UM00 ACS6000PrevMaintenance 3BHS214896 E01 RevA

ABBACS 6000 Medium Voltage Drives 3 to 27 MVA Preventive Maintenance Manual Document No.: 3BHS214896 ZAB E01 Rev. A Issued: 26-01-2007 © 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. 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance ABB Table of Contents General Information Contact Information Related Documentation Tools and Personal Equipment Chapter 1 - Safety 1.1 1.2 1.3 Intended Audience and Required Qualifications Safety Instructions Safety Labels and Signs 1-1 1-1 1-1 1-2 Chapter 2 - Inspection and Maintenance 2.1 2.2 2.3 Visual Checks of Converter Cleaning Verification of Software and EPLD Versions, Fault Logger and Parameters 2.4 Inspection of Bolted Connections 2.5 Current-Carrying Connections 2.6 Pipe Joints 2.7 Roof Attachments 2.8 Electric Plugs 2.9 Inspection of Fiber Optic Cables 2.9.1 Visual Checks 2.9.2 Fiber Optic Links to be Tested 2.10 Testing Auxiliary Fans 2.11 Cleaning and Testing Roof Fan Units 2.12 Door Filter Mats 2.13 Inspection of Capacitors 2.13.1 DC Link Capacitors 2.14 Insulation Test 2.15 Board Replacement 2.16 Water Cooling Unit 2-1 2-1 2-2 2-2 2-3 2-3 2-3 2-4 2-4 2-5 2-5 2-5 2-10 2-13 2-16 2-18 2-18 2-19 2-20 2-20 Chapter 3 - Test Run 3-1 ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 1 (2) 2 4.3 Spare Parts and Documentation Documentation and Back-up Copies for Supportline DriveMonitor 4-1 4-1 4-1 4-1 2 (2) 3BHS214896 ZAB E01 Rev.1 4. A ACS 6000 Preventive Maintenance .Spare Parts. Documentation and Software 4.ABB Chapter 4 . Commissioning and Maintenance Emergency Off/Stop Modes and Prevention of Operation Alarms and Faults Troubleshooting Guide ACS 6000 Service and Maintenance Manual ACS 6000 User’s Manual ACS 6000 Commissioning Manual Document Number 3BHS125090 3BHS125149 3BHS125150 3BHS125092 3BHS125393 3BHS125088 3BHS125093 3BHS130246 3BHS196243 3BHS204855 3BHS202077 3BHS212794 3BHS135824 ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Title Power Cable Specification Main Circuit Breaker Specification LSU Main Transformer Specification ARU Main Transformer Specification Voltage Transformer Requirement Specification Asynchronous Motor Specification Synchronous Motor Specification Tool Sets for Installation. A 1 (2) . ABB can be contacted as follows: ABB Switzerland Ltd Medium Voltage Drives CH-5300 Turgi.ac.ABB General Information Contact Information If information is required beyond the instructions in this [email protected] Related Documentation The following documents can be optained from ABB for supplementary information.abb. Switzerland Phone: Fax: E-mail +41 844 845 845 +41 58 589 2984 mv. ABB Tools and Personal Equipment The toolbox provided by ABB contains all necessary tools and equipment for installation. 10ZP Adapter Tempo 557B Power Meter (set to 660nm. no modulation). ZXXX-TM0 • Personal computer with NDPA-02 PCMCIA-card. NDPC-12 optical transmitter / receiver.. optical cables and DriveWindows or DriveDebug • Antistatic vacuum cleaner (for example SV-497 ABF . Commissioning and Troubleshooting. The content of the tool sets is described in detail in document Tool Sets for Installation. commissioning and maintenance of the converter. 96524 Neuhaus-Schierschnitz. for example Fluke 87 • 5 kV Megger.VACUUM 3M 220V from 3M) for cleaning of printed circuit boards • Antistatic brush for cleaning of printed circuit boards • Cloths and brushes for general cleaning • Safety glasses and dust respirator 2 (2) 3BHS214896 ZAB E01 Rev. the following items are recommended for preventive maintenance: • Multimeter with test wires and clips. for example AVO BM11D • Fiber-optic cable tester. 10ZP Adapter • Photom 205A – Optical Power Meter. document no. Haktronics Co. A ACS 6000 Preventive Maintenance . such as • Tempo 253B Led source (set to 660nm. 3BHS130246: In addition to the toolbox. Ltd • LEONI Optical Power Meter LEONI Optical Sender ZXXX-TS0 Fiber Optic GmbH. dBm). the machine and the environment. ! IMPORTANT! Emphazises hints and highlights information. If not observed. If not observed. This manual contains all scheduled maintenance and replacement actions that must be carried out according to the maintenance schedule. Safety instructions must be strictly followed! Non-compliance can jeopardise the safety of personnel. certified and fully acquainted with medium voltage equipment. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev.1 Intended Audience and Required Qualifications The preventive maintenance manual addresses service and maintenance personnel who are responsible for the maintenance of the converter. 1. it will lead to death or life-threatening injury. on time. it could lead to minor or moderate injury or property damage. The personnel must be qualified. and in the described sequence. it could result in death or life-threatening injury. If not observed.ABB Chapter 1 . CAUTION! ! Indicates a potentially dangerous situation. DANGER! Indicates an imminent hazardous situation. NOTICE! Indicates important information related to personal safety and protection of property.2 Safety Instructions Safety instructions are used to highlight a potentially dangerous situation when working on the converter.Safety 1. A 1-1 (2) . WARNING! Indicates a potentially dangerous situation. Chapter 1 .3 Safety Labels and Signs Safety labels are attached to the converter enclosure to alert personnel of potential hazards when working on the converter. The safety labels must always be followed and kept in perfectly legible condition. A ACS 6000 Preventive Maintenance . 1-2 (2) 3BHS214896 ZAB E01 Rev.Safety ABB 1. Appropriate fastening of cables and wires and connection of cable shields and screens. It is strongly recommended to carry out all maintenance work according to the maintenance schedule at the end of this manual and the applicable service instructions. A digital temperature/hygrometer is provided in the tool box for verification.Inspection and Maintenance ! IMPORTANT! Before starting with maintenance. A 2-1 (20) . on time and at the stated intervals. All auxiliary voltages connected to the converter are switched off and cannot be switched on during work (see electrical wiring diagrams for additional voltage supplies). make sure that: • The main supply voltage cannot be switched on during work. check that the voltage at the supply terminals is 0 V. • Integrity of cable insulation. water drops. Permitted range of ambient air temperature and humidity of the converter. Chapter Electrical Information for information. Lock the switch(es) in open position and attach a safety tag. Pay attention to the following: • • Dumpness. Rack out the MCB. The air temperature range is specified on the name plate of the converter.ABB Chapter 2 .1 Visual Checks of Converter Check visually the converter and the ambience. Using a multimeter. It is recommended to have the Inspection and Maintenance Report at hand and to fill it in as you go along with the inspection and maintenance of the converter. See Converter User’s Manual. • • The main supply and the converter are grounded. • • Dust built-up inside the converter room and inside the converter. lock it in open position and tag it. puddles inside the converter. 2. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Save the parameters including parameter groups above 100 in txt or dwp file formats. busbars etc. should be removed with water. Fault Logger and Parameters • Check if it is necessary to update the software or EPLD version. The outside of the converter enclosure can be cleaned using a vacuum cleaner and cleaning cloths.Chapter 2 . A ACS 6000 Preventive Maintenance . Dust inside the cabinets (assemblies. busbars etc.) can be removed with a vacuum cleaner and lint-free cleaning cloths. Use a nylon brush or a vacuum cleaner to remove dust or deposits from holes. Leaks in the water cooling system. components. oily or greasy deposits on assemblies. 2-2 (20) 3BHS214896 ZAB E01 Rev. • • • • 2. • Correct type of signal and power cables. If necessary. Water. Corrossion on electronic boards. Do not use alcohol or solvents when cleaning inside the cabinets. See applicable cable specifications for reference. connectors or busbars. • • • Signs for overheated components. electrostatic-sensitive precautions must be applied and suitable tools must be used when cleaning boards and assemblies which are sensitive to electrostatic discharge. upgrade the EPLD to the recommended version. Cover equipment to prevent dirt from falling into it. 2. See ACS 6000 Software Compatibility List for information.Inspection and Maintenance ABB The outer jacket of a cable must not be damaged. Therefore.and oil-absorbing microfibers such as “3M Scotch Brite”. • • Save the content of the fault logger and clear the fault logger afterwards.2 Cleaning When cleaning inside the converter cabinets observe the following: • The converter contains components which are sensitive to electrostatic discharge. • • • Only use a vaccum cleaner with a soft nozzle. cables or busbars.3 Verification of Software and EPLD Versions. wires. Boards should be cleaned with special care using antistatic brushes and a vacuum cleaner. 