ACS 2000 ServiceMan 3BHS344169 E01 Rev

Service manual

Medium voltage AC driveACS 2000, 400 - 1000 kVA, 6,0 - 6,9 kV

ABB

ABB

Table of contents

General information on manual and equipment 1

Copyright notice 1Document identification 1Equipment covered by the manual 1Contact information 1Target groups and required qualifications 1Writing conventions 2

Meaning of icons 2Text conventions 2

Trademarks 3Meaning of terms and abbreviations 3Related documentation 4Tools and personal equipment 4

Personal safety 4Module tray 4Personal computer 5Hand tools 5Measuring equipment 5Cleaning equipment 6

Chapter 1 - Safety 1-1

1.1 Classification of safety signs used in this manual 1-11.2 Stopping the drive 1-21.3 Deenergizing the drive 1-3

Chapter 2 - Grounding switch and door safety switch 2-1

2.1 Malfunctioning grounding switch 2-12.2 Doors and door locks 2-22.2.1 Door safety switch 2-3

Chapter 3 - Replacing phase modules 3-1

3.1 Overview 3-13.2 Dimensions and weight 3-23.3 Required tools and accessories 3-23.3.1 Procedure 3-2

ACS 2000 Service manual 3BHS344169 ZAB E01 Rev. - 1 (4)

Table of contents ABB

Chapter 4 - Checking phase modules 4-1

4.1 Checking a phase module for short-circuit 4-14.1.1 Visual check of the phase module 4-14.1.2 Measuring the voltage across the phase module terminals 4-24.2 Measuring phase capacitors 4-44.2.1 Required tools and accessories 4-44.2.2 Procedure 4-44.3 Dismantling the phase module 4-54.3.1 Required tools and accessories 4-54.3.2 Overview 4-54.3.3 Procedure 4-64.4 Checking IGBT modules 4-94.4.1 Required tools and accessories 4-94.4.2 Procedure 4-94.4.3 Checking the free-wheeling diodes 4-114.4.4 Checking the gate unit 4-114.5 Replacing the IGBT heatsink assembly 4-124.5.1 Required tools and accessories 4-124.5.2 Procedure 4-124.6 Replacing phase capacitors 4-144.6.1 Required tools and accessories 4-144.6.2 Procedure 4-14

Chapter 5 - Removing the NP frame 5-1

5.1 Required tools and accessories 5-15.2 Procedure 5-1

Chapter 6 - Converter insulation test 6-1

6.1 Required tools and accessories 6-16.2 Procedure 6-1

Chapter 7 - Replacing circuit boards (PCBs) 7-1

7.1 Location of circuit boards 7-17.2 Handling instructions for PCBs and fiber-optic cables 7-27.2.1 PCBs 7-27.2.2 Fiber-optic cables 7-27.3 Replacing an AMC circuit board 7-27.3.1 Changing the AMC software flash memory 7-47.4 Replacing the main INT circuit board 7-67.5 Replacing ASE and SYN circuit boards 7-7

2 (4) 3BHS344169 ZAB E01 Rev. - ACS 2000 Service manual

ABB Table of contents

7.5.1 ASE circuit board 7-87.5.2 SYN circuit board 7-97.6 Replacing the VLSCD circuit boards 7-97.6.1 Rear access 7-107.6.2 Front access 7-10

Chapter 8 - Function of LEDs 8-1

8.1 Safety 8-18.2 Main INT circuit board 8-28.3 Phase Int INT circuit board 8-3

Chapter 9 - Uploading data from the black box 9-1


Table of contents ABB


ABB

List of figuresFigure 1-1 Connecting a grounding set 1-5Figure 2-1 Door locks 2-2Figure 2-2 Location of door safety switch 2-3Figure 3-1 AFE and INU compartment 3-1Figure 3-2 Phase module 3-2Figure 4-1 Measuring point locations 4-1Figure 4-2 Measuring points 4-3Figure 4-3 Top view of a phase module 4-5Figure 4-4 Dismantling the phase module 4-10Figure 4-5 IGBT module 4-11Figure 7-1 Location of circuit boards 7-1Figure 7-2 AMC circuit board 7-2Figure 7-3 AMC flash memory 7-4Figure 7-4 Main INT circuit board 7-6Figure 7-5 Location of SYN and ASE circuit board 7-7Figure 7-6 ASE circuit board 7-8Figure 7-7 Location of VLSCD circuit board 7-9Figure 8-1 AMC circuit board 8-1Figure 8-2 Main INT circuit board 8-2Figure 8-3 Phase INT circuit board 8-3Figure 9-1 Black box 9-1


ABB


ABB

List of tablesTable 4-1 Readings of a healthy phase module in diode mode 4-2Table 4-2 Readings of a healthy phase module in diode mode 4-2Table 4-3 Readings of a healthy IGBT module in diode mode 4-11Table 4-4 Readings of a healthy IGBT module in resistance mode 4-11Table 8-1 Function of LEDs on the AMC circuit board 8-1Table 8-2 LEDs on the main INT circuit board 8-2Table 8-3 LEDs on the phase INT circuit board 8-3


ABB


ABB

General information on manual and equipment

Copyright noticeThe information in this manual is subject to change without notice.

This manual and parts thereof must not be reproduced or copied, or disclosed to third parties, nor used for any unauthorized purpose without written permission from ABB Switzerland Ltd, Medium Voltage Drives.

Document identification

Ownership ABB Switzerland LtdMedium Voltage Drives

Document number 3BHS344169 ZAB E01

Revision index -

Issue date 13.10.2010

Equipment covered by the manualThe manual does not claim to cover all variations and details of the equipment, nor to consider all eventualities that may arise during service of the equipment.

