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ABB

ACS 1000
Medium Voltage Drives

315 to 5000 kW
400 to 6700 hp

User’s Manual
Water Cooling Unit

Document No.: 3BHS204366 ZAB E02 Rev. A

Issued: 29-06-2005

© ABB Switzerland Ltd. All Rights Reserved.


ABB reserves all rights to this document, also in the event of patent issue
or 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.

3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit


ABB
Table of Contents

Chapter 1 - Safety 1-1

Chapter 2 - Installation 2-1

2.1 Raw Water Connections 2-1


2.1.1 Hose Connection (Standard) 2-1
2.1.2 Hose Connection Side Entry 2-3
2.1.3 Flange Connection (Option 2-3
2.2 Drain Connection 2-4

Chapter 3 - Starting up the Cooling System 3-1

3.1 Checks before Start-up 3-1


3.2 Filling the Cooling System 3-1
3.3 Adding Water to the Cooling System 3-5

Chapter 4 - Draining the Cooling System 4-1

Chapter 5 - Checking Actual Values 5-1

5.1 Water Conductivity 5-1


5.2 Water Pressure 5-1
5.3 Water Temperature 5-2
5.4 Water Level 5-3

Chapter 6 - Tightening Torques, Threaded Connections 6-1

6.1 Tightening Torques 6-1


6.2 Sealing off Threaded Connections without O-rings and
Gaskets 6-1

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

This manual should be read thoroughly and understood before work on


the cooling system is started.
See ACS 1000 User's Manual, Chapter 1- Safety for explanation on how
the safety messages are categorized and used in this manual.

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

2.1 Raw Water Connections

2.1.1 Hose Connection (Standard)


When preparing the piping for the raw water supply, consider the
maximum length (2 m) of the flexible hoses and the specifications of the
raw water interface. See Water Cooling Datasheet in Appendix A - Water
Cooling Unit.

Top entry Bottom entry

Figure 2-1 Raw Water Entries

1 Connect the hoses for the raw water circuit following Figure 2-2 à
Figure 2-6.

Exchange duct plate (top) and


blanking plate when hoses are
Inlet
entered from below
Outlet

Figure 2-2 Duct Plates

ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-1 (6)
Chapter 2 - Installation ABB

Customer side piping

Enter flexible hoses

Figure 2-3 Connecting the Water Hoses

Customer side piping

Connect hoses to raw water


supply using appropriate
flanges (inner diameter of
hoses 32 mm)

Figure 2-4 Connecting the Water Hoses

Customer side piping

Cut hoses to length

Figure 2-5 Connecting the Water Hoses

2-2 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 2 - Installation

Customer side piping

Connect hoses to
inlet

Fasten hoses with supplied


clamps

Figure 2-6 Connecting the Water Hoses

Figure 2-7 Nipple Dimensions

2.1.2 Hose Connection Side Entry


If the hose cannot be entered through the standard openings, a cut-out in
the side wall can be made (not possible if the converter is equipped with
a braking chopper).
The drawing 3BHS127525 shows the cut-out.
If the duct plate (see Figure 2-2) is mounted on the side, an additional
blanking plate (3BHL000641) must be used to cover the standard entry
opening.

2.1.3 Flange Connection (Option


As an option, the converter can be equipped with flanges for raw water
connection through the side (not possible if the converter is equipped with
a braking chopper), back or bottom of the cooling unit. The external water

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.

Upward bend Downward bend

Figure 2-8 Flange Connections

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.

2.2 Drain Connection

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

Figure 2-9 Leaking Water Connection

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)

13 15 R1/2 22 50.5 29.5 12

Figure 2-10 Drain Connector

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.

3.1 Checks before Start-up

Information on the positions of all valves in the operating state can be


obtained from the Flow Diagram:
Flowdiagram for 1 pump and 2 way valve 3-9531-001
Flowdiagram for 2 pumps and 2 way valve 3-9531-002
Flowdiagram for 1 pump and 3 way valve 3-9531-003
Flowdiagram for 2 pumps and 3 way valve 3-9531-004

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.

3.2 Filling the Cooling System

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!

! Inhibitors and other chemicals must not be added to the water.

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!

! Ethylene glycol is a hazard for humans and animals when swallowed.


Avoid skin and eye contact and wear protective clothing including rubber
gloves and goggles when handling ethylene glycol. Food stuffs and
beverages must be kept separate from the place of work.The safety data
sheet supplied by the supplier of ethylene glycol must be followed.

IMPORTANT!

! The conductivity of glycol as it is used in cars is too high.The converter


cannot be started if the conductivity level is too high.Only pure ethylene
glycol which acts only as an anti-freeze and has no inhibitors for corrosion
protection is permitted for the converter.

