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ACS 1000
Medium Voltage Drives
315 to 5000 kW
400 to 6700 hp
User’s Manual
Water Cooling Unit
Issued: 29-06-2005
Appendices
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)
ABB
2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 1 - Safety
NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage is switched on. The pump is switched on depending on
temperature and conductivity of the pure water or internal air temperature.
NOTICE!
Valves, tubes and hoses are delicate parts. Do not bend or put any
pressure on the valves, tubes and hoses.
NOTICE!
Where possible, all components and sub-assemblies weighting over 25 kg
have been clearly marked with weight details. Pumps and electric motors
are equipped with lifting eyes as supplied by the manufacturers. If lifting of
heavy and/or awkwardly positioned items is necessary, extreme caution
shall be exercised. Safe, reliable mechanical lifting equipment shall be
used wherever possible. Under no circumstances shall items be lifted by
means of straps, ropes, chains etc. connected to piping or other system
components.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1-1 (2)
Chapter 1 - Safety ABB
1-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 2 - Installation
1 Connect the hoses for the raw water circuit following Figure 2-2 à
Figure 2-6.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-1 (6)
Chapter 2 - Installation ABB
2-2 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 2 - Installation
Connect hoses to
inlet
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-3 (6)
Chapter 2 - Installation ABB
pipes can be connected directly to the flanges. An example is shown in
Figure 2-8.
The dimensions and position of the flanges are shown in the layout
drawing. The tightening torque of the bolds depends on the size and must
be determined by the installation personal.
The water cooling unit is equipped with a drain connector. The drain
connector is located behind a cover below the door of the water colling
unit. The drain connector is suitable for a hose with an internal diameter of
13 mm (0.5118 ") (see Figure 2-10).The drain hose is not supplied with the
converter. To prevent water from leaking, a shut-off valve must be installed
2-4 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 2 - Installation
ØD Ø D1 C F L L1 ØT
(mm) (mm) (mm) (mm) (mm) (mm)
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-5 (6)
Chapter 2 - Installation ABB
2-6 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 3 - Starting up the Cooling System
NOTICE!
Do not run the pumps if the cooling circuit is empty, not even for a short
time. If a pump runs dry the pump seals will be damaged immediately.
Filled valve symbols in the flow diagram indicate valves in shut position.
Proceed as follows:
1 Open valves V1, (V2), V5, V11 and V15.
2 Close valves V12, V14, V80, (V81), and V82.
Cooling Water Drinking water of good quality must be used in the main cooling circuit.
However, it is recommended to fill the circuit with deionized water to
extend the lifetime of the ion exchange resin.
The cooling water should conform to the values in Table 3-1.
If in doubt about the quality of the drinking water on your premises contact
your local water utility.
Table 3-1 Drinking Water Specification
Parameter Value
pH 7 – 8.5
Specific conductivity < 300 µS / cm
Hardness 3 – 10° dH
Chloride (Cl) < 300 mg/l
Copper (Cu) < 0.1 mg/l
Total dissolved salt < 1000 mg/l
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-1 (6)
Chapter 3 - Starting up the Cooling System ABB
IMPORTANT!
Cooling Water with When the converter has been ordered with an anti-freeze, a container with
Anti-Freeze the appropriate type and amount of glycol is supplied with the converter.
CAUTION!
IMPORTANT!
3-2 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 3 - Starting up the Cooling System
Table 3-3 Water Glycol Concentration for the Desired Frost proofing
Frost proofing Pure Ethylene Glycol Distilled Water
- 10 °C (14 °F) 20 % 80 %
- 20 °C (-4 °F) 34 % 66 %
- 30 °C (-22 °F) 44 % 56 %
- 40 °C (-40 °F) 52 % 48 %
IMPORTANT!
Filling the System 6 Switch off the motor protection switch(es) -Q11 [-Q5021] /
( -Q12 [-Q5023] of the pump(s).
7 Switch on the auxiliary voltage.
8 Close valves V1, V11, V15, V80, V81*.
9 Open valves V2*, V5, V12.
(*only if redundant pump is present)
10 Connect the filling hose to the ISO-R1/2" connector of valve V14.
A pressure of approx. 1 to 2 bar is required for filling water into the
circuit. Using a small pump might be necessary.
11 Open valve V14 and start the filling.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-3 (6)
Chapter 3 - Starting up the Cooling System ABB
If the cooling unit is not equipped with the check valve V18 (as in the
previous version of the cooling unit) the water does not start to flow
through the filter Z2. Valve V15 has to be opened additionally..
IMPORTANT!
12 Stop filling water when the level in the expansion vessel is approx.
80 %.
13 Close valve V14 and open valve V1, V11 and V15 (if it has not been
opened yet).
14 Open the priming plug on the pump house(s) (see Figure 3-1) and
vent the pump(s). Close the plug again.
3-4 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 3 - Starting up the Cooling System
DANGER!
Hazardous voltage!
Voltage can cause physical injury and death.The auxiliary supply must be
turned off before starting work on terminal X10.
