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ABB ACS 6000 Commissioning Manual

Medium voltage ac drive
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ABB
Document No.:
Issued:
ABB Switzerland Ltd. All Rights Reserved.
Medium Voltage AC Drives
Commissioning Manual
3BHS135824 ZAB E01Rev. D
05.10.2004
ACS 6000

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Summary of Contents for ABB ACS 6000

  • Page 1 ACS 6000 Medium Voltage AC Drives Commissioning Manual Document No.: 3BHS135824 ZAB E01Rev. D Issued: 05.10.2004 ABB Switzerland Ltd. All Rights Reserved.
  • Page 2 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.

  • Page 3: Table Of Contents

    Selection Switches and Protective Settings ..............25 Connecting the Auxiliary Supply ................... 25 Filling the Cooling System .................... 26 Starting up the Water Cooling System ......Error! Bookmark not defined. ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev. D 3 (of 62)
  • Page 4 Motor Idle Run ......................51 10.1.1 First Start-up with No Load....................51 Chapter 11 - ACS 6000sd Start-up....................53 11.1 Excitation Start-up......................53 11.2 Motor Idle Run ......................53 11.2.1 Absolute Encoder Positioning Routine ................53 4 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...
  • Page 5 Table of Contents 11.2.2 First Start with No Load ....................53 Chapter 12 - ACS 6000 Final Tuning ..................55 12.1 Mechanical Heat Run ....................55 12.2 Final Tuning........................55 Chapter 13 - Speed Controller Tuning ..................57 13.1 Preliminary Tinung of Speed Controller ................ 57 13.2...
  • Page 6 Table of Contents 6 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 7: Chapter 1 - Overview

    Safety instructions, safety concept, warnings, intended audience, required qualification, responsibilities etc. apply according to the ACS 6000 User’s Manual. Operation and Maintenance According to the ACS 6000 User’s Manual, Chapter 11 and 12. Predefined preventive maintenance packages are from ABB Switzerland Ltd. Medium Voltage Drives...

  • Page 8: Preparation For Commissioning (Project Management Input)

    After insulation test the mains cables can be connected, except at converter end. General Preconditions The Installation of the ACS 6000 must be completed according to the ACS 6000 User’s Manual Chapter 8 – Mechanical Installation and Chapter 9 – Electrical Installation.

  • Page 9: Auxiliary Voltage Supply And Control

    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.

  • Page 10: Cold Commissioning

    PC-tool, attached to the commisioning report, 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: •...

  • Page 11: Chapter 2 - Checking The Scope Of Delivery

    (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 Commissioning Manual 3BHS135824 ZAB E01Rev. D 11 (of 62)

  • Page 12: Scope Of Delivery

    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.

  • Page 13: Chapter 3 - Inspection Of Installation

    Follow the checklist of the commissioning report regarding transformer installation. 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.

  • Page 14: Ambient Conditions

    The requirements for the raw water must be fulfilled. Refer to the Data Sheets of the Water Cooling Units for details. The 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.

  • Page 15: Converter Power Circuit Connections

    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.

  • Page 16: Control Cables

    Wiring of MV-cables on insulated trays • 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 CI810B type adapter) and GRAY encoder cable installation inside ACS 6000 cabinet.

  • Page 17: Converter Earthing Connections

    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)

  • Page 18: Power Cable

    Power Cables 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.

  • Page 19: Cleanliness

    The doors of the slip ring compartment must be closed. All covers for the power cable terminals or terminal boxes in the ACS 6000, motor, transformers and MCB must be closed. Open transformer and motor cable ends must be tied together and properly earthed.
  • Page 20 Chapter 3 - Inspection of Installation 20 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 21: Chapter 4 - Commissioning Other Drive Components

    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...

  • Page 22: Transformer

    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 - 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.
  • Page 23 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. Follow the checkpoints of the commissioning report. ACS 6000 Commissioning Manual 3BHS135824 ZAB E01Rev. D 23 (of 62)
  • Page 24 Chapter 4 - Commissioning Other Drive Components 24 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 25: Chapter 5 - Preparing The Converter

    The supportline must be informed if any changes have been made! 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.

  • Page 26: Filling The Cooling System

    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.
  • Page 27 3-way valve. • 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)
  • Page 28 Chapter 5 - Preparing the Converter 28 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 29: Chapter 6 - Insulation Resistance Measurement

    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 MΩ a megger with a current capability of 2 mA is required.

  • Page 30: Teu Preparation

    Otherwise the cooling water conductivity might become too high. Switch off the auxiliary voltage of the converter. Prepare each ACS 6000 cabinet for the measurement as described in the following chapters. The preparation described in this manual refers to insulation measurement which is carried out with 5kV DC voltage.

  • Page 31: Lsu Preparation

    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_plus 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)

  • Page 32: Cbu Preparation

    Short circuit the common mode filter capacitor CGND. Disconnect the common mode filter capacitor CGND from PE (protective earth). Disconnect the HV-line from the coupling unit AGH520S, if included in the converter configuration. 32 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 33: Aru / Inu Preparation

    Short circuit of phase outputs and DC link busbars is already made in TEU. 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)
  • Page 34 Chapter 6 - Insulation Resistance Measurement ABB 3BHE006414R0001 XV C770 AE Disconnect and ground all three LEM current transducers on CVMI board (ADCVI board in older drive versions). 34 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 35: Ifu Preparation

    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)

  • Page 36: Excitation Circuit

    Chapter 6 - Insulation Resistance Measurement 6.2.7 Excitation Circuit 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): Make a short circuit between the two output terminals.
  • Page 37 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)
  • Page 38 Chapter 6 - Insulation Resistance Measurement 38 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 39: Chapter 7 - Parameter Settings

    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.
  • Page 40 (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...
  • Page 41 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.

  • Page 42: Communication Parameters

    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.

  • Page 43: Advant Bus Communication

    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 –...

  • Page 44: Gray And Pulse Encoders

    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...

  • Page 45: Chapter 8 - Checking I/O

    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)

  • Page 46: Converter Internal Signals

    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...

  • Page 47: Transformer Signals

    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.

  • Page 48: Serial Data Communication

    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.

  • Page 49: Chapter 9 - Energizing The Converter

    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.

  • Page 50: Mcb Control Test

    Check emergency stop and off functionality before starting up the drive and later also while the motor is in running condition! ---------------------------------------------------------------------------------------------------------------------------------- Note: Depending on the type of ACS 6000 proceed with chapter 10 or 11. 50 (of 62) 3BHS135824 ZAB E01Rev. D...

  • Page 51: Chapter 10 - Acs 6000Ad Start-Up

    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...
  • Page 52 Chapter 10 - ACS 6000ad Start-up 52 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 53: Chapter 11 - Acs 6000Sd Start-Up

    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.
  • Page 54 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...

  • Page 55: Chapter 12 - Acs 6000 Final Tuning

    Chapter 12 - ACS 6000 Final Tuning 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.
  • Page 56 Chapter 12 - ACS 6000 Final Tuning 56 (of 62) 3BHS135824 ZAB E01Rev. D ACS 6000 Commissioning Manual...

  • Page 57: Chapter 13 - Speed Controller Tuning

    Run motor to speed you are using for the test. Set DriveWindow 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)
  • Page 58 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...

  • Page 59: Final Tuning Of Speed Controller

    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)
  • Page 60 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...

  • Page 61: Chapter 14 - Finishing The Commissioning

    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.

  • Page 62: Documents And Data For Customer

    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...

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