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[Page 1] ABB ACS 6000 ABB Switzerland Ltd. All Rights Reserved. ACS 6000 Medium Voltage Drives 3 to 27 MVA Service and Maintenance Manual Document No.: 3BHS202077 ZAB E01 Rev. C Issued: 21-01-2005 ABB |
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[Page 2] ABB ACS 6000 2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual ABB reserves all rights to this document, also in the event of patent issue or registration of any other industrial property protection right. Misuse, in particular duplication and forwa… |
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[Page 3] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1 (4) Table of Contents Chapter 1 — Introduction and Safety 1-1 1.1 Introduction 1-1 1.2 Safety 1-1 Chapter 2 — Checking IGCTs and Diodes 2-1 2.1 Safety 2-1 2.2 Checking IGCTs 2-1 2.2.1 R… |
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[Page 4] ABB ACS 6000 ABB 2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Chapter 7 — Changing 7/9 MVA Phase Modules 7-1 7.1 Required Tools and Accessories 7-1 7.2 Removing a Phase Module 7-2 7.3 Installing a Phase Module 7-5 Chapter 8 — Changing Diodes… |
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[Page 5] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3 (4) 10.3.1 Preperatory Steps 10-2 10.3.2 Replacing Upper Diode 10-2 10.3.3 Replacing IGCTs 10-3 10.3.4 Replacing Lower Diode 10-5 10.3.5 Finishing Steps 10-5 Chapter 11 — Changing IGC… |
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[Page 6] ABB ACS 6000 ABB 4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 7] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 1-1 (2) Chapter 1 — Introduction and Safety The manual must be thoroughly read and understood before maintenance work on the ACS 6000 is started. The manual is addressed to qualified persons … |
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[Page 8] ABB ACS 6000 Chapter 1 — Introduction and Safety ABB 1-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Danger: Before power is applied to the drive, check that: • Mains and motor connections are ok • Auxiliary power and control cable connections a… |
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[Page 9] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-1 (6) Chapter 2 — Checking IGCTs and Diodes IGCTs and diodes of phase modules can only be tested after the converter has been deenergized and grounded. Danger: The ACS 6000 is a high violta… |
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[Page 10] ABB ACS 6000 Chapter 2 — Checking IGCTs and Diodes ABB 2-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Note: When checking be careful not to disconnect the fiber optic cable while the IGCT is energized to prevent an undefined control state. 3 Test… |
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[Page 11] ABB ACS 6000 ABB Chapter 2 — Checking IGCTs and Diodes ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-3 (6) Figure 2-3 INT Board A712 A713 A714 |
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[Page 12] ABB ACS 6000 Chapter 2 — Checking IGCTs and Diodes ABB 2-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 4 Switch on the auxiliary power to the gate unit. 5 Switch on the power supply of the INT board to apply a constant light to the IGCT. 6 Measure … |
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[Page 13] ABB ACS 6000 ABB Chapter 2 — Checking IGCTs and Diodes ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 2-5 (6) Figure 2-4 Extracting the Phase Module 6 Check the diode using the multimeter in diode verification mode and suitable probes. Expected result of… |
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[Page 14] ABB ACS 6000 Chapter 2 — Checking IGCTs and Diodes ABB 2-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 15] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-1 (6) Chapter 3 — Changing Diodes and Thyristors in LSU The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • Spreader tool Figure 3-1 Spr… |
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[Page 16] ABB ACS 6000 Chapter 3 — Changing Diodes and Thyristors in LSU ABB 3-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 1 Deenergize and ground the ACS 6000. 2 Stop the cooling water pumps and make sure that they cannot be switched on by accident. Dange… |
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[Page 17] ABB ACS 6000 ABB Chapter 3 — Changing Diodes and Thyristors in LSU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-3 (6) The replacement of diodes and thyristors is explained using the example of a 9 MVA LSU. Note: When replacing diodes or thyristors of… |
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[Page 18] ABB ACS 6000 Chapter 3 — Changing Diodes and Thyristors in LSU ABB 3-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 1 Deenergize the drive. See section 3.2 Safety. 2 Insert the clamp pressure loading spanner (see B in Figure 3-2 ). 3 Insert the spr… |
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[Page 19] ABB ACS 6000 ABB Chapter 3 — Changing Diodes and Thyristors in LSU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 3-5 (6) In case a stack becomes misaligned, the coolers can be pushed back into place and the semiconductors can be centered using a fixture … |
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[Page 20] ABB ACS 6000 Chapter 3 — Changing Diodes and Thyristors in LSU ABB 3-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 21] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-1 (10) Chapter 4 — Changing 3/5 MVA Phase Modules The tools listed below are part of the tool set (ident. No. 3BHS130246) delivered with the ACS 6000. • Lifting device (customer crane or … |