20 Cooling unit with one pump: run the pump for 30 minutes to vent
the converter and proceed with step 25.
21 Cooling unit with two pumps: install a temporary jumper.
• Disconnect the connector X22 from IOEC board 1
• Connect a jumper (cross-section 1 mm2) between
X22-1 and X22-3 of connector X22.
• Plug the connector X22 back into IOEC board 1.
22 Let the first pump run for 10 minutes and then turn off -Q11 (-Q5021).
23 Switch on -Q12 (-Q5023).
24 Run the second pump for 30 minutes to vent the cooling system.
25 Close valve V11 and fill up the expansion vessel according to step 11
to 12.
26 Close valve V12.
27 Disconnect the hose.
28 Remove the temporary jumper.
IMPORTANT!
If the level in the expansion tank is below 80 %, the cooling circuit must be
topped up with additional water via valve V14. Use cooling water as
specified in section 3.2 Filling the Cooling System.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-5 (6)
Chapter 3 - Starting up the Cooling System ABB
Cooling water can be added, while the converter is in operation, provided
the conductivity is below 0.4 µS/cm.
IMPORTANT!
DANGER!
Hazardous voltage!
When the drive is in operation, voltages are present in the control section.
Do not touch any live circuitry!
Proceed as follows:
1 Connect the filling hose to the ISO-R1/2" connector of valve V14.
A pressure of approx. 1 to 2 bar is required for filling water into the
circuit. Using a small pump might be necessary.
2 Close valve V11.
3 Open valve V14 and start the filling.
IMPORTANT!
! When filling cooling water during operation, fill the water in slowly to
prevent that the converter shuts down on a conductivity fault.
Recommended filling rate: less or equal 2 l/min.
3-6 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 4 - Draining the Cooling System
WARNING!
If glycol is used in the cooling water, see section Cooling Water with Anti-
Freeze, page 3-2, for safety information.
Proceed as follows:
1 Shut down the converter according to the ACS 1000 User's Manual,
Chapter 6- Operation.
2 Switch off the motor protection switch(es) -Q11 [-Q5021] /
( -Q12 [-Q5023]) of the pump(s) to prevent the pumps from being
switched on accidentally.
CAUTION!
! Do not run the pumps if the cooling circuit is empty, not even for a short
time. If a pump runs dry the pump seals will be damaged immediately.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 4-1 (2)
Chapter 4 - Draining the Cooling System ABB
4-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 5 - Checking Actual Values
Reading the 1 Select the Actual Display mode on the control panel (see ACS 1000
Conductivity on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 04 InvWtrConductivity. The conductivity should be
below 0.5 µS/cm.
• If the conductivity exceeds the alarm threshold of 0.5
µS (see parameter 190.09), the control panel will
display the alarm message WtrConduct.
• If the conductivity exceeds the trip threshold of 0.7 µS
(see parameter 190.10), the converter will shut down
and the panel will display the message WtrConduct.
The actual value of the water pressure (displayed in bar) can be read on
the control panel.
Proceed as follows:
Reading the Water 1 Select the Actual Display mode on the control panel (see ACS 1000
Pressure on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 03 InvWtrCoolPressure.
3 The reaction of the converter, if the water pressure decreases below
the trip threshold of 1.5 bar (see parameter 190.12), depends on the
number of pumps:
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 5-1 (4)
Chapter 5 - Checking Actual Values ABB
• Cooling unit with two pumps: the control panel will
display the alarm WtrPressure and the second pump
will be switched on. If the water pressure does not
increase above the trip threshold after a
programmable time, the converter will trip.
• Cooling unit with one pump: the control panel will
display the alarm WtrPressure. If the water pressure
does not increase above the trip threshold after a
programmable time, the converter will shut down.
The actual value of the water temperature (displayed in °C) can be read
on the control panel.
Proceed as follows:
Reading the Water 1 Select the Actual Display mode on the control panel (see ACS 1000
Temperature on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 02 InvWtrCoolTemp.
• If the temperature exceeds the alarm threshold (see
parameter 190.6), the control panel will display the
alarm message WtrTemp.
• If the temperature exceeds the trip threshold (see
parameter 190.7), the converter will trip and the
control panel will display the trip message WtrTemp.
5-2 (4) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 5 - Checking Actual Values
DANGER!
Hazardous voltage!
When the drive is in operation, voltages are present in the control section.
Do not touch any live circuitry!
Proceed as follows:
1 Check the water level at the level sight-glass located at the front of
the expansion tank.
The water level should be approximately 80%.
2 If the water level is below 80 % the cooling circuit must be topped up.
See section 3.3 Adding Water to the Cooling System.
The minimum water level is monitored by level switch B10. If the switch is
activated, the converter will shut down.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 5-3 (4)
Chapter 5 - Checking Actual Values ABB
5-4 (4) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 6 - Tightening Torques, Threaded Connections
1 2 3 4
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 6-1 (2)
Chapter 6 - Tightening Torques, Threaded Connections ABB
6-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Appendices
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)
ABB
2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit