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Commissioning Manual

1. O LN DC_NP 1 Short circuit the NP capacitor 6 2 6 Main Circuit Measurement e The insulation measurement is carried out with 5kV DC voltage e The plus terminal is connected to the combined circuit of the DC link The minus terminal is connected to the ground potential e The measurement time is 60 sec e The lowest value is to be recorded e The value of the insulation resistance must be higher than 0 5 MQ F In the commissioning record write down the measured value of the insulation resistance and the value of the water conductivity present at the time of measurement Carry out the measurement as soon as the pumps have stopped to avoid an error in the conductivity reading ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 35 of 62 Chapter 6 Insulation Resistance Measurement AA ED ED 6 2 7 Excitation Circuit Direct Excitation Brushless Excitation When commissioning an ACS 6000 for synchronous motors the insulation resistance of the excitation circuit must measured as well Take the following preparatory measures for an Excitation Unit EXU 1 Make a short circuit between the two output terminals 2 Make a short circuit between the input phases and connect it to the output terminals Short circuit switch K6201 Short circuit circuit and ground terminal block X614 1 4 Short circuit and ground terminal block X617 1 2 Short circuit and ground terminal
2. Follow the checkpoints of the commissioning report ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 23 of 62 Chapter 4 Commissioning Other Drive Components AA EDER 24 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 5 Preparing the Converter 5 1 Selection Switches and Protective Settings Settings of control board selection switches protective circuit breakers of fans and pumps earth fault relays and timers etc must be checked according to the project related circuit diagrams See ACS 6000 User s Manual Appendix D Electrical Drawings 1 Check that the node addresses of the I O cluster modules in COU WCU and possible customer specific control cabinets are as specified in the circuit diagrams 2 In case of a synchronous drive 1 Check the node address switches or jumpers of excitation control boards CCB PAI MTR and MUB boards in EXU cabinet according to the wiring diagrams 2 Check the node address switch of the rotor shaft position measurement unit GRB unit in the COU cabinet When finished check off the above mentioned items in the commissioning report The supportline must be informed if any changes have been made 5 2 Connecting the Auxiliary Supply Normally the ACS 6000 is connected to a 3 phase 380 690 VAC auxiliary supply Typically there may also be a single phase secured auxiliary supply for the control electronics The terminals and the m
3. 6 Control cable shields must be earthed as described above Safety Ground Check that converter earthing is carried out according to above 4 checkpoints 3 4 Motor Check that the motor installation meets the requirements and fulfills the local regulations For details see the motor documentation The motor installation includes alignment of mechanics piping of the lubrication system and water cooling piping An alignment protocol must be available on site Ee Note Couplings between the motor and the driven machine must be left uncoupled The motor frame must be connected to the plant earthing network at least at one point For more details refer to the instructions of the motor manufacturer Motor bearing sleeves must be insulated from the motor frame at least in one bearing For more details see instructions of the motor manufacturer ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 17 of 62 Chapter 3 Inspection of Installation AA ED ED 3 5 3 6 d Follow the checklist of the commissioning report regarding the motor installation Power Cables d Three phase cables with individually shielded conductors are the preferred cable type for the ACS 6000 Single phase cables can be used if the cable length is less than 100 m These cables must be configured as shown in Figure 3 2 Figure 3 2 Configuration of single phase Cables An additional grounding cable along the power ca
4. 8 1 8 1 1 8 1 2 8 1 3 Digital Inputs After all parameter settings have been done certain internal and external I O signals must be tested When parameter setting has been completed it is reasonable to clear the fault logger and re boot AMC board by cycling the auxiliary power Drive should be in local mode and in ReadyOn state with no alarms or trips active This way observing correct operation of the signals and drive is possible Checking Principle Main principle is that the wiring which has been implemented on site only should be tested Note that correct operation of main circuit breaker signals will be tested also later in connection with charging discharging test All signals should be checked as primary as possible meaning that the state of each sensor should be changed Checking of binary input signals is done by changing the state of each input in process side that is CBs contactors etc If state of switch can not be changed test is done from the nearest terminals of the device All signals are connected to S800 IO modules S800 I O modules have led indication of input status for each channel and an indication of trip alarm is shown in SW e In CDP panel the alarms are displayed in Actual Signal Display Mode The alarm name should correspond in relation to input signal name shown in circuit diagrams e In DriveWindow the alarms are displayed in Fault Logger display Name of each signal
5. Checking I O 8 3 2 Transformer Signals Cleanness rating plate values and thermal protective devices of dry type transformers ABB Resibloc Follow the checkpoints of the commissioning report All checks and insulation measurements of the motor and its auxiliary systems must be carried out according to the instructions of the motor manufacturer Checking of the motor includes the following Insulation resistance The insulation resistance must be measured or the confirmation of the measurement must be obtained Oil quantity Visual check of electrical and pneumatic instrumentation 22 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual All electrical instruments as well as pumps and electrically controlled valves are shown in the circuit diagram of the motor auxiliaries Operation of these devices will be checked when the external signals of the drive are tested see Chapter 8 Checking I O 8 3 1 Motor Signals Quality and flow rate of the cooling water Visual check of the instrumentation Instruments and cooling fans are shown in the circuit diagram of the motor auxiliaries Operation of these devices will be checked when the external signals of the drive are tested see Chapter 8 Checking I O 8 3 1 Motor Signals Leakage During the first operating hours of the water cooling system it must be checked that the cooling system of the motor does not leak Connection of space and oil heaters
6. AC 80 controller option CIU are both present in the converter The task of the FBA is to communicate with the overriding control system and the AC 80 is used to control and monitor external equipment 7 2 1 Fieldbus Adapters Parameter 75 1 Comm Module defines if FBA or ABB Advant Controller is used to communicate an overriding control system After setting parameter 75 1 the ACS 6000 identifies the type of communication interface and opens parameter group 51 Group 51 becomes visible after the signal and parameter table has been uploaded again The content of this group depends on the type of communication interface in use Changes to the group do not come into effect immediately but only after the power of the fieldbus adapter has been switched off and on again Parameter groups 90 and 91 define the dataset communication of the FBA Refer to the customer automation supplier for information on the dataset communication 42 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual ABB Chapter 7 Parameter Settings 7 2 2 Advant Bus Communication If an ABB Advant controller e g AC80 FCI NPBA 02 NCSA 01 is part of the converter parameter 75 1 Comm Module is set to 4 DSET 10 R W or 5 ReadOnly mode for DS10 In this case dataset communication groups 92 95 will be opened in the signal and parameter table 7 2 3 AC 80 Communication Th AC 80 controller connected to channel 4 is activated with parameter 75 2
7. CBU Preparation The following preparatory measures must be taken in a Capacitor Bank Unit CBU DC_plus DC_NP DC_minus Short circuit of DC link busbars is already made in TEU 1 Make a short circuit between the auxiliary contacts of the earthing isolator and connect it to ground X715 9 10 Note that the earthing isolator must be in position NOT EARTHED 2 Short circuit and ground the coil of the charging relay K2CHU X714 1 2 3 Ground the primary side of the charging transformer TCHU X710 7 4 Connect the secondary side of the charging transformer TCHU to the DC link and short circuit the charging diode bridge 5 Short circuit the common mode filter capacitor CGND 6 Disconnect the common mode filter capacitor CGND from PE protective earth 7 Disconnect the HV line from the coupling unit AGH5208S if included in the converter configuration 32 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual 6 2 4 Chapter 6 Insulation Resistance Measurement I le le 5 4 3 8 In case a Braking Chopper Unit BCU is part of the drive make a short circuit between the output terminals of the external resistor ARU INU Preparation The following preparatory measures must be taken in an Inverter Unit INU The same
8. Chapter 13 Speed Controller Tuning AA ED ED Error Step height gt Time Required response time Figure 13 1 Step Response of Speed Control A undercompensated too short intergration time and low proportional gain B undercompensated too low proportional gain C normal D norma when better dynamic performance is needed E overcompensated short intergration time and high proportional gain 60 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 14 Finishing the Commissioning 14 1 Spare Parts Check that the spare parts are available at site and are according to ordered scope of supply If they have not been ordered make a remark in the commissioning report If there is a spare AMC board the final version of the FLASH circuit must be copied on it 14 2 Customer Training Instruct the customer s operators how to use the drive Explain different control modes local remote if applicable If customer has not been trained by ABB explain that the customer has the possibility to participate ABB training programs in training centers worldwide 14 3 Parameter Back up Read all the parameters from the drive by using Drives Window program and save them into a file Be sure that all parameter groups are open and that all parameter values are saved properly In DrivesWindow use the option open all groups Hand out a copy of the parameter settings to the custom
9. function needed to run mechanics Most commonly fast stop signal is used for this purpose 12 2 Final Tuning It is assumed in this chapter that checking and possible tuning is done on line during the loading conditions which are defined by the process during normal operation Measures must only be taken if unwanted operation of the drive is detected See ACS 6000AD TC SW Torque Controller Software commissioning manual for details See also Chapter 13 Speed Controller Tuning section 13 2 for final tuning of speed controller ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 55 of 62 Chapter 12 ACS 6000 Final Tuning AA ED ED 56 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 13 Speed Controller Tuning 13 1 Preliminary Tinung of Speed Controller The first start is normally made using slow speed controller For the first start change Kp temporarily from the initial value 10 for example to 3 Par 24 02 After the first start the speed controller can be made faster step by step Final tuning of the speed controller will be done with coupled mechanics but it is recommended to check the tuning preliminary also as uncoupled This is to clarify that speed controller loop works correctly With uncoupled motor one should reach a better step response as finally with the coupled motor The idea is to get the drive performing as well as required by the driven process The main requir
10. instructions apply to an Active Rectifier Unit ARU if present in the line up _N phase__ _W phase Short circuit of phase outputs and DC link busbars is already made in TEU 1 Disconnect and isolate the high voltage measurement on the HVD board ADCVI board in older drive versions ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 33 of 62 Chapter 6 Insulation Resistance Measurement OO VU O ABB _3BHE006414R0001 XV C770AE_ EY OO Disconnect and ground all three LEM current transducers on CVMI 2 board ADCVI board in older drive versions i av 2949 4N 10102 9003HEE aay SCA O x1 x8 x7 x6 x4 x3 O 34 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA EDER Chapter 6 Insulation Resistance Measurement 6 2 5 IFU Preparation The following preparatory measures must be taken in an Input Filter Unit IFU
11. it must be reported to the carrier s representative and to ABB and or ABB representative Any damage during transportation or installation must be photographed and reported to the manufacturer Note The inspection of transportation damages must be done before the installation of the drive immediately after the components have arrived on site Before starting the commissioning work try to find out if any damages have been reported earlier Check if there are any transportation damages in the delivered components Check if the ACS 6000 User s Manual has been delivered together with the drive and that it includes the description of all relevant options Check that the scope of delivery is in condition and that there are no missing parts or components 12 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 3 Inspection of Installation The mechanical installation and the electrical connections of the converter transformer and motor should be checked and be confirmed that they have been carried out in accordance with the manufacturer s installation instructions The installation of the whole drive equipment must also fulfill the local electrical safety regulations It depends on the project which parts of other drive system are included in the scope of commissioning However the items below have always to be checked or one needs to get the confirmation that they had been checked before 3 1
12. lower DC voltages in all of the units and compare that the values are the same See from the recording that charging and discharging looks normal ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 49 of 62 Chapter 9 Energizing the Converter AA ED ED 9 1 2 MCB Control Test In order to test correct operation of the MCB control the breaker must still remain in TEST position Charge the DC to full level and record the MCB control and feedback signals see example in Figure 9 1 below Note that signal numbering in the picture may be different in the current SW version Discharge the DC voltage using Emergency OFF button from the cabinet door or from external emergency OFF Check that the MCB control works properly that feedback signals comes correctly to the SW and DC is discharged with VLU RBU Charge and close the MCB again and open this time by making a trip to the drive for example changing parameter 32 4 Earth Fault Alarm to FC1 Record the MCB signals and DC voltage Check that signal are correct and that the DC is discharged short delay based on rotor time constant is used before discharging is started MAX een 4 0 5 10 MCB OrderClose Z 2 4 0 5 11 MCB OrderOpen Gi 4 0 5 12 MCB OrderTripN 0 4 TTT 7 0 3 13 MCE Statasciose 0 10 eee ee eege 0 0 5 14 MGB StatusOporn Age __ 208 0 4 14 C1P3 STATUS Di9 16 a Figure 9 1 Values MIN 9 1 3 MCB Eme
13. the parameter has been set See the wiring diagrams for optional S800 I O module configuration and set the parameters accordingly ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 41 of 62 Chapter 7 Parameter Settings AA ED ED Parameter Group 77 System Configuration Parameter group 77 defines the drive configuration e g asynchronous or synchronous drive the type of line rectifier the number of inverter units etc Parameter 77 9 Drive Type activates the control and monitoring functions related to the excitation unit Parameter Groups 81 84 Optional I O These groups provide settings for optional S800 I O modules of Cluster 3 in the WCU Refer to the wiring diagramsto see if UO modules are installed and set the parameters accordingly Parameter Group 98 Real Time Clock The local time is set manually 98 07 SET unless there is automatic time synchronization from the overriding system 7 2 Communication Parameters This section provides information on parameters related to communication interfaces Communication to an overriding control system is typically accomplished via a fieldbus adapter FBA or an ABB Advant controller e g AC110 Both are connected to channel 0 of the AMC board H an AC 80 Advant controller is part of the converter CIU option the overriding system can communicate via this controller which is linked to channel 4 of the AMC board A possible configuration an be that FBA and
14. 2 14 TORQUE_REF_5 and 161 2 TORQUE_NOFILT to datalogger like shown below Variables SE 120 10 SPEED STEP 122 4 MOTOR SPEED 122 14 TORQUE REF 5 161 2 TORQUE_NOFILT Samo Number of samples before ho Sample interval ms a ai Conai m Variable for Level or DEE triggering DN Faults ee Trigger 120 10 SPEED STEP _Select _ Limits Rising edge fo X Level C Falling edge Hysteresis 0 0 I Difference X External A Start datalogger and apply steps Tuning is done by using AMC parameters 121 01 KPS which is proportinal gain and 121 05 TIS which is integration time of speed controller After speed controller has been tuned the speed ramp test with short acceleration and deceleration time must be done Ramp can be shortened until appr nominal current is reached This test is done only from nominal speed Also normal acceleration and deceleration shoud be tested from maximum positive to maximum negative speed 58 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA EDER Chapter 13 Speed Controller Tuning 13 2 Final Tuning of Speed Controller The next step is to make the final tuning of the speed controller The idea is to get the drive performing as well as required by the driven process The main requirement is not to make the control as fast as possible but only fast enough to make the changes required by the process without conflicting with other control loops Too fast sp
15. 2 Converter Internal SIGMAlS E 46 8 3 External ME ture tee EEE E TE EE OE PE EE OEE E 46 8 3 1 Oe ee le E 46 8 3 2 Ke tele e CEET Sates ani aaa aine 47 8 3 3 Switchgear SIQMAlS E 47 8 3 4 Serial Data een e EE 48 Chapter 9 Energizing the Converter sssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn 49 9 1 Energizing Bun RTE 49 9T Charging A ee een Oe eer E ee ee eee eee eee ere 49 STE MGB Gontrol Testor ai n ron ERE ORAE GE E RE nisl eege 50 9 1 3 MCB Emergency Stop Off w c244 eege ee EE 50 Chapter 10 ACS 6000ad Start Up cccccscceeeeeeeeeeeeeeeneeeeeeeeeeeeeeesaaeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeseeees 51 10 1 Motor lal e FRU EEN 51 10 1 1 First Start up with No Lee eet geed ER 51 Chapter 11 ACS 6000sd Start Up E 53 11 1 See 4 Yrojte 4 EE 53 11 2 Motor idle RO a E utiles 53 11 2 1 Absolute Encoder Positioning Routine AEN 53 4 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual A EDEB Table of PAIDID able of Contents 1132 2 _ First Start with NO LOad eeneg ee en nh ene rebetvaasnch teas abeteea nn dhteedebecaana ent ere en Hee 53 Chapter 12 ACS 6000 Final Tuning sisececccccccicccctccececccesteed cuectneeceanseaccteweneeeneceesccieweaeeehecesanenente 55 12 1 Mechanical Heat Run iiscccscicettgasacecscthieetstaeeeussechivcs eda tens ldeteehidde tenes abel idexlges ety eadataneg 55 12 2 Final TUNNG EE 55 Chapter 13 Speed Controller Tuning cccccccssseeseeeeeeeeeeeeeeeee
