ACS 1000WCU Manual 3BHS204366 E02 RevA

ABBACS 1000 Medium Voltage Drives 315 to 5000 kW 400 to 6700 hp User’s Manual Water Cooling Unit 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 2 5.ABB Table of Contents Chapter 1 .2 2.1 2. Threaded Connections 6.3 5. A 1 (2) .2 Raw Water Connections Hose Connection (Standard) Hose Connection Side Entry Flange Connection (Option Drain Connection 2-1 2-1 2-1 2-3 2-3 2-4 Chapter 3 .1.1 3.2 6-1 Tightening Torques 6-1 Sealing off Threaded Connections without O-rings and Gaskets 6-1 Appendices ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.Starting up the Cooling System 3.3 2.1 6.4 Water Conductivity Water Pressure Water Temperature Water Level 5-1 5-1 5-1 5-2 5-3 Chapter 6 .1.Installation 2.Checking Actual Values 5.Tightening Torques.1 5.1.3 Checks before Start-up Filling the Cooling System Adding Water to the Cooling System 3-1 3-1 3-1 3-5 Chapter 4 .Safety 1-1 Chapter 2 .1 2.2 3.Draining the Cooling System 4-1 Chapter 5 . A ACS 1000 Water Cooling Unit .ABB 2 (2) 3BHS204366 ZAB E02 Rev. A 1-1 (2) . reliable mechanical lifting equipment shall be used wherever possible.Safety This manual should be read thoroughly and understood before work on the cooling system is started. tubes and hoses are delicate parts. NOTICE! Valves. ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. chains etc. NOTICE! Where possible. extreme caution shall be exercised. tubes and hoses. See ACS 1000 User's Manual. Safe. ropes. Pumps and electric motors are equipped with lifting eyes as supplied by the manufacturers. The pump is switched on depending on temperature and conductivity of the pure water or internal air temperature. Do not bend or put any pressure on the valves. NOTICE! The cooling system may start automatically as soon as the auxiliary voltage is switched on. connected to piping or other system components. Chapter 1. Under no circumstances shall items be lifted by means of straps. If lifting of heavy and/or awkwardly positioned items is necessary.ABB Chapter 1 . all components and sub-assemblies weighting over 25 kg have been clearly marked with weight details.Safety for explanation on how the safety messages are categorized and used in this manual. A ACS 1000 Water Cooling Unit .Chapter 1 .Safety ABB 1-2 (2) 3BHS204366 ZAB E02 Rev. Water Cooling Unit.1 Raw Water Connections Hose Connection (Standard) When preparing the piping for the raw water supply. A 2-1 (6) . See Water Cooling Datasheet in Appendix A .1. Top entry Figure 2-1 1 Raw Water Entries Bottom entry Connect the hoses for the raw water circuit following Figure 2-2 à Figure 2-6.ABB Chapter 2 .1 2.Installation 2. consider the maximum length (2 m) of the flexible hoses and the specifications of the raw water interface. Inlet Outlet Exchange duct plate (top) and blanking plate when hoses are entered from below Figure 2-2 Duct Plates ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. Installation ABB 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 2-2 (6) 3BHS204366 ZAB E02 Rev.Chapter 2 . A ACS 1000 Water Cooling Unit . The drawing 3BHS127525 shows the cut-out.2 Hose Connection Side Entry If the hose cannot be entered through the standard openings. back or bottom of the cooling unit. If the duct plate (see Figure 2-2) is mounted on the side.ABB Chapter 2 . 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). a cut-out in the side wall can be made (not possible if the converter is equipped with a braking chopper).3 Flange Connection (Option As an option.1.1. 2. A 2-3 (6) . The external water ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. an additional blanking plate (3BHL000641) must be used to cover the standard entry opening.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. Chapter 2 . The tightening torque of the bolds depends on the size and must be determined by the installation personal. The drain connector is suitable for a hose with an internal diameter of 13 mm (0.2 Drain Connection The water cooling unit is equipped with a drain connector. An example is shown in Figure 2-8. To prevent water from leaking. The drain connector is located behind a cover below the door of the water colling unit. a shut-off valve must be installed Figure 2-9 Leaking Water Connection 2-4 (6) 3BHS204366 ZAB E02 Rev. 2. A ACS 1000 Water Cooling Unit .Installation ABB pipes can be connected directly to the flanges.5118 ") (see Figure 2-10). Upward bend Figure 2-8 Flange Connections Downward bend The dimensions and position of the flanges are shown in the layout drawing.The drain hose is not supplied with the converter. 5 ØT (mm) 12 R1/2 22 Figure 2-10 Drain Connector ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.Installation ØD (mm) 13 Ø D1 (mm) 15 C F (mm) L (mm) 50.5 L1 (mm) 29. A 2-5 (6) .ABB Chapter 2 . Chapter 2 . A ACS 1000 Water Cooling Unit .Installation ABB 2-6 (6) 3BHS204366 ZAB E02 Rev. V11 and V15. 