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ABB

ACS 1000
Medium Voltage AC Drives

315 to 5000 kW
400 to 6700 hp

Operation and Maintenance Manual


Water Cooling Unit

Document No.: 3BHS204366 ZAB E01 Rev. -

Issued: 20.06.2004

 ABB Switzerland Ltd. All Rights Reserved.


2 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
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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 - Installation

2.1 Raw Water Connections

2.1.1 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 Bottom entry

Figure 2-1 Raw Water Entries

1 Connect the hoses for the raw water circuit following Figure 2-2 to
Figure 2-6.

Exchange duct plate (top) and


blanking plate when hoses are
Inlet entered from below

Outle

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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ABB Chapter 2 - Installation

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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Chapter 2 - Installation
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external water pipes can be connected directly to the flanges. An
example is shown in Figure 2-8.

Upward bend Downward bend

Figure 2-8 Flange Connections

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

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.

3.1 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 3-9531-001
Flowdiagram for 2 pumps and 2 way valve 3-9531-002
Flowdiagram for 1 pump and 3 way valve 3-9531-003
Flowdiagram for 2 pumps and 3 way valve 3-9531-004

Filled valve symbols in the flow diagram indicate valves in shut


position.

1 Open valves V1, (V2), V5, V11 and V15.


2 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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Table 3-1 Drinking Water Specification

Parameter Value

pH 6 – 8.5
Specific conductivity < 300 µS/cm
Hardness 3 – 10° dH
Chloride (Cl) < 300 mg/l
Copper (Cu) < 0.1 mg/l
Total dissolved salt < 1000 mg/l

Note: Inhibitors and other chemicals must not be added to the water.

Cooling Water with Anti- When the ACS 1000 has been ordered with an anti-freeze, a
Freeze 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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ABB 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 Value

Content >99.8 %
3
Density at 20 °C (68 °F) 1.1133 - 1.1140 g/cm
2
Viscosity at 20 °C (68 °F) 19 mm /s

Specific heat capacity at


2.3 kJ/kgK
20 °C (68 °F)

Thermal conductivity 0.29 W/mK

pH-Value neutral

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 Pure Ethylene Glycol Distilled Water

- 10 °C (14 °F) 20 % 80 %
- 20 °C (-4 °F) 34 % 66 %
- 30 °C (-22 °F) 44 % 56 %
- 40 °C (-40 °F) 52 % 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 Check that the type of ethylene glycol is appropriate. See Table
3-2.
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).
3 Fill in distilled water until the level in the container is at approx.
3/4.

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4 Thoroughly mix the ethylene glycol mixture.

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 Switch off the motor protection switch(es) -Q11/( -Q12) of the
pump(s).
7 Switch on the auxiliary voltage with switch -Q1.
8 Close valves V1, V11, V15, V80, V81*.
9 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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ABB Chapter 3 - Starting up the Cooling System

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
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21 In case of a redundant pump install a temporary jumper.
• 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 µS/cm, conductivity trip
level: 0.7 µS/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 µS/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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ABB Chapter 3 - Starting up the Cooling System

1 Connect the filling hose to the ISO-R1/2” connector of valve V14.


2 A pressure of approx. 1 to 2 bar is required for filling water into the
circuit. Using a small pump might be necessary.
3 Close valve V11.
4 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 Stop the filling after about 5 l of water have been added.


6 Close valve V14.
7 Open valve V11.
8 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%.
9 Remove the hose.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 17 (of 72)
Chapter 3 - Starting up the Cooling System
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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 De-energize the ACS 1000 according to Chapter 8 – Operation,


De-energizing the ACS 1000.
2 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 Remove the fastening screws of the swing frame and open it by


pulling strongly.
4 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
½).
5 Open valve V12.
6 Open the drain valve and drain the inverter.
A pump can be used to speed up the procedure.
7 Open V80 / (V81) to drain the water cooling unit.
Approx. water quantity to be expected:7-8 liter.
8 Close the valves and remove the hoses.
9 Close the converter swing frame and remount the fastening
screws.

Note: So far, the converter has only been drained for repair
purposes. To drain the converter completely (for storage purposes)
contact your ABB representative.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 19 (of 72)
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 µS/cm) can be


read on the control panel.

