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CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE

160

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10.5 LEDs and switches on printed

circuit boards and I/O devices

The following section provides an overview on the meaning of LEDs
and switches of the main circuit boards and I/O devices.

The LEDs presented in the following section can be
checked easily while the auxiliary voltage is
switched on without having to remove covers first.
The LEDs provide information on the status of the
devices and can be used for diagnostic purposes.

10.5.1 AMC circuit board

The LEDS of the AMC board are identified in

—
References

—
10-3 AMC34 circuit board

—

LED

Color

Meaning

Status when SW loaded

Status when SW not loaded

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*

OFF

Flashing*

OFF

R

P

S1

F

M

T1

S3

S2

T2

S0

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Summary of Contents for ACS2000 AFE 2MVA

Page 1: ...LTAGE DRIVES ACS2000 AFE 2MVA User Manual High reliability due to proven design and low parts count Fuseless design Air cooled Application tailored design Softstarter Arc resistant design Direct torque control Power range from 900 to 1600 kW ...

Page 2: ... ABB Sp z o o System Drives Placydowska 27 95 070 Aleksandrow Lodzki Poland Document name ACS2000 AFE 2MVA User Manual Document number 3BHS355653 ZAB E01 Rev H Issue date 2020 07 ...

Page 3: ...ote on main circuit breaker 24 Safety 30 Power electronics and cabinet features 48 Control system 70 Transportation storage and disposal 80 Mechanical installation 86 Electrical installation 112 Commissioning 118 Commissioning check list 122 Operation 136 CDP control panel 154 Preventive and corrective maintenance ...

Page 4: ...s of the drive 35 IFU Input filter unit 36 AFE Active front end 37 Phase module 38 DC link 39 Grounding switch 39 Grounding circuit 39 Grounding the drive 40 INU Inverter unit 41 EMC filter 42 Terminal compartment 44 Door locks 45 Fan unit types 46 Example for the operating time of the fan units 46 Air flow inside the cabinet 47 Air pressure switches 49 Block diagram of control system 50 Control c...

Page 5: ...on 98 Preparing power cables for EMC plates 99 Preparing power cables for sealing modules 100 Power cable entry 101 Bolted busbar connection 103 Control cable entry 103 Preparing control cables for EMC plates 105 Preparing control cables for sealing modules 106 Preparing control cables for cable glands 107 Shield grounding point for encoder cable 109 Connecting the fan units 126 Local operator pan...

Page 6: ...171 Unlocking the doors of medium voltage compartments 172 Service covers 173 Replacing filter mats 174 Phase modules location 174 Phase module Dimensions and weight 175 Phase module replacement kit ...

Page 7: ...nal allocation 62 3 9 Standard analog output signal allocation 63 3 10 Optional digital output signal allocation 64 3 11 Optional digital input signal allocation 64 3 12 Optional analog input signal allocation 65 3 13 Optional analog output signal allocation 72 4 1 Transport conditions 77 4 2 Storage conditions 91 6 1 Auxiliary power terminal sizes 91 6 2 I O module terminal sizes 123 8 1 Operatin...

Page 8: ...General information on manual and equipment ...

Page 9: ...p z o o Placydowska 27 95 070 Aleksandrow Lodzki Poland Phone 1 479 648 5912 E Mail drivessupport abb com Web http www abb com drives Equipment covered by the manual This manual covers standard drive and provides generic information on the drive The manual does not claim to cover all variations and details of the drive nor to consider all eventualities that may arise during installation commission...

Page 10: ...e functions of the operating panel be adequately trained for the drive and know the driven process Special knowl edge of frequency converter technology is not required Maintenance The personnel include all persons who are qualified to carry out preventive and correc tive maintenance on drive as described in this manual are thoroughly familiar with the drive have a sound knowledge of the relevant e...

Page 11: ...ive standards EC Conformity Declaration List of the standards the drive complies with Items covered by delivery The delivery comprises the following items see figure below Drive 1 Transformer can be integrated or non inte grated 2 Fan units 3 shipped separately Phase module replacement kit 4 if selected as additional option Set of door keys 5 T handle screwdriver with torx bit T30 6 Rating label 7...

Page 12: ...ccessories are identified by the type code printed on the rating label 7 The rating label is located on the front of the con trol 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 ...

Page 13: ...13 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H ...

Page 14: ...Terms abbreviations trademarks ...

Page 15: ...er equipment status and improve equipment performance Equipment Frequency converter and related equipment EMC Electromagnetic compatibility All measures to suppress electromagnetic disturbances caused by different electrical equipment in the same electromagnetic environment and to strengthen the immunity of the equipment to such disturbances FE Functional earth Ground Earth To ground The conductin...

Page 16: ...ndition of a circuit or device SW Software TC Short form for terminal compartment of the drive Zero speed threshold Used in the manual to indicate that the drive has reached the value zero speed that is set in a parameter The value can be set in the range of 0 and maximum speed the unit for the speed is rpm Term Abbreviation Meaning ...

Page 17: ... registrations and trademarks are used in this man ual Term Abbreviation Meaning Windows Registered trademark of Microsoft Corporation Industrial ITTM Trademark of ABB DriveWare Registered trademark of ABB Advant Registered trademark of ABB Advant FieldbusTM Trademark of ABB Ethernet Registered trademark of Xerox Corporation Profibus Registered trademark of Profibus International P I Modbus Regist...

Page 18: ... Motor Spec 3BHS824805 ZAB E01 ABB MVD ACS High Speed Motor Spec 3BHS824806 ZAB E01 ACS2000 power cable specification 3BHS189994 ZAB E01 Power cables engineering guideline 3BHS542290 ZAB E01 Maintenance Preventive maintenance schedule ACS2000 4MFB005215 ZP3 E01 Drive monitoring DriveMonitor user manual 3BHS268039 ZAB E01 Serial communications interfaces AF 100 fieldbus NAFA 01 installation and sta...

Page 19: ...19 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H ...

Page 20: ...Important note on main circuit breaker ...

Page 21: ...ut transformer 0 1 shows the conceptual single line diagram of a typical drive system including main power supply MCB input transformer drive and electrical motor The MCB is defined as a switching device to dis connect the power supply whenever required by the process or when a fault occurs Typical devices used as MCBs are Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor cont...

Page 22: ...ice position the drive must have exclusive control of closing the MCB Local closing of the MCB is not permitted The maximum opening time of the MCB shall never exceed the product or project specific maximum time defined in the MCB specifica tions Typical maximum values for the drive are defined as follows Maximum protection trip time 75 ms The maximum protection trip time is the maximum allowed br...

Page 23: ...23 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H Maintenance recommendation The MCB trip circuits should be checked once yearly ...

Page 24: ...Chapter 1 Safety 25 Meaning of safety instructions 26 General safety information 27 Possible residual risks 28 Safety labels and signs 28 Safety labels 29 Cyber Security Requirements ...

Page 25: ...afety colors and safety signs Part 2 Design principles for product safety labels ANSI Z535 6 American National Standard for Product Safety Information in Product Manuals Instructions and Other Collateral Materials DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situation which if not avoided could resul...

