UM00 ACS6000PrevMaintenance 3BHS214896 E01 RevA

ACS 6000Medium Voltage Drives

3 to 27 MVA

Preventive Maintenance Manual

ABB

Document No.: 3BHS214896 ZAB E01 Rev. A

Issued: 26-01-2007

© 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.

3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance

ABB

Table of Contents

General Information

Contact InformationRelated DocumentationTools and Personal Equipment

Chapter 1 - Safety 1-1

1.1 Intended Audience and Required Qualifications 1-11.2 Safety Instructions 1-11.3 Safety Labels and Signs 1-2

Chapter 2 - Inspection and Maintenance 2-1

2.1 Visual Checks of Converter 2-12.2 Cleaning 2-22.3 Verification of Software and EPLD Versions,

Fault Logger and Parameters 2-22.4 Inspection of Bolted Connections 2-32.5 Current-Carrying Connections 2-32.6 Pipe Joints 2-32.7 Roof Attachments 2-42.8 Electric Plugs 2-42.9 Inspection of Fiber Optic Cables 2-52.9.1 Visual Checks 2-52.9.2 Fiber Optic Links to be Tested 2-52.10 Testing Auxiliary Fans 2-102.11 Cleaning and Testing Roof Fan Units 2-132.12 Door Filter Mats 2-162.13 Inspection of Capacitors 2-182.13.1 DC Link Capacitors 2-182.14 Insulation Test 2-192.15 Board Replacement 2-202.16 Water Cooling Unit 2-20

Chapter 3 - Test Run 3-1

ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 1 (2)

ABB

Chapter 4 - Spare Parts, Documentation and Software 4-1

4.1 Spare Parts and Documentation 4-14.2 Documentation and Back-up Copies for Supportline 4-14.3 DriveMonitor 4-1

2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance

ABB

General Information

If information is required beyond the instructions in this manual, ABB can be contacted as follows:ABB Switzerland Ltd Medium Voltage DrivesCH-5300 Turgi, Switzerland

The following documents can be optained from ABB for supplementary information.

Contact Information

Phone: +41 844 845 845

Fax: +41 58 589 2984

E-mail [email protected]

Related Documentation

Title Document Number

Power Cable Specification 3BHS125090

Main Circuit Breaker Specification 3BHS125149

LSU Main Transformer Specification 3BHS125150

ARU Main Transformer Specification 3BHS125092

Voltage Transformer Requirement Specification 3BHS125393

Asynchronous Motor Specification 3BHS125088

Synchronous Motor Specification 3BHS125093

Tool Sets for Installation, Commissioning and Maintenance

3BHS130246

Emergency Off/Stop Modes and Prevention of Operation

3BHS196243

Alarms and Faults Troubleshooting Guide 3BHS204855

ACS 6000 Service and Maintenance Manual 3BHS202077

ACS 6000 User’s Manual 3BHS212794

ACS 6000 Commissioning Manual 3BHS135824

ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 1 (2)

ABB

The toolbox provided by ABB contains all necessary tools and equipment for installation, commissioning and maintenance of the converter. The content of the tool sets is described in detail in document Tool Sets for Installation, Commissioning and Troubleshooting, document no. 3BHS130246:In addition to the toolbox, the following items are recommended for preventive maintenance:

• Multimeter with test wires and clips, for example Fluke 87

• 5 kV Megger, for example AVO BM11D

• Fiber-optic cable tester, such as

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

Tempo 557B Power Meter (set to 660nm, dBm), 10ZP Adapter

• Photom 205A – Optical Power Meter, Haktronics Co., Ltd

• LEONI Optical Power Meter

LEONI Optical Sender ZXXX-TS0

Fiber Optic GmbH, 96524 Neuhaus-Schierschnitz, ZXXX-TM0

• Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical transmitter / receiver, optical cables and DriveWindows or DriveDebug

• Antistatic vacuum cleaner (for example SV-497 ABF - VACUUM 3M 220V from 3M) for cleaning of printed circuit boards

• Antistatic brush for cleaning of printed circuit boards

• Cloths and brushes for general cleaning

• Safety glasses and dust respirator

Tools and Personal Equipment

2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance

ABB

Chapter 1 - Safety

The preventive maintenance manual addresses service and maintenance personnel who are responsible for the maintenance of the converter. The personnel must be qualified, certified and fully acquainted with medium voltage equipment.

