medium voltage ac drive megadrive-lci air-cooled

8/17/2019 Medium voltage AC drive MEGADRIVE-LCI air-cooled

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User’s manual

Medium voltage AC drive

MEGADRIVE-LCI air-cooled


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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 1 (6)

Table of contents

L is t o f figu res 1

L is t o f tab les 1

Terms, abbrev iat ions, trademarks 1

General in fo rmation on manual and equ ipment 1

Copyright notice 1Document identification 1Contact information 1Equipment covered by the manual 1Structure of the user documentation 2Target groups and required qualifications 3

Relevant chapters of the manual 4User’s responsibilities 4Intended equipment use 5Quality certificates and applicable standards 5

Writing conventions 5Text conventions 5

Important note on inpu t c ircu it b reaker design 1

Safety and protection requirements 2Minimum requirements for ICB and ICB control 2Maintenance recommendation 3

Chap ter 1 - Safety 1-1

1.1 Meaning of safety instructions 1-11.2 General safety information 1-21.3 Possible residual risks 1-21.4 Safety labels and signs 1-41.4.1 Safety labels 1-41.4.2 Safety signs 1-4


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Table of contents ABB

2 (6) 3BHS343596 ZAB E01 Rev. D MEGADRIVE-LCI A User’s manual

Chapter 2 - Hardware and features of the driv e 2-1

2.1 Overview 2-12.2 General modules 2-2

2.2.1 Converter unit 2-22.2.2 Line-side and machine-side connection unit 2-32.2.3 DC link reactor 2-42.2.4 Control unit 2-52.2.5 Air cooling system 2-82.3 Application-specific modules 2-92.3.1 Excitation unit 2-92.3.2 Synchronization unit (SYNCHROTACT 5) 2-102.3.3 Bypass disconnector for output transformer 2-112.4 Other features 2-122.4.1 Door interlock 2-12

2.4.2 Optional heating 2-14

Chapter 3 - Transpo rtation, stor age and dis pos al 3-15

3.1 Transportation 3-153.1.1 Transportation conditions 3-153.1.2 Unpacking and inspection 3-153.1.3 Lifting and transportation 3-153.2 Storage 3-173.2.1 Storage conditions 3-173.2.2 Storage 3-173.3 Storage and handling instructions for spare parts 3-173.4 Disposal of packaging materials and components 3-18

Chapter 4 - Mechanic al installat ion 4-1

4.1 Safety 4-14.2 General notes on installation 4-14.2.1 Ambient operation conditions 4-1

4.2.2 Recommendations for cable ducts and fire protection 4-14.2.3 Dimensions and clearances 4-24.2.4 Foundation requirements 4-24.2.5 Cabinet roof 4-34.2.6 Floor fixings 4-34.2.7 Installing roof-mounted fan units 4-3

Chapter 5 - Electrical ins tallat ion 5-1

5.1 Safety 5-1


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5.2 Overview of installation work 5-15.3 Feeder and motor cables 5-15.3.1 Cable requirements 5-15.3.2 Further information 5-2

5.3.3 Terminal sections 5-25.3.4 Determining the cable length 5-25.3.5 Preparing the cable entry 5-25.3.6 Selecting the cable lugs 5-25.3.7 Bolted busbar connections 5-35.3.8 Checking cable insulation 5-45.3.9 Connecting points for cable screens 5-45.3.10 Final checks 5-45.4 Auxiliary power and control cables 5-45.4.1 Cable requirements 5-45.4.2 Cable connection 5-5

Chapter 6 - Inform at ion on commiss ioning 6-1

6.1 Required qualification 6-16.2 Commissioning procedure 6-16.3 Commissioning check list 6-16.4 Customer assistance 6-16.5 Customer acceptance 6-1

Comm iss ion ing check lis t 1

Mechanical installation 1Electrical installation 1Input circuit breaker (ICB) 1Motor 2Insulation tests 2Power supply 2

Miscellaneous 3

Chapter 7 - Loc al operation 7-1

7.1 Overview 7-17.2 Safety 7-17.3 Overview of control terminal 7-17.4 Starting the drive system locally 7-37.4.1 Checks before starting the drive system 7-37.4.2 Start sequence of the drive 7-47.5 Stop sequences 7-57.5.1 Coasting down sequence 7-5


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7.5.2 Electric braking 7-67.6 Emergency-off pushbutton 7-6

Chapter 8 - Contr ol termin al (LCT) 8-1

8.1 Overview 8-18.1.1 Status bar 8-28.1.2 Panel control key 8-38.1.3 Menu bar 8-38.1.4 Standard keys 8-38.2 Login / Logout 8-48.2.1 User types 8-68.2.2 Passwords 8-68.3 Control terminal menus 8-7

8.3.1 Diagrams 8-78.3.2 Events 8-108.3.3 Operations 8-138.3.4 Parameters 8-178.3.5 Slow Trending 8-268.3.6 Test Programs 8-348.3.7 Transient Recorder 8-358.3.8 Options 8-438.4 Operation bar and reference value input feature 8-478.4.1 Operation bar 8-478.4.2 Reference value input feature 8-498.5 PecUp 8-508.5.1 Software backup 8-508.5.2 Monthly reboot 8-518.5.3 Delayed start 8-518.5.4 Logging 8-518.6 Print screen function 8-518.7 Troubleshooting hardware faults 8-538.7.1 AC 800PEC faults 8-538.7.2 LCT panel faults 8-53

Chapter 9 - Troub leshoo ting and maint enance 9-1

9.1 General information 9-19.1.1 Required qualification 9-19.1.2 Warranty period 9-19.1.3 Training courses 9-19.1.4 DriveMonitorTM 9-19.1.5 Maintenance schedule 9-19.1.6 Logbook 9-29.1.7 Spare parts 9-2


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9.2 Standard troubleshooting procedure 9-29.3 Maintenance 9-39.3.1 Overview on maintenance and service tasks 9-39.3.2 Safety 9-3

9.3.3 De-energizing the drive 9-49.3.4 Visual checks on the drive 9-59.3.5 Cleaning 9-69.3.6 Checking wire and cable connections 9-6

Main tenance schedu le 1

App endix A - Technical data

App endix B - Mechanical drawings

App endix C - Electr ical diagrams

Ap pendix D - Signal and parameter table

App endix E - Spare parts l ist

App endix F - Test reports and cert i f icates

App endix G - Addit ion al manuals and opt ions

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List of f igures

Figure 1-1 Safety labels 1-4Figure 2-1 Typical air-cooled LCI.SO with optional Synchrotact 5 device 2-1

Figure 2-2 Air-cooled thyristor stacks 2-2Figure 2-3 Connection units 2-3Figure 2-4 Air-cooled DC link reactor with iron core 2-4Figure 2-5 Control unit (with optional Synchrotact 5 terminal) 2-5Figure 2-6 AC 800PEC 2-5Figure 2-7 Control system and peripherals (with MV-GDR) 2-6Figure 2-8 Control hardware and principle 2-7Figure 2-9 Air cooling system (converter unit left, DC link reactor right) 2-8Figure 2-10 Air flow diagram (front view on the left, side view on the right) 2-8Figure 2-11 Excitation unit 2-9Figure 2-12 Synchronization unit (SYNCHROTACT 5) 2-10Figure 2-13 Bypass disconnector 2-11Figure 2-14 Location of locks by key type 2-12Figure 2-15 Location of door safety switches 2-13Figure 2-16 Heating element 2-14Figure 2-17 Typical location of heating elements 2-14Figure 3-1 Lifting lug 3-16Figure 4-1 Incline and unevenness of the floor 4-2Figure 4-2 Protection plate 4-3Figure 4-3 Fan tag 4-3Figure 4-4 Self-tapping screws 4-4