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[Page 22] ABB ACS 6000 Chapter 4 — Changing 3/5 MVA Phase Modules ABB 4-2 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 4-2 Phase Modules 1 Deenergize and ground the ACS 6000. 2 Stop the cooling water pumps and make sure that they cannot be switched on… |
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[Page 23] ABB ACS 6000 ABB Chapter 4 — Changing 3/5 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-3 (10) 4 Disconnect all cooling water input and output couplings of the three phase modules (see arrows in Figure 4-3 a ). To disconnect the wa… |
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[Page 24] ABB ACS 6000 Chapter 4 — Changing 3/5 MVA Phase Modules ABB 4-4 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 7 Slide each rail under the phase module to be changed until the rail inserts properly into the bracket at the back of the module. Figure 4… |
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[Page 25] ABB ACS 6000 ABB Chapter 4 — Changing 3/5 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-5 (10) 9 Unscrew the fastening bolts at the back. There are two bolts on each side. Unscrew the lower fastening bolts and then the upper fastening… |
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[Page 26] ABB ACS 6000 Chapter 4 — Changing 3/5 MVA Phase Modules ABB 4-6 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Using the Hoist 12 Attach the hoist to the cabinet at the three connection points (see circles in Figure 4-8 ). Figure 4-8 Attaching the H… |
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[Page 27] ABB ACS 6000 ABB Chapter 4 — Changing 3/5 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-7 (10) 14 Lift the phase module high enough to be able to withdraw the rails. Figure 4-10 Phase Module Attached to Hoist 15 After the rails have be… |
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[Page 28] ABB ACS 6000 Chapter 4 — Changing 3/5 MVA Phase Modules ABB 4-8 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 1 Grease the four fastening bolts of the phase module with MOLYKOTE (type D). Figure 4-12 Greasing Fastening Bolts 2 Grease the ends of the… |
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[Page 29] ABB ACS 6000 ABB Chapter 4 — Changing 3/5 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 4-9 (10) (see section Using the Hoist ) or an overhead crane (see section Using a Crane ). 4 Remove the lifting attachments. 5 Push the phase modu… |
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[Page 30] ABB ACS 6000 Chapter 4 — Changing 3/5 MVA Phase Modules ABB 4-10 (10) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 31] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 5-1 (2) Chapter 5 — Changing RC-IGCTs in 3/5 MVA Phase Modules 1 Follow section 4.2 Removing a Phase Module until the phase module has been extracted from the cabinet. The phase module can … |
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[Page 32] ABB ACS 6000 Chapter 5 — Changing RC-IGCTs in 3/5 MVA Phase Modules ABB 5-2 (2) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual them on the new IGCT. Figure 5-3 IGCT 6 Thoroughly clean the contact surfaces of the cooler and the anode and cathode of the new… |
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[Page 33] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 6-1 (4) Chapter 6 — Changing Clamp Diodes in 3/5 MVA Phase Modules See section 4.1 Required Tools and Accessories . 1 Remove the phase module from the cabinet. Follow section 4.2 Removing a… |
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[Page 34] ABB ACS 6000 Chapter 6 — Changing Clamp Diodes in 3/5 MVA Phase Modules ABB 6-2 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 6-2 Phase Module Placed on two Wooden Beams 4 Slide the clamp pressure loading gauge under the clamp ring of the pres… |
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[Page 35] ABB ACS 6000 ABB Chapter 6 — Changing Clamp Diodes in 3/5 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 6-3 (4) 6 Lift the cooler which is above the diode to be changed and then remove the diode. Figure 6-5 Removing the Diode 7 Thorough… |
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[Page 36] ABB ACS 6000 Chapter 6 — Changing Clamp Diodes in 3/5 MVA Phase Modules ABB 6-4 (4) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 37] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 7-1 (6) Chapter 7 — Changing 7/9 MVA Phase Modules The tools and accessories listed below are part of the tool set (Ident. no. 3BHS130246) delivered with the ACS 6000. • ACS 6000 lifting ta… |
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[Page 38] ABB ACS 6000 Chapter 7 — Changing 7/9 MVA Phase Modules ABB 7-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 7-2 Phase Modules 1 Deenergize and ground the ACS 6000. 2 Stop the cooling water pumps and make sure that they cannot be switched on … |
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[Page 39] ABB ACS 6000 ABB Chapter 7 — Changing 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 7-3 (6) 4 Before disconnecting the top water hose, cover the equipment below a coupling with a plastic sheet (see Figure 7-3 ) or hold a towel or c… |
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[Page 40] ABB ACS 6000 Chapter 7 — Changing 7/9 MVA Phase Modules ABB 7-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 7 Cut off the cable ties on the side of the phase module (see circles in Figure 7-5 ) and then disconnect the fiber optic cables and the pow… |
