ABB ACS580MV Commissioning Manual
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ABB ACS580MV Commissioning Manual

ABB ACS580MV Commissioning Manual

200kw to 6300 kw,3.3kv to 11 kv
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ABB INDUSTRIAL DRIVES
ACS580MV Commissioning Manual
(200kW to 6300 kW,3.3kV to 11 kV)

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Summary of Contents for ABB ACS580MV

  • Page 1 — ABB INDUSTRIAL DRIVES ACS580MV Commissioning Manual (200kW to 6300 kW,3.3kV to 11 kV)
  • Page 2 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.
  • Page 3 Commissioning manual ACS580MV drives 200 kW to 6300 kW 3.3 kV to 11 kV Table of contents Safety instructions Introduction to the manual Standard Commissioning Process Option Preventive Maintenance  2021 ABB Beijing Drive Systems Company Ltd. 2UBB005441 Rev E EFFECTIVE:2021-07-15...

  • Page 5: Table Of Contents

    Table of contents Terms ..............9 Trademarks .
  • Page 6 Close MCB and Load Power Module software ......75 Cooling and heating system testing ........75 Motor first run .
  • Page 7 Converter insulation resistance ........143 Transformer insulation resistance .

  • Page 9: Terms

    The following table lists the terms and abbreviations you should be familiar with when using the manual. Some of the terms and abbreviations used in the manual are unique to ABB and might differ from the normal usage. Term / Abbreviation...

  • Page 10: Trademarks

    The power module is a compact assembly of electronic components including power semiconductors and circuit boards that serves as a standardized building block for the INU of the drive. Safeline ABB synonym for uninterruptible power supply. Terminal Unit Short form for terminal compartment of the drive. Transformer unit Short form for transformer compartment of the drive.

  • Page 11: Safety Instructions

    Safety instructions 11 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, commission and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Safety instructions are used to highlight a potential hazard when working on the equipment.
  • Page 12 Maintenance ACS580MV Hardware Manual (2UBB004520). Local safety regulations must be also observed to maintain safety. For 13.8kV input voltage, PPE and Safety should follow “ABB Electrical Safety Matrix” (SA-S-101-07-01) and be defined by each country’s HSE department.

  • Page 13: Introduction To The Manual

    Introduction to the manual Contents of this chapter The purpose of the manual is to assist in commissioning the ACS580MV frequency converter. It includes necessary instructions, practical hints and references to related documentation to successfully commission the converter and the related equipment as needed for the application.

  • Page 14: Mv Drives Supportline Contact

    14 Introduction to the manual MV Drives Supportline contact Before starting the commissioning, please contact ABB Drives Supportline to get the license key: Email address: drivessupport@abb.com Queue in Salesforce: GLO-MO/Global Drive support Exception / different contacts for large countries: •...

  • Page 15: Standard Commissioning Process

    Standard Commissioning Process 15 Standard Commissioning Process Pre-Commissioning check lists Contents of this chapter  This chapter provides information on pre-commissioning check lists. Office preparation check list  In order to achieve an efficient commissioning, make sure that the following items are completed before traveling to site: •...

  • Page 16: Required Tools

    16 Standard Commissioning Process • License for the drive • Digital camera or mobile phone for taking photo Required tools  The tools list is shown as below, for reference: Name Pictures Descriptions USB transfer Mini USB Communication cable, cable (3M) between PC and control panel [Code: 3ABD00036680]...
  • Page 17 Standard Commissioning Process 17 Name Pictures Descriptions Multi meter Such as FLUKE 179 Safety Lockout General tools, including nut 10 - 75 Nm for driver, screw driver and hexagon head screws torque wrench, etc. M6 to M12 Insulation Tester Such as KYORITSU KEW3122A General personal PPE safe helmet, work...

  • Page 18: Scope Of Delivery

    Missing parts should then have been reported immediately to the carrier and the project responsible ABB organization. All claims for damage should have been made to the carrier and ABB should have been notified.
  • Page 19 Grounding cables of MCB, converter and motor are connected and tighten. The cross section of the ground cable must be bigger than 150 mm². • Types and cross sections of power cables are selected according to the ACS580MV Engineering Guideline (2UBB013672). •...
  • Page 20 The connection to system ground has to be established in compliance with local regulations. Main circuit breaker (MCB) • The type of MCB is selected as per ACS580MV Engineering Guideline (2UBB013672). • The MCB is ready to be tested with the converter. •...
  • Page 21 16: denotes manufacturing year (2016). 04: manufacturing week. 0009: running manufacturing number. • Regarding the instruction of reforming, refer to the documentation: ACS580MV PM Capacitor Reforming Instructions (2UBB017371). BCON board Provide below information, ask for the license from MV Drives Supportline: •...

  • Page 22: Inspection Of Installation

    22 Standard Commissioning Process Motor • Motor is installed, aligned and alignment protocol is available. • Motor is not coupled to the driven load. • Grounding is completed in compliance with local regulation. • Motor auxiliaries (bearing lubrication, heater cooling etc.) are ready. •...

