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Manuals and User Guides for ABB PCS6000. We have
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ABB PCS6000 manuals available for free PDF download: Service Manual, User Manual
ABB PCS6000 Service Manual (272 pages)
SYSTEM DRIVES
Brand:
ABB
| Category:
DC Drives
| Size: 31.58 MB
Table of Contents
Table of Contents
3
About this Manual
17
Equipment Covered by this Manual
17
Overview
17
Contents of this Manual
18
Related Documents
19
Table 1-1 Product-Specific Documentation
19
Table 1-2 Standards
19
Target Groups and Required Qualification
20
Handling
20
Mechanical Installation
20
Electrical Installation
20
Operation
20
Maintenance
20
User's Responsibilities
21
Intended Use of the Equipment
21
Document Conventions
22
Important Safety Information
23
Safety Messages and Safety Signs in this Document
23
Safety Messages
23
Safety Signs
23
Product Safety Labels
24
Figure 2-1 Product Warning Label Examples (Label Placement Depends on the Drive)
24
Electrical Safety
25
General Safety Instructions
25
The 7 Steps that Save Lives
26
Possible Residual Risks
28
Service Tools
31
Overview
31
Converter Service Tools
31
Commissioning Tools
31
Replacement Tools
31
Table 3-1 Converter Service Tool List
31
Table 3-2 Commissioning Tool List
31
Table 3-3 Replacement Tool List
31
Converter Service Tools
32
Converter Service Toolbox
32
Figure 3-1 Converter Service Toolbox
32
Table 3-4 Converter Service Toolbox Content (3BHB008753R0002)
32
Figure 3-2 Spreading Tool (Part of Converter Service Toolbox)
33
Figure 3-3 Stabilizer Plate (Part of Converter Service Toolbox)
34
Figure 3-4 Semiconductor Test Device FADEC 3
34
Grounding Kit
35
Figure 3-5 Grounding Kit
35
Tube Cutter
36
Figure 3-6 Tube Cutter
36
Polishing Kit for Fiber Optics
37
Figure 3-7 Polishing Kit for Fiber Optics (Used with All Connection Types)
37
Commissioning Tools
38
RCI-Box XU D194
38
Figure 3-8 RCI-Box XU D194 with Power Cables and Fiber Optic Cables
38
Pcs6000 Hmi
39
Figure 3-9 User Interface of the PCS6000 HMI
39
Filling Kit for PCS6000 Water Cooling
40
Figure 3-10 Filling Kit for PCS6000 Water Cooling
40
Filling Kit Extension Tube
41
Replacement Tools
41
Reactor Replacement Kit
41
Figure 3-11 Filling Kit Extension Tube
41
Figure 3-12 Reactor Replacement Kit
41
Base Beam Lifting Jack
42
Figure 3-13 Base Beam Lifting Jack (3BHE039648R0001)
42
Chain-Block
43
Figure 3-14 Chain-Block
43
Pump Maintenance Table Kit (Only for Swedewater WCU)
44
Figure 3-15 Pump Maintenance Table Kit
44
Generator Breaker Replacement Kit
45
Figure 3-16 Generator Breaker Replacement Kit
45
Preventive Maintenance
47
General
47
Safety Information
47
General Directives
48
Preventive Maintenance Report
48
Preventive Maintenance Schedule
49
Preventive Maintenance Tasks
49
Inspection
49
Table 4-1 Visual Inspection
50
Checking Semiconductor Stack Tightness
52
Checking Bolt Connections
52
Figure 4-1 Bolt Connections, Checking the Tightening Torque Markings
52
Cleaning
53
Replacing Components
54
Table 4-2 Replacement Procedures
54
DC-Link Performance Check
56
DC-Link Component Check
57
Figure 4-2 ASM10
58
Filter Components Performance Check
59
Grid Side Filter Components Performance Check
59
Neutral Point Performance Check
61