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[Page 41] ABB ACS 6000 ABB Chapter 7 — Changing 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 7-5 (6) 9 Position the lifting table in front of the phase module and adjust the height of the table. 10 Make sure that the disconnected water hoses… |
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[Page 42] ABB ACS 6000 Chapter 7 — Changing 7/9 MVA Phase Modules ABB 7-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 6 Reconnect the two water hoses. First the bottom hose and then the upper hose. To connect a water hose coupling pull the locking sleeve of… |
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[Page 43] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-1 (18) Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • Spreader tool … |
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[Page 44] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-2 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual The phase module must be extracted from the cabinet to replace the clamp, NP and free wheeling diodes but can remain in… |
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[Page 45] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-3 (18) Figure 8-3 Phase Module Clamp diode NP diode Clamp diode NP diode Free wheeling diodes IGCTs |
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[Page 46] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-4 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Before starting any work on the phase module do the following: 1 Deenergize and ground the ACS 6000. Danger: The ACS 60… |
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[Page 47] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-5 (18) Clamp and NP Diodes are mounted in the same stack. See Figure 8-3 to locate the semiconductors. 8.4.1 Preparatory Ste… |
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[Page 48] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-6 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Remove the top nut using the 13 mm wrench while holding the set screw with a 4 mm hex key (see Figure 8-6 ). Do the sa… |
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[Page 49] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-7 (18) 6 Remove the top isolator disc from the stack to create more clearance facilitating work on the diodes. Figure 8-8 Remo… |
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[Page 50] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-8 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 8.4.2 Replacing Clamp Diodes Upper Clamp Diode After the steps of section 8.4.1 Preparatory Steps have been carried ou… |
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[Page 51] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-9 (18) Lower Clamp Diode After the steps of section 8.4.1 Preparatory Steps have been carried out do the following: 6 Remove… |
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[Page 52] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-10 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 8 By adjusting the spreader tool push up the cooler above the diode until the diode is free. Remove the lower clamp di… |
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[Page 53] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-11 (18) 8.4.3 Replacing NP Diodes Removing Upper NP Diode After the steps of section 8.4.1 Preparatory Steps have been carrie… |
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[Page 54] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-12 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 3 Continue with section Removing Lower NP Diode if the lower diode has to be replaced. If not, continue with sectio… |
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[Page 55] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-13 (18) 4 Continue with section 8.4.4 Finishing Steps for remounting the capacitors, adjusting the clamp pressure and instal… |
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[Page 56] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-14 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 1 Deenergize the drive. See section 8.3 Safety . 2 Slide the clamp pressure loading gauge under the clamp ring of the … |
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[Page 57] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-15 (18) 4 Lift the cooler above the diode to be removed with one hand and extract the diode with the other. Figure 8-20 Removi… |
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[Page 58] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-16 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 12 Remount the phase module in the cabinet following section 7.3 Installing a Phase Module . 13 If a defective part h… |
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[Page 59] ABB ACS 6000 ABB Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 8-17 (18) 3 Disconnect the fiber optic cable and the power supply lead of the IGCT to be replaced. 4 Loosen all hexagon fastenin… |
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[Page 60] ABB ACS 6000 Chapter 8 — Changing Diodes and IGCTs in 7/9 MVA Phase Modules ABB 8-18 (18) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 8 Prepare the components for reassembly. Check the contact surfaces of the new IGCT, the cooler and the isolator disk … |
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[Page 61] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-1 (8) Chapter 9 — Changing Thyristors in EXU The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • 1/2 » reversible ratchet • 13 m… |
