3BHS204366 Rev - ACS1000WCU OperMainManual

ABB
ACS 1000 Medium Voltage AC Drives 315 to 5000 kW 400 to 6700 hp
Operation and Maintenance Manual

Water Cooling Unit
Document No.: Issued:
3BHS204366 ZAB E01 Rev. 20.06.2004
ABB Switzerland Ltd. All Rights Reserved.
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3BHS204366 ZAB E01Rev.-
ACS 1000 Water Cooling Unit
ABB
Table of Contents
Chapter 1 - Safety...................................................................................................................... 5 Chapter 2 - Installation.............................................................................................................. 7 2.1 Raw Water Connections ................................................................................................. 7 2.1.1 Hose Connection (Standard) .......................................................................................... 7 2.1.2 Hose Connection Side Entry........................................................................................... 9 2.1.3 Flange Connection (Option)............................................................................................ 9 Chapter 3 - Starting up the Cooling System.......................................................................... 11 3.1 Checks before Start-up................................................................................................. 11 3.2 Filling the Cooling System ............................................................................................ 11 3.3 Adding Water to the Cooling System ............................................................................ 16 Chapter 4 - Draining the Cooling System .............................................................................. 19 Chapter 5 - Checking Actual Values ...................................................................................... 21 5.1 Water Conductivity ....................................................................................................... 21 5.2 Water Pressure ............................................................................................................ 22 5.3 Water Temperature ...................................................................................................... 22 5.4 Water Level .................................................................................................................. 23 Chapter 6 - Tightening Torques and Threaded Connections............................................... 25 6.1 Tightening Torques....................................................................................................... 25 6.2 Sealing off Threaded Connections without O-rings and Gaskets .................................. 26 Chapter 7 - Cooling Pump Motor............................................................................................ 27 7.1 Removing and Installing a Cooling Pump ..................................................................... 27 7.1.1 Removing the Pump in a Single Pump WCU ................................................................ 27 7.1.2 Remounting the Pump in a Single Pump WCU............................................................. 30 7.1.3 Removing a Pump in a Double Pump WCU.................................................................. 31 7.1.4 Remounting a Pump in a Double Pump WCU .............................................................. 33 7.1.5 Changing Rotation of a Pump....................................................................................... 35 7.2 Lubrication.................................................................................................................... 35 Chapter 8 - Ion Exchange Resin............................................................................................. 37 8.1 Removing the Ion Exchange Vessel ............................................................................. 37 8.2 Mounting a New Exchange Vessel ............................................................................... 39 8.3 Disposal of Ion Exchange Vessel ................................................................................. 39 Chapter 9 - Plate Heat Exchanger .......................................................................................... 41 9.1 General Description...................................................................................................... 41 9.2 Removing the Heat Exchanger ..................................................................................... 43 9.3 Start-up ........................................................................................................................ 44 9.4 Disassembling the Plates ............................................................................................. 46 9.5 Assembling the Plates .................................................................................................. 47 9.6 Leakage ....................................................................................................................... 48 9.7 Cleaning ....................................................................................................................... 49 Chapter 10 -Replacing Filter Cartridge of Filter Z2 ................................................................ 51 ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.3 (of 72)
Table of Contents
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Chapter 11 -Cleaning Strainer Z1 ............................................................................................53 Chapter 12 -Conductivity Sensor B12.....................................................................................55 12.1 Removing and Installing the Sensor..............................................................................55 12.2 Operation......................................................................................................................58 12.2.1 Transmitter Operating and Control Elements ................................................................58 12.2.2 Operation Mode Display................................................................................................59 12.2.3 Calibration Mode...........................................................................................................60 12.3 Menu Test.....................................................................................................................64 12.3.1 Offset Compensation ....................................................................................................64 12.3.2 Span Compensation .....................................................................................................65 12.3.3 Display of non-compensated Conductivity.....................................................................65 12.3.4 Conductivity-Simulation.................................................................................................65 12.4 Testing the Sensor........................................................................................................66 Chapter 13 -Pressure Transmitter B11....................................................................................67 Chapter 14 -Temperature Sensor B13.....................................................................................69 Appendices ...............................................................................................................................71
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Chapter 1 Safety
This manual should be thoroughly read and understood before commissioning of the pure water cooling system is started.
Caution: Where possible, all components and sub-assemblies weighting over 25 kg have been clearly marked with weight details. Pumps and electric motors are equipped with lifting eyes as supplied by the manufacturers. If lifting of heavy and/or awkwardly positioned items is necessary, extreme caution shall be exercised. Safe, reliable mechanical lifting equipment shall be used wherever possible. Under no circumstances shall items be lifted by means of straps, ropes, chains etc. connected to piping or other system components. Caution: The water cooling system conforms to international standards for noise emission. However, wear suitable hearing protection if long exposure to the system during operation is necessary. Caution: Take care when handling deionizer resin and glycol. Protective clothing including rubber gloves and safety goggles must always be worn when handling chemicals. Take care to avoid spilling resin, as floor can become slippery, resulting in possible personal injury. Caution: To allow maintenance work during drive operation, in case of redundant pumps, the pump motor can be switched off in the control unit. Always make sure that the equipment has been electrically isolated before maintenance work is started.
! ! ! ! !
Caution: Do not work alone. When working on the water cooling system during operation of the drive system be careful not to touch live parts of the equipment
Caution: The cooling system may start automatically as soon as the auxiliary voltage is switched on, even if the converter is de-energized. The pump is switched on depending on the pure water temperature, the pure water conductivity or on the drives internal air temperature. Switch off the auxiliary voltage to shut down the cooling system.
Note: Valves, tubes and hoses are delicate parts. Do not bend or put any pressure on the valves, plastic tubes and hoses.
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Chapter 1 - Safety
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Note: Refer to the flow diagram and layout drawings for details on the cooling circuit and location of the valves.
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Chapter 2 2.1
2.1.1
Installation
Raw Water Connections

Hose Connection (Standard)
When preparing the piping for the raw water supply, consider the maximum length (2 m) of the flexible hoses and the specifications of the raw water interface. See Water Cooling Datasheet in Appendix L Subsupplier Data.
Top entry Figure 2-1 Raw Water Entries 1
Bottom entry
Connect the hoses for the raw water circuit following Figure 2-2 to Figure 2-6.
Inlet Outle
Exchange duct plate (top) and blanking plate when hoses are entered from below
Figure 2-2 Duct Plates
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Chapter 2 - Installation
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Customer side piping
Enter flexible hoses
Figure 2-3 Connecting the Water Hoses Customer side piping
Connect hoses to raw water supply using appropriate flanges (inner diameter of hoses 32 mm)
Figure 2-4 Connecting the Water Hoses Customer side piping
Cut hoses to length
Figure 2-5 Connecting the Water Hoses
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Customer side piping
Connect hoses to inlet
Fasten hoses with supplied clamps Figure 2-6 Connecting the Water Hoses
Figure 2-7 Nipple Dimensions
2.1.2
Hose Connection Side Entry

