ABBACS 1000Medium Voltage Drives315 – 5000 kW400 – 6200 hpCommissioning ManualDocument No.: 3HBS210669 ZAB E01 Rev.-Issued 13-10-2006ABB ABB reserves all rights to this document, also in the event of patent issueor registration of any other industrial property protection right. Misuse, in particular duplication and forwarding to third parties, is not permitted. This document has been checked with due care and attention. However,should the user find any errors, these should be reported to ABB. ABB aims to maintain the most modern standard, therefore, entries in this manual may differ from the actual product.ABBTable of ContentsChapter 1 -Overview (5)1.1.Safety (5)1.2.Scope of Commissioning (5)1.3.Reports (6)1.4.Related Documents and Parameter References (6)1.5.Tools (6)Chapter 2 -Precommissioning Check List (7)2.1.Office Preparations (7)2.2.Scope of Delivery (8)2.3.Pre-Conditions for Commissioning (8)Chapter 3 -Inspection of Installation (11)3.1.MCB (11)3.2.Transformer (ACS 1000i: N.A.) (11)3.3.Converter Room (12)3.4.Converter (13)3.5.Ground Connections (14)3.6.Motor (14)Chapter 4 -Safety (15)Chapter 5 -Connecting Auxiliary Supply to the Converter (17)5.1.EPS Auxiliary Power Supply (17)5.2.Phoenix Auxiliary Power Supply (18)5.3.Checking Of Auxiliary Backup Batteries (21)Chapter 6 -Commissioning of the Cooling System (23)6.1.Water-Cooled ACS 1000 (23)6.1.1.Checking the Internal and External Cooling Circuits (23)6.1.2.Filling Up the Internal Cooling Circuit (24)6.1.3.Functional Test of the Redundant Fan (24)6.2.Air-Cooled ACS 1000 and ACS 1000i (24)Chapter 7 -Insulation Resistance Measurements (27)7.1.Preparations (27)7.2.External MCB (27)7.3.Internal MCB (only ACS 1000i) (28)7.4.Transformer (28)7.5.Converter (Standard Air- and Water-Cooled ACS 1000) (30)7.6.Converter (ACS 1000i) (33)Chapter 1 - Overview ABB 7.7.Motor (35)7.8.Power Cables (36)Chapter 8 -Preparing the System (37)8.1.MCB and Protection Relay (37)8.2.Transformer (37)8.3.Converter (38)8.3.1.Standard Hardware (38)8.3.2.Optional Hardware (40)8.3.3.Customer Parameters (40)8.3.4.Motor Parameters in Group 99 And 112 (40)8.3.5.Testing of the MCB Control and the Tripping Loop (43)8.3.6.Testing of I/O’s (45)8.3.7.Testing of Fieldbus-Communication (45)8.4.Motor (45)Chapter 9 -Energizing, First Start and Load Test (47)9.1.Energizing the Converter (47)9.2.First Start (50)9.3.Load Test (51)9.4.Testing of Ride Through and Auto Restart Functions (51)9.4.1.Main Power Ride Through (51)9.4.2.Auxiliary Power Ride Through (52)9.4.3.Auto Restart (53)Chapter 10 -Final Work (55)10.1.Spare Parts (55)10.2.Customer Training (55)10.3.Parameter Backup (55)10.3.1.Saving Parameters and System Software using DriveWindow (56)10.3.2.Saving Parameters and System Software using DriveDebug (59)10.4.Customer Approval (63)10.5.Customer Documentation (63)10.6.Documentation and Back-up Copies for Supportline (63)10.6.1.Supportline Contact Information (64)ABB Chapter 1 - OverviewChapter 1 - OverviewThe purpose of the manual is to assist in commissioning the ACS 1000frequency converter. It includes necessary instructions, practical hints andreferences to related documentation to successfully commission theconverter and the related equipment as needed for the application.NOTICE!Commissioning of the converter may only be carried out by personnelwho have been certified at “expert” or “master” level by the ProductResponsible Unit.1.1. SafetyThe safety instructions in this manual, in the User’s Manual and the localsafety regulations must be observed to maintain safety to all thoseinvolved in commissioning the drive system.DANGER!Working on energized equipment can be a life hazard.Mechanical forces, electric shock and burn can cause severe injuries ordeath.Safety related work practices must be followed at all times.Take appropriate measures when working on the drive system.1.2. ScopeofCommissioningNormally, the commissioning engineer is only responsible