This manual contains all scheduled maintenance and replacement actions that must be carried out according to the maintenance schedule, on time, and in the described sequence.

Safety instructions are used to highlight a potentially dangerous situation when working on the converter. Safety instructions must be strictly followed! Non-compliance can jeopardise the safety of personnel, the machine and the environment.

DANGER!

Indicates an imminent hazardous situation. If not observed, it will lead to death or life-threatening injury.

WARNING!

Indicates a potentially dangerous situation. If not observed, it could result in death or life-threatening injury.

CAUTION!

Indicates a potentially dangerous situation. If not observed, it could lead to minor or moderate injury or property damage.

NOTICE!

Indicates important information related to personal safety and protection of property.

IMPORTANT!

Emphazises hints and highlights information.

1.1 Intended Audience and Required Qualifications

1.2 Safety Instructions

!

!

ACS 6000 Preventive Maintenance 3BHS214896 ZAB E01 Rev. A 1-1 (2)

Chapter 1 - Safety ABB

Safety labels are attached to the converter enclosure to alert personnel of potential hazards when working on the converter. The safety labels must always be followed and kept in perfectly legible condition.

1.3 Safety Labels and Signs

1-2 (2) 3BHS214896 ZAB E01 Rev. A ACS 6000 Preventive Maintenance

ABB

Chapter 2 - Inspection and Maintenance

IMPORTANT!

Before starting with maintenance, make sure that:

• The main supply voltage cannot be switched on during work.

Rack out the MCB, lock it in open position and tag it.

• The main supply and the converter are grounded.

• All auxiliary voltages connected to the converter are switched off and cannot be switched on during work (see electrical wiring diagrams for additional voltage supplies).

Lock the switch(es) in open position and attach a safety tag.

Using a multimeter, check that the voltage at the supply terminals is 0 V.

It is strongly recommended to carry out all maintenance work according to the maintenance schedule at the end of this manual and the applicable service instructions, on time and at the stated intervals.It is recommended to have the Inspection and Maintenance Report at hand and to fill it in as you go along with the inspection and maintenance of the converter.

Check visually the converter and the ambience. Pay attention to the following:

• Dumpness, water drops, puddles inside the converter.

• Permitted range of ambient air temperature and humidity of the converter.

A digital temperature/hygrometer is provided in the tool box for verification.

The air temperature range is specified on the name plate of the converter.

• Dust built-up inside the converter room and inside the converter.

• Appropriate fastening of cables and wires and connection of cable shields and screens.

See Converter User’s Manual, Chapter Electrical Information for information.

• Integrity of cable insulation.

!

2.1 Visual Checks of Converter


Chapter 2 - Inspection and Maintenance ABB

The outer jacket of a cable must not be damaged.

• Correct type of signal and power cables.

See applicable cable specifications for reference.

• Signs for overheated components, wires, cables or busbars.

• Corrossion on electronic boards, connectors or busbars.

• Leaks in the water cooling system.

When cleaning inside the converter cabinets observe the following:

• The converter contains components which are sensitive to electrostatic discharge. Therefore, electrostatic-sensitive precautions must be applied and suitable tools must be used when cleaning boards and assemblies which are sensitive to electrostatic discharge.

Boards should be cleaned with special care using antistatic brushes and a vacuum cleaner.

• Only use a vaccum cleaner with a soft nozzle.

• Dust inside the cabinets (assemblies, busbars etc.) can be removed with a vacuum cleaner and lint-free cleaning cloths.

