ABB ACS1000I (01) PDF Document

1) Minimize hazards

2) Before energizing the drive:

• Remove all foreign objects from the drive
• Fasten all internal and external covers securely
• Close, lock, and/or bolt all doors
• Move the release dial of the door safety switches into the locked position

3) Before working on the drive:

• Turn off, lock out, and tag out the main and auxiliary power supplies to the drive
• De-energize the drive
• Ensure that the safety ground connections are in place
• Ensure that the appropriate personal protective equipment (PPE) is available and used when required
• Inform the involved personnel about the potential safety hazards
• Wear hearing protection when a drive is running.

4) While working on the drive:

• DO NOT step on the roof
• DO NOT install foreign objects on the roof

5) Before working on a water cooling unit (WCU):

In addition to the safety instructions for working on a drive, always read the WCU safety data sheet for relevant safety information, eg, the type of ion exchange resin and glycol.

6) Before working simultaneously on the drive and on other drive system equipment:

• Observe the relevant safety codes and standards
• Turn off all energy sources for the equipment
• Ensure that all lockout and tagout devices are in place
• Install barriers around and use appropriate covers on the equipment that is still energized
• Inform the involved personnel about the potential safety hazards

7) In case of fire in the drive room:

• Observe the established rules and regulations for fire safety
• Only allow firefighters with the appropriate PPE to enter the drive room

ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations.

1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash.

• Be in possession of a clear work order to execute the work.
• When required, the access or work permit is to be obtained by a person who is authorized for the specific electrical system.
• Engage the person responsible for electrical equipment or system to review single-line diagrams, schematics, switching plans, etc.
• Ensure the competence of workers.
• Check for proper tools for the job.
• Determine and select the proper arc-rated Personal Protective Equipment (PPE).
• Decide of the appropriate work methods and initiate the Permit To Work (PTW) process.

2) Clearly identify the work location and equipment.

• Use your senses (sight, hearing and smell) to identify problem areas.
• Define the work area via barriers and barricading and label equipment.
• Avoid distractions such as talking or texting on the phone.

3) Disconnect all sources of supply and secure against reconnection by applying Lockout/Tagout.

• If ABB is responsible for switching and it cannot be done remotely, then the person performing the switching must be properly trained and wearing the proper PPE identified in step 1.
• The Person in Charge of Work (PICW) must ensure that switching is performed in the proper manner by witnessing it from a safe distance if present on site or by engaging the person responsible for switching to identify all isolation points.
• Apply Lockout/Tagout (LOTO) to the energy isolation device and if multiple energy isolation devices are involved, then Group LOTO must be implemented with the PICW serving as the Group LOTO Leader.

4) Verify the absence of operating voltage: always test before you touch!

Only use properly rated and inspected voltage detection devices and wear proper PPE identified in step 1:

• Test voltage detection device
• Test for voltage
• Test voltage detection device

It is highly important that the voltage detection device is tested on a known voltage source such as a Proving Unit or by performing an internal self-test, according to the manufacturer’s instructions, before and after testing for the absence of operating voltage.

5) Carry out earthing and short-circuiting.

• Close and lock the earthing switch if the electrical equipment is designed for this purpose or apply portable equipment for earthing and short-circuiting.

If this is carried out by the customer, then the PICW must ensure that this equipment is properly earthed as a part of the integration/verification and during step 7 when the PICW walks the PTW.

6) Protect against adjacent live parts and take special precautions when close to bare conductors.

• Determine minimum approach distances, apply screening or shrouding, and when applicable, padlock both cable and busbar shutters.
• If working within the restricted approach boundary or vicinity zone where inadvertent movement could cause contact with live parts, special precautions must be employed, such as the use of the properly rated insulated gloves and tools.

7) Complete the permit to work and “Walk the Permit”.

• Check isolation points
• Verify that all circuits are isolated and secured
• Ensure all parties are integrated with the Lockout/Tagout
• Check the earths are properly applied
• Answer specific questions from the working group
• Ensure the work can proceed without danger
• Complete and verify the “Permit to Work”

• The MCB open and / or trip command has to be wired directly from the drive to the MCB.
  • It is not permitted to wire the trip command through any PLC or DCS system if it is not certified to meet SIL three-level requirements and to fulfill the timing requirements outlined below.
  • Opening of the MCB by the drive must be possible at any time. It is not permitted to interrupt the open and / or trip command, eg, by a local-remote switch in the MCB.
• When the MCB is in service position, the drive must have exclusive control of closing the MCB. Local closing of the MCB is not permitted.
• The maximum opening time of the MCB must never exceed the product- or project-specific maximum time defined in the MCB specifications.