  • Page 23: Converter Room

    (2UBB004520). If the installation of the converter has not been carried out as required or the condition of the converter hampers effective commissioning, the customer and the responsible ABB project engineer must be informed immediately. When inspecting the converter, the Pre-Commissioning Check Lists in...

  • Page 24: Commissioning Third-Party Equipments

    NOTICE For later tests, motor and driven equipment is recommended to be uncoupled. Commissioning third-party equipments If third party equipment has to be commissioned by an ABB commissioning engineer, the scope of the work involved and the responsibilities must be agreed by contract and the commissioning engineer must be informed accordingly.
  • Page 25 Standard Commissioning Process 25 The following has to be checked: • Check the main cables are well installed according to the ACS580MV Hardware Manual (2UBB004520). • Measure the resistance of the output busbars by multimeter. The typical values would be several ohms based on the motor data if the motor is connected.
  • Page 26 26 Standard Commissioning Process Terminal compartment, original view from front Voltage dividers Motor side terminals Input terminals Cable entry plate Cabinet grounding busbar...

  • Page 27: Protection Relays

    Standard Commissioning Process 27 Protection relays  ACS580MV with integrated transformer The protection relays in the feeding switchgear for the converter’s transformer must be commissioned and tested as per the manufacturer’s documentation. The settings for the protection relay are defined by the protection or system engineer. The commissioning engineer should only verify these values.

  • Page 28: Motor

    28 Standard Commissioning Process NOTICE! The pickup current for the time over current protection must be given by the system engineer. This strongly depends on the particular application. If the drive integrated with MBU cabinet, pay more attention to the ‘Bypass mode’, the rated input current is based on the motor current.

  • Page 29: Converter Insulaiton Test

    Standard Commissioning Process 29 Converter Insulaiton Test  NOTICE Drive insulation test is not mandatory, it shall be applied or recommended only • Long storage time of the drive (such as >6 months). • Humid environment (Respectively humid storage condition). •...

  • Page 30: Motor Insulation Test

    30 Standard Commissioning Process 13. Reverse all disconnections and remove the short circuit wires. NOTICE A short-circuit in any part of the drive will lead to severe damage. Therefore, check that all short-circuit leads have been removed before energizing the drive.

  • Page 31: Power Cables Insulation Test

    Standard Commissioning Process 31 • If the motor star point is reachable, measure each phase separately as shown below. Insulation resistance measuring when star point is reachable (3 measuring values) • If the star point is not reachable, measure all phases together as shown below. Insulation resistance measuring when star point is not reachable (1 measuring value) •...

  • Page 32: Preparing The Converter For Start-Up

    Preparing the converter for start-up Connecting the auxiliary supply  The ACS580MV uses different auxiliary voltage supplies. • 3 phase supply is needed for powering the cooling fans. According to option the power supply can also come from the integrated transformer.
  • Page 33 Standard Commissioning Process 33 F24V:5 and X24V1:4 PLC DI0 and DI1 2. Inform customer send MCB close/open status signal, and measure voltage as below table, the values should not be higher than 5V. Probe+ Probe- X1:20 < 5V < 5V X1:22 <...

  • Page 34: Other Checking Items

    34 Standard Commissioning Process 3. Inform customer send remote MCB close/open CMD, and measure voltage as below table. The values should not be higher than 5V. Probe+ Probe- X1:42 < 5V < 5V X1:44 < 5V < 5V X1:46 < 5V <...
  • Page 35 Standard Commissioning Process 35 3. Confirm that the installation and wiring of the cooling fan is correct if the fan has been removed by customer. When the cooling fan needs removing for some reason, just pull off the left side plug. Cooling Fan wiring 4.