Figure 4-5 Grille screws and bolts 4-4Figure 4-6 Air guide plate 4-5Figure 4-7 Terminal box connections 4-5Figure 4-8 Installed fan unit 4-6Figure 5-1 Connection with spring and flat washers 5-3Figure 7-1 Control terminal 7-2Figure 8-1 Start menu 8-1Figure 8-2 Status bar 8-2Figure 8-3 Login window 8-4Figure 8-4 Diagrams menu 8-7Figure 8-5 Events menu 8-10

Figure 8-6 Operations menu 8-13Figure 8-7 Parameters menu 8-17Figure 8-8 Slow Trending menu 8-26Figure 8-9 Browse Items window 8-27Figure 8-10 Signal list 8-28Figure 8-11 Trend view of selected signals 8-29Figure 8-12 Log Browser window 8-31Figure 8-13 Loaded recordings 8-32Figure 8-14 Transient Recorder menu 8-35Figure 8-15 tTransient Recorder Browser window 8-37


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2

Figure 8-16 Select Recorder File window 8-37Figure 8-17 Log Browser window 8-38Figure 8-18 Configure Recorder window 8-41Figure 8-19 Select File window 8-41

Figure 8-20 Chart Export Settings window 8-42Figure 8-21 Options menu 8-43Figure 8-22 Export settings window 8-45Figure 8-23 Standard operation keys 8-48Figure 8-24 Reference value input 8-49Figure 9-1 Four-way grounding set 9-4Figure 9-2 Connecting a grounding set 9-5


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List o f tables

Table 2-1 Excitation unit availability by drive type 2-10Table 2-2 Key types 2-12

Table 5-1 Control cable requirements 5-4Table 8-1 Signals on the status bar 8-2Table 8-2 User types and their rights 8-6Table 8-3 Default passwords for different user types 8-6Table 8-4 Display configuration parameters 8-16Table 8-5 Installed recorders 8-40Table 8-6 User types and their rights in the Options menu 8-43


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Terms, abb reviat ions, trademarks

Terms and abb reviat ions

The following table lists terms and abbreviations you should be familiar with when using the manual.

Some of the terms and abbreviations used in the manual are unique to ABB and might differ from the

normal usage.

Term / Abbrev iat ion Mean ing

Converter Short form for frequency converter

DTL operation Direct-to-line operation

The motor is connected to the fixed frequency power supply.

Drive Short form for frequency converter

Drive system The drive system includes all equipment used to convert electrical into mechanical power

to give motion to the machine.

Equipment Frequency converter and related equipment

EMC Electromagnetic compatibility

All 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.

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.

ICB Input circuit breaker

The ICB is a major protection device of the drive system. The circuit breaker connects /

disconnects the main power supply to the drive.

LCT LCI Control Terminal

Local drive control device incorporating a touchscreen and a panel PC.

Line voltage RMS voltage of the main power supply of the drive

PE Protective earth


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Trademarks

Names 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 offense

of the legal status of any trademark. The following registrations and trademarks are used in this

manual:

Trademark

Windows XP® Registered trademark of Microsoft ® Corporation

MATLAB® / Simulink® Registered trademark of The MathworksTM

Real-Time Workshop® Registered trademark of The MathworksTM

IBM® 750 FX Registered trademark of IBM ®

Molycote® D Paste Registered trademark of Molycote®

Microsoft Excel® Registered trademark of Microsoft ®

Scotch BriteTM Trademark of 3M


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General informat ion on manual and equipment

Copyr ight not ice

The 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.

The hardware and software described in this manual is provided under a

license and may be used, copied, or disclosed only in accordance with the

terms of such license.

Document ident i f icat ion

Ownership ABB Switzerland Ltd

Medium Voltage Drives

Document number 3BHS343596 ZAB E01

Revision index D

Issue date 26.03.2013

Contact informat ion

Address ABB Switzerland Ltd

Medium Voltage Drives

CH-5300 Turgi, Switzerland

Phone +41 844 845 845

Fax +41 58 589 2984

Email [email protected]

Equipment covered by the manual

This manual covers standard equipment and provides generic information

on the equipment. The manual does not claim to cover all variations and

details of the equipment, nor to consider all eventualities that may arise

during installation, commissioning, operation and maintenance of the

equipment.

If the equipment is adapted to specific customer needs or applications,

and handling, installation and operation of the equipment are affected by

these modifications, information on these modifications is provided in the

appropriate documentation (e.g. layout drawings, wiring diagrams,

technical data, engineering notes).


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If information is required beyond the instructions in this manual refer the

matter to ABB.

Structure of th e user docum entat ion

The complete set of user documentation of a standard drive consists of

this manual and supplementary documentation that is provided in the

following appendices:

• Appendix A - Technical data

The appendix contains information on the Rating plate and the

Design data of the drive.

• Appendix B - Mechanical drawings

The appendix provides the following drawings:

• The Outline drawing provides information on the dimensions and

weight of the drive, floor fixing, degree of protection and cabinet

section identification.

• The Connection plan provides information on the dimensions of

the drive, the location of cable entries and busbar details.

• Transport suspension drawing provides information to observed

when lifting the drive.

• Appendix C - Electrical diagrams

• The Converter hardware diagram contains the circuit diagrams

with information on device designation, cross-reference and

device-identification conventions.• The Interface diagram provides information on grounding princi-

ples and cable and wire termination.

• The Flow chart describes the main operating states the drive

passes through when it is put into operation, stopped or a fault

condition occurs.

• Document Utility consumption data states the power consump-

tion of the auxiliaries of the drive and provides information on the

required amount of cooling air (air-cooled drives), or raw water

flow (water-cooled drives).

• Appendix D - Signal and parameter table

The appendix provides information on parameters and their settings

of the control devices present in the drive (e.g. AC 800PEC controller,

serial interface, synchronizing and excitation unit etc.).

• AC 800PEC Parameter l ist

• DCS 800 Signal and parameter table (present if drive is

equipped with an excitation unit)

• List of signals (present if drive is equipped with a serial commu-

nication interface)

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• Synchrotact signal and parameter table (present if drive is

equipped with a synchronizing unit)

• Component modification list provides information on the soft-

ware and control hardware versions of the drive.

• Appendix E - Spare parts list

The parts list is produced for each project and contains all information

to identify a component.

• Appendix F - Test reports and certificates

The appendix provides:

• Test reports of the drive and related equipment

• Quality certificates, and codes and standards the drive complies

with

• Appendix G - Additional manuals and optionsThe appendix includes information on optional equipment of the drive

(e.g. synchronizing unit, excitation unit etc.)