Typical maximum values for the drive are defined as follows:

• Maximum protection trip time: 120 ms
• Maximum safety trip time: 250 ms

1. Remove all packaging material carefully.
2. Check the drive and accompanying equipment for damages.
3. Compare the complete delivery with the purchase order and the packing list.
4. If parts are missing or damaged, immediately inform the shipping company and ABB.

NOTE – For damaged parts, ABB recommends sending a photograph.

Lifting plates are factory-installed on the base frame of transport units. The following information is for crane lifting operations.

1. Verify that the factory torque marks on the mounting bolts and washers of the lifting plates are aligned. If the marks are not aligned or are not visible, tighten the mounting bolt to the torque that is specified in Table 5-1.
2. Attach slings to the lifting plates with load-appropriate safety hooks or shackles. CAUTION! DO NOT run a sling through the hole of a lifting plate!
3. Wrap a sling horizontally around the upper 1/3 of the load height and secure in place with vertical slings.
4. Protect the edges and other protrusions on the load from direct contact with the lifting gear, eg, slings.
5. Lift the load slowly and steadily, with no abrupt stops, in an upright position to the required clearance height.

Table 5–1 Lifting attachment specifications

If the drive is taken out of service for a longer time proceed as follows:

1. Remove the batteries (if applicable).
2. Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil and a wooden panel.
3. Add a desiccant of the appropriate quality:
   • 1 unit desiccant (30 g) absorbs 6 g water vapor.
   • NOTE – The following quantity is required when using a polyethylene foil: 10 units/m² foil
4. Close and lock the doors of the cabinet.
5. Use polyethylene or equivalent for packaging: 0,3 g/m²/24h water vapor diffusion
6. Attach humidity indicators to the packaging.

The storage conditions and the packaging should be checked regularly. Any damages that occur during the storage period should be repaired immediately.

Condition of the floor:

• Must support the weight of the cabinet
• Overall incline across 5 m must not exceed 5 mm
• Even
• Non-flammable, smooth and non-abrasive
• Protected against humidity diffusion

1. Drill fixing holes into the floor as indicated on the layout drawing.
2. When the cabinet is in place, check if the doors are misaligned. NOTE – If the doors do not open and close properly, place leveling plates at the appropriate points. Recommended size: 80 x 300 x 0.5 mm.
3. Fix the cabinet to the floor. NOTE – Floor fixings are not supplied.
4. Anchor bolts as illustrated, or screws and nuts of size M16 are recommended.
5. Insert the screws from the ends of the cabinet base or via the holes inside the cabinet.

1. Remove the cover from the fan cutout in the roof.
2. Unbolt and remove the top cover of the fan housing. IMPORTANT! Keep the bolts in order to reattach the top cover.
3. Install rotating eyebolts in the top corners of the on the top plate of the fan unit in one of the following configurations:
   • 2 diagonal corners for 2 leg lifts
   • 4 corners for 4 leg lifts
4. Attach lifting gear to 2 diagonal or all 4 rotating eyebolts.
5. Orient the rotating eyebolts in the direction of force. CAUTION! Rotation during transportation must be avoided.
6. Lift and suspend the fan over the roof cutout.
7. Feed the fan motor cable into the drive cabinet.
8. Align and lower the fan over the cutout on the drive roof. Align the shock absorbers on the base or the base plate of the fan with the holes in front of and behind the cutout.
9. Bolt the base of the large fan to the drive roof. Use two M8×12 bolts from the top and two M8 locking washers inside the cabinet at the front of the drive and two M8×10 bolts, two locking washers, and two sealing rings inside the fan unit.
10. Remove the rotating eyebolts that you installed in step 3.
11. Reattach the top cover of the fan housing with the bolts that you set aside in step 2.
12. Connect the fan motor cable according to the wiring diagram.

1. Determine the required length of a cable between the point of entry and the connection point inside the cabinet.
2. Cut the cable to the required length before connection.

Installing the cable entry box on the terminal compartment roof:

1. Remove the transport cover from the cabinet roof.
2. Fasten the cable entry box to the roof of the terminal compartment.

Installing the insulating barrier for top cable entry (if input voltage is higher than 6.9 kV):

1. Fasten a bracket at the places indicated.
2. Remove the protective film from the insulating barrier.
3. Fasten the insulating barrier at the places indicated using 2x M6x12 (self-tapping) screws.

