overview of grou...

Page 249: ...CTIVE MAINTENANCE Figure 10 20 Connect the grounding sets in COU1 A and C TEU1 B INU1 D and INU2 E 1 Busbars for secondary transformer windings 2 Busbars for motor cables 3 INU busbars 4 PE 5 Ground ball stud B A C D E 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 ...

Page 250: ...6000 USER MANUAL 250 278 4 Inside TEU1 or COU1 remove the busbar connectors in the sequence shown in Fig 10 21 CAUTIONA busbar connector weighs approximately 10 kg Figure 10 21 Busbar connector removal sequence in TEU1 or COU1 5 Remove the grounding sets 1 2 3 4 5 6 ...

Page 251: ...se and lock the doors 9 Check that the power operating mode POM of the drive corresponds to the busbar connectors fitted 10 Start the drive according to the established procedures 10 4 9 2 Fitting the busbar connectors 1 Shut down the drive according to the established procedures 2 Fit the busbar connectors in the sequence shown in Fig 10 22 Figure 10 22 Fitting sequence for busbar connectors 1 2 ...

Page 252: ...ounding sets 4 Check that the LEDs are lit as shown 5 Check that tools and foreign objects are not left inside the cabinets 6 Close and lock the doors 7 Check that the power operating mode POM of the drive corresponds to the busbar connectors fitted 8 Start the drive according to the established procedures ...

Page 253: ...removal of phase module from an ARU INU eg to access the back of the cabinet or to work on the phase module 10 4 10 1 Removing a phase module 1 Disconnect the water hoses Note To disconnect the water hose pull the locking sleeve of the coupling towards the front of the cabinet arrow 2 Cut off the cable ties 1 and disconnect the optical fibers and the power supply leads 2 1 1 2 ...

Page 254: ...of the phase module 5 Adjust the height of the table so that it is level with the rails on the underside of the phase module 6 Pull the phase module onto the table CAUTIONA phase module weighs approximately 190 kg When pulling out the phase module make sure that the disconnected water hoses optical fibers and power supply leads are out of the way 1 1 2 2 80 mm 3 17 mm 4 Location of bolts to remove...

Page 255: ...y towards the back of the cabinet until the busbars engage with the connectors at the back of the cabinet 5 Screw in and tighten the bolts 6 Pull the locking sleeve of the female half of the water hose coupling back as far as possible 7 While holding it in this position push it over the fixed male half of the coupling until it stops 8 Let go of the locking sleeve and firmly push the female part ag...

Page 256: ...ble cable specifications 10 4 12 Cleaning 10 4 12 1 Cleaning the drive cabinet When cleaning the drive cabinet mind the following To keep dirt out cover the equipment or assemblies Take electrostatic sensitive precautions and use suitable tools to prevent electrostatic discharge To prevent damage use antistatic brushes and a vacuum cleaner with a soft nozzle to carefully clean circuit boards with ...

Page 257: ...on class IP 54 The filter mats are located between the ventilation grid and the wire mesh The wire mesh is always installed NOTICE Risk of component damage Vibration can loosen electrical connections and cause equipment failure Excessive force damages the capacitor bushings Tighten to the torque value on the label attached to the capacitor IMPORTANT DO NOT exceed 20 Nm if the tightening torque val...

Page 258: ...behind the ventilation grids start automatically when the temperature rises above a preset level 2 Remove the bolt at the top of the fan cover 3 Slide the cover up and pull it out of the slots 4 Turn the cover over and remove the filter mat 5 Insert the new filter mat and reinstall the ventilation grid 1 Ventilation grid 2 Wire mesh 3 Filter mat only for protection class IP 54 10 mm 250 mm 250 mm ...

Page 259: ...g auxiliary fan units To switch the fan units on and off for the test use the thermostats of the fan units Procedure 1 Switch on the auxiliary voltage for the fan unit to be tested 2 Take note the setting of the thermostat The factory set value is also stated on the Settings label The label is attached to the inside of the cabinet door 3 To switch on a fan unit turn the dial of the thermostat from...

Page 260: ...iniature circuit breaker see Appendix D Wiring diagrams 2 Only for fan units of the optional REB Unscrew the ventilation grid circles and flip the grid downward arrow IMPORTANT The ventilation grid is hinged You DO NOT need to remove it Figure 10 25 Accessing the fan units in the WCU roof box 3 Disconnect the wires 1 and unscrew 2 the fan units 4 Remove the fan unit 5 Reinstall the new one in reve...

Page 261: ...r heat exchanger overview type LT 5 5165 UL 1 Ambient fan 2 2 Ambient fan 1 3 Internal fan 1 4 Circuit board location 5 Internal fan 2 6 Miniature circuit breaker 7 Red LED off and green LED on 8 Heat exchanger is healthy 9 Red LED on and green LED off 10 Alarm condition 11 Red LED off and green LED off 12 Auxiliary voltage missing Table 10 3 Air to air heat exchanger specifications Thermostat loc...

Page 262: ...ng the fan units To switch the fan units on and off for the test use the thermostats of the fan units Procedure 1 Switch on the auxiliary voltage for the air to air heat exchanger 2 Take note of the setting of the thermostat The factory set value is also stated on the Settings label The label is attached to the inside of the cabinet door 3 To start a fan or a group of fans adjust the setting of th...