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[Page 62] ABB ACS 6000 Chapter 9 — Changing Thyristors in EXU ABB 9-2 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 9-1 3-phase AC Power Controller 9.3.1 Preparatory Steps 1 Check that the drive has been deenergized and voltages have been removed from t… |
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[Page 63] ABB ACS 6000 ABB Chapter 9 — Changing Thyristors in EXU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-3 (8) 4 Open the bolts completely and remove the broken thyristor together with the plastic guide. Figure 9-3 Removing a Thyristor 5 Remove the plasti… |
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[Page 64] ABB ACS 6000 Chapter 9 — Changing Thyristors in EXU ABB 9-4 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 4 Place the deflection gauge in the middle of the clamp (see Figure 9-5 ) and reset the dial to zero. Figure 9-5 Placing the Deflection Gauge 5 … |
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[Page 65] ABB ACS 6000 ABB Chapter 9 — Changing Thyristors in EXU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-5 (8) Figure 9-6 6-pulse Thyristor Rectifier 9.4.1 Preparatory Steps 1 Deenergize the drive. See section 9.2 Safety . 2 Remove the fuse and the fuse s… |
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[Page 66] ABB ACS 6000 Chapter 9 — Changing Thyristors in EXU ABB 9-6 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 4 Pull the broken thyristor out of the plastic guide. Figure 9-8 Removing a Thyristor 5 Remove the gate wires from the broken thyristor. 9.4.2 Tr… |
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[Page 67] ABB ACS 6000 ABB Chapter 9 — Changing Thyristors in EXU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 9-7 (8) under warranty, follow the procedures as stated in the Warranty Directive (this is recommended even if the warranty period has expired). Figure… |
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[Page 68] ABB ACS 6000 Chapter 9 — Changing Thyristors in EXU ABB 9-8 (8) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 69] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 10-1 (6) Chapter 10 — Changing Semiconductors in VLU The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • 1/2 » reversible ratchet �… |
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[Page 70] ABB ACS 6000 Chapter 10 — Changing Semiconductors in VLU ABB 10-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 10.3.1 Preperatory Steps 1 Check that the drive has been deenergized and voltages have been removed from the cabinet. See section 10.2 Sa… |
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[Page 71] ABB ACS 6000 ABB Chapter 10 — Changing Semiconductors in VLU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 10-3 (6) 1 Remove the isolator disk above the diode and pull the diode out. 2 Continue with section 10.3.5 Finishing Steps , step 1. 10.3.3 Replac… |
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[Page 72] ABB ACS 6000 Chapter 10 — Changing Semiconductors in VLU ABB 10-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 3 Pull down the retaining rods until the faulty IGCT is free. Figure 10-5 4 Remove the isolator disk and the diode above the IGCT. 5 Pull o… |
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[Page 73] ABB ACS 6000 ABB Chapter 10 — Changing Semiconductors in VLU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 10-5 (6) 10.3.4 Replacing Lower Diode When only one person replaces the lower diode it is recommended to remove all components in the stack above t… |
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[Page 74] ABB ACS 6000 Chapter 10 — Changing Semiconductors in VLU ABB 10-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 5 Tighten the pressure adjusting bolt until the clamp pressure loading gauge is released 6 Refit the clamp loading gauge in its storage pl… |
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[Page 75] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 11-1 (6) Chapter 11 — Changing IGCTs in DIU The tools listed below are part of the tool set (ident. no. 3BHS130246) delivered with the ACS 6000. • 1/2 » reversible ratchet • 24 mm s… |
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[Page 76] ABB ACS 6000 Chapter 11 — Changing IGCTs in DIU ABB 11-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual The DIU is located in the bottom left corner of a CBU. The CBU is available in two different sizes depending on the power rating of the converter (… |
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[Page 77] ABB ACS 6000 ABB Chapter 11 — Changing IGCTs in DIU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 11-3 (6) 3 Take off the clamp head to release the clamp pressure. Figure 11-2 Clamp Head The clamp head is fairly heavy and the DIU is not very well access… |
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[Page 78] ABB ACS 6000 Chapter 11 — Changing IGCTs in DIU ABB 11-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 4 Remove the fastening bolts of the IGCT. The bolts require a 10 mm socket. Figure 11-4 Fastening Bolts 5 Remove the faulty IGCT. Figure 11-5 IGCT … |
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[Page 79] ABB ACS 6000 ABB Chapter 11 — Changing IGCTs in DIU ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 11-5 (6) 1 In case the new IGCT is not fitted with a mounting bracket (see Figure 11-5 ) remove this part from the faulty IGCT and mount it on the new IGC… |
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[Page 80] ABB ACS 6000 Chapter 11 — Changing IGCTs in DIU ABB 11-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual |
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[Page 81] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-1 (14) Chapter 12 — Replacing Printed Circuit Boards 1 Deenergize and ground the ACS 6000. Danger: The ACS 6000 is a high voltage device. Make sure that the cabinet has been completely de… |
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[Page 82] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-2 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 12-1 AMC Board 12.2 Replacing an AMC3 Board |
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[Page 83] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-3 (14) AMC3 boards are mounted inside a COU cabinet. Depending on the layout of the COU the fitting position of the board is on the swing fram… |
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[Page 84] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-4 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 7 Attach the new AMC3 board. Note: It is important that all fastening screws are used to ensure proper grounding of the board. 8 Recon… |
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[Page 85] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-5 (14) 3 Remove the flash memory PCB by holding it with both hands and pulling it at a 90° angle away from the AMC board. Figure 12-4 Removin… |
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[Page 86] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-6 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 12-6 Inserting the New Flash Memory PCB 5 Put the defective board into an antistatic bag. 6 Power up the drive and confirm its pr… |
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[Page 87] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-7 (14) Figure 12-7 INT Board 12.4 Replacing an INT Board b EPLDs c Pulse Pattern Flash a |
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[Page 88] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-8 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Depending on the configuration of the ACS 6000, INT boards are located in the following cabinets: •ARU The INT board is mounted on t… |
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[Page 89] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-9 (14) •COU Figure 12-9 shows the INT board installed on the back side of the right front door. Depending on the layout of the cabinet and … |
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[Page 90] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-10 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 1 Put the new INT board next to the board being re- placed. Transferring the EPLD Chips 2 Extract the EPLD chip using an appropriate to… |
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[Page 91] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-11 (14) 9 Mount the new INT board using all fastening screws. Note: Use all fastening screws to ensure proper grounding of the board. 10 Recon… |
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[Page 92] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-12 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 12-11 CVMI Board 12.5 Replacing a CVMI Board SCA Board SVA Board |
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[Page 93] ABB ACS 6000 ABB Chapter 12 — Replacing Printed Circuit Boards ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 12-13 (14) CVMI Boards are installed in the following cabinets: •ARU •INU In converters with power ratings above 7 MVA, the CVMI board is moun… |
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[Page 94] ABB ACS 6000 Chapter 12 — Replacing Printed Circuit Boards ABB 12-14 (14) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual 9 Verify the connections by comparing them with the corresponding wiring diagram. 10 Put the defective board into an antistatic bag. 1… |
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[Page 95] ABB ACS 6000 ABB ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-1 (6) Chapter 13 — Function of LEDs Figure 13-1 AMC3 Board 13.1 AMC Board R P T2 S1 S0 F M T1 S3 S4 |
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[Page 96] ABB ACS 6000 Chapter 13 — Function of LEDs ABB 13-2 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Table 13-1 LEDs LED LED Color Function Run green Always OFF Fault red Not used (ON when booting) P green Supply OK M green Not used (ON when booting) T1 … |
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[Page 97] ABB ACS 6000 ABB Chapter 13 — Function of LEDs ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-3 (6) Figure 13-2 INT Board 13.2 INT Board V561 V562 V563 V564 V565 V566 V567 V568 |
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[Page 98] ABB ACS 6000 Chapter 13 — Function of LEDs ABB 13-4 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Table 13-2 LEDs of INT Board in ARU LED LED Color Function Y561 yellow Always OFF Y562 yellow ON = ARU modulating Y563 yellow ON = tripped Y564 yellow ON… |
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[Page 99] ABB ACS 6000 ABB Chapter 13 — Function of LEDs ACS 6000 Maintenance Manual 3BHS202077 ZAB E01 Rev. C 13-5 (6) Figure 13-3 GUSP Table 13-5 is applicable for GUSP units with the following ID numbers: • 3BHB005243R0105 (GUSP type KU C755AE105) • 3BHB005243R0106… |
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[Page 100] ABB ACS 6000 Chapter 13 — Function of LEDs ABB 13-6 (6) 3BHS202077 ZAB E01 Rev. C ACS 6000 Maintenance Manual Figure 13-4 IGCT 13.4 IGCT Yellow Green Table 13-6 LEDs Yellow LED Green LED Function ON ON Output stage functions correctly (U out > 10 V) No overl… |
(Ocr-Read Summary of Contents of some pages of the ABB ACS 6000 Document (Main Content), UPD: 08 February 2023)