If information is required beyond the instructions in this manual refer the matter to ABB. See section Contact information.

Contact information

Address ABB Switzerland LtdMedium Voltage DrivesCH-5300 Turgi, Switzerland

Phone +41 844 845 845

Fax +41 58 589 29 84

Email [email protected]

Target groups and required qualificationsThe equipment presented in this manual is part of an industrial environment where voltages are present that contain a potential hazard of electric shock and / or burn.

For this reason, only personnel who have a thorough knowledge of the equipment and the industrial environment and have obtained the required


General information on manual and equipment ABB

qualification may service the equipment. Personnel must know the safe shutdown and grounding procedures for the equipment.

Writing conventionsThe following icons and text conventions are used in the manual.

Meaning of icons

Illustrates an illuminated lamp or pushbutton.

Illustrates a button or key to be pressed.

Arrows indicate an alternating display message.

Refers to further information in a separate document.

Text conventions• Bulleted list

Used to list items or steps in a procedure, where the sequence does not matter.

• Bulleted list of a subsection following a main paragraph

Used to list items for procedures, where the sequence does not matter.

1 Steps of a procedure, to be followed in the specified order (e.g. 1, 2, 3.....)

1 Figure legend, numbers identify the items referred to in the illustration above (e.g. 1, 2, 3.....)

Arial Bold is used to highlight switches to be operated, status messages shown in a display and special terms.

UPPERCASE letters refer to a parameter.

Italic is used for references to illustrations, chapters and supplementary documentation.


ABB General information on manual and equipment

TrademarksNames that are believed to be trademarks of other companies and organizations are designated as such. The absence or presence of such a designation should however not be regarded as an offence of the legal status of any trademark. The following registrations and trademarks are used in this manual:

Fluke® Registered trademark of Fluke Corporation

Meaning of terms and abbreviations

Abbreviation Meaning

AFE Active Front EndThe AFE, also referred to as ARU (Active Rectifier Unit), is the line-side rectifier of the drive that enables four-quadrant operation and reactive power compensation.

AMC Application and Motor ControllerThe digital signal processor is the heart of the control system of the drive. A separate AMC circuit board is assigned to the line-side rectifer (AFE) and the motor inverter (INU) of the drive.

DC Direct current

Drive Short form for ACS 2000 frequency converter

EMC Electromagnetic compatibilityAll measures to suppress electromagnetic disturbances caused by different electrical equipment in the same electromagnetic environment, and to strengthen the immunity of the equipment to such disturbances.

Equipment Frequency converter and related equipment

Ground Earth

To ground The conducting path (e.g. conductor) between the electric equipment (e.g. frequency converter) and the earth. The electric equipment is connected to the earth, e.g. by a grounding set or a grounding switch.

Drive Short form for ACS 2000 frequency converter

HVD High voltage divider

INT Interface

INU Inverter unit of the drive. The INU converts the DC voltage to the required AC motor voltage and frequency.

IPS Isolated power supply

LED Light emitting diode

NP Neutral point

OEI Optical electrical interface

PCB Printed circuit board



Related documentationThe following documents are available for supplementary information:

Tools and personal equipment

Personal safety• Safety goggles or spectacles

• Dust mask

• Hearing protection earmuffs

• Safety helmet

• Soft leather mechanic’s gloves

Module trayThe module tray is delivered with each drive. The tray is used if a phase module of the drive has to be removed from the cabinet.

SW Software

VLSCD Voltage level short circuit detection

Abbreviation Meaning

Title Document number

ACS 2000 User’s manual 3BHS297030 ZAB E01

Warranty directives 3BHS404420 ZAB E01

Wiring diagrams 3BHS319007 ZAB E01


ABB General information on manual and equipment

Personal computer• Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical

transmitter / receiver, optical cables and DriveWindow or DriveDebug

Hand tools• Drive socket set with ratchets and extension bars

• Spanner set

• Screwdriver set

• Side cutter

• Hex key set

Measuring equipment• Multimeter (e.g. Fluke 87)

• Test leads of sufficient length

• Test probes

The test probes should have sufficient length and short uninsulated tips (see circles).

• 5 kV Megger, for example AVO BM11D

• Fiber-optic cable tester, e.g:

• Tempo 253B Led source (set to 660nm, no modulation), 10ZP Adapter

• Tempo 557B power meter (set to 660nm, dBm), 10ZP Adapter

• Photom 205A - optical power meter, Haktronics Co., Ltd

• LEONI optical power meter

• LEONI optical sender ZXXX-TS0

• Fiber optic GmbH, 96524 Neuhaus-Schierschnitz, ZXXX-TM0

~30 cm



Cleaning equipment• Antistatic vacuum cleaner (for example SV-497 ABF - VACUUM 3M

220V from 3M) for cleaning of sensitve electronic components (e.g. printed circuit boards)

• Antistatic brush for cleaning of printed circuit boards

• Cloths and brushes for general cleaning


ABB

Chapter 1 - Safety

1.1 Classification of safety signs used in this manualSafety instructions are used to highlight a potential hazard when working on the equipment. Safety instructions must be strictly followed! Non-compliance can jeopardise the safety of personnel, the equipment and the environment.

DANGERDANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGWARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONCAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICENOTICE is used to address practices not related to personal injury.

The safety instructions are derived from the following standards:

• ISO 3864-2:2004 (E)

Graphical symbols – Safety colours and safety signs – Part 2: Design principles for product safety labels

• ANSI Z535.6

American National Standard for Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials

ACS 2000 Service manual 3BHS344169 ZAB E01 Rev. - 1-1 (6)

Chapter 1 - Safety ABB

1.2 Stopping the drivePress the stop key on the CDP control panel.

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 ReadyRef. The run status indication blinks during the stop sequence.