for theconverter. If agreed by contract, the commissioning engineer can take onthe commissioning of:•Motor,•Transformer,•MCB,•Protection relays,•External devises (actuators, sensors etc.).Chapter 1 - Overview ABB1.3. ReportsDuring commissioning, the Commissioning Report and the Field ServiceReport and must be filled in. Templates of the documents are available onthe MV AC Drives Portal.1.4. Related Documents and Parameter ReferencesThe following manuals and specifications provide information on the driveequipment:•ACS 1000 User’s Manual,•WCU Operation and Maintenance Manual,•Signal and Parameter Table,•Main Circuit Breaker Specification and Application Note,•Tripping Loop Application Note,•Power Cable Specification,•Main Transformer Specification,•Motor Specification,•ACS 1000 Service and Maintenance Manual.When third-party equipment is included in the scope of commissioningsee also:•Main circuit breaker manual,•Transformer manual,•Motor manual.1.5. Tools•Toolbox with normal tools like screwdrivers, spanners etc.•Torque spanner 10 - 75 Nm for hexagon head screws M6 to M12•Personal computer with NDPA-02 PCMCIA-card, NDPC-12 opticaltransmitter / receiver, optical fiber cables and DriveWindows orDriveDebug•Multimeter with test wires and clips, for example Fluke 87• 5 kV Megger, for example AVO BM11D•Water pump equipped with hoses and ISO-R½ female connector, forexample Wolfcraft 2200 3000 L/H (PartsOnline code 09811402)ABB Chapter 2 - Precommissioning Check ListChapter 2 - Precommissioning Check List2.1. OfficePreparationsFor an efficient commissioning, make sure that the following items arecompleted before travelling to site:•Copy of field service report•Copy of commissioning report•Copy of converter documentation•Information about the scope of delivery•Information about SW and EPLD updates 1 and 3•Special tuning instructions for converter 1•Information on possible converter upgrades 1•Setting values for motor parameters (equivalent circuit of the motor)•Commissioning program (to be agreed with customer) •Needed tools 2•Suitable megger for insulation test 2•Digital camera•(Spare parts for commissioning)1 Contact MV AC Supportline for information, see chapter 10.6.1Supportline Contact information2 See chapter 1.5 Tools3 Preprogrammed EPLD’s have to be ordered from PartsOnline,delivering of the ordered part can take several days depending on where it has to be deliveredChapter 2 - Precommissioning Check List ABB ofDelivery2.2. ScopeAfter receiving the converter and related equipment, the customer isasked to check all items against the bill of material and for shippingdamages. Missing parts should be reported immediately to the carrier andthe project responsible ABB organization. All claims for damage shouldbe made to the carrier and ABB should be notified.To avoid unnecessary delay of the commissioning, the commissioningengineer must assure himself that the equipment is complete and intact.It is recommended practice to photograph damaged equipment and sendthe photographs to ABB and the carrier.2.3. Pre-Conditions for CommissioningIn order to ensure an uncomplicated and fast commissioning, it isimportant that the converter and associated equipment are ready forcommissioning. Reviewing and completing the items in the below listbefore the commissioning engineer arrives on site will help to achievethis.1. Mechanical Installation of the Converter•Converter is securely fixed to the floor•Customer side raw water piping is completed and the pipesare connected to the converter•Raw water supply is ready2. Electrical Installation of the Converter•All control cables going into the converter are connected,appropriately labelled and the customer side connections arecompleted•Types and cross sections of control cables are suitable forthe signal type and signal level•Types and cross section of power cables are selectedaccording to the “ABB power cable specification”•Ground cable of