Page 26: ...ppropriate personal protective equipment is provided and used when required everyone involved is informed When working near the running drive wear pro tective earmuffs Before work is carried out simultaneously on the drive and on other drive system equipment make sure that the relevant safety codes and standards are observed all energy sources of the equipment are turned off lockout and tagout dev...

Page 27: ...alled equip ment Wrongly connected cables External influence on or damage of the equipment Wrong parameter settings Software errors Faulty hardware Hazardous touch voltages can be present on drive system components caused by eg Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltages by external equipment Condensation on e...

Page 28: ... Safety labels are attached to the cabinet to alert personnel of potential hazards when working on the equipment The instructions on the safety labels must always be followed and the labels must be kept in a perfectly legible condition References 1 1 Safety labels 1 1 ...

Page 29: ...aches unauthorized access interference intrusion leakage and or theft of data or informa tion ABB and its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage and or theft of data or information 1 5 2 User Lock For better cyber security it is highly recommended that you set a master pass code to prevent e g the...

Page 30: ...Chapter 2 Power electronics and cabinet features 31 Overview 32 Power supply configurations 34 Drive topology 42 Terminal compartment 43 Cabinet design 44 Door locking system 45 Cooling system ...

Page 31: ... auxiliary power configu rations the power electronic components of the drive the cooling system cabinet features such as the grounding switch and the electro mechanical door interlock For information on the power and voltage range of the drive see the technical spec ifications and or the rating plate of the drive References 2 1 Overview of ACS2000 2MVA AFE drives 2 1 ACS2000 for connection to a n...

Page 32: ...type transformer is used Non integrated The transformer is external to the drive The transformer can either be an oil immersed or dry type device The distance between drive and transformer is determined by the maximum possible cable length for the transformer sec ondary cables Drives with a non integrated transformer are equipped with a common mode choke Direct to line connection For applications ...

Page 33: ...tion if the auxiliary power fails the drive can be furnished with one three phase power supply and one single phase power supply Independent of the power supply scheme the drive provides an internal back up supply for 100 ms This safety feature enables the control system to shut down the drive in a controlled manner if the auxiliary power fails Optionally the drive can be equipped with an addi tio...

Page 34: ...er electronics components of a typical ACS2000 1 DTL compartment with common mode choke A and line choke B 2 Swing frame of control unit 3 IFU input filter unit 4 DC link capacitors 5 AFE Active front end 6 INU Inverter unit 7 Grounding switch 8 EMC filter 9 Charging transformer References 2 4 Main components of the drive 2 4 1 2 3 4 7 5 6 8 9 B A ...

Page 35: ...es injected to the supply network 2 3 2 DTL compartment The DTL compartment 2 4 1 is present in drives configured for direct to line connection The func tions of the compartment are twofold It smoothes the current harmonics in the power supply It decouples the common mode voltages of the drive from the network References 2 5 IFU Input filter unit 2 5 AFE DC link DC NP DC U1 V1 W1 To NP IFU To INU ...

Page 36: ...nects its output to the minus neu tral point and plus side of the DC link The AFE maintains the DC link voltage at the required level and provides the desired input power factor at the point of common coupling PCC The input power factor is adjusted by the AFE to near unity References 2 6 AFE Active front end 2 6 1 2 3 4 Phase module 1 Phase module 2 Phase module 3 Extracted phase module 1 2 3 4 IF...

Page 37: ...cuit board of the AFE The high voltage IGBT is a power semiconductor switching device specially developed for medium voltage drives The device is based on well estab lished transistor technology and combines high speed switching capabilities with high blocking voltage and low conduction losses as known from GTOs References 2 7 Phase module 2 7 3 4 2 3 1 5 6 Phase capacitors Phase INT board Gate dr...

Page 38: ...the charging unit is disconnected from the medium voltage circuit the MCB is closed and the DC link will reach its nominal level Stand by mode Once the DC link is charged it is possible to keep the drive in this state to facilitate a more rapid start up procedure The losses during stand by mode are approx 1 of the nominal power and are caused from small losses from the AFE the INU and the auxiliar...

Page 39: ...C link capacitor is still charged Grounding the drive is only possible after the main power supply has been disconnected and the DC link has discharged When the voltage is below 50 V DC press the pushbutton Grounding Switch Unlocked 1 located on the control compartment door the pushbutton lights up and at the same time turn the grounding switch to the position grounded 2 When the grounding switch ...

Page 40: ...evel topol ogy the drive produces an optimum number of switching levels nine levels phase to phase The resulting waveforms permits the application of standard motors The INU is composed of three identical phase mod ules see Phase module The phase modules can be extracted from the cabinet to facilitate mainte nance and service on the INU References 2 12 INU Inverter unit 2 12 Phase module of phase ...

Page 41: ...ncludes a three phase du dt filter con nected to its AC output The filter chokes 1 resis tors 2 and capacitors 3 protect the motor against excessive voltage slopes du dt is limited to 500 V s References 2 13 EMC filter 2 13 INU DC link DC NP DC U2 V2 W2 EMC filter To NP 1 2 3 ...

Page 42: ...s for the termination of the ground cable and the cable screens The cable entry is prepared in the factory for to the cable entry configuration ordered Top or bottom cable entry Type of entry plate For information on the type of cable entry in the drive see Appendix C Mechanical drawings For further information see 6 8 Cable entries References 2 14 Terminal compartment 2 14 ...

Page 43: ...plying a cabinet design consisting of folded galvanized sheet metal plates approximately 2 mm thick and mini mizing the space between the rivets The inside walls of the cabinet are not painted because paint tends to reduce the effectiveness of metallic bond ing which is important for successful EMC Accordingly only the front of the cabinet is painted while all other walls are galvanized However th...

Page 44: ...rtment door The different lock inserts ensure that these doors can only be opened by personnel authorized to do so The covers of the integrated transformer are bolted References 2 15 Door locks 2 15 Door of DTL compartment bolted Door of control compartment lockable Door of medium voltage compartment electromechanically locked Door cannot be opened when the drive is energized Door of medium voltag...

Page 45: ...nfigurations Optionally the drive and the integrated trans former can have a redundant fan configuration ensuring full operation in the event of fan failure The drive can be equipped with fan units of the fol lowing types References 2 16 Fan unit types 2 16 ACS2000 DTL ACS2000 with integrated transformer 2 1 2 1 1 1 1 1 1 Fan unit type 1 Fan unit type 2 1 2 ...

Page 46: ...oup continues to run for a preset time after the main power has been switched off and the DC link voltage has decreased below a preset value Operating intervals Parameter setting allows to run one of the two fans continuously or to run the fans alternately in adjustable intervals The intervals are set with parameters Air flow inside the drive The fan group of the cabinet feeds the cooling air to t...

Page 47: ...aches the specified final pressure loss the message Conv1CoolAirFilter is displayed on the CDP control panel and the alarm fault lamp lights up on the control compartment door When a fan of the drive or a fan of the integrated transformer fails the control system of the drive switches on the stand by fan automatically The failure of a fan is indicated on the CDP control panel of the drive as follo...

Page 48: ...Chapter 3 Control system 49 Control unit 50 Main components 55 I O interfaces ...

Page 49: ...l control system and or remote operator stations References 3 1 Block diagram of control system ACS2000 IOEC I O modules INT circuit board INU Phase module Phase module Phase module INU External devices Pulse encoder DriveWare DriveMonitor RS485 PPCS DDCS PPCS PPCS PPCS option DDCS CDP control panel Fieldbus adapter AMC circuit board AFE AMC circuit board INU INT circuit board AFE Phase module Pha...

Page 50: ...n provides a short functional overview of the main hardware components of the control system and their interconnection References 3 2 Control compartment 3 2 Shown is the ACS2000 for direct to line DTL connection Control compartment Local control panel 1 2 1 2 ...

Page 51: ...h the AMC circuit board via optical fibers The circuit board is fitted with a Motorola DSP pro cessor and features two PPCS and eight DDCS communication channels The communication channels are used for high speed data transfer via the INT circuit boards to the Phase INT circuit boards inside the phase modules AFE and INU have their own AMC circuit board For information on the devices present in th...

Page 52: ...CHAPTER 3 CONTROL SYSTEM 52 3 4 AMC and main INTerface circuit board of the INU AMC and main INTerface circuit board of the AFE INTerface circuit board AMC circuit board 1 2 3 4 1 2 3 4 ...

Page 53: ...ystem Cooling system These tasks are implemented in the AMC circuit board of the INU Parameters The control system is configured customized and tuned with a set of application parameters The application parameters are organized in functional groups and have factory set default values The default parameter values are adjusted during com missioning to the specific application of the drive to activat...

Page 54: ...tly determines the optimum switch positions every 50 microseconds and initiates switching whenever required Peripheral I O devices The peripheral input and output devices connected to the AMC circuit board of the INU include Local CDP control panel I O interfaces for parallel signal transfer to exter nal devices Optional fieldbus adapters for serial data trans fer to a higher level control system ...

Page 55: ...fficient for most applications The drive can include optional expansion I O that includes an external module IOEC 4 and an inter nal module IOEC 3 These expansion modules pro vide extra inputs and outputs for control and supervision as may be required by ABB or the cus tomer to support various control options References 3 6 IOEC modules overview 3 7 IOEC modules location 3 6 IOEC 1 IOEC 2 IOEC 3 I...

Page 56: ...input Common mode voltage Maximum 48 V Isolation level 350 V AC Analog outputs No of I O 2 Signal range 0 20 mA load impedance max 250 Resolution 12 bit Isolation level 350 V AC Digital inputs No of I O 14 Signal level 22 80 V DC 22 120 V DC with IOEC Adapter 3BHE040914R0101 22 250 V AC Logical thresholds 13 V AC or DC 0 16 V AC or DC 1 Input current 13 mA steady state 14 mA max inrush at 24 V DC ...

Page 57: ... X12 6 DI8 X12 7 X12 8 DI9 X12 9 X12 10 DI10 X13 1 X13 2 DI11 X13 3 X13 4 DI12 X13 5 X13 6 DI13 X13 7 X13 8 DI14 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 24 VIR OVIR V IR OK OFF ON X13 9 X13 10 AI1 OV AI2 AI3 AI4 AO1 AO2 AI1 10V AI2 AI3 AI4 AI1 20mA AI1 10V AI2 20mA AI2 10V AI3 20mA AI3 10V AI4 20mA AI4 10V AO1 AO2 X6 1 X6 2 X6 3 X6 4 2 DDCS TX DDCS RX MCB OFF IN 4V DC IOEC I O...

Page 58: ...kind of part an assembly the next three digits are the page num ber the part is located on page 340 and the last digit 1 means that the part is the first assembly on the page This identification label number is the key to track electrical devices throughout the drive and in ABB documentation The designation for each IOEC module is shown in Table 3 3 Table 3 3 IOEC module identification I O module ...

Page 59: ...ter air temperature X32 3 X31 4 AI3 AI3 Freely programmable 72 X32 4 X31 5 AI4 AI4 Freely programmable 72 X32 5 Table 3 5 Standard digital output signal allocation Terminal Channel Default setting Par group X21 1 DO01 Ready on drive is ready for operation X21 2 X21 3 X22 1 DO02 Ready ref drive is running X22 2 X22 3 X23 1 DO03 Alarm fault alarm fault is present X23 2 X23 3 X24 1 DO04 Tripped drive...

Page 60: ...05 Freely programmable 72 X11 10 Common X12 1 DI06 Freely programmable 72 X12 2 Common X12 3 DI07 Freely programmable 72 X12 4 Common X12 5 DI08 Freely programmable 72 X12 6 Common X12 7 DI09 MV switchgear open X12 8 Common X12 9 DI10 MV switchgear closed X12 10 Common X13 1 DI11 MV switchgear available not tripped X13 2 Common X13 3 DI12 Freely programmable 72 X13 4 Common X13 5 DI13 Freely progr...

Page 61: ...1 10 Common X12 1 DI06 Constant speed select 24 25 X12 2 Common X12 3 DI07 External ON request start DC link charge 72 02 72 03 X12 4 Common X12 5 DI08 Process stop stops drive 72 43 72 44 X12 6 Common X12 7 DI09 MV switchgear open X12 8 Common X12 9 DI10 MV switchgear closed X12 10 Common X13 1 DI11 MV switchgear available not tripped X13 2 Common X13 3 DI12 Remote reset 72 33 72 34 X13 4 Common ...

Page 62: ...X31 4 AI3 AI3 Motor winding V temperature X32 4 X31 5 AI4 AI4 Motor winding W temperature X32 5 Remote speed supply output specifications Output voltage 10 V Available output current 5mA X31 1 X32 4 X32 1 X31 2 X32 2 X31 3 X32 3 X31 4 X31 5 X32 5 10 V 0 V AI1 Wiring example remote speed Internal supply voltage Remote speed control Table 3 9 Standard analog output signal allocation Terminal Channel...

Page 63: ... X21 1 DO01 Freely programmable X21 2 X21 3 X22 1 DO02 Freely programmable X22 2 X22 3 X23 1 DO03 Freely programmable for motor space heater then motor heater OFF command X23 2 X23 3 X24 1 DO04 Freely programmable for motor cooling fan then motor cooling fan ON command X24 2 X24 3 X25 1 DO05 Freely programmable X25 2 X25 3 X26 1 DO06 Freely programmable X26 2 X26 3 NC NO NC NO NC NO NC NO NC NO NC...

Page 64: ...12 7 DI09 Freely programmable X12 8 Common X12 9 DI10 Motor protection monitoring X12 10 Common X13 1 DI11 Motor vibration 2 bearing 2 alarm trip X13 2 Common X13 3 DI12 Motor vibration 1 bearing 1 alarm trip X13 4 Common X13 5 DI13 Ext mot trip ovrtmp ovrspd space heater fan X13 6 Common X13 7 DI14 External motor alarm X13 8 Common X13 9 24 V 0 V 24 V control logic X13 10 Common Table 3 12 Option...