Reading the Conductivity 1 Select the Actual Display mode on the control panel (refer to the
on the Control Panel User’s Manual, Chapter 5 – Parameter Viewing and Editing and
Control Panel Functions, Actual Signal Display Mode).

2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select


actual signal 04 InvWtrConductivity. The conductivity should be
below 0.5 µS/cm.
• If the conductivity exceeds the alarm threshold of 0.5 µS
(see parameter 190.09), the control panel displays the alarm
message WtrConduct.
• If the conductivity exceeds the trip threshold of 0.7 µS (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 1 Select the Actual Display mode on the control panel (refer to the
Pressure on the Control User’s Manual, Chapter 5 – Parameter Viewing and Editing and
Panel Control Panel Functions, Actual Signal Display Mode).

2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select


actual signal 03 InvWtrCoolPressure. The pressure is displayed in
bar.
3 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.

Reading the Water 1 Select the Actual Display mode on the control panel (refer to
Temperature on the Chapter 5 – Parameter Viewing and Editing and Control Panel
Control Panel Functions, Actual Signal Display Mode).
2 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.

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ABB Chapter 5 - Checking Actual Values

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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 23 (of 72)
Chapter 5 - Checking Actual Values
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Chapter 6 - Tightening Torques and Threaded
Connections

6.1 Tightening Torques

Table 6-1 Tightening Torque for Pumps


Part Part No. 1) Thread Tightening Torque 2)
Diameter
Hex. head bolt 93 M6 5 - 6 Nm
Pump fixing bolts 21-26 Nm
1)
see Figure 6-1
2)
for unlubricated threads

5 – 6 Nm

21 – 26 Nm

Figure 6-1

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 25 (of 72)
Chapter 6 - Tightening Torques and Threaded Connections
ABB
Table 6-2 Tightening Torque for Coupling
Part Thread Tightening Torque
Diameter
Hex. nut M10 30 – 35 Nm

Table 6-3 Tightening Torque for Flanges


DN Hexagon Nut Washer Gasket Tightening
Screw (D x d x t) (D x d x t) Torque
1 2 3 4
25 M12-55 M12 24 x 13 x 2 73 x 40 x 1.5 24 - 33 Nm
32 M16-65 M16 30 x 73 x 3 84 x 48 x 1.5 60 - 80 Nm
40 M16-65 M16 30 x 73 x 3 92 x 57 x 1.5 60 - 80 Nm
50 M16-70 M16 30 x 73 x 3 107 x 66 x 1.5 60 - 80 Nm
65 M16-70 M16 30 x 73 x 3 128 x 83 x 1.5 60 - 80 Nm
80 M16-75 M16 30 x 73 x 3 144 x 97 x 1.5 60 - 80 Nm
100 M16-80 M16 30 x 73 x 3 162 x 125 x 1.5 60 - 80 Nm

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 De-energize the ACS 1000 according to Chapter 8 – Operation,


De-energizing the ACS 1000.
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.

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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 27 (of 72)
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 Close valve V1, V5, V11 and V15. Secure the valves from being
opened unintentionally.
5 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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ABB Chapter 7 - Cooling Pump Motor

6 Remount the drain plug.


7 Open the motor terminal box and check the pump terminals for
voltage.
8 Disconnect the power supply cable in the motor terminal box (see
Figure 7-4).

Note: Mark the cables for later identification.

9 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 29 (of 72)
Chapter 7 - Cooling Pump Motor
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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 Move the pump back into the water cooling cabinet


2 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.
3 Remount the four pump fixing bolts and tighten them slightly by
hand.
4 Remount the ring clamp to the pump house and tighten the bolt to
the final torque rate of 5...6 Nm.
5 Tighten the four pump fixing bolts to the final torque rate of
21...26 Nm.
6 Connect the power supply cable to the motor terminal box.
7 Open valve V1 and V11.

30 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 7 - Cooling Pump Motor

8 Open the priming plug on the pump house (see Figure 7-3) and
vent the pump. Close the plug again when finished.
9 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 µS) 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).

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 31 (of 72)
Chapter 7 - Cooling Pump Motor
ABB
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.
3 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 Open the motor terminal box and check the pump terminals for
voltage.
6 Disconnect the power supply cable in the motor terminal box (see
Figure 7-4).

Note: Mark the cables for later identification.

7 Loosen the metal clamp ring of the pump house (see Figure 7-4).
8 If necessary, fasten the pump motor in a suitable way to prevent it
from falling down.
9 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.