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60, POWER ELECTRONICS AND CABINET FEATURES PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 60/266 3.2.6.1. Cooling circuit The water cooling system distinguishes two circuits for dissipating heat losses (Fig. 3-19): – Internal cooling circuit: circulates coolant (distilled/deionized cooling liquid) and transfers the heat losses of the main power components to the exterior. The internal cooling circuit…
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180, OPERATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 180/266 8.10. Stopping the drive 8.10.1. Stopping the drive locally 1. To stop the drive, press the STOP key on the control panel. The motor stops according to the preset stop function. While the motor stops, the status line of the display shows ReadyRef and the run status message blinks. NOTE – During the stop sequence, you can restart the drive by pressing the START key.…
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13, ABB ACS 6000 FIGURES PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 13/266 Figure 6-2 Grounding the input side (A) and output side (B) of the drive system ………………………………………………………………………………………………………119 Figure 6-3 System ground connection (1) in a 600 mm TEU ………………………………. 120 Fi…
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201, CDP CONTROL PANEL PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 201/266 9.2.4.1. Adjusting the display contrast 1. To enter the functions mode, press the FUNC key. 2. To select the contrast adjustment function, press the slow navigation keys until the blinking cursor reaches the CONTRAST line. 3. Press the ENTER key. 4. To change the contrast, press the slow navig…
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132, ELECTRICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 132/266 6.7. Power, ground and equipotential bonding conductor cables Overview The following sections describe how to prepare and route cables. For a description on how to prepare the cable entries, see “6.6 Preparing cable entry systems for TEU, ARU and EXU cabinets” on page 128. See “Appendix C — Mechanical …
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135, ELECTRICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 135/266 3. Slide the grommet onto the cable and ensure that the grommet fits tightly to prevent water from entering the cabinet. NOTE – If cables are entered through the cabinet floor, the grommets can be discarded. 4. If necessary, remove the entry plate and push the cable through the entry holes. 5. Prepare standard cables according to Fig. 6-20. 6. Prepare EXU cables accord…
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82, ABB ACS 6000 TRANSPORTATION, STORAGE AND DISPOSAL PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 82/266 4.6. Storage The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. For information on longer storage periods, contact the ABB service organization. 4.6.1 Storage conditions The minimum requirements for storage are base…
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242, ABB ACS 6000 PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 242/266 10.4.10.2. Installing a phase module 1. Check that the busbars (arrows) of the phase module are lubricated. NOTE – If necessary, apply a thin layer of the supplied electrical contact grease. 2. Make sure that the disconnected water hoses, fiber optics and power supply leads are out of the way b…
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83, TRANSPORTATION, STORAGE AND DISPOSAL PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 83/266 4.6.3.1. Warranty information IMPORTANT! Check the spare parts immediately after receipt for damages and report any damage to the shipping company and the ABB service organization. Observe the following to maintain spare parts in good condition and to keep the warranty valid during the warranty period: – Keep spare parts in their orig…
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189, CDP CONTROL PANEL PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 189/266 The actual signals display appears first when entering the actual signals mode. However, when the drive is in a fault condition, the fault memory display appears instead. The actual signals display is used to monitor the drive without interfering with its operation. It continuously displays th…
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238, PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 238/266 6. Check that the LEDs are lit as shown. 7. Check that tools and foreign objects are not left inside the cabinets. 8. Close and lock the doors. 9. Check that the power operating mode (POM) of the drive corresponds to the busbar connectors fitted. 10. Start the drive acc…
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34, IMPORTANT SAFETY INFORMATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 34/266 2.5. The 7 steps that save lives ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. 1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash. …
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263, PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 263/266 5. Disconnect the water tubes (1) from the air-to-water heat exchanger, unplug the cables (2) and remove the fastening screws. Figure 10-30 Air-to-water heat connections 6. Lift the heat exchanger out of the cabinet. CAUTION! The heat exchanger weighs approximate…
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259, PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 259/266 2. Remove the 6 screws from the fan cover and then remove the fan cover. 3. Unplug the fan cables. 4. Remove the 4 fastening screws from the outside panel of the fan unit.