• Water, oily or greasy deposits on assemblies, components, busbars etc. should be removed with water- and oil-absorbing microfibers such as “3M Scotch Brite”.

• Use a nylon brush or a vacuum cleaner to remove dust or deposits from holes.

• Do not use alcohol or solvents when cleaning inside the cabinets.

• Cover equipment to prevent dirt from falling into it.

• The outside of the converter enclosure can be cleaned using a vacuum cleaner and cleaning cloths.

• Check if it is necessary to update the software or EPLD version. See ACS 6000 Software Compatibility List for information.

If necessary, upgrade the EPLD to the recommended version.

• Save the content of the fault logger and clear the fault logger afterwards.

• Save the parameters including parameter groups above 100 in txt or dwp file formats.

2.2 Cleaning

2.3 Verification of Software and EPLD Versions, Fault Logger and Parameters


ABB Chapter 2 - Inspection and Maintenance

Note, that with DriveDebug all parameters can be saved in one file but with DriveWindows the parameters must be saved in two different files. One file includes parameter groups 112 and 190 and the other file includes all parameter groups above 100.

• If the old parameter file of the drive is available, compare it with the current parameter settings using the compare function in DriveWindows or DriveDebug and save the result of the comparison in txt file format.

• Save the software in bpg or tar file format.

2.5 Current-Carrying ConnectionsThe inspection includes the following connections:

• Terminals of mains and motor cables.

• Busbar fastening bolts on the back of the converter.

• DC busbar joints

• Ground busbar joints

RecommendedProcedure

Make spot checks first. If several of the bolted connections are not tightened properly, carry out or a more extensive check to be able to decide whether all connections have to be checked.

2.6 Pipe JointsCheck that all pipe joints are correctly installed and orientated. Refer to the Converter User’s Manual, Chapter 3 Mechanical Installation for reference.

Figure 2-1 Pipe Joint

2.4 Inspection of Bolted Connections

Torque rate



2.7 Roof AttachmentsCheck that the roof attachments are installed according to the Converter User’s Manual, Chapter 3 Mechanical Installation.

Figure 2-2 Roof Attachment

Figure 2-3 Roof Joining Pieces

2.8 Electric PlugsCheck that the power leads are properly connected and the coupling rings tightened.

Figure 2-4 Electric Connections of Roof Fan Units



2.9.1 Visual ChecksCheck visually the condition of the fiber-optic cables. Note especially the following:

• Cracks in core or coating of a fiber

• Minimum bend radius (25 mm)

• Condition of connectors (both male & female)

• Installation across sharp edges

• Tightening of cable ties

Cable ties must not deform the fiber-optic cable

2.9.2 Fiber Optic Links to be TestedVia the following fiber optic links a continuous signal is transmitted if no fault is present and no signal is sent if a fault has occured. These fiber optic links can therefore be tested without unplugging the cable at the transmitter, after the auxiliary voltage has been switched on and no fault is present. The fiber optic cable is only disconnected at the receiver and the attenuation of the link is measured with an optical power meter. If the attentuation is not within the limit, the cable and the sender must be checked separately.

Depending on the used type of fiber optic cable the measured attenuation should be not be higher but preferably be below the following limit values:

Plastic fiber optic: -16 dBm

Hard clad silica fiber: -20 dBm

OEI Board (-A2951) inCOU 1

The OEI board is used to open the main circuit breaker if a fault condition occurs which requires the main power supply to be disconnected from the converter. The OEI board receives the command to open the main circuit breaker through a fiber-optic link from the master INT board.

To verify the attenuation of the fiber, disconnect the fiber optic cable from the RX connector of the OEI board (see arrow in Figure 2-5) and measure the light using an optical power meter.

2.9 Inspection of Fiber Optic Cables



Figure 2-5 OEI Board

The OEI board is illustrated in the wiring diagram of COU 1. The INT board can be found in the wiring diagrams of INU 1.

