ABB ACS6000 medium voltage frequency converter

ABB ACS6000 medium voltage frequency converter

Chapter 1 Basic Manual Description and Equipment Overview

Scope of application of the manual: For standard ACS600 medium voltage frequency converters, customized project supporting drawings and special materials will be supplemented separately; The complete set of materials includes this manual and appendices A to G (attachment manual, technical parameters, mechanical drawings, wiring diagrams, spare parts list, factory report, parameter signal table).

Terminology and Trademarks: Includes abbreviations from the entire manual (cabinet abbreviations such as ARU/INI/LSU/COO/EXU, and control terms such as DTC/DDCS/S800); Label ABB and third-party registered trademarks (Modbus, Profibus, Windows, etc.).

Applicable personnel qualifications: Requirements for 5 types of positions including disassembly and loading, mechanical installation, electrical construction, on-site operation, and maintenance. Equipment commissioning and operation are only carried out by ABB certified engineers.

Responsibilities and Compliance:

Users must ensure that their operators have received training and are using the equipment in accordance with regulations. Unauthorized modification or use of non original spare parts is prohibited;

The product complies with electrical, mechanical, and safety standards from multiple countries such as ANSI, IEC, EN, and ISO, and comes with ISO9001/14001 and EC compliance certificates;

Network access security disclaimer: The customer is fully responsible for industrial control network security protection.

Equipment identification and supporting tools: The equipment nameplate is located on the inside of the COUP cabinet door and can be distinguished by model and number for configuration; ABB provides specialized complete sets of maintenance tools.

Chapter 2 Key Safety Regulations (General Safety Principles of the Whole Manual)

Safety classification: According to ANSI, it is divided into four levels of warning: danger, warning, attention, and reminder. Corresponding safety signs (high pressure, high temperature, anti pinch, pacemaker prohibited entry, fire warning, etc.) are posted on the cabinet.

ABB's seven life safety operation steps: pre operation risk assessment → equipment identification → power outage tagging and locking (LOTO) → electrical verification to confirm no voltage → grounding short circuit → isolation of adjacent live parts → closed-loop work permit, which is a mandatory process for power outage maintenance.

Key requirements for Main Circuit Breaker (MCB):

MCB is the first level protection for frequency converters, divided into vacuum/SF6/fuse contactor types, with two time limits for fault protection tripping ≤ 75ms and safety tripping ≤ 500ms;

The fault disconnection command needs to be hard wired and directly connected to the MC. It is prohibited to transfer through ordinary PLC (if transfer is required, SIL3 certification is required). The manufacturer recommends three configuration schemes: double opening coil/undervoltage coil/upper level backup protection;

MCB circuit undergoes annual routine calibration.

Residual risk warning: Electromagnetic field poses potential hazards such as personnel implanted with medical devices, component misoperation, induced high voltage, and harmful gases at high temperatures.

Chapter 3 Power Devices and Cabinet Structure (Product Hardware Core)

The ACS600 adopts a modular design with a common DC bus, which is divided into two categories: standard cabinet and optional cabinet. It supports single machine/multi motor transmission and has two cooling schemes: water cooling and air cooling.

1. Standard standard cabinet

Full name of cabinet code, core function

ARU active rectifier unit IGCT three-level self commutation rectification, supporting energy feedback regenerative braking

The DC inverter of the INO inverter unit drives the motor with adjustable three-phase AC power, and multiple units can be connected in parallel for expansion

LSU diode incoming rectification 12 pulse uncontrolled rectification, no feedback, power factor ≈ 0.95

CBU capacitor cabinet DC bus filtering capacitor, built-in pre charge/discharge unit, DC grounding switch

TEU terminal cabinet high and low voltage cable connection terminals, collecting incoming and outgoing busbars

The complete control core of the COUP control cabinet is equipped with an AMC main control board, S800 IO, and CD operation panel

WCU water cooling cabinet closed cycle water cooling system, including dual redundant water pumps, water water heat exchangers, and deionization devices

2. Optional cabinet body

IRU incoming reactor, IF incoming filter, VLU voltage limiting unit, BCU brake chopper, R resistor brake cabinet, EXU synchronous motor excitation cabinet (with DCS800 rectification), CIU customer interface cabinet (optional arc protection Arc Guard).

3. Cabinet matching design

Heat dissipation: Water cooling is standard, while air cooling is equipped with an air-to-air heat exchanger and auxiliary fan;

Cabinet protection: standard IP32, optional IP42/IP54, RAL7035 light gray spray coating, meets EMC sealing requirements;

Anti arc: 4 levels of IAC arc protection level, the cabinet busbar is divided into four types: AC AC, DC positive/negative/NP neutral point, PE protection ground, PG shielding ground.

Chapter 4 Transportation, Storage, and Scrap Disposal

Transportation: Following the IEC transportation environment standards, large items are shipped separately in containers, and only special lifting equipment is used to lift the base. Forklifts are prohibited from directly lifting the container or lifting it as a whole after splicing. The lifting angle should be ≤ 15 °; The packing list and box labels are used to distinguish between individual equipment boxes.

Storage: Under original packaging, it can be stored for 1 year. ABB evaluation is required if it exceeds the expiration date; Long term disuse requires emptying the water cooling medium or adding antifreeze, sealing the ventilation openings, and placing desiccants; Anti static storage of spare parts such as circuit boards.