As long as the stop sequence is in progress, the drive can always be restarted by pressing the start key on the CDP control panel.

Just before the motor will come to a standstill, the CDP control panel displays shortly the message Stopping.

When the drive has stopped modulating, the CDP control panel displays ReadyRun:

1 L -> 600.0 rpm StateINU ReadyRefMOTOR SP 300.00 rpmPOWER 20.0 kW

1 L -> 600.0 rpm 0StateINU StoppingMOTOR SP 0.00 rpmPOWER 0.0 kW

1 L -> 600.0 rpm 0StateINU ReadyRunMOTOR SP 0.00 rpmPOWER 0.0 kW

1-2 (6) 3BHS344169 ZAB E01 Rev. - ACS 2000 Service manual

ABB Chapter 1 - Safety

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

1.3 Deenergizing the drive

DANGERHazardous voltage!

Do not try to gain access to the input transformer, the medium voltage compartments of the drive, nor the motor, as long as the drive system is energized and not grounded.

To disconnect the drive from the main power supply, proceed as follows:

1 Stop the motor as described in 1.2 Stopping the drive.

When the motor has reached zero speed, the display shows ReadyRun:

2 Press the SUPPLY OFF pushbutton to disconnect the drive from the main power supply. The following takes place:

• The MCB opens.

• The DC link discharges.

While the DC link discharges, the display shows OffSeqOn:

• The SUPPLY OFF pushbutton flashes and changes to a perma-nent light when the DC link is discharged completely.

1 L -> 600.0 rpm 0StateINU ReadyRunMOTOR SP 0.00 rpmPOWER 0.0 kW

1 L -> 600.0 rpm StateINU OffSeqOnMOTOR SP 0.00 rpmPOWER 0.0 kW



When the DC link is discharged, the display shows ReadyOn:

3 Rack-out, lock-out, ground and tag-out the MCB.

4 Turn the grounding switch to the grounded position when the lamp GROUNDING SWITCH UNLOCKED is on.

NOTICEDo not turn the grounding switch to the grounded position before the light GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will be damaged.

The lamp is only turned on after the fan has stopped. The fan contin-uous running for a preset time after the main power supply has been switched off to dissipate the heat from the resistor assembly in the back of the cabinet.

If the lamp does not light up and there is reason to believe that the grounding circuit is malfunctioning, refer to Chapter 2 - Grounding switch and door safety switch, 2.1 Malfunctioning grounding switch for further information.

When the grounding switch is in the grounded position, the status line of the display alternates between DCGnd NOpen, NotReadyOn, AFE NotRdy:

1 L -> 600.0 rpm StateINU ReadyOnMOTOR SP 0.00 rpmPOWER 0.0 kW

1 L -> 600.0 rpm StateINU DCGnd NOpenMOTOR SP 0.00 rpmPOWER 0.0 kW

DCGnd NopenNotReadyOnAFE NotRdy


ABB Chapter 1 - Safety

DANGERThe grounding switch connects the DC link of the drive to the PE ground bus.

If it is planned to perform maintenance on the drive that includes the removal of phase modules, the connection of grounding equipment at the appropriate locations is a must. This is to ensure that hazardous voltages cannot be fed into the drive neither from the main power supply nor the motor.

Figure 1-1 shows an example how the terminals of the feeder cables (1) are grounded at the PE ground bus (2) using a 4-way grounding set (3).

Figure 1-1 Connecting a grounding set

5 Switch off all auxiliary voltages from external sources.

The drive is now dead, and safe access is possible.

3

1

2




ABB

Chapter 2 - Grounding switch and door safety switch

2.1 Malfunctioning grounding switchWhen the DC link of the drive has been deenergized, the lamp GROUNDING SWITCH UNLOCKED lights up to indicate that the grounding switch is released and can be turned to the grounded position. If the lamp does not light up and there is reason to assume that the grounding circuit is malfunctioning, proceed as follows:

1 Do not try with force to turn the grounding switch in any direction.

The handle and / or the switch could be damaged if tried.

2 Verify that the MCB is in the open position.

3 Check the drive status on the CDP control panel.

The message ReadyOn is displayed when the DC link of the drive has been discharged.

4 Verify that the DC link has been discharged.

The discharging level can be viewed in parameter 2.01 DC VOLTAGE. The value should be below 50 V.

5 Check if there are any alarm and fault messages on the display.

If there are any, look up the messages in the Troubleshooting guide and follow the instructions.

6 Try to rectifiy the reason for the alarms and faults, and then press the reset key on the CDP control panel.

1 L -> 0.0 rpm StateINU ReadyOnMOTOR SP 0.00 rpmPOWER 0.0 kW


Chapter 2 - Grounding switch and door safety switch ABB

2.2 Doors and door locksTo ensure safety and to prevent the doors being opened unintentionally, all doors are lockable, and the doors of compartments where medium voltages are present during operation are bolted or electromechanically secured. Additionally, the doors of the medium voltage compartments have locks with different inserts than the control compartment door. The different lock inserts ensure that these doors can only be opened by personnel authorized to do so.

Figure 2-1 Door locks

1 Door of terminal compartment: bolted and lockable

2 Door of control compartment: lockable

3 Door of AFE / INU compartment: electromechanically locked

Door cannot be opened when the main power has been applied.

The louvered panels can be removed during operation to replace the filter mat.

4 Cover of input filter compartment: bolted

The louvered panel can be removed during operation to replace the filter mat.