1. Remove the transport cover from the cabinet roof.
2. Remove the galvanized steel plate from the top of the cable entry box and fasten the plate to the roof of the terminal compartment.

Installing the insulating barrier for bottom cable entry (if input voltage is higher than 6.9 kV):

1. Remove the protective film from the insulating barrier.
2. Fasten three brackets to the insulating barrier using 3x M6x12 (self-tapping) screws.
3. Fasten the insulating barrier to the roof at the places indicated.

Material requirements:

Use stainless steel bolts and nuts with the appropriate steel grade and property class for the connection (recommended: A2-70).

Connection type:

• Spring washer and flat washer on each side of the busbar.
• Use cable lugs suitable for M12 bolts.
• If two conductors are used per phase, install the second conductor on the opposite side of the busbar.

Lubrication:

If stainless steel bolts and nuts are used, lubricate the thread and head contact surface of the bolt using recommended pastes, eg, Molykote D paste. If a coated nut is used, the connection does not have to be lubricated.

Tightening torque:

Tighten bolted connections with bolts of sizes M10 and greater with the recommended nominal torque for the bolt size used.

Mechanical installation checklist

• Drive installed according to the instructions in the user manual.
• Drive securely fastened to the floor (if applicable).
• Redundant fan unit installed (if applicable).
• Visual inspection: No badly affixed or damaged components; No foreign objects left in the cabinet; No dirt, dust or moisture in the cabinet.

Electrical installation checklist

• Types and cross sections of control cables suitable for the signal type and signal level.
• Types and cross sections of power cables selected according to the instructions in the user manual.
• Pulse encoder connected according to the relevant manual (only applicable for drives with pulse encoder interface).
• Cable entries prepared according to the instructions in the user manual.
• Control cable screens and conductors are connected as instructed in the user manual, labeled appropriately, and the customer side connections are completed.
• Equipotential bonding conductor of drive securely connected at both ends.
• Converter transformer and motor cables not connected at both ends (cables and drive must be insulation resistance tested (Megger test) before connection).

Main circuit breaker (MCB) checklist

• Type of MCB selected as per the MCB specification from ABB.
• High-voltage power connections completed.
• MCB ready to be tested with drive.
• MCB protection relay settings tested.
• Safety devices (eg, door locks) are tested and in operation.

Motor checklist

• Motor is installed, aligned and alignment protocol available.
• Motor is not coupled to driven load.
• Grounding is completed.
• Motor auxiliaries (eg, bearing lubrication) are ready.
• Control and monitoring signals are connected.

Insulation tests checklist

• All power cables to converter transformer, between drive and motor measured, and measured values within the required limits.
• Test report of the Megger insulation resistance test available.

Power supply checklist

• Medium voltage available for start-up of drive.
• Low voltage is available for start-up of drive.

Miscellaneous checklist

• Sufficient number and correct type of spare parts available.
• Air conditioning of drive room ready for load run of drive.
• Optional equipment ready.

1. Enable the local control mode of the drive by pressing the LOC-REM key on the CDP control panel (ensure ‘L’ is displayed).
2. Check that no alarm or fault messages are displayed on the CDP control panel. If a fault message is displayed, reset the fault.
3. When no alarms and faults are present and the drive is ready, the CDP control panel displays “RdyForMCBOn”.
4. Press the MAIN SUPPLY ON push button on the control compartment door to close the MCB and charge the DC link. The push button lights up and the status line changes to “Charging”.
5. After charging has been finished, the protection IGCTs are closed, the status line changes to “Rdy to Strt”.
6. Enter the reference value using the REF key and navigation keys.
7. Start the motor by pressing the START key.

1. Press the STOP key on the CDP control panel.
2. The motor stops according to the preset stop function and the drive stops modulating. While the motor stops, the status line of the display shows “Stopping”.
3. When the drive has stopped modulating, the CDP control panel displays “Rdy to Strt”.

Note: As long as the MCB has not been opened, the motor can be started again.

Initiating an emergency-off:

To initiate an emergency off, press the EMERGENCY-OFF push button on the control compartment door, or an external EMERGENCY-OFF push button (if present) linked to the emergency-off circuit.

When an emergency-off is initiated during drive operation, the following takes place:

• MCB opens
• Drive coasts down
• Status line of the CDP control panel displays the message “Emerg Off”
• The DC link of the drive discharges.