  • Page 36: Loading Software And Prepare Drivestartup

    7. Check remaining control signals connected the converter and also the 3rd part equipment control signal are connected correctly and tighten. Observe the limited contact rating of the ACS580MV I/O relays. Use the interposing relays for higher current rated as a solution.
  • Page 37 To verify integrity of software being downloaded, following additional steps are recommended. The purpose of integrity verification is to ensure that local copy of release zip file is consistent with zip file originally released by ABB. • Get the software package from Medium Voltage Drives Portal (or other trusted source).
  • Page 38 38 Standard Commissioning Process Loading the BCON software • Install the Drive_loader_2_3_setup tool (or new) to local PC. • Connect PC to the assistant control panel (ACS-AP-W/S), through the USB to Mini USB cable. Switch on the control power supply.
  • Page 39 Standard Commissioning Process 39 • Start Drive loader 2 and select the file LP_FirmwareUpgrade.lp from the loading package (folder: \01_BCON SW).
  • Page 40 40 Standard Commissioning Process • Wait until the tool identifies the port and reads data from BCON. Click “Download” button and wait until the download finished successfully.
  • Page 41 Standard Commissioning Process 41 • Open Drive composer, click on System info to check version of MHDFA and MHDAP.Check if the date and time are correct, otherwise set time. Loading the ACS-AP-W/S assistant panel firmware • Remove the panel from the drive. Connect PC to the assistant control panel (ACS-AP- W or ACS-AP-S), through the USB to mini USB cable.
  • Page 42 42 Standard Commissioning Process • Start DLoaderWin32.exe from the loading package. (folder: \05_ControlPanelFW) • Press the button “Open”, select the *.dlp file in software package.
  • Page 43 Standard Commissioning Process 43 • Press the button “Load SW” and wait till update is finished.
  • Page 44 44 Standard Commissioning Process Loading the control hub firmware • Install the XILINX lab tools 14.7. Copy the files as below to local disk, unzip the first one. • Start the xsetup.exe to install the software tool. Note: Do not connect Xilinx cable to PC during the whole installation.
  • Page 45 Standard Commissioning Process 45 • In this step, should select Lab Tools – Standalone Installation.
  • Page 46 46 Standard Commissioning Process • In this step, only select Install Cable Drivers. Till to finish successfully. • Switch off the control power. • Remove the daughter boards DB2 and DB3 to get access the X5 connector on control hub. •...
  • Page 47 Standard Commissioning Process 47 • Run the PROG_MHDCH.bat batch file to program the control hub. (folder: \03_Controlhub FW) Note: If the error information like below, it means that the location of the IMPACT program needs to be added to the system path.
  • Page 48 48 Standard Commissioning Process Copy the IMPACT path from the properties of program. Such as ‘C:\xilinx\14.7\LabTools\LabTools\bin\nt64\’. Open the System variables by the path: Start -> Settings -> Control panel -> System and Security -> System -> Advanced system settings -> Environment variables. Add to the value of “Path”...
  • Page 49 Standard Commissioning Process 49 Note: If the error information like below, please create a folder named temp in drive C. • Waiting nearly 5 minutes, programming successfully finished. Press any key to exit. • Turn off the control power. • Remove the XILINX platform cable USB II.
  • Page 50 50 Standard Commissioning Process Loading the CVMI2 firmware • Install the XILINX lab tools 14.7. Refer to the previous step. • Switch off the control power. • Connect XILINX platform cable USB II to X1301 connector on CVMI2. • Switch on the control power. •...
  • Page 51 Standard Commissioning Process 51 Copy the IMPACT path from the properties of program. Such as ‘C:\xilinx\14.7\LabTools\LabTools\bin\nt64\’. Open the System variables by the path: Start -> Settings -> Control panel -> System and Security -> System -> Advanced system settings -> Environment variables. Add to the value of “Path”...
  • Page 52 52 Standard Commissioning Process Note: If the error information like below, please new a folder named temp in drive C. • Waiting nearly 25 seconds, programming successfully finished. Press any key to exit. • Turn off the control power. • Remove the XILINX platform cable USB II.
  • Page 53 Standard Commissioning Process 53 • Switch on the control power. Update operation starts. Observe the LEDs on PM55X: a. RUN LED flashing slowly = reading from SD memory card b. RUN LED flashing fast = programing in progress c. RUN LED permanent on, ERR LED off = SW download successfully •...
  • Page 54 54 Standard Commissioning Process • Please operate the converter according to the description of “DriveStartup”. Loading the DSP software manually to power modules • Necessary tools: 5.5 VDC power, USB to POF cable and fiber cable. • Install the Tera term programing tool, select the default components. •...
  • Page 55 Standard Commissioning Process 55 • We can find USB Serial Port in Device manager by selection of Computer/Manage from desktop, such as COM12. • Select serial port and set baud rate to 115200 from Properties. • Open the programing tool Tera Term. •...
  • Page 56 56 Standard Commissioning Process • Connect the 5.5 VDC cable to power module X1 and PC. Note: terminal DC+ is the one which close to the fiber terminal. • The Tera Term will ask you whether to erase the flash. Note: If no action in 5 seconds, we need reboot the board.
  • Page 57 Standard Commissioning Process 57 • Type e to erase the flash, once erasing done, step to Ready for application code transfer... • Open the File/Send file…, select the PEBB1_CellController.bin from the software package (folder \02_PowerModule SW). Note: Confirm the Binary is enabled.
  • Page 58 58 Standard Commissioning Process • Click the OPEN button to start programming. • Several seconds later the message is shown as below, “application is programed”. • Repeat the steps to program all the power modules. • Disconnect the programing tools.

  • Page 59: Commissioning Software Tools On Pc

    Standard Commissioning Process 59 • Once all the power modules are energized, check the software version through the parameter group 07 and group 70/71/72. Commissioning software tools on PC  With 2018-A software release, field engineers will be supposed to do commissioning with new PC tools, embedded version of DriveStartup that integrated into Drive composer pro.
  • Page 60 60 Standard Commissioning Process • Complete the installation, press Finish.
  • Page 61 Standard Commissioning Process 61 • Open the Drive composer in offline mode. Enter registration code from menu: Help/Enter license code. Reboot the drive composer pro. Open the DriveStartup tool from the Drive composer pro • Start the registered Drive composer pro tool. •...
  • Page 62 62 Standard Commissioning Process • DriveStartup launched. OPC server does not need to set again. • Add the loading package from the menu: View/Package Manager.
  • Page 63 Standard Commissioning Process 63 • Open the file from the below location (folder\08_DriveStartup\ACS580MV) • Add the template of Field service report also from the menu: View/Package Manager.