1 2 3

4


ABB Chapter 2 - Grounding switch and door safety switch

2.2.1 Door safety switch

2.2.1.1 Function

The safety switch of the AFE / INU compartment door is tied into an interlocking mechanism that operates in conjunction with the grounding switch and the interlocks from the main circuit breaker in the main power supply circuit of the drive:

• The interlocking system ensures that the main power cannot be initialized to the drive unless the door is securely closed and the grounding switch is in position not grounded.

• The interlocking system also ensures that the door cannot be opened until the main power is disconnected, the DC link capacitors are discharged and the grounding switch is in position grounded.

The door of the control compartment is not integrated into the interlocking mechanism and can always be opened.

The safety switch is located under the roof plate behind the door of the AFE / INU compartment (see arrow).

Figure 2-2 Location of door safety switch

2.2.1.2 Manual release

Before the drive leaves the factory, the safety switch is put to position unlocked. If the safety switch is in postion locked by mistake and the auxiliary voltage is turned off, the door cannot be opened. To open the door, the safety switch must then be unlocked manually.



The safety switch is equipped with a mechanical release (1) that has two adjustable positions:

• Unlocked (2)

The mechanical release is put into this position in the factory.

The auxiliary voltage can either be switched on or off.

• Locked (3)

This is the normal operating position.

To open the door, the DC link must be discharged and the auxiliary voltage must be switched on.

If the auxiliary voltage is switched off and the door is locked, the safety switch must be unlocked manually as described in the following section.

Procedure 1 Open the control compartment door to access the release dial of the safety switch (see arrow).

2 31


ABB Chapter 2 - Grounding switch and door safety switch

2 Using a slotted or Philips screwdriver, screw out the locking screw (1) until the release dial (2) can be turned.

3 Using a slotted screwdriver (tip width 5 mm), turn the release dial from the locked to the unlocked position.

4 After the door has been opened, turn the release dial to the locked position and screw in the locking screw.

Note: After the mechanical and electrical installation has been finished, it is the task of the commissioning personnel to check that the manual release of the safety switch is in the locked position. Otherwise, the drive cannot be started up.

1

2




ABB

Chapter 3 - Replacing phase modules

3.1 Overview

Figure 3-1 AFE and INU compartment

1 Phase module 1 of INU



4 Phase module 1 of AFE



1

2

3

4

5

6


Chapter 3 - Replacing phase modules ABB

3.2 Dimensions and weight

Figure 3-2 Phase module

Dimensions (L x W x H) 650 x 490 x 25 (mm)

Weight Approximately 30 kg

3.3 Required tools and accessories• Module tray

• Reversible ratchet with extension

• 5 mm hex-head drive socket

• 6 mm hex-head drive socket

3.3.1 Procedure1 Switch off the main power supply and ground the equipment.

See Chapter 1 - Safety, 1.3 Deenergizing the drive if information on deenergizing is required.

2 Switch off the auxiliary power supply.

Depending on the auxiliary power supply configuration of the drive, switch off the following miniature circuit breakers:

Drives with common auxiliary power supply (no safeline):

• Miniature circuit breaker -Q1302 disconnects the complete single-phase auxiliary voltage from the drive.

Drives with separate auxiliary power supplies (safeline):


ABB Chapter 3 - Replacing phase modules

• Miniature circuit breaker -Q1354 disconnects the auxiliary voltage from the phase modules.

• Miniature circuit breaker -Q1352 disconnects the auxiliary voltage from the control compartment.

See the Wiring diagrams to identifiy the miniature circuit breakers and the electric circuits.

CAUTIONAfter the miniature circuit breakers have been switched off, the charging transformer and the fan unit are still connected to their power supplies.

3 Remove the acrylic panel (1).

• Screw type: M10 socket-head screw

• Required tool: 6 mm hex-head drive socket

When working on the AFE, first pull out the air pressure tube at the bottom of the panel.

l

4 Remove the screws on each side of the phase module.

• Screw type: M10 socket-head screw

• Required tool: 6 mm hex-head drive socket

1



5 Attach the module tray to the cabinet.

The tray is attached to two brackets, one on each side (see arrows). .

Hold the tray at an angle (1) to slide the hook-shaped ends of the tray behind the brackets. Lower it down (2) to engage the hooks with the brackets.



.

CAUTIONMake sure the module tray is securely attached to the cabinet (see arrows) to prevent dropping the phase module when placed on the tray.

1

2



6 Holding the phase module at the handles, pull it out until it is flush with the leading edge of the tray.



7 Disconnect all cables going into the cabinet from the phase INT circuit board (1):

• Auxiliary power supply cable (2)

• Two fiber-optic cables (3)

The cables are partly concealed by the grounding strap.

• Current transformer cable (4)

Note: This cable is only present in phase modules of the AFE..

8 Detach the cable chain on the side of the phase module (1, 2). Pull down the end of the chain a little (3) and pull it into the direction of the arrow (4) to disengage the chain from the mounting bracket.

.

1 2 3 4

1 2



9 Lift the phase module off the module tray.

Owing to the weight (approximately 35 kg [77 lb]), it is recommended that two persons, one on each side, lift the phase module off the tray. Hold the phase module at the positions indicated by the arrows.

.

10 After the phase module has been replaced, proceed in reverse order of removal.

3 4



11 When reconnecting the fiber-optic cables, pay attention to connect them to their corresponding receptacles (see arrows).

.

12 When all cables have been reconnected, check that the drive control system and the phase module communicate with each other. Depending on the auxiliary power supply configuration of the drive, switch on the following miniature circuit breakers:

Drives with common auxiliary power supply (no safeline):

Switch on miniature circuit breaker -Q1302.