6 Pipe Joints Check that all pipe joints are correctly installed and orientated. • If the old parameter file of the drive is available. that with DriveDebug all parameters can be saved in one file but with DriveWindows the parameters must be saved in two different files. A 2-3 (20) .Inspection and Maintenance Note. 2. Torque rate Figure 2-1 Pipe Joint ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Chapter 3 Mechanical Installation for reference. • 2. Refer to the Converter User’s Manual. Save the software in bpg or tar file format. Busbar fastening bolts on the back of the converter.ABB Chapter 2 .4 2. One file includes parameter groups 112 and 190 and the other file includes all parameter groups above 100. carry out or a more extensive check to be able to decide whether all connections have to be checked.5 Inspection of Bolted Connections Current-Carrying Connections The inspection includes the following connections: • • • • Recommended Procedure Terminals of mains and motor cables. DC busbar joints Ground busbar joints Make spot checks first. compare it with the current parameter settings using the compare function in DriveWindows or DriveDebug and save the result of the comparison in txt file format. If several of the bolted connections are not tightened properly. Figure 2-4 Electric Connections of Roof Fan Units 2-4 (20) 3BHS214896 ZAB E01 Rev.Inspection and Maintenance ABB 2.7 Roof Attachments Check that the roof attachments are installed according to the Converter User’s Manual.Chapter 2 . Chapter 3 Mechanical Installation.8 Electric Plugs Check that the power leads are properly connected and the coupling rings tightened. Figure 2-2 Roof Attachment Figure 2-3 Roof Joining Pieces 2. A ACS 6000 Preventive Maintenance . To verify the attenuation of the fiber. Depending on the used type of fiber optic cable the measured attenuation should be not be higher but preferably be below the following limit values: Plastic fiber optic: -16 dBm Hard clad silica fiber: -20 dBm OEI Board (-A2951) in COU 1 The OEI board is used to open the main circuit breaker if a fault condition occurs which requires the main power supply to be disconnected from the converter.2 Fiber Optic Links to be Tested Via the following fiber optic links a continuous signal is transmitted if no fault is present and no signal is sent if a fault has occured. the cable and the sender must be checked separately.9 2.9. Note especially the following: • • • • • Cracks in core or coating of a fiber Minimum bend radius (25 mm) Condition of connectors (both male & female) Installation across sharp edges Tightening of cable ties Cable ties must not deform the fiber-optic cable 2. If the attentuation is not within the limit. The fiber optic cable is only disconnected at the receiver and the attenuation of the link is measured with an optical power meter. disconnect the fiber optic cable from the RX connector of the OEI board (see arrow in Figure 2-5) and measure the light using an optical power meter. The OEI board receives the command to open the main circuit breaker through a fiber-optic link from the master INT board. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 2-5 (20) .Inspection and Maintenance Inspection of Fiber Optic Cables Visual Checks Check visually the condition of the fiber-optic cables. These fiber optic links can therefore be tested without unplugging the cable at the transmitter.ABB 2. after the auxiliary voltage has been switched on and no fault is present.9.1 Chapter 2 . GUSP and CVMI board are illustrated in the wiring diagram of the INU. The cables are not present in all converters. 207 The fiber optic cable transmits fault signals from the GUSP. • Connector 208 The fiber optic cable transmits a hardware based overcurrent signal from the CVMI board. 2-6 (20) 3BHS214896 ZAB E01 Rev.Inspection and Maintenance ABB OEI board -A2951 AMC board -A2401 AMC board -A1401 Figure 2-5 OEI Board The OEI board is illustrated in the wiring diagram of COU 1. INT Board (-A4121) in INU The fiber optic cables at the following connectors of the INT board are disconnected and checked one after the other (see Figure 2-6 to identify the connectors): • Connector A205. A206. INT board. • Connector 208 The fiber optic cable transmits a hardware based overcurrent signal from the CVMI board. INT Board (-A3121) in ARU The fiber optic cables at the following connectors of the INT board are disconnected and checked one after the other (see Figure 2-6 to identify the connectors): • Connector A205. A ACS 6000 Preventive Maintenance . The INT board can be found in the wiring diagrams of INU 1.Chapter 2 . 