User manual

ACS1000
Water cooling unit
ABB
ABB

Table of contents

List of figures

List of tables

General information on manual and drive

Chapter 1 - Safety 1-1

1.1 Meaning of safety instructions 1-1

Chapter 2 - Hardware and features of the unit 2-1

2.1 Function 2-1

2.2 Types of water cooling units 2-1
2.3 Cooling circuits 2-1
2.4 Main components 2-3
2.4.1 Pumps 2-4
2.4.2 Heat exchanger 2-4
2.4.3 Enclosure cooler (option) 2-4
2.4.4 Expansion vessel 2-4
2.4.5 Deionizer 2-4
2.4.6 Heater (option) 2-5
2.4.7 Valves 2-6
2.4.8 Junction box 2-7
2.5 Control system 2-8
2.6 I/O modules and circuit breakers 2-9
2.6.1 I/O modules 2-9
2.6.2 Circuit breakers 2-10

Chapter 3 - Tightening torques and sealings 3-1

3.1 Tightening torques 3-1

3.2 Sealings 3-1

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Chapter 4 - Installation 4-1

4.1 Water supply connections 4-1

4.1.1 Rubber coolant hoses (standard) 4-1
4.1.2 Water supply flanges (option) 4-3
4.1.3 Metal hoses with flanges (option) 4-3
4.1.4 External heat exchanger (option) 4-3
4.1.5 Enclosure cooler (option) 4-3
4.2 Drain connections 4-4
4.2.1 Drain connector / hose 4-4
4.2.2 Drain flange (option) 4-4

Chapter 5 - Commissioning 5-1

5.1 Overview 5-1

5.2 Preparing the coolant for the internal cooling circuit 5-2
5.2.1 Requirements 5-2
5.2.2 Mixing glycol into the coolant 5-3
5.3 Filling the internal cooling circuit 5-5
5.3.1 Tools and equipment 5-5
5.3.2 Preparatory steps 5-6
5.3.3 Filling the internal cooling circuit 5-10
5.4 Venting the internal cooling circuit 5-11
5.4.1 Venting pump 1 5-11
5.4.2 Venting pump 2 (option) 5-16
5.5 Final settings and adjustments 5-19
5.5.1 Adjusting the flow meter (option) 5-19
5.5.2 Adjusting the temperature of the enclosure cooler (option) 5-20
5.5.3 Preparing the cooling system for operation 5-20

Chapter 6 - Preventive maintenance 6-1

6.1 Inspection checklist 6-1

6.2 Checking actual values 6-3

Chapter 7 - Inspecting and replacing a pump 7-1

7.1 General information 7-1

7.2 Inspection 7-1
7.3 Removal 7-1
7.3.1 Isolating the pump 7-2
7.3.2 Draining the pump 7-4
7.3.3 Removing the pump 7-4
7.4 Installing the pump 7-5

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7.5 Filling / venting – unit with one pump 7-6

7.6 Filling – unit with two pumps – front access 7-7
7.7 Filling – unit with two pumps – side / rear access 7-8
7.8 Final settings – unit with one pump 7-9
7.9 Venting / final settings – unit with two pumps 7-9

Chapter 8 - Replacing deionizer and filter 8-1

8.1 General information 8-1

8.2 Removal 8-1
8.2.1 Preparatory steps 8-2
8.2.2 Replacing the deionizer 8-2
8.2.3 Replacing the filter 8-3
8.2.4 Filling and venting the coolant treatment circuit 8-4
8.2.5 Disposal 8-4

Chapter 9 - Cleaning the strainer Z1 9-1

9.1 General information 9-1

9.2 Overview 9-1
9.3 Cleaning 9-2
9.3.1 Internal heat exchanger 9-2
9.3.2 External heat exchanger 9-3

Chapter 10 - Draining the internal cooling circuit 10-1

10.1 General information 10-1

10.2 Tools and equipment 10-1
10.3 Location of drain valves 10-2
10.4 Draining 10-3
10.4.1 Preparatory steps 10-3
10.4.2 Draining 10-4
10.4.3 Final steps 10-4