3. (V81).Starting up the Cooling System NOTICE! Do not run the pumps if the cooling circuit is empty.5 < 300 µS / cm 3 – 10° dH < 300 mg/l < 0. Proceed as follows: 1 2 Open valves V1. V80. it is recommended to fill the circuit with deionized water to extend the lifetime of the ion exchange resin. Close valves V12. Table 3-1 Drinking Water Specification Value 7 – 8. A 3-1 (6) . V14. and V82. If a pump runs dry the pump seals will be damaged immediately.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 Flowdiagram for 2 pumps and 2 way valve Flowdiagram for 1 pump and 3 way valve Flowdiagram for 2 pumps and 3 way valve 3-9531-001 3-9531-002 3-9531-003 3-9531-004 Filled valve symbols in the flow diagram indicate valves in shut position. not even for a short time. However. 3. (V2). The cooling water should conform to the values in Table 3-1.1 mg/l < 1000 mg/l Parameter pH Specific conductivity Hardness Chloride (Cl) Copper (Cu) Total dissolved salt ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.2 Filling the Cooling System Cooling Water Drinking water of good quality must be used in the main cooling circuit. V5.ABB Chapter 3 . If in doubt about the quality of the drinking water on your premises contact your local water utility. it must be guaranteed. the values for the desired frost proofing are listed: 3-2 (6) 3BHS204366 ZAB E02 Rev. CAUTION! ! Ethylene glycol is a hazard for humans and animals when swallowed.The safety data sheet supplied by the supplier of ethylene glycol must be followed. A ACS 1000 Water Cooling Unit . a container with the appropriate type and amount of glycol is supplied with the converter.8 % 1. Avoid skin and eye contact and wear protective clothing including rubber gloves and goggles when handling ethylene glycol.The converter cannot be started if the conductivity level is too high. For storing and mixing only clean containers specifically designated and appropriately labelled must be used.1140 g/cm3 19 mm2/s 2.29 W/mK neutral Value When transferring.Only pure ethylene glycol which acts only as an anti-freeze and has no inhibitors for corrosion protection is permitted for the converter. Food stuffs and beverages must be kept separate from the place of work. mixing and filling the anti-freeze. remnants or any other impurities infiltrate the coolant.1.1133 . that no chips.Starting up the Cooling System ABB ! Cooling Water with Anti-Freeze IMPORTANT! Inhibitors and other chemicals must not be added to the water.3 kJ/kgK/l 0. In the following table.Chapter 3 . ! IMPORTANT! The conductivity of glycol as it is used in cars is too high. grease. When the converter has been ordered with an anti-freeze. Table 3-2 Characteristic Values of the Anti-freeze Parameter Content Density at 20 °C (68 °F) Viscosity at 20 °C (68 °F) Specific heat capacity at 20 °C (68 °F) Thermal conductivity pH-value > 99. the mixing procedure should take place at ambient temperature (+ 5 °C to + 30 °C).g. 3BHL001483P0021 corresponds to 21 liter). Close valves V1.Starting up the Cooling System Water Glycol Concentration for the Desired Frost proofing Pure Ethylene Glycol 20 % 34 % 44 % 52 % Distilled Water 80 % 66 % 56 % 48 % Ideally. 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. When mixing the following procedure must be observed: 1 2 Check that the type of ethylene glycol is appropriate (see Table 3-2). V81*. Afterwards. V80. A 3-3 (6) . 3 4 ! Filling the System IMPORTANT! There will be negative effects on the thermal and hydraulic behaviour of the coolant if the water-glycol mixture is not mixed thoroughly. 6 7 8 9 Switch off the motor protection switch(es) -Q11 [-Q5021] / ( -Q12 [-Q5023] of the pump(s).40 °C (-40 °F) Chapter 3 . Open valves V2*. (*only if redundant pump is present) 10 Connect the filling hose to the ISO-R1/2" connector of valve V14.10 °C (14 °F) . V11. e.20 °C (-4 °F) . After filling the system (see following section) the remaining liquid can be used for refills after maintenance or repairs. 11 Open valve V14 and start the filling. Thoroughly mix the ethylene glycol mixture. 1 to 2 bar is required for filling water into the circuit. Fill in distilled water until the level in the container is at approx. Switch on the auxiliary voltage. V15. ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. 3/4. A pressure of approx.30 °C (-22 °F) . V5.ABB Table 3-3 Frost proofing . Using a small pump might be necessary. 5 Fill the container completely. V12. thoroughly mix the liquid again! The required frost proofing has been reached now. if stored in a closed container. 12 Stop filling water when the level in the expansion vessel is approx. If the level drops below 10% stop the pump and top up water. • Disconnect the connector X21 from IOEC board 1.. 80 %. 17 Close the motor protection switch -Q11 (-Q5021). 14 Open the priming plug on the pump house(s) (see Figure 3-1) and vent the pump(s). Close the plug again. 