Page 65: ...ut signal allocation Terminal Channel Default setting Par group X31 6 AO1 AO1 Freely programmable X32 6 X31 7 AO2 AO2 Freely programmable X32 7 For further information on data transmis sion and on data and signal allocation to the transmitted datasets see Signal and parameter table Installation and start up guide of the installed fieldbus interface Engineering documents Fieldbus Interface type AF ...

Page 66: ...y 24 VDC 10 X2 7 24 V X2 8 PE Ground NPBA 12 terminal assignment X1 1 A Data negative conductor 2 in twisted pair Customer connections X1 2 B Data positive conductor 1in twisted pair X1 3 A Data negative conductor 2 in twisted pair X1 4 B Data positive conductor 1in twisted pair X2 5 24 V Power supply 24 VDC 10 X2 6 0 V X2 7 DG Cable data ground optional 3rd conductor Connected to module ground vi...

Page 67: ... module communicates with the AMC cir cuit board of the INU via a fast optical link using the standard DDCS protocol The optical fibers are connected to channel 1 of the AMC circuit board Location The NTAC interface is DIN rail mounted inside the control compartment 3 10 2 The indicated mounting position may vary depend ing on the number of optional devices present on the swing frame References 3 ...

Page 68: ...or temperature supervision Motor temperature supervision is accomplished via optional PT100 input modules These modules are suitable for connection of PT100 resistance thermometers in accordance with IEC60751 in 2 3 or 4 conductor systems ...

Page 69: ...69 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H ...

Page 70: ...ransportation storage and disposal 71 Safety 72 Transport conditions 73 Unpacking and inspection 74 Lifting and transportation 77 Storage 78 Storage of spare parts 79 Disposal of packaging materials and components ...

Page 71: ...71 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H 4 1 Safety The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment ...

Page 72: ... temperature 45 C High air temperature Unventilated enclosures 70 C Ventilated enclosures outdoor 40 C Relative humidity 100 Absolute humidity 60 2B1 Biological conditions Flora No Fauna No 2M4 Mechanical conditions Stationary vibration random Acceleration spectral density 10 m2 s3 2 3 Hz 1 m2 s3 10 20 Hz 0 5 m2 s3 50 2000 Hz Non stationary vibration including shock Shock response spectrum 100 m s...

Page 73: ... packaging material carefully 2 Check the drive and accompanying equipment for damages 3 Compare the complete delivery with the pur chase order and the packing list 4 If parts are missing or damaged immediately inform the shipping company and the ABB ser vice organization It is recommended to photograph the damages and send the photographs to ABB ...

Page 74: ...tion Therefore the cabinet must be transported in an upright position When transporting the cabinet ensure that no dirt enters Keep the doors closed Metallic dust in particular may cause damage and lead to malfunction when the cabinet is powered up It is recommended to have the following information at hand before transporting the cabinet Appendix C Mechanical drawings provides details on dimensio...

Page 75: ...ls can be removed after the cabinet has been installed at its final location Do not pass a sling through the hole Use appropriate safety hooks or shackles to attach a sling Verify that the slope angle 1 is appropriate to the weight of the cabinet Observe the center of gravity Lift the cabinet slowly and steadily to the required clearance height maintaining the cabi net in upright position Check th...

Page 76: ...lace a pallet truck on the left and on the right of the cabinet Capacity and fork length for pallet trucks Insert the forks fully to transport the cabinet Make sure that the forks are on the same height Pallet Truck 1 2 3 4 Capacity 3000 kg 2000 2200 kg Fork length 2 m 1 m References 4 3 Transporting the cabinet by pallet trucks 4 3 1 2 3 4 ...

Page 77: ...aluminum foil and a wooden panel 2 Add a desiccant of the appropriate quality 1 unit desiccant 30 g absorbs 6 g water vapor The following quantity is needed when using a polyethylene foil 10 units m2 foil 3 Close and lock the doors of the cabinet 4 Use polyethylene or equivalent for packaging 0 3g m2 24h water vapor diffusion 5 Attach humidity indicators to the packaging The storage conditions and...

Page 78: ...er 4 6 2 Handling precautions To maintain spare parts in good condition and to keep the warranty valid during the warranty period observe the following Check the spare parts immediately after receipt for damages Report any damage to the ship ping company and the ABB service organiza tion Keep spare parts in their original packaging Store printed circuit boards in antistatic bags or boxes Ground yo...

Page 79: ...AFE 2MVA UM 3BHS355653 ZAB E01 REV H 4 7 Disposal of packaging materials and components Dispose of the packaging materials and the components at the end of the life time of the drive according to local regulations ...

Page 80: ...Chapter 5 Mechanical installation 81 Safety 82 Overview on installation work 83 General notes on installation 84 Fixing the cabinet to the floor 85 Installing fan units ...

Page 81: ...2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H 5 1 Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations ...

Page 82: ...CHAPTER 5 MECHANICAL INSTALLATION 82 5 2 Overview on installation work The installation includes the following work Preparing the floor Fixing the cabinet to the floor Installing fan units ...

Page 83: ...re fore it is not permitted to install any foreign device on the roof 5 3 3 Fire protection Suitable fire protection measures should be applied to prevent fire spreading into the drive 5 3 4 Cable duct material Cable ducts should be of non flammable material with a non abrasive surface All cable entries and exits should be protected to prevent dust humidity and animals entering the drive 5 3 5 Pre...

Page 84: ...e cabinet provides a hole in each corner of the base for floor fixings The holes are accessible from the outside A Floor fixings are not supplied Anchor bolts as illus trated B or screws and nuts of size M20 are rec ommended References 5 1 Fixing the base to the floor 5 1 A B ...

Page 85: ...ate for DTL fans 2 Mounting plates for standard fans 2 Use the supplied screws to fasten the fan unit s to the fan mounting plate s on the cabi net roof Redundant DTL fan configurations Redundant DTL fan configurations require prior installation of the appropriate redundancy adaptor box on the cabinet roof Adaptor box for redundant DTL fan units For information on the number of fan units to be ins...

Page 86: ...r cables 91 Terminal sizes 92 Ground cable and cable shield connections 94 Cables between integrated transformer and drive 96 Cable entries 97 Power cables ground cables equipotential bonding conductor 102 Auxiliary power control and serial communication cables 108 Control and power supply cables for fan units 110 Final checks ...

Page 87: ... 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 the consent of the ABB commissioning personnel Take appropriate measures to prevent main and auxiliary power supply being switched on during installation ...

Page 88: ...ctrical installation includes the following wire and cable connections Cables between integrated transformer and drive Power cables ground cables equipotential bonding conductor Auxiliary power control and serial communica tion cables Control and power supply cables for fan units ...

Page 89: ...to the converter and from the converter to the motor For information on the requirements for power cables ground cable and equipo tential bonding conductor see ACS2000 power cable specification Power cables engineering guideline For information on the requirements for the auxiliary power cable and the control cables see Auxiliary power and control cables guideline ...