In case the hose cannot enter the drive through the standard openings, a cut-out in the side wall can be made (not possible if the drive is equipped with a braking chopper). The drawing 3BHS127525 shows the cut-out. In this case the duct plate (see Figure 2-2) has to be mounted on the side and an additional blanking plate (3BHL000641) must be used to cover the standard entry opening.
2.1.3
Flange Connection (Option)

As an option, the drive can be equipped with flanges for raw water connection through the side (not possible if the drive is equipped with a braking chopper), back or bottom of the water cooling cabinet. The
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external water pipes can be connected directly to the flanges. An example is shown in Figure 2-8.
Upward bend Figure 2-8 Flange Connections
Downward bend
The dimensions and position of the flanges is shown in the layout drawing. The tightening torque of the bolds depends on the size and must be determined by the installation personal.
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Chapter 3 Starting up the Cooling System
!
3.1
Caution: Do not run the pumps if the cooling circuit is empty, not even for a short time. If a pump runs dry the pump seals will be damaged immediately.
Checks before Start-up

Information on the positions of all valves in the operating state can be obtained from the Flow Diagram: Flowdiagram for 1 pump and 2 way valve Flowdiagram for 2 pumps and 2 way valve Flowdiagram for 1 pump and 3 way valve Flowdiagram for 2 pumps and 3 way valve 3-9531-001 3-9531-002 3-9531-003 3-9531-004
Filled valve symbols in the flow diagram indicate valves in shut position. 1 2 Open valves V1, (V2), V5, V11 and V15. Close valves V12, V14, V80, (V81), and V82.
3.2
Filling the Cooling System

Cooling Water Drinking water of good quality must be used in the main cooling circuit. However, it is recommended to fill the circuit with deionized water to extend the lifetime of the ion exchange resin. The cooling water should conform to the values in Table 3-1. If in doubt about the quality of the drinking water on your premises contact your local water utility.
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Chapter 3 - Starting up the Cooling System
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Value 6 8.5 < 300 S/cm 3 10 dH < 300 mg/l < 0.1 mg/l < 1000 mg/l
Table 3-1 Drinking Water Specification

Parameter pH Specific conductivity Hardness Chloride (Cl) Copper (Cu) Total dissolved salt
Note: Inhibitors and other chemicals must not be added to the water.
Cooling Water with AntiFreeze
When the ACS 1000 has been ordered with an anti-freeze, a container with the appropriate type and amount of glycol is delivered with the drive.
Warning: Ethylene glycol is a hazard for humans and animals when swallowed. Avoid skin and eye contact and wear protective clothing including rubber gloves and goggles when handling ethylene glycol. Food stuffs and beverages must be kept separate from the place of work. The safety data sheet supplied by the supplier of ethylene glycol (e.g. SwedeWater) must be followed.
Caution: The conductivity of glycol as it is used in cars is too high. The converter cannot be started since the conductivity level remains too high. Only pure ethylene glycol which acts only as an anti-freeze and has no inhibitors for corrosion protection is permitted for the ACS 1000.
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Chapter 3 - Starting up the Cooling System In the following table, the characteristic values of the anti-freeze are listed: Table 3-2 Characteristic Values of the Anti-freeze
Parameter Content Density at 20 C (68 F) Viscosity at 20 C (68 F) Specific heat capacity at 20 C (68 F) Thermal conductivity pH-Value Value >99.8 % 1.1133 - 1.1140 g/cm 19 mm /s 2.3 kJ/kgK 0.29 W/mK neutral
2 3
When transferring, mixing and filling the anti-freeze, it must be guaranteed, that no chips, grease, remnants or any other impurities infiltrate the coolant. For storing and mixing only clean containers specifically designated and appropriately labelled must be used. In the following table, the values for the desired frost proofing are listed: Table 3-3 Water Ethylene Glycol Concentration for the Desired Frost proofing
Frost proofing - 10 C (14 F) - 20 C (-4 F) - 30 C (-22 F) - 40 C (-40 F) Pure Ethylene Glycol 20 % 34 % 44 % 52 % Distilled Water 80 % 66 % 56 % 48 %
Ideally, the mixing procedure should take place at ambient temperature (+ 5 C to + 30 C). When mixing the following procedure must be observed: 1 2 Check that the type of ethylene glycol is appropriate. See Table 3-2. Check that the blue 60 liter plastic container which is part of the delivery contains approximately the same amount of glycol as declared on the label (last two digits of the item number correspond to the amount of glycol in liter; e.g. 3BHL001483P0021 corresponds to 21 liter). Fill in distilled water until the level in the container is at approx. 3/4.
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Chapter 3 - Starting up the Cooling System 4 Thoroughly mix the ethylene glycol mixture.
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Note: There will be negative effects on the thermal and hydraulic behaviour of the coolant if the water-glycol mixture is not mixed thoroughly. 5 Fill the container completely. Afterwards, thoroughly mix the liquid again!
The required frost proofing has been reached now. After filling the system (see following section) the remaining liquid can be used for refills after maintenance or repairs, if stored in a closed container.
Filling the System
6 7 8 9
Switch off the motor protection switch(es) -Q11/( -Q12) of the pump(s). Switch on the auxiliary voltage with switch -Q1. Close valves V1, V11, V15, V80, V81*. Open valves V2*, V5, V12, (*only if redundant pump is present )
10 Connect the filling hose to the ISO-R1/2 connector of valve V14. A pressure of approx. 1 to 2 bar is required for filling water into the circuit. Using a small pump might be necessary. 11 Open valve V14 and start the filling. If the water cooling unit is not equipped with the check valve V18 (as in the previous version of the cooling unit) the water does not start to flow through the filter Z2. Valve V15 has to be opened additionally. Note: Filling rate <= 15 l/min.
12 Stop the filling when the water level in the expansion vessel is approx. 80 %. 13 Close valve V14 and open valve V1, V11 and V15 (in case it has not been opened yet). 14 Open the priming plug on the pump house(s) (see Figure 3-1) and vent the pump(s). Close the plug again.
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Figure 3-1 Pump with Priming Plug 15 Close the disconnected terminals X2:22 to X2:27 16 Install a temporary jumper. Disconnect the connector X21 from IOEC board 1. Connect a jumper (cross-section 1 mm2) between X21-1 and X21-3 of connector X21. Plug the connector X21 back into IOEC board 1.
Note: The temporary jumper must be removed before the drive resumes operation. 17 Close the motor protection switch -Q11. 18 Check the level in the expansion vessel. If the level drops below 10% stop the pump and top up water. Danger: High voltage! High voltage can cause physical injury and death. The auxiliary supply has to be turned off before starting work at terminal X10. 19 Check the system pressure. If the pressure remains below trip level (2 bar) the rotation of the pump is not correct. In this case, the rotation of the pump must be reversed by changing two phases on the terminal -X10. 20 In case of a single pump WCU run the pump for 30 minutes to vent the drive and proceed with step 25.
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Chapter 3 - Starting up the Cooling System 21 In case of a redundant pump install a temporary jumper.
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Disconnect the connector X22 from IOEC board 1. Connect a jumper (cross-section 1 mm2) between X22-1 and X22-3 of connector X22. Plug the connector X22 back into IOEC board 1.
22 Let the first pump run for 10 minutes and then turn off Q11. 23 Switch on Q12. 24 Run the second pump for 30 minutes to vent the cooling system. 25 Close valve V11 and fill up the expansion vessel according to step 11 to step 13. 26 Close valve V12. 27 Disconnect the hose. 28 Remove the temporary jumper (step 16 to step 21) 29 In case of a redundant pump close Q11. 30 Reset the alarm. After filling the cooling circuit, the conductivity value might not be in the permitted range (conductivity alarm level: 0.5 S/cm, conductivity trip level: 0.7 S/cm). If this is the case, an auto-cooling sequence is started. For more information refer to Appendix H Signal and Parameter Table.
3.3
Adding Water to the Cooling System