32 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 7 - Cooling Pump Motor

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 Move the pump back into the water cooling cabinet


2 Slide the impeller into the pump house. Be careful not to damage
the O-ring between the pump house and the motor.
3 Remount the four pump fixing bolts and tighten them by slightly
hand.
4 Remount the clamp ring at the pump house and tighten the bolt to
the final torque rate of (5-6 Nm).
5 Tighten the four fixing bolts to the final torque rate of 21...26 Nm.
6 Connect the power supply cable to the motor terminal box.
7 Open valve V1/(V2).
8 Close valve V12.
9 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 33 (of 72)
Chapter 7 - Cooling Pump Motor
ABB
Manual start of pump 2 (by closing K12 (see Figure 7-2)):
• 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.

34 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 7 - Cooling Pump Motor

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.

2 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.
3 Change two phases of the power supply cables of the
corresponding pump.
4 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.

7.2 Lubrication

Pump and motor are maintenance-free.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 35 (of 72)
Chapter 7 - Cooling Pump Motor
ABB

36 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
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.

Warning: When the drive is in operation voltages are present in the


control units.
!
Do not touch any live circuitry!

8.1 Removing the Ion Exchange Vessel

Distributor head

Upper distributor

Mix bed resin

Lower distributor

Figure 8-1 Ion Exchange Vessel

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 37 (of 72)
Chapter 8 - Ion Exchange Resin
ABB
1 Close valve V11 and V15.
2 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 Unhook the 2 rubber belts (2 in Figure 8-1) and carefully move the
vessel out of the cabinet.
4 Cover the openings of the hose couplings appropriately to prevent
dirt from entering.
3
Out In
3
4
1

Resin

4
2

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.
6 Slowly pull the distributor head and tube (3 and 4 in Figure 8-1) out
of the vessel.
7 Clean the tube by rinsing it with water.

38 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
8.2 Mounting a New Exchange Vessel

1 Dismount the distributor head of the spare vessel according to step


5 and step 6.
2 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 Lift the ion exchange vessel back to the cabinet and fix it with the
two rubber belts.
4 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 Check for leaks.


7 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 39 (of 72)
Chapter 8 - Ion Exchange Resin
ABB

40 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
Chapter 9 - Plate Heat Exchanger

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 inlet S3 > outlet S4
• Media 2 inlet S1 > outlet S2

Figure 9-1 Heat Exchanger

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 41 (of 72)
Chapter 9 - Plate Heat Exchanger
ABB
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

42 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 9 - Plate Heat Exchanger

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 50°C.

1 De-energize the ACS 1000 according to Chapter 8 – Operation, De-


energizing the ACS 1000.
2 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 43 (of 72)
Chapter 9 - Plate Heat Exchanger
ABB
4 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 Close of the raw water supply and drain through V82.


6 Loosen the clamp of the heat exchanger.
7 Loosen the fitting at the heat exchanger terminals S1, S2 and S4.
8 Loosen the connecting pipe to B14 at the fitting of B14.
9 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 Make sure that the dimension TM (see Figure 9-8) is correct


according to the label on the backside of the heat exchanger.
2 Close V82.
3 Open the valve on the raw water discharge side (outlet)
4 Slowly open the valve on the raw water supply side.

44 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 9 - Plate Heat Exchanger

5 Close the valve on the raw water discharge side about 90%.
6 Check for leaks.
7 Open the raw water valves fully.
8 Open valve V5.
9 Close valve V1 and (V2) about 90%.
10 Install a temporary jumper.
• 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.

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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 45 (of 72)
Chapter 9 - Plate Heat Exchanger
ABB

9.4 Disassembling the Plates

1 Unscrew the center nut and remove the bolt.


2 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

46 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 47 (of 72)
Chapter 9 - Plate Heat Exchanger
ABB

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.

48 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 9 - Plate Heat Exchanger

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, 50°C).
Precipitates of calcium components are removed with either:
• 10% nitric acid (HNO3) or
• 2% sodium
• 2% polymetaphosphate, 50°C
• 2% sodium trimetaphosphate, 50°C
• 5% 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 49 (of 72)
Chapter 9 - Plate Heat Exchanger
ABB

50 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
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 Close valve V11 and V15.