Page 90: ...g of power cables Independent of the distance between the non integrated transformer and the drive and the drive and the motor one single core cable per each phase must be used The current carrying capacity must not be increased by laying cables in parallel ...

Page 91: ...X1 5 N PE Optional single phase UPS Terminal Wire cross section mm2 Solid wire Flexible wire X1 11 1 5 to 25 X1 12 PE Optional auxiliary power supply for converter space heater Terminal Wire cross section mm2 Solid wire Flexible wire X1 15 1 5 to 25 X1 16 PE Table 6 2 I O module terminal sizes Wire cross section mm2 Solid wire Flexible wire Digital inputs 0 5 to 2 5 Digital outputs Analog inputs A...

Page 92: ...elds of the cables and for the connection of the ground cable To identify the ground busbar see Appendix C Mechanical drawings References 6 1 Grounding drive system and integrated transformer 6 1 1 2 3 1 2 3 PE PE U V W U2 V2 W2 U1 V1 W1 M Input transformer Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ...

Page 93: ...1 W1 U V W U2 V2 W2 1 2 3 1 2 3 PE PE U2 V2 W2 U1 V1 W1 M Input transformer Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 References 6 2 Grounding drive system and non integrated transformer ...

Page 94: ...filter and pressure monitoring cable Heating cable option Optical fiber and power supply for primary cur rent measurement The cables are identified by their specific number and are labeled with the designation of the termi nal where they are connected to The cables are prepared for connection Power cables are rolled up in the transformer cabinet control cables in the drive cabinet For further info...

Page 95: ...port units and are equipped with a heating cable 1 Connect the power supply of the heating cable 2 Connect the heating cables of two adjoining transport units with each other 3 Fasten the connectors with cable ties For further information on power supply connections see the applicable Wiring diagrams References 6 4 Heating cable connection 6 4 ...

Page 96: ...ons 1 on the underside of the EMC plate if the cable entry is used for control cables 6 8 2 Cable entry with sealing modules type 1 Usage Power cables ground cables bonding conductors Included in delivery Cable entry frame 1 Not included in delivery Sealing modules 2 accessories tools 6 8 3 Cable entry with sealing modules type 2 Usage Auxiliary power cables control cables Included in delivery Fra...

Page 97: ...g diagrams for information on Conventions for cross references and device identification 6 9 2 Preparing the cable entry and the cables 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 before con nection See the applicable Mechanical drawings for information on NOTIC...

Page 98: ...ed through the cabinet floor 5 If necessary remove the entry plate and push the cable through the entry holes 6 Prepare the cables as illustrated in 6 5 A illustrates how cables with an outer cable screen or shield are prepared for EMC bond ing with the metal enclosure of the cabinet B illustrates how cables without an outer screen or shield are prepared References 6 5 Preparing power cables for E...

Page 99: ...n References 6 6 Preparing power cables for sealing modules 6 6 Outer cable sheath Sealing module Frame Conductive foil of sealing module Cable sheath removed to expose cable shield Cable clamp Shrinkable sheath seal Shield extension to be connected to PG busbar Conductor screen extension to be connected to the PG busbar Heat shrinkable termination Cable lug as specified by the cable supplier and ...

Page 100: ...V1 W1 1 the motor cables to busbars U2 V2 W2 2 the screen ends of all conductors and the shields of all cables to the PE ground bus the ground cable to the PE ground bus 3 the equipotential bonding conductor to the PE ground bus 4 References 6 7 Power cable entry 6 7 A B 3 4 2 1 1 2 2 1 U2 V2 W2 U1 V1 W1 Top cable entry Bottom cable entry A B ...

Page 101: ...ing washer 1 and flat washer 2 on each side of the busbar 3 Other washers can be used provided they maintain the required contact pressure Cable lugs suitable for M12 bolts Lubrication If stainless steel bolts and nuts are used lubri cate the thread and head contact surface of the bolt using recommended pasts eg Molykote D paste If a coated nut eg with bonded molybdenum disulfide MoS2 coating is u...

Page 102: ...or cross references and device identification Terminal designations The power feed for the auxiliary supply must be protected with a suitable circuit protection rated for the inrush current For infor mation see utility consumption list of the drive 6 10 2 Preparing the cable entry and the cables Determining the cable length 1 Determine the required length of a cable between the point of entry and ...

Page 103: ... corresponds to the cable diameter 3 Slide the grommet onto the cable The grom met must fit tightly to prevent water entering the cabinet The grommets can be discarded if cables are entered through the floor 4 If necessary remove the entry plate and the cable through the entry holes 5 Loosen all screws of the EMC cushion brackets and push the cushions apart References 6 9 Control cable entry 6 10 ...

Page 104: ...the cable screen in the middle of the stripped area 1 To turn the conductive side inside out pull the cable screen ends over the cable insulation 2 Connect the screens ends with a continuous conducting foil 3 7 Pull the cables through the EMC cushions 8 Push the cushions together so they fit tightly around the bare screen and tighten the screws ...

Page 105: ...uter cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in 6 11 For information on removing and install ing the sealing modules see Appendix A Additional manuals References 6 11 Preparing control cables for sealing modules 6 9 Sealing module Conductive foil Cable sheath removed to expose cable shield Conductor screen extension to be connected to PE terminal 1 2 3 4...

Page 106: ...e cable gland remove the outer cable sheath to bring the conductive foil of the sealing module 2 in contact with the cable shield 3 References 6 12 Preparing control cables for cable glands 6 12 Outer cable sheath Cable gland Conductor insulation removed to expose cable shield Plate Conductor screen extension to be connected to PE ter minal 1 2 3 4 5 1 2 3 4 5 ...

Page 107: ...lded conductor ends as short as possible not longer than 50 mm Cable shields 1 Connect the shield of serial communications cables to the fieldbus adapter 2 Connect the overall shield and the individual shields of the encoder cable to the separate shield grounding bracket 3 Do not connect the shields directly to the encoder adapter 1 To accommodate encoder cables of different diameters ground clamp...

Page 108: ...ly cable of the fan unit to the terminals inside the corresponding terminal box see picture below Standard fan units 1 Pull the control and power supply cables through the rear cable entry located in the floor of the fan unit see picture below 2 Route the cables through the fan cable entry on the cabinet roof and connect them to the appropriate terminals inside the cabinet For information on conne...

Page 109: ...3 ZAB E01 REV H References 6 14 Connecting the fan units 6 14 1 1 1 2 2 7 7 2 7 5 6 2 4 3 DTL fan unit Standard fan unit Power supply cable Terminal box Front cable entry Rear cable entry Fan cable entries on cabinet roof 1 2 3 4 5 6 7 ...

Page 110: ...N 110 6 12 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 111: ...111 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H ...

Page 112: ...Chapter 7 Commissioning 113 Required qualification 114 Commissioning procedure 115 Commissioning check list 116 Customer assistance 117 Customer acceptance ...

Page 113: ...S2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H 7 1 Required qualification Commissioning parameter adjustments and functional tests of the drive must be carried out only by commissioning personnel certified by ABB ...

Page 114: ...ISSIONING 114 7 2 Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB To contact the ABB service organization see Contact information ...