DV/Dt Filter Components Performance Check
61
Functionality and Security Procedure
62
GRB Opening Time Verification
63
Insulation Measurement 1CL
63
Figure 4-3 Insulation Measurements PCS6000 Converter 1CL with PCM
64
Figure 4-4 Insulation Measurements PCS6000 Converter 1CL Without PCM
64
Insulation Measurement 2CL
65
GDM Performance Check
66
Figure 4-5 Insulation Measurements PCS6000 Converter 2CL
66
Braking Resistor Performance Check
67
Energizing, Grounding and Start-Up
69
General
69
Safety Information
69
Lockout/Tagout
70
Start-Up after Maintenance or Troubleshooting
70
Figure 5-1 Key Switch
71
Figure 5-2 DC-Link Grounding Isolator in Position "Not Grounded
71
Troubleshooting
73
General
73
Safety Information
73
Standard Procedure for Troubleshooting
75
Figure 6-1 Commissioning Tool (Optional), Error Messages Window
75
Figure 6-2 Standard Procedure for Troubleshooting (Overview)
76
Figure 6-3 Commissioning Tool (Optional), Typical Window
77
Checking Control Components
81
General
81
Safety Information
81
Checking Procedure
81
LED Status Indications
81
Leds on AC 800PEC
82
Leds on Combi IO
82
Table 7-1 Leds on AC 800PEC
82
Table 7-2 Leds on Combi IO UA D155
82
Leds on PECINTM
83
Leds on ASE2 Board
83
Table 7-3 Leds on PECINTM PC D237
83
Table 7-4 ASE2 Board UD C920
83
Leds on UPS
84
Table 7-5 UPS/24DC/40
84
Replacing Control Components
85
General
85
Safety Information
85
Overview of Replaceable Control Components
86
Replaceable Control Components in CCU
87
Table 8-1 CCU Control Components Replaceable by Customer
87
Replaceable Control Components in POU
88
Replaceable Control Components in FIU
88
Table 8-2 POU Control Components Replaceable by Customer
88
Table 8-3 FIU Control Components Replaceable by Customer
88
Replaceable Control Components in DLU
89
Replaceable Control Components in DRU
89
Table 8-4 DLU Control Components Replaceable by Customer
89
Table 8-5 DRU Control Components Replaceable by Customer
89
Replacing AC 800PEC
90
Figure 8-1 AC 800PEC
90
Figure 8-2 UPS -G302 Selector Switch "Bat.-Select
90
Figure 8-3 Removing a AC 800PEC Module
91
Replacing Combi IO
92
Figure 8-4 AC 800PEC Combi IO UA D155
92
Replacing S800 I/O Modules
93
Figure 8-5 S800 Assembly
93
Figure 8-6 S800 I/O Module
94
Figure 8-7 S800 I/O Module Address
94
Replacing Voltage (AE01) and Current (AE02) Transducer Boards
95
Figure 8-8 Voltage and Current Transducer Boards UUD 148 AE01/2
95
Figure 8-9 Short-Circuit of Current Transducer
96
Replacing PECINTM
97
Figure 8-10 PECINTM PC D237
97
Figure 8-11 UPS -G402 Selector Switch "Bat.-Select
97
Replacing IPS
99
Figure 8-12 GCT Power Supply (IPS)
99
Replacing HVD
100
Figure 8-13 HVD XV C770
100
Replacing VLSCD
101
Figure 8-14 VLSCD XV C724
101
Replacing ASE
102
Figure 8-15 ASE2B UD C920
102
Replacing AC/DC Converter
103
Replacing AC/DC Converter -G301 in CCU or -G401 in POU
103
Figure 8-16 AC/DC Converter Quint-PS/3AC/24DC/40
103
Replacing AC/DC Converter -G501 in FIU
104
Figure 8-17 AC/DC Converter Quint-PS/1P24/10
104
Replacing DC/DC Converter
105
Figure 8-18 DC/DC Converter Quint-PS-24DC/24DC/10
105
Replacing UPS
106
Replacing UPS -G302 in CCU or -G402 in POU
106
Figure 8-19 Quint-DC-UPS/24DC/40
106
Replacing UPS -G502 in FIU
107
Figure 8-20 Quint-DC-UPS/24DC/10
107