207 The fiber optic cable transmits fault signals from the GUSP. • Connector A817 and A818 The fiber optic cables transmit diode monitoring signals from LSU 1 and LSU 2. A206. A 2-7 (20) . This cable is only present in converters driving synchronous motors. A802). ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. • Fiber optic cable between AMC board -A2401 in COU 1 (see Figure 2-8 connectors A715. A716) and CCB board -A6081 in the EXU (see Figure 2-9 connectors A801. The fiber optic cable is connected to the cluster modem -A2501 in COU 1 (see Figure 2-7).ABB Chapter 2 .Inspection and Maintenance A818 A817 A205 A206 A207 A208 A203 Figure 2-6 Fiber Optic Cables INT Board The following fiber optic cables must be tested with the cables unplugged at both ends: • Fiber optic cable between AMC board -A2401 in COU 1 (see Figure 2-8 connectors A719. A720) and cluster modem -A5201 in WCU. A A716 A715 ACS 6000 Preventive Maintenance .Inspection and Maintenance ABB AMC board -A2401 is behind AMC board -A1401 Cluster modem -A2501 Figure 2-7 COU 1 A720 A719 Figure 2-8 AMC Board 2-8 (20) 3BHS214896 ZAB E01 Rev.Chapter 2 . ABB Chapter 2 . Refer to the following wiring diagrams for identification of the boards and the fiber optic cables: • • • Wiring diagrams of COU 1 for AMC board -A2401 and cluster modem -A2501 Wiring diagrams of WCU for cluster modem -A5201 Wiring diagrams of EXU for CCB board -A6081) ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev.Inspection and Maintenance CCB board A801 A802 Figure 2-9 EXU Control Swing Frame The attenuation of the cables is verified using a light source which feeds a signal with a defined wavelength (660 nm) into the cable and measuring the attenuation with a power meter at the other end. A 2-9 (20) . The measured values should not exceed the limit values as stated in Table 3-1. (These units are not used in drives which were manufactured before the beginning of year 2004.) Location of Fans Figure 2-10 • Door-mounted Fan Single fan units (see Figure 2-11) are only installed if the converter is equipped with roof fan units. A thermostat can control a single fan or a group of fan units.10 Testing Auxiliary Fans Two types of fan units are used.Electrical Diagrams of the User’s Manual. 2-10 (20) 3BHS214896 ZAB E01 Rev.Inspection and Maintenance ABB 2. The fans are mounted on the back of the hinged cover in the top section of ARU and INU cabinets.Chapter 2 . • Four-fan units (see Figure 2-10) are always installed on the back of the cabinet doors of a COU. A ACS 6000 Preventive Maintenance . Fan Figure 2-11 Location of Thermostats Fan on Printed Circuit Board The fans are controlled by thermostats. To identy the thermostat and the fans connected to it. EXU and WCU. refer to the wiring diagrams of the above mentioned cabinets in Appendix D . A 2-11 (20) .ABB Chapter 2 . Thermostat Figure 2-12 Fan Thermostat in COU The thermostat for the fan unit in an EXU is installed in the EXU cabinet. ARUs and INUs are located on the control swing frame of a COU. See Figure 2-12.Inspection and Maintenance The thermostats for fans installed in COUs. See Figure 2-13. Test Procedure ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Thermostat Figure 2-13 Fan Thermostat in EXU The thermostat controlling the fans in a WCU is installed on the control swing frame inside the WCU. To switch on a fan or a group of fans. restart the drive system according to the Operating Instructions of the User’s Manual. adjust the setting of the thermostat to a low value (see arrow in Figure 2-14).Chapter 2 . 6 7 Turn the setting of the thermostat back to its original value. The fans in COU. replace the complete fan unit. EXU and WCU can be tested while the converter is in operation. A ACS 6000 Preventive Maintenance . Check that the 24 VDC power supply for the fans to be tested is available. 2-12 (20) 3BHS214896 ZAB E01 Rev. Note the setting of the thermostat. 