Starting the drive after an emergency-off:

1. To start the drive after an emergency-off, unlatch the EMERGENCY-OFF push button. The button returns to its initial position when turned in the direction indicated by the arrows.
2. To reset the emergency-off safety relay of the drive, press the RESET button on the control keypad.
3. After resetting, the status message of the drive changes to “RdyForMCBOn”.

1. To enter the parameters mode, press the PAR key.
2. To select a different group, press the corresponding fast navigation key.
3. To select a parameter, press the corresponding slow navigation key.
4. To enter the parameter setting function, press the ENTER key.
5. To change the parameter value, press the:
   • Slow navigation key for numbers and text
   • Corresponding fast navigation key for numbers only
6. To confirm the selection and to return to the actual signals display, press the ENTER key.

1. To enter the actual signals mode, press the ACT key.
2. To change to the fault memory display, press a fast navigation key.
3. To display a specific fault, press the slow navigation keys. The up key selects the previous fault and the down key selects the next fault.
4. To clear the fault memory, press the RESET key.
5. To return to the actual signals display, press a fast navigation key.

If a fault shuts down the drive, proceed as follows:

1. DO NOT switch off the auxiliary supply voltage or try to reset a fault message before all information at the time of the occurrence of the fault condition has been saved.
2. Select the fault history display on the CDP control panel, but DO NOT clear the buffer!
3. Identify the fault and make a logbook entry.
4. Save the content of the data logger when a PC is available that has the DriveWindow or DriveDebug tool installed.
5. Contact ABB service if a fault cannot be rectified.
6. After the fault has been rectified, start the drive.

1. Enable the local control mode of the CDP control panel.
2. Press the stop key. When the motor has reached zero speed, the display shows “Rdy to Strt”.
3. Press the MAIN SUPPLY OFF push button to disconnect the drive from the main power supply. The MCB opens and the DC link discharges for approximately five minutes.
4. Rack-out, lock-out, ground and tag-out the main power feeder.
5. If the grounding switch is equipped with the optional lock that secures the switch in the ungrounded position, unlock the grounding switch.
6. Wait until the yellow lamp GROUNDING SWITCH UNLOCKED lights up.
7. If the yellow lamp is on, turn the grounding switch to the grounded position.
8. To de-energize the drive completely, switch off and lockout all auxiliary voltages from external sources.
9. If necessary, connect a grounding set.

1. Switch off the motor starter of the fan. The fan unit is now isolated from the auxiliary power supply.
2. Unplug both ends of the power supply cable of the fan unit.
3. Unbolt and remove the top cover of the fan housing.
4. Unbolt the top plate of the fan unit.
5. Install rotating eyebolts in the top corners of the on the top plate of the fan unit.
6. Attach lifting gear to 2 diagonal or all 4 rotating eyebolts.
7. Orient the rotating eyebolts in the direction of force.
8. Lift the top plate off of the fan unit. Note that the impeller motor remains attached to the top plate.
9. Unbolt the impeller motor from the top plate.
10. Bolt the replacement impeller motor to the top plate.
11. Remove the rotating eyebolts.
12. Assemble and install the fan unit in reverse order of removal.

1. When the drive is in operation, set the 31.05 DISABLE BATTERY TEST parameter to ON. The battery monitoring function is now disabled.
2. Disconnect the wires.
3. Unbolt the battery at the front and at the back.
4. Install the new battery in reverse order of removal.
5. Record the date of battery replacement in the logbook.

If the grounding switch is not released, check the following:

1. Check that the auxiliary voltage is switched on.
2. Main power supply is disconnected from the drive:
   • Check that the MCB is open.
   • Check that the feedback signal “MCB is open” arrives at the drive (LED of digital input DI08 of I/O module is lit).
   • Check that the MAIN SUPPLY ON push button is lit.
3. Discharge level of the DC link:
   • Check if the value of parameter 2.06 DC VOLTAGE is below 50 V.
4. GROUNDING SWITCH UNLOCKED lamp and the wiring of the lamp:
   • Check if the CDP control panel displays a fault. A fault prevents the lamp from lighting.
   • If no fault is displayed, check that digital output DO04 of I/O module -A5191 (-A1) is energized.
   • If DO04 is not energized, check the auxiliary voltage at the supply terminals of the I/O module (X6:1, X6:2).
   • Check that LED V726 and LED V740 of the I/O module -A5191 are lit.
   • If DO04 is energized, check that the control voltage is present at the terminals of the lamp.
5. Check that hazardous voltages from the motor cannot be fed into the drive.