INT Board (-A3121) inARU

The fiber optic cables at the following connectors of the INT board are disconnected and checked one after the other (see Figure 2-6 to identify the connectors):

• Connector A205, A206, 207

The fiber optic cable transmits fault signals from the GUSP.

• Connector 208

The fiber optic cable transmits a hardware based overcurrent signal from the CVMI board.

INT board, GUSP and CVMI board are illustrated in the wiring diagram of the INU.

INT Board (-A4121) inINU

The fiber optic cables at the following connectors of the INT board are disconnected and checked one after the other (see Figure 2-6 to identify the connectors):

• Connector A205, A206, 207

The fiber optic cable transmits fault signals from the GUSP.

• Connector 208

The fiber optic cable transmits a hardware based overcurrent signal from the CVMI board.

• Connector A817 and A818

The fiber optic cables transmit diode monitoring signals from LSU 1 and LSU 2. The cables are not present in all converters.

AMC board -A2401AMC board -A1401

OEI board -A2951



Figure 2-6 INT Board

Fiber Optic Cables The following fiber optic cables must be tested with the cables unplugged at both ends:

• Fiber optic cable between AMC board -A2401 in COU 1 (see Figure 2-8 connectors A719, A720) and cluster modem -A5201 in WCU.

The fiber optic cable is connected to the cluster modem -A2501 in COU 1 (see Figure 2-7).

• Fiber optic cable between AMC board -A2401 in COU 1 (see Figure 2-8 connectors A715, A716) and CCB board -A6081 in the EXU (see Figure 2-9 connectors A801, A802). This cable is only present in converters driving synchronous motors.

A817A818

A205A206A207

A208A203



Figure 2-7 COU 1

Figure 2-8 AMC Board

Cluster modem -A2501

AMC board -A2401 is behindAMC board -A1401

A72

0A

719

A71

6A

715



Figure 2-9 EXU Control Swing Frame

The attenuation of the cables is verified using a light source which feeds a signal with a defined wavelength (660 nm) into the cable and measuring the attenuation with a power meter at the other end. The measured values should not exceed the limit values as stated in Table 3-1.

Refer to the following wiring diagrams for identification of the boards and the fiber optic cables:

• Wiring diagrams of COU 1 for AMC board -A2401 and cluster modem -A2501

• Wiring diagrams of WCU for cluster modem -A5201

• Wiring diagrams of EXU for CCB board -A6081)

CCB board

A801A802



Location of Fans Two types of fan units are used.

• Four-fan units (see Figure 2-10) are always installed on the back of the cabinet doors of a COU, EXU and WCU. (These units are not used in drives which were manufactured before the beginning of year 2004.)

Figure 2-10 Door-mounted Fan

• Single fan units (see Figure 2-11) are only installed if the converter is equipped with roof fan units. The fans are mounted on the back of the hinged cover in the top section of ARU and INU cabinets.

Figure 2-11 Fan on Printed Circuit Board

Location ofThermostats

The fans are controlled by thermostats. A thermostat can control a single fan or a group of fan units. To identy the thermostat and the fans connected to it, refer to the wiring diagrams of the above mentioned cabinets in Appendix D - Electrical Diagrams of the User’s Manual.

2.10 Testing Auxiliary Fans

Fan



The thermostats for fans installed in COUs, ARUs and INUs are located on the control swing frame of a COU. See Figure 2-12.

Figure 2-12 Fan Thermostat in COU

The thermostat for the fan unit in an EXU is installed in the EXU cabinet. See Figure 2-13.

Figure 2-13 Fan Thermostat in EXU

The thermostat controlling the fans in a WCU is installed on the control swing frame inside the WCU.

Test Procedure

Thermostat

Thermostat



CAUTION!

To test the fans in ARU or INU, the converter must be de-energized and grounded in order to open the cabinet doors. The fans in COU, EXU and WCU can be tested while the converter is in operation.

