Professional Documents
Culture Documents
ACS 6000
Medium Voltage Drives
3 to 27 MVA
Issued: 26-01-2007
General Information
Contact Information
Related Documentation
Tools and Personal Equipment
Contact Information
Related Documentation
Document
Title
Number
The toolbox provided by ABB contains all necessary tools and equipment
for installation, commissioning and maintenance of the converter. The
content of the tool sets is described in detail in document Tool Sets for
Installation, Commissioning and Troubleshooting, document no.
3BHS130246:
In addition to the toolbox, the following items are recommended for
preventive maintenance:
• Multimeter with test wires and clips, for example Fluke 87
• 5 kV Megger, for example AVO BM11D
• Fiber-optic cable tester, such as
• Tempo 253B Led source (set to 660nm, no modula-
tion), 10ZP Adapter
Tempo 557B Power Meter (set to 660nm, dBm),
10ZP Adapter
• Photom 205A – Optical Power Meter, Haktronics Co.,
Ltd
• LEONI Optical Power Meter
LEONI Optical Sender ZXXX-TS0
Fiber Optic GmbH, 96524 Neuhaus-Schierschnitz,
ZXXX-TM0
• Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical
transmitter / receiver, optical cables and DriveWindows or DriveDebug
• Antistatic vacuum cleaner (for example SV-497 ABF - VACUUM 3M
220V from 3M) for cleaning of printed circuit boards
• Antistatic brush for cleaning of printed circuit boards
• Cloths and brushes for general cleaning
• Safety glasses and dust respirator
DANGER!
Indicates an imminent hazardous situation. If not observed, it will lead to
death or life-threatening injury.
WARNING!
Indicates a potentially dangerous situation. If not observed, it could result
in death or life-threatening injury.
CAUTION!
NOTICE!
Indicates important information related to personal safety and protection
of property.
IMPORTANT!
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 1-1 (2)
Chapter 1 - Safety ABB
1-2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB
Chapter 2 - Inspection and Maintenance
IMPORTANT!
Check visually the converter and the ambience. Pay attention to the
following:
• Dumpness, water drops, puddles inside the converter.
• Permitted range of ambient air temperature and humidity of the
converter.
A digital temperature/hygrometer is provided in the tool box for
verification.
The air temperature range is specified on the name plate of the
converter.
• Dust built-up inside the converter room and inside the converter.
• Appropriate fastening of cables and wires and connection of cable
shields and screens.
See Converter User’s Manual, Chapter Electrical Information for
information.
• Integrity of cable insulation.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-1 (20)
Chapter 2 - Inspection and Maintenance ABB
The outer jacket of a cable must not be damaged.
• Correct type of signal and power cables.
See applicable cable specifications for reference.
• Signs for overheated components, wires, cables or busbars.
• Corrossion on electronic boards, connectors or busbars.
• Leaks in the water cooling system.
2.2 Cleaning
2-2 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
Note, that with DriveDebug all parameters can be saved in one file but
with DriveWindows the parameters must be saved in two different
files. One file includes parameter groups 112 and 190 and the other
file includes all parameter groups above 100.
• If the old parameter file of the drive is available, compare it with the
current parameter settings using the compare function in
DriveWindows or DriveDebug and save the result of the comparison
in txt file format.
• Save the software in bpg or tar file format.
Recommended Make spot checks first. If several of the bolted connections are not
Procedure tightened properly, carry out or a more extensive check to be able to
decide whether all connections have to be checked.
Torque rate
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-3 (20)
Chapter 2 - Inspection and Maintenance ABB
2.7 Roof Attachments
Check that the roof attachments are installed according to the Converter
User’s Manual, Chapter 3 Mechanical Installation.
2-4 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
OEI Board (-A2951) in The OEI board is used to open the main circuit breaker if a fault condition
COU 1 occurs which requires the main power supply to be disconnected from the
converter. The OEI board receives the command to open the main circuit
breaker through a fiber-optic link from the master INT board.
To verify the attenuation of the fiber, disconnect the fiber optic cable from
the RX connector of the OEI board (see arrow in Figure 2-5) and measure
the light using an optical power meter.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-5 (20)
Chapter 2 - Inspection and Maintenance ABB
The OEI board is illustrated in the wiring diagram of COU 1. The INT board
can be found in the wiring diagrams of INU 1.
INT Board (-A3121) in The fiber optic cables at the following connectors of the INT board are
ARU disconnected and checked one after the other (see Figure 2-6 to identify
the connectors):
• Connector A205, A206, 207
The fiber optic cable transmits fault signals from the GUSP.
• Connector 208
The fiber optic cable transmits a hardware based overcurrent signal
from the CVMI board.
INT board, GUSP and CVMI board are illustrated in the wiring diagram of
the INU.
INT Board (-A4121) in The fiber optic cables at the following connectors of the INT board are
INU disconnected and checked one after the other (see Figure 2-6 to identify
the connectors):
• Connector A205, A206, 207
The fiber optic cable transmits fault signals from the GUSP.