Drives with separate auxiliary power supplies (safeline):

Switch on miniature circuit breaker -Q1354.

Wait a few seconds.

Check that the LEDs onthe phase INT circuit board of the phase module are on (see rectangle).

13 Push the phase module back into the rack as far as it goes and tighten the fastening bolt on each side.



14 Remove the module tray and reinstall the acrylic panel.

15 Switch on all miniature circuit breakers in the control compartment.

16 Start the drive.

See the User’s manual, 8.5 Starting the drive system locally if infor-mation on the start-up procedure is required.


ABB

Chapter 4 - Checking phase modules

4.1 Checking a phase module for short-circuitA faulty phase module can be detected by one of the two methods:

• Visually checking the phase module

• Measuring the voltage across the phase module terminals

4.1.1 Visual check of the phase moduleNote: For the visual check, the phase module needs to be pulled half way out of the cabinet. To do this, follow the instructions up to step 7 in Chapter 3 - Replacing phase modules, 3.3.1 Procedure.

Each phase module contains one phase INT circuit board (2) which interfaces with the six gate drives (1). Each gate drive controls two IGBTs.

Figure 4-1 Measuring point locations

Visually check the six gate drives of the phase module. Possible findings:

• All LEDs on the gate drives are on.

R4011Measuring point E

PH DC- NP DC+

Measuring point C

11 2


Chapter 4 - Checking phase modules ABB

This means that the phase module could be healthy or faulty. For further investigation, proceed with section 4.1.2 Measuring the voltage across the phase module terminals.

• The LEDs on one or several gate drives are off.

This means that these gate drives are short-circuited at the output. Either the gate drive or one the associated IGBTs cause the problem. In this case, the phase module has to be replaced to get the drive running again. Check the faulty phase module according to section 4.1.2 Measuring the voltage across the phase module terminals.

4.1.2 Measuring the voltage across the phase module terminalsNote: The phase module needs to be completely pulled out of the cabinet. To do this, follow the instructions up to step 7 in Chapter 3 - Replacing phase modules, 3.3.1 Procedure.

With the multimeter in diode test mode, measure the voltages at the measuring points shown in Figure 4-2. The reading should be as stated inTable 4-1 below. If the measured values are different, contact the MV drives supportline for further advice.

Note: The threshold voltage for each IGBT is ~0.35 V; the measurement includes two IGBTs.

Table 4-1 Readings of a healthy phase module in diode mode

Plus probe Minus probe Reading

PH C ~0.7 V

C DC+ ~0.7 V

NP C ~0.7 V

DC- E ~0.7 V

E PH ~0.7 V

E NP ~0.7 V

Table 4-2 Readings of a healthy phase module in diode mode

Minus probe Plus probe Display reading

PH C OL

C DC+ OL

NP C OL

DC- E OL

E PH OL

E NP OL


ABB Chapter 4 - Checking phase modules

Figure 4-2 Measuring points



4.2 Measuring phase capacitors

4.2.1 Required tools and accessories• LCR meter or multimeter with high capacitance range, e.g. Fluke 179

• 5 mm hex key

• Module tray

4.2.2 ProcedureNote: This test does not require the complete removal of the phase module.

1 Switch off the main and the auxiliary power supply and ground the equipment.


2 Attach the module tray and place the phase module on the tray.

See Chapter 3 - Replacing phase modules, 3.3.1 Procedure. Follow the instructions up to step 7.

3 Considering the polarity, measure directly on the terminals of the phase capacitor.

The measurement should show the value in μF as printed on the capacitor rating plate, plus or minus the stated tolerance.



4.3 Dismantling the phase module

IMPORTANTThe phase module must only be dismantled or repaired on site after checking this with the MV drives supportline.

4.3.1 Required tools and accessories• Small slotted screwdriver

• 5 mm hex key

• Side cutter

4.3.2 Overview

Figure 4-3 Top view of a phase module

1 Phase capacitor

2 Phase INT circuit board

3 Cover plate

1 2 3

6NP DC-DC+ 4 45PH 7



4 Gate drives

5 DC busbars

6 HVD circuit board

7 IGBT heatsink assembly

4.3.3 Procedure1 Cut the cable ties which connect the ferrite rings (1) to the phase

module frame and put them aside.

2 Carefully unplug the six gate drive plugs (2) which connect the gate units to the phase INT circuit board.

3 Unplug the DE-9 connector (3) from the phase INT circuit board . The cable connects the HVD circuit board to the phase INT circuit board.

11 3 22



4 Disconnect the cable between the HVD circuit board and the neutral point plug (see arrow).

5 Remove the screw of the cable which connects the phase-input-output bus end (see arrow) to the IGBTs (V4012 and V4013) and push the cable out of the current transducer (1).

6 Remove the six screws (see arrows) connecting the internal DC busbars to the cover plate.

1



7 Remove the four socket-head fastening screws of the cover plate (see arrows in Figure 4-3).

8 Carefully remove the cover plate.

The circuit board can break easily. Therefore, pay attention not to touch any part of the gate drive circuit boards with the sharp edges of the cover plate.

DC bus screws (wo)



4.4 Checking IGBT modules

4.4.1 Required tools and accessories• Multimeter, e.g. Fluke-87

• 5 mm hex key

• 10 mm spanner

4.4.2 Procedure1 Switch off the main and the auxiliary power supply and ground the

equipment.


2 Remove the phase module from the cabient as described in Chapter 3 - Replacing phase modules.

3 Place the phase module on a clean and stable working surface suit-able for the weight of the phase module (approximately 35 kg [77 lb]).