16. AC80 Advant Controller Parameter groups 60 63 define the dataset communication Refer also to the AC 80 documentation if this option is used Check that parameter 16 7 Comm module control place is set to channel 4 if the AC 80 controls on off start stop n ref the converter Check that parameter 70 17 CH4 Baud Rate is set to 4 Mbit s 7 2 4 DDCS Communication Settings regarding node address and link control of channel 4 are made in parameter group 70 Check that parameter 70 3 CHO Baud Rate is set to 4 Mbit s 7 3 Limiting Parameters 7 3 1 Dynamic Torque Limiters and VLU RBU Settings There are three dynamic torque limiters They are able to change limit torque reference in order to prevent overvoltage undervoltage or too high angular frequency The dynamic limiters are located after the static limiters In principle they are P controllers with a threshold level and gain as parameters See section 6 of the ACS 6000AD Torque Control SW TC SW TC SW Commissioning manual VLU RBU Voltage Limiter Unit Resistor Braking Unit thermal model protects resistors of VLU RBU against overheating This task is carried out by enabling and disabling VLU which is based on either resistor temperature model or pre defined enabling disabling pulse mode control scheme A separate thermal model control for both halves of VLU RBU upper and lower is implemented Same SW module also delivers discharging command to VLU RBU control l
17. ACS 6000 Medium Voltage AC Drives Commissioning Manual Document No 3BHS135824 ZAB E01Rev D Issued 05 10 2004 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 2 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual el IT Table of Contents Chapter Te Overview ees deeg ed 7 1 1 SIN EE 7 1 2 Related DO CUM GMS E 7 1 3 TEE Ee EE Ee 7 1 4 Operation and Mee sci vest neceiveen eevee eege bedreet Ee bec genrgedeeininss 7 1 5 Preparation for Commissioning Project Management Input 8 1 6 Preconditions for Commissioning sc iesse oan ue ee SEENEN 8 General Preconditions EE 8 High Voltage Ge ele EE 8 Auxiliary Voltage Supply and Control 9 Ee TEE 9 1 7 Purpose of COMMISSIONING eera ee e EER AEO EEEE ERC 9 Cold Commissioning E 10 MOPCOMmMISSiONING ee EE 10 1 8 COMMISSIONING RE DOM E 10 Chapter 2 Checking the Scope Of DeliVery ccssseeeeeeeeeeeeeeeeeneeeeeeeeeeaneeeeeeeeeeeeeeeeaneeeenenees 11 2 1 Faktor Plate Datel EEEE EARE terse
18. Main Circuit Breaker MCB Check that the main circuit breaker installation is according to the requirements and fulfills the local regulations For details see the MCB documentation and document Main Circuit Breaker Specification document number 3BHS125149 Follow the checklist of the commissioning report regarding MCB installation 3 2 Transformer Check that the transformer installation is according to the requirements and fulfills the local regulations For details see the transformer documentation Transformer tank oil transformers or frame dry type transformers must be connected to the plant earthing network at least in one point For more details see instructions of the transformer manufacturer Follow the checklist of the commissioning report regarding transformer installation 3 3 Converter For the installation requirements of the ACS 6000 Refer to the information given in the ACS 6000 User s Manual Appendix D Mechanical Drawings For example Marine installations usually require mounting brackets to the converter roof for additional cabinet support ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 13 of 62 Chapter 3 Inspection of Installation AA ED ED 3 3 1 3 3 2 3 3 3 3 3 4 Follow the checklist of the commissioning report regarding converter installation Ambient Conditions Derating may be necessary due to the presence of elevated levels in ambie
19. ain switch of the auxiliary supply are located in the WCU cabinet Before closing the main switch proceed as follows 1 Make sure that all auxiliary switches optional circuit breakers and protection switches have been switched off and power supplies have been removed from the boards er Note Do not switch on the motor protection switches of the cooling pumps before the cooling system has been filled If a pump runs dry the pump seals will be damaged immediately Since the software has already been downloaded to the AMC board in the factory the pumps will start after the Emergency OFF signal has been reset depending on the setting of parameter 33 20 ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 25 of 62 Chapter 5 Preparing the Converter AA ED ED 5 3 2 Check that the voltage selection at the 3 phase auxiliary transformers is made correctly in each phase 3 Check that the external 3 phase auxiliary voltage is according to the project data and within the permitted range 4 The main switch of auxiliary supply can now be turned on Note The EMC filter Z5002 inside the drive may need to be temporarily bypassed in case the fault current relay on the customer side trips 5 Check the output voltage of the auxiliary transformers After that the voltage distribution inside the converter cabinets can be switched on one by one by closing the respective circuit breakers and protection switches 6 Che
20. also advisable to compare the measured results with the test reports from the supply factory 6 1 Type of Measuring Device The insulation test of the ACS 6000 drive system is carried out with a test voltage of 5 kV DC Since the insulation resistance of a mult drive converter may be as low as 0 5 MQ a megger with a current capability of 2 mA is required These devices are not common Therefore it is important that such the megger is ordered in time If a less powerful megger is used and the 5 kV test voltage cannot be reached smaller the converter has to be tested in smaller sections To do this the section to be tested is isolated from the adjacent sections by opening the busbar connectors 6 2 Preparations for the Measurement Before starting the insulation measurements do the following 1 Check that the power cables are disconnected and securely grounded 2 Make sure that the main circuit breaker is not able to close by means of mechanical interlocking Note that the grounding switch of the ACS 6000 must be in the unearthed position during the measurement 3 Make sure that no energy can be fed from the motor side No motor must be rotating ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 29 of 62 Chapter 6 Insulation Resistance Measurement AA ED ED 4 The cooling water conductivity must be below 0 5 uS Note that the insulation measurement must be carried out within 1 hour Otherwise the cooling water conduc
21. ay test protocols must be available at site during the whole period of the commissioning For details on MCB requirements refer to the Main Circuit Breaker Specification document number 3BHS125149 See project related documentation wiring diagrams for applications where the auxiliary power for the MCB undervoltage opening coil is supplied by the ACS 6000 Follow the checkpoints of the commissioning report ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 21 of 62 Chapter 4 Commissioning Other Drive Components AA EDER 4 2 4 3 Transformer Motor Alll checks and insulation measurements of transformers must be performed according to the instructions of the transformer manufacturer Note that the I O interface to the converter will be tested later Checking of the transformer includes the following Insulation resistance The insulation resistance must be measured or the confirmation of the measurement must be obtained Oil quantity in case of oil type transformer Oil quantity can be checked on the oil level gauge located on the oil expansion vessel Valves between transformer tank and radiator All valves must be in open position to allow free oil flow between tank and radiators Condition of dehydrating breathers Sense of rotation of fans and pumps if applicable Protection devices of transformers Will be checked together with the external signals of the ACS 6000 see Chapter 8
22. bles prevents screen overloading because of potential differences in the plant This is needed if the cross section of the cable screens is less than 50 of the cross section of one phase conductor Refer to the ACS 6000 User s Manual Chapter 9 Electrical Installation section Busbars and Grounding and the Power Cable Specification document number 3BHS125090 Follow the checklist of the commissioning report regarding the power cabling Protection Against Injuries All earthing inspections described in the previous chapters must be carried out carefully to avoid any dangerous potential rise in any parts that are subject to touching Protections are checked as follows 1 Protection covers inside converter cabinets must refitted if they had been taken off If covers have to be removed for measuring purposes for instance warning signs and temporary covers must be used 2 Cabinet door locks must be checked The door keys should be given exclusively to persons taking part in the commissioning The doors should be kept closed whenever possible This also helps to keep the cabinets clean 18 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA EDER Chapter 3 Inspection of Installation 3 All openings in the motor must be closed and the protective covers over the shaft must be reinstalled The doors of the slip ring compartment must be closed 4 Allcovers for the power cable terminals or terminal bo