• Connector 208
The fiber optic cable transmits a hardware based overcurrent signal
from the CVMI board.
• Connector A817 and A818
The fiber optic cables transmit diode monitoring signals from LSU 1
and LSU 2. The cables are not present in all converters.
2-6 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
A818
A817
A205
A206
A207
A208
A203
Fiber Optic Cables The following fiber optic cables must be tested with the cables unplugged
at both ends:
• Fiber optic cable between AMC board -A2401 in COU 1 (see Figure
2-8 connectors A719, A720) and cluster modem -A5201 in WCU.
The fiber optic cable is connected to the cluster modem -A2501 in
COU 1 (see Figure 2-7).
• Fiber optic cable between AMC board -A2401 in COU 1 (see Figure
2-8 connectors A715, A716) and CCB board -A6081 in the EXU (see
Figure 2-9 connectors A801, A802). This cable is only present in
converters driving synchronous motors.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-7 (20)
Chapter 2 - Inspection and Maintenance ABB
A716
A715
2-8 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
CCB board
A801
A802
The attenuation of the cables is verified using a light source which feeds
a signal with a defined wavelength (660 nm) into the cable and measuring
the attenuation with a power meter at the other end. The measured values
should not exceed the limit values as stated in Table 3-1.
Refer to the following wiring diagrams for identification of the boards and
the fiber optic cables:
• Wiring diagrams of COU 1 for AMC board -A2401 and cluster modem
-A2501
• Wiring diagrams of WCU for cluster modem -A5201
• Wiring diagrams of EXU for CCB board -A6081)
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-9 (20)
Chapter 2 - Inspection and Maintenance ABB
• Single fan units (see Figure 2-11) are only installed if the converter is
equipped with roof fan units. The fans are mounted on the back of the
hinged cover in the top section of ARU and INU cabinets.
Fan
Location of The fans are controlled by thermostats. A thermostat can control a single
Thermostats fan or a group of fan units. To identy the thermostat and the fans
connected to it, refer to the wiring diagrams of the above mentioned
cabinets in Appendix D - Electrical Diagrams of the User’s Manual.
2-10 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
The thermostats for fans installed in COUs, ARUs and INUs are located
on the control swing frame of a COU. See Figure 2-12.
Thermostat
The thermostat for the fan unit in an EXU is installed in the EXU cabinet.
See Figure 2-13.
Thermostat
Test Procedure
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-11 (20)
Chapter 2 - Inspection and Maintenance ABB
CAUTION!
! To test the fans in ARU or INU, the converter must be de-energized and
grounded in order to open the cabinet doors. The fans in COU, EXU and
WCU can be tested while the converter is in operation.
2-12 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
DANGER!
DC busbars, carrying dangerous voltages, are installed underneath the
fan units.
Therefore, the fan units may only be checked and cleaned after the
converter has been de-energized and grounded.
CAUTION!
! When working on the fan units make sure that small parts cannot fall into
the cabinets. Any part which accidentally dropped into a cabinet must be
retrieved immediately. Otherwise, damage or injury may occur.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-13 (20)
Chapter 2 - Inspection and Maintenance ABB
Cover
Testing The fans are controlled by thermostats. For testing the fans, the doors of
the cabinets (ARU, LSU, INU, CBU) must be opened in order to access
the thermostats (see Figure 2-17). Since these doors are linked to the
integral door locking system, they can only be opened after the converter
has been de-energized and grounded.
Provided that the power supply of the fans is available, the fans can be
switched on by turning the dial of the thermostat to a low value.
2-14 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
To identify the thermostat, refer also to the wiring diagrams of the above
mentioned cabinets in Appendix D - Electrical Diagrams of the User’s
Manual.
Proceed as follows:
1 De-energize the drive system according to the Operating Instructions
of the User’s Manual.
2 Check that the 230 VAC power supply for the fans to be tested is
switched on.
3 Note the setting of the thermostat.
4 To start the fan, adjust the setting of the thermostat to a low value.
See arrow in Figure 2-18.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-15 (20)
Chapter 2 - Inspection and Maintenance ABB
Door filter mats are mounted in the cabinets of COU, EXU and WCU, if the
converter has been specified for insulation protection 54.
The filter mats can be changed while the converter is in operation.
Proceed as follows:
1 Take off the filter cover.
Two types of filter covers can be present.
Type 1 is made of sheet metal and has two hooks on each side which
insert into slots of the door. To take off the cover, push it upwards (see
arrows in Figure 2-19) as far as it goes and pull it away from the door.
2-16 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-17 (20)
Chapter 2 - Inspection and Maintenance ABB
Visual Inspection Visual inspection should be carried out in the intervals stated in the
maintenance schedule. Pay especially attention to leaking and bulged
capacitors. The capacitors can be bulged as much as 10 mm. If a
capacitor has expanded too much, it must be replaced by a new one.
2-18 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB Chapter 2 - Inspection and Maintenance
Perform the insulation test every 4th year on the converter, supply
transformer and motor. The power cables to the converter (incoming and
outgoing) need to be disconnected for the test.