converter is tightened on both ends•Transformer and motor cables are not fastened at both ends(cables and converter must be meggered before connection)ABB Chapter 2 - Precommissioning Check List3. Main Circuit Breaker (MCB)•The MCB is selected as per “ABB MCB specification”•High voltage power connections are completed•The MCB is ready to be tested with the converter•The MCB protection relay settings are set and tested•Safety devices (door locks etc.) are tested and in operation4. Converter Transformer•Grounding is completed•Transformer auxiliaries (dehydrating breathers, cooling,protection devices) are ready•Safety devices (door looks etc.) are tested and in operation4. Motor•Motor is installed, aligned and alignment protocol is available•Grounding is completed•Motor auxiliaries (bearing lubrication, space heater, coolingetc.) are ready5. Megger Tests•All power cables to converter transformer, between convertertransformer and converter and between converter and motorare meggered and the measured values are within therequired limits•Test report of the megger test is availableIf the test is carried out by the converter commissioningengineer, one additional day per converter-motor combinationneeds to be reserved. After the test, the mains cables can beconnected, except at the converter end. The test must complywith the specification (5 kV / 60 seconds).Chapter 2 - Precommissioning Check List ABB6. Power•Medium voltage is available for start-up of the converter•Low voltage auxiliary power is available for start-up of theconverter7. Miscellaneous•Sufficient number and correct type of spare parts are available•Sufficient quantity of deionised water is available •Air conditioning of drive room is ready for load run of converter•Optional equipment (chiller unit etc.) is readyABB Chapter 3 - Inspection of InstallationChapter 3 - Inspection of InstallationIn order to achieve a trouble-free commissioning, it is mandatory that theinstallation, including third-party equipment, is inspected.The status of the installation is checked and it is verified that converterand related equipment are as specified for the application and have beeninstalled according to the installation instructions and the applicablesafety regulations.Checking the installation is performed with the guidance of theCommissioning Report. Equipment data asked for in the report must beobtained and noted in the corresponding sections of the report.If further information on the equipment is required, the applicabledocumentation of the manufacturers should be consulted.3.1. MCBCheck that the main circuit breaker is installed properly according to thelocal requirements and according to the instructions in the MCBdocumentation. Pay special attention to the following:•Ambient conditions,•MCB power circuit connections,•MCB grounding connections,•MCB auxiliary voltage supply,•Interface cabling between the MCB and the ACS 1000,•Prevention of local control.The local control of the MCB must be inhibited; all external controls tothe MCB must go through the ACS 1000.ACS 1000i: N.A. in case the MCB is installed in the converter.3.2. Transformer (ACS 1000i: N.A.)Check that the transformer is installed properly according to localrequirements and according to the instructions in the transformerdocumentation. Pay special attention to:•Ambient conditions,•Transformer power circuit connections,•All connections must be done with appropriate ends,Chapter 3 - Inspection of Installation ABB•Cables and busbars must have sufficient cross-sections inaccordance with load current,•Sharp bends in high-voltage conductors must be avoided,•Minimum clearances between phase-to-phase and phase-to-earthparts must always be observed (this includes also the distances fromcables to windings),•All connections must be tight and mechanically secure, it isrecommended to use a torque-wrench when tightening bolts forelectrical connections (see Table 3-1),Table 