  • Page 64: Cold Commissioning By Drivestartup

    64 Standard Commissioning Process NOTICE In the display settings adjust view to be 100%. (DriveStartup, informs to do this during installation.) Check the display setting on PC: Control panel/Appearance and personalization/Display, use the default selection Smaller - 100%. The recommend resolution of display is at least 1366x768. Cold commissioning by DriveStartup Create the new project ...
  • Page 65 Standard Commissioning Process 65 • Fill in all necessary information. Note: Must fill in the full type code in Drive configuration, such as: ACS580MV-066-A04A-J5- 010+AUX0000+AWL0000+HAS0000+ARC0000+ASC0010+COL0001+EPC0021+CCS00 00+CMC0000+CEO0000+CPR0004+CSC0001+CSV0003+DMT0001+SEO0000+CIT000 0+EXT0000+FAT0000+FAD0002+FWE0000+FAB0000+GDS0001+HWS0000+TRR0073 +LOD0011+LCH0000+PCE0041+MCE0041+MCC0000+RMC0001+EAT0000+EWT0000 +MOF0120+MST0000+MHP0000+TSM0000+OCH0000+OCA0000+PAK0000+CPF0002 +TRV0000+SHT0000+SPP0000+SPF0050+SMV0066+CEP0012+PCM0100+WMT0001 The full type code can be copied from the project information in MoR by search the series...
  • Page 66 66 Standard Commissioning Process Site inspection step by step. • Take photos and prepare the ACS580MV Drive and Site Condition Check List. Attached in the project folder once completed.

  • Page 67: Connected Equipment Inspection

    Standard Commissioning Process 67 Connected equipment inspection  • Fill in all necessary information from the equipment report. Including protection relays, MCB, integrated transformer, motor and power cables. Note: Check every item carefully.

  • Page 68: Cold Commissioning

    Check if the power cable connection on the secondar side of the integrated transformer is correct. passed case failed case NOTICE The connection of power cable must be solid. It is not allowed to have any washer between two cable lugs. The tightening torque should follow ACS580MV Hardware Manual (2UBB004520).
  • Page 69 Standard Commissioning Process 69 • Drive insulation test is not mandatory. Setting parameters and checking control signals • Switch on the control and auxiliary power supply accordingly. Return to Drive composer, select Refresh in menu View, get into the online mode. Note: Refresh and check the service access level once restarting the connection, enter again the service level passcode if needed.
  • Page 70 70 Standard Commissioning Process • Refer to the motor nameplate for the following settings. Whenever possible, enter the values exactly as shown on the motor nameplate. • According to the requirement of customer and project side, set the parameters which are specific for the project: a.
  • Page 71 Note: Including the logic test, refer to the DriveStartup. • MCB available / MCB ON prevention / MCB external protection monitoring, in parameter group 82. Note: Including the logic test, refer to the DriveStartup. • For particular parameter description refer to the ACS580MV Firmware Manual (3BHS811381).
  • Page 72 72 Standard Commissioning Process • Configurate and test the IO signals, such as control supply monitoring and door interlock. Note: Including the logic test, refer to the DriveStartup. MCB testing The Main circuit breaker (MCB) is the connection to medium voltage and plays a major role in all safety concepts of the drive.
  • Page 73 Standard Commissioning Process 73 • Press emergency off button on front door, fault AFEB Emergency OFF button pressed is active. Release emergency off button, the fault should deactivated. • Press ON button on front door, MCB should be closed. Press OFF button on front door, MCB should be opened.
  • Page 74 Engineering Guideline (2UBB013672). ABB engineer should check the logic before connecting the drive to medium voltage. NOTICE If ABB bypass unit as the option (MBU=0001, MBU=0002 or MBU=0003) is ordered, the MBU should pass the commissioning described in Commissioning. DANGER For testing the MCB make sure the MCB is racked out into test position.

  • Page 75: Hot Commissioning By Drivestartup

    After completing the tasks in the previous chapters, the converter can be energized. DANGER From this step MCB is in normal position and controlled only by ACS580MV. Medium voltage can be connected to the converter! Confirm safety area of motor is cleared and auxiliary equipment of motor is in operation.
  • Page 76 2400 3200 ( 6R9 ) 6KV400A INU and XFMR ACS580MV standard fan configuration • Test run the fan by setting the TEST RUN on parameter 83.12 Fan control. Check the fan's direction of rotation. a. For AC fan, if the direction is wrong, swap two phases of power supply and test again.