Chapter 11 - Adding coolant to the internal cooling circuit 11-1

11.1 General information 11-1

11.2 Tools and equipment 11-1
11.3 Preparing the coolant 11-1
11.4 Adding the coolant 11-2

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Chapter 12 - Checking and changing the pump rotation 12-1

12.1 Rotation indicator 12-1

12.2 Changing the rotation during commissioning 12-2
12.3 Changing the rotation after a pump replacement 12-3

Terms, abbreviations, trademarks

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List of figures
Fig. 2-1 Block diagram of the cooling system 2-2
Fig. 2-2 Types of water cooling units 2-3
Fig. 2-3 External water heater 2-5
Fig. 2-4 Two-way and three-way control valve 2-6
Fig. 2-5 Safety valve F2 2-7
Fig. 2-6 Conductivity – alarm and trip levels 2-8
Fig. 2-7 Location of I/O modules and circuit breakers 2-9
Fig. 2-8 Circuit breakers 2-10
Fig. 3-1 Pipe coupling 3-1
Fig. 4-1 Entering hoses into the water cooling compartment 4-1
Fig. 4-2 Connecting the hoses 4-2
Fig. 4-3 Drain connector 4-4
Fig. 5-1 Location of drain valve in inverter compartment 5-7
Fig. 5-2 Adjusting the control valve 5-8
Fig. 5-3 Connecting the filling pump to valve V14 5-9
Fig. 5-4 Level indication 5-13
Fig. 5-5 Pressure gauge B16 5-15
Fig. 5-6 Flow meter B15 5-19
Fig. 8-1 Deionizer – distributor head 8-2
Fig. 9-1 Strainer Z1 9-1
Fig. 10-1 Location of drain valves 10-2
Fig. 11-1 Adding coolant 11-3
Fig. 12-1 Rotation indicator 12-1

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List of tables
Tab. 2-1 Circuit breakers by component 2-10
Tab. 3-1 Tightening torque for couplings 3-1
Tab. 3-2 Tightening torques for flanges 3-1
Tab. 5-1 Water specification 5-2
Tab. 5-2 Glycol specification 5-3
Tab. 5-3 Water-monoethylene glycol concentration 5-4
Tab. 5-4 Water-propylene glycol concentration 5-4

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General information on manual and drive

Copyright notice
The information in this manual is subject to change without notice.
This manual and parts thereof must not be reproduced or copied, nor
disclosed to third parties, nor used for any unauthorized purpose without
written permission from ABB Switzerland Ltd, Medium Voltage Drives.

Document identification
Ownership ABB Switzerland Ltd
Medium Voltage Drives

Document ID 3BHS204366 ZAB E01

Revision E

Issue date 07.08.2014

Contact information
Address ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi, Switzerland

Phone +41 844 845 845

Fax +41 58 589 2984

E-mail mvdrives@ch.abb.com

Equipment covered by the manual

This manual supplements the user manual of the drive and provides
information on the water cooling unit. The manual covers the standard
water cooling unit and provides generic information on the water cooling
unit. The manual does not claim to cover all variations and details of the
water cooling unit, nor to consider all eventualities that may arise during
installation, commissioning, operation and maintenance of the water
cooling unit.
Depending on the components included in the water cooling unit, not all of
the instructions may apply.
If the water cooling unit is adapted to specific customer needs or
applications and handling, installation, and operation of the drive are
affected by these modifications, information on these modifications is

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General information on manual and drive ABB
provided in the appropriate documentation (eg, layout drawings, wiring
diagrams, technical data, engineering notes).
The water cooling unit comes in various layouts and uses various devices
for measuring and monitoring flow, pressure, temperature, level and
conductivity of the coolant.

For information on the components included in the water cooling unit, see
the flow diagram and the list of components.
For information on the following topics, see the user manual of the drive:
■ Target groups and required qualifications
■ User’s responsibilities
■ Intended equipment use
If information is required beyond the instructions in this manual, refer the
matter to ABB.

Writing conventions
The following icons and text conventions are used in the manual.
■ marks items in a list.
> marks an optional device in a procedure or in instructions
(eg, > V-20). If the device is not included in the water cooling unit,
skip the procedure or the instruction.
• marks steps of a procedure when there is no specified sequence.
1 marks steps of a procedure to be followed in the specified sequence
(eg, 1, 2, 3).
1 used in figure legends to identify the item in an illustration.
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.

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

Gray-shaded areas are used to highlight text.

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Chapter 1 - Safety

1.1 Meaning of safety instructions

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.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

CAUTION
CAUTION 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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Chapter 2 - Hardware and features of the unit

2.1 Function
The water cooling system transfers the heat of the power electronics
components of the drive to the exterior.
The heat of non-water-cooled components inside the drive is transferred
to the exterior by a fan. The air is directed to an optional enclosure cooler
that is connected to the water circuit.
Therefore, virtually no heat losses are dissipated into the control room
(typically < 1 kW, depending on room and water temperature).
If the drive is constructed for the optional enclosure class IP42, no
enclosure cooler is used. Instead, the air in the control room is used for
cooling. The heat losses of up to 7 kW are dissipated into the control room.

2.2 Types of water cooling units

The drive is equipped with one of the following types of water cooling units:
■ Open water cooling unit (A in Fig. 2-2)
The cooling unit is equipped with an expansion vessel that is open to
the atmosphere.
The pressure inside the cooling system is the same as the ambient
atmospheric pressure. The expansion vessel is at the highest point of
the cooling system and maintains the inside pressure.
■ Pressurized water cooling unit (B in Fig. 2-2)
The cooling unit is equipped with an expansion vessel that is closed
to the atmosphere. This type of cooling unit enables a higher system
pressure.
The cooling unit is used for non-stationary applications (eg, marine)
or for applications that require the components of the cooling system
at a higher position than the expansion vessel.

2.3 Cooling circuits

Both types of water cooling units consist of the following circuits:
■ Air cooling circuit (1 in Fig. 2-1)
The circuit transfers the heat of non-water-cooled components to the
exterior.
■ Internal cooling circuit (2 in Fig. 2-1)
The internal cooling circuit is filled with deionized or distilled coolant
or a coolant-antifreeze mixture. It transfers the heat from the power
electronics components to the heat exchanger.

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■ Coolant treatment circuit (3 in Fig. 2-1)
The coolant treatment circuit is part of the internal cooling circuit. It
keeps the conductivity of the coolant at a low level. The coolant treat-
ment circuit also includes the make-up water connection.
■ External cooling circuit (4 in Fig. 2-1)
The external cooling circuit transfers the heat to the exterior.

Valve 1 4
M
Pump

Pressure
PT
transmitter

Temperature 3 PT TT QT M
TT transmitter

Conductivity
TT transmitter 2

Heat exchanger

Deionizer

Example for
power electronics
component
1 4
M

Fan

3 PT TT QT

Fig. 2-1 Block diagram of the cooling system

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2.4 Main components

The components included in the cooling unit (eg, pumps, deionizers, heat exchangers, sensors)
depend on the configuration of the cooling system. For information on the components included, see
the applicable flow diagram and list of components.

A B
1 1

3 2

11 11

4 4

10 10

7 9
5
5
6
8 6 8

7 7

A Typical open unit 7 Pump 2 (option)

B Typical pressurized unit 8 Enclosure cooler (option)
1 Fan 9 Filter Z2
2 Pressurized expansion vessel 10 Water-to-water heat exchanger
3 Open expansion vessel 11 Junction box
4 Control valve
5 Pump 1
6 Deionizer (option)

Fig. 2-2 Types of water cooling units

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2.4.1 Pumps

Function The pump circulates the coolant through the internal cooling circuit

Standard Pump P-1

Option Additional pump P-2

The redundant configuration allows one pump to be serviced while the
drive is in operation.
The default operating scheme is such that both pumps run in
programmable intervals. The pump on standby switches on automatically
when the running pump fails.

For further information on the pump configurations, see Appendix G -

Signal and parameter table.

2.4.2 Heat exchanger

Function The heat exchanger transfers the heat from the drive to the external
cooling circuit.

