ABB变频器 ACS1000_调试手册

ABB

ACS 1000

Medium Voltage Drives

315 – 5000 kW

400 – 6200 hp

Commissioning Manual

Document No.: 3HBS210669 ZAB E01 Rev.-

Issued 13-10-2006

ABB 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.

ABB

Table of Contents

Chapter 1 -Overview (5)

1.1.Safety (5)

1.2.Scope of Commissioning (5)

1.3.Reports (6)

1.4.Related Documents and Parameter References (6)

1.5.Tools (6)

Chapter 2 -Precommissioning Check List (7)

2.1.Office Preparations (7)

2.2.Scope of Delivery (8)

2.3.Pre-Conditions for Commissioning (8)

Chapter 3 -Inspection of Installation (11)

3.1.MCB (11)

3.2.Transformer (ACS 1000i: N.A.) (11)

3.3.Converter Room (12)

3.4.Converter (13)

3.5.Ground Connections (14)

3.6.Motor (14)

Chapter 4 -Safety (15)

Chapter 5 -Connecting Auxiliary Supply to the Converter (17)

5.1.EPS Auxiliary Power Supply (17)

5.2.Phoenix Auxiliary Power Supply (18)

5.3.Checking Of Auxiliary Backup Batteries (21)

Chapter 6 -Commissioning of the Cooling System (23)

6.1.Water-Cooled ACS 1000 (23)

6.1.1.Checking the Internal and External Cooling Circuits (23)

6.1.2.Filling Up the Internal Cooling Circuit (24)

6.1.3.Functional Test of the Redundant Fan (24)

6.2.Air-Cooled ACS 1000 and ACS 1000i (24)

Chapter 7 -Insulation Resistance Measurements (27)

7.1.Preparations (27)

7.2.External MCB (27)

7.3.Internal MCB (only ACS 1000i) (28)

7.4.Transformer (28)

7.5.Converter (Standard Air- and Water-Cooled ACS 1000) (30)

7.6.Converter (ACS 1000i) (33)

Chapter 1 - Overview ABB 7.7.Motor (35)

7.8.Power Cables (36)

Chapter 8 -Preparing the System (37)

8.1.MCB and Protection Relay (37)

8.2.Transformer (37)

8.3.Converter (38)

8.3.1.Standard Hardware (38)

8.3.2.Optional Hardware (40)

8.3.3.Customer Parameters (40)

8.3.4.Motor Parameters in Group 99 And 112 (40)

8.3.5.Testing of the MCB Control and the Tripping Loop (43)

8.3.6.Testing of I/O’s (45)

8.3.7.Testing of Fieldbus-Communication (45)

8.4.Motor (45)

Chapter 9 -Energizing, First Start and Load Test (47)

9.1.Energizing the Converter (47)

9.2.First Start (50)

9.3.Load Test (51)

9.4.Testing of Ride Through and Auto Restart Functions (51)

9.4.1.Main Power Ride Through (51)

9.4.2.Auxiliary Power Ride Through (52)

9.4.3.Auto Restart (53)

Chapter 10 -Final Work (55)

10.1.Spare Parts (55)

10.2.Customer Training (55)

10.3.Parameter Backup (55)

10.3.1.Saving Parameters and System Software using DriveWindow (56)

10.3.2.Saving Parameters and System Software using DriveDebug (59)

10.4.Customer Approval (63)

10.5.Customer Documentation (63)

10.6.Documentation and Back-up Copies for Supportline (63)

10.6.1.Supportline Contact Information (64)

ABB Chapter 1 - Overview

Chapter 1 - Overview

The purpose of the manual is to assist in commissioning the ACS 1000

frequency converter. It includes necessary instructions, practical hints and

references to related documentation to successfully commission the

converter and the related equipment as needed for the application.

NOTICE!

Commissioning of the converter may only be carried out by personnel

who have been certified at “expert” or “master” level by the Product

Responsible Unit.

1.1. Safety

The safety instructions in this manual, in the User’s Manual and the local

safety regulations must be observed to maintain safety to all those

involved in commissioning the drive system.

DANGER!

Working on energized equipment can be a life hazard.

