ACS 1000WCU Manual 3BHS204366 E02 RevA

ACS 1000Medium Voltage Drives

315 to 5000 kW400 to 6700 hp

User’s ManualWater Cooling Unit

ABB

Document No.: 3BHS204366 ZAB E02 Rev. A

Issued: 29-06-2005

© ABB Switzerland Ltd. All Rights Reserved.

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 forwarding to third parties, is not permitted.

This document has been checked with due care and attention. However, should the user find any errors, these should be reported to ABB.

ABB aims to maintain the most modern standard, therefore, entries in this manual may differ from the actual product.

3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit

ABB

Table of Contents

Chapter 1 - Safety 1-1

Chapter 2 - Installation 2-1

2.1 Raw Water Connections 2-12.1.1 Hose Connection (Standard) 2-12.1.2 Hose Connection Side Entry 2-32.1.3 Flange Connection (Option 2-32.2 Drain Connection 2-4

Chapter 3 - Starting up the Cooling System 3-1

3.1 Checks before Start-up 3-13.2 Filling the Cooling System 3-13.3 Adding Water to the Cooling System 3-5

Chapter 4 - Draining the Cooling System 4-1

Chapter 5 - Checking Actual Values 5-1

5.1 Water Conductivity 5-15.2 Water Pressure 5-15.3 Water Temperature 5-25.4 Water Level 5-3

Chapter 6 - Tightening Torques, Threaded Connections 6-1

6.1 Tightening Torques 6-16.2 Sealing off Threaded Connections without O-rings and

Gaskets 6-1

Appendices

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)

ABB

2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit

ABB

Chapter 1 - Safety

This manual should be read thoroughly and understood before work on the cooling system is started.

See ACS 1000 User's Manual, Chapter 1- Safety for explanation on how the safety messages are categorized and used in this manual.

NOTICE!

The cooling system may start automatically as soon as the auxiliary voltage is switched on. The pump is switched on depending on temperature and conductivity of the pure water or internal air temperature.

NOTICE!

Valves, tubes and hoses are delicate parts. Do not bend or put any pressure on the valves, tubes and hoses.

NOTICE!

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.

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1-1 (2)

Chapter 1 - Safety ABB

1-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit

ABB

Chapter 2 - Installation

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 A - Water Cooling Unit.

Figure 2-1 Raw Water Entries

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

Figure 2-2 Duct Plates

2.1 Raw Water Connections

Bottom entryTop entry

Exchange duct plate (top) and blanking plate when hoses are entered from belowInlet

Outlet


Chapter 2 - Installation ABB

Figure 2-3 Connecting the Water Hoses



Customer side piping

Enter flexible hoses


Connect hoses to raw water supply using appropriate flanges (inner diameter of hoses 32 mm)


Cut hoses to length


ABB Chapter 2 - Installation


Figure 2-7 Nipple Dimensions

2.1.2 Hose Connection Side EntryIf the hose cannot be entered through the standard openings, a cut-out in the side wall can be made (not possible if the converter is equipped with a braking chopper).

The drawing 3BHS127525 shows the cut-out.

If the duct plate (see Figure 2-2) is mounted on the side, an additional blanking plate (3BHL000641) must be used to cover the standard entry opening.

2.1.3 Flange Connection (OptionAs an option, the converter can be equipped with flanges for raw water connection through the side (not possible if the converter is equipped with a braking chopper), back or bottom of the cooling unit. The external water


Connect hoses to inlet

Fasten hoses with supplied clamps



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

Figure 2-8 Flange Connections

The dimensions and position of the flanges are shown in the layout drawing. The tightening torque of the bolds depends on the size and must be determined by the installation personal.