4 Remove the phase module cover as described in section 4.3 Disman-tling the phase module.

5 Unplug cables 1 and 2 at the position indicated in Figure 4-4.

6 Unscrew cable 3 at the position indicated in Figure 4-4.

7 Remove the link (see squares in Figure 4-4).

8 Remove the fastening screws (see circles in Figure 4-4) of the DC busbars.



Figure 4-4 Dismantling the phase module

9 Proceed with section

• 4.4.3 if the free wheeling diodes have to be checked,

• 4.4.4 if the gate unit has to be checked.

3

1 2



4.4.3 Checking the free-wheeling diodesCheck the free-wheeling diode with the multimeter in diode test mode.

Figure 4-5 IGBT module

4.4.4 Checking the gate unitCheck the gate units with a multimeter in resistance mode.

Table 4-3 Readings of a healthy IGBT module in diode mode

Plus probe Minus probe Display

1 2 OL

2 3 OL

2 1 ~0.35 V

3 2 ~0.35 V

Table 4-4 Readings of a healthy IGBT module in resistance mode

Plus probe Minus probe Display

5 6 OL

8 7 OL

6 2 0 Ω

7 3 0 Ω



4.5 Replacing the IGBT heatsink assembly

IMPORTANTAny replacement work must only be carried out after checking this with the MV drives supportline.

4.5.1 Required tools and accessories• 5 mm hex key

• 10 mm spanner

4.5.2 Procedure1 Switch off the main and the auxiliary power supply and ground the

equipment.


2 Remove the cover plate as described in section 4.3 Dismantling the phase module.

3 Remove the DC busbars as described in section 4.4 Checking IGBT modules.

4 Remove all connections between the gate drive and the IGBT modules using long nose pliers.



5 Remove the link (see arrow) at the capacitor terminals .

6 Remove the four fastening screws of the IGBT heatsink assembly.

7 Lift the IGBT heatsink assembly carefully out of the phase module.

Best is to take out the heat sink with two people. Avoid touching any connecting part of a busbar or IGBT. Otherwise the electric contacts might be affected. Best is to wear thin leather gloves.



4.6 Replacing phase capacitors

4.6.1 Required tools and accessories• 5 mm hex key

• 10 mm spanner

4.6.2 Procedure1 Remove the cover plate of the phase module as described in section

4.3 Dismantling the phase module.

2 Remove the DC busbars as described in section 4.4 Checking IGBT modules.

3 Remove the link of the capacitor terminals and the cables connected to the terminals of the phase capacitor as described in section 4.5 Replacing the IGBT heatsink assembly.

4 Remove the four screws fixing the capacitor using the hex key.


ABB

Chapter 5 - Removing the NP frame

5.1 Required tools and accessories• Side cutter

• Reversible ratchet

• 5 mm hex key

• 17 mm spanner

5.2 Procedure1 Switch off the main and the auxiliary power supply and ground the

equipment.


2 Remove all phase modules from the cabinet as described in Chapter 3 - Replacing phase modules.

3 Cut off all cable ties which fasten the cable chains to the side of the NP frame (see arrows).


Chapter 5 - Removing the NP frame ABB

4 Remove the two fastening screws of all cable chains.

Secure the cable chains so they will not be damaged when the NP frame is removed from the cabinet.

5 Use the hex key to remove all fastening screws (see arrows) on both side walls of the NP frame.


ABB Chapter 5 - Removing the NP frame

6 Remove the four fastening screws on the bottom of the frame using the 17 mm spanner.

7 Remove the cable (1) connected to the ground switch (2).

1

2


Chapter 5 - Removing the NP frame ABB

8 Place a metal plate in front of the NP frame.

Adjust the height of the metal plate so it is level with the bottom of the NP frame (see arrows).

9 Hook the module tray to the NP frame. The module tray will serve as a handle to remove the NP frame from the cabinet.

10 Pull out the NP frame and slide it on the metal plate

Note: When pulling out the NP frame, take care not to damage the cables.


ABB

Chapter 6 - Converter insulation test

IMPORTANTThe insulation test must only be carried out if recommended by the MV drives supportline. The test is not performed when the drive is commis-sioned for the first time.

6.1 Required tools and accessories• 5 mm hex-head key

• Multimeter

• Test leads for short-circuiting the terminals

• 5 kV insulation tester (megger)

6.2 ProcedureNote: The terminals and components referred to in the following section correspond to those in the Power electronics overview on page 6-3.

1 Switch off the main and auxiliary power supply and ground the equip-ment.


Preparation 2 Short-circuit all medium voltage input and output terminals (U1, V1, W1, U2, V2, W2).

3 Short-circuit all symmetrical resistors (Rsu, Rsv, Rsw, Rsr, Rss, Rst) of the phase modules and connect them to the neutral point (NP).

4 Short-circuit the terminals of all phase capacitors (Cfu, Cfv, Cfw, Cfr, Cfs, Cft) and connect them to NP.

5 Short-circuit the IFU capacitors (Cr, Cs, Ct) and connect them to NP.

6 Short-circuit the EMC capacitors (Cu, Cv, Cw ) and connect them to NP.

7 Disconnect the NP-to-ground-capacitor (C1021) and short-circuit the terminals of capacitor C1012.

8 Short-circuit the high voltage charging relay by short-circuiting the secondary of the charging transformer with the low voltage side of the relay.

9 Short-circuit the terminals of the grounding switch.

10 Put the grounding switch to the position not grounded.


Chapter 6 - Converter insulation test ABB

11 Connect the insulation tester between the main terminals (U1, V1, W1, U2, V2, W2) and ground.

Test 12 Perform the insulation test between the main circuit and ground.