Mechanical forces, electric shock and burn can cause severe injuries or

death.

Safety related work practices must be followed at all times.

Take appropriate measures when working on the drive system.

1.2. Scope

of

Commissioning

Normally, the commissioning engineer is only responsible for the

converter. If agreed by contract, the commissioning engineer can take on

the commissioning of:

?Motor,

?Transformer,

?MCB,

?Protection relays,

?External devises (actuators, sensors etc.).

Chapter 1 - Overview ABB

1.3. Reports

During commissioning, the Commissioning Report and the Field Service

Report and must be filled in. Templates of the documents are available on

the MV AC Drives Portal.

1.4. Related Documents and Parameter References

The following manuals and specifications provide information on the drive

equipment:

?ACS 1000 User’s Manual,

?WCU Operation and Maintenance Manual,

?Signal and Parameter Table,

?Main Circuit Breaker Specification and Application Note,

?Tripping Loop Application Note,

?Power Cable Specification,

?Main Transformer Specification,

?Motor Specification,

?ACS 1000 Service and Maintenance Manual.

When third-party equipment is included in the scope of commissioning

see also:

?Main circuit breaker manual,

?Transformer manual,

?Motor manual.

1.5. Tools

?Toolbox with normal tools like screwdrivers, spanners etc.

?Torque spanner 10 - 75 Nm for hexagon head screws M6 to M12

?Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical

transmitter / receiver, optical fiber cables and DriveWindows or

DriveDebug

?Multimeter with test wires and clips, for example Fluke 87

? 5 kV Megger, for example AVO BM11D

?Water pump equipped with hoses and ISO-R? female connector, for

example Wolfcraft 2200 3000 L/H (PartsOnline code 09811402)

ABB Chapter 2 - Precommissioning Check List

Chapter 2 - Precommissioning Check List

2.1. Office

Preparations

For an efficient commissioning, make sure that the following items are

completed before travelling to site:

?Copy of field service report

?Copy of commissioning report

?Copy of converter documentation

?Information about the scope of delivery

?Information about SW and EPLD updates 1 and 3

?Special tuning instructions for converter 1

?Information on possible converter upgrades 1

?Setting values for motor parameters (equivalent circuit of the motor)

?Commissioning program (to be agreed with customer) ?Needed tools 2

?Suitable megger for insulation test 2

?Digital camera

?(Spare parts for commissioning)

1 Contact MV AC Supportline for information, see chapter 10.6.1

Supportline Contact information

2 See chapter 1.5 Tools

3 Preprogrammed EPLD’s have to be ordered from PartsOnline,

delivering of the ordered part can take several days depending on where it has to be delivered

Chapter 2 - Precommissioning Check List ABB of

Delivery

2.2. Scope

After receiving the converter and related equipment, the customer is

asked to check all items against the bill of material and for shipping

damages. Missing parts should be reported immediately to the carrier and

the project responsible ABB organization. All claims for damage should

be made to the carrier and ABB should be notified.

To avoid unnecessary delay of the commissioning, the commissioning

engineer must assure himself that the equipment is complete and intact.

It is recommended practice to photograph damaged equipment and send

the photographs to ABB and the carrier.

2.3. Pre-Conditions for Commissioning

In order to ensure an uncomplicated and fast commissioning, it is

important that the converter and associated equipment are ready for

commissioning. Reviewing and completing the items in the below list

before the commissioning engineer arrives on site will help to achieve

this.

1. Mechanical Installation of the Converter

?Converter is securely fixed to the floor

?Customer side raw water piping is completed and the pipes

are connected to the converter

?Raw water supply is ready

2. Electrical Installation of the Converter

?All control cables going into the converter are connected,

appropriately labelled and the customer side connections are

completed

?Types and cross sections of control cables are suitable for

the signal type and signal level

?Types and cross section of power cables are selected

according to the “ABB power cable specification”

?Ground cable of converter is tightened on both ends

?Transformer and motor cables are not fastened at both ends

(cables and converter must be meggered before connection)

ABB Chapter 2 - Precommissioning Check List

3. Main Circuit Breaker (MCB)

?The MCB is selected as per “ABB MCB specification”