If the level in the expansion tank is below 80 %, the cooling circuit must be topped up with additional water via valve V14. Use cooling water as specified in section 3.2 Filling the Cooling System. Cooling water can be added, while the ACS 1000 is in operation, provided the conductivity is below 0.4 S/cm. Note: When filling cooling water while the ACS 1000 is in operation, the conductivity will rise due to the high conductivity of the added water. Using deionized water is recommended. Fill the water in slowly to avoid a trip.
Warning: When the drive is in operation, voltages are present in the control section. Do not touch any live circuitry!
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1 2 3 4
Chapter 3 - Starting up the Cooling System Connect the filling hose to the ISO-R1/2 connector of valve V14. A pressure of approx. 1 to 2 bar is required for filling water into the circuit. Using a small pump might be necessary. Close valve V11. Open valve V14 and start the filling.
Note: When filling cooling water while the ACS 1000 is in operation, the drive may trip on a conductivity fault. Fill the water in slowly to avoid a trip.
Note: Filling rate less or equal 2 l/min.
5 6 7 8
Stop the filling after about 5 l of water have been added. Close valve V14. Open valve V11. After the conductivity is down to 0.4 uS/cm again, repeat steps 3 to 7. Stop the filling when the water level in the expansion vessel is approximately 80%. Remove the hose.
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Chapter 4 Draining the Cooling System
Warning: In case glycol is used in the cooling water refer to section Cooling Water with Anti-Freeze, page 12 for safety information.
1 2
De-energize the ACS 1000 according to Chapter 8 Operation, De-energizing the ACS 1000. Switch off the motor protection switch(es) -Q11/( -Q12) of the pump(s) to prevent the pumps from being switched on accidentally.
Caution: Do not run the pumps if the cooling circuit is empty, not even for a short time. If a pump runs dry the pump seals will be damaged immediately. 3 4 Remove the fastening screws of the swing frame and open it by pulling strongly. Connect a hose (long enough to reach out of the drive) to the drain valve located inside the inverter section at the bottom (ISO G ). Open valve V12. Open the drain valve and drain the inverter. A pump can be used to speed up the procedure. 7 8 9 Open V80 / (V81) to drain the water cooling unit. Approx. water quantity to be expected:7-8 liter. Close the valves and remove the hoses. Close the converter swing frame and remount the fastening screws.
5 6
Note: So far, the converter has only been drained for repair purposes. To drain the converter completely (for storage purposes) contact your ABB representative.
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Chapter 4 - Draining the Cooling System
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Chapter 5 Checking Actual Values
It is recommended to record the values of conductivity, water temperature and pressure regularly to determine when water has to be added or the ion exchange resin renewed.
Note: Actual values can be monitored while the ACS 1000 is in operation
Note: Water conductivity and pressure depend on the water temperature. Only values registered at the same temperature should be compared.
Warning: When the drive is in operation voltages are present in the control units. Do not touch any live circuitry!
5.1
Water Conductivity
The actual value of the water conductivity (displayed in S/cm) can be read on the control panel.
Reading the Conductivity on the Control Panel
Select the Actual Display mode on the control panel (refer to the Users Manual, Chapter 5 Parameter Viewing and Editing and Control Panel Functions, Actual Signal Display Mode). Select parameter group 4 ACTUAL SIGNALS. In group 4, select actual signal 04 InvWtrConductivity. The conductivity should be below 0.5 S/cm. If the conductivity exceeds the alarm threshold of 0.5 S (see parameter 190.09), the control panel displays the alarm message WtrConduct. If the conductivity exceeds the trip threshold of 0.7 S (see parameter 190.10), the drive shuts down and the panel displays the message WtrConduct.
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Chapter 5 - Checking Actual Values
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5.2
Water Pressure
The actual value of the water pressure (displayed in bar) can be read on the control panel.
Reading the Water Pressure on the Control Panel
Select the Actual Display mode on the control panel (refer to the Users Manual, Chapter 5 Parameter Viewing and Editing and Control Panel Functions, Actual Signal Display Mode). Select parameter group 4 ACTUAL SIGNALS. In group 4, select actual signal 03 InvWtrCoolPressure. The pressure is displayed in bar. The reaction of the ACS 1000, if the water pressure decreases below the trip threshold of 1.5 bar (see parameter 190.12), depends on the number of pumps: If the ACS 1000 is equipped with two pumps, the control panel displays the alarm WtrPressure and the second pump is switched on. If the water pressure does not increase above the trip threshold after a programmable time, the drive will trip. If the ACS 1000 has only one pump, the control panel displays the alarm WtrPressure. If the water pressure does not increase above the trip threshold after a programmable time, the drive shuts down.
5.3
Water Temperature
The actual value of the water temperature (displayed in C) can be read on the control panel. 1 Select the Actual Display mode on the control panel (refer to Chapter 5 Parameter Viewing and Editing and Control Panel Functions, Actual Signal Display Mode). Select parameter group 4 ACTUAL SIGNALS. In group 4, select actual signal 02 InvWtrCoolTemp. The temperature is displayed in C. If the temperature exceeds the alarm threshold (see parameter 190.6), the control panel displays the alarm message WtrTemp. If the temperature exceeds the trip threshold (see parameter 190.7), the drive will trip and the control panel displays the trip message WtrTemp.
Reading the Water Temperature on the Control Panel
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5.4 Water Level
The water level can be checked while the ACS 1000 is in operation. 1 Check the water level at the level sight-glass located at the front of the expansion tank. The water level should be approximately 80%. 2 If the water level is below 80 % the cooling circuit must be topped up. Refer to section 3.3 Adding Water to the Cooling System.
The minimum water level is monitored by level switch B10. If the switch is activated, the drive shuts down.
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Chapter 6 - Tightening Torques and Threaded Connections
6.1 Tightening Torques
Table 6-1 Tightening Torque for Pumps Part Hex. head bolt Pump fixing bolts 1) see Figure 6-1
2)
Part No. 1) 93
Thread Diameter M6
Tightening Torque 2) 5 - 6 Nm 21-26 Nm
for unlubricated threads
5 6 Nm 21 26 Nm
Figure 6-1
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Chapter 6 - Tightening Torques and Threaded Connections Table 6-2 Tightening Torque for Coupling Part Hex. nut Thread Diameter M10 Tightening Torque 30 35 Nm
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Table 6-3 Tightening Torque for Flanges DN Hexagon Screw