Replacing Batteries
108
Replacing Battery -G303 in CCU
108
Figure 8-21 Battery -G303
108
Replacing Battery -G403 in POU
109
Figure 8-22 Battery -G403
109
Replacing Battery in UPS -G502 in FIU
110
Replacing Fiber Optic Cables
111
Checking Diodes, Igcts and IPS
115
General
115
Safety Information
115
Fault Identification in Triple Stack (POM)
116
Location of Components
117
Freewheeling Diode Stack
118
Figure 9-2 Freewheeling Diode Stack
118
Neutral Point and Clamp Diode Stack
119
Figure 9-3 Neutral Point and Clamp Diode Stack
119
Clamp Capacitors and Symmetry Resistors
120
Figure 9-4 Clamp Capacitors and Symmetry Resistors
120
Semiconductor Checking Sequence
121
Figure 9-5 Semiconductor Orientation
121
Checking Igcts with FADEC 3
122
Table 9-1 State of Gate Unit (GU) and IGCT (X = Irrelevant)
122
Checking Power Diodes with FADEC 3
123
Preparation for Checking Power Diodes
123
Figure 9-6 Correct Measuring with FADEC 3
123
Figure 9-7 FADEC 3 Indication of Defective Semiconductor
123
Checking Freewheeling Diodes
124
Figure 9-8 Correct Measuring with FADEC 3
124
Figure 9-9 FADEC 3 Indication of Defective Semiconductor
124
Checking Clamp Diodes
125
Figure 9-10 Correct Measuring with FADEC 3
125
Figure 9-11 FADEC 3 Indication of Defective Semiconductor
125
Checking Neutral Point (NP) Diodes
126
Figure 9-12 Correct Measuring with FADEC 3
126
Figure 9-13 FADEC 3 Indication of Defective Semiconductor
126
Checking Igcts with Multimeter (if a FADEC 3 Is Unavailable)
127
Table 9-2 State of Gate Unit (GU) and IGCT
127
Figure 9-14 Correct Measuring between Gate and Cathode
128
Figure 9-15 Wrong Measuring between Gate and Cathode
128
Checking Power Diodes with Multimeter
129
Preparation for Checking Power Diodes
129
Checking Freewheeling Diodes
129
Checking Clamp Diodes
130
Figure 9-16 Clamp Resistor Connections
130
Checking Neutral Point (NP) Diodes
131
Checking IPS
132
Figure 9-17 IGCT Power Supply (IPS)
132
Table 9-3 Input and Output Voltages of IPS
132
Table 9-4 IPS Analysis
132
Replacing Power and Cooling Components
133
Overview
133
Safety Information
133
Figure 10-1 ESD Precautions
134
Overview of Serialized Power Components
135
General Directives
135
Correct Tightening Torques of Bolted Connections
135
Table 10-1 Serialized Power Components
135
Capacitors
136
Training for Maintenance and Repair Personnel
136
Service Training
136
List of PCS6000 Components > 25 Kg
136
Table 10-2 Standard Tightening Torques for Bolted Connections
136
Table 10-3 List of Components > 25Kg of PCS6000 Product Family
137
Preparation of Cooling Liquid Circuit before Replacing Components
138
Releasing the over Pressure from the Cooling Liquid Circuit
138
Emptying the Cooling Liquid Circuit
139
Replacing Components in POU
139
General Procedure to Replace Power Semiconductors
140
Figure 10-2 Clamping Components
140
Releasing the Stacks
141
Figure 10-3 Pressure Loading Gauges
141
Figure 10-4 Pressure Loading Gauges Inserted
142
Figure 10-5 Gate Unit Fixation
142
Figure 10-6 Order of Loosening the Clamping Screws
143
Figure 10-7 Stabilizer Plate Insertion
144
Using the Spreading Tool
145
Figure 10-8 Manual Support During Spreading Tool Insertion
145
Figure 10-9 Spreading Tool Insertion
146
Figure 10-10 Spreading Tool Expansion
146