Page 115: ...In order to ensure uncomplicated and speedy commissioning it is important that drive and associated equipment are ready for commissioning Reviewing and completing the items in the Commissioning check list before the commissioning personnel arrive on site will help to achieve this ...

Page 116: ...el for assistance who are experienced with medium and low voltage equipment and with the local safety regula tions familiar with the driven process authorized to operate associated medium and low voltage equipment eg main circuit breaker other low and medium voltage switch gear authorized to operate the driven process for functional tests ...

Page 117: ...cceptance When commissioning has been completed the commissioning report is signed by the responsible commissioning personnel and by the customer as a sign of acceptance A copy of the report and a copy of the actual parameter settings are handed out to the customer ...

Page 118: ...Commissioning check list ...

Page 119: ...according to the power cable specification 3 Pulse encoder cable screens connected to screen grounding point and not connected directly to the pulse encoder interface only applicable for drives with pulse encoder interface 4 Cable entry prepared according to the instructions in the user manual 5 All control cable screens and conductors are connected according to the instructions of the user manual...

Page 120: ...elay settings tested 5 Safety devices eg door locks tested and in operation 1 Ground connection completed 2 Transformer auxiliaries eg dehydrating breathers cooling protection devices ready 3 Safety devices eg door locks tested and in operation 1 Motor installed aligned and alignment protocol available 2 Motor not coupled to driven load 3 Ground connection completed 4 Motor auxiliaries eg bearing ...

Page 121: ...ut by the commissioning engineer of the drive an additional day per drive motor combination needs to be reserved After the test the feeder cables can be connected except at the drive end The test must comply with the specification 1 Medium voltage available for the start up of the drive 2 Low voltage auxiliary power available for the start up of the drive 1 Sufficient number and correct type of sp...

Page 122: ...Chapter 8 Operation 123 Ambient operation conditions 124 Safety 125 Overview 126 Overview of local operator panel 128 Status messages 132 Starting the drive 134 Stopping the drive 135 Emergency off ...

Page 123: ...substances Sea salt and road salts Salt mist Mean value Max value Sulphur dioxide 0 3 mg m3 1 0 mg m3 Hydrogen sulfide 0 1 mg m3 0 5 mg m3 Chlorine 0 1 mg m3 0 3 mg m3 Hydrogen chloride 0 1 mg m3 0 5 mg m3 Hydrogen fluoride 0 01 mg m3 0 03 mg m3 Ammonia 1 mg m3 3 mg m3 Ozone 0 05 mg m3 0 1 mg m3 Nitrogen oxides 0 5 mg m3 1 0 mg m3 3S2 Mechanically active substances Sand 30 mg m3 Dust suspension 0 ...

Page 124: ...CHAPTER 8 OPERATION 124 8 2 Safety The drive must only be operated by qualified and authorized personnel ie personnel who are familiar with the operation of the drive and the hazards involved ...

Page 125: ...l con trol system is not described in this chapter If the drive is controlled from remote see the appropri ate manuals for information The panel messages 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 messages and parameter settings in the drive ...

Page 126: ...and turns the main power supply on the main circuit breaker closes and the DC link charges 3 Supply OFF Illuminated pushbutton When pressed it lights up and turns the main power supply off the main circuit breaker opens and the DC link discharges 4 Alarm Fault lamp Fault permanent light Alarm flashing light 5 Grounding Switch Unlocked Illuminated pushbutton It lights up if the grounding switch can...

Page 127: ...V H For further information on the CDP control panel see Chapter 9 CDP control panel 8 4 1 Lamp test The lamp test is activated via the CDP control panel by setting parameter 16 7 to LAMP TEST The lamp test function resets itself after a set time ...

Page 128: ...ated by pressing the SUPPLY ON pushbutton on the control com partment door The status message ReadyOn changes to Charging when the DC link capacitors of the drive are being charged The status message ReadyRun tells the operator that the drive is energized and ready for operation As soon as the start command is initiated the motor is magnetized and the drive starts to modu late When the drive is in...

Page 129: ...eady on Ready on Ready run Ready ref On command AFE Ready on DC link charges MCB closes INU starts to modulate Start command Operation AFE Ready ref Ready on conditions Auxiliary supply on AFE INU door closed and locked Drive not grounded No emergency off No fault Charging Fan switches on ...

Page 130: ...y on Ready ref Off command MCB opens Operation AFE Ready on Stop command Speed ramps down INU stops to modulate Stop command to AFE Actions Auxiliary supply is switched AFE INU door is released for opening Drive is grounded Stopping DC link discharges Fan switches off after a delay off ...

Page 131: ...4 Emergency off sequence of the drive For the sake of simplicity the flow diagrams of the AFE were omit ted in the above diagrams Not ready on Ready ref Operation Emergency off command MCB opens INU stops to modulate Stop command to AFE Speed coasts down ...

Page 132: ...nnected to the INU to be able to start up the drive locally The CDP control panel is only con nected to the AFE if it is required to view status and fault messages of the AFE When the drive is running the CDP control panel can be connected back and forth without inter rupting the operation of the drive However to stop the drive the CDP control panel must be connected to the INU Switching the CDP c...

Page 133: ...C link The pushbutton lights up The status line of the CDP control panel alter nates between Charging and AuxiliaryOn After charging has been finished the AFE starts to modulate If the CDP control panel was switched to the AFE you would first see the message Modu lating and then after a short instant the message ReadyRef in the status line of the display When the AFE is in ReadyRef state the state...

Page 134: ... stop sequence is in progress the drive can always be restarted by pressing the START key on the CDP control panel Just before the motor will come to a standstill the CDP control panel displays shortly the message Stopping When the drive has stopped modulating the CDP control panel displays ReadyRun As long as the MCB has not been opened the motor can be started again 1 L 600 0 rpm StateINU ReadyR...

Page 135: ... linked to the emergency off circuit When an emergency off is initiated during drive operation the following takes place The MCB opens The drive coasts down The DC link of the drive discharges The status line of the CDP control panel alter nates between the message EmergencyOff NotReadyOn The EMERGENCY RESET pushbutton flashes The SUPPLY OFF pushbutton flashes 8 8 3 Starting the drive after an eme...

Page 136: ...CDP control panel functions 139 CDP control panel modes 140 Identification mode 141 Actual signals mode 141 Overview 144 Parameter mode 147 Function mode 149 Drive selection mode 151 Disabling enabling local lock function 152 Operational commands ...

Page 137: ...ontrol panel features a 4 line LCD display and a 16 key keypad The keys are identified in 9 1 References 9 1 CDP control panel 9 1 1242 0 rpm 1 L StateINU ReadyOn 1242 rpm MOTOR SP 86 0 kW POWER Display Keypad Mode selection keys Fast navigation keys select and or change a value fast Slow navigation keys select and or change a value slowly Enter key terminates a procedure Local remote selection ke...

Page 138: ...ol panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first Using the CDP control panel it is possible to enter start up data to control the drive with a reference value and start stop and direction commands to display actual values three values can be read simultaneously to display and adjust parameters to display information on the most re...