?High voltage power connections are completed

?The MCB is ready to be tested with the converter

?The MCB protection relay settings are set and tested

?Safety devices (door locks etc.) are tested and in operation

4. Converter Transformer

?Grounding is completed

?Transformer auxiliaries (dehydrating breathers, cooling,

protection devices) are ready

?Safety devices (door looks etc.) are tested and in operation

4. Motor

?Motor is installed, aligned and alignment protocol is available

?Grounding is completed

?Motor auxiliaries (bearing lubrication, space heater, cooling

etc.) are ready

5. Megger Tests

?All power cables to converter transformer, between converter

transformer and converter and between converter and motor

are meggered and the measured values are within the

required limits

?Test report of the megger test is available

If the test is carried out by the converter commissioning

engineer, one additional day per converter-motor combination

needs to be reserved. After the test, the mains cables can be

connected, except at the converter end. The test must comply

with the specification (5 kV / 60 seconds).

Chapter 2 - Precommissioning Check List ABB

6. Power

?Medium voltage is available for start-up of the converter

?Low voltage auxiliary power is available for start-up of the

converter

7. Miscellaneous

?Sufficient number and correct type of spare parts are available

?Sufficient quantity of deionised water is available ?Air conditioning of drive room is ready for load run of converter

?Optional equipment (chiller unit etc.) is ready

ABB Chapter 3 - Inspection of Installation

Chapter 3 - Inspection of Installation

In order to achieve a trouble-free commissioning, it is mandatory that the

installation, including third-party equipment, is inspected.

The status of the installation is checked and it is verified that converter

and related equipment are as specified for the application and have been

installed according to the installation instructions and the applicable

safety regulations.

Checking the installation is performed with the guidance of the

Commissioning Report. Equipment data asked for in the report must be

obtained and noted in the corresponding sections of the report.

If further information on the equipment is required, the applicable

documentation of the manufacturers should be consulted.

3.1. MCB

Check that the main circuit breaker is installed properly according to the

local requirements and according to the instructions in the MCB

documentation. Pay special attention to the following:

?Ambient conditions,

?MCB power circuit connections,

?MCB grounding connections,

?MCB auxiliary voltage supply,

?Interface cabling between the MCB and the ACS 1000,

?Prevention of local control.

The local control of the MCB must be inhibited; all external controls to

the MCB must go through the ACS 1000.

ACS 1000i: N.A. in case the MCB is installed in the converter.

3.2. Transformer (ACS 1000i: N.A.)

Check that the transformer is installed properly according to local

requirements and according to the instructions in the transformer

documentation. Pay special attention to:

?Ambient conditions,

?Transformer power circuit connections,

?All connections must be done with appropriate ends,

Chapter 3 - Inspection of Installation ABB

?Cables and busbars must have sufficient cross-sections in

accordance with load current,

?Sharp bends in high-voltage conductors must be avoided,

?Minimum clearances between phase-to-phase and phase-to-earth

parts must always be observed (this includes also the distances from

cables to windings),

?All connections must be tight and mechanically secure, it is

recommended to use a torque-wrench when tightening bolts for

electrical connections (see Table 3-1),

Table 3-1 Recommended tightening torques for different bolt sizes

Bolt size Tightening torque

Nm

M6 6 (9)

Nm

M8 15 (22)

M10 30 (44)

Nm

Nm

M12 50 (75)

Nm

M16 120 (190)

?Transformer grounding connections,

?Make sure that transformer secondary power circuit protective shield

connections are made according to recommendations (both ends

connected to ground),

?The transformer frame must be connected to the protective

grounding system,

?Interface cabling between the transformer and the ACS 1000.

Room

3.3. Converter

When inspecting the converter room, attention must be paid to the

following:

?Building work must be finished in the converter room.

?The converter room must be clean (free of dust) and dry.

?Air filters must be in place.

?Air conditioning must be available latest when the converter will be

operated continuously.

If the condition of the converter room hampers effective commissiong, the

customer and the responsible ABB project engineer must be informed

immediately.

Cleanness of the converter room should be checked several times during

commissioning.

ABB Chapter 3 - Inspection of Installation

3.4. Converter

The inspection includes the mechanical and electrical installation of the

converter. By visually checking the converter, the commissioning

engineer obtains an overview of the condition of the converter and can

react in time if corrections have to be made.

Useful information on the requirements for the installation site is written in

the User’s Manual of the converter, Chapter 3 - Mechanical Installation

and Appendix C – Mechanical Drawings.

If the installation of the converter has not been carried out as required or

the condition of the converter hampers effective commissiong, the

customer and the responsible ABB project engineer must be informed

immediately.

When inspecting the converter, the checklist below can be used as a

guide. Depending on the configuration of the converter and applicable

options, there might be less or more check items. Always see supplied

parts list, mechanical and electrical drawings for reference.

Check List

?Installation and damages of components.

?Cable openings should be closed to avoid dust entering into the

cabinets.

?Foreign parts, dust and moisture must not be present in the converter

cabinets.

It is very important that there is no dust and moisture inside the

cabinets. Dust and moisture weaken the busbar insulation. Dust

tends to build up on air-cooling elements, thus impairing cooling.

?Converter doors must open and close easily.

If the doors cannot be opened and closed properly, the alignment of

the converter must be checked and corrected.

?Floor fixings must be mounted.

The mounting holes are indicated in Appendix C- Layout Drawing in

the User’s Manual of the converter.

?Cooling water connections must be made.

Information on the flange sizes or project specific features are shown

in Appendix C- Layout Drawing in the User’s Manual of the converter.

?Termination and routing of power cables.

All cable connections between converter and transformer and

between converter and motor are shown in Appendix D – Electrical

Drawings in the User’s Manual of the converter. Project specific cable

entries are indicated in Appendix C – Mechanical Drawings in the

User’s Manual of the converter.

Chapter 3 - Inspection of Installation ABB

IMPORTANT!

Power cables must not be connected at the converter before the

insulation resistance of the converter and the motor have been

measured.

Ground connections must be carried out carefully to prevent that high

potentials will occur in any parts, which can be touched easily.

Inspection of ground connections includes the following:

?The converter must be connected to the ground system of the factory

(system ground).

?The shields of all power cables must be connected to the ground

busbar.

?The cross section of the cable shields must be in accordance with the

Power Cable Specification.

3.6. Motor

The motor area must be cleaned so that it is safe to run the motor. All

waste that can come in contact with the shaft or the cooling air inlets must

be removed.

The motor installation includes the piping of lubrication and water-cooling

system and the alignment of the motor. An alignment protocol must be

available on site.

The motor frame must be connected to the ground network of the plant.

For more details see instructions of the motor manufacturer.

ABB Chapter 4 - Safety

Chapter 4 - Safety

Before power is applied to the converter, it must be checked that all

covers are back in place so that voltage-carrying parts cannot be touched

accidentally. Interlocks, which prevent that medium and high voltage units

can be accessed accidentally, must be in operation.

?Protection covers inside the converter must be refitted.

If covers have to be removed for measuring purposes, appropriate

safety signs and temporary barriers must be installed and personnel

involved in the commissioning must be informed.

?Cabinet door locks must be checked.

The doors should be kept closed whenever possible. This also helps

to keep the cabinets clean.

Door keys should only be given to persons who take part in the

commissioning.

?All openings of the motor must be closed and shaft covers must be

installed.

The area around the motor must be cordoned off to prevent

accidents during the uncoupled motor tests.

?All covers of power cable terminals or terminal boxes in the

converter, motor, transformer and MCB must be closed.

?Open transformer and motor cable ends must be tied together and

properly grounded.

Chapter 4 - Safety ABB

ABB

Chapter 5 - Connecting Auxiliary Supply to the Converter

Chapter 5 - Connecting Auxiliary Supply to the Converter

For the next steps, auxiliary voltage is needed.

The auxiliary power supply can be made according to two different concepts in the ACS 1000. ? With EPS-board (old concept).

?

With Phoenix power supply modules (new concept).

5.1. EPS Auxiliary Power Supply

When the ACS 1000 is equipped with EPS-board(s), it is supplied with one common 3-phase 400, 480 or 575 VAC (other voltages as

engineered option) auxiliary supply for the control electronics and the cooling system.

Procedure for switching on the auxiliary voltage: 4 Make sure that the protection switches Q1, Q11, Q12, Q13, Q14 and all optional switches are off.

5

Check the settings of the protection switches Q1, Q11, Q12, Q13 and Q14 (see Table 5-1 and Table 5-2).

The settings for all other switches are project specific.

Table 5-1 Settings for protection switches (ACS 1000A)

Frame size

A1 A2 / A3

Supply Frequency [Hz] 50 Hz 60 Hz 50 Hz 60 Hz

Q1 (control) 0.94 0.94 0.94 0.94

Q11 (fan 1)

4.25 4.25 7.30 6.87 400 Q12 (fan 2)

4.25 4.25 7.30 6.87 Q1 (control) N.A. 0.78 N.A. 0.78

Q11 (fan 1)

N.A. 3.54 N.A. 5.73 480 Q12 (fan 2)

N.A. 3.54 N.A. 5.73 Q1 (control) N.A. 0.65 N.A. 0.65

Q11 (fan 1)

N.A. 2.95 N.A. 4.78 Auxiliary

Supply Voltage

[V]

575 Q12 (fan 2) N.A. 2.95 N.A. 4.78

Chapter 5 - Connecting Auxiliary Supply to the Converter

ABB

Table 5-2 Settings for protection switches (ACS 1000W)

Frame size

W1 W2 / W3

Supply Frequency [Hz]

50 Hz 60 Hz 50 Hz 60 Hz Q1 (control) 1.62 1.62 1.62 1.62 Q11 (pump 1)

4.10 4.50 4.10 4.50 Q12 (pump 2)

4.10 4.50 4.10 4.50 Q13 (fan 1) 2.61 3.10 2.61 3.10 400 Q14 (fan 2) 2.61 3.10 2.61 3.10 Q1 (control) N.A. 1.35 N.A 1.35 Q11 (pump 1)N.A 4.20 N.A 4.20 Q12 (pump 2)

N.A 4.20 N.A 4.20 Q13 (fan 1)

N.A 2.59 N.A 2.59 480 Q14 (fan 2) N.A 2.59 N.A 2.59 Q1 (control) N.A 1.12 N.A 1.12 Q11 (pump 1)

N.A 3.50 N.A 3.50 Q12 (pump 2)

N.A 3.50 N.A 3.50 Q13 (fan 1) N.A 2.16 N.A 2.16 Auxiliary

Supply Voltage [V] 575 Q14 (fan 2)

N.A 2.16 N.A 2.16

6 Check that the voltage selection in the 3-phase auxiliary transformer T1 is correct selected for each phase.

7

Check that the 3-phase auxiliary voltage supplied from customer side is within tolerance and write down the value (can be measured from terminal X10).

8 Switch on the auxiliary voltage to the converter control electronics with the circuit breaker Q1.

9

Check that the 24 VAC auxiliary voltages at the transformer secondary are correct in all three phases.

10 Check that the 32 VAC auxiliary voltages at the transformer

secondary are correct in all three phases. 11 Check that the output voltage of the EPS-board(s) are ok (27 VDC,

27 VAC and +/- 20 VDC). 12 Check that both the yellow and green LED’s on all subprints on both

GUSP-units (Gate Unit power Supply) are on.

5.2. Phoenix Auxiliary Power Supply

When the ACS 1000 is equipped with Phoenix auxiliary power supplies, the supply can be arranged different ways. The exact configuration can be checked from position 18 in the typecode.

A External 3-phase supply and external 1-phase safe line for control.

B External 3-phase supply and internal UPS.

ABB

Chapter 5 - Connecting Auxiliary Supply to the Converter

D Internal 3-phase supply and external 1-phase supply (no safe line) for

control and internal back-up battery. E Internal 3-phase supply and internal 1-phase supply for control and

internal back-up battery. F Only available for 575 VAC 3-phase supply.

IMPORTANT!

Configurations A and B are only available for 400 VAC / 480 VAC 3-phase supply.

Configurations D and E are only available for ACS 1000i with 60Hz supply network.