Figure 10-11 Spreading Tool Applied over Three Heat Sinks
147
Figure 10-12 Spreading Tool Use Example
148
Replacing Igcts
149
Figure 10-13 Disconnecting Cables from IGCT
149
Figure 10-14 Removing the Gate Unit Fixations of the IGCT
149
Figure 10-15 Extracting the IGCT
150
Figure 10-16 Correct Handling of IGCT
150
Figure 10-17 Inserting the IGCT
151
Figure 10-18 IGCT Components
152
Replacing Power Diodes
153
Replacing Freewheeling Diodes
153
Figure 10-19 Centering Freewheeling and Neutral Point Diodes
153
Figure 10-20 Diode Marking
154
Replacing Clamp Diodes
155
Figure 10-21 Clamp Diodes
155
Figure 10-22 Centering Upper (A) and Lower (B) Clamp Diodes
156
Replacing Neutral Point (NP) Diodes
157
Figure 10-23 NP Diodes
157
Figure 10-24 Centering Freewheeling and Neutral Point Diodes
158
Checking Stacks Alignment
159
Aligning an IGCT Stack
159
Figure 10-25 Example of Positioning and Stop Device Not Fully Inserted yet
159
Diode Stack (Freewheeling / Neutral Point and Clamping)
161
Figure 10-26 Freewheeling Diode Stack with Aligned Heat Sinks (A) and Misaligned Heat Sinks (B)
161
Figure 10-27 Heat Sink with Loosened Flexible Bus Bar
162
Figure 10-28 Power Module Assembly (Back View)
162
Figure 10-29 Heat Sink Moved Back into Position
163
Effects of Stack Misalignment on Semiconductors Pole Pieces
164
Tightening the Stacks
166
Figure 10-30 Order of Tightening the Clamping Screws
166
Figure 10-31 Tightening the Clamping Screw
166
Figure 10-32 Adjusting Clamp Pressure of Stack
167
Figure 10-33 Pressure Loading Gauges Storage Place
167
Figure 10-34 Gate Unit Fixation
168
Replacing Clamp Capacitor
169
Figure 10-35 Clamp Capacitors
169
Replacing Symmetry Resistor
170
Figure 10-36 Symmetry Resistor
170
Replacing Clamp Resistor
172
Figure 10-37 Clamp Resistor
172
Replacing Clamp Reactor
173
Figure 10-38 Clamp Reactor
173
Replacing LEM Current Transducer
175
Figure 10-39 LEM Current Transducers
175
Replacing DC Capacitor
176
Figure 10-40 Mounting Screws of ASM in Front of DC Capacitor
176
Figure 10-41 DC Capacitor
177
Replacing Components in DRU
178
General
178
Figure 10-42 Spreader Tools
178
Releasing the Stacks
179
Figure 10-43 Applying Spreader Tool
179
Centering Misaligned Stacks
180
Figure 10-44 Rearranging Misaligned Stacks
181
Replacing Components in DLU
182
Replacing Grounding Isolator
182
Figure 10-45 Earth Isolator Mounting Screws
182
Replacing Resistor -R462_1, -R462_2
183
Figure 10-46 Resistor -R462_1, -R462_2
183
Replacing Resistor -R751 to -R754 or Capacitor -C751 to -C752
184
Figure 10-47 Rear View of VLM
184
Replacing Resistor -R461
185
Figure 10-48 Resistor -R461
185
Replacing Capacitor -C461
186
Figure 10-49 Capacitor -C461
186
Replacing Igcts and Diodes
187
Figure 10-50 VLM
187
Replacing VLM
189
Figure 10-51 VLM
189
Replacing Pre-Charging Transformer
190
Figure 10-52 Precharging Transformer (VLM Removed)
190
Replacing DV/Dt Filter Reactor in DLU
191
Figure 10-53 DV/Dt Filter Reactor
191
Figure 10-54 DV/Dt Filter Reactor Mounting Bolts (Different VFM Variants)
192
Replacing DV/Dt Filter Resistor in DLU
193
Figure 10-55 DV/Dt Filter Resistors
193
Replacing DV/Dt Filter Capacitor in DLU
194
Figure 10-56 DV/Dt Filter Capacitors
194
Replacing Grid/Generator Disconnector Module in DLU
195
