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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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ABB
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ABB
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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 3 (6)
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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Table of contents ABB
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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 1 (2)
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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 1 (6)
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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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 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
• External influence on, or damage of the equipment
• 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
• External influence on, or damage of the equipment
• 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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’ 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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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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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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• 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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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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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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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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 4-5 (6)
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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 5-1 (6)
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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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.
See Connection plan in Appendix B - Mechanical drawings for information
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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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.
See Connection plan in Appendix B - Mechanical drawings for information
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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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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 6-1 (2)
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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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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2 (4) 3BHS343596 ZAB E01 Rev. D MEGADRIVE-LCI A User’s manual
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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MEGADRIVE-LCI A User’s manual 3BHS343596 ZAB E01 Rev. D 3 (4)
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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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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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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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.
This is an optional feature. See Interface diagram in Appendix C -
Electrical diagrams if the drive has this feature.
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
This is an optional feature. See Interface diagram in Appendix C -
Electrical diagrams if the drive has this feature.
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