3-1 Recommended tightening torques for different bolt sizesBolt size Tightening torqueNmM6 6 (9)NmM8 15 (22)M10 30 (44)NmNmM12 50 (75)NmM16 120 (190)•Transformer grounding connections,•Make sure that transformer secondary power circuit protective shieldconnections are made according to recommendations (both endsconnected to ground),•The transformer frame must be connected to the protectivegrounding system,•Interface cabling between the transformer and the ACS 1000.Room3.3. ConverterWhen inspecting the converter room, attention must be paid to thefollowing:•Building work must be finished in the converter room.•The converter room must be clean (free of dust) and dry.•Air filters must be in place.•Air conditioning must be available latest when the converter will beoperated continuously.If the condition of the converter room hampers effective commissiong, thecustomer and the responsible ABB project engineer must be informedimmediately.Cleanness of the converter room should be checked several times duringcommissioning.ABB Chapter 3 - Inspection of Installation3.4. ConverterThe inspection includes the mechanical and electrical installation of theconverter. By visually checking the converter, the commissioningengineer obtains an overview of the condition of the converter and canreact in time if corrections have to be made.Useful information on the requirements for the installation site is written inthe User’s Manual of the converter, Chapter 3 - Mechanical Installationand Appendix C – Mechanical Drawings.If the installation of the converter has not been carried out as required orthe condition of the converter hampers effective commissiong, thecustomer and the responsible ABB project engineer must be informedimmediately.When inspecting the converter, the checklist below can be used as aguide. Depending on the configuration of the converter and applicableoptions, there might be less or more check items. Always see suppliedparts list, mechanical and electrical drawings for reference.Check List•Installation and damages of components.•Cable openings should be closed to avoid dust entering into thecabinets.•Foreign parts, dust and moisture must not be present in the convertercabinets.It is very important that there is no dust and moisture inside thecabinets. Dust and moisture weaken the busbar insulation. Dusttends to build up on air-cooling elements, thus impairing cooling.•Converter doors must open and close easily.If the doors cannot be opened and closed properly, the alignment ofthe converter must be checked and corrected.•Floor fixings must be mounted.The mounting holes are indicated in Appendix C- Layout Drawing inthe User’s Manual of the converter.•Cooling water connections must be made.Information on the flange sizes or project specific features are shownin Appendix C- Layout Drawing in the User’s Manual of the converter.•Termination and routing of power cables.All cable connections between converter and transformer andbetween converter and motor are shown in Appendix D – ElectricalDrawings in the User’s Manual of the converter. Project specific cableentries are indicated in Appendix C – Mechanical Drawings in theUser’s Manual of the converter.Chapter 3 - Inspection of Installation ABBIMPORTANT!Power cables must not be connected at the converter before theinsulation resistance of the converter and the motor have beenmeasured.Ground connections must be carried out carefully to prevent that highpotentials will occur in any parts, which can be touched easily.Inspection of ground connections includes the following:•The converter must be connected to the ground system of the factory(system ground).•The shields of all power cables must be connected to the groundbusbar.