Replacing Components in VFU
203
Replacing Grid/Generator Disconnector Module (GDM1) at the Front of the VFU
203
Figure 10-57 Framework for Chain-Block
203
Figure 10-58 GDM1 Mounting Screws and Aluminum Plate
207
Figure 10-59 GDM1 with Framework for Chain Block
208
Replacing Grid/Generator Disconnector Module (GDM2) at the Back of the VFU
210
Figure 10-60 Framework for Chain-Block
210
Replacing DV/Dt Filter Reactor at the Front of the VFU (VFM1)
213
Figure 10-61 DV/Dt Filter Reactor
213
Figure 10-62 DV/Dt Filter Reactor Mounting Screws (Different VFM Variants)
214
Replacing DV/Dt Filter Reactor at the Back of the VFU (VFM2)
215
Figure 10-63 Position of VFM
215
Replacing DV/Dt Filter Resistor in VFU
217
Figure 10-64 DV/Dt Filter Resistors
217
Figure 10-65 Position of Mounting Screws DV/Dt Filter Resistors
218
Replacing DV/Dt Filter Capacitor in VFU
219
Figure 10-66 DV/Dt Filter Capacitors
219
Replacing Components in WCU (Swedewater)
220
Replacing or Cleaning Conductivity Meter
220
Figure 10-67 Conductivity Meter
220
Figure 10-68 Conductivity Meter
221
Replacing Inlet Water Temperature Meter
222
Figure 10-69 Temperature Meter
222
Replacing Pressure Gauge and Pressure Transmitter
223
Figure 10-70 Pressure Gauge and Transmitter
223
Replacing Deionizer Flow Meter
224
Figure 10-71 Deionizer Flow Meter
224
Replacing the Ion Exchange Vessel
225
Figure 10-72 Ion Exchange Vessel (Right Side: Old Version)
225
Figure 10-73 Ion Exchange Vessel
226
Replacing the Water Filter
227
Figure 10-74 Water Filter
227
Replacing Pump
228
Figure 10-75 Pump Support
229
Figure 10-76 Pump Flange
229
Figure 10-77 Connecting Pipes Turned Aside
230
Figure 10-78 Drilling Plan
230
Figure 10-79 Pump Maintenance Table with Long Legs (for Upper Pump)
231
Figure 10-80 Use of Chain-Block to Lift out Pump
231
Replacing Pump Slip Ring Sealing
232
Figure 10-81 Pump Components (Swedewater)
232
Figure 10-82 Opening Pump Case
232
Figure 10-83 Pump Shaft
233
Figure 10-84 Pump Sealing
233
Replacing the 3-Way Valve
234
Figure 10-85 3-Way Valve
234
Replacing Expansion Vessel
235
Figure 10-86 Expansion Vessel
235
Figure 10-87 Expansion Vessel
236
Replacing Automatic Deaeration Valve
237
Figure 10-88 Automatic Deaeration Valve
237
Replacing (Checking) Ball Valve ¾
238
Figure 10-89 Ball Valve ¾
238
Figure 10-90 Gland from the Ball Valve ¾
238
Replacing (Checking) Ball Valve ½
239
Figure 10-91 Ball Valve ½
239
Replacing Components in WCU (ARMATEC)
240
Replacing Components in FIU
241
Figure 10-92 FIU with FCM (Left) and with FIM (Right)
241
Replacing HFM Filter Reactor
242
Figure 10-93 HFM Filter Reactor
242
Replacing HFM Filter Capacitor
243
Figure 10-94 HFM Filter Capacitor
243
Figure 10-95 FCM Removal (Circles Show Bolt Locations)
244
Figure 10-96 Top and Bottom Views of Capacitor
244
Figure 10-97 Lifting out Capacitor
245
Replacing HFM Filter Resistor
246
Figure 10-98 HFM Filter Resistor
246
Replacing Filter Reactor
247
Figure 10-99 Filter Reactor
247
Figure 10-100 Removed Filter Reactor
248
Figure 10-101 Ground Connection
248
Replacing Pressure Transmitter
249
Figure 10-102 Pressure Transmitter
249
Replacing Components in GBU
250
Replacing Generator Breaker (GEB) / Grid Breaker (GRI)
250
Figure 10-103 GBU
250
Figure 10-104 Generator Breaker (GEB)