Page 139: ...000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H 9 3 CDP control panel modes The CDP control panel provides the following modes Identification mode Actual signals mode Parameter mode Function mode Drive selection mode ...

Page 140: ...nitialized as described before the display changes as follows After 2 3 seconds information on the drive 1 2 the application software in use 3 and the drive identification 4 is displayed After another few seconds After another few seconds the display changes to the actual signals mode The status line of the dis play alternates between DCGnd NOpen NotReadyOn CDP312 PANEL V5 30 ACS2000 xxxx Device N...

Page 141: ...is described in section 9 5 7 Dis playing and resetting an active fault When a fault or warning is generated in the drive the message will be displayed immediately except when in drive selection mode Changing from the fault display mode to other dis play modes is possible without resetting the fault first When no keys are pressed the fault or warn ing text is displayed as long as the fault is pend...

Page 142: ...o select a parameter group press the corre sponding fast navigation key 5 To select an actual signal press the corre sponding slow navigation key 6 To accept the selection and to return to the actual signals mode press the ENTER key 7 To cancel the selection and keep the original selection press any of the mode selection keys The selected CDP control panel mode is entered 1 L 600 0 rpm 1 LAST FAUL...

Page 143: ...T key 5 To return to the actual signals mode press a fast navigation key 9 5 7 Displaying and resetting 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 StateINU MOTOR SP POWER ReadyOn 0 00 rpm 0 0 kW 1 L 600 0 rpm 1 LAST FAULT PANEL LOST 0707730 12 30 02 3256 1 L 600 0 rpm 2 LAST FAULT AMC Fault Class 1 9 H 38 MIN 48 S 1 L 600 0...

Page 144: ...he display will show the first parameter of parameter group 11 The next time the parameter mode is entered the previously selected parameter is shown Some parameter values cannot be changed while the drive is running If tried the following warning will be displayed Group 07 Control words 21 01 Start function Group 08 Status words 21 02 Start function Group 09 Fault alarm words 21 03 Off1 stop mode...

Page 145: ...for numbers and text the corresponding fast navigation key for numbers only 6 To confirm the selection and to return to the actual signals mode press the ENTER key 7 To cancel the setting and keep the original selection press any of the mode selection keys The selected keypad mode is entered 1 L 600 0 rpm 77 SYSTEM CONFIG 01 INU IdentifySel INU1 MASTER 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 L 600 0 rpm...

Page 146: ...K and 16 03 PASSCODE and belong to parameter group 16 SYSTEM CTRL INPUTS Enabling the parameter lock 1 Select parameter 16 02 PARAMETER LOCK 2 Set parameter 16 02 to LOCKED 3 Save the setting and exit the parameter mode Unlocking the parameter lock 1 Select parameter 16 03 PASSCODE 2 Set the correct pass code 3 Save the setting and exit the parameter mode For further information see Signal and par...

Page 147: ...eys until the blinking cursor reaches the CONTRAST line 3 To enter the contrast setting function press the ENTER key 4 To change the contrast value press a slow navi gation key 5 To confirm the selection and to return to the actual signals mode press the ENTER key 6 To cancel the setting and keep the original set ting press any of the mode selection keys The selected keypad mode is entered 1 L 0 0...

Page 148: ...CHAPTER 9 CDP CONTROL PANEL 148 9 7 3 Upload and Download functions The Upload and download functions of the CDP are not supported in ACS2000 ...

Page 149: ...ng example that the CDP control panel is connected to the INU 1 To enter the drive mode press the DRIVE key 2 To select the ID number of the AFE and to con nect the CDP control panel to the AFE press any of the slow navigation keys If none of the keys is pressed the display auto matically returns to the actual signals display after a while If the ID number of the AFE or INU is changed by accident ...

Page 150: ...ing the LOC REM key arrow when the CDP control panel is con nected to the AFE If the drive is in operation the AFE will stop modu lating and the drive will shutdown If the drive is stopped and the CDP control panel is set to LOCAL the drive cannot be started up ...

Page 151: ...ART STOP DIR 10 KEYPAD or 12 06 EXT REF2 SELECT 1 KEYPAD and 12 02 EXT1 EXT2 SELECT 2 EXT2 To enter remote control press the LOC REM key Full remote control from a higher level control system is indicated by a blank space Partial remote control some commands enabled locally is indicated by the letter R 9 9 3 Disabling enabling local lock function Accidental switching from remote control to local c...

Page 152: ...ps down to zero speed and re accelerates in the opposite direction to the preset speed The arrow changes at zero speed 9 10 2 Entering a reference value Entering a reference 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 3 To enter change the reference value press th...

Page 153: ...153 ACS2000 AFE 2MVA UM 3BHS355653 ZAB E01 REV H ...

Page 154: ...ctive maintenance 155 General information 156 Identifying electrical equipment 157 Alarm fault indications 159 Removing the CDP control panel 160 LEDs and switches on printed circuit boards and I O devices 167 Corrective maintenance ...

Page 155: ...e ABB service organization To contact the ABB service organization see Con tact information 10 1 2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule on time and at the stated intervals in the ACS2000 Preventive maintenance schedule 10 1 3 Logbook It is recommended to record all maintenance activ ities in the maintenance logbook including Date and time Detai...

Page 156: ...grams and parts lists all devices are labeled in accor dance with IEC 81346 1 10 2 2 Identifying cables and wires Cables and wires in the drive are equipped with marker sleeves which carry the same identification number as in the wiring diagrams 10 2 3 Understanding the wiring diagrams For information on item designation and cross reference conventions see Appen dix D Wiring diagrams References 10...

Page 157: ...does not shut down the drive If the con dition causing the alarm is not corrected a persist ing alarm can often lead to a fault An alarm cannot be reset manually The alarm message is deleted from the display as soon as the alarm condition has been corrected Fault A fault shuts down the drive The type of shutdown depends on the origin of the fault Depending on the type of fault the drive opens the ...

Page 158: ...ult 1 Fault AMC Fault Class 2 classifies the fault 10 3 4 Troubleshooting procedure If a fault shuts down the drive proceed as follows 1 Do not switch off the auxiliary power supply or try to reset a fault message before all informa tion at the time of the occurrence of the fault condition has been saved 2 Select the Fault History Display on the CDP control panel For further information see Chapte...

Page 159: ... When the CDP control panel has been removed during operation the drive can only be stopped by pressing the emergency off but ton 2 To remove the panel proceed as illustrated Meaning of the LEDs The green LED 4 signals that the control voltage has been switched on Communication with AMC circuit board The CDP control panel 1 is connected to the AMC circuit board of the INU 2 and the AFE 3 via an RS...

Page 160: ...an be used for diagnostic purposes 10 5 1 AMC circuit board The LEDS of the AMC board are identified in 10 3 References 10 3 AMC34 circuit board 10 3 LED Color Meaning Status when SW loaded Status when SW not loaded 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...

Page 161: ...ule 10 4 3 The factory set value must not be changed For information on IOEC switch settings see Appendix D Wiring diagrams References 10 4 IOEC circuit board 10 4 LED Meaning Status LEDs of digital outputs On when output is energized Link error light Either on or off On only when there is a problem with the optical fibers Status LEDs of digital inputs On when input is energized Status LED of the ...