Standard Water-to-water heat exchanger, internal to the cooling unit

Option Water-to water or water-to-air heat exchanger, external to the cooling unit

2.4.3 Enclosure cooler (option)

Function The enclosure cooler is an air-to-water heat exchanger that transfers the
heat of non-water cooled enclosure to the exterior. It connects to the
external cooling circuit, the internal cooling circuit or to a separate water
supply.

2.4.4 Expansion vessel

Function The expansion vessel compensates for volume changes in the internal
cooling circuit (due to temperature changes, for example). Depending on
the application, it is either an open or a pressurized type (see also Types
of water cooling units).

2.4.5 Deionizer

Function The deionizer continuously purifies the coolant in the internal cooling
circuit and maintains the water conductivity at a specified level.

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2.4.6 Heater (option)

The heater ensures a minimum flow of the coolant through the external
heat exchanger. This flow prevents an increase of the coolant conductivity
when the heat losses of the drive are low, ie, when the drive is on standby
and a water pump is running.

Fig. 2-3 External water heater

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2.4.7 Valves

Control valve The control valve regulates the water temperature by controlling the raw
water flow through the heat exchanger. It is either a two-way valve or a
three-way valve.
Depending on the temperature of the internal cooling circuit,
■ the two-way valve (1 in Fig. 2-4) increases or decreases the raw
water flow through the heat exchanger,
■ the three-way valve (2 in Fig. 2-4) opens a bypass around the heat
exchanger. This allows maintaining the water flow in the external
cooling circuit at a constant level while varying the flow through the
heat exchanger.

1 2

Fig. 2-4 Two-way and three-way control valve

Valve K1 (option) Valve K1 adjusts the water flow through the enclosure cooler, thus
regulating the temperature and minimizing condensation in the drive.

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Safety valve F2 Safety valve F2 (1 in Fig. 2-5) is a pressure relief valve on the outside of
(option) the drive cabinet. It is installed if flanges (2 in Fig. 2-5) are used for raw
water connection and the flanges include shut-off valves (3 in Fig. 2-5).
If the shut-off valves are closed and the pressure inside the internal
cooling circuit increases above 16 bar, safety valve F2 releases excess
water.
The quantity of released water is very small, so that no additional draining
is required.

Fig. 2-5 Safety valve F2

Other valves The installed shutoff valves enable work on the components of the water
cooling unit without having to drain the whole pipe system.
The valves present in the water cooling unit depend on the installed
optional equipment.

For information, see the flow diagram and the list of components in
Appendix A - Additional manuals.

2.4.8 Junction box

The water cooling unit includes sensors for monitoring the temperature,
the pressure and the conductivity of the coolant. These sensors, the pump
motor and the control valve motor are wired to the junction box (Fig. 2-2).

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2.5 Control system
Monitoring functions The control system of the drive continuously monitors the operating
condition of the cooling system.
■ The actual values of temperature, pressure and conductivity of the
coolant in the internal cooling circuit are measured and compared to
their preset alarm and trip levels. If an alarm or fault level is exceeded,
a specific message appears on the display of the control panel of the
drive. The reaction of the drive on an alarm or fault condition depends
on the setting of the related parameters.
■ In addition, the status of the pumps, the water level in the expansion
vessel and the auxiliary fan is monitored.

Auto-cooling sequence
The control system of the drive provides an auto-cooling sequence. If
enabled (auxiliary power is switched on, auto-cooling is selected in the
related parameter), the pump starts when the conductivity of the coolant
exceeds the alarm threshold. The coolant is circulated until the
conductivity decreases below the alarm threshold again.
Conductivity µS/cm

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1

Nominal Alarm Trip

Fig. 2-6 Conductivity – alarm and trip levels

For further information on parameters and control functions, see Appendix

G- Signal and parameter table.

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2.6 I/O modules and circuit breakers

2.6.1 I/O modules

2
1

1 I/O module A5191 (IOEC1)

2 I/O module A5211 (IOEC3)
3 Circuit breakers

Fig. 2-7 Location of I/O modules and circuit breakers

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Chapter 2 - Hardware and features of the unit ABB
2.6.2 Circuit breakers
Either ABB or Möller circuit breakers are installed. If the water cooling unit
has two pumps, the circuit breakers are lockable.