251
Figure 10-105 Grid Breaker (GRI)
251
Figure 10-106 Drawer Mounting Screws
252
Figure 10-107 Corner Braces
252
Figure 10-108 GBM Push Button Locking Device
252
Figure 10-109 Lower Front Beam Mounting Screws
253
Figure 10-110 Differential Pressure Measurement Device
253
Figure 10-111 Fan Drawer below the GEB
253
Figure 10-112 Protection Cushion
254
Figure 10-113 Breaker's Lower Power Cable Connections
254
Figure 10-114 Breaker's Upper Power Cable Connection
254
Figure 10-115 Breaker's Protecting Earth Connection
255
Figure 10-116 Fiber Optic Cable
255
Figure 10-117 Breaker's Protecting Earth Connection
256
Figure 10-118 Trolley Track Beams
256
Figure 10-119 Support by Reactor Replacement Kit
257
Figure 10-120 Trolley Track Beams (Top View)
257
Figure 10-121 Trolley with Loose Wing Nuts
257
Figure 10-122 Fixing the GEB to the Lever
258
Figure 10-123 Rising the Lever
258
Figure 10-124 Unbolting the GEB
258
Figure 10-125 GEB Pulled out of the Cabinet
259
Figure 10-126 Releasing the Retaining Spring (Flap Closed)
260
Figure 10-127 Releasing the Retaining Spring (Flap Open)
260
Figure 10-128 Flap Open and Engaged
260
Replacing DV/Dt Filter Reactor in GBU
261
Figure 10-129 DV/Dt Filter Reactor
261
Figure 10-130 DV/Dt Filter Reactor Mounting Bolts
262
Replacing DV/Dt Filter Resistor in GBU
263
Figure 10-131 DV/Dt Filter Resistors
263
Replacing DV/Dt Filter Capacitor in GBU
264
Figure 10-132 DV/Dt Filter Capacitors
264
Replacing Fan of GBU Fan Drawer
265
Figure 10-133 Fan of GBU Fan Drawer
265
Figure 10-134 Drawer Mounting Screws
265
Figure 10-135 Lower Front Beam Mounting Screws
266
Figure 10-136 Fan Drawer below the GEB
266
Figure 10-137 Fan Drawer Removed
266
Figure 10-138 Releasing the Retaining Spring (Flap Closed)
267
Figure 10-139 Releasing the Retaining Spring (Flap Open)
267
Figure 10-140 Flap Open and Engaged
267
Replacing Fans in Miscellaneous Units
268
Replacing Door Fan with Heater
268
Figure 10-141 Door Fan with Heater
268
Replacing Roof Fan and Air Filter Mats
269
Figure 10-142 Roof Fan
269
Figure 10-143 Filter Fan Replacement
270
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ABB PCS6000 User Manual (114 pages)
System drives
Brand:
ABB
| Category:
Industrial Equipment
| Size: 7.25 MB
Table of Contents
Table of Contents
3
Introduction, Terms, Trademarks and Related Documents
11
Equipment Covered by this Manual
11
Overview
11
Contents of this Manual
12
Relevant Chapters of the Manual
12
Standard Documentation
13
Related Documents
13
Terms and Abbreviations
14
Table 1-1 Terms and Abbreviations
14
Target Groups and Required Qualification
15
Handling
15
Mechanical Installation
15
Electrical Installation
15
Operation
15
Maintenance
16
User's Responsibilities
16
Intended Use of the Equipment
16
Quality Certificates and Applicable Standards
17
Table 1-2 Standards that Are Referred to in this Document
17
Tools
18
Important Safety Information
19
Safety Standards
19
Safety Messages
19
Product Safety Labels
20
Figure 2-1 Product Warning Label Examples (Label Placement Depends on the Converter)
20
General Safety Instructions
21
The 7 Steps that Save Lives
22
Possible Residual Risks
24
Important Note - Main Circuit Breaker
26
Figure 2-2 Converter System Overview
26
Safety and Protection Requirements
27
Safety and Protection Requirements for the MCB
27
Maintenance Recommendation
28
Figure 2-3 MCB Opening Timing Diagram
28
Product Description
29
Field of Application
29
Converter Configuration
29
Figure 3-1 PCS6000 Converter Configurations
29
Figure 3-2 PCS6000 Configuration Examples
30
Figure 3-3 PCS6000 Configuration Example
30
POU Power Unit (POU)
31
Figure 3-4 POU
31
DC-Link Unit (DLU)
32
Figure 3-5 DLU
32
Neutralpoint Connection Module (NCM)
33
Voltage Limiting Module (VLM)
33
Figure 3-6 NCM
33
Figure 3-7 VLM
33
DV/Dt Filter Module (VFM)
34
DC-Link Grounding Isolator
34
Figure 3-8 VFM
34
Figure 3-9 DC-Link Grounding Isolator
34
Generator Disconnector Module (GDM)
35
Figure 3-10 GDM
35
Grid Breaker Unit (GBU)
36
DV/Dt Filter Module
36
Figure 3-11 Circuit Breaker and Three Position Switch
36
Figure 3-12 Operator Tools (A), GBU (B) and GBM (C)
36
Water Cooling Unit (WCU)
37
Figure 3-13 WCU (Typical Design)
37
Filter Unit (FIU)
38
Figure 3-14 Typical HFM and FRM Implemented in FIU
38
Braking Resistor Unit (BRU)
39
Figure 3-15 Typical BRU
39
Table 3-1 Overview of Available Brus
39
Converter Control Unit (CCU)
40
Figure 3-16 CCU- Mounted to Left Side of Cabinet
40
Figure 3-17 CCU - Converter Control Unit (Typical Design)
40
Cabinet Design
41
Figure 3-18 Basic Cabinet Design
41
Transportation, Storage and Disposal
43
Safety
43
Transportation
43
Packing for Land Transportation
44
Wood Pallet Requirements
44
Figure 4-1 Type and Dimensions of Wood Pallet
44
Preparing the Wood Pallet
45
Applying the Foil Barrier
46
Wrapping
48
Securing Cabinets to the Pallet
49
Figure 4-2 Roof Beam Placement
49
Packing for Sea Transportation
51
Wood Box
51
Band Strapping
51
Foil Barrier Material
51
Humidity Indicator
51
Figure 4-3 Packing Overview
52
Packing Symbols
53
Loading and Unloading
54
Loading and Unloading by Crane
55
Figure 4-4 Loading and Unloading In-Line PCS6000 with Suspension Beam
55
Loading and Unloading by Fork Lift Truck
56
Fork Lift Truck Requirements
56
Figure 4-5 Typical Lifting with Fork Lift Truck (Top: In-Line Layout / Bottom: Back-To-Back Layout)
56
Unpacking
57
Figure 4-6 Unpacking the Equipment
58
Unpacking Additional Parts
59
Moving Equipment to Place of Installation
59
Moving by Crane
60
Figure 4-7 Moving PCS6000 with Suspension Beam
60
Moving by Transport Rolls
61
Disposal of Packing Materials
61
Figure 4-8 Moving PCS6000 by Transport Rolls
61
Transport Conditions
62
Storage
62
Storage Conditions
62
Storage and Handling of Spare Parts
63
Disassembly and Disposal of Equipment
63
Mechanical Installation
65
Safety
65
Installation Planning and Execution
65
Cabinet Mounting Instructions
66
Concluding Work
66
Damage to Paintwork
66
Final Work
66
Electrical Installation
67
Safety
67
Installation Planning and Execution
67
EMC Concept
68
Purpose
68
EMC Zone Concept
68
Cable Requirements
69
Power Cables
69
Figure 6-1 EMC Zone Concept According to IEC 61800-3
69
Recommended Cable Types
70
Power Cable Dimensions
70
Cable Shielding, Routing and Separate Earth Wires
71
Grid Side
71
Generator Side (Converter - Generator)
72
Braking Resistor Connection
72
Auxiliary and Control Cables
73
Requirements for Auxiliary Power Cables
73
Requirements for Control Cables
73
Grid Side VT and CT Measurement Cables