• Test voltage: 5 kV for 60 seconds.

• Duration: 60 seconds

The insulation test is passed if the measured insulation resistance is 100 Mohm or higher.

13 Remove the short-circuit leads.

NOTICEA 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.


ABB Chapter 6 - Converter insulation test

++

+C

fuC

fvC

fw

Rv

Rw

Cv

CwU

2 V2 W2

VW

DC

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Ru

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Rsu

Rsv

Rsw

EM

C

Lu Lv Lw

DC

+

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U1 V1 W1

ST

Cfr

Cfs

Cft

Ct

Cs

Cr

Lr Ls Lt

AFE

C10

12

C10

21

L102

1R

1021

R10

14/1

5

Rsr

Rss

Rst

IFU

RU

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RC

M? =

R10

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5

CC

M? =

C10

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RP

GN =

R10

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Chapter 6 - Converter insulation test ABB


ABB

Chapter 7 - Replacing circuit boards (PCBs)

7.1 Location of circuit boards

Figure 7-1 Location of circuit boards

1 AMC and main INT circuit board of INU (AMC at the front)

2 AMC and main INT circuit board of AFE (AMC at the front)

3 OEI circuit board

4 CD circuit board

5 IPS (IGBT power supply)

6 SYN circuit board

7 ASE circuit board

8 VLSCD circuit board

1

2

4

6

3

7

5

8


Chapter 7 - Replacing circuit boards (PCBs) ABB

7.2 Handling instructions for PCBs and fiber-optic cables

7.2.1 PCBsDo not touch circuit boards or other sensitive components without applying static-sensitive handling precautions. Static electricity can damage circuit boards and components.

• Do not touch the components without wearing a properly grounded wrist strap.

• Put the circuit board or component on a grounded working surface protected against electrostatic discharges.

• Hold a circuit board only at the edge.

• Handle a faulty circuit board as carefully as a new one.

7.2.2 Fiber-optic cablesHandle fiber-optic cables with care. Do not touch the ends of the fibers. They are extremely sensitive to dirt. Always hold the connector when unplugging a fiber-optic cable. Fiber-optic cables can be damaged if bent sharply. Observe the minimum bend radius of 25 mm.

7.3 Replacing an AMC circuit board

Figure 7-2 AMC circuit board


ABB Chapter 7 - Replacing circuit boards (PCBs)

1 Before replacing the AMC circuit board, check that the installed soft-ware version and the parameter settings of the new circuit board correspond to those in the drive.

See Commissioning manual for information on loading software and firmware to new AMC circuit board.


See Chapter 1 - Safety, 1.3 Deenergizing the drive if information on

2 Ground yourself at the converter frame with a wrist strap before touching the AMC circuit board.

3 Unplug the fiber-optic cables, the power supply connector and the control panel connector.

4 Remove the fastening screws (7 pcs.) and the AMC circuit board.

5 Attach the new AMC board.

Use all fastening screws to ensure proper grounding of the circuit board.

6 Reconnect the fiber-optic cables, the power supply connector and the control panel connector.

7 Verify the connections by comparing them with the corresponding wirIng diagram.

8 Put the defective circuit board into an antistatic bag.

9 Power up the drive and check if it is functioning properly.

10 Follow the procedures as stated in the MV Warranty Directive if a defective circuit board has to be returned to ABB, particularly if it is still under warranty. This procedure is also recommended even if the warranty period has already expired.



7.3.1 Changing the AMC software flash memoryThe application control software and the parameter settings are saved in the flash memory which is on a separate flash memory PCB (see rectangle).

Figure 7-3 AMC flash memory

When the AMC circuit board is replaced, the old flash memory can still be used if the software has not been upgraded in the meantime.

If only the flash memory has to be replaced, the AMC circuit board can remain in the cabinet. It is also not necessary to disconnect the fiber-optic cables.



2 Ground yourself with a wrist strap before touching the circuit board.



3 Remove the flash memory PCB by holding it with both hands and pulling it at a 90° angle away from the AMC circuit board.

.

4 Make sure that the white dot on the flash memory PCB is on top of that on the AMC circuit board when attaching the new PCB.

NOTICEThe correct orientation of the new PCB is important. If attached wrongly, the new PCB will be damaged immediately when the auxiliary power is switched on.

5 Press the PCB down firmly making sure that all pins are inserted properly.

.

6 Mount the AMC circuit board.







7.4 Replacing the main INT circuit boardThe main INT circuit board is located behind the AMC circuit board.

Figure 7-4 Main INT circuit board



2 Remove the AMC circuit board as described in section 7.3 Replacing an AMC circuit board.

Ground yourself at the drive frame with a wrist strap before touching the main INT circuit board.

3 Unplug the fiber-optic cables and the power supply connector.

4 Remove the fastening screws (13 pcs.).

Take all necessary precautions to prevent screws and washers from falling into other components.

AMC circuit board

Main INT circuit board



5 Remove the main INT circuit board and place it on a grounded working surface.

6 Install the new main INT circuit board.


7 Reconnect the fiber-optic cables and the power supply connector.

8 Carry out a visual check and verify the connections by comparing them with the corresponding Wiring diagram.




7.5 Replacing ASE and SYN circuit boards

Figure 7-5 Location of SYN and ASE circuit board

1

2



1 ASE circuit board (behind the cover)

2 SYN circuit board

7.5.1 ASE circuit board

Figure 7-6 ASE circuit board



2 Open the control section door and remove the cover of the IFU compartment (screw type: Phillips).

3 Remove the cover of the ASE circuit board (screw type: Phillips).

4 Ground yourself at the drive frame with a wrist strap before touching the ASE circuit board.

5 Unplug the auxiliary power, fiber-optics and DC connections.

6 Remove the fastening screws of the board (screw type: Phillips).

Take all necessary precautions to prevent screws and washers falling into other components.