Target gro up s and requ ired qual i f icat ions

The equipment presented in this manual is part of an industrial environ-

ment 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 qualification should handle, install, operate, or main-

tain the equipment.The manual addresses personnel who are responsible for unpacking,

transportation, installation, operation and maintenance of the equipment.

The personnel must carry out the below listed tasks in a manner that does

not cause physical harm or danger, and to ensure the safe and reliable

functioning of the equipment.

Note: Commissioning of drive equipment must only be performed by ABB

personnel who are certified to commission the MEGADRIVE-LCI.

Handling Personnel must be skilled and experienced in unpacking and transporting

heavy equipment.

Mechanical installation Personnel must be qualified to prepare the installation site according to

the site and equipment requirements and to perform the installation

accordingly.

Electrical installation Personnel must have a sound knowledge of the relevant electrical codes

and specifications covering low and medium voltage equipment, and be

experienced with electrical wiring principles and know the electrical

symbols typically used in wiring diagrams.

Operation Personnel include all persons who operate the equipment as required for

the specified application. Personnel must know the driven process and be

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In tended equipment u se

Those in charge of the equipment must ensure that the equipment is only

used as specified in the contractual documents, operated under the

conditions stipulated in the technical specifications and on the rating plate

of the equipment, and serviced in the intervals as specified by ABB.

Use of the equipment outside the scope of the specifications is not

permitted.

Intended equipment use also implies that only spare parts recommended

and approved by ABB must be used.

Unauthorized modifications and constructional changes of the equipment

are not permitted.

Quali ty cert i f icates and appl icable standards

The following certificates and conformity declarations are available with ABB:

• ISO 9001 / ISO 14001 certificates stating that ABB Switzerland Ltd

has implemented and maintains a management system that fulfills

the requirements of the normative standards

• EC Conformity Declaration

• List of the standards the drive complies with

Writ ing con vent ions

The info sign refers to further information in a separate document.

Text conv ent ions

• 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 or 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


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Impor tant note on input ci rcu i t breaker design

The input circuit breaker (ICB) is a major protection device of the drive. If

a serious fault occurs in the drive, the ICB must disconnect the main power

supply to the drive immediately. The main power supply must be

disconnected without delay on an open or trip command from the drive to

prevent hazard to the personnel and further damage to the equipment.

Depending on the main power supply configuration of the drive system,

the ICB is either located on the primary side of the converter transformer

or on the primary side of the drive if the drive is connected directly to the

line (DTL).

Figure 1 Drive system overview

Figure 1 shows the conceptual single-line diagram of a typical drive

system, including main power supply, ICB, converter transformer, drive

and electrical motor.

M

CT

ICB control interface

Higher-level control system

Local ICB control

Main power supply

ICB

Protectionrelay

Converter transformer

Drive

Motor


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The ICB is defined as a switching device to disconnect the power supply

whenever required by the process or when a fault occurs. Typical devices

used as MCBs are:

• Vacuum circuit breakers

• SF6 circuit breakers

• Fused contactors or motor control centers

A dedicated protection relay is used for:

• Transformer or converter primary cable protection (DTL)

• Transformer protection (if applicable)

• Transformer secondary cable protection (if applicable)

• Backing up the drive protection

In general, these protective measures are not included in the drive as

provided by ABB.

Safety and pro tect ion requirements

For safety and protection reasons, the ICB must meet the stipulated

minimum requirements of the specifications of ABB MV Drives. It is the

system integrator's responsibility to ensure that the minimum require-

ments are met. The minimum requirements for the ICB are stated in this

note and in the respective ICB specifications, which are available for each

medium voltage drive from ABB.

The safety requirements for the drive are based on the following

standards:

• ISO 13849-1 Safety of machinery - Safety-related parts of control

systems - Part 1: General principles for design, section 6.2.6

Category 3

• IEC 60204-1 Safety of machinery - Electrical equipment of machines

- Part 1: General requirements

Minimum requirements for ICB and ICB contro l

• The ICB open and / or trip command has to be wired directly from the

drive to the ICB. It is not permitted to wire the trip command throughany PLC or DCS system if it is not certified to meet SIL 3 level

requirements and to fulfill the timing requirements outlined below.

• The maximum opening time of the ICB shall never exceed the

product or project-specific maximum time defined in the ICB

specifications. Typical maximum values for the drive are defined as

follows:

• Maximum protection trip time: not applicable

The maximum protection trip time is the maximum allowed

breaking time (open and arcing) of the breaking device after the


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open command has been initiated to prevent further damage to

the drive, e.g. diode failures.

• Maximum safety trip time: 500 ms

The maximum safety trip time is the maximum allowed time to

ensure safe disconnection of the main power supply to preventany hazard to personnel.

Figure 2 ICB opening timing diagram

In order to meet the stipulated safety requirements, it is recommended

that:

• the ICB is equipped with two independent opening coils, or

• the ICB is equipped with one opening coil and an undervoltage coil

for monitoring of the control voltage, or

• an upstream protection coordination scheme is provided which usesthe "breaker failure" (ANSI 50BF) signal to automatically trip the

upstream breaker, in case the ICB does not open. The upstream

breaker must open within the maximum safety trip time after a failure

has occurred.

Maintenance recommendat ion

The ICB trip circuits should be checked once yearly.

Short-circuit occurs

Open and or trip command is set at thedrive control output

No further damage to drive No hazard to personnel

Max. protection trip time

Max. safety trip time


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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 1-1 (6)

Chapter 1 - Safety

1.1 Mean in g o f safety ins tru ct io ns

Safety instructions are used to highlight a potential hazard when working

on the equipment. Safety instructions must be strictly followed! Non-

compliance can jeopardize 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.

NOTICE NOTICE 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 colors 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


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1-2 (6) 3BHS343596 ZAB E01 Rev. D MEGADRIVE-LCI A User’s manual

1.2 General safety in fo rm ation

To maintain safety and minimize hazards observe the following:

• Before the drive is energized, make sure that:

• all foreign objects are removed from the drive,

• all internal and external covers are securely fastened and all

doors are closed, locked and / or bolted.

• Before starting to work on the drive, make sure that:

• the main and auxiliary power supply to the drive is switched off,

locked out, and tagged out,

• the drive is dead,

• safety ground connections are in place,

• appropriate personal protective equipment is provided and used

when required,

• everyone involved is informed.

• When working near the running drive protective earmuffs should be

worn.

• Before work is carried out simultaneously on the drive and on other

drive system equipment, make sure that

• the relevant safety codes and standards are observed,

• all energy sources of the equipment are turned off,• lockout and tagout devices are in place,

• barriers and appropriate covers are used on equipment which is

still live,

• everyone involved is informed.

• In case of fire in the drive room:

• Observe the established rules and regulations for fire protection.

• Only firemen with appropriate protective equipment are allowed

to enter the drive room.

1.3 Poss ib le res idual r isks

The following risks can arise from a drive system and pose a hazard to

people. These risks must therefore be taken into account by the system

integrator and / or the plant owner when assessing the risks of the

machinery.

• Electric power equipment generates electro-magnetic fields which

can cause a hazard to people with metal implants and / or a

pacemaker.