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221, PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 221/266 • If the LED is lit, the grounding switch is released. 6. Check the discharging level of the DC link. • If the value of the parameter 2.01 DC VOLTAGE is below 50 V, the DC link is discharged. • If the DC link is discharged, the drive is in “ReadyOn” status. • Check that the me…
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96, MECHANICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 96/266 5.7.2. Ground busbars Figure 5-6 Ground busbar joints Item Quantity Technical parameters Identification 1) Connecting plate 2 Flex 3BHB010246R0001/R0051 2) Hex-head bolt 4 M12 x 40-A2 NB 312350P8119 3) Hex-head nut 4 M12-A2-70, coated HZN 452198P1022 4) Conical spring washer 8 13 x 2…
Table of Contents for ABB ACS 6000:
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MECHANICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 92/266 5. After adjusting a pipe joint, alternately tighten the bolts lightly. 6. Tighten the bolts to the torque indicated on the pipe joint. 5.6.1. Removing a pipe joint 1. Loosen the bolts alternately but do not remove them completely. 2. Slide the pipe joint to the side. NOTE – The sealing lip can touch the pipe end. 3. Turn and move the pipe joint
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CONTENTS PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 6/266 6.5.2. Frame with type 2 sealing modules ……………………………….. 127 6.5.3. Plates with cable glands ……………………………………………….. 127 6.5.4. EMC plates with sealing grommets ………………………………. 128 6.6. Preparing cable entry systems for TEU, ARU and EXU cabinets ……………
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PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 222/266 Figure 10-9 Grounding switch grounded 2. Slide the locking bar from the locked (1) to the unlocked (2) position. • Door hinged on the left: • Door hinged on the right: 3. To release the door handle, insert and turn the key to the right. The door handle pops out. 1) White lamp 2) Yellow lamp 1 2 1 2 1 2 8 mm
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— SYSTEM DRIVES ACS6000 User manual OWNING ORGANIZATION ABB Switzerland Ltd. DATE 2020-11-18 STATUS Approved SECURITY LEVEL Public DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 1/266 © Copyright 2005 ABB All rights reserved.
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MECHANICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 90/266 5.5. Joining transport units This section applies to drives that are delivered in multiple transport units. Procedure 1. Join the transport units at the connection points that are indicated in Fig. 5-1. NOTE – Some of the connection points might not be accessible in certain configurations. In such cases, you only need to join the connection points that you can access. Figure 5-1 Connection point locations on transport unit
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CDP CONTROL PANEL PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 191/266 2. To select a line where the actual signal is to be displayed, press the slow navigation keys. A blinking cursor indicates the selected line. 3. To enter the actual signals selection function, press the ENTER key. 4. To select a parameter group, press a fast navigation keys. 5. To select an actual signal, press a slow navigation keys
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POWER ELECTRONICS AND CABINET FEATURES PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 52/266 3.2.5.2. Control system configuration The control system of the drive has a decentralized structure to support the modular design of the drive and to ensure fast and reliable data and signal transfer between the individual drive units. Identical hardware is used for control, monito
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PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 263/266 5. Disconnect the water tubes (1) from the air-to-water heat exchanger, unplug the cables (2) and remove the fastening screws. Figure 10-30 Air-to-water heat connections 6. Lift the heat exchanger out of the cabinet. CAUTION! The heat exchanger weighs approximately 16 kg and requires a minimum overhead clearance of 85 cm. Figure 10-31
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MECHANICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 103/266 5.8.1.1. Installation Procedure: 1. Before lifting the heat exchanger onto the roof, cut off the cable ties. 2. Loop the cables as illustrated and fasten them to the cable tie mounts (circles). 3. Loop a length of the cables and fasten them to the cable tie mount (circle). NOTICE Risk of damage! Incorrect installation
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ELECTRICAL INSTALLATION PRODUCT ACS6000 DOCUMENT KIND User manual DOCUMENT ID. 3BHS212794 E01 REV. N LANG. en PAGE 122/266 6.4.1. Optical fiber cables 6.4.1.1. Installing the standard optical fibers 1. Pull all cables through the cable duct (3) at the top of the cabinets. NOTE – Cut-outs in the ducts provide entry into the cabinets. Figure 6-5 Cable tray and cable ducts in an LSU (A = front) 2. Lay the cables into their designated
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ABB ACS 6000 frequency transformer Manual
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