  • Page 77: Motor First Run

    Standard Commissioning Process 77 • Set the limitation in Parameter 83.32/34 INU air pressure low/high limit. Frame 3.3/4.16kV 3.3/4.16kV Size Limit 83.32 High Limit 83.34 • Check the below signals should be similar value to ambient temperature.a.a a. 1.31 Ambient temperature b.

  • Page 78: Fly Start

    78 Standard Commissioning Process • Observe and save the measurement, attach plot to report. • If the motor rotates in the opposite direction correct the motor cabling or change the parameter 99.16 Phase order to UWV. Fly start  If flystart is required by the project, do the below test, otherwise skip this step. •...
  • Page 79 Standard Commissioning Process 79 • In case of issues occurred in the above step, try to tune the parameters below. Refer ACS580MV Troubleshooting manual (2UBB005092) for more information. a. 21.02 Magnetization time b. 21.30 Flystart current level c. 21.31 Flystart flux ramp time d.

  • Page 80: Control From Overriding System

    80 Standard Commissioning Process Control from overriding system  Two external control locations EXT1 and EXT2 are available. The user can select the sources of the MCB open and MCB close commands separately for each location by parameters 82.20 MCB Ext1 commands and 82.21 MCB Ext2 commands.

  • Page 81: Motor Ramp Up And Down With Load

    Standard Commissioning Process 81 • Observe and save the measurement, attach plot to report. Motor ramp up and down with load  DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.After the motor has been coupled and run with the driven equipment, all interlocks from an overriding control system must be in operation.These interlocks should stop the drive if a critical condition occurs in the process.If the trip levels, acceleration or deceleration times are set wrong it may cause...

  • Page 82: Vector Control

    82 Standard Commissioning Process • Motor speed ramp up a. Set the speed reference to motor rated speed in drive control toolbar. b. Start the motor and observe the related signals, compare the current with parameter 30.17 Maximum current. • Motor speed ramp down a.
  • Page 83 Standard Commissioning Process 83...

  • Page 84: Grid Loss Ride Through Test

    84 Standard Commissioning Process • Record operation trend and add it to report with comments. Grid loss ride through test  Test Grid loss ride-through. Test with the driven machine coupled and with load, if possible. NOTICE! Grid loss ride through test is not the standard commissioning task, which is only for the particular project permitted by MV Drives Supportline.The MCB will open and close automatically during the test.

  • Page 85: Sd Card Data Backup

    SD card data backup  • Copy the Date from the SD memory card to PC. Refer to Maintenance ACS580MV Hardware Manual (2UBB004520), section “Replacing the SD memory card”. Spare parts software version  Before leaving the site, the customer spare parts are to be checked against the bill of material.

  • Page 86: Customer Approval

    86 Standard Commissioning Process • Safety training • Overview of the system and cabinet • Door interlocking system • Control panel a. Reading and interpreting status, alarm and fault messages b. Control modes (local/remote) • Energizing and starting the converter •...

  • Page 87: Prepare The Field Service Report By Drivestartup

    Standard Commissioning Process 87 • Create report by going to menu Reports and select report type. Prepare the Field service report by DriveStartup  Please download the latest Field Service Report template (version 2.0 or newer) from the MV Drives Portal Software Station and only use the latest version for all future reports.
  • Page 88 88 Standard Commissioning Process NOTICE In the display settings adjust view to be 100% (DriveStartup, informs to do this during installation).Check the display setting on PC: Control panel/Appearance and personalization/Display, use the default selection Smaller - 100%. • Create the new project. In the step ‘Service provider’, fill in the email and password to connect to MoR database.
  • Page 89 Standard Commissioning Process 89 • Pay more attention to the ‘Recommended Services’ and ‘Updates’, contact MV Drives Supportline if necessary. • If the drive is not registered to a site/customer in ServIS, the Registration step appears. Please locate the correct site with the link in ServIS and copy the Site ID to the ServIS Site ID box.
  • Page 90 90 Standard Commissioning Process When a component is changed, the new serial number should be reported. If a component is added, removed or replaced with a different part number, this is updated in the BOM in order to show what is currently installed in the drive. Fill in the responding information in the blanks below.
  • Page 91 Standard Commissioning Process 91 Note: If you have spare time while you are on-site, please take a moment to update the part lists with the correct part locations in order to improve the quality of our data. • All the drive data that is collected in 'Drive Data and Software' step should be added to the table, including the firmware and software version of AC500eco, ACS-AP-S/W, BCON, CVMI2 and Control hub.
  • Page 92 92 Standard Commissioning Process Note: Select the correct drive status in step Service summary. Which would impact the drives life time management in MoR database. • Return to the step ‘Reports and attachment’. Create the service report and field service report by going to menu Reports and select report type.
  • Page 93 Standard Commissioning Process 93 • Complete the site condition report ‘2UBB021641_ACS580MV Drive and Site Condition Check List’, together with the commissioning report (service report) and field service report, add to the attachment. • Update all the drive data and reports to MoR by pressing ’Upload ALL to Installed base (MoR)’...