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• Drive system components can move unintentionally when being

commissioned, operated, or serviced due to, for example:

• Operation of the equipment outside the scope of the specifica-

tions

• Incorrectly assembled or installed equipment

• Wrongly connected cables

• External influence on, or damage of the equipment

• Wrong parameter settings

• Software errors

• Faulty hardware

• Hazardous touch voltages can be present on drive system

components caused by, for example:

• Operation of the equipment outside the scope of the specifica-tions


• Induced voltages by external equipment

• Condensation on equipment components, or pollution

• Faulty hardware

• High temperatures, noise, particles, or gases can be emitted from

drive system components caused by, for example:

• Operation of the equipment outside the scope of the specifica-

tions


• Wrong parameter settings

• Software errors

• Faulty hardware

• Hazardous substances can be emitted from drive system

components due to, for example:

• Incorrect disposal of components


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1.4 Safety labels and s igns

1.4.1 Safety labels

Safety labels are attached to the cabinet where necessary to alertpersonnel of potential hazards when working on the equipment. The

instructions on the safety labels must always be followed, and the labels

must be kept in a perfectly legible condition.

Figure 1-1 Safety labels

1.4.2 Safety signs

Depending on the delivery, the following additional safety signs are

provided:

Fire fighting The sign explains the procedure when fighting fire in electrical equipment.

The sign should be installed well visible near the drive.


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Pacemaker The magnetic field of the drive can influence the functioning of

pacemakers. The sign should be installed at the entrance to the drive

room or at a minimum distance of 6 meters (20 ft.) from the drive to stop

personnel with pacemakers approaching the drive.

High voltage The sign should be installed clearly visible at the main circuit breaker in

the switchgear room. The sign alerts personnel to the high voltage which

can be present on the secondary side of the input transformer until the

main circuit breaker has been opened and secured and the drive has been

deenergized and grounded.

Dimensions: 50 x 30 cm

Diameter: 32 cm

Dimensions: 20 x 10 cm


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Chapter 2 - Hardware and features o f the driv e

2.1 Overv iew

The MEGADRIVE-LCI is a variable speed drive for continuous operation

(LCI.DR) and soft starting (LCI.SO) of synchronous machines as well as

for starting gas turbines (LCI.ST).

Figure 2-1 Typical air-cooled LCI.SO with optional Synchrotact 5 device

Because the drive is engineered according to different configurations and

in different sizes depending on its field of application, the following

sections provide a general overview of:

• general modules

• converter unit

• line-side and machine-side connection unit

• DC link reactor

• control unit

• air cooling system

• application-specific modules

• excitation unit

• bypass disconnector for output transformer

• other features

• door interlock

• optional heating

Legend

1 DC link reactor

2 Line-side

connection unit

3 Converter unit

4 Machine-side

connection unit

5 Control unit

2 1 3 4 5


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Chapter 2 - Hardware and features of the drive ABB


’ See Appendix B - Mechanical drawings and Appendix C - Electrical

diagrams or the Rating plate on the drive or in Appendix A - Technical data

for more information on your drive and applicable and voltage.

2.2 General modules Regardless of the field of application and configuration, each air-cooled

drive includes at least one of the following modules:

• converter unit (i.e. rectifier and inverter)

• line-side and machine-side connection unit

• DC link reactor (air-cooled)

• control unit

• air cooling system

2.2.1 Converter un it

A converter unit of a MEGADRIVE-LCI consists of a rectifier and an

inverter.

Rectifier/inverter Both the rectifier and the inverter use thyristor stacks of identical design

and comprise apart from the thyristors also heat sinks, snubber circuits

and gate firing circuits.

The rectifier converts the alternating supply current to direct current. The

inverter then converts the direct current into a three-phase alternating

current that modulates into variable frequency and voltage depending on

the process requirements.

Figure 2-2 Air-cooled thyristor stacks

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2.2.2 L ine-s ide and machi ne-s ide connec ti on un it

The standard connection unit (one installed for each 3-phase system)

consists of the following main components:

Main components • power cable connection points from the transformer or to the machinerespectively (busbars)

• gland plate (cable entry)

• required measuring and protection equipment (current and voltage

transformers, surge arrestors)

• control interface (LIN)

Figure 2-3 Connection units


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2.2.3 DC link reacto r

The DC link reactor interconnects the rectifier and inverter and smooths

the rectified current.

With air-cooled drives, the DC link reactor is always integrated with the

converter unit, either beside or in between the rectifier and inverter, and

has an iron core.

Figure 2-4 Air-cooled DC link reactor with iron core


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2.2.4 Contro l un it

The control unit comprises the hardware for drive control, monitoring and

protection as well as a control terminal, customer connection interfaces

and interface units.

The control unit consists of the following main components:

Main components • AC 800PEC control and protection system

• MEGADRIVE-LCI Control Terminal (LCT)

• customer connection interfaces

• power supply units for 24Vdc and 48 Vdc

• low voltage distribution

Figure 2-5 Control unit (with optional Synchrotact 5 terminal)

2.2.4.1 A C 800PEC

The control unit of the MEGADRIVE-LCI uses ABB’s high-end process

control system AC 800PEC. It is a modular high-speed control system,with modules arranged according to the required I/O configuration and

process.

Figure 2-6 AC 800PEC


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2.2.4.2 Perip her als

The following peripherals connect to the AC 800PEC (6 in Figure 2-7 ):

1 MEGADRIVE-LCI Control Terminal (LCT)

2 LCI interfaces (LIN)3 gate firing circuits (GDI or MV-GDR) connected via LIN

4 S800 input/ouput system (S800)

5 combined input/output unit (CIO)

Figure 2-7 Control system and peripherals (with MV-GDR)

LCT The LCT bases on Windows and is used to:

• display actual values, status messages and fault messages

• reset fault messages

• display and set parameters

• operate the drive locally

• test the drive

See Chapter 7 - Local operation and Chapter 8 - Control terminal (LCT)

for more information on local operation and the MEGADRIVE-LCI Control

Terminal (LCT).

1 2 3

4 5 6


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LIN Each LIN controls a 6-pulse thyristor bridge and fires the thyristors

according to the magnetic or indirect light firing principle. It connects to the

AC 800PEC via fast fiber optics and provides analog inputs for converter

voltages and currents as well as digital contact inputs.

Gate firing circuits Depending on the numbers of thyristors per branch, different firingprinciples apply.

• If your drive has one thyristor per branch (ns=1), it follows the

magnetic firing principle and uses a gate driver interface (GDI) and

pulse transformers for gate firing.

• If your drive has more than one thyristor per branch (ns=2-8), it

follows the indirect light firing principle and uses an MV gate driver

(MV-GDR) for gate firing.

S800 The S800 provides an interface for processing slow analog and digital

signals.

CIO The CIO provides an interface for processing fast analog and digital

signals.

Figure 2-8 Control hardware and principle


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2.2.5 A ir coo ling system

In order to dissipate heat losses the MEGADRIVE-LCI uses fans for air

cooling. The specially designed fans maintain the equipment within safe

operating temperatures and ensure optimal operation.