Page 162: ... tool user s manual Modbus RTU NMBA 01 installation and start up guide Profibus NPBA 12 installation and start up guide References 10 5 AF 100 interface 10 5 Status LEDs Service connector AF 100 station address selectors Power supply terminals AF 100 terminals 1 2 3 4 5 1 2 3 4 5 Table 10 1 AF 100 LED description LED Meaning F Fault Red Module fault Also lights up during module start up Turns off ...

Page 163: ... USB USB host connector for third party extensions PNL 1 PNL 2 connector providing an interface for a panel bus that can be used for communication with certain drive types Reset button 1 2 3 4 5 6 7 8 9 1 2 7 8 8 3 4 5 6 9 Table 10 2 NETA 21 LED description LED Color Meaning USB Off No USB mass storage devices attached Green USB mass storage device attached and mounted Blinking green Device attach...

Page 164: ... UI 1 second blinking green At least one user has been logged on to the user interface Blinking yellow Factory level access operation Firmware update in progress Note System status STAT LED blinks during the firmware update PWR Off Power off Green Power on Yellow Timed power off or standby NETA 21 can go to the standby mode as a protective measure eg if the environmental temperature is too high To...

Page 165: ... Interface transmits a response or an exception REC Flashing Interface receives a command from the Modbus network ERROR Flashing If the received command has a parity error or if the received command has a CRC error or if the received command is not supported by the interface or if the interface has detected an error Table 10 3 Modbus RTU LED description LED Error indication Meaning XMIT REC ERROR ...

Page 166: ...then off Off Green then red then off Off Green then red then off Off Off DDCS link initialization Off Off Flashing green then green Transfer rate detection Flashing green then green Off Green Communication established Green Flashing green then green Green Operation Green Green Green Table 10 4 Profibus LED description LED Cause Master MSG DDCS Red Red Off RAM test failure Off Red Red ROM test fail...

Page 167: ...iary power supply to the drive is switched off locked out and tagged out the drive is dead safety ground connections are in place personal protective equipment is provided and used when required everyone involved is informed Before energizing the drive again make sure that all foreign objects are removed from the drive all internal and external covers are securely fastened and all doors are closed...

Page 168: ...NDING SWITCH UNLOCKED lights up to indicate that the grounding switch is released and can be turned to the grounded posi tion If the lamp does not light up proceed as fol lows 1 Do not force the grounding switch in any direc tion 2 To test the lamp GROUNDING SWITCH UNLOCKED activate the lamp test with param eter 16 7 For information on setting parameters see 9 6 Parameter mode If the lamp does not...

Page 169: ...d position if it has been verified that hazardous voltages cannot be fed into the drive from the main power supply or the motor that the DC link is discharged that the grounding switch is released DO07 is energized that the drive status is ReadyOn If you cannot turn the grounding switch continue with 10 6 6 Unlocking doors of medium voltage compartments 8 Switch off and lockout all auxiliary volta...

Page 170: ... ing frame 2 Use the telescopic insulating pole to connect the busbar ground clamps 10 10 2 to the ground ball studs of the busbars and to tighten each connection Connect the inner most busbar first 10 10 3 then the middle busbar 10 10 4 and then the outer busbar 10 10 5 The drive is now dead and safe access is possible References 10 10 Connecting a grounding set 10 10 1 2 5 4 3 ...

Page 171: ...nding switch is in position grounded The doors of medium voltage compartments can also not be opened if the drive is disconnected from the auxiliary power If the auxiliary voltage is switched off and the doors are locked and cannot be opened unlock the doors as described in the following section Do the following to release the doors of the medium voltage compartments 1 Open the door of the control...

Page 172: ...itable tools Clean circuit boards with special care To pre vent the components being damaged use anti static brushes and a vacuum cleaner with a soft nozzle Remove dust on assemblies and busbars inside the cabinet with a vacuum cleaner and lint free cleaning cloths Remove water oily or greasy deposits on assemblies components and busbars with water and oil absorbing microfibers such as 3M Scotch B...

Page 173: ...er mat 3 and clean it by using compressed air or a vacuum cleaner Perform this operation away from the drive to prevent dust from entering NOTICE Excessive force damages the capacitor bushings Tighten to the torque value on the label attached to the capacitor If the tightening torque value is not specified do not exceed 20 Nm For information on replacement intervals see the ACS2000 Preventive main...

Page 174: ...ocation Dimensions and weight References 10 14 Phase modules location 10 15 Phase module Dimensions and weight 10 14 INU phase module 1 INU phase module 2 INU phase module 3 AFE phase module 1 AFE phase module 2 AFE phase module 3 10 15 W width L length H height Weight 900 mm 650 mm 250 mm 63 kg L H W ...

Page 175: ...ules The parts can be order as a kit standard option or separately Other tools The tools below are not included in the scope of supply References 10 16 Phase module replacement kit 10 16 3BHB029201R0001 Module tray 2MVA 2UBA005486R0001 Cantilever 3BHB032083R0001 Lifting hoist 3BHB030813R0001 Hoisting brackets 3 arms 1 2 3 4 1 2 3 4 10 13 17 mm 225 mm 3x M8x13 ...

Page 176: ...ase module If using a module tray Anchor the tray to the phase module To do it Holding the tray at an angle insert the hook shaped ends of the tray behind the two brackets of the phase module Then lower the tray to engage the hooks with the brackets DANGER Hazardous voltages When a phase module is removed from the cabinet the grounding path between grounding switch and PE ground busbar is interrup...

Page 177: ...ng strap Current transformer cable 4 This cable is only present in phase modules of the AFE 8 Detach the cable chain on the side of the phase module 1 2 Pull down the end of the chain a little 3 and then pull it into the direction of the arrow 4 to disengage the chain from the mounting bracket 9 Fasten the bolt eyes to the phase module 10 Connect the lifting brackets to the bolt eyes and lift the ...

Page 178: ...w completed and the drive can be started again For further information see 8 6 Starting the drive 10 6 13 Replacing a fan The fan housing can stay on the roof when only the impeller is replaced 1 Disconnect all power supplies to the drive and ground the drive For further information see 10 6 3 De energiz ing the drive locally To isolate the fan unit from the auxiliary power supply switch off the m...

Page 179: ... box 9 Unscrew the cover from the fan housing 10 Lift off the cover and the fan attached to it 11 Disconnect the cable at the exit of the terminal box unscrew the locknut of the cable gland unscrew the cover from the fan 12 Replace the fan and re assemble in reverse order of removal Terminal box Disconnect here Disconnect here ...

Page 180: ......

Page 181: ...hird parties nor used for any unauthorized purpose without written permission from ABB Sp z o o Medium Voltage Drives The hardware and software described in this manual is provided under a license and may be used copied or disclosed only in accordance with the terms of such license ABB Sp z o o Placydowska 27 95 070 Aleksandrow Lodzki Poland Phone 1 479 648 5912 E Mail drivessupport abb com www ab...

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