Table 3-2 Characteristic Values of the Anti-freeze


Parameter Value

Content > 99.8 %


Density at 20 °C (68 °F) 1.1133 - 1.1140 g/cm3
Viscosity at 20 °C (68 °F) 19 mm2/s
Specific heat capacity at 20 °C (68 °F) 2.3 kJ/kgK/l
Thermal conductivity 0.29 W/mK
pH-value neutral

When transferring, mixing and filling the anti-freeze, it must be


guaranteed, that no chips, grease, remnants or any other impurities
infiltrate the coolant.
For storing and mixing only clean containers specifically designated and
appropriately labelled must be used.
In the following table, the values for the desired frost proofing are listed:

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 %

Ideally, the mixing procedure should take place at ambient temperature


(+ 5 °C to + 30 °C).
When mixing the following procedure must be observed:
1 Check that the type of ethylene glycol is appropriate (see Table 3-2).
2 Check that the blue 60 liter plastic container which is part of the
delivery contains approximately the same amount of glycol as
declared on the label (last two digits of the item number correspond
to the amount of glycol in liter; e.g. 3BHL001483P0021 corresponds
to 21 liter).
3 Fill in distilled water until the level in the container is at approx. 3/4.
4 Thoroughly mix the ethylene glycol mixture.

IMPORTANT!

! There will be negative effects on the thermal and hydraulic behaviour of


the coolant if the water-glycol mixture is not mixed thoroughly.

5 Fill the container completely.


Afterwards, thoroughly mix the liquid again!
The required frost proofing has been reached now.
After filling the system (see following section) the remaining liquid can be
used for refills after maintenance or repairs, if stored in a closed container.

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!

! Filling rate <= 15 l/min.

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.

Figure 3-1 Pump with Priming Plug

15 Close the disconnected terminals -X2:22 to -X2:27.


16 Install a temporary jumper.
• Disconnect the connector X21 from IOEC board 1.
• Connect a jumper (cross-section 1 mm2) between
X21-1 and X21-3 of connector X21.
• Plug the connector X21 back into IOEC board 1.
17 Close the motor protection switch -Q11 (-Q5021).
18 Check the level in the expansion vessel. If the level drops below 10%
stop the pump and top up water.
19 Check the system pressure. If the pressure remains below trip level
(2 bar) the rotation of the pump is not correct. In this case, the rotation
of the pump must be reversed by changing two phases on the
terminal -X10.

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!

! The temporary jumper must be removed before the converter resumes


operation.

29 Cooling unit with one pump: close -Q11 (-Q5021).


30 Reset the alarm.
After filling the cooling circuit, the conductivity value might not be in the
permitted range (conductivity alarm level: 0.5 µS/cm, conductivity trip
level: 0.7 µS/cm). If this is the case, an auto-cooling sequence is started.
For more information see Appendix G - Signal and Parameter Table.

3.3 Adding Water to the Cooling System

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!

! When filling cooling water while the converter is in operation, the


conductivity will rise due to the high conductivity of the added water. Using
deionized water is recommended. Fill the water in slowly to avoid a trip.

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.

4 Stop the filling after about 5 l of water have been added.


5 Close valve V14.
6 Open valve V11.
7 After the conductivity is down to 0.4 µS/cm again, repeat steps 3 to 7.
Stop the filling when the water level in the expansion vessel is approx-
imately 80%.
8 Remove the hose.

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.

3 Remove the fastening screws of the swing frame and open it by


pulling strongly.
4 Connect a hose (long enough to reach out of the converter) to the
drain valve located inside the inverter section at the bottom (ISO G
½).
5 Open valve V12.
6 Open the drain valve and drain the inverter.
A pump can be used to speed up the procedure.
7 Open V80 / (V81) to drain the cooling unit.
Approx. water quantity to be expected: 7-8 liters.
8 Close the valves and remove the hoses.
9 Close the converter swing frame and remount the fastening screws.
Up to here, the converter has only been drained for repair purposes. To
drain the converter completely (for storage purposes) contact the ABB
service organization.

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

It is recommended to record the values of conductivity, water temperature


and pressure regularly to determine when water has to be added or the
ion exchange resin renewed.
Actual values can be monitored while the converter is in operation.
Water conductivity and pressure depend on the water temperature. Only
values registered at the same temperature should be compared.

5.1 Water Conductivity

The actual value of the water conductivity (displayed in µS/cm) can be


read on the control panel.
Proceed as follows:

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.

5.2 Water Pressure

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.

5.3 Water Temperature

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

5.4 Water Level

The water level can be checked while the converter is in operation.

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

6.1 Tightening Torques

Table 6-1 Tightening Torque for Flanges

Hexagon Washer Gasket Tightening


DN Nut
Screw (D x d x t) (D x d x t) Torque

1 2 3 4

25 M12-55 M12 24 x 13 x 2 73 x 40 x 1.5 24 - 33 Nm

32 M16-65 M16 30 x 73 x 3 84 x 48 x 1.5 60 - 80 Nm

40 M16-65 M16 30 x 73 x 3 92 x 57 x 1.5 60 - 80 Nm

50 M16-70 M16 30 x 73 x 3 107 x 66 x 1.5 60 - 80 Nm

65 M16-70 M16 30 x 73 x 3 128 x 23 x 1.5 60 - 80 Nm

80 M16-75 M16 30 x 73 x 3 144 x 97 x 1.5 60 - 80 Nm

100 M16-80 M16 30 x 73 x 3 162 x 125 x 1.5 60 - 80 Nm

6.2 Sealing off Threaded Connections without O-rings and Gaskets

A sealant such as Loctite 755 and Loctite 401 activator spray is


recommended to ensure a leak proof joint between stainless steel to
stainless steel connections.
Thread tape is recommended to seal off:
• stainless steel to plastic connections,
• plastic to plastic connections.

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