Main components The air cooling system consists of the following components:

• air inlets in doors

• filter mats for air inlets (optional)

• fans

Figure 2-9 Air cooling system (converter unit left, DC link reactor right)

2.2.5.1 Co olin g c ir cu it

Fans integrated with the compartments of the converter units and the DC

link reactor draw the air in through the front doors, force it through the

thyristor stacks and DC link reactor and blow it out through the air gratings

in the roof.

Figure 2-10 Air flow diagram (front view on the left, side view on the right)

1

2

Legend

1 Fans

2 Air inlets (optional

filter mats inside)


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2.3 Appl ic atio n-s pec if ic modu les

If your drive is used for speed/torque control (LCI.DR) or soft starting

(LCI.SO), it may also include the following modules:

• excitation unit• bypass disconnector for the output transformer (used in LCI.SO only)

• synchronization unit (used in LCI.SO only)

See Appendix B - Mechanical drawings or Appendix C - Electrical

diagrams for more information on your drive configuration.

2.3.1 Excitat ion un it

An excitation unit is delivered as part of the drive when a synchronous

machine has to be supplied with excitation power.

All components of the excitation unit are located in a separate

compartment and controlled via the control unit.

Figure 2-11 Excitation unit

LCI.DR type drives always have a built-in excitation. LCI.SO and LCI.ST

type drives may or may not have one, depending on whether the machine

package has its own exciter for direct-on-line operation.

Two types of excitation units are available:

• AC excitation unit (ac-EXU) with an AC controller for synchronous

machines with brushless exciter

• DC excitation unit (dc-EXU) with a DC controller for synchronous

machines with slip rings

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2.3.2 Synch ron izat io n un it (SYNCHROTACT 5)

The synchronization unit is only required for soft starting (LCI.SO) and is

mounted in the control unit compartment. It automatically synchronizes

and parallelizes machines with power lines.

All paralleling parameters are stored in parameter sets that define the

paralleling conditions as well as the voltage and frequency matchercharacteristics.

See the corresponding appendix for more information on

SYNCHROTACT 5 (if applicable)..

Figure 2-12 Synchronization unit (SYNCHROTACT 5)

Table 2-1 Excitation unit availability by drive type

Type Standard Op t ion

LCI.DR ac-EXU dc-EXU, with crowbar

LCI.SO n.a. dc-EXU

LCI.ST n.a. dc-EXU


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2.3.3 Bypass d is connec to r f or ou tpu t t rans fo rmer

The bypass disconnector is only required for soft starting (LCI.SO) and

only if an output transformer is in use.

It allows bypassing the output transformer to run up the machine in thelower speed range (approximately 10% to 15% of nominal speed). Once

the machine reaches a predefined speed, the disconnector switches to

transformer position and the drive accelerates the machine to nominal

speed.

Figure 2-13 Bypass disconnector


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2.4 Other featu res

2.4.1 Door in ter lock

To ensure safety and prevent the doors from opening unintentionally, alldoors are lockable.

2.4.1.1 L oc ks an d k ey ty pes

To ensure that only authorized personnel is able to open medium voltage

compartments, their locks use different inserts than the locks of the control

and excitation unit compartments.

The following key types are in use.

Figure 2-14 Location of locks by key type

Table 2-2 Key types

Key type Compartment

1 Square box wrench Control unit

Excitation unit (if applicable)

2 Double bit key Converter unit

DC link reactor

Line-side connection unit

Machine-side connection unit

2 2 2 2 1


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2.4.1.2 Doo r s af et y sw it ch es

In addition to the locks, door safety switches are mounted in the door

frames of some compartments. They ensure that the drive is deenergized

whenever one of those doors opens while the drive is in operation. This

protects personnel from electric shock..

Figure 2-15 Location of door safety switches


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2.4.2 Opt ional heating

The optional heating system protects electrical components of the drive

from condensation. The heating system consists of heating elements with

humidistats and thermostats.

The humidistats and thermostats monitor the humidity and the

temperature inside the modules. The heating system activates as soon as

the temperature falls below and the humidity climbs above their

predefined thresholds.

Figure 2-16 Heating element

The heating elements are typically mounted above the compartment floor

plates of the control unit, connection units, DC link reactor and the

excitation unit.

See Appendix C - Electrical diagrams for more information on the location

of heating elements in your drive (if applicable).

Figure 2-17 Typical location of heating elements

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Chapter 3 - Transpo rtat ion, storage and disp osal

3.1 Transpor tat ion

3.1.1 Tr an sp ortatio n c on dit io ns

The transport conditions for the drive are based on IEC 60721-3-2

'Classification of environmental conditions: Classification of groups of

environmental parameters and their severities; Transportation'.

Classification: 2K1 / 2B1 / 2C1 / 2S2 / 2M1

3.1.2 Un pac kin g an d in sp ec tio n

To protect the drive, remove the transportation packaging only if

necessary.

Proceed as follows:

1 Remove all packaging material carefully.

2 Check the drive and accompanying equipment for damage.

3 Compare the complete delivery with the purchase order and the

packing list.

4 If parts are missing or damaged, immediately inform the shipping

company and the ABB service organization.

It is recommended to photograph the damages and send the photo-graphs to ABB.

5 After the drive has been unpacked, check regularly that the storage

conditions specified for the drive are complied with. See section 3.2.1

Storage conditions for information.

3.1.3 L if t in g an d tran sp ortat io n

It is recommended to have the following information at hand before

transporting the drive:

• Outline drawing in Appendix B - Mechanical drawings provides

information on dimensions of the drive.

• Transport suspension drawing in Appendix B - Mechanical drawings

provides details on the weight, dimensions and transportation of the

drive.

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Chapter 3 - Transportation, storage and disposal ABB


NOTICE The drive or parts of the drive could be damaged while moving and/or

unpacking the drive.

Observe the following points when transporting the drive.

• Do not lift and move the drive or a transport unit using a forklift. The

frame of the cabinet could be damaged.

• Drive components can be damaged during transportation. Therefore,

the drive must be transported in an upright position.

• When transporting the drive, ensure that no dirt enters. Keep doors

closed. Metallic dust in particular may cause damage and lead to

malfunction when the drive is powered up.

• Material and diameter of the lifting cables must correspond to theweight of the drive.

• When lifting the drive use the lifting lugs which are attached to the

base frame (see Figure 3-1). It is recommended to remove the lugs

after the drive has been installed at its final location to prevent people

stumbling.

Figure 3-1 Lifting lug

• Do not pass a cable or sling through the fastening hole of a lug.

Use a safety hook or a shackle to attach a cable or a sling to a lug.

• Connect a cable or sling to each lug.

• Observe the center of gravity.

• It is recommended to use lift frames or lift spreaders with the crane.If lift frames or lift spreaders are not available, see that the cables or

slings are approximately at an angle as indicated on the Transport

suspension drawing in Appendix B - Mechanical drawings to ensure

a balanced lift.

• Protect the roof edges of the cabinet using appropriate means.

• Lift the drive slowly and steadily to the required clearance height

maintaining the drive in upright position.

• Check the horizontal position of the drive. Reposition the cables if

necessary.

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ABB Chapter 3 - Transportation, storage and disposal


3.2 Storage

3.2.1 Storage cond it ions

The minimum requirements for storage are based on IEC 60721-3-1'Classification of environmental conditions: Classification of groups of

environmental parameters and their severities; Storage'.