1
Nut
2
Washer (D x d x t)
3
Gasket (D x d x t)
4
Tightening Torque 24 - 33 Nm 60 - 80 Nm 60 - 80 Nm 60 - 80 Nm 60 - 80 Nm 60 - 80 Nm 60 - 80 Nm
25 32 40 50 65 80 100
M12-55 M16-65 M16-65 M16-70 M16-70 M16-75 M16-80
M12 M16 M16 M16 M16 M16 M16
24 x 13 x 2 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3
73 x 40 x 1.5 84 x 48 x 1.5 92 x 57 x 1.5 107 x 66 x 1.5 128 x 83 x 1.5 144 x 97 x 1.5 162 x 125 x 1.5
Figure 6-2
6.2
Sealing off Threaded Connections without O-rings and Gaskets

A sealant such as Loctite 755 and Loctite 401 activator spray is recommended to ensure a leak proof joint between stainless steel to stainless steel connections.
Thread tape is recommended to seal off: stainless steel to plastic connections plastic to plastic connections.
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Chapter 7 Cooling Pump Motor
Caution: Disconnect the power supply of the pump before starting work on a pump
Switch of and lock the corresponding motor starter Q11 is assigned to pump 1 Q12 is assigned to pump 2
Note: If equipped with a second pump, maintenance and repair work on a pump/motor can be carried out during operation of the ACS 1000.
7.1
Removing and Installing a Cooling Pump

It is recommended to leave the pump house connected to the piping and remove only the motor part. The impeller and the mechanical seal are mounted on the motor shaft.
7.1.1
Removing the Pump in a Single Pump WCU

1 2 De-energize the ACS 1000 according to Chapter 8 Operation, De-energizing the ACS 1000. Unhook the 2 rubber mounting belts (see Figure 7-1) and carefully lift the ion exchange vessel out of the cabinet. The vessel does not have to be disconnected from the tubes, since they are long enough.
Figure 7-1 Removing Ion Exchange Vessel 3 Switch off the motor protection switch -Q11 of the pump. The motor protection switch is located in the control section. Make sure that it cannot be switched on by accident.
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Chapter 7 - Cooling Pump Motor
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Pump 1
Motor protection switch (-Q11, -Q12) any of the 4 positions K11/K12
Pump 2 (optional)
Figure 7-2 Location of Motor Protection Switches and Pumps 4 5 Close valve V1, V5, V11 and V15. Secure the valves from being opened unintentionally. Drain pump P1 through the drain plug on the lower side of the pump house (not visible in Figure 7-3) Approx. water quantity to be expected: 4 liters. Priming plug (drain plug is situated below) Pump fixing
Figure 7-3 Pump with Priming Plug and Fixing Bolts
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6 7 8 Remount the drain plug.
Open the motor terminal box and check the pump terminals for voltage. Disconnect the power supply cable in the motor terminal box (see Figure 7-4).
Note: Mark the cables for later identification.
Loosen the metal clamp ring of the pump house (see Figure 7-4).
Metal clamp
Motor terminal box
Figure 7-4 Motor Terminal Box and Power Supply 10 If necessary, fasten the pump motor in a suitable way to prevent it from falling down. 11 Loosen the four fixing bolts of the pump (see Figure 7-3). 12 The motor, including impeller and the mechanical seal can now be pulled from the pump house out of the converter cabinet.
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Figure 7-5 Pump removed from Pump House
Note: Be careful not to damage the O-ring between the pump house and the motor. Do not use sharp-edged tools. Use a suitable lifting device.
Note: The pump motor might be stuck and is therefore hard to remove.
7.1.2
Remounting the Pump in a Single Pump WCU

1 2 Move the pump back into the water cooling cabinet Slide the impeller into the pump house (moisten the O-ring with water). Be careful not to damage the O-ring between the pump house and the motor. Remount the four pump fixing bolts and tighten them slightly by hand. Remount the ring clamp to the pump house and tighten the bolt to the final torque rate of 5...6 Nm. Tighten the four pump fixing bolts to the final torque rate of 21...26 Nm. Connect the power supply cable to the motor terminal box. Open valve V1 and V11.
3 4 5 6 7
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8 9
Chapter 7 - Cooling Pump Motor Open the priming plug on the pump house (see Figure 7-3) and vent the pump. Close the plug again when finished. Open valve V14 to release the air. Close the valve again when finished.
10 Open valve V5 and V15. 11 Open valve V12. 12 Install a temporary jumper. Disconnect the connector X21 from IOEC board 1. Connect a jumper (cross-section 1 mm2) between X21-1 and X21-3 of connector X21. Plug the connector X21 back into IOEC board 1.
Note: The temporary jumper must be removed again before the drive resumes operation. 13 Switch on the motor protection switch -Q11 (see Figure 7-2) and the auxiliary power supply (-Q1). 14 Check the system pressure. If the pressure remains below trip level (2 bar) the rotation of the pump is not correct. It must be reversed by changing two phases in the motor terminal box (refer to 7.1.5 Changing Rotation of a Pump on page 35). 15 After running the pump for 30 min. close valve V12. 16 Check for leaks. 17 Remove the temporary jumper. 18 Carefully lift the ion exchange vessel back to the cabinet and remount the two rubber belts. 19 If needed, refill cooling liquid according to section 3.3 Adding Water to the Cooling System. 20 Reset the any active alarm. 21 As soon as the conductivity is below the alarm level (0.5 S) the drive can be started again.
7.1.3
Removing a Pump in a Double Pump WCU

1 Switch off the motor protection switch of the pump to be removed -Q11 for pump 1 (upper pump) -Q12 for pump 2 (lower pump).
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The motor protection switches are located in the control section. Make sure that they cannot be switched on by accident. See also Figure 7-2.
Warning: When the drive is in operation voltages are present in the control units. Do not touch any live circuitry! 2 Unhook the 2 rubber mounting belts (see Figure 7-1) and carefully lift the ion exchange vessel out of the cabinet. The vessel does not have to be disconnected from the tubes, since they are long enough. Close valve V1/(V2). Secure the valves from being opened unintentionally (e.g. secure the handle with a tape or take it off). The pump is now isolated between valve V1/(V2) and check valve V3/(V4). 4 Drain the pump P1/(P2) through the drain plug on the lower side of the pump house (not visible in Figure 7-3). Approx. water quantity to be expected: 3 liters. Remount the drain plug again when finished. 5 6 Open the motor terminal box and check the pump terminals for voltage. Disconnect the power supply cable in the motor terminal box (see Figure 7-4).
Note: Mark the cables for later identification.
7 8 9
Loosen the metal clamp ring of the pump house (see Figure 7-4). If necessary, fasten the pump motor in a suitable way to prevent it from falling down. Loosen the four pump fixing bolts (see Figure 7-3).
10 The motor, including impeller and the mechanical seal can now be pulled from the pump house out of the converter cabinet. Note: Be careful not to damage the O-ring between the pump house and the motor. Do not use sharp-edged tools. Use a suitable lifting device.
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Note: The pump motor might be stuck and is therefore hard to remove.
7.1.4
Remounting a Pump in a Double Pump WCU