•The cross section of the cable shields must be in accordance with thePower Cable Specification.3.6. MotorThe motor area must be cleaned so that it is safe to run the motor. Allwaste that can come in contact with the shaft or the cooling air inlets mustbe removed.The motor installation includes the piping of lubrication and water-coolingsystem and the alignment of the motor. An alignment protocol must beavailable on site.The motor frame must be connected to the ground network of the plant.For more details see instructions of the motor manufacturer.ABB Chapter 4 - SafetyChapter 4 - SafetyBefore power is applied to the converter, it must be checked that allcovers are back in place so that voltage-carrying parts cannot be touchedaccidentally. Interlocks, which prevent that medium and high voltage unitscan be accessed accidentally, must be in operation.•Protection covers inside the converter must be refitted.If covers have to be removed for measuring purposes, appropriatesafety signs and temporary barriers must be installed and personnelinvolved in the commissioning must be informed.•Cabinet door locks must be checked.The doors should be kept closed whenever possible. This also helpsto keep the cabinets clean.Door keys should only be given to persons who take part in thecommissioning.•All openings of the motor must be closed and shaft covers must beinstalled.The area around the motor must be cordoned off to preventaccidents during the uncoupled motor tests.•All covers of power cable terminals or terminal boxes in theconverter, motor, transformer and MCB must be closed.•Open transformer and motor cable ends must be tied together andproperly grounded.Chapter 4 - Safety ABBABBChapter 5 - Connecting Auxiliary Supply to the ConverterChapter 5 - Connecting Auxiliary Supply to the ConverterFor the next steps, auxiliary voltage is needed.The auxiliary power supply can be made according to two different concepts in the ACS 1000. • With EPS-board (old concept).•With Phoenix power supply modules (new concept).5.1. EPS Auxiliary Power SupplyWhen the ACS 1000 is equipped with EPS-board(s), it is supplied with one common 3-phase 400, 480 or 575 VAC (other voltages asengineered option) auxiliary supply for the control electronics and the cooling system.Procedure for switching on the auxiliary voltage: 4 Make sure that the protection switches Q1, Q11, Q12, Q13, Q14 and all optional switches are off.5Check the settings of the protection switches Q1, Q11, Q12, Q13 and Q14 (see Table 5-1 and Table 5-2).The settings for all other switches are project specific.Table 5-1 Settings for protection switches (ACS 1000A)Frame sizeA1 A2 / A3Supply Frequency [Hz] 50 Hz 60 Hz 50 Hz 60 HzQ1 (control) 0.94 0.94 0.94 0.94Q11 (fan 1)4.25 4.25 7.30 6.87 400 Q12 (fan 2)4.25 4.25 7.30 6.87 Q1 (control) N.A. 0.78 N.A. 0.78Q11 (fan 1)N.A. 3.54 N.A. 5.73 480 Q12 (fan 2)N.A. 3.54 N.A. 5.73 Q1 (control) N.A. 0.65 N.A. 0.65Q11 (fan 1)N.A. 2.95 N.A. 4.78 AuxiliarySupply Voltage[V]575 Q12 (fan 2) N.A. 2.95 N.A. 4.78Chapter 5 - Connecting Auxiliary Supply to the ConverterABBTable 5-2 Settings for protection switches (ACS 1000W)Frame sizeW1 W2 / W3Supply Frequency [Hz]50 Hz 60 Hz 50 Hz 60 Hz Q1 (control) 1.62 1.62 1.62 1.62 Q11 (pump 1)4.10 4.50 4.10 4.50 Q12 (pump 2)4.10 4.50 4.10 4.50 Q13 (fan 1) 2.61 3.10 2.61 3.10 400 Q14 (fan 2) 2.61 3.10 2.61 3.10 Q1 (control) N.A. 1.35 N.A 1.35 Q11 (pump 1)N.A 4.20 N.A 4.20 Q12 (pump 2)N.A 4.20 N.A 4.20 Q13 (fan 1)N.A 2.59 N.A 2.59 480 Q14 (fan 2) N.A 2.59 N.A 2.59 Q1 (control) N.A 1.12 N.A 1.12 Q11 (pump 1)N.A 3.50 N.A 3.50 Q12 (pump 2)N.A 3.50 N.A 3.50 Q13 (fan 1) N.A 2.16 N.A 2.16 AuxiliarySupply Voltage [V] 575 Q14 (fan 2)N.A 2.16 N.A 2.166 Check that the voltage selection in the 3-phase auxiliary transformer T1 is correct selected for each phase.7Check that the 3-phase auxiliary voltage supplied from customer side is within tolerance and write down the value (can be measured from terminal X10).8 Switch on the auxiliary voltage to the converter control electronics with the circuit breaker Q1.9Check that the 24 VAC auxiliary voltages at the transformer secondary are correct in all three phases.10 Check that the 32 VAC auxiliary voltages at the transformersecondary are correct in all three phases. 