7 Remove the ASE circuit board and place it on a grounded working surface.

8 Mount the new circuit board.


9 Reconnect all cables.

10 Carry out a visual check and verify the connections by comparing them with the corresponding Wiring diagram.

11 Reinstall the cover.





7.5.2 SYN circuit boardThe replacement procedure for the SYN circuit board is the same as for the ASE circuit board with the exception that no circuit board cover has to be removed.

7.6 Replacing the VLSCD circuit boards

The AFE and the INU of the drive are each equipped with two VLSCD circuit boards (device designation: F1031, F1032, F1061and F1062).

The circuit boards can be accessed in two ways:

• Through the rear of the cabinet

Rear access requires the service cover in the rear of the cabinet to be removed.

• Through the front of the cabinet

Front access requires the NP frame to be removed.

Figure 7-7 Location of VLSCD circuit board

1 INU negative VLSCD

2 INU positive VLSCD

1

2

3

4



3 AFE positive VLSCD

4 AFE negative VLSCD

7.6.1 Rear access

DANGERHazardous voltage!

Do not remove the service cover before the drive has been deenergized and grounded and the fan has stopped.



2 Remove the service cover (screw type: Phillips).

3 Replace a circuit board following the instructions in section 7.5 Replacing ASE and SYN circuit boards, from step 9 onwards.

7.6.2 Front access1 Switch off the main and the auxiliary power supply and ground the

equipment.


2 Remove the NP frame as described in Chapter 5 - Removing the NP frame.

3 Proceed as described in section 7.5 Replacing ASE and SYN circuit boards when replacing the circuit boards.


ABB

Chapter 8 - Function of LEDs

8.1 Safety

Figure 8-1 AMC circuit board

Fault

M

T1

S3

S2

Run

P

T2

S1

S0

Table 8-1 Function of LEDs on the AMC circuit board

LED LED color Function

R green Run indication

F red Fault indication

P green supply OK

M green not used (ON when booting)

T1 yellow ON = receiving data on DDCS channel 0

T2 yellow ON = receiving data on DDCS channel 3

S0 yellow always OFF





Chapter 8 - Function of LEDs ABB

8.2 Main INT circuit board

Figure 8-2 Main INT circuit board

LED

_1LE

D_2

LED

_3LE

D_4

LED

_5LE

D_6

LED

_7LE

D_8

LED

_9

Table 8-2 LEDs on the main INT circuit board


1 yellow all configured PPCS phase INT links enabled

2 yellow any latched fault (fc1/fc2)

3 yellow supply OK

4 yellow reserved for future use

5 yellow internal use

6 yellow firing-through-link faulty

7 yellow PFF link to / from AFE faulty

8 yellow PFF link to / from INU faulty

9 yellow yellow, green, FPGA successfully configured


ABB Chapter 8 - Function of LEDs

8.3 Phase Int INT circuit board

Figure 8-3 Phase INT circuit board

Table 8-3 LEDs on the phase INT circuit board


Done green board ready

R_OK green reset released

GDerr red any gate driver link shut down (short circuit detected)

Alarm red alarm pending

Fault red fault pending

LED1 red not used

LED2 red not used

+ 5 V green power supply on

+ 3.3 V green power supply on

- 15 V green power supply on


Chapter 8 - Function of LEDs ABB


ABB

Chapter 9 - Uploading data from the black box

The AMC34 circuit board is equipped with an additional flash memory PCB (see rectangle). The PCB serves as a black box which saves data and fault loggers of the drive for a longer time even if the auxiliary power has been switched off. When a fault occured in the drive, it is recom-mended to send the black box data to the MV Drives Supportline of ABB for assistance in analysing the fault.

Figure 9-1 Black box

The tools for uploading the content of the black box are part of the loading package. The tools become only visible after the command l_acs has been entered in a DOS window. Afterwards the folder BlackBox is created in the loading package. The folder contains one file: blackbox_upload.exe

1 To upload any data from the black box, open a DOS window and open folder BlackBox. All files downloaded from the black box will be saved in this folder.

2 After uploading move the files to another folder or rename them. Otherwise they will be overwritten the next time a file is downloaded from the black box.

The black box has two separate parts:

• the data loggers and

• the fault / parameter loggers.


Chapter 9 - Uploading data from the black box ABB

Uploadingthe fault logger

To upload the fault logger, enter the command:

blackbox_upload 1 /bb_upload_data /mbaud=8

1 indicates the channel 3 node number of the circuit board.

To upload data from a circuit board with node number 2, the command would be:

blackbox_upload 2 /bb_upload_data /mbaud=8

Uploadingthe data logger

To upload the dataloggers, enter the command:

blackbox_upload 1 /dl_upload_data /mbaud=8

1 indicates the channel 3 node number of the circuit board.

Each data logger is uploaded to a new file. Empty data loggers are not uploaded.

If the black box is full, uploading the data can take up to 15 minutes. Once started, do not interrupt the upload. If the upload is interrupted (e.g. by closing the DOS window), some communication services will not be closed properly and it will not be possible to start the upload again. If this happens, do the following:

Open DriveDebug set any bit of parameter 103.01 to 1.

Uploading of data should work again.


2

ABB Switzerland LtdMedium Voltage DrivesCH-5300 Turgi

Phone: +41 58 589 27 95

Fax: +41 58 589 29 84

E-Mail: [email protected]

www.abb.com/drives

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ACS 2000 ServiceMan 3BHS344169 E01 Rev