Page 263: ...INTENANCE 10 4 16 2 Replacing the complete heat exchanger For information on replacing the complete heat exchanger see Mechanical installation on page 56 10 4 16 3 Replacing the circuit board 1 Unscrew the front and top cover 2 Disconnect the ground wire from the front cover arrow ...

Page 264: ...cuit board on the spacers and gently push the circuit board onto the spacers until they snap in properly 7 Reconnect the wires to the circuit board Fig 10 27 Figure 10 27 Wire connection points on the circuit board No Description Pin Pin Pin Pin 1 Ground wire J15 2 Supply phase L 3 Supply neutral N 4 4x external capacitors 1x J3 2x J5 3x J7 4x J9 5 4x fan power supply 1x J4 2x J6 3x J8 4x J10 6 4x...

Page 265: ...TENANCE 8 Reconnect the ground wire to the front cover 9 Fasten the covers 10 4 16 4 Replacing internal fan 1 left side Procedure 1 Unscrew the front top cover 2 Unplug the plug in connectors arrows and unscrew the screws 1 2 3 and 4 which fix the fan mounting bracket to the housing ...

Page 266: ...S212794 E01 REV M ACS6000 USER MANUAL 266 278 3 Remove the fan from the housing and unscrew the fan from the mounting bracket 4 Replace the fan and reassemble the unit in reverse order of removal 10 4 16 5 Replacing internal fan 2 right side 1 2 ...

Page 267: ...3BHS212794 E01 REV M ACS6000 USER MANUAL 267 278 10 PREVENTIVE AND CORRECTIVE MAINTENANCE Procedure 1 Unscrew the front top cover 2 Remove the front cover and disconnect the ground wire arrow ...

Page 268: ...board mounting bracket 1 2 and 3 4 Take out the circuit board mounting bracket and place it on the heat exchanger housing 5 Disconnect the ground wire 1 cut off the cable tie 2 unplug the plug in connectors arrows and unscrew the screws 3 4 5 and 6 fixing the fan mounting bracket to the housing 1 2 3 1 2 3 4 5 6 ...

Page 269: ...NCE 6 Remove the fan from the housing and unscrew the fan from the mounting bracket 7 Replace the fan and reassemble the unit in reverse order of removal 10 4 16 6 Replacing the ambient fans 1 Unscrew the rear cover 2 Lift the hinged cover up a little and disconnect the ground wire arrow ...

Page 270: ...rews 1 2 3 and 4 4 Replace the fan and reassemble the unit in reverse order of removal 10 4 17 Replacing the fan unit in an EXU with a DCS800 D4 size controller Figure 10 28 DCS800 controller size D4 Procedure 1 Switch off the miniature circuit breaker of the fan unit Note To identify the miniature circuit breaker see Appendix D Wiring diagrams 1 2 3 4 1 2 3 4 ...

Page 271: ...0 USER MANUAL 271 278 10 PREVENTIVE AND CORRECTIVE MAINTENANCE 2 Remove the 6 screws from the fan cover and then remove the fan cover 3 Unplug the fan cables 4 Remove the 4 fastening screws from the outside panel of the fan unit ...

Page 272: ... falling onto you place a support ie a box underneath 6 Install the new fan in reverse order of removal 10 4 18 Replacing the fan unit in an EXU with DCS800 size D5 controller Figure 10 29 DCS800 controller size D5 Procedure 1 Switch off the miniature circuit breaker of the fan unit Note To identify the miniature circuit breaker see Appendix D Wiring diagrams ...

Page 273: ...0 USER MANUAL 273 278 10 PREVENTIVE AND CORRECTIVE MAINTENANCE 2 Remove the 6 screws from the fan cover and then remove the fan cover 3 Unplug the fan cables 4 Remove the 4 fastening screws from the outside panel of the fan unit ...

Page 274: ...l the new fan in reverse order of removal 10 4 19 Replacing the air to water heat exchanger of the EXU 1 Switch off the miniature circuit breaker of the heat exchanger Note To identify the miniature circuit breaker see Appendix D Wiring diagrams 2 Close valves V30 and V31 in the water cooling unit 3 Disconnect the hose from valve V30 to drain the WCU NOTICE Expect approximately 5 liters of water 4...

Page 275: ...ug the cables 2 and remove the fastening screws Figure 10 30 Air to water heat connections 6 Lift the heat exchanger out of the cabinet CAUTIONThe heat exchanger weighs approximately 16 kg and requires a minimum overhead clearance of 85 cm Figure 10 31 Lift heat exchanger out of EXU cabinet 1 Water tube connections 1 Fastening screw 2 Cable connections 1 1 2 3 3 ...

Page 276: ...he new heat exchanger proceed in reverse order of removal Note For information on adding water to the cooling system see the manual for the ACS5000 ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 and ACS5000 ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 ...

Page 277: ... Ltd CH 5300 Turgi Switzerland new abb com drives medium voltage ac drives Copyright 2020 ABB All rights reserved The information in this document is subject to change without notice 3BHS212794 E01 Rev M 18 06 2020 278 ...

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