11 Check that the output voltage of the EPS-board(s) are ok (27 VDC,27 VAC and +/- 20 VDC). 12 Check that both the yellow and green LED’s on all subprints on bothGUSP-units (Gate Unit power Supply) are on.5.2. Phoenix Auxiliary Power SupplyWhen the ACS 1000 is equipped with Phoenix auxiliary power supplies, the supply can be arranged different ways. The exact configuration can be checked from position 18 in the typecode.A External 3-phase supply and external 1-phase safe line for control.B External 3-phase supply and internal UPS.ABBChapter 5 - Connecting Auxiliary Supply to the ConverterD Internal 3-phase supply and external 1-phase supply (no safe line) forcontrol and internal back-up battery. E Internal 3-phase supply and internal 1-phase supply for control andinternal back-up battery. F Only available for 575 VAC 3-phase supply.IMPORTANT!Configurations A and B are only available for 400 VAC / 480 VAC 3-phase supply.Configurations D and E are only available for ACS 1000i with 60Hz supply network.Procedure for switching on the auxiliary voltage: 1 Make sure that the switch S5001 (in configration E only) is in position 1 (i.e. the external commissioning auxiliary power supply is used). 2 Make sure that the protection switches Q5051, Q5052, Q5073, Q5021, Q5022, Q5023, Q5024 and all optional switches are off. 3 Check the settings of all protection switches (see Table 5-3, Table 5-4, Table 5-5 and Table 5-6).Table 5-3 Settings for protection switches (control hardware supply)1P- Auxiliary SupplyVoltage [V]3P- Auxiliary SupplyVoltage [V]120 230 400 480Q5052 (control) N.A. N.A. 1.6 1.4 Q5073 (aux. trans.)1 0.5 0.3 / 0.85* 0.25 / 0.7**if ACS 1000i with intergrated contactor and configuration BTable 5-4 Settings for protection switches (ACS 1000A)Frame sizeA1 A2 / A3Supply Frequency (Hz)50 Hz 60 Hz 50 Hz 60 Hz Q5021 (fan 1)4.25 4.25 7.30 6.87 400Q5023 (fan 2) 4.25 4.25 7.30 6.87 Q5021 (fan 1)N.A. 3.54 N.A. 5.73 480Q5023 (fan 2) N.A. 3.54 N.A. 5.73 Q5021 (fan 1)N.A. 2.95 N.A. 4.78 Auxiliary SupplyVoltage [V]575Q5023 (fan 2)N.A. 2.95 N.A. 4.78Chapter 5 - Connecting Auxiliary Supply to the ConverterABBTable 5-5 Settings for protection switches (ACS 1000W)Frame sizeW1 W2 / W3Supply Frequency (Hz)50 Hz 60 Hz 50 Hz 60 Hz Q5021 (pump 1) 4.10 4.50 4.10 4.50 Q5023 (pump 2)4.10 4.50 4.10 4.50 Q5022 (fan 1) 2.61 3.10 2.61 3.10 400Q5024 (fan 2) 2.61 3.10 2.61 3.10 Q5021 (pump 1) N.A 4.20 N.A 4.20 Q5023 (pump 2)N.A 4.20 N.A 4.20 Q5022 (fan 1) N.A 2.59 N.A 2.59 480Q5024 (fan 2) N.A 2.59 N.A 2.59 Q5021 (pump 1) N.A 3.50 N.A 3.50 Q5023 (pump 2)N.A 3.50 N.A 3.50 Q5022 (fan 1) N.A 2.16 N.A 2.16 Auxiliary SupplyVoltage [V]575Q5024 (fan 2)N.A 2.16 N.A 2.16Table 5-6 Settings for protection switches (ACS 1000i)Frame sizeA1 A2 / A3Supply Frequency (Hz)50 Hz 60 Hz 50 Hz 60 Hz Q5021 (fan 1) 3.54 3.54 3.54 3.54 Q5022 (fan 2)5.73 5.73 5.73 5.73 Q5023 (fan 3) 3.54 3.54 3.54 3.54 400Q5024 (fan 4) 5.73 5.73 5.73 5.73 Q5021 (fan 1) N.A 3.54 N.A 3.54 Q5022 (fan 2)N.A 3.54 N.A 5.73 Q5023 (fan 3) N.A 3.54 N.A 3.54 Auxiliary SupplyVoltage [V]480Q5024 (fan 4)N.A 3.54 N.A 5.734Check that the one-phase and / or three-phase auxiliary voltage supplied from customer side is within tolerance and write down the value, can be measured from.• Terminals X11:1 and X11:2 in case of external 1-phase auxiliary power supply.• Terminals X11:3 and X11:4 in case of internal 1-phase supply (only applicable in ACS 1000i). •Terminals X10:1, X10:2 and X10:3 in case ofinternal (only applicable in ACS 1000i) or external 3-phase auxiliary power supply.5Check that the settings of the UPS modules are correct (if applicable).