  • Page 94: Customer Documentation

    Warranty report(s) of replaced components if any. Duration and description of commissioning The time schedule describes a typical ACS580MV commissioning (excluding special options like synchronized bypass etc.). To be able to follow the schedule, the preconditions must be fulfilled. Commissioning of the drive must be done by a certified engineer.

  • Page 95: Duration And Description Of Typical Commissioning

    Standard Commissioning Process 95 Duration and description of typical commissioning  Description Duration • Collecting information about the drive system (electrical part 4 hours list, wiring diagrams, application notes etc.) • Preparing the needed software and drive license. Preparations Note: the commissioning preparations does not include any practical travel arrangement etc.
  • Page 96 96 Standard Commissioning Process...

  • Page 97: Mbu Commissioning

    Option 97 Option MBU Commissioning Manual bypass is an option used as a backup for a drive failure (e.g. a trip) or drive maintenance, then the motor can be switched to bypass (DOL) mode. As standard option there are 3 types shown as below, •...
  • Page 98 98 Option Configuration of drive and bypass for MBU=0001 and MBU=0002 or MBU=0003 DANGER Three isolation switches are forbidden to be operated when MCB is closed. Illegal operation will result in death or serious injury.The position of the knives must be checked through the observation window after operation to make sure they are in the right position.
  • Page 99 Option 99 Customer interface or MBU (New) Customer interface or ABU (Old) Customer interface or ABU (New) New relay for Manual bypass unit upgrade...

  • Page 100: Insulation Test

    100 Option Insulation test  The insulation test is not recommended, if necessary check the description in Insulation Resistance Measurements. Commissioning for MBU=0001 option  • Confirm the MCB has been racked out and grounded. • Ground the input busbar in TRU cabinet by grounding harness for safety. •...
  • Page 101 Option 101 • Check all three switches can fully close after ‘close switches operation’. The movable contacts can fully contact the stationary contacts, below pictures show one passed case and failed cases. passed case failed case • Check all three switches can fully open after ‘open switches operation’. The clearance between open contacts should be bigger than 150mm.

  • Page 102: Commissioning For Mbu=0002 Or Mbu=0003 Option

    102 Option Item QS1(Q1) open QS1(Q1) open QS1(Q1) close QS1(Q1) Result close QS2(Q2) open QS2(Q2) open QS2(Q2) open QS2(Q2) QS3(Q3) close QS3(Q3) open QS3(Q3) open close Bypass mode OFF mode QS3(Q3) open VSD mode VSD mode lamp Bypass mode lamp H7202(P7202) On: switch on S7201 Off: switch off S7201...
  • Page 103 Option 103 Check of the contactors operation • Check the switch S7804 can’t be operated when it is locked at any of three status (Local, Stop and Remote). • Local, stop and remote mode have interlocked function. Check these functions with special contactor operations as below table, and all the test result shall be ‘X’.
  • Page 104 104 Option Check of the logic and lamp status For lamp test, the cabinet shall be fed Auxiliary supply, and close Q7601 and Q7651. The lamps status can be checked as below table. Item KM1(Q1) KM1(Q1) open, KM1(Q1) KM1(Q1) Result open, close, close,...

  • Page 105: Sbu Commissioning

    The Latest software is recommended. Inspection of installation  Complete installation checklist before commissioning can take place. ACS580MV Hardware Manual (2UBB004520) for other information of installation. Notice: 1. Mains and converter output PT should be same type. Single phase PT is recommended.

  • Page 106: Insulation Test

    Marshalling PLC software Marshalling PLC is optional, just for multi motor mode. As Loading software and prepare DriveStartup described, take the loading package for the latest software release and download to Marshalling PLC using thes same procedure as to AC500 of ACS580MV.
  • Page 107 Option 107 CP610 software Download the SW to Panel (CP610) if it has this option as below. • Save the following file to root folder of a USB disk. • Switch off the control power. • Plug in the USB disk to the HMI device CP610. •...

  • Page 108: Sbu Phase Order Check Procedure

    SBU function, instead of something specially for ACS580MV; Meanwhile, SBU commissioning needs to count on expertise of FSE to judge on site which method is safe/applicable and easy to carry out,...
  • Page 109 Option 109 Below is an example (available when SBN=0001): 1. Confirm that the upper side phase order of MCB and MB1 are clockwise (customer’s responsibility); 2. Disconnect the motor cable at the motor side; 3. Short-circuit both the input cable and output 3 phases cables of the VFD one by one; 4.
  • Page 110 1. Disconnect the input cables from -X117:1, -X117:2, -X118:1, -X118:2; 2. Remove the bridge between -X117:2 -X117:3, -X118:2 -X118:3 if available (SBP=0001, PTs provided by ABB); 3. Connect the test circuit as above, two single phase breakers (-Q1 and -Q2) are proposed to be added between 220Vac and terminal -X107(or-X117) and -X108 (or - 118) for safety and easy controlling;...