Scrap: Packaging materials and components are dismantled and recycled according to local environmental regulations.

Chapter 5 Mechanical Installation and Construction

Preliminary preparation: basic leveling, cabinet fixing (bolt/welding two methods, welding requires cabinet PE grounding), prefabrication of water-cooled external pipelines;

Multi panel cabinet operation: cabinet alignment (coaxial deviation ≤ 3mm, angle ≤ 5 °), cabinet bolt tightening, water cooling pipeline docking (STRAUB clamp locked with specified torque);

Mother busbar installation: DC/PE/AC various types of mother busbar docking, M12 bolts: 2-layer mother busbar 40Nm, ≥ 3-layer 60Nm, standard disc spring washer; Subdivision of installation specifications for different power busbars such as 5/7/9MVA and 14MVA;

Installation of air cooler, pressure relief valve, top plate seal, and seismic accessories: The air cooler weighs 65kg, and after disassembly and assembly, the control line is reconnected. The IP54 cabinet is equipped with sealing tape, and the marine model is equipped with top shock absorber support.

Chapter 6 Electrical Installation Specification

General wiring rules: The distance between power cables and control cables should be ≥ 30cm, and they should be laid horizontally and vertically at a 90 ° angle. The shielding layer should be properly grounded; The minimum bending radius of optical fiber is 25mm, and the tensile force is ≤ 1N;

System grounding: The PE busbar of the whole machine runs through the entire cabinet, and the main grounding point is set at the TEU. The cable shielding is uniformly connected to the PG busbar, and the EX excitation cabinet is independently grounded according to the standard;

Four types of cable entry: Roxtec sealing module, cable gland, EMC sealing plate, divided into TEU/ARU/EXU cabinet upper and lower entry construction rules;

Cable pre-processing: Power/control/fiber optic cables are stripped, shielded and grounded separately, and EXU is equipped with DCS800 fiber optic cable fixed point access to COM8x board;

Final acceptance: Check the incoming line blockage and sealing, and connect the terminals only after all cable insulation tests are qualified.

Chapter 7 On site Debugging (Operation)

Personnel requirements: Only ABB certified engineers are allowed to perform parameter tuning and functional testing;

Customer cooperation: Equip certified personnel familiar with high and low voltage processes to assist in the inspection of transformers, motors, and auxiliary equipment;

Eight pre inspection checklist for operation: mechanical installation, electrical wiring, MCB circuit breaker, input transformer, motor, insulation withstand voltage, high and low voltage power supply, spare parts and auxiliary materials are inspected item by item, and can only be powered on for commissioning after all are qualified; Complete debugging, sign acceptance documents, and deliver parameter backups.

Chapter 8 On site Operation

Each cabinet panel: ARU/INO main control panel, EXU (DCS800) panel, distinguishing between local/remote start stop, fault reset, and emergency stop;

Device status word: NotReadyOn → ReadyOn → Charging → ReadyRun → ReadyRef → Stopping → Tripped (Fault) full process;

Start stop logic: Normal start stop, emergency stop disconnection logic (emergency stop triggers MC disconnection, DC discharge), emergency stop reset requires unlocking+waiting for bus voltage<50V;

Interlocking system: CBU DC grounding switch, cabinet door safety interlock. Only after the DC is fully discharged can the grounding be closed and the door be unlocked;

Optional arc protection Arc Guard: After a fault, the MC will immediately disconnect, and the arc fault needs to be checked at a fixed point, reset the protection, and then restart.

Chapter 9 CDP Control Panel Operation

CDP is the human-machine interface of ACS600, with five major operating modes:

Automatically display the model and firmware version when the recognition mode is powered on;

Actual measurement mode: Simultaneously display 3 operating parameters, switchable fault history (storing 64 fault records);

Parameter mode: Parameter grouping (start stop, limiting, communication, etc.), set parameter lock (default password 358), and prohibit modification of some parameters during operation;

Function mode: screen contrast adjustment;

Local/remote switching: Parameter 16.04 locks local permissions, and the speed/direction can be set on the panel.

Chapter 10 Preventive and Fault Maintenance

1. Maintenance foundation

According to ABB's official maintenance schedule, spare parts are limited to original factory parts, and the entire maintenance process is recorded in a ledger. ESD anti-static operation of circuit boards is also required.

2. Fault diagnosis

Distinguish between alarms (automatic reset without stopping) and faults (divided into FC1/FC2, FC1 tripping MC, FC2 not tripping circuit breaker), and quickly locate them through AMC and S800 module onboard LED indicator lights;

3. Standard procedures for power outage maintenance

Local shutdown → MC disconnection → waiting for DC ＜ 50V → closing CBU grounding switch → unlocking cabinet door → hanging three-phase short-circuit grounding rod is a mandatory process for high-voltage maintenance;

4. Disassembly and assembly of typical components

Power phase module (single weight 190kg), output isolation busbar, various types of fans (COUP/WCU/EXU air-cooled/water-cooled fans), air cooler, heat exchange core disassembly and replacement steps, including torque and wiring specifications;

5. Daily inspection: cabinet dust removal, filter/mesh replacement, wiring fastening, water cooling system inspection.