1 De-energize the drive system according to the Operating Instructions of the User’s Manual.

2 Check that the 24 VDC power supply for the fans to be tested is available.

3 Note the setting of the thermostat.

4 To switch on a fan or a group of fans, adjust the setting of the thermostat to a low value (see arrow in Figure 2-14).

Figure 2-14 Fan Thermostat

5 Check that the fans run smoothly.

In case a fan is defect, replace the complete fan unit.

6 Turn the setting of the thermostat back to its original value.

7 When finished, restart the drive system according to the Operating Instructions of the User’s Manual.

!



Figure 2-15 Roof Fan Units

DANGER!

DC busbars, carrying dangerous voltages, are installed underneath the fan units.

Therefore, the fan units may only be checked and cleaned after the converter has been de-energized and grounded.

Cleaning Proceed as follows:


2 Remove the four cover screws and the cover (see Figure 2-16).

CAUTION!

When working on the fan units make sure that small parts cannot fall into the cabinets. Any part which accidentally dropped into a cabinet must be retrieved immediately. Otherwise, damage or injury may occur.

3 Clean the deflectors of the fan unit (see Figure 2-16).

Use compressed air to remove dry dust.

Wash off grease and oil residues with lye (max. 75 °C).

Dry thoroughly before re-assembly.

2.11 Cleaning and Testing Roof Fan Units

!



Figure 2-16 Cleaning the Fan Unit

4 Remount the cover and fasten the screws.

5 When finished, restart the drive system according to the Operating Instructions of the User’s Manual.

Testing The fans are controlled by thermostats. For testing the fans, the doors of the cabinets (ARU, LSU, INU, CBU) must be opened in order to access the thermostats (see Figure 2-17). Since these doors are linked to the integral door locking system, they can only be opened after the converter has been de-energized and grounded.

Provided that the power supply of the fans is available, the fans can be switched on by turning the dial of the thermostat to a low value.

Figure 2-17 Location of Thermostats

Cover

ThermostatARU / INU CBU



To identify the thermostat, refer also to the wiring diagrams of the above mentioned cabinets in Appendix D - Electrical Diagrams of the User’s Manual.

Proceed as follows:


2 Check that the 230 VAC power supply for the fans to be tested is switched on.

3 Note the setting of the thermostat.

4 To start the fan, adjust the setting of the thermostat to a low value. See arrow in Figure 2-18.

Figure 2-18 Adjusting the Fan Thermostat

5 Check that the fans run smoothly.

6 If neccessary, replace the faulty unit.

7 Turn the setting of the thermostat back to its original value.

8 When finished, restart the drive system as described in Operating Instructions of the User’s Manual.



Door filter mats are mounted in the cabinets of COU, EXU and WCU, if the converter has been specified for insulation protection 54.

The filter mats can be changed while the converter is in operation.

Proceed as follows:

1 Take off the filter cover.

Two types of filter covers can be present.

Type 1 is made of sheet metal and has two hooks on each side which insert into slots of the door. To take off the cover, push it upwards (see arrows in Figure 2-19) as far as it goes and pull it away from the door.

Figure 2-19 Door Filter Type 1

Type 2 is made of plastic and has two semicircular cut-outs at the bottom edge.

To take off the cover, reach into the cut-outs with two fingers and pull the cover carefully off the door. For details of the door filter assembly see Figure 2-20.

Figure 2-20 Door Filter Type 2

2 Replace the filter mat, if necessary.

2.12 Door Filter Mats



3 Remount the cover.

Figure 2-21 Door Filter Assembly Type 2 (IP54)

Sealing kit SK 3192 100

E = F =

223 +/- 0.5 mm234 +/- 0.5 mm



The power capacitors in the DC link are of self-healing design. Because of their design the capacitance can decrease due to aging. Voltage and temperature are the two main stress factors that influence the lifetime of the capacitors. Less than 2 % reduction of capacitance from the capacitors individual name plate value is allowed. The name plate value is not necessarily identical with the manufacture value. The manufacture tolerance is 0…+10 % of the nominal value.