18 Check the level in the expansion vessel. A ACS 1000 Water Cooling Unit . • Plug the connector X21 back into IOEC board 1. 16 Install a temporary jumper. 13 Close valve V14 and open valve V1. 19 Check the system pressure. In this case. ! IMPORTANT! Filling rate <= 15 l/min.Chapter 3 . Valve V15 has to be opened additionally. • Connect a jumper (cross-section 1 mm2) between X21-1 and X21-3 of connector X21. V11 and V15 (if it has not been opened yet). If the pressure remains below trip level (2 bar) the rotation of the pump is not correct.Starting up the Cooling System ABB 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. 3-4 (6) 3BHS204366 ZAB E02 Rev. Figure 3-1 Pump with Priming Plug 15 Close the disconnected terminals -X2:22 to -X2:27. the rotation of the pump must be reversed by changing two phases on the terminal -X10. 23 Switch on -Q12 (-Q5023).Starting up the Cooling System Voltage can cause physical injury and death.2 Filling the Cooling System. 25 Close valve V11 and fill up the expansion vessel according to step 11 to 12.3 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. A 3-5 (6) . conductivity trip level: 0. 24 Run the second pump for 30 minutes to vent the cooling system. 28 Remove the temporary jumper. 3. After filling the cooling circuit. 22 Let the first pump run for 10 minutes and then turn off -Q11 (-Q5021). For more information see Appendix G . • Disconnect the connector X22 from IOEC board 1 • Connect a jumper (cross-section 1 mm2) between X22-1 and X22-3 of connector X22.ABB DANGER! Hazardous voltage! Chapter 3 .The auxiliary supply must be turned off before starting work on terminal X10. ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. Use cooling water as specified in section 3. 29 Cooling unit with one pump: close -Q11 (-Q5021). 26 Close valve V12. ! IMPORTANT! The temporary jumper must be removed before the converter resumes operation.Signal and Parameter Table.5 µS/cm. • Plug the connector X22 back into IOEC board 1.7 µS/cm). the conductivity value might not be in the permitted range (conductivity alarm level: 0. 27 Disconnect the hose. 20 Cooling unit with one pump: run the pump for 30 minutes to vent the converter and proceed with step 25. If this is the case. 30 Reset the alarm. 21 Cooling unit with two pumps: install a temporary jumper. an auto-cooling sequence is started. 4 µS/cm. repeat steps 3 to 7. Close valve V14. 4 5 6 7 Stop the filling after about 5 l of water have been added. ! IMPORTANT! When filling cooling water during operation. After the conductivity is down to 0. Using deionized water is recommended. 1 to 2 bar is required for filling water into the circuit. 8 3-6 (6) 3BHS204366 ZAB E02 Rev. while the converter is in operation. Fill the water in slowly to avoid a trip.Chapter 3 . 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. A ACS 1000 Water Cooling Unit . DANGER! Hazardous voltage! When the drive is in operation. provided the conductivity is below 0. Remove the hose. fill the water in slowly to prevent that the converter shuts down on a conductivity fault. 2 3 Close valve V11. ! IMPORTANT! When filling cooling water while the converter is in operation. Using a small pump might be necessary.Starting up the Cooling System ABB Cooling water can be added. Stop the filling when the water level in the expansion vessel is approximately 80%. Open valve V11.4 µS/cm again. Open valve V14 and start the filling. the conductivity will rise due to the high conductivity of the added water. Recommended filling rate: less or equal 2 l/min. voltages are present in the control section. A pump can be used to speed up the procedure. see section Cooling Water with AntiFreeze. 8 9 Close the valves and remove the hoses. 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). Close the converter swing frame and remount the fastening screws. ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. the converter has only been drained for repair purposes.Draining the Cooling System WARNING! If glycol is used in the cooling water. To drain the converter completely (for storage purposes) contact the ABB service organization. Approx. If a pump runs dry the pump seals will be damaged immediately. A 4-1 (2) . 3 4 Remove the fastening screws of the swing frame and open it by pulling strongly.ABB Chapter 4 . Open the drain valve and drain the inverter. 7 Open V80 / (V81) to drain the cooling unit. Switch off the motor protection switch(es) -Q11 [-Q5021] / ( -Q12 [-Q5023]) of the pump(s) to prevent the pumps from being switched on accidentally. not even for a short time. Open valve V12. water quantity to be expected: 7-8 liters. for safety information. page 3-2. 5 6 Up to here. Proceed as follows: 1 2 Shut down the converter according to the ACS 1000 User's Manual.Operation. CAUTION! ! Do not run the pumps if the cooling circuit is empty. Chapter 6. Draining the Cooling System ABB 4-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit .Chapter 4 . 