1 2 3 4 De-energize the drive system according to the Operating Instructions of the User’s Manual. the converter must be de-energized and grounded in order to open the cabinet doors.Inspection and Maintenance ABB CAUTION! ! To test the fans in ARU or INU. Figure 2-14 5 Fan Thermostat Check that the fans run smoothly. In case a fan is defect. When finished. A 2-13 (20) . Any part which accidentally dropped into a cabinet must be retrieved immediately. damage or injury may occur.Inspection and Maintenance Figure 2-15 Roof Fan Units DANGER! DC busbars. CAUTION! ! When working on the fan units make sure that small parts cannot fall into the cabinets. are installed underneath the fan units. Therefore. Use compressed air to remove dry dust. Dry thoroughly before re-assembly. Cleaning Proceed as follows: 1 2 De-energize the drive system according to the Operating Instructions of the User’s Manual. carrying dangerous voltages. Remove the four cover screws and the cover (see Figure 2-16). the fan units may only be checked and cleaned after the converter has been de-energized and grounded. Wash off grease and oil residues with lye (max. 75 °C). 3 Clean the deflectors of the fan unit (see Figure 2-16). Otherwise.ABB 2. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev.11 Cleaning and Testing Roof Fan Units Chapter 2 . When finished. ARU / INU Figure 2-17 Thermostat CBU Location of Thermostats 2-14 (20) 3BHS214896 ZAB E01 Rev. For testing the fans.Chapter 2 .Inspection and Maintenance ABB Cover Figure 2-16 4 5 Testing Cleaning the Fan Unit Remount the cover and fasten the screws. LSU. The fans are controlled by thermostats. they can only be opened after the converter has been de-energized and grounded. Provided that the power supply of the fans is available. INU. the fans can be switched on by turning the dial of the thermostat to a low value. A ACS 6000 Preventive Maintenance . Since these doors are linked to the integral door locking system. the doors of the cabinets (ARU. CBU) must be opened in order to access the thermostats (see Figure 2-17). restart the drive system according to the Operating Instructions of the User’s Manual. See arrow in Figure 2-18. Proceed as follows: 1 2 3 4 De-energize the drive system according to the Operating Instructions of the User’s Manual. Turn the setting of the thermostat back to its original value. replace the faulty unit. restart the drive system as described in Operating Instructions of the User’s Manual. Note the setting of the thermostat.Electrical Diagrams of the User’s Manual. refer also to the wiring diagrams of the above mentioned cabinets in Appendix D . Figure 2-18 5 6 7 8 Adjusting the Fan Thermostat Check that the fans run smoothly. If neccessary. A 2-15 (20) .Inspection and Maintenance To identify the thermostat. When finished.ABB Chapter 2 . Check that the 230 VAC power supply for the fans to be tested is switched on. adjust the setting of the thermostat to a low value. To start the fan. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Figure 2-19 Door Filter Type 1 Type 2 is made of plastic and has two semicircular cut-outs at the bottom edge. The filter mats can be changed while the converter is in operation. Proceed as follows: 1 Take off the filter cover. To take off the cover. Figure 2-20 2 Door Filter Type 2 Replace the filter mat. EXU and WCU. To take off the cover.Inspection and Maintenance ABB 2. A ACS 6000 Preventive Maintenance . push it upwards (see arrows in Figure 2-19) as far as it goes and pull it away from the door. Type 1 is made of sheet metal and has two hooks on each side which insert into slots of the door. Two types of filter covers can be present.12 Door Filter Mats Door filter mats are mounted in the cabinets of COU. if the converter has been specified for insulation protection 54. For details of the door filter assembly see Figure 2-20. if necessary.Chapter 2 . reach into the cut-outs with two fingers and pull the cover carefully off the door. 2-16 (20) 3BHS214896 ZAB E01 Rev. A 2-17 (20) .Inspection and Maintenance E= F= 223 +/.0.5 mm 234 +/.ABB 3 Remount the cover. Chapter 2 .0.5 mm Sealing kit SK 3192 100 Figure 2-21 Door Filter Assembly Type 2 (IP54) ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. For the measurement: • If the manufacture value of a capacitor is not available. The manufacture tolerance is 0…+10 % of the nominal value. The clamp capacitors are of self-healing design and therefore regular measurements are recommended.13. The capacitance should be measured in the intervals stated in the maintenance schedule. check if the capacitance was recorded during commissioning. Measurements • 2-18 (20) 3BHS214896 ZAB E01 Rev. Refer to the Wiring Diagrams to identify the capacitors. it must be replaced by a new one.Inspection and Maintenance ABB 2. This value can be used for reference. The converter has also capacitors in the snubber circuit to protect the rectifier diodes and in the clamping circuit to protect the inverter diodes. A capacitance meter is provided in the tool box of the converter. Because of their design the capacitance can decrease due to aging. Pay especially attention to leaking and bulged capacitors. 