73
Installation Rules for Busbars, Cabling and Wiring
74
Summary
75
Figure 6-2 Segregation of Cables of Different Classes
75
Table 6-1 Cable Types and Shielding Method
75
Electrical Installation Instruction of MV Connection
76
Figure 6-3 Layout of Panel Socket with Coding AF01
76
Types of Pfisterer® PLUG Connectors
77
Figure 6-4 Details of the Pfisterer® PLUG Straight Connector
77
Figure 6-5 Details of the Pfisterer® PLUG Elbow Connector for 1 Cable
77
Pfisterer® PLUG Connector Details (P3SC)
78
Figure 6-6 Details of the Pfisterer® PLUG Elbow Connector for 2 Cables
78
Figure 6-7 Schematic Drawing of Tailoring a Pfisterer® PLUG Connector
78
Cable Connection Systems
79
Figure 6-8 DLU and GBU Rear Cable Connections (A) and Rear Cable
79
Figure 6-9 DLU and GBU Top Cable Connections (A) and Top Cable Entry (B)
79
Grounding the Converter System
80
General Requirements
80
Protective Earth (PE) and Functional Earth (FE)
80
Converter Grounding
81
Figure 6-10 Grounding Cam at a Base Frame with M12 Bolt
81
Figure 6-11 Ground Rail for Cable Shield Connections
81
Figure 6-12 Grounding the Grid Side (A) and Generator Side (B) of a
82
Figure 6-13 Grounding the Generator Side of the Converter System of a 2CL Converter System
83
Auxiliary Connection
84
Auxiliary Cable Entry
84
Auxiliary Power Supply Connection
85
Figure 6-14 Position of the Auxiliary Power Terminals Inside the CCU
85
Figure 6-15 Position of the Cutouts for Cable Entry into the CCU
86
Control Cable Connection
87
Figure 6-16 Position of the Control Cable Terminals Inside the CCU
87
Commissioning
89
Required Qualification
89
Commissioning Procedure
89
Commissioning Checklist
89
Customer Assistance
89
Customer Acceptance
89
Commissioning Checklists
90
Mechanical Installation Checklist
90
Electrical Installation Checklist
91
Main Circuit Breaker (MCB) Checklist
92
Input Transformer Checklist
92
Generator Checklist
92
Insulation Test Checklist
93
Power Checklist
93
Miscellaneous Checklist
93
Operation
95
Operation Conditions
95
Safety
96
Control Interfaces and Local Control Equipment
97
Local Control Equipment
97
Figure 8-1 Local Control Equipment
97
User Interfaces and Diagnostics
98
Operating States and Sequences
98
Table 8-1 Local Control Binary Indications
98
Table 8-2 Local Control Binary Commands (Controller Input Signals)
98
Table 8-3 Local Control Commissioning Ports
98
Anti-Dew Startup Sequence
99
Figure 8-2 Flow Chart of Anti-Dew Startup Sequence (PF2)
100
Starting the PCS6000 Converter
101
Checks before Starting
101
Figure 8-3 DC-Link Grounding Switch in Position "Not Grounded", LED Indication
102
Lockout/Tagout
103
EMERGENCY off Button
103
Figure 8-4 Releasing EMERGENCY off Button
103
Key Switch
104
Alarm and Fault Handling
104
Alarm and Trip Reset
104
Figure 8-5 Key Switch
104
Preventive Maintenance
105
Safety
105
General Directives
106
Log Book
106
Preventive Maintenance Explanations
106
Visual Inspection
106
Cleaning
106
Performance
107
Replacement of Components
107
Maintenance Schedule
107
Troubleshooting
109
Safety
109
General Directives
110
Log Book
110
Standard Procedure for Troubleshooting
110
Alarms and Faults
111
Fault Levels
111
Alarm and Fault Messages
111
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