23. ck the level of the AC DC voltages 24 and 27 VDC Filling and Starting up the Cooling System Follow the instructions in the Operation and Maintenance Manual in Appendix A Water Cooling Unit of the ACS 6000 User s Manual when filling and starting up the water cooling system Related parameter settings and measuring signals must be checked before the cooling pumps are started Note References to the parameter indices are valid for software versions 3xxx For other software versions refer to the latest signal and parameter documents delivered with the loading package Water cooling related parameters and signals are located in the following groups e Group 4 Actual Values from S800 I O e Group 33 WCU Control e Group 34 WCU Supervision The following signals and parameters must be checked and set e Parameter 34 06 Water Inp Press Supervis The parameter enables disables the measurement the inlet pressure of the cooling pumps in closed type water cooling systems e Parameter 34 21 FAIL Safe EOFF Input The parameter enables disables the Emergency OFF fail safe function If enabled thesSource of the Emergency OFF signal is input C2P3 Al810 Ch8 e Parameters 34 26 31 26 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA EDER Chapter 5 Preparing the Converter The parameters enable optional monitoring functions and select the trip reaction Refer to the WCU diagram and set the param
24. cording to the ACS 6000 User s Manual Chapter 11 and 12 Predefined preventive maintenance packages are from ABB Switzerland Ltd Medium Voltage Drives CH 5300 Tugi Switzerland ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 7 of 62 Chapter 1 Overview 1 5 Preparation for Commissioning Project Management Input Preparatory steps must be taken and data must be collected before the commissioning is started Make sure that the following list is fulfilled Motor parameters are available Pre setting of parameters is available Commissioning spares are available or sent Tools according to the list are available Special tuning instructions are available Commissioning program is available Instructions for commissioning is received Preparative work for possible drive upgrade is done Latest updates of SW is received 1 6 Preconditions for Commissioning General Preconditions High Voltage Equipment The following preconditions must be fulfilled before the commissioning of the drive can start NOTE The item 7 ie insulation test of cables transformers and motor can be made by the commissionig engineer In that case one additional day per motor drive combination needs to be reserved After insulation test the mains cables can be connected except at converter end 1 2 The Installation of the ACS 6000 must be completed according to the ACS 6000 User s Manual Chapter 8 Mechanical Instal
25. d doorlock monitoring signals of each medium voltage cabinet e External EOFF and ESTOP wiring e Wiring of internal EOFF signal from COU doors e Interlocking and status signals of grounding switch e Cabinet temparature supervision signals e Control and supervision signals of optional output isolator e Control and status signals of excitation circuit breaker in case of ACS 6000sd drive 8 3 External LO All external signals are shown in application related circuit and terminal diagrams and in I O list Project related circuit diagrams must be referred in order to check what optional supervision functions are wired to ACS 6000 control 8 3 1 Motor Signals Motor may have the following optional signals 1 Typically the synchronous motor has at least the following instruments giving binary signals cooling water flow indicators oil flow indicators jack up oil pressure indicators oil filter condition 46 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual 8 3 2 8 3 3 Chapter 8 Checking I O indicators Lubrication unit signals are supervised by control only when pumps are running Winding temperature signals should be tested as discribed above Cooling fans lubrication and jack up pumps are controlled with binary outputs Direction of the pumps should be checked 4 Operation of the disk brake should be done by using test mode Brake is opened and closed to see correct operation If adjusting
26. d operable Control cables are connected MCB control cables are connected directly to the converter e Tripping loop Remote control cabling 12 Cabling of options transformer motor protection tachometer etc 13 Auxiliary voltage supply is available 14 The plate of the grounding switch lock override is attached and secured 15 Spare parts available 16 All necessary process information has been handed over to your ABB sales representative For details contact ABB 1 7 Purpose of Commissioning The purpose of commissioning is to accomplish the operation of the drive which corresponds to the customer requirements This is achieved by following the instructions given in this manual and performing the actions needed until the required operation is accomplished After the commissioning is finished the customer receives a commissioning report When properly filled in the warranty time is initiated The condition for proper warranty is that the commissioning report together with the parameter files are sent to mv ac supportline ch abb com It must be pointed out that only an electrical engineer who has been properly trained and certified is allowed to commission an ACS 6000 frequency converter ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 9 of 62 Chapter 1 Overview Cold Commissioning Hot Commissioning AA ED ED PADDED Typically commissiong has two parts i e so called Cold and Hot c
27. ding the possible motor rushing during first start special first start mode can be used See ACS 6000AD TC SW Torque Controller Software commissioning manual for detailed instructions Before the first start see also Chapter 13 Speed Controller Tuning section 13 1 for preliminary tuning of speed controller 54 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 12 ACS 6000 Final Tuning 12 1 Note Before the coupling test can be started the no load run must be properly carried out If the motor is equipped with speed encoder the recommendation is also to take recordings from the speed actual signal while the motor is still uncuopled After the motor can be run up to maximum speed and down to minimum speed without problems the driven equipment can be connected Open the main circuit breaker and ground the converter before connecting the driven equipment Make sure that the driven equipment is ready for speeding up Mechanical Heat Run After mechanics are connected some mechanics manufacturer require mechanical heat run In mechanical heat run the speed is increased step by step to maximum during few hours and at the same time bearing temperatures etc are measured Note After motor is coupled and run with driven equipment all the interlockings from automation systems has to be in operation These interlocks should stop the drive if there is lack of lubrication or other critical
28. e Data Sheets are enclosed in Appendix A Water Cooling Unit of the ACS 6000 User s Manual If you have any doubt about the local water quality contact ABB immediately 14 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 3 Inspection of Installation Check the customer interface of the cooling water system Information on the raw water connection can be obtained from e Layout Drawing in Appendix C Mechanical Drawings of the User s Manual Plant specific pipe entry Flange size e Water Cooling Datasheet in Appendix A Water Cooling Unit of the User s Manual Nominal values of flow rate pressure range etc Industrial cooling water specification e Rating Plate of the converter Type of water cooling unit Project specific values of flow rate pressure range etc 3 3 5 Converter Power Circuit Connections Ler The power cable routing mains and motor cables must be carried out in compliance with the local regulations and according to the specifications and recommendations of the cable manufacturer All cable connections of the ACS 6000 to the transformer and motor are shown in the ACS 6000 User s Manual Appendix D Electrical Drawings Project specific cable entries are indicated in Appendix F Mechanical Drawings Note The incoming cables must not touch the terminals of any other phase A minimum sparking distance of 40 mm must be maintained betwee
29. eed controller may cause unnecessary stress on the mechanical system gearbox belts etc The tuning must be checked under different load conditions and over the whole speed range When carrying out tuning under actual load conditions the values obtained during pre tuning normally need readjustment Some methods to tune the speed controller are given next but methods other than those presented in this chapter can also be used Speed steps of 2 of maximum speed or bigger are applied to see the response behaviour of actual speed See instructions for speed step tests and for monitored signals in the previous section 13 1 Preliminary Tinung of Speed Controller The integral time constant 24 08 TIS is reduced until overshoot is observed in the response The integral time constant is then adjusted such that there is no overshoot or only a slight overshoot depending on the drive application The function of the integral part is to remove as quickly as possible the difference caused by the proportional control between the reference and the actual value If the drive is stable and allows a high proportional gain the integral time constant can be set short and an overcompensated step response is obtained If the drive goes to the torque limit in a step a further compensation of the response should not be attempted See Figure 13 1 for different kind of step responses ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 59 of 62
30. eeeneeeeeeeeeseseeeeeeeeeeeeeeseneeeeenees 57 13 1 Preliminary Tinung of Speed Controller ANNE 57 13 2 Final Tuning of Speed Controller Zeg eg eg de eege de dE ee Ye dase eens tapeaea veel canndensk 59 Chapter 14 Finishing the COMMISSIONING sceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeneeseneeees 61 14 1 SEENEN 61 14 2 Gu stomer TAMING at ee ee ee 61 14 3 Parameter e EE 61 14 4 CUSLOMERS SIGMALUNG EE 61 14 5 Documents and Data for Customer ENEE 62 14 6 Documents and Back Up Copies ENEE 62 ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 5 of 62 Table of Contents A EE 6 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 1 Overview 1 1 General This manual describes the commissioning and operation of the ACS 6000 frequency converter including all checking and tuning principles as well as measurements and recordings added with hints based on practical experience er Note Parameter references in this manual are applicable for software versions LxOC 3xxxx 1 2 Related Documents 3BHS125195 SigParACS6000 ARU_LNACxxxx Technical Note ACS 6000SD VC SW Commissioning Manual 3BHS120865 SigParACS6000AD_SD_INU Technical Note ACS 6000AD TC SW Commissioning Manual 1 3 Safety Safety instructions safety concept warnings intended audience required qualification responsibilities etc apply according to the ACS 6000 User s Manual 1 4 Operation and Maintenance Ac