2 Unscrew bottom of the housing. Some residual water may spill out.
Remove large O-ring or gasket, and set aside.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 51 (of 72)
Chapter 10 - Replacing Filter Cartridge of Filter Z2
ABB

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 Discard used cartridge. Rinse out bottom of housing.


4 Wipe clean O-ring of old lubricant.
5 Lubricate O-ring or gasket with clean petroleum jelly (vaseline) or
silicone lubricant.
6 Place O-ring back into groove and smooth into place with finger (or
place gasket on rim of bottom of housing).
7 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 Screw bottom of housing onto cap and hand tighten. Do not


overtighten. Make sure cap standpipe slips into cartridge.
9 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.

52 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
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 De-energize the system according to the ACS 1000 User’s Manual,


Chapter 8 – Operation, De-energizing the ACS 1000.
2 Turn off the raw water supply.
3 Open V82 to drain the raw water pipe and close the valve again,
when finished.
4 Unscrew and remove the strainer. Some residual water may spill
out.

Figure 11-1 Removing Strainer

5 Clean and re-mount the strainer.


6 Turn on the raw water supply.
7 Check for leaks.
8 Restart the ACS 1000 as described in the ACS 1000 User’s
Manual, Chapter 8 – Operation, De-energizing the ACS 1000.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 53 (of 72)
Chapter 11 - Cleaning Strainer Z1
ABB

54 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB
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 De-energize the ACS 1000 according to Chapter 8 – Operation,
De-energizing the ACS 1000.
2 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 55 (of 72)
Chapter 12 - Conductivity Sensor B12
ABB
3 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 Close valve V1, V5 and V15. Secure the valves from being opened
unintentionally.
5 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 Loosen the nut by hand and remove the conductivity meter.
7 Disconnect the electric cable.
8 Clean the sensor.

56 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB 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.

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.

Remounting the Sensor 1 Reconnect the cable


2 Remount the conductivity meter and tighten the nut by hand.
3 Open valve V1, V5, V12 and V15
4 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 Switch on the motor protection switch -Q11 (see Figure 7-2) and
the auxiliary power supply (-Q1).
6 After running the pump for 30 min. close valve V12.
7 Check for leaks.
8 Remove the temporary jumper.
9 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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E01Rev.- 57 (of 72)
Chapter 12 - Conductivity Sensor B12
ABB

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 Acceptance of selected
or adjusted parameter
Menu navigation
Digit selection
Relay 2: contact closed
Relay 1: contact closed

Figure 12-4 Operating and Control Elements

58 (of 72) 3BHS204366 ZAB E01Rev.- ACS 1000 Water Cooling Unit
ABB Chapter 12 - Conductivity Sensor B12

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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Chapter 12 - Conductivity Sensor B12
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12.2.3 Calibration Mode

Press simultaneously for 5 seconds.


The following adjustments are set in the calibration mode display:
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

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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ABB Chapter 12 - Conductivity Sensor B12

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: µS; 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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Chapter 12 - Conductivity Sensor B12
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Temperature The transmitter offers three different modes for temperature


Compensation Coefficient 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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ABB Chapter 12 - Conductivity Sensor B12

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 4…20 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 20…4 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 µS/cm = 4…20 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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Chapter 12 - Conductivity Sensor B12
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12.3 Menu Test

To test the menu, press simultaneously for 5 seconds.


The following compensations and controls can be set in the menu:
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.

12.3.1 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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ABB Chapter 12 - Conductivity Sensor B12

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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Chapter 12 - Conductivity Sensor B12
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12.4 Testing the Sensor

The proper functioning of the conductivity measuring circuit can be


verified by connecting a 50 kΩ 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 Remove the conductivity transducer following section Removing the
Sensor page 55 until step 6.
2 Read off the conductivity value on the display of the transducer.
With a dry and clean sensor, the displayed value must be 0.0 µS/cm.
3 Connect a 50 kΩ resistor between the two electrodes of the sensor.

Sensor seen from below

50 kΩ

4 Calculate the conductivity value according to the following formula:

 µS  K cm
Conductivity   =
[
−1
]
⋅10 6
 cm  R [Ω]

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 typical: 3 % of measured value
max: 5 % of measured value
6 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 Drain the cooling system according to Chapter 4 - Draining the


Cooling System.
2 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 De-energize the ACS 1000 according to Chapter 8 – Operation, De-


energizing the ACS 1000.
2 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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