Classification: 1K2* / 1B1 / 1C1 / 1S1 / 1M3

* maximum storage temperature: 55 °C

The drive can be stored for up to 1 year in the original packaging as long

as it is not damaged or opened. Contact the ABB service organization for

information on longer storage periods.

3.2.2 Storage

If the drive is taken out of service for a longer time, proceed as follows to

prepare the drive for storage:

1 Cover all cable inlets and ventilation slots with an impermeable plastic

or aluminum foil and a wooden panel.

2 Add the desiccant of the appropriate quality:

• 1 unit desiccant (30g) absorbs 6 g water vapor.

The following quantity is needed when using a polyethylene foil:

• 10 units/sqm foil

3 Close and lock the doors of the drive.4 Use polyethylene or equivalent for packaging:

• 0.3 g/sqm/24 h water vapor diffusion

5 Attach humidity indicators to the packaging.

The storage conditions and the packaging should be checked regularly.

Any damages which occur during the storage period should be repaired

immediately.

3.3 St orage and handl in g in str uc tio ns fo r s pare part s

NOTICE Static electricity can damage printed circuit boards.

Apply static-sensitive precautions when handling these components.

Inspect the spare parts immediately after receipt for damages. Report any

damage to the shipping company and the ABB service organization.

Observe the following to maintain spare parts in good condition and to

keep the warranty valid during the warranty period:


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Chapter 3 - Transportation, storage and disposal ABB


• Keep spare parts in their original packaging.

• Store printed circuit boards in antistatic bags or boxes.

• Keep the storage temperature range at: -5 °C to + 55 °C (23 °F to

131 °F)

• Maintain the storage place as follows:

• Free of vibration and shock

• Protected against dust, sand, vermin and insects

• Free of corrosive gases, salt or other impurities that could

damage electronic equipment

• Dry, no condensation

Relative air humidity: 5 to 85%

If in doubt whether the maximum allowed humidity is exceeded,

protect spare parts by an external heater.

• Do not touch a component without wearing a wrist grounding

strap.

• Put the component on a grounded working surface protected

against electrostatic discharges.

• Hold the component only at the edge.

3.4 Dis po sal o f pac kag in g mater ials and componen ts

Dispose of the packaging materials and components at the end of the life

time of the drive according to local regulations.


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ABB


Chapter 4 - Mechanical ins tal lat ion

4.1 Safety

All installation work must be carried out by qualified personnel according

to the site and equipment requirements and in compliance with local

regulations.

4.2 Gen eral n otes o n in stallat io n

NOTICE When working on the drive ensure that foreign matter cannot enter the

cabinet. Close the doors and cover openings completely when work is

discontinued. Any foreign matter which accidentally dropped into the

cabinet must be retrieved. Metallic dust in particular could cause malfunc-

tion and damage when the drive is energized.

4.2.1 Amb ien t o per atio n co nd it io ns

Ambient factors such as temperature, relative humidity, air contamination,

shock and vibration must be in compliance with the stated maximum

permissible levels.

Contact the ABB service organization if the condition of the installation site

is not within the specifications or if the transportation or the installation

require special measures.

• Maximum ambient temperature: see Rating label of drive

• Operation with respect to climatic and environmental conditions is

based on IEC 60721-3

Classification: 3K3 / 3B1 / 3C1R / 3S1 / 3M1

4.2.2 Recommendat ions fo r cab le duc ts and f ire p ro tec t ion

Cable ducts should be of non-flammable material with non-abrasive

surface.

All cable entries and exits should be protected to prevent dust, humidity

and animals from entering into the drive.

Suitable fire protection measures should be applied to prevent fire from

spreading into the drive.


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Chapter 4 - Mechanical installation ABB


4.2.3 Dimen sio ns an d c lear an ces

See Outline drawing in Appendix B - Mechanical drawings for information

on the overall dimensions of the drive, clearances to be observed, and

information on dimensions and mounting hole sizes.

4.2.4 Fo un dat io n req uir emen ts

The floor must be of non-flammable material, with smooth and non-

abrasive surface, protected against humidity diffusion, leveled and able to

support the weight of the drive.

The maximum recommended allowable overall unevenness is 1mm

(0.04 in).

The overall incline of the floor must not exceed +/-0.5% of the length of the

drive.

If the mounting surface is uneven or the incline is too steep, thecompartment doors become misaligned and do not open or close properly

and strain is put on the water pipe connections.

Figure 4-1 Incline and unevenness of the floor

It is recommended to check the evenness and incline of the mounting

surface well in advance so that work to improve the surface is completed

before the installation of the drive. When checking the floor surface, a spirit

level or flooring rule with a vial can be used for example. The tool shouldbe of sufficient length (1 to 2 m [5 to 6.5 ft.]).

If the floor surface cannot be improved, shims or leveling plates must be

placed under the base frame at appropriate points to adjust the position of

the transport units to the above stated requirement regarding the

maximum displacement of the transport units.

Leveling plates of the following size are recommended 10 x 10 mm (0.4 x

0.4 in).

Depending on the unevenness and incline of the floor, the leveling plates

should be placed at appropriate distances to prevent that the base frame

0.5 mm

0.5 mm

Length of the drive

Legend:

Tolerance from mean ground: +/- 1 mm

Surface / floor

Tolerance for incline: +/- 0.5%



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ABB Chapter 4 - Mechanical installation


bends under the weight of the drive (i.e. every 1 m [3.2 ft.]). They should

be placed at least in the corners of the shipping split.

4.2.5 Cab inet roo f

The cabinet roof is not designed as a mounting base for foreign devices,cable ducts etc. Therefore, it is not permitted to install any foreign device

on the roof.

4.2.6 Floor fix ings

The base frame provides holes for fixing the drive to the floor. Floor fixings

are not supplied. Screws and nuts of size M16 (3/4") are recommended.

See Outline drawing in Appendix B - Mechanical drawings for information

on the location and the size of the fixing holes in the base frame.

4.2.7 In st all in g ro of-moun ted fan uni ts

To install fan units on top of the MEGADRIVE-LCI, proceed as follows:

1 Remove the protection plate from the corresponding compartment.

Figure 4-2 Protection plate

2 If applicable, remove the grille from the fan unit.

3 Position the fan unit according to the fan tag number.

Figure 4-3 Fan tag

Protection plate on Protection plate off



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4 Attach the fan unit to the compartment with self-tapping M6 screws on

the front and rear side.

Figure 4-4 Self-tapping screws

5 Attach the grille to the fan unit with the centering bolt (A) and the fixing

screws (B).

Figure 4-5 Grille screws and bolts


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ABB Chapter 4 - Mechanical installation


6 Mount the air guide plate.

Figure 4-6 Air guide plate

7 Remove the cover from the terminal box and connect the cables to

the corresponding terminals.

Figure 4-7 Terminal box connections


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8 Reattach the cover of the terminal box.

Figure 4-8 Installed fan unit


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ABB


Chap ter 5 - Electr ical ins tal lat ion

5.1 Safety

WARNINGHazardous voltage!

Improper work could lead to life-threatening injury or death.

The electrical installation must be carried out by qualified personnel

according to the site and equipment requirements, and the relevant

electrical codes.