  • Page 111: Sbu Cold Commissioning

    Option 111 SBU Cold commissioning  Set SBU parameter • Use the standard AI2 as the RSYC-01 board BUF_OUT signal interface. Select AI2 unit selection to V on the front of the BCON. • Set parameters for MSS and MB control. Set following parameters via drive startup：...
  • Page 112 Define the ratio of grid PT (potential transformer). For example, if the voltage transducer ratio of PT is 11000V / 110V, set this value to 100. If the PT is provided by ABB, the type is RZL10 (11000V / 110V). 85.06 Ratio of Refer to 85.05...
  • Page 113 Option 113 Drive Parameter setting Description 85.20 MB open by Disabled If it’s enabled, 1 →0 of MB DOL command (BCU DI4, or 85.01 SBU direct online control and monitoring CW bit 2) will open MB. For Multi motor, (example) disabled is necessary.
  • Page 114 114 Option Drive parameter Setting Description 16.19 DIO3 function Output Select DIO3 as output 16.21 DIO3 output P 85.2.14 Inductor bypass contactor close command signal is from source SBU function SW bit 14 16.24 DIO4 function Output Select the DIO4 as the output 16.26 DIO4 output P 85.2.15 Inductor bypass contactor open command signal is from...
  • Page 115 Option 115 3. Marshalling PLC parameter setting The following parameters are necessary. Marshalling PLC Setting Description parameter Par.1 Control IOs control Select Marshalling PLC control source. source (example) Par.2 Number of 2 (example) Define number of motors. motors Par.3 MB Define how many feedback signals MB has.
  • Page 116 116 Option Marshalling PLC Setting Description parameter Par.10 MSS close Define maximum operating time for closing MSS time limit (example) Par.11 MB open Define maximum operating time for opening MB time limit (example) Par.12 MSS open Define maximum operating time for opening MSS time limit (example) Par.13 MSS close...
  • Page 117 System Configuration Note: It is important to set Par.2 number of motors at first. More Marshalling PLC parameters, please refer to ACS580MV Marshalling Unit firmware manual (2UBB005340). • Select “Motor1-4” and “Motor5-8” to set motors parameters according to Par.2, the...
  • Page 118 118 Option Note: In case Marshalling PLC reports F002 PLC IO module fault, refresh Par16 PLC IO refresh, to match actual IO modules. After refreshing, Marshalling PLC will reboot and be configured to correct HW variants. Customer interface SBU marshalling PLC has 3 control sources: IOs control, Fieldbus control and Panel control. 1.
  • Page 119 Write date %MW0.1 Access data setting for communication For status word, control word and fault word please refer to ACS580MV Marshalling Unit firmware (2UBB005340). 3. Panel control source Panel control is an option for customers. The control interface is applied only when...
  • Page 120 120 Option Parameter 1 Control source selects Panel. NOTICE Only after user logs in, the control command can be sent to system. You can see all the panel interface after you log in the system as below. interface Main...
  • Page 121 Option 121 IO signals...
  • Page 122 122 Option Panel control interface System fault...
  • Page 123 Option 123 System fault history For parameters setting details please reference to 2UBB005340 ACS580MV Marshalling Unit firmware. Circuit breaker tests DANGER The MCB, MSS, MB must stay in TEST position during the following test! Make sure that MB should have hardwiring interlock with MSS, MSS cannot close when MB is closed.

  • Page 124: Sbu Hot Commissioning

     DANGER From this step MCB and all of MB, MSS is in normal position and controlled only by ACS580MV. Medium voltage can be connected to the converter! Confirm safety area of motor is cleared and auxiliary equipment of motor is in operation.
  • Page 125 Option 125 Make sure parameter 85.12 is multiple motors mode. Test steps: 1. Let drive in remote mode and start monitoring trend. 2. Select motor, MSS will close. 3. Give MCB close command and start command. Set a reference and wait for drive reaches the setpoint.
  • Page 126 126 Option T1: First time RSYC-01 SYNC signal is high, which means voltage frequency and phase angle of main and converter output are matching. RMS of voltage adjusting starts. T2: Voltage amplitude matching is high, which means voltage amplitude of main and converter output are matching.
  • Page 127 Option 127 • Please set the DL as per below example. Most important signals are 1.40, 1.41, 1.42, 85.2. Note: A current controller is designed to limit the inrush current from grid when MB is closed, while its performance can be changed via tuning the SBU current gain parameter value.
  • Page 128 128 Option The graph should be similar to the example below. Notice: Please remember to attach the datalogger recording to the data uploaded to MoR. • Observe and save the measurement, attach plot to report...

  • Page 129: Master/Follower Functionality

    Option 129 Successful example for reference as below: Master/follower functionality Contents of this chapter  The master/follower functionality is usually used to link several drives together, so that the load can be evenly distributed between the drives. This is ideal in applications where the motors are coupled to each other via gearing, chain, belt, etc.
  • Page 130 130 Option FF7E Follower Fault shown with aux code on Master when Follower has fault. (Aux code is the node of follower). Make sure following items have been checked before M/F test. 1. All drives have been tested completely as vector control mode. 2.