2. Voltage and temperature are the two main stress factors that influence the lifetime of the capacitors.13 Inspection of Capacitors The power capacitors in the DC link are of self-healing design. The name plate value is not necessarily identical with the manufacture value.1 DC Link Capacitors Visual Inspection Visual inspection should be carried out in the intervals stated in the maintenance schedule. If a capacitor has expanded too much. Disconnect the wires / busbars which connect the DC link capacitors to the rectifier / inverter (see Figure 2-22). A ACS 6000 Preventive Maintenance . Less than 2 % reduction of capacitance from the capacitors individual name plate value is allowed. The capacitors can be bulged as much as 10 mm.Chapter 2 . record the serial number of each capacitor in the inspection report. ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. Record the insulation resistance values of each measurement in the inspection report. 2. If the tightening torque is not specified on the capacitor. use 20 Nm tightening torque. For the measurement: • • Perform the test according to the ACS 6000 Commissioning Manual. A 2-19 (20) . If the capacitance is more than 2 % off the manufacture value the capacitor must be replaced. The power cables to the converter (incoming and outgoing) need to be disconnected for the test. Connect the wires / busbars from the rectifier / inverter with the marked tightening torque (see separate sticker on the capacitor).ABB Chapter 2 . supply transformer and motor.Inspection and Maintenance Figure 2-22 • • CBU Front If available.14 Insulation Test Perform the insulation test every 4th year on the converter. 16 Water Cooling Unit See Service and Maintenance Manual of the water cooling unit for information on : • • • • • • • Water cooling pumps Ion exchange resin Plate heat exchanger Filter Cartridge of Filter Z1 Conductivity Sensor Pressure Transmitter Temperature Sensor 2-20 (20) 3BHS214896 ZAB E01 Rev. it is recommended to install all spare printed circuit boards which are equipped with these capacitors in the converter and use the replaced boards as spares.Inspection and Maintenance ABB 2. The following boards are equipped with electrolytic capacitors: • • • • AMC board INT board IGCT CVMI board 2.15 Board Replacement For reasons of aging of electrolytic capacitors. A ACS 6000 Preventive Maintenance .Chapter 2 . 06 DC2 VOLTAGE Control signals to and from the MCB Observe the functioning of the drive under normal load conditions.01 DC1 VOLTAGE (sum of upper and lower DC voltages) 2.19 SWITCHING FREQUENCY 3. a test run must be performed. During the test run. Using DriveWindows or DriveDebug record the following signals: • • • • • • 1.02 DC1 VOLTAGE 2. all covers are mounted. A 3-1 (2) .01 DC1 VOLTAGE (sum of upper and lower DC voltages) 2.08 MOTOR SPEED (in rpm) 1. equipment grounding is removed. monitor (using DriveWindows or DriveDebug) the behaviour of the DC voltage when the DC link is charged and record the following signals: • • • • 2.Test Run After the maintenance work has been completed.21 MOTOR TORQUE FILT 1. Before starting. no foreign objects are inside the converter. check that: • • • • • all cables are properly connected and all electrical connections are tight.19 MOTOR RMS CURRENT FLT 2. running the motor / process is safe.02 USED TORGUE REF (in %) ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev.ABB Chapter 3 . Test Run ABB 3-2 (2) 3BHS214896 ZAB E01 Rev.Chapter 3 . A ACS 6000 Preventive Maintenance . 3 DriveMonitor Depending on the operation time of DriveMonitor.1 Spare Parts and Documentation When checking the spare parts observe that: • The software version of the spare AMC3 flash memory must correspond to the software version used in the drive. 