31. em WEE 26 5 4 Starting up the Water Cooling Gystem Error Bookmark not defined ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 3 of 62 AA EDER Table of Contents AARDED Chapter 6 Insulation Resistance Measurement ssssssunnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna 29 6 1 Type of Measuring DeViCe iic ceskccccecetcetsecheves ste scons ss EEN teeeceasse ceks tae tvenseevveal itaateescateenae 29 6 2 Preparations before Measurement ANEN 29 en EE GER E e EE 30 622 SUDEP Dea AO E 31 6 2 37 CBU Preparer EE 32 6 24 EEN TEE Lee EE 33 6 2 5 TEU Preparations si cecceicseiotaectisoniteneds watepdec e E E R R E 35 6 2 6 Main Circuit Measurement i208 EEGEN 35 6 2 7 VEXCKANON GICUINC EE 36 BITTEN 36 Br shless UE ees e hte ied deed 36 Chapter 7 Parameter dl EE 39 7 1 Esingen 39 7 2 Communication NEE 42 7 2140 Fieldbus AdaptefS s iga a a Nee Ne KENE deu 42 7 2 2 Advant Bus COmmMuUnICAONe ssn ex As ea sen hak eater daa eases eae 43 7 2 3 AC 80 Communication eege eege or enctiesnspaevioid act eene iar eahtantededpmenteaadie 43 724 vw DDCS EELER 43 7 3 LG FIP ARAN GLONS sacs eet Seege Eege Dee 43 7 3 1 Dynamic Torque Limiters and VLU RBU Settings 00 0 0 eeieeeeeeeeee eee eeeeeeeeeeeeeeee teens 43 73 2 Gray ang Pulse Encoders erso a e e NEEN 44 0 FET oI ae a aE IG NO T 45 8 1 CHECKING Principle sire E EA EE EE REEERE 45 e M llt EE EE EE EE EE Ee 45 812 Digital UMS eich creat EE 45 Bolo a e e Blat E 45 8
32. ement is not to make the control as fast as possible but only fast enough to make the changes required by the process without conflicting with other control loops Too fast speed controller may cause unnecessary stress on the mechanical system gearbox belts etc Tuning of the speed controller must be checked at few different speeds for example at 50 of base speed and 50 of maximum speed with 2 step of the maximum speed The tested speed points depend naturally on the process requirement See also section 73 2 for final tuning for performance criterias Speed step is given in the following way Pictures in Drive Window 2 x versions or in DriveDebug differ from the following but the monitored signals are still the same 1 Run motor to speed you are using for the test 2 Set Drive Window STEP function to the signal 120 10 SPEED_STEP Set step to 2 of the maximum speed and duration for 3000 ms as shown in the figure below ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 57 of 62 Chapter 13 Speed Controller Tuning AA ED ED PAID ED Step Rising edge 2 00 Falling edge EI Active time 3000 ms L Hee fecal if TC Falling first Note Active time is optional Step Variable Variable 120 10 SPEED STEP Value 0 00 rpm Minimum value 100 00 Maximum value 100 00 3 Get datalogger to trig from 120 10 SPEED_STEP signal Add signals 120 10 SPEED STEP 122 4 MOTOR SPEED 12
33. ent is carried out with 1 kV DC voltage and a measurement time is 60 sec The plus terminal is connected to the combined circuit of output and three input terminals The minus terminal is connected to the ground potential The value of insulation resistance must higher than 1 MQ In the commissioning record write down the measured insulation value and the value of the water conductivity present at the time of measurement Note Remove all short circuit connections and restore the original state when finished ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 37 of 62 Chapter 6 Insulation Resistance Measurement IR II 38 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA ED ED Chapter 7 Parameter Settings Chapter 7 Parameter Settings Project related parameter settings must be made on site This chapter describes only parameters requiring special attention In general the signal and parameter table and the motor control SW documentation delivered with the loading package must be used when setting parameters Ee Note References to the parameter indices are applicable for software version 3200 ACS 6000 with asynchronous motors and 300x ACS 6000 with synchronous motors For other software versions refer to the latest signal and parameter documents delivered with the loading package 7 1 Common Parameters The converter must be in RDY ON state MCB open and DC link un c
34. er or if available save parameter files on the PC of the customer 14 44 Customer s Signature After the test runs have been performed and the commissioning report has been filled in properly print out the report and ask the customer for acceptance This will initiate the warranty period The commissioning report must be sent to the MV AC Supportline for address see 14 6 Documents and Back up Copies preferably in electrical format Thus fill in information about customer s representative who signed the report ie name date and place and where the original document with the signature is stored ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 61 of 62 Chapter 14 Finishing the Commissioning AA EDER 14 5 Documents and Data for Customer After the commissioning the following data need to be given to the customer Paper copy of the commissioning report Back up files of the AMC3 CCB signal and parameter table in Drive Window and TXT format Possible changes made in the mechanical and or electrical drawings CHIND is to be informed about changes to converter part 14 6 Documents and Back up Copies MV AC Supportline address below Commissioning report preferably as file Parameter back up files Travel report Warranty reports of replaced components if any to Logistics Center If you have possibility to take photographs of the installation send also the pictures to MV AC Supportline Del
35. er to the motor data the documentation of the motor manufacturer and the project related documentation Parameter Group 21 Start Stop MCB Function Parameter 21 1 Start Function selects the start mode for asynchronous motors only Parameters 21 3 5 select the process stop mode and the MCB reaction Note Source of the process stop if enabled is selected with parameter 16 1 Process Stop Parameters 21 10 11 select number and monitoring of MCB feedback signals Refer to MCB data for correct setting Parameter Group 22 Ramp Functions Parameter 22 1 Acc Dec 1 2 Sel selects the acceleration decelaration ramp Typical seting ACC DEC 1 Parameters 22 2 3 determine the ramp times It is recommended to set slow ramp times when commissioning is started and to decrease the values to suit the process requirements when commissioning proceeds Parameter Group 23 Speed Reference Parameters 23 2 3 Inching Speed 1 2 dertermine the reference for the inching speed applicable for metals applications Parameter Group 24 Speed Control Parameters goup 24 provides all settigs for soeed controller tuning At this stage of commissioning it is recommended to decrease the setting for the gain to 1 2 24 2 KPS Tuning of speed controller is discussed later in this document Parameter Group 25 Torque Reference Torque reference settings are applicable when the drive is in torque control mode selected with paramete
36. eters accordingly e Parameters 33 8 9 The parameters limit the upper value of the measuring range of the output pressure sensors The measuring rangemay vary depending on the type of the WCU The measuring range of the sensors is given in the component list of the WCU e Parameter 33 20 EOFF WCU Stop The parameter determines the reaction of the water cooling unit on an Emergency OFF command If set to 1 an Emergency OFF command stops the main pumps and the 3 way valve e Actual value groups 4 01 04 In this parameter groups the actual values of conductivity temperature and pressure can be checked ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 27 of 62 Chapter 5 Preparing the Converter AA ED ED 28 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 6 Insulation Resistance Measurement Before any of the drive system components is energized the insulation resistance of each component must be measured to verify their ablility to withstand voltage stress The results of the measuremnets must be noted in the commissioning record The water conductivity must be lower than 0 5 uS during the insulation check of the converter In case you need to wait for the conductivity to come down you can proceed with the section about parameter settings In case checks of motor and transformer are included in the commissioning refer to the applicable manual for additional information It is
37. harged when parameters are initialized External signals may have to be masked to avoid tripping of the drive warnings coming up emergency stop being activated etc Ee Note If the drive does not proceed to the ReadyOn state check the condition and proper connection of the PPCS communication fibers and the condition of all the control HW boards Check also the optical fibers of the FT link Parameter Group 11 Start Stop Direction MCB Control Group 11 defines the source of start stop and on commands for external control location 1 11 01 and 2 11 02 If fieldbus communication is used the setting is 11 COMM MODULE Parameter Group 12 Reference Selection Group 12 defines the source of the external reference value If fieldbus communication is used parameter 12 2 EXT1 EXT2 Select is typically set to EXT1 and 12 3 EXT REF1 Select to COMM REF Parameter Group 16 System CTRL Inputs Parameter 16 7 Comm module Control Place selects the serial communication channel 0 or 4 Channel 4 is to be selected if an AC 80 controller is used to control the I O interfaces of the converter and to communicate to an overriding control system Parameter Group 20 Limit Values In the beginning of the commissioning torque and overspeed limits 12 5 7 should be set to a low value ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 39 of 62 Chapter 7 Parameter Settings AA ED ED When setting limit values always ref