1 2 3 4 5 6 7 8 9 Move the pump back into the water cooling cabinet Slide the impeller into the pump house. Be careful not to damage the O-ring between the pump house and the motor. Remount the four pump fixing bolts and tighten them by slightly hand. Remount the clamp ring at the pump house and tighten the bolt to the final torque rate of (5-6 Nm). Tighten the four fixing bolts to the final torque rate of 21...26 Nm. Connect the power supply cable to the motor terminal box. Open valve V1/(V2). Close valve V12. Open the priming plug on the pump house (see Figure 7-3) and vent the pump. Close the plug again when finished.
The pump that has been exchanged must be vented and must therefore run for a short time together with the other pump. For this reason, the pump must be started manually according to the following procedure: 10 Depending on which pump has been exchanged one of the following two procedures must be followed: Manual start of pump 1 (by closing K11 (see Figure 7-2)): Disconnect the connector X21 (digital output DO 1.1) on IOEC board 1. Connect a temporary jumper (cross-section 1 mm2) between X21-1 and X21-3, but do not loosen X21-2.
Note: When inserting the jumper, do not loosen or disconnect the wire in terminal X21-2. If the wire is loosened or disconnected the drive will trip! Plug the connector X21 back into IOEC board 1.
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Chapter 7 - Cooling Pump Motor Manual start of pump 2 (by closing K12 (see Figure 7-2)):
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Disconnect the connector X22 (digital output DO 1.2) from IOEC board 1. Install a temporary jumper (cross-section 1 mm2) between X22-1 and X22-3.
Note: When inserting the jumper, do not loosen or disconnect the wire in terminal X22-2. If the wire is loosened or disconnected the drive will trip! Plug the connector X22 back into IOEC board 1.
Note: The temporary jumper must be removed before the drive resumes operation.
11 Monitor the system pressure and remember the value. Refer to section Water Pressure on page 22. 12 Switch on -Q11/(-Q12) to start the pump. 13 Run the pump for 10 seconds and monitor the system pressure. If the system pressure rises by 0,3 bar or more, the pump is working correctly. If the system pressure does not rise, the rotation of the pump must be reversed by changing two phases in the motor terminal box (refer to 7.1.5 Changing Rotation of a Pump on page 35). 14 Switch off -Q11/(-Q12) to stop the pump. 15 Wait for 1 minute (to avoid overloading of the external overload protection) and then start the pump again and run it for 10 seconds. 16 Remove the temporary jumper at -X21/(-X22). 17 Close -Q11/(-Q12) and reset the alarm. 18 Open valve V12. 19 Close V12 after 30 minutes. 20 Check for leaks. 21 Carefully lift the ion exchange vessel back into the cabinet and remount the two rubber belts. 22 Refill cooling liquid if needed according to section 3.3 Adding Water to the Cooling System, page 16.
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7.1.5 Changing Rotation of a Pump
1
Switch off the motor protection switch of the pump -Q11 for pump 1 (upper pump) -Q12 for pump 2 (lower pump).
The motor protection switches are located in the control section. Make sure that they cannot be switched on by accident. See also Figure 7-2.
Danger: High voltage! High voltage can cause physical injury and death.
Open the connection box in the water-cooling section and check the pump terminals 22, 23, 24 (upper pump) or 25, 26, 27 (lower pump) if voltage is still present. Change two phases of the power supply cables of the corresponding pump. In case of a single pump WCU proceed with section Remounting the Pump in a Single Pump WCU, page 31, step 14 In case of a redundant pump proceed with section Removing a Pump in a Double Pump WCU, page 34 step 13.
3 4
7.2
Lubrication
Pump and motor are maintenance-free.
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Chapter 8 Ion Exchange Resin
Note: The ion exchange resin and vessel (C2) can be replaced during operation.
Note: The changing procedure must not last longer than 30 minutes. The conductivity level could rise above trip level.
Caution: Avoid skin and eye contact with the deionizer resin. Contact may result in minor irritation. Wear protective clothing including rubber gloves and safety goggles. Refer to the Safety Data Sheet 8-1000-193 at the end of this manual.
!
8.1
Warning: When the drive is in operation voltages are present in the control units. Do not touch any live circuitry!
Removing the Ion Exchange Vessel

Distributor head
Upper distributor
Mix bed resin
Lower distributor
Figure 8-1 Ion Exchange Vessel
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Chapter 8 - Ion Exchange Resin 1 2 Close valve V11 and V15.
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Disconnect the 3 hoses on top of the vessel (1 in Figure 8-2), by pressing the outer ring in the coupling with two fingers towards the vessel and pulling the hose away from the vessel. Mark the hoses for easy identification when refitting.
Note: Do not use force. If the hose gets stuck, push it first towards the coupling and then out. Note: Some residual water may spill out of the tubes.
3 4
Unhook the 2 rubber belts (2 in Figure 8-1) and carefully move the vessel out of the cabinet. Cover the openings of the hose couplings appropriately to prevent dirt from entering. 3 3 1 Out 4 In
Resin
Figure 8-2 Removing Tubes from Ion Exchange Vessel 5 Dismount the distributor head (3 in Figure 8-1) by unscrewing it from the vessel. The head is sealed with an O-ring. Hand force should be sufficient to remove the head. Slowly pull the distributor head and tube (3 and 4 in Figure 8-1) out of the vessel. Clean the tube by rinsing it with water.
6 7
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8.2 Mounting a New Exchange Vessel
1 2 Dismount the distributor head of the spare vessel according to step 5 and step 6. Slowly push the distributor head and tube of the used vessel with the hose couplings into the spare vessel.
Note: Hand force should be sufficient to tighten the head.
3 4
Lift the ion exchange vessel back to the cabinet and fix it with the two rubber belts. Reconnect the 3 hoses to the vessel in the correct order (to be pushed in approx. 10 mm).
Note: IN and OUT is marked on the distributor head. The hose from the distributor head to the filter Z2 must be connected to OUT. 5 Carefully open valve V11.
Note: The pump pressure can drop to trip level if V11 is opened too fast. 6 7 Check for leaks. Open valve V15.
Refill cooling liquid if needed according to 3.3 Adding Water to the Cooling System, page 16.
8.3
Disposal of Ion Exchange Vessel