4. A 4-1 (2) .ABB Chapter 4 . verify that: • • A complete set of documentation (on paper or in electronic format) is on site. When checking the documention. If necessary. load the correct software version and the parameters used in the drive.supportline@ch. mvac.com): • • • • • • Inspection record (xls) Field report (use the MV AC Drives field report template) Parameter backup files (txt or dwp file formats) Software backup files (bpg. All spare boards are of the correct type.Spare Parts. the following is recommended to prevent data loss and to provide the necessary memory space on the harddisk of the DriveMonitor computer: • After 1 to 2 years of operation: data backup on an external harddisk drive or a PC ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. tar file formats) Fault logger data file (dwf or txt file formats) Test run recordings (DriveWindows or DriveDebug monitoring files or paper copy attached to the field report) 4.abb. • • The EPLD chip on the spare INT board correspond to the EPLD version used in the drive. Documentation and Software 4.2 Documentation and Back-up Copies for Supportline For revising and archiving of the factory documentation and for later assistance of the customer sent the following to the MV AC Supportline (MV AC Supportline/CHIND. The Signal and Parameter Table on site corresponds to the software version of the drive. Documentation and Software ABB • After 5 years of operation: change of harddisk of the DriveMonitor computer.Chapter 4 . 4-2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance .Spare Parts. closing-. 5. Rev. not on time The printed circuit boards in the converter and among the spare parts can be replaced with new ones or replaced with refurbished ones Only the printed circuit boards needs to be replaced. waiting. ind. 7. Typical needed working time on the converter (does not include preparation-. software modifications etc. correction and replacement if needed) Performance of on-site work (commissioning. it is recommended to replace both when the actual conductivity reaches the alarm level. 3. the expected lifetime is about 200 000 hours. corrosion and temperature Improvements Improvements 7 Measurements Measurements with auxiliary voltage Insulation test Spare Parts Spare parts 5 I I I P6 I I I P6 I I I R6 I I I P6 I I I P6 P P P P P P P P P P P P P P P P P P P P P P P P P I I I I I I I I I I I I I I I I I I I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I I P I R P I I P P R P I I P I R P I I P P R P I I P I R P I I P R R P I I P I R P I I P P R P I I R I R P I I P P R R I P I I I I R I P I I I I R I P I I I I R R P R I R I R I P I I I I R I P I R I I R I P I I I I R R P R I R I P I I I I R I P R I I I R I P I I I I R R P R R I R I P I I I I R I P I I I I R I P I I I I R R P R I R I R I P I I I I R I P I R I I R I P I I I I R R P R I R I P 4 8 4 12 4 8 4 16 4 8 4 32 4 8 4 16 4 8 4 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1. for the other spare parts are no actions needed Converter improvements based on development. Document number Lang.or traveling-time) The cooling pumps and fans can either be serviced by an authorized service-representative or completely replaced The average lifetime of the deionizer is 2 . Please refer to service instructions and product manuals for more information. etc. the micro filter should be replaced at the same time as the deionizer. based on the maximum allowed temperature in the converter. 4. ©ABB Switzerland Ltd ACS 6000 Maintenance Schedule Legend: Replacement of component Inspection (visual inspection.4 years. depending mainly on the actual water quality. use or disclosure to third parties without express authority is strictly forbidden.) No Action R I P - Years from start-up 0 Start-up Estimated Working Time (hours) 1 Cooling Air filters (if installed) Cooling fan (if installed) 2 De-Ionizer and micro filter 3 Cooling pump gasket Cooling pump (including gasket) 2 Auxiliary cooling fan (if installed) Strainer Aging Capacitors 4 Printed Circuit Boards 5 Battery of UPS (if installed) Connections & Surroundings Fiber optic cables Cable connections Dustiness. not preventively The expected life time of the capacitors depends mainly on the ambient conditions. the actual replacement should be based on the annual measurements. Note! Recommended service intervals and component replacements are based on the operational environment specified by ABB. tests. Page ABB Switzerland Ltd 3BHS224716 en A 1 . measurements. 2.We reserve all rights in this document and in the information contained therein. 6. Reproduction.