For the measurement:
• Perform the test according to the ACS 6000 Commissioning Manual.
• Record the insulation resistance values of each measurement in the
inspection report.
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-19 (20)
Chapter 2 - Inspection and Maintenance ABB
See Service and Maintenance Manual of the water cooling unit for
information on :
• Water cooling pumps
• Ion exchange resin
• Plate heat exchanger
• Filter Cartridge of Filter Z1
• Conductivity Sensor
• Pressure Transmitter
• Temperature Sensor
2-20 (20) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB
Chapter 3 - Test Run
After the maintenance work has been completed, a test run must be
performed. Before starting, check that:
• all cables are properly connected and all electrical connections are
tight,
• no foreign objects are inside the converter,
• all covers are mounted,
• equipment grounding is removed,
• running the motor / process is safe.
During the test run, monitor (using DriveWindows or DriveDebug) the
behaviour of the DC voltage when the DC link is charged and record the
following signals:
• 2.01 DC1 VOLTAGE (sum of upper and lower DC voltages)
• 2.02 DC1 VOLTAGE
• 2.06 DC2 VOLTAGE
• Control signals to and from the MCB
Observe the functioning of the drive under normal load conditions. Using
DriveWindows or DriveDebug record the following signals:
• 1.08 MOTOR SPEED (in rpm)
• 1.21 MOTOR TORQUE FILT
• 1.19 MOTOR RMS CURRENT FLT
• 2.01 DC1 VOLTAGE (sum of upper and lower DC voltages)
• 2.19 SWITCHING FREQUENCY
• 3.02 USED TORGUE REF (in %)
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 3-1 (2)
Chapter 3 - Test Run ABB
3-2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
ABB
Chapter 4 - Spare Parts, Documentation and Software
For revising and archiving of the factory documentation and for later
assistance of the customer sent the following to the MV AC Supportline
(MV AC Supportline/CHIND, mvac.supportline@ch.abb.com):
• Inspection record (xls)
• Field report (use the MV AC Drives field report template)
• Parameter backup files (txt or dwp file formats)
• Software backup files (bpg, tar file formats)
• Fault logger data file (dwf or txt file formats)
• Test run recordings (DriveWindows or DriveDebug monitoring files or
paper copy attached to the field report)
4.3 DriveMonitor
ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 4-1 (2)
Chapter 4 - Spare Parts, Documentation and Software ABB
• After 5 years of operation: change of harddisk of the DriveMonitor
computer.
4-2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. ©ABB Switzerland Ltd
Start-up P
Cooling
¾ Air filters (if installed) R R R R R R R R R R R R R R R R R R R R
¾ Cooling fan (if installed) 2 I I I R I I I R I I I R I I I R I I I R
¾ De-Ionizer and micro filter 3 P P P P P P P P P P P P P P P P P P P P
¾ Cooling pump gasket I I I R I I I - I R I - I I I R I I I R
¾ Cooling pump (including gasket) 2 I I I I I R I I I I R I I I I I R I I
¾ Auxiliary cooling fan (if installed) I I I R I I I R I I I R I I I R I I I R
¾ Strainer I I I I I I I I I I I I I I I I I I I I
Aging
¾ Capacitors 4 P P P P P P P P P P P P P P P P P R P P
¾ Printed Circuit Boards 5 I I I P I I I P I I I R I I I P I I I P
¾ Battery of UPS (if installed) I R I R I R I R I R I R I R I R I R I R
Connections & Surroundings
¾ Fiber optic cables P P P P P P P P P P P P P P P P P P P P
¾ Cable connections I I I I I I I I I I I I I I I I I I I I
¾ Dustiness, corrosion and temperature I I I I I I I I I I I I I I I I I I I I
Improvements
¾ Improvements 7 I I I I I I I I I I I I I I I I I I I I
Measurements
Spare Parts
¾ Spare parts 5 I I I P6 I I I P6 I I I R6 I I I P6 I I I P6
1. Typical needed working time on the converter (does not include preparation-, closing-, waiting- or traveling-time)
2. The cooling pumps and fans can either be serviced by an authorized service-representative or completely replaced
3. The average lifetime of the deionizer is 2 - 4 years, depending mainly on the actual water quality, the micro filter should be replaced at the
same time as the deionizer, it is recommended to replace both when the actual conductivity reaches the alarm level, not preventively
4. The expected life time of the capacitors depends mainly on the ambient conditions, based on the maximum allowed temperature in the
converter, the expected lifetime is about 200 000 hours, the actual replacement should be based on the annual measurements, not on time
5. The printed circuit boards in the converter and among the spare parts can be replaced with new ones or replaced with refurbished ones
6. Only the printed circuit boards needs to be replaced, for the other spare parts are no actions needed
7. Converter improvements based on development, software modifications etc.
Note! Recommended service intervals and component replacements are based on the operational environment specified by ABB. Please refer to
service instructions and product manuals for more information.