ABB MEGADRIVE LCI. W water-cooled load commutation inverter

ABB MEGADRIVE LCI. W water-cooled load commutation inverter

Whole machine hardware and configuration

The whole machine is a modular cabinet with multiple cabinets, including universal units, application option units, and additional functions.

Universal basic unit (mandatory for all models)

Converter unit: thyristor stack, rectifier bridge (grid side)+inverter bridge (machine side); Water cooling and heat dissipation, equipped with absorption circuit and gate trigger circuit.

Network side/machine side terminal unit: busbar, current/voltage transformer, lightning arrester, LIN interface board, power cable connection.

DC link unit: iron core DC smoothing reactor (can be external).

Control unit: Core controller AC 800PEC; Supporting facilities:

LIN board: Control 6-pulse thyristor bridge, fiber driven gate; Magnetic triggering GDI (single thyristor per arm), indirect light triggering MV-GDR (multiple thyristors in series);

CIO: High speed analog/digital IO; S800: Low speed IO;

LCT local touch terminal (Windows touch screen);

Cooling system WCU water cooling unit: The main heat dissipation relies on water cooling; The cabinet auxiliary fan adopts a 3-to-2 redundancy mode.

Application specific unit (configured according to selection)

Excitation unit EXU

AC-EXU AC excitation: used for brushless excitation synchronous motors, LCI.DR standard configuration;

DC-EXU DC excitation: slip ring synchronous motor, LCI.SO/ST optional configuration.

SyncHROTACT 6 synchronization unit: only used for LCI.SO soft start; Realize smooth switching of the motor from the frequency converter to the power grid operation, with multiple sets of parameter sets stored.

BPU bypass isolation switch: LCI.SO soft start+output transformer scheme dedicated; During the low-speed stage, bypass the transformer and switch the transformer circuit when the specified speed is reached.

Additional functions of cabinet

Door lock system: The high-voltage compartment uses a double toothed key; Low voltage (control/excitation) uses triangular/square keys with differentiated permissions.

Cabinet door safety switch (standard): Opening the high-voltage cabinet door directly triggers the driver to trip; Optional electromagnetic interlocking door lock: The cabinet door can only be unlocked when the power circuit is powered off and grounded (in a safe state); Emergency mechanical release is possible (complete power outage must be confirmed before operation).

Cabinet heating (optional): temperature and humidity linkage to prevent condensation.

Anti arc cabinet IAC (optional, IEC 62477-2)

Class I: Arc prevention, without third-party IAC certification;

Class II: Cabinet body arc resistant, third-party IAC certification;

Class III: Relying on external high-voltage fuses for current limiting; Class IV: Rapid detection of arc extinguishing;

The pressure relief valve is installed on the top of the cabinet, with a clearance of ≥ 900mm above the pressure relief valve; The cable must enter from the bottom.

Transportation, storage, and disposal of scrap

Transport conditions IEC 60721-3-2; Open the box and inspect the appearance for damage, check the packing list, take photos of the damage and report to ABB.

Lifting specifications (mandatory)

Only original lifting lugs (base lifting plate, rotating lifting ring) can be used, and forklifts are prohibited from being used;

The torque of the suspension plate bolts is specified, and the suspension plate can be removed and properly stored after installation; The rotating lifting ring is used for hoisting the cooling unit on the top of the cabinet, and after hoisting, it is removed and stored; Keep the whole machine vertical during lifting and prohibit tilting.

Storage conditions IEC 60721-3-1

Original intact packaging can be stored for up to 1 year; Contact ABB beyond the deadline;

Long term shutdown storage: Drain the water cooling circuit or add antifreeze to prevent freezing; Block the ventilation and cable ports; Place desiccant; Paste humidity indicator cards and conduct regular inspections;

Spare parts storage: circuit board anti-static bag, -5~+55 ℃, no corrosion, no condensation; Wear an anti-static wristband with the circuit board and only touch the edge of the board.

Scrap: Dispose of packaging and components in accordance with local environmental regulations.

Mechanical installation

Basic requirements: The ground is non combustible and the load-bearing capacity meets the requirements of the cabinet; The overall inclination of the ground is ≤± 0.5%, and the flatness is ≤ 1mm; the cabinet base can be fixed with bolts or welded; M16 wedge-shaped anchor bolts are recommended for concrete.

Split shipment cabinet assembly

Align multiple transport unit base frames and fasten them with original connectors; Connect the PE busbar;

Water cooling pipeline docking: Straub/VICTAULIC pipe joints of different sizes and diameters; Limit axial offset to ± 3mm and angular offset to ≤ 5 °; Bolts shall be tightened according to the torque specified on the joint nameplate; Copper grounding strip must be installed on the pipeline to ensure equipotential;

Install cabinet top IP42/IP54 cooling fan unit; Install pressure relief ventilation valves for arc resistant cabinets; Install a top ventilation hood for the excitation unit.

Attention: It is prohibited to install any external devices on the top cover of the cabinet; The cabinet door must be closed during construction interruptions to prevent metal dust from entering the cabinet.

Electrical installation

Important reminder: After all wiring is completed, it is prohibited to connect the main/auxiliary power supply without the permission of the ABB commissioning engineer.