Dispose of the vessel and the exhausted resin according to local regulations. Refer to the Safety Data Sheet 8-1000-193 or consult your local ABB service organization.
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Chapter 8 - Ion Exchange Resin
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Chapter 9 9.1 General Description
The heat exchanger consists of a number of pressed heat transfer plates. Between the plates elastomer gaskets are applied and seal off the liquid from the atmosphere and separate the liquid. A flow channel is created by the gasket and the gap between two plates. The plates are made out of stainless steel or titanium. A frame with tightening bolts keeps the plates in the correct position, the frame plate with holes for the connections at the front and the pressure plate at the back. The frame is made either of carbon steel or stainless steel. The connectors are mounted on a stainless steel plate, which is located between the first channel plate and the frame plate. See Figure 9-1 for numbering and location of the connectors. An outer current flow is used, causing the two medias to flow in opposite directions. Media 1 Media 2 inlet S3 > outlet S4 inlet S1 > outlet S2
Plate Heat Exchanger
Figure 9-1 Heat Exchanger
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Chapter 9 - Plate Heat Exchanger
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The plates, which are corrugated in a herring bone pattern, form a single-pass arrangement. The water flow is evenly distributed across the width of the channel by means of flow directors in the port inlet areas. The thin channel plate in combination with the turbulent flow gives the efficient heat transfer coefficient. Start Plate All four port holes are sealed with gaskets. The liquid passes through this plate which does not form a channel on its front side.
Figure 9-2 Start Plate and Channel Plate
Channel Plate
When the herring bone pattern points down, the ports to the left are open and create a parallel channel across the heat transfer surface. Since every second plate is inverted the primary media is guided into every second channel and the secondary media is guided into the channels in between. The last channel plate has no holes.
Figure 9-3 Single-Pass Arrangement
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9.2 Removing the Heat Exchanger
Note: The weight of the heat exchanger is less than 15 kg.
Note: Let the heat exchanger cool down before starting to work. Do not work on the heat exchanger as long as its temperature is above 50C. 1 2 De-energize the ACS 1000 according to Chapter 8 Operation, Deenergizing the ACS 1000. Switch off the motor protection switch(s) -Q11/(-Q12) of the pump(s). The motor protection switch is located in the control section. Make sure that it cannot be switched on by accident.
Pump 1
Motor protection switch (-Q11, -Q12) any of the 4 positions K11/K12
Pump 2 (optional)
Figure 9-4 Location of the Motor Protection Switches and Pumps 3 Close valve V1, (V2), V5 and V15. Secure the valves from being opened by accident.
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Drain the heat exchanger. Water cooling units with one pump: drain through the drain plug of pump P1. The drain plug is on the lower side of the pump house. Water cooling units with two pumps: drain through valve V81. Approx. water quantity to be expected: 4 liters. Open V14 to let air into the pipes. Remount the drain plug/V81 and close V14 when finished. Priming plug (drain plug is located below)
Figure 9-5 Pump with Priming Plug and Fixing Bolts 5 6 7 8 9 Close of the raw water supply and drain through V82. Loosen the clamp of the heat exchanger. Loosen the fitting at the heat exchanger terminals S1, S2 and S4. Loosen the connecting pipe to B14 at the fitting of B14. Remove the heat exchanger.
If the heat exchanger will be replaced take off the fittings and mount them on the new unit.
9.3
Start-up
When starting-up a revised plate heat exchanger with gaskets, the pressure and water flow must be increased slowly to operating level. 1 2 3 4 Make sure that the dimension TM (see Figure 9-8) is correct according to the label on the backside of the heat exchanger. Close V82. Open the valve on the raw water discharge side (outlet) Slowly open the valve on the raw water supply side.
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5 6 7 8 9 Check for leaks. Open the raw water valves fully. Open valve V5.
Chapter 9 - Plate Heat Exchanger Close the valve on the raw water discharge side about 90%.
Close valve V1 and (V2) about 90%. Disconnect the connector X21 from IOEC board 1. Connect a the jumper (cross-section 1 mm2) between X21-1 and X21-3 of connector X21. Plug the connector X21 back into IOEC board 1.
10 Install a temporary jumper.
Note: The temporary jumper must be removed before the drive resumes operation. 11 Close the motor protection switch Q11. 12 Slowly open valve V1. 13 Close valveV5 about 90%. 14 Check for leaks. 15 Switch off Q11 and remove the temporary jumper. 16 Open valves V5 and V15.
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9.4
Disassembling the Plates

1 2 Unscrew the center nut and remove the bolt. Clamp the heat exchanger in a vice or similar before removing the outer bolts. Thus, the heat exchanger will be compressed and cannot expand due to swelling gaskets.
Figure 9-6
Note: Do not punch the bolts through the plate pack. The heat transfer plates can be damaged. 3 Remove the outer tightening bolts. Pull them out alternately at a maximum of 2 to 3 mm at a time to keep the plate pack in parallel. A hydraulic hand pump will facilitate this. 4 Disassemble the plate pack. Observe the following: Keep the unit lying on the pressure plate. Keep frame and pressure plate as parallel as possible when removing the plates. Try to keep the plate pack together since the gaskets are not glued. Remove one plate at a time. The gasket of the start plate is made of two half channel plate gaskets. Put aside the two halves to copy them later, if necessary. The ring gasket on each plate, which seals the hole for the center bolt, can only be placed in the groove in one way. Therefore, the gasket of the start plate has to be trimmed with
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Chapter 9 - Plate Heat Exchanger a pair of scissors to fit into the gasket groove. Make a copy of the gasket of the start plate.
9.5
Assembling the Plates