When the electrical installation is completed, the main and auxiliary power

supply to the drive must not be switched on without the consent of the ABBcommissioning personnel.

Take appropriate measures to prevent main and auxiliary power supply

being switched on during installation.

5.2 Overv iew of in stallat io n wo rk

The electrical installation includes the following wire and cable

connections:

• Feeder and motor cables, ground cable

See section 5.3 Feeder and motor cables.

• Auxiliary power and control cables

See section 5.4 Auxiliary power and control cables.

5.3 Feeder and moto r cab les

5.3.1 Cable req uirem en ts

Cables See the Cable specification for information on suitable power cables

(incoming feeder cables, motor cables) or contact ABB.

Ground cable It is important that the drive is properly grounded to maintain safety and to

ensure smooth functioning of the equipment.

See Interface diagram in Appendix C - Electrical diagrams for information

on grounding principles and cable cross-section



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Chapter 5 - Electrical installation ABB


5.3.2 Furth er in fo rm at ion

See Converter hardware diagram in Appendix C - Electrical diagrams for

information on designation, cross-reference and device-identification

conventions.

5.3.3 Term inal sec tions

The feeder and motor cables are connected to the busbars inside their

corresponding cabinet sections.

See Connection plan in Appendix B - Mechanical drawings for information

on location of terminal sections

5.3.4 Det ermi ni ng t he cab le len gt h

NOTICE If possible, do not cut cables inside the terminal compartment. Make sure

that waste from cable cutting and stripping cannot enter the cabinet. Any

waste which accidentally dropped into the cabinet must be retrieved. The

waste could cause damage or malfunction.

Enter the cables into the terminal compartment to measure the conductor

length.

Mark the required conductor length, withdraw the cable and cut it to the

correct length.


on distances between point of cable entry and termination bars

5.3.5 Pr ep ar in g th e c ab le en try

The cabinet is furnished with undrilled aluminum plates with a thickness of

approx. 3 mm (approx. 0.2 in) to customize the cable entry.

All material for cable entry, EMC requirements and IP protection are to be

provided by the customer.

The cable transits must be made according to local regulations.

5.3.6 Selec tin g th e c ab le lu gs

Cables must be terminated with lugs according to the specification of the

cable manufacturer.

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ABB Chapter 5 - Electrical installation


5.3.7 B olted b us bar c on nec tio ns

NOTICE

High voltages will be present in the terminal compartment. High voltagescan cause flashover between the electric potential of different phase

conductors, and the electric potential of a phase conductor and earth.

Therefore, a minimum clearance of 55 mm must be maintained between

phase conductor and the terminals of any other phase conductor, and

between a phase conductor and earth.


on terminal hole sizes

Material requirements Use stainless steel bolts and nuts with the appropriate steel grade andproperty class for the connection (recommended: A2-70 [designation

according to ISO 3506]). Nuts with bonded coating can be used as an

alternative to uncoated stainless steel nuts.

Connection type The following connection type is recommended when connecting a cable

lug (3) to a busbar:

Spring washer (1) and flat washer (2) on each side of the busbar (4).

Figure 5-1 Connection with spring and flat washers

Other washers may be used, provided they are capable of maintaining therequired contact pressure.

Lubrication If stainless steel bolts and nuts are used, lubricate the thread and head

contact surface of the bolt using recommended pasts, e.g. Molykote D

paste.

Note: If a coated nut (e.g. with bonded molybdenum-disulfide [MoS2]

coating) is used, the connection does not have to be lubricated.

Tightening torque Tighten bolted connections with bolts of sizes M10 and greater with the

recommended nominal torque for the bolt size used.

1 4 132 2



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5.3.8 Ch ec kin g c ab le in su latio n

Check the insulation of each cable before connecting it and verify that the

results are within the specification of the cable manufacturer.

Note the measured values in the corresponding test report.

Leave the cable conductors unconnected at both ends until the

commissioning engineer has given his permission.

5.3.9 Connec tin g po in ts fo r cab le s cr een s

See Block diagram in Appendix C - Electrical diagrams for information on

termination principles

5.3.10 Fin al check s

Check that the entry plates are properly fastened.If rubber grommets are used, check that they fit tightly to prevent water

entering the cabinet. If necessary, seal the gaps with silicone rubber.

5.4 A ux il iary power and co ntro l cab les

5.4.1 Cab le requ irem en ts

Auxiliary power cable When dimensioning the auxiliary power cable(s), see

• Utility consumption list for information on auxiliary power loads,

consumption and voltage level.

Control cables Control cables should be provided in accordance with Table 5-1. Either

single or multiple-twisted pair cables may be used.

Control cables should not be laid in parallel to the power cables. If this

cannot be avoided, a minimum distance of 30 cm (12 in) must be

maintained between control and power cables. Control and power cables

should be crossed at an angle of 90°.

Table 5-1 Control cable requirements

Signal type General cab le type Cross-sect ion

Analog in Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to 12

Analog out Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to 12

Digital in Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to 12

Digital out Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to 12

Speed

encoder

Twisted pair cable with separately

shielded pairs and overall shield

0.5 mm2 / 4 x (2+1)



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ABB Chapter 5 - Electrical installation


5.4.2 Cab le connection

Connect the auxiliary power and the control cables to their corresponding

terminals inside the control section of the drive.

See Connection plan in Appendix B - Mechanical drawings for informationon:

• Location of the control section

• Project-specific cable entry

See Interface diagram in Appendix C - Electrical diagrams for information

on:

• Terminal allocation

• Terminal types and sizes

• Maximum conductor cross-section



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ABB


Chapter 6 - Inform ation on comm issioning

6.1 Requ ired qual if icat ion

Commissioning, parameter adjustments and functional tests are to be

carried out only by qualified commissioning personnel certified by ABB.

6.2 Commiss ion ing procedu re

Information on the commissioning procedure and the start conditions for

commissioning can be obtained from ABB.

6.3 Commiss ion ing check l is t

In order to ensure uncomplicated and speedy commissioning, it isimportant that drive and associated equipment are ready for

commissioning. Reviewing and completing the items in the

Commissioning check list before the commissioning personnel arrive on

site will help to achieve this.

6.4 Customer ass is tance

During the commissioning period, the customer is requested to provide

qualified personnel for assistance, who are

• experienced with medium and low voltage equipment and with the

local safety regulations,• familiar with the driven process,

• authorized to operate associated medium and low voltage equipment

(input circuit breaker, other low and medium voltage switchgear etc.),

• authorized to operate the driven process for functional tests.

6.5 Customer accep tance

When commissioning has been completed, the commissioning report is

signed by the responsible commissioning personnel and by the customer

as a sign of acceptance. A copy of the report and a copy of the actualparameter settings are handed out to the customer.


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Chapter 6 - Information on commissioning ABB



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ABB


Comm iss ion ing check l is t

Mechanical instal lat ion

Electr ical in stal lat ion

Input c ircuit breaker (ICB)

1 Drive installed according to the instructions in the User’s manual

2 Drive securely fastened to the floor (if applicable)

3 All outside covers fastened

4 Visual inspection:- no badly affixed or damaged components

- no foreign objects inside cabinet

- no dirt, dust and humidity inside cabinet

1 Types and cross sections of control cables suitable for the signal type and signal level

2 Types and cross sections of power cables selected according to the Power cable speci-fication

3 Cable entries completed

4 All control cable screens and conductors connected, appropriately labeled, and the

customer-side connections completed.