Procedure for switching on the auxiliary voltage: 1 Make sure that the switch S5001 (in configration E only) is in position 1 (i.e. the external commissioning auxiliary power supply is used). 2 Make sure that the protection switches Q5051, Q5052, Q5073, Q5021, Q5022, Q5023, Q5024 and all optional switches are off. 3 Check the settings of all protection switches (see Table 5-3, Table 5-4, Table 5-5 and Table 5-6).

Table 5-3 Settings for protection switches (control hardware supply)

1P- Auxiliary Supply

Voltage [V]

3P- Auxiliary Supply

Voltage [V]

120 230 400 480

Q5052 (control) N.A. N.A. 1.6 1.4 Q5073 (aux. trans.)

1 0.5 0.3 / 0.85* 0.25 / 0.7*

*if ACS 1000i with intergrated contactor and configuration B

Table 5-4 Settings for protection switches (ACS 1000A)

Frame size

A1 A2 / A3

Supply Frequency (Hz)

50 Hz 60 Hz 50 Hz 60 Hz Q5021 (fan 1)

4.25 4.25 7.30 6.87 400

Q5023 (fan 2) 4.25 4.25 7.30 6.87 Q5021 (fan 1)

N.A. 3.54 N.A. 5.73 480

Q5023 (fan 2) N.A. 3.54 N.A. 5.73 Q5021 (fan 1)

N.A. 2.95 N.A. 4.78 Auxiliary Supply

Voltage [V]

575

Q5023 (fan 2)

N.A. 2.95 N.A. 4.78

Chapter 5 - Connecting Auxiliary Supply to the Converter

ABB

Table 5-5 Settings for protection switches (ACS 1000W)

Frame size

W1 W2 / W3

Supply Frequency (Hz)

50 Hz 60 Hz 50 Hz 60 Hz Q5021 (pump 1) 4.10 4.50 4.10 4.50 Q5023 (pump 2)

4.10 4.50 4.10 4.50 Q5022 (fan 1) 2.61 3.10 2.61 3.10 400

Q5024 (fan 2) 2.61 3.10 2.61 3.10 Q5021 (pump 1) N.A 4.20 N.A 4.20 Q5023 (pump 2)

N.A 4.20 N.A 4.20 Q5022 (fan 1) N.A 2.59 N.A 2.59 480

Q5024 (fan 2) N.A 2.59 N.A 2.59 Q5021 (pump 1) N.A 3.50 N.A 3.50 Q5023 (pump 2)

N.A 3.50 N.A 3.50 Q5022 (fan 1) N.A 2.16 N.A 2.16 Auxiliary Supply

Voltage [V]

575

Q5024 (fan 2)

N.A 2.16 N.A 2.16

Table 5-6 Settings for protection switches (ACS 1000i)

Frame size

A1 A2 / A3

Supply Frequency (Hz)

50 Hz 60 Hz 50 Hz 60 Hz Q5021 (fan 1) 3.54 3.54 3.54 3.54 Q5022 (fan 2)

5.73 5.73 5.73 5.73 Q5023 (fan 3) 3.54 3.54 3.54 3.54 400

Q5024 (fan 4) 5.73 5.73 5.73 5.73 Q5021 (fan 1) N.A 3.54 N.A 3.54 Q5022 (fan 2)

N.A 3.54 N.A 5.73 Q5023 (fan 3) N.A 3.54 N.A 3.54 Auxiliary Supply

Voltage [V]

480

Q5024 (fan 4)

N.A 3.54 N.A 5.73

4

Check that the one-phase and / or three-phase auxiliary voltage supplied from customer side is within tolerance and write down the value, can be measured from.

? Terminals X11:1 and X11:2 in case of external 1-phase auxiliary power supply.

? Terminals X11:3 and X11:4 in case of internal 1-phase supply (only applicable in ACS 1000i). ?

Terminals X10:1, X10:2 and X10:3 in case of

internal (only applicable in ACS 1000i) or external 3-phase auxiliary power supply.

5

Check that the settings of the UPS modules are correct (if applicable).

? Battery Select: 7.2 Ah ?

Tmax: 5 min