38. is the same as in CDP and in circuit diagrams Digital Outputs Cabling can be checked by forcing the status setting releasing with jumper on I O modules end Analog Inputs External analog signals mainly consist of temperature measurements Pt 100 sensors may be used for stator winding cooling air and bearing temperature supervision Also transformer temperature may be measured with Pt 100 ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 45 of 62 Chapter 8 Checking UO AA EDEB PN IEIDEID Inspection of analog input signals to S800 I O modules must be done by reading the actual value of the measurement in group 4 81 and 82 optionals Actual Values S800 I O values of AMC table Pt 100 temperature measurement signals can be checked by disconnecting one wire from sensor end The signal should then go to the negative value and sensor failure fault should appear AMC table group 85 Other type of analogue signals should be tested by changing the analog signal value as primary as possible 8 2 Converter Internal Signals The following internal wiring may have been done on site depending on the drive configuration also and should thus be checked e Internal fiber optics of FSCD boards to INT board on the next unit e Firing through FT link which is an optical link between all INT and PINT boards e Power Forward Link in case of multidrive configuration e Status indication of both door monitoring an
39. ivating the emergency off button on the door of the ACS 6000 The emergency off signal a normally closed loop can come from one or more pushbuttons one button on the door of the ACS 6000 Operation of this signal must be tested it gives open command to breaker ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 47 of 62 h Chasing AA ED ED Chapter 8 Checking I O TO 8 3 4 Serial Data Communication Connection of the ACS 6000 to a higher level automation system is typically done via a fieldbus adapter The signals can be tested when the auxiliary supply of the converter is on and the main and excitation supply is off Confirm with automation commissioning personnel customer that interface operates as intented Follow the checklist of the I O signals in the commissioning report 48 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 9 Energizing the Converter After the insulation tests have been finished and all cables have been connected the next step in commissioning is to energise the converter and to close the Main Circuit Breaker MCB The first energising of the converter must be done by a qualified electrician who has been trained in the product During the energising follow carefully the safety instructions given at the beginning of this document and in the ACS 6000 User s Manual Before energizing the converter all doors and possibly removed cover plates must be properly clo
40. ivery address of the documentation is as follows Lotus Notes MV AC Supportline CHIND ABB Internet mv ac supportline ch abb com In addition If any changes red corrections are made to part lists spare part lists or to circuit diagrams this information is to be delivered to the responsible project manager of the converter factory CHIND 62 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual
41. lation and Chapter 9 Electrical Installation Shortly these installation requirements are the following e Deionised water available on site and raw water connections ready Auxiliary supply voltage available and related cable connections ready The permission to switch on the auxiliary voltage must always be granted by the commissioning engineer ref 5 2 Drive mechanical installation ready External wiring from and to the converter ready High voltage HV switchgear is installed connected and ready for operation Converter transformer is installed connected and ready for operation 8 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Auxiliary Voltage Supply and Control Miscellaneous Chapter 1 Overview 4 The motor is installed aligned uncoupled and ready for operation An official protocol document must be available 5 Grounding cables of transformers converter and motor are connected All cable screens are connected 7 Insulation of cables transformers and motor has been tested and complies with the specification 5 kKV 60 sec An official test report must be available Insulation test of the converter will be performed by the commissioning engineer 8 Mains voltage supply is available The motor driven load process is ready for coupling and for operation under nominal conditions 10 All auxiliary cables are connected 11 Auxiliary voltage switchgear is connected an
42. n each cable and the terminals of any other phase Check especially that the entry and termination of the cables is done as required Refer to the requirements in the ACS 6000 User s Manual Chapter 9 Electrical Installation External Power Cabling Note Power cabling is still left open at converter end until the insulation resistance of the converter has been verified Thus this part needs to be checked afterwards 3 3 6 Converter Internal Wiring The ACS 6000 manufacturer delivers internal cables These are cables between transportation units inside the converter The correct connection and routing of these cables must be checked during the cable inspection Information on cable connections can be found in the project related documentation of the ACS 6000 User s Manual Appendix D Electrical Drawings ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 15 of 62 Chapter 3 Inspection of Installation AA ED ED Ee Note The incoming cables must not touch the terminals of any other phase A minimum sparking distance of 40 mm must be maintained between each cable and the terminals of any other phase 3 3 7 Control Cables The installation of the control cables on cable trays or in channels must be checked Power cables and control cables must not be located on the same cable trays A minimum distance between these cables is 30 cm Make sure that the cable entry and termination is done as required S
43. nt air temperature altitude from the sea level or external cooling water temperature Reffer the drive rating plate data for information Other ambient factors are e Relative humidity gt Condensation is not allowed e Air contamination gt No visible dust or corrosive gases e Shock and vibration gt Drive not subjected to vibration Dimensions and Clearances The converter must be mounted with adequate free space as described in the ACS 6000 User s Manual Appendix D Mechanical Drawings Spaces for access to installation site clearances of passageways etc must follow the local requirements in each country Installation Place and Cable Ducts The floor must be of non flammable material with smooth and non abrasive surface protected against humidity diffusion levelled and able to support the weight of the drive cabinets min 1 000 kg m2 The maximum allowable overall unevenness is lt 5 mm 5 m Check that all converter doors can be opened and locked properly If not the cabinet levelling needs improvement Cable ducts must be of non flammable material with non abrasive surface and protected against humidity dust and penetration of animals Take appropriate fire protection measures e g seal all openings to prevent the fire from spreading into the cabinets Cooling Water System The requirements for the raw water must be fulfilled Refer to the Data Sheets of the Water Cooling Units for details Th
44. of the brake is needed it should be done according the manufacturer s documentation Transformer Signals Checking of transformer protection signals digital inputs must be done in similar way Oil immersed transformers may have the following optional instrumentation giving binary signals to the ACS 6000 control gas relay pressure relief valve oil thermometer and oil level indicator Dry type transformers have normally only winding temperature measurements The supervision is implemented with thermistor relays Oil transformers may also have Pt 100 measurements for oil temperature supervision Later when main circuit breaker control is checked also gas relay s opening of main circuit breaker is tested Switchgear Signals From feeding switchgear there are normally three signals two status signals from high voltage circuit breaker and pretrip signal from MCB overcurrent relay Operation of the MCB will be verified during charging test later The Excitation circuit breaker ECB can be tested manually In most cases there is no control signal from the ACS 6000 to the ECB and only the drive internal excitation contactor is controlled and monitored 1 Pull supply breaker to TEST position so that closing of the breaker without energising transformers is possible Close the breaker manually from switchgear or from ACS 6000 if control possible Check the status from S800 I O module and from AMC table 2 Open the breaker by act
45. ogic and takes care of configuring VLU RBU operation on EPLD level ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 43 of 62 Chapter 7 Parameter Settings AA ED ED PAEDED Another routine calculates generative torque limit corresponding to RBU breaking power capability RBU braking power is selected according to RBU maximum temperature with hysteresis See ACS 6000 TC SW Torque Controller Soft Ware commissioning manual for details ACS6000ad or sd 7 3 2 Gray and Pulse Encoders Synchronous motor control requires always shaft speed and position measurement feedback signals The following parameters are needed for encoder initialization Parameter Name 165 23 Pulse number of the speed encoder NTAC pulses rev pulse number 165 30 Selection if the used speed encoder has zero TRUE FALSE channel signal 166 21 Position encoder type GRAY pos source TRUE FALSE 166 22 Position encoder bit number GRAY bit number All others than zero channel selection and position encoder type are explicit values Zero channel selection is defined TRUE zero channel is used FALSE zero channel is not used Position encoder type is defined TRUE SSI serial communication interface FALSE Parallel communication interface F Confirmation that the parameters have been checked is asked in the commissioning report 44 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 8 Checking LO