5 Ground cable(s) securely connected at both ends

6 Input transformer and motor cables not connected at both ends (cables and drive must

be meggered before connection)

1 High voltage connections completed


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Commissioning check list ABB


Motor

Insulat ion tests

Power supply

2 ICB ready to be tested with drive

3 ICB protection relay settings tested

4 Safety devices (door locks etc.) tested and in operation

1 Motor installed, aligned and alignment protocol available

2 Motor not coupled to driven load

3 Ground connection completed

4 Motor auxiliaries (bearing lubrication, heater cooling etc.) ready

1 All power cables to input transformer, between input transformer and drive, and from

drive to motor are meggered, and measured values are within the required limits.

2 Test report of the megger test available

Note: If the test is carried out by the commissioning engineer of the drive, an additional

day per drive motor combination needs to be reserved. After the test, the feeder cables

can be connected, except at the drive end. The test must comply with the specification.

1 Medium voltage available for start-up of drive

2 Low voltage auxiliary power available for start-up of drive


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ABB Commissioning check list


Miscel laneous

1 Sufficient number and correct type of spare parts available

2 Air conditioning of drive room ready for load run of drive

3 Optional equipment ready

4 Information boards, safety signs, protection covers attached


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ABB


Chapter 7 - Local operat ion

7.1 Overv iew

The chapter outlines the local operation using the control terminal on the

compartment door of the control unit.

Control of the drive via a PLC or higher-level control systems is not

described in this chapter. If the drive is controlled from remote, see the

appropriate manuals for information.

7.2 Safety

The drive system must only be operated by qualified and authorized

personnel, i.e. personnel who are familiar with the operation of the drive

system and the hazards involved.

7.3 Overv iew o f contro l term inal

The control terminal enables the operator to control the drive without

restrictions provided that all requirements for normal operation are met.

The functions of the control terminal include:

• Switching on / off the auxiliaries

• Connecting / disconnecting the main power supply

This is an optional feature. See Interface diagram in Appendix C -

Electrical diagrams if the drive has this feature.

• Setting the reference value

• Starting, stopping the drive system

• Displaying:

• Actual values

• Status messages

• Alarm and fault messages

• Viewing, setting parameters

• Resetting alarm and fault messages

• Activating the emergency-off circuit

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Chapter 7 - Local operation ABB


Figure 7-1 Control terminal

Legend

1 Control terminal

Main functions:

Starts and stops the motor

Displays status, alarm and fault messages of the drive

Resets alarm and fault messages

2 Emergency-off pushbutton

Prevents starting when pressed at standstill of the drive

Input circuit breaker opens immediately when pressed during

operation of the drive

See Flow chart in Appendix C - Electrical diagrams for information on the

operating sequences on starting and stopping

1 2



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ABB Chapter 7 - Local operation


7.4 Start in g th e d rive sys tem lo cally

It is recommended to have the following documents at hand when starting

the drive system locally for the first time after commissioning or after it has

been taken out of service for a longer period:• Converter hardware diagram and Interface diagram in Appendix C -

Electrical diagrams to identify the circuit breakers to be switched on

• Flow chart in Appendix C - Electrical diagrams for information on the

main operating states the drive passes through when it is put into

operation, stopped or a fault condition occurs

• Chapter 8 - Control terminal (LCT) for information on functions and

features of the control terminal

7.4.1 Checks bef ore s tar ti ng the d r ive syst em

When the drive system is put into service after it has been commissioned

or after it has been taken out of service for a longer period, check the drive

according to the following list:

• Check that no tools and foreign objects are left inside the drive.

• Check that:

• all internal circuit breakers of the drive are closed.

• all auxiliary power supplies from external sources are switched

on.

• Check that all covers are mounted and the doors are closed and

locked.

DANGERHazardous voltage!

All covers must be screwed in place to prevent unintentional contact with

energized components.

• Check that the drive is ready for operation.

Check that no alarm or fault messages are displayed on the statusbar of the control terminal.

When a fault message is displayed, reset the fault. If a fault cannot be

reset, it must be rectified by the responsible personnel.

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7.4.2 Start seq uen ce o f th e d riv e

Note: All drive-related messages mentioned in this section are displayed

on the status bar of the control terminal (see section 8.1.1 Status bar for

further information).

The softkeys illustrated below are shown on the operation bar of the

control terminal (see section 8.4 Operation bar and reference value input

feature for further information).

The following message is shown on the status bar when the drive is ready

for operation:

AUX READY (Auxiliaries are ready)

The auxiliaries of the drive can now be switched on.

1 Touch the softkey AUX ON (auxiliaries on) to switch on the auxiliaries.

After the auxiliaries have been switched on, the following messageappears on the status bar of the control panel:

MV READY (Medium voltage is ready)

The input circuit breaker of the drive can now be closed.

2 Touch the softkey MV ON (medium voltage on) to close the input

circuit breaker.



After the input circuit breaker has been switched on, the followingmessage appears on the status bar of the control panel:

OPERATION READY

The drive can now be started.

3 Touch the softkey OP ON (operation on) to start the drive.

After the drive has been started, the following message appears on

the status bar of the control panel:

OPERATION ON

The firing pulses for the line-side and motor-side converter and theexcitation unit (if present) are released, and the motor accelerates to

the preset reference value.



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7.5 Stop sequences

Note: All drive-related messages mentioned in this section are displayed

on the status bar of the control terminal (see section 8.1.1 Status bar for

further information).

The softkeys illustrated below are shown on the operation bar of the

control terminal (see section 8.4 Operation bar and reference value input

feature further information).

The drive can be stopped in two ways:

• Coasting down

• Electric braking

7.5.1 Co as ting down s eq uenc e

1 Touch the softkey OP OFF (operation off) to coast down the motor.

The softkey switches off the firing pulses of the line-side and motor-

side converter and the excitation unit (if present).

The following message appears on the status bar of the control panel:

OPERATION OFF

The input circuit breaker of the drive can now be opened.

2 Touch the softkey MV OFF (medium voltage off) to open the input

circuit breaker



After the input circuit breaker has opened, the following message

appears on the status bar of the control panel:

MV READY (Medium voltage ready)

The auxiliaries of the drive can now be switched off.

3 Touch the softkey AUX OFF (auxiliaries off) to switch off the auxilia-

ries.

After the auxiliaries have been switched on, the following messageappears on the status bar of the control panel:

AUX OFF (Auxiliaries off)



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7.5.2 Electr ic brak ing

Electric braking is an optional feature that allows reversing the energy flow

back into the supply network. When electric braking is used, the motor-

side converter operates as rectifier and the line-side converter as inverter.

Electric braking takes place down to a speed of 1% of the rated speed.

When this threshold has been reached, the drive switches off automati-

cally.

The drive can be stopped manually by touching the softkey OP OFF. The

stop sequence is the same as described in section 7.5.1 Coasting down

seq

medium voltage ac drive megadrive-lci air-cooled

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