• Battery Select: 7.2 Ah •Tmax: 5 minABB Chapter 5 - Connecting Auxiliary Supply to the ConverterIMPORTANT!During commissioning the Battery Select switch on the UPS modulescan be set to “Service”. In the service mode, the UPS module will notkeep the control hardware supplyed from the backup batteries and thusrebooting of the converter is faster.6 Switch on the auxiliary voltage to the control electronics with thecircuit breakers Q5051 and / or Q5052 (see the drive specific wiringdiagrams).7 Check that the output voltages of the power supply modules are ok(27 VDC +/- 0.5 VDC), in case necessary tune the output voltage oneach power supply.8 Switch on the 24 VAC power supply with the circuit breaker Q5073and measure the.9 Check that both the yellow and green LED’s on all subprints onGUSP1 and GUSP2 (Gate Unit power Supply) are on.5.3. Checking Of Auxiliary Backup BatteriesIf it is more than 6 months from the dispatch of the converter from thefactory in Switzerland, check the charging of the auxiliary backupbatteries and check the function of the auxiliary ride-through function. Ifnecessary replace the batteries with new ones.IMPORTANT!Auxiliary batteries are considered to be wear-and-tear-parts and cannotbe replaced as warranty.Chapter 5 - Connecting Auxiliary Supply to the Converter ABBABB Chapter 6 - Commissioning of the Cooling System Chapter 6 - Commissioning of the Cooling System6.1. Water-Cooled ACS 10006.1.1. Checking the Internal and External Cooling CircuitsCAUTION!Do not switch on a cooling pump if the cooling circuit is empty. If a pumpruns dry, the pump seals will be immediately damaged.Check that the installation is made as described in chapter 2 – Installationin the WCU Operation and Maintenance Manual.Check especially:•Connection of raw water hoses / pipes.•Direction of raw water flow.•Requirements for the raw water (temperature, flow, pressure etc.).•Leakage water connection.•For bent hoses and visible damages in the internal cooling circuit.NOTICE!Especially the hoses on the sinus filter choke can easily be bent during the installation, see Figure 6-1).Figure 6-1 Hoses on sine filter chokeChapter 6 - Commissioning of the Cooling System ABB•Cleanness of the strainer Z1.This should be checked again after some days of operation becauseduring the first time of water flow possible loose particles and dirtfrom the water pipes should be flushed out and caught in the strainer.6.1.2. Filling Up the Internal Cooling CircuitFill the internal cooling circuit according to the instructions in chapter 3 –Starting up the Cooling System in the WCU Operation and MaintenanceManual.After filling up the internal cooling circuit, remember to:•Vent (deaerate) the internal cooling pumps.•Check the direction of internal water flow (check the direction ofrotation of the pumps).•Check the direction of rotation of the auxiliary cooling fans.•Check the water level in the expansion vessel.of the Redundant FanTest6.1.3. FunctionalIn case the converter is equipped with redundant cooling fans, check thefunction according to the instruction below.1 Start pump number 1, fan number 1 (standard fan inside cabinet)starts rotating, the air-flaps under the redundant fan should be closedand the air flaps under the internal fan should open.2 Feel the air flow (how strong does the fan blow).3 Switch off the motor circuit breaker of the standard fan, the redundantfan starts rotating, the air flaps under the redundant fan should openand the air flaps under the internal fan should close.4 Feel the air flow of redundant fan, it should blow as strong as fannumber 1.5 In case the air flow is much weaker you have to change the directionof rotation of the redundant fan.ACS 1000 and ACS 1000i6.2. Air-Cooled•Check that the air exhaust box on top of the converter is assembledaccording to the instructions (ACS 1000i: N.A.).•Check that all applicable fans installed on top of the converter areinstalled (only ACS 1000i).•Check that the fan(s) are rotating smoothly and in the right direction.•In case of redundant fans check that the installation of the fan box ismade according to the instructions.。