The water cooling unit is equipped with a drain connector. The drain connector is located behind a cover below the door of the water colling unit. The drain connector is suitable for a hose with an internal diameter of 13 mm (0.5118 ") (see Figure 2-10).The drain hose is not supplied with the converter. To prevent water from leaking, a shut-off valve must be installed

Figure 2-9 Leaking Water Connection

Upward bend Downward bend

2.2 Drain Connection


ABB Chapter 2 - Installation

Figure 2-10 Drain Connector

Ø D(mm)

Ø D1(mm)

C F(mm)

L(mm)

L1(mm)

Ø T(mm)

13 15 R1/2 22 50.5 29.5 12


ABB

Chapter 3 - Starting up the Cooling System

NOTICE!

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.

Information on the positions of all valves in the operating state can be obtained from the Flow Diagram:

Filled valve symbols in the flow diagram indicate valves in shut position.

Proceed as follows:

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

2 Close valves V12, V14, V80, (V81), and V82.

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.

3.1 Checks before Start-up

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

3.2 Filling the Cooling System

Table 3-1 Drinking Water Specification

Parameter Value

pH 7 – 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


Chapter 3 - Starting up the Cooling System ABB

IMPORTANT!

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

Cooling Water withAnti-Freeze

When the converter has been ordered with an anti-freeze, a container with the appropriate type and amount of glycol is supplied with the converter.

CAUTION!

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 must be followed.

IMPORTANT!

The conductivity of glycol as it is used in cars is too high.The converter cannot be started if the conductivity level is too high.Only pure ethylene glycol which acts only as an anti-freeze and has no inhibitors for corrosion protection is permitted for the converter.

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 3-2 Characteristic Values of the Anti-freeze

Parameter Value

Content > 99.8 %

Density at 20 °C (68 °F) 1.1133 - 1.1140 g/cm3

Viscosity at 20 °C (68 °F) 19 mm2/s

Specific heat capacity at 20 °C (68 °F) 2.3 kJ/kgK/l

Thermal conductivity 0.29 W/mK

pH-value neutral

!

!


ABB Chapter 3 - Starting up the Cooling System

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.

4 Thoroughly mix the ethylene glycol mixture.

IMPORTANT!

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 [-Q5021] /( -Q12 [-Q5023] of the pump(s).

7 Switch on the auxiliary voltage.

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.

Table 3-3 Water 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 %

!



If the 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..

IMPORTANT!

Filling rate <= 15 l/min.

12 Stop filling water when the level in the expansion vessel is approx. 80 %.

13 Close valve V14 and open valve V1, V11 and V15 (if 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.

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.

17 Close the motor protection switch -Q11 (-Q5021).

18 Check the level in the expansion vessel. If the level drops below 10% stop the pump and top up water.

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.

!


ABB Chapter 3 - Starting up the Cooling System

DANGER!

Hazardous voltage!

Voltage can cause physical injury and death.The auxiliary supply must be turned off before starting work on terminal X10.

20 Cooling unit with one pump: run the pump for 30 minutes to vent the converter and proceed with step 25.

21 Cooling unit with two pumps: 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 (-Q5021).

23 Switch on -Q12 (-Q5023).

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 12.

26 Close valve V12.

27 Disconnect the hose.

28 Remove the temporary jumper.

IMPORTANT!

The temporary jumper must be removed before the converter resumes operation.

29 Cooling unit with one pump: close -Q11 (-Q5021).

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 see Appendix G - Signal and Parameter Table.

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.

!

3.3 Adding Water to the Cooling System



Cooling water can be added, while the converter is in operation, provided the conductivity is below 0.4 µS/cm.

IMPORTANT!

When filling cooling water while the converter 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.

DANGER!

Hazardous voltage!

When the drive is in operation, voltages are present in the control section. Do not touch any live circuitry!

Proceed as follows:

1 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.

2 Close valve V11.

3 Open valve V14 and start the filling.

IMPORTANT!

When filling cooling water during operation, fill the water in slowly to prevent that the converter shuts down on a conductivity fault. Recommended filling rate: less or equal 2 l/min.