When stacking the plates observe the following: Plates with a gasket always face the frame plate, see Figure 9-8. The ring gaskets in the middle of the heat transfer surface must be correctly positioned in the gasket groove. The herring bone pattern of the start plate must point into the same direction as the arrow on the front of the frame plate. The direction of the pattern of the following plates points into the opposite direction than the proceeding plate.
Figure 9-7 Front Mark 5 Compress the unit (e.g. using a vice or a screw clamp) before inserting the bolts. Insert the outer bolts first and the centre bolt last Note: If a bolt gets stuck do not force the bolt through the plate pack but screw it in. Otherwise the heat transfer plates can be damaged. 6 Tighten the screws alternately. Measure the dimension TM (see Figure 9-8) regularly. When TM is 10 to 20 mm more than stated on the label, check TM in shorter intervals. Note: The performance of the heat exchanger and the service Iife of the gaskets depend on how careful the screws are tightened. If the heat exchanger leaks after assembly, this is caused by misaligned gaskets or other damages, even if the dimension TM has been maintained. The leakage cannot be stopped by further tightening the screws. The unit must be disassembled again to examine gaskets and plates and to possibly adjust or replace parts.
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Figure 9-8 Dimension TM
9.6
Leakage
No measures have to be taken if the heat exchanger leaks when the unit is cold and does not leak at normal operating temperatures. Tightening of the screws is necessary if leakage occurs at normal operating conditions. Note: The dimension TM is the absolute limit when tightening the screws! When TM has been reached try to locate the leakage and remove the affected plates. An even number of 4-hole channel plates can be removed without replacing them. The capacity of the heat exchanger will only be slightly reduced. Gaskets have to be replaced on all leaking plates. It is important that frame and pressure plates are lined up in parallel, otherwise, this could be the cause of the leakage.
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9.7 Cleaning
The heat exchanger must be cleaned if the heat exchanger cannot maintain the temperature and/or the pressure drop increases too much. Open the heat exchanger according to section Disassembling the Plates, page 46. Since the gaskets are not glued the plates can be cleaned easily. Use a fibre brush and water. DO NOT use a steel brush or steel wool. Greasy deposits (e.g. oil) are removed with a soft brush and paraffin (Kerosene). Organic deposits are removed with a soft brush and an alkaline detergent (2% caustic soda, 50C). Precipitates of calcium components are removed with either: 10% nitric acid (HNO3) or 2% 2% 2% 5% sodium polymetaphosphate, 50C sodium trimetaphosphate, 50C EDTA
After cleaning, the heat exchanger should be thoroughly flushed with clean water.
Caution: Caustic soda and concentrated nitric acid can cause serious injuries of skin and mucous membranes. Use them with great care. Always put on protective goggles and protect the hands with rubber gloves.
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Chapter 10 - Replacing Filter Cartridge of Filter Z2
Note: The filter Z2 can be changed while the ACS 1000 is in operation!
Note: The changing procedure must not last longer than 30 minutes. The conductivity level could rise above trip level.
Warning: When the drive is in operation voltages are present in the control units. Do not touch any live circuitry! See List of Components of the water cooling system for information on component data. The filter cartridge has a limited life. It is recommended to replace the cartridge when the deionizer vessel is serviced or changed.
Figure 10-1 Filter
1 2
Close valve V11 and V15. Unscrew bottom of the housing. Some residual water may spill out. Remove large O-ring or gasket, and set aside.
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Chapter 10 - Replacing Filter Cartridge of Filter Z2
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Figure 10-2 Removing Micro Filter
Note: Although it should be possible to unscrew the filter housing by hand, oil filter pliers can be helpful 3 4 5 6 7 Discard used cartridge. Rinse out bottom of housing. Wipe clean O-ring of old lubricant. Lubricate O-ring or gasket with clean petroleum jelly (vaseline) or silicone lubricant. Place O-ring back into groove and smooth into place with finger (or place gasket on rim of bottom of housing). Insert new cartridge over standpipe in bottom of housing.
Note: Cartridges with tapered ends need to be specifically installed with the tapered end towards the threads of the housing. 8 9 Screw bottom of housing onto cap and hand tighten. Do not overtighten. Make sure cap standpipe slips into cartridge. Carefully open valve V11.
Note: The pump pressure can drop to trip level if V11 is opened too fast. 10 Check for leaks and then open valve V15. 11 Open valve V12. 12 Close V12 after 30 minutes.
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Chapter 11 - Cleaning Strainer Z1
Note: The strainer can only be serviced after the ACS 1000 has been shut down. See List of Components of the water cooling system for information on component data. 1 2 3 4 De-energize the system according to the ACS 1000 Users Manual, Chapter 8 Operation, De-energizing the ACS 1000. Turn off the raw water supply. Open V82 to drain the raw water pipe and close the valve again, when finished. Unscrew and remove the strainer. Some residual water may spill out.
Figure 11-1 Removing Strainer 5 6 7 8 Clean and re-mount the strainer. Turn on the raw water supply. Check for leaks. Restart the ACS 1000 as described in the ACS 1000 Users Manual, Chapter 8 Operation, De-energizing the ACS 1000.
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Chapter 11 - Cleaning Strainer Z1
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Chapter 12 - Conductivity Sensor B12
Note: The conductivity sensor can only be serviced after the ACS 1000 has been shut down. See List of Components of the water cooling system for information on component data.
12.1
Removing and Installing the Sensor
Figure 12-1 Conductivity Sensor
Removing the Sensor
1 2
De-energize the ACS 1000 according to Chapter 8 Operation, De-energizing the ACS 1000. Unhook the 2 rubber mounting belts (see Figure 12-2) and carefully lift the ion exchange vessel out of the cabinet. The vessel does not have to be disconnected from the tubes, since they are long enough.
Figure 12-2 Removing Ion Exchange Vessel.
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Chapter 12 - Conductivity Sensor B12 3
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Switch off the motor protection switch(es) -Q11/(-Q12) of the pump(s). The motor protection switches are located in the control section. Make sure that a switch cannot be switched on by accident.
Pump 1
Motor protection switch (-Q11, -Q12) any of the 4 positions
Pump 2 (optional)
Figure 12-3 Location of Motor Protection Switches and Pumps 4 5 Close valve V1, V5 and V15. Secure the valves from being opened unintentionally. Drain approx. 1 liter of water. Water cooling units with one pump: drain through the drain plug of pump P1. The drain plug is on the lower side of the pump house. Water cooling units with two pumps: drain through valve V81. Open V14 to let air into the pipes. Remount the drain plug and close V14 when finished. 6 7 8 Loosen the nut by hand and remove the conductivity meter. Disconnect the electric cable. Clean the sensor.
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Chapter 12 - Conductivity Sensor B12 Stainless steel conductivity measuring cells do not require special maintenance. However, the electrodes must always be kept in clean condition. In case of contamination, they can easily be cleaned with slightly acid solutions or solvents. Use a clean cotton cloth or similar for cleaning.
!
Remounting the Sensor
Caution: Do not use abrasive material in contact with the electrode surface and avoid contact with bare hands. It is recommended to use rubber gloves while cleaning the sensor.
1 2 3 4
Reconnect the cable Remount the conductivity meter and tighten the nut by hand. Open valve V1, V5, V12 and V15 Install a temporary jumper. Disconnect the connector X21 from IOEC board 1. Connect a jumper (cross-section 1 mm2) between X21-1 and X21-3 of connector X21. Plug the connector X21 back into IOEC board 1.
Note: The temporary jumper must be removed again before the drive resumes operation. 5 6 7 8 9 Switch on the motor protection switch -Q11 (see Figure 7-2) and the auxiliary power supply (-Q1). After running the pump for 30 min. close valve V12. Check for leaks. Remove the temporary jumper. Carefully lift the ion exchange vessel back to the cabinet and remount the two rubber belts.
10 If needed, refill cooling liquid according to section 3.3 Adding Water to the Cooling System. 11 Reset the any active alarm.
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12.2
Operation
The operation of the transmitter is organized in three levels:
Display Conductivity, temperature and output current are indicated in this level. The HOLD function can be accessed in this menu. Parameter Definition All the necessary adjustments, such as language, technical units, cell constant, temperature compensation factor, 4...20 mA measuring range, relay and filter are set in this level. Test A conductivity value can be simulated in this menu, allowing testing of a process in dry condition. The non-compensated conductivity of the transmitter is also displayed in this menu. The basic settings (Offset, Span) of the device can be changed in this menu.
The conductivity meter faces to the right. Therefore, a torch and a mirror is needed to read the display.
12.2.1
Transmitter Operating and Control Elements
Adjustment of numeric values Menu navigation Digit selection
Acceptance of selected or adjusted parameter Relay 2: contact closed Relay 1: contact closed
Figure 12-4 Operating and Control Elements
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12.2.2 Operation Mode Display
The following units are indicated on the operation mode display: Conductivity in the required technical unit. If 0000 or 9999 is displayed, input value is too low, respectively too high. Change unit or decimal point. Temperature in C or F. If "----C or ----F is displayed, temperature is out of range (-50+150) or connection with Pt 1000 is interrupted. Output signal 4...20 mA proportional to conductivity according to the selected measuring range. HOLD function. If this function is activated, the transmitter generates an output current corresponding to the last value before this option was entered. The relays are blocked in their last state. This allows to clean the electrode without interruption of the process. The display in the operation mode is flashing and there is no access to the parameter definition or the test menu, as long as the HOLD function is activated.
To deactivate the HOLD function, enter again HOLD option and confirm HOLD NO.
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simultaneously for 5 seconds. Selection between English, German, French or Italian Selection of engineering units for conductivity and temperature Entering the sensor cell constant Selection of temperature compensation mode (linear, automatic or Teach-in function Determination of 4...20 mA measuring range
12.2.3
Calibration Mode
Press
The following adjustments are set in the calibration mode display:
Dampening selection. Ten different steps are available Back to the operation mode and storage of new parameters
Language The selected language is confirmed by the ENTER key and becomes immediately active.
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Engineering Units
The conductivity can be displayed in any engineering unit with 0, 1, 2 or 3 decimal points but always with 4 digits.
Note: Setting for ACS 1000: S; DECPT 2, CELCIUS.
Cell Constant
The cell constant of the sensor is entered in this mode. This value is indicated on a sticker on the enclosure. The cell constant is an average value over the hole measuring range. It can be readjusted as follows:
K-new = (Cond. reference I Cond. 8225) x K-real.
The reference conductivity can be given either by buffer solution or reference device. If K=00.0000 the device is blocked and the displayed conductivity is equal to zero.
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Temperature Compensation Coefficient
The transmitter offers three different modes for temperature compensation Linear compensation The user enters one value for a compensation over the entire conductivity and temperature range (e.g. 2.1%/C). For no compensation enter 0.0%/C. Note: Setting for ACS 1000: 0.0%/C (no compensation).
Compensation with memorized coefficient (AUTO) Teach-in function
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Output Current
The cell constant of the sensor is entered in this mode. This value is indicated on a sticker on the enclosure and on the sensor cable. In this mode, the conductivity measuring range is entered, which corresponds to the output current of 420 mA. E.g. 0 to 10 mS/cm corresponds to 4...20 mA. The beginning of the measuring range might be larger than the end of it, e.g. 0 to 10 mS/cm corresponds to 204 mA (inverted output signal). The adjustments (engineering unit and decimal point) which have been made for the conductivity display are valid.
Entering lower limit of measuring range
Entering upper limit of measuring range
Note: Setting for ACS 1000: 0.05...2 S/cm = 420 mA.
Filter Function
The damping set in this sub-menu prevents display and output current fluctuations. There are 10 steps available. However, the first step (FILTER 0) has no damping function.
Note: Setting for ACS 1000: FILTER 0.
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simultaneously for 5 seconds. Zero point compensation (4 mA) Span compensation (4 mA) Display of non-compensated conductivity Entering the conductivity to be simulated The outputs are reacting according to this input Returning to the operation mode and storing new parameters for OFFSET and SPAN. If one of the two values is wrong, the device displays OFFSET and new values must be entered.
12.3
Menu Test
To test the menu, press
The following compensations and controls can be set in the menu:
12.3.1
Offset Compensation
In this mode, the user has the possibility to correct the basic setting for 4 mA. An ammeter is required. The transmitter generates 4 mA, if the ENTER key is pressed while OFFSET is displayed. If this value is incorrect it can be corrected by entering the measured value.
Entering the measured value
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12.3.2 Span Compensation
In this mode, the user can change the basic setting for 20 mA. The procedure is identical to the Offset Compensation. The transmitter generates 20 mA, if the ENTER key is pressed while SPAN is displayed. If the displayed value is incorrect it can be corrected by entering the measured value.
Entering the measured value
12.3.3
Display of non-compensated Conductivity