The converter has also capacitors in the snubber circuit to protect the rectifier diodes and in the clamping circuit to protect the inverter diodes.

The clamp capacitors are of self-healing design and therefore regular measurements are recommended.

Refer to the Wiring Diagrams to identify the capacitors.

A capacitance meter is provided in the tool box of the converter.

2.13.1 DC Link Capacitors

Visual Inspection Visual inspection should be carried out in the intervals stated in the maintenance schedule. Pay especially attention to leaking and bulged capacitors. The capacitors can be bulged as much as 10 mm. If a capacitor has expanded too much, it must be replaced by a new one.

Measurements The capacitance should be measured in the intervals stated in the maintenance schedule.

For the measurement:

• If the manufacture value of a capacitor is not available, check if the capacitance was recorded during commissioning. This value can be used for reference.

• Disconnect the wires / busbars which connect the DC link capacitors to the rectifier / inverter (see Figure 2-22).

2.13 Inspection of Capacitors



Figure 2-22 CBU Front

• If available, record the serial number of each capacitor in the inspection report.

• Connect the wires / busbars from the rectifier / inverter with the marked tightening torque (see separate sticker on the capacitor). If the tightening torque is not specified on the capacitor, use 20 Nm tightening torque.

If the capacitance is more than 2 % off the manufacture value the capacitor must be replaced.

Perform the insulation test every 4th year on the converter, supply transformer and motor. The power cables to the converter (incoming and outgoing) need to be disconnected for the test.

For the measurement:

• Perform the test according to the ACS 6000 Commissioning Manual.

• Record the insulation resistance values of each measurement in the inspection report.

2.14 Insulation Test



For reasons of aging of electrolytic capacitors, it is recommended to install all spare printed circuit boards which are equipped with these capacitors in the converter and use the replaced boards as spares.

The following boards are equipped with electrolytic capacitors:

• AMC board

• INT board

• IGCT

• CVMI board

See Service and Maintenance Manual of the water cooling unit for information on :

• Water cooling pumps

• Ion exchange resin

• Plate heat exchanger

• Filter Cartridge of Filter Z1

• Conductivity Sensor

• Pressure Transmitter

• Temperature Sensor

2.15 Board Replacement

2.16 Water Cooling Unit


ABB

Chapter 3 - Test Run

After the maintenance work has been completed, a test run must be performed. Before starting, check that:

• all cables are properly connected and all electrical connections are tight,

• no foreign objects are inside the converter,

• all covers are mounted,

• equipment grounding is removed,

• running the motor / process is safe.

During the test run, monitor (using DriveWindows or DriveDebug) the behaviour of the DC voltage when the DC link is charged and record the following signals:

• 2.01 DC1 VOLTAGE (sum of upper and lower DC voltages)

• 2.02 DC1 VOLTAGE

• 2.06 DC2 VOLTAGE

• Control signals to and from the MCB

Observe the functioning of the drive under normal load conditions. Using DriveWindows or DriveDebug record the following signals:

• 1.08 MOTOR SPEED (in rpm)

• 1.21 MOTOR TORQUE FILT

• 1.19 MOTOR RMS CURRENT FLT

• 2.01 DC1 VOLTAGE (sum of upper and lower DC voltages)

• 2.19 SWITCHING FREQUENCY

• 3.02 USED TORGUE REF (in %)


Chapter 3 - Test Run ABB


ABB

Chapter 4 - Spare Parts, Documentation and Software

When checking the spare parts observe that:

• The software version of the spare AMC3 flash memory must correspond to the software version used in the drive.

If necessary, load the correct software version and the parameters used in the drive.

• The EPLD chip on the spare INT board correspond to the EPLD version used in the drive.

• All spare boards are of the correct type.

When checking the documention, verify that:

• A complete set of documentation (on paper or in electronic format) is on site.

• The Signal and Parameter Table on site corresponds to the software version of the drive.