ON

OFF

Fig. 2-8 Circuit breakers

Tab. 2-1 Circuit breakers by component

Circuit breaker Related component

Q5021 Pump 1

Q5023 Pump 2

Q5033 Water heater

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Chapter 3 - Tightening torques and sealings

This chapter provides an overview of tightening torques and sealing
procedures relevant to installation, commissioning and maintenance of
the cooling unit.

3.1 Tightening torques

Couplings
Tab. 3-1 Tightening torque for couplings

Part Thread diameter Tightening torque

Hex nut M10 30-35 Nm

Fig. 3-1 Pipe coupling

Flanges
Tab. 3-2 Tightening torques for flanges

Hexagon Washer Gasket Tightening

DN Nut
screw (D x d x t) (D x d x t) torque

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

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

40 M16-65 M16 30 x 17 x 3 92 x 57 x 1.5 60-80 Nm

50 M16-70 M16 30 x 17 x 3 107 x 66 x 1.5 60-80 Nm

3.2 Sealings
To ensure leakproof sealing, seal threaded connections that do not have
O-rings or gaskets as follows:
• For stainless steel to stainless steel connections, use a sealant such
as Loctite 755 and Loctite 401 activator spray.
• For stainless steel to plastic connections, use thread tape.
• For plastic to plastic connections, use thread tape.

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Chapter 4 - Installation

For information on the type of coolant connections and on optional

equipment installed, see:
■ Outline drawing in Appendix C - Mechanical drawings
■ Flow diagram
■ List of components in Appendix A - Additional manuals

4.1 Water supply connections

4.1.1 Rubber coolant hoses (standard)

Included in delivery

Hose identification 3BHB022984R0002

Number of hoses 1

Length 3m

Inner diameter 38 mm

Outer diameter 58 mm

Connection 1 If necessary, exchange the duct plate (3 in Fig. 4-2) with the blanking
plate (4 in Fig. 4-2).
2 Enter the hoses through the duct plate.

Fig. 4-1 Entering hoses into the water cooling compartment

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3 Route the hoses into the space between the side wall and the base
frame of the cooling unit to where the inlet and the outlet are.
4 Connect the hoses to the coolant supply pipes.
5 Cut the hose to the appropriate length so that they can connect to the
inlet and outlet.
6 Connect the hoses to the inlet and outlet (40 mm diameter).
7 Fasten the hoses with the supplied clamps (5 in Fig. 4-2).
8 Prepare the coolant supply pipes for the connection of the hoses (6
in Fig. 4-2).

Fig. 4-2 Connecting the hoses

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4.1.2 Water supply flanges (option)

For information on the flange location, see the outline drawing of the drive.

Specifications and Standard flange size:

requirements
■ DN50 / PN16
■ ANSI 2” / 150 lbs

Steel grade of flange pipe: conforms with ASTM 316

Tightening torque: 60 - 80 Nm (M16 bolts)

4.1.3 Metal hoses with flanges (option)

For information on metal hoses with flanges, see the outline drawing of the
drive.

4.1.4 External heat exchanger (option)

The design of the external heat exchanger depends on project-specific
requirements.

Specifications and The steel grade of the pipes to the external heat exchanger must conform
requirements with ASTM 304L, ASTM 304, ASTM 316L or ASTM 316.
The maximum installation height of the external heat exchanger must not
be higher than 6 m above the drive.
The maximum pressure drop across the external heat exchanger and the
connecting pipe must not be higher than 0.5 bar.

Connection • If the external heat exchanger uses hoses, the same principles apply
as in 4.1.1 Rubber coolant hoses (standard).
• If the external heat exchanger uses flanges, connect them according
to the outline drawing of the drive. The same principles apply as in
4.1.2 Water supply flanges (option).

4.1.5 Enclosure cooler (option)

The enclosure cooler can connect to the raw water circuit, the internal
cooling circuit or to a separate coolant