46. ommissioning e Spare parts available e Internal cabling auxiliary voltage converter cooling system e Drive I O insulation resistance measurements MCB e SW parameterisation no load tuning and running tests e Spare parts available e Coupling test integrated tests with the automation system e Load tests tuning controllers mechanical operation and heat run Additional work for the drive commissioning engineer if so agreed e Commissioning of the motor transformer e Commissioning of MCB protection relays e Adjusting and tuning of external devises like sensors switches 1 8 Commissioning Report While commissioning the ACS 6000 the commissioning report must be filled out After the commissioning this report must be mailed to mv ac supportline ch abb com Parameter and back up file s must be 1 stored with Drive Window and if possible also with DriveDebug PC tool 2 attached to the commisioning report 3 printed out and filed in the ACS 6000 User s Manual on site In addition to the above mentioned commissioning report also the internal field service report must always be filled out In this internal service report the following summary and data needs to be given e Open items e Deviations to standard commissioning time e Drive tuning report pictures tuning problems e Special problems experiences etc 10 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 2 Checking
47. otations are different To avoid the possible motor rushing during the first start make the following precautions e Check phase order between the inverter and motor e Use DC magnetizing mode by setting parameter 131 01 to value CNST DC MAGN e use encoderless operation mode parameter 111 02 set to TRUE See ACS 6000AD TC SW Torque Controller Software Commissioning Manual for detailed instructions Before the first start see Chapter 13 Soeed Controller Tuning section 13 1 for preliminary tuning of speed controller ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 51 of 62 Chapter 10 ACS 6000ad Start up AA ED ED 52 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 11 ACS 6000sd Start up 11 1 11 2 11 2 1 11 2 2 Before idle running the motor all preparatory works such as inspections measurements and I O signal tests must be done That means all actions described in the previous chapters should be done and possible defects found must be eliminated No alarms are allowed to be active neither in the ACS 6000 nor in related switchgear feeders Check that the motor is ready for start aligned coupling is OK necessary lubrication is OK etc and that starting the motor does not cause any danger It is recommended that the driven equipment is discoupled from the motor when the first start is performed if there is a risk of damage to the driven equipment in case of inco
48. pecial caution needs to be taken for the following e Shield grounding of encoders e Wiring of MV cables on insulated trays e Bending radius of fiber optics Refer to the ACS 6000 User s Manual Appendix D Electrical Drawings Example of communication interface in Figure 3 1 AMC3 controller is connected to AF100 fieldbus using an Cl810B type adapter and GRAY encoder cable installation inside ACS 6000 cabinet Sp BU UE REE EE PPV LW S E T o Q Figure 3 1 16 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual ABB Chapter 3 Inspection of Installation 3 3 8 Converter Earthing Connections The following items must be checked 1 PE and safety ground busbars going through the converter cabinets must be connected with accessories delivered with the ACS 6000 2 The safety ground busbar must be connected to the earthing network of the plant factory at only one point at the busbar inside the TEU closest to the CBU All these connections must be checked and if necessary verified by measuring the conductivity of the connected parts 3 The routing of the grounding connection must comply with local regulations In some countries redundant cable routing is required 4 Metal shields of all power cables must be connected to the ground potential Power Ground as described above 5 The cross section of the cable shields must be in accordance with the Power Cable Specification document number 3BHS125090
49. r 26 1 Torque Selector Parameter Group 30 Motor Fault Functions Activation and trip reaction of stall protection function is set with parameter 30 1 Stall Function Pay special attention to stall protection parameters 30 2 4 so that it does not cause unnecessary trips in such processes where torque is required at low speeds In case of ACS 6000sd a special SW overload protection function for the excitation circuit is used The protection function is tuned with parameters 30 5 9 see example in Signal and Parameter Table SigParACS 6000AD_SD_INU_LXAC Parameter Group 31 Standard Converter Fault Functions Hint In case of a multi drive configuration cabinet temperature monitoring must be disabled with parameters 31 2 and 31 4 6 40 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA EDEB F j FPR EDID Chapter 7 Parameter Settings Parameter Group 32 Other Fault Functions This group includes several optional monitoring functions To see which optional protection functions are in use the actual hardware set up must be compared with the ACS 6000 circuit diagrams and the parameters set accordingly Note All the monitoring functions are enabled by default and thus the default settings are fail safe Parameter Group 33 and 34 WCU Control and Supervision The parameters provide settings for the internal water cooling system of the converter see Signal and Parameter Table version LXAC Paramete
50. r Group 35 DC Link Control The default settings of this group do not have to be changed The only exception is parameter 35 9 VLU Ctrl amp Supervision which needs to disabled in case a slave control unit is present in a multi drive configuration Parameter Group 40 Load Sharing This parameter group is only used only in case the AMC3 DDCS channel 2 is used for load sharing function between two drives in speed control mode e g hot rolling mill top and bottom motor Parameter Group 50 Speed Measurement Parameter 50 1 Speed Scaling defines the scaled value which corresponds to the actual speed in rpm Parameter groups above 100 provide further settings regarding speed and position measurements See documents e ACS 6000AD Torque Control SW TC SW TC SW Commissioning manual e ACS 6000AD Torque Control SW TC SW TC SW Commissioning manual Parameter Group 57 Critical Speed Note Parameter group 57 is not available in all software versions Speed ranges which have to be avoided during operation because of resonances can be defined in parameter group 57 Refer to project data if the function is required Parameter Group 75 Option Modules See also section 7 2 Communication Parameters for information on settings for the communication module Parameter 75 3 Encoderless Drive activates the pulse encoder for the motor speed measurement of an asynchronous drive Note that the AMC controller must be re booted to activate after
51. rgency Stop Off Check emergency stop and off functionality before starting up the drive and later also while the motor is in running condition Her Note Depending on the type of ACS 6000 proceed with chapter 10 or 11 50 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 10 ACS 6000ad Start up Before idle running the motor all preparatory works such as inspections measurements and I O signal tests must be done That means all actions described in the previous chapters should be done and possible defects found must be eliminated No alarms are allowed to be active neither in the ACS 6000 nor in related switchgear feeders 10 1 Motor Idle Run Check that the motor is ready for start aligned coupling is OK necessary lubrication is OK etc and that starting the motor does not cause any danger It is recommended that the driven equipment is discoupled from the motor when the first start is performed if there is a risk of damage to the driven equipment in case of incorrect rotation direction of the motor 10 1 1 First Start up with No Load When doing the first start one should keep in mind that in order to prevent the unnecessary rushing of the motor all limits should be set to safe values If there is no certainty that phase order of the motor and positive direction of rotation on the speed encoder coincides there is the possibility that first start ends with rushing of the motor direction of r
52. rrect rotation direction of the motor Excitation Start up Excitation current control should be tested first Constant excitation current test can be used for that purpose The excitation current control can be activated when ARU is in MODULATING state INU control at READY RUN state Motor Idle Run Prior to the first start the absolute encoder has to be positioned Using following semi automatic procedure it is possible to measure the offset of the encoder Absolute Encoder Positioning Routine At the same time it is possible to check that current measurement chain is operating correctly It is also possible to measure the transient inductances of the motor Operation is done via AMC table group 191 DIAGNOSTICS First Start with No Load During positioning routine the operation of the excitation converter power stage modulation and phase order of the current measurement was already checked Drive should be now ready to first start When doing the first start one should keep in mind that in order to prevent the unnecessary rushing of the motor all limits should be set to safe values If there is no certainty that phase order of the motor and positive direction of rotation on the speed encoder coincides there is the possibility that first start ends to rushing of the motor direction of ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 53 of 62 Chapter 11 ACS 6000sd Start up ABB rotations are different For avoi