For revising and archiving of the factory documentation and for later assistance of the customer sent the following to the MV AC Supportline (MV AC Supportline/CHIND, [email protected]):

• Inspection record (xls)

• Field report (use the MV AC Drives field report template)

• Parameter backup files (txt or dwp file formats)

• Software backup files (bpg, tar file formats)

• Fault logger data file (dwf or txt file formats)

• Test run recordings (DriveWindows or DriveDebug monitoring files or paper copy attached to the field report)

Depending on the operation time of DriveMonitor, the following is recommended to prevent data loss and to provide the necessary memory space on the harddisk of the DriveMonitor computer:

• After 1 to 2 years of operation: data backup on an external harddisk drive or a PC

4.1 Spare Parts and Documentation

4.2 Documentation and Back-up Copies for Supportline

4.3 DriveMonitor


Chapter 4 - Spare Parts, Documentation and Software ABB

• After 5 years of operation: change of harddisk of the DriveMonitor computer.


We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. ©ABB Switzerland Ltd

Document number Lang. Rev. ind. Page

ABB Switzerland Ltd 3BHS224716 en A 1

ACS 6000 Maintenance Schedule Legend:

Replacement of component R

Inspection (visual inspection, correction and replacement if needed) I

Performance of on-site work (commissioning, tests, measurements, etc.) P

No Action -

Years from start-up

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Start-up P

Estimated Working Time (hours) 1 4 8 4 12 4 8 4 16 4 8 4 32 4 8 4 16 4 8 4 12

Cooling

Air filters (if installed) R R R R R R R R R R R R R R R R R R R R Cooling fan (if installed) 2 I I I R I I I R I I I R I I I R I I I R De-Ionizer and micro filter 3 P P P P P P P P P P P P P P P P P P P P Cooling pump gasket I I I R I I I - I R I - I I I R I I I R Cooling pump (including gasket) 2 I I I I I R I I I I R I I I I I R I I Auxiliary cooling fan (if installed) I I I R I I I R I I I R I I I R I I I R Strainer I I I I I I I I I I I I I I I I I I I I

Aging

Capacitors 4 P P P P P P P P P P P P P P P P P R P P Printed Circuit Boards 5 I I I P I I I P I I I R I I I P I I I P Battery of UPS (if installed) I R I R I R I R I R I R I R I R I R I R

Connections & Surroundings

Fiber optic cables P P P P P P P P P P P P P P P P P P P P Cable connections I I I I I I I I I I I I I I I I I I I I Dustiness, corrosion and temperature I I I I I I I I I I I I I I I I I I I I

Improvements

Improvements 7 I I I I I I I I I I I I I I I I I I I I

Measurements

Measurements with auxiliary voltage P P P P P P P P P P P P P P P P P P P P Insulation test - - - P - - - P - - - P - - - P - - - P

Spare Parts

Spare parts 5 I I I P6 I I I P6 I I I R6 I I I P6 I I I P6

1. Typical needed working time on the converter (does not include preparation-, closing-, waiting- or traveling-time) 2. The cooling pumps and fans can either be serviced by an authorized service-representative or completely replaced 3. The average lifetime of the deionizer is 2 - 4 years, depending mainly on the actual water quality, the micro filter should be replaced at the

same time as the deionizer, it is recommended to replace both when the actual conductivity reaches the alarm level, not preventively 4. The expected life time of the capacitors depends mainly on the ambient conditions, based on the maximum allowed temperature in the

converter, the expected lifetime is about 200 000 hours, the actual replacement should be based on the annual measurements, not on time 5. The printed circuit boards in the converter and among the spare parts can be replaced with new ones or replaced with refurbished ones 6. Only the printed circuit boards needs to be replaced, for the other spare parts are no actions needed 7. Converter improvements based on development, software modifications etc. Note! Recommended service intervals and component replacements are based on the operational environment specified by ABB. Please refer to service instructions and product manuals for more information.

UM00 ACS6000PrevMaintenance 3BHS214896 E01 RevA

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