Fiber optic cabling: Cabinets that are disassembled for transportation need to be reconnected with fiber optic cables; Do not touch the fiber end face, take out the connector housing, and label each one accordingly.

Internal prefabricated cables: mostly plug type docking, label matching; Unplugged coiled cables should be restored according to the markings.

Power cables, grounding, equipotential

The busbar bolt connection uses A2-70 stainless steel bolts; Apply lubricating grease to threads (excluding nuts with molybdenum disulfide coating); Specify torque; Configure spring washer+flat washer;

The minimum air gap between the high-voltage terminal conductor and the ground/phase is 55mm;

The insulation test of the cable is completed outside the cabinet. After entering the cabinet, the cable end remains suspended and can only be connected to the busbar with the permission of the commissioning personnel;

All grounding cables are reliably grounded at both ends.

Debugging and commissioning

Debugging personnel must hold ABB certification and certification; Customers need to provide personnel who are familiar with medium and high voltage, as well as process equipment; After debugging, sign the acceptance report and deliver the parameter backup file.

Complete checklist before debugging

Mechanical: Cabinet fixing, fan, pressure relief valve, excitation fan cover, no foreign objects;

Electrical: Cable specifications, shielding grounding, secondary wiring, complete PE; The cable insulation test report is complete;

ICB circuit breaker: High voltage wiring completed, protection relay test, door interlock function test;

Motor: Alignment completed, auxiliary equipment such as bearing lubrication and heater ready; Try to detach the load as much as possible;

Power supply: medium voltage and low voltage auxiliary power supplies are ready;

Other: spare parts, deionized cooling water, computer room air conditioning, safety signs in place.

Local operation of the device

Only describe LCT local panel operations; Refer to other manuals for remote DCS/PLC operation.

Startup sequence

Pre startup inspection: No tools left behind; All cabinet doors are locked; No fault alarm;

AUX ON: Activate auxiliary systems (water cooling, fans, etc.); Status "AUX READY";

MV ON: Close the input circuit breaker ICB; Status "MV READY";

OP   ON: The driver is put into operation, triggering the thyristor pulse, and the motor rises to the set reference; The status is' Operation ON '.

Two shutdown modes

Coasting down with free taxiing: OP   OFF to cancel pulse; Disconnect the main circuit breaker by turning off the MV; AUX OFF cuts off the auxiliary power supply.

Electrical braking (optional): Energy feedback to the power grid, can automatically stop after braking to 1% of rated speed.

Emergency stop - OFF

Red emergency stop button on the cabinet door; Press to immediately jump ICB during operation, and the motor slides freely; Reset requires rotating the unlock button.

Equipped with electromagnetic interlocking cabinet door operation (optional)

Normal: The control power supply is present, and the power circuit must be safely disconnected and grounded before unlocking and opening the door;

Emergency release: After confirming that the entire machine is completely powered off, remove the screw cap and rotate the release dial to unlock the cabinet door; After the maintenance is completed, restore the locked position.

Detailed functions of LCT local touch terminal

LCT is a Windows touch panel with multi-level permission accounts (1-3 level operators, administrators); Automatic timeout logout (will change the runtime settings and needs to be carefully set). Main menu:

Diagrams menu (default homepage): Visualization diagram of the main circuit; Real time display of all key analog quantities such as network side, DC bus, machine side, excitation, speed, etc; The status bar displays auxiliary/medium voltage/operation, alarm, fault, excitation, pulse, direction, and login identity.

Events menu: Save the last 1000 events (information, alarms, faults); View details, freeze views, save CSV, print, and clear event records; Support fault reset.

Operations menu: Customize analog dial, select signal and customize range threshold for on-site monitoring.

Parameters menu: Browse and modify all parameters of AC 800PEC; Support snapshot (parameter backup), saving/loading parameter sets; ⚠️ Only certified personnel who understand the impact of parameters can make modifications.

Slow Trending: Long term data recording, configuring sampling, saving and exporting record curves.

Transient Recorder: Fault recording; Trigger condition configuration, waveform export; Used to capture short-term disturbances and instantaneous waveforms of faults.

Test Programs: Factory/Debug specific testing function, high authority.

WCU Water Cooling Unit Menu: Water Cooling System Monitoring Parameters.

Options menu: Software backup PecUp files, screenshot, scheduled restart, software upgrade, configuration file import and export.

The operation bar can set the speed/torque settings; Support panel control switching (local/remote).

Preventive and Corrective Maintenance

Qualification of maintenance personnel: Familiar with medium and high voltage safety, proficient in complete power-off and grounding procedures; Suggest establishing equipment operation logs; Can be paired with NETA-21 remote monitoring tool; Use ABB original spare parts.

Standard maintenance process: shutdown, disconnect all power sources, hang and lock; Electrical verification; Hang portable grounding short-circuit kit; Complete maintenance, remove grounding and restore power supply.

Maintenance project:

Visually inspect the cabinet, cables, and busbar; Tightening bolt torque; Clean the cabinet;

Isolation switch maintenance; Replacement of cabinet top fan and maintenance of fan control board;

Maintenance of water cooling unit WCU; Replacement of excitation unit fan;

Attention: Static electricity protection for circuit boards; Anti static storage of spare parts.