The non-compensated conductivity is displayed in this mode. Press the ENTER key to change the display. The point behind the unit distinguishes the display from the normal function mode
12.3.4
Conductivity-Simulation
A conductivity value can be simulated in this menu allowing the user to test his system in dry conditions. The simulated value influences the current output and the relays. The units and decimal points as selected in the sub-menu UNIT are active.
Enter the conductivity value
The simulation remains active until the user enters another sub-menu.
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12.4
Testing the Sensor

The proper functioning of the conductivity measuring circuit can be verified by connecting a 50 k resistor to the sensor and by comparing the calculated conductivity value with the displayed value. With this method, the complete measuring circuit including the control parameters is checked. 1 2 3 Remove the conductivity transducer following section Removing the Sensor page 55 until step 6. Read off the conductivity value on the display of the transducer. With a dry and clean sensor, the displayed value must be 0.0 S/cm. Connect a 50 k resistor between the two electrodes of the sensor. Sensor seen from below
50 k 4 Calculate the conductivity value according to the following formula:

1 S K cm 10 6 Conductivity = cm R []
K = cell constant see label attached to the transducer 5 Compare the calculated value with the values shown on the transducer display and the control panel of the converter. The value shown on the transducer and control panel display may differ from the calculated value by the measuring error of the transducer. Measuring error 6 typical: 3 % of measured value max: 5 % of measured value Remount the transducer following section Remounting the Sensor page 57.
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Chapter 13 - Pressure Transmitter B11
Note: The pressure transmitter can only be worked on after the ACS 1000 has been shut down. See List of Components of the water cooling system for information on component data.
Figure 13-1 Pressure Transmitter The pressure transmitter is maintenance-free. If problems occur system components such as pipes, valves, electrical wiring, etc. should be checked as well. 1 2 Drain the cooling system according to Chapter 4 - Draining the Cooling System. Disconnect the sensor and remove it from the drive.
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Chapter 13 - Pressure Transmitter B11
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Chapter 14 - Temperature Sensor B13
Note: The temperature sensor can only be checked or replaced after the ACS 1000 has been shut down. See List of Components of the water cooling system for information on component data.
Retaining screw
Figure 14-1 PT 100 Temperature Sensor 1 2 De-energize the ACS 1000 according to Chapter 8 Operation, Deenergizing the ACS 1000. Remove the retaining screw (see Figure 14-1) and pull the temperature sensor out of the pipe.
Note: The pipe can remain in the drive. If the new head does not fit in the old pipe, the pipe must be mounted, therefore the cooling unit must be drained as described in section 12.1.
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Chapter 14 - Temperature Sensor B13
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Appendices
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Appendices
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ACS 1000 Medium Voltage AC Drives 315 to 5000 kW 400 to 6700 hp

Operation and Maintenance Manual

Document No.: Issued:

3BHS204366 ZAB E01 Rev. 20.06.2004

ABB Switzerland Ltd. All Rights Reserved.

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

Raw Water Connections

Top entry Figure 2-1 Raw Water Entries 1

Figure 2-2 Duct Plates

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Enter flexible hoses

Figure 2-3 Connecting the Water Hoses Customer side piping

Figure 2-4 Connecting the Water Hoses Customer side piping

Cut hoses to length

Figure 2-5 Connecting the Water Hoses

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

Customer side piping

Connect hoses to inlet

Figure 2-7 Nipple Dimensions

Hose Connection Side Entry

Flange Connection (Option)

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Upward bend Figure 2-8 Flange Connections

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

Checks before Start-up

Filling the Cooling System

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Chapter 3 - Starting up the Cooling System

Table 3-1 Drinking Water Specification

Cooling Water with AntiFreeze

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Filling the System

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

Chapter 3 - Starting up the Cooling System

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Adding Water to the Cooling System

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit

Note: Filling rate less or equal 2 l/min.

ACS 1000 Water Cooling Unit

3BHS204366 ZAB E01Rev.-

Chapter 3 - Starting up the Cooling System

3BHS204366 ZAB E01Rev.-

ACS 1000 Water Cooling Unit