  • Page 131: General Parameter Setting

    Option 131 General parameter setting  Parameters setting in this section is just for your reference. The specific parameters should be set according to the user’s control requirements.
  • Page 132 Follower node 4 data 3 sel 25.8 Drooping rate Defines the droop rate (in percent of the User dependent motor nominal speed) 2. General configuration of Torque Follower ACS580MV Follower Parameter Settings — Torque Follower Parameter Name Setting Description 19.11 Ext1/Ext2 selection Ext2 19.14...
  • Page 133 Option 133 ACS580MV Follower Parameter Settings — Torque Follower 20.6 Ext2 commands M/F link 20.7 Ext2 start trigger type level 26.12 Torque ref2 source M/F reference 2 60.1 M/F comm port RDCO CH2 Channel of DDCS M/F 60.2 M/F node address...
  • Page 134 134 Option ACS580MV Follower Parameter Settings — Speed Follower 61.1 M/F data 1 selection SW 16bit (Optional) Follower select the data which transmit to the master, and they 61.2 M/F data 2 selection User dependent are effective when this follower is selected by Master’s P60.14...
  • Page 135 Option 135 BCU1: BCU2: BCU3: Step1 20.01 Ext1 command = In1 20.01 Ext1 command = In1 20.01 Ext1 command = In1 start In2 Dir start In2 Dir start In2 Dir 20.06 Ext2 command = M/F 20.06 Ext2 command = M/F 20.06 Ext2 command = M/F link link...

  • Page 136: Remote Connectivity

    136 Option BCU1: BCU2: BCU3: Step4 Stop set DI1=0 60.15 Force master = True 60.15 Force follower = True 60.15 Force follower = True 19.11 Ext1/Ext2 selection = 19.11 Ext1/Ext2 selection = EXT1 EXT2 19.11 Ext1/Ext2 selection = EXT2 19.12 Ext1 control mode = 19.14 Ext2 control mode = Speed Torque...

  • Page 137: Neta-21 Setup

    Option 137 Parameter setting Activate XETH port for NETA-21 connection. NETA-21 Setup  1. Download latest firmware and package to NETA-21 and login by using local Ethernet cable. 2. Set “BCU SD upload” to “Latest month” (Find it in Settings -> Device Interface -> Ethernet ->...
  • Page 138 138 Option 3. Setup ETH1 port 4. Setup ETH2 port NOTE: Settings in the picture is just an example, it works only for China domestic installation with 4G router. 5. Reboot NETA-21...

  • Page 139: Finalizing The Connection

    Option 139 Finalizing the connection  When NETA-21 is connected to network, 4 green ticks will appear on the home page of NETA-21. Send detailed record list to Follow The Sun/Supportline:...
  • Page 140 140 Option...

  • Page 141: Preventive Maintenance

    WARNING Obey the instruction in Safety instructions ACS580MV Hardware Manual (2UBB004520). If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 142: Regular Inspection

     The following table contains an overview of the most relevant inspection checks for the drive. ABB recommends that inspections be carried out whenever the drive has been shut down, i.e., to replace components or for any other field intervention.

  • Page 143: Insulation Resistance Measurement

    Stop, de-energize and ground the drive following the steps in section Shutting down the drive for maintenance ACS580MV Hardware Manual (2UBB004520) before you start the work. 2. Disconnect all electrical connections between integrated transformer and drive, isolate the cables from ground or frames.

  • Page 144: Motor Insulation Resistance

    144 Preventive Maintenance Motor insulation resistance  Insulation resistance measurement for motor, please refer to Motor Insulation Test. Optical fibers Visual check  Pay special attention to the following: 1. Cracks in the core or the coating. 2. Minimum bend radius (25 mm). 3.

  • Page 145: Communication Test

    Preventive Maintenance 145 2. Unplug the optical fiber. 3. Check the ends of the optical fiber. If necessary, clean the fiber ends. 4. Connect the light source to one end and the power meter to the other end of the optical fiber.

  • Page 146: Bypass Unit

    146 Preventive Maintenance Bypass unit Isolation switches for Manual Bypass  Pay special attention to the following: 1. The isolation switches should be easy for operation. 2. Conductive grease like “OKS VP980” is applied on contact surface of isolation switches, apply more if necessary. 3.
  • Page 147 Preventive Maintenance 147 1. Overall impression: no damage, and firmly mounted. 2. Connection points: no overheating, corrosion or rustiness. 3. Mechanical latch: no damage, deformation or rustiness. 4. Auxiliary contacts: no corrosion; moving contacts acts easily after pressing connection-rod. 5. Check interlock of isolator knife switches as below table:...
  • Page 148 148 Preventive Maintenance...
  • Page 149 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to abb.com/searchchannels.
  • Page 150 © 2021 ABB Beijing Drive Systems Company Ltd.

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