53. s 3 and 7 of board A6032 Short circuit and ground terminals x13 and x14 of board A6033 Disconnect inputs P and N of power supply G6041 CG AON OO P Go Short circuit and ground the 24V output on terminal blocks X66 and X68 10 Disconnect and isolate terminals 5 9 20 22 of MR 627 A6041 11 Disconnect and isolate terminals 25 and 33 of MZ 611 A61 42 if present in the configuration 12 Short and ground terminals X2_7 X2_8 X2_11 and X2_12 of board A6051 1 Make a short circuit between the three output terminals 2 Make a short circuit between the input phases and connect it to the output terminals Short circuit circuit switch K6201 Short circuit and ground terminal block X614 1 4 Short circuit and ground terminal block X617 1 2 oo P Q Short circuit and ground terminals 3 and 7 of boards A6032 and A6034 7 Short circuit and ground terminals X13 and X14 of boards A6033 and A6035 8 Disconnect inputs P and N of power supply G6041 Short circuit and ground the 24 V output on terminal blocks X66 and X68 36 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Za Chapter 6 Insulation Resistance Measurement 10 Disconnect and isolate terminals 4 7 10 20 22 of MR 627 A6041 11 Short circuit and ground terminals X2_11 and X2_12 of board A6051 The water conductivity must be lower than 0 5 uS during the measurement Measurem
54. sed and all preparatory works such as inspections measurements and I O signal tests must be done This means all actions described in the previous chapters should be done and possible defects found must be eliminated No alarms are allowed to be active neither in the ACS 6000 nor in related switchgear feeders Instructions given in the ACS 6000 TC SW Commissioning Manual must be followed 9 1 Energizing the Drive In the ACS 6000 converter charging of the intermediate DC link is done from auxiliary power supply by means of a charging transformer This allows to charge up the DC link to the nominal voltage level without the main HV supply Note Never connect the ACS 6000 drive to the live supply network before the DC link is charged up close to nominal operation level gt 4kV See parameter group 35 DC link control for charging level settings SigParACS 6000AD_SD_INU_LXAC 9 1 1 Charging Test le Note Before this DC charging test is started the MCB must be pulled out into a TEST position in a way that it can be controlled without energising the transformer Converter s must be in Ready On state without any active faults Control location needs to be local Discharge mode must initially be with VLU RBU Start charging by pressing local ON push button on COU door Charge the DC link up to approximately 1000 V and start discharging before MCB closing level is reached using OFF push button Record upper and
55. the Scope of Delivery 2 1 Rating Plate Data The following items must be reported according to the list in the commissiong report Manufacturer information manufacturing identification and rating plate data of the installed components MCB transformers converters and motors Accessories and options of the installed components Manufacturer type and length of the power cables Example of rating plate of an ACS 6000 multi drive ACS 6000 Ordernumber OO a a a aa ne En o wa toon too tt Number ofphases J 2m d ws te w ti Input voltage outputvoltagerange map OM 115 Excitation Unit 2 Unit 3 Unit 4 Lime ee cot inputvotage too tov tov Rated outputcurent NEE a E S Aa 150 605 Ambient temperature range a e Deionised water volume 3001 ooo Altitude above sealevel Ja ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 11 of 62 Chapter 2 Checking the Scope of Delivery AA EDER 2 2 Scope of Delivery Before the drive system can be commissioned properly it is necessary to inspect all system components carefully to make sure that all components ordered have been delivered properly and that there are no transportation damages Normally all delivered components have been insured during transportation and if there are damages they can be claimed back from the insurance company If the inspection indicates a shortage damage or evidence of any damage
56. thea cones fe tank ederqhoek E nage ETET 11 2 2 BCONe Ol DEWEY eieiei E ae ace aunt aad A AE AAE Oe ata aa edt 12 Chapter 3 Inspection of Installation cccccccesseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeneeeeneees 13 3 1 Mair Circuit Breaker MCB egene ee enee ee Eege 13 3 2 TPIS EE ee EE 13 3 3 DEET eet eene deene deene dee deiere e 13 3 3 1 EELER NEIE een Sa ete ose Se ete a ah ek ato ege 14 3 3 2 Dimensions and Ree 14 3 3 3 Installation Place and Cable Ducts guest zenge erfreet e eren due EENG dee 14 S204 Cooling Wat r SYStEM estern iai e Er E AE ATE EE E peters hades 14 3 3 5 Converter Power Circuit Connechons ENEE 15 3 3 6 Converter Internal Wiring ss ue NSA 15 33 7 70 19 11 0 Gr EE 16 3 3 8 Converter Earthing Connections cccesceete eet ced ecn eat a eae a seak tert eat ee ata etel 17 3 4 ere 17 3 5 Power Cable EE 18 3 6 Protection Against Injuries issesteectsenorieveiiancctiteneueredd secs nacediwnehd adie eege 18 3 7 CIGANIINGSS en eenegen ge EEN 19 Chapter 4 Commissioning Other Drive Component cssseeeeeeeeeeeeeeeeneeeeeeeeeeeneeeeeneeees 21 4 1 Main Circuit Breaker MCK eege eege eege Eege ENEE Mele 21 4 2 TESTOR eene ee ee 22 4 3 Lee 22 Chapter 5 Preparing the Converter ccccccesseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeneeeeeeeeeeeaneeeenneees 25 5 1 Selection Switches and Protective Settings ENEE 25 5 2 Connecting the Auxiliary MEss ee eebe 25 5 3 Filling the Cooling Syst
57. tivity might become too high 5 Switch off the auxiliary voltage of the converter 6 Prepare each ACS 6000 cabinet for the measurement as described in the following chapters F The preparation described in this manual refers to insulation measurement which is carried out with 5kV DC voltage For high voltage tests additional preparation will be necessary 6 2 1 TEU Preparation The following preparatory measures must be taken in a Terminal Unit TEU 1 Short circuit input and output motor terminals optional isolator rit ti it 2 Make a short circuit between shorted terminals DC plus DC neutral point and DC minus busbars 3 Turn optional isolators into the required position Type 1 Isolator switch must be closed Type 2 Grounding isolator must be open E 30 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual Chapter 6 Insulation Resistance Measurement Type 3 Grounding switch must be open 6 2 2 LSU Preparation The following preparatory measures must be taken in aLine Supply Unit LSU DC_NP DC_minus All necessary short circuit connections are already made in TEU ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 31 of 62 Chapter 6 Insulation Resistance Measurement AA ED ED 6 2 3
58. twice during commissioning ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev D 19 of 62 Chapter 3 Inspection of Installation AA ED ED 20 of 62 3BHS135824 ZAB E01Rev D ACS 6000 Commissioning Manual AA ED ED PRN IEDIEID Chapter 4 Commissioning Other Drive Components In general the scope of the commissioning is determined by the project The items in the following sections must be checked or confirmation obtained that they have been checked e g measurement results of insulation resistances of other drive components and cables 4 1 Main Circuit Breaker MCB Refer to the manufacturer s documentation for commissioning instructions of the MCB The correct operation of the MCB will be tested later when the converter will be energized for the first time If MCB is new and insulation tests have not been carried out all tests must be carried out according to the instructions of the manufacturer The must have the following features e 1 closing shunt release ON coil e 2 opening shunt release OFF coils Installation of only 1 opening coil is not recommended e 1 undervoltage release coil e Amaximum total breaking time of 60 ms must be guaranteed Note Protection relays in feeding switchgear must be tested and in operation especially the relays of converter transformers The set values of these relays must be checked by the commissioning engineer and compared with the calculated drive currents Rel
59. xes in the ACS 6000 motor transformers and MCB must be closed 5 Open transformer and motor cable ends must be tied together and properly earthed Check that the above mentioned points are fulfilled before commissioning is continued 3 7 Cleanness Civil works must be finished in the converter room Cable openings should be closed to avoid dust entering into the cabinets The converter room must be clean and free of dust Waste from any installation work must be removed The air conditioning of the room must be in operation Requirements for ambient temperature cooling water and converter room can be found on the rating plate of the ACS 6000 Before any test is carried out it must be checked that foreign parts and dust have been removed from the converter cabinets It is very important that the cabinets are free of dust to prevent weakening of the busbar insulation and dust building up on air cooling elements Cooling air filters must be checked The motor area must be cleaned so that it is safe to run the motors All waste that can be in contact with the shaft or the cooling air inlets must be removed The slip rings brushes and brush holders of synchronous motors must e checked for cleanness Cleaning of the whole slip ring compartment before start up is recommended The transformer area must be cleaned and waste from installation work must be taken away Cleanness of the equipment should be checked at least

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