5 bar (see parameter 190. In group 4.09). The reaction of the converter.10). • If the conductivity exceeds the trip threshold of 0. A 5-1 (4) . the converter will shut down and the panel will display the message WtrConduct. if the water pressure decreases below the trip threshold of 1. Chapter 7 . Select parameter group 4 ACTUAL SIGNALS.ABB Chapter 5 .Parameter Viewing and Editing and Control Panel Functions. Only values registered at the same temperature should be compared. Proceed as follows: Reading the Conductivity on the Control Panel 1 Select the Actual Display mode on the control panel (see ACS 1000 User's Manual. Actual Signal Display Mode). the control panel will display the alarm message WtrConduct.1 Water Conductivity The actual value of the water conductivity (displayed in µS/cm) can be read on the control panel. In group 4. • If the conductivity exceeds the alarm threshold of 0. select actual signal 04 InvWtrConductivity.Checking Actual Values It is recommended to record the values of conductivity.2 Water Pressure The actual value of the water pressure (displayed in bar) can be read on the control panel.7 µS (see parameter 190. Actual Signal Display Mode). Actual values can be monitored while the converter is in operation.5 µS (see parameter 190. Chapter 7 . The conductivity should be below 0. Select parameter group 4 ACTUAL SIGNALS. Water conductivity and pressure depend on the water temperature.12). Proceed as follows: Reading the Water Pressure on the Control Panel 1 Select the Actual Display mode on the control panel (see ACS 1000 User's Manual. depends on the number of pumps: 2 3 ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.Parameter Viewing and Editing and Control Panel Functions. 2 5. water temperature and pressure regularly to determine when water has to be added or the ion exchange resin renewed. 5.5 µS/cm. select actual signal 03 InvWtrCoolPressure. • If the temperature exceeds the alarm threshold (see parameter 190.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. Select parameter group 4 ACTUAL SIGNALS. the control panel will display the alarm message WtrTemp. 2 5-2 (4) 3BHS204366 ZAB E02 Rev. Proceed as follows: Reading the Water Temperature on the Control Panel 1 Select the Actual Display mode on the control panel (see ACS 1000 User's Manual.Parameter Viewing and Editing and Control Panel Functions. If the water pressure does not increase above the trip threshold after a programmable time.Chapter 5 . Chapter 7 .6). 5. • If the temperature exceeds the trip threshold (see parameter 190. In group 4. the converter will trip and the control panel will display the trip message WtrTemp. the converter will trip.7). select actual signal 02 InvWtrCoolTemp.3 Water Temperature The actual value of the water temperature (displayed in °C) can be read on the control panel. A ACS 1000 Water Cooling Unit . the converter will shut down. Actual Signal Display Mode). • 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. If the switch is activated. 2 If the water level is below 80 % the cooling circuit must be topped up.Checking Actual Values The water level can be checked while the converter is in operation. voltages are present in the control section. DANGER! Hazardous voltage! When the drive is in operation. See section 3.4 Water Level Chapter 5 . 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.ABB 5. A 5-3 (4) . ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.3 Adding Water to the Cooling System. The minimum water level is monitored by level switch B10. The water level should be approximately 80%. the converter will shut down. A ACS 1000 Water Cooling Unit .Chapter 5 .Checking Actual Values ABB 5-4 (4) 3BHS204366 ZAB E02 Rev. Thread tape is recommended to seal off: • • stainless steel to plastic connections. ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev.ABB Chapter 6 .80 Nm 6.5 162 x 125 x 1.80 Nm 60 .5 84 x 48 x 1.80 Nm 60 .80 Nm 60 .5 128 x 23 x 1.5 144 x 97 x 1.5 107 x 66 x 1. plastic to plastic connections. A 6-1 (2) .Tightening Torques.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.5 92 x 57 x 1. Threaded Connections 6.80 Nm 60 .1 Tightening Torques Table 6-1 DN Hexagon Screw Nut Tightening Torque for Flanges Gasket (D x d x t) Tightening Torque Washer (D x d x t) 1 25 32 40 50 65 80 100 M12-55 M16-65 M16-65 M16-70 M16-70 M16-75 M16-80 2 M12 M16 M16 M16 M16 M16 M16 3 24 x 13 x 2 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 30 x 73 x 3 4 73 x 40 x 1.5 24 .33 Nm 60 .80 Nm 60 . A ACS 1000 Water Cooling Unit .Tightening Torques. Threaded Connections ABB 6-2 (2) 3BHS204366 ZAB E02 Rev.Chapter 6 . A 1 (2) .ABB Appendices ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit .ABB 2 (2) 3BHS204366 ZAB E02 Rev.