4 Stop the filling after about 5 l of water have been added.

5 Close valve V14.

6 Open valve V11.

7 After the conductivity is down to 0.4 µS/cm again, repeat steps 3 to 7. Stop the filling when the water level in the expansion vessel is approx-imately 80%.

8 Remove the hose.

!

!


ABB

Chapter 4 - Draining the Cooling System

WARNING!

If glycol is used in the cooling water, see section Cooling Water with Anti-Freeze, page 3-2, for safety information.

Proceed as follows:

1 Shut down the converter according to the ACS 1000 User's Manual, Chapter 6- Operation.

2 Switch off the motor protection switch(es) -Q11 [-Q5021] /( -Q12 [-Q5023]) 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 converter) 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 cooling unit.

Approx. water quantity to be expected: 7-8 liters.

8 Close the valves and remove the hoses.

9 Close the converter swing frame and remount the fastening screws.

Up to here, the converter has only been drained for repair purposes. To drain the converter completely (for storage purposes) contact the ABB service organization.

!


Chapter 4 - Draining the Cooling System ABB


ABB

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.Actual values can be monitored while the converter is in operation.Water conductivity and pressure depend on the water temperature. Only values registered at the same temperature should be compared.

The actual value of the water conductivity (displayed in µS/cm) can be read on the control panel.

Proceed as follows:

Reading theConductivity on the

Control Panel

1 Select the Actual Display mode on the control panel (see ACS 1000 User's Manual, Chapter 7 - 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 will display the alarm message WtrConduct.

• If the conductivity exceeds the trip threshold of 0.7 µS (see parameter 190.10), the converter will shut down and the panel will display the message WtrConduct.

The actual value of the water pressure (displayed in bar) can be read on the control panel.

Proceed as follows:

Reading the WaterPressure on the

Control Panel


2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select actual signal 03 InvWtrCoolPressure.

3 The reaction of the converter, if the water pressure decreases below the trip threshold of 1.5 bar (see parameter 190.12), depends on the number of pumps:

5.1 Water Conductivity

5.2 Water Pressure


Chapter 5 - Checking Actual Values ABB

• Cooling unit with two pumps: the control panel will display the alarm WtrPressure and the second pump will be switched on. If the water pressure does not increase above the trip threshold after a programmable time, the converter will trip.

• Cooling unit with one pump: the control panel will display the alarm WtrPressure. If the water pressure does not increase above the trip threshold after a programmable time, the converter will shut down.

The actual value of the water temperature (displayed in °C) can be read on the control panel.

Proceed as follows:

Reading the WaterTemperature on the

Control Panel


2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select actual signal 02 InvWtrCoolTemp.

• If the temperature exceeds the alarm threshold (see parameter 190.6), the control panel will display the alarm message WtrTemp.

• If the temperature exceeds the trip threshold (see parameter 190.7), the converter will trip and the control panel will display the trip message WtrTemp.

5.3 Water Temperature


ABB Chapter 5 - Checking Actual Values

The water level can be checked while the converter is in operation.

DANGER!

Hazardous voltage!

When the drive is in operation, voltages are present in the control section. Do not touch any live circuitry!

Proceed as follows:

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. See 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 converter will shut down.

5.4 Water Level


Chapter 5 - Checking Actual Values ABB


ABB

Chapter 6 - Tightening Torques, Threaded Connections

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.

6.1 Tightening Torques

Table 6-1 Tightening Torque for Flanges

DN Hexagon Screw Nut Washer

(D x d x t)Gasket

(D x d x t)Tightening

Torque

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 23 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

1 2 3 4

6.2 Sealing off Threaded Connections without O-rings and Gaskets


Chapter 6 - Tightening Torques, Threaded Connections ABB


ABB

Appendices

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)

ABB

2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit

ACS 1000WCU Manual 3BHS204366 E02 RevA

Documents

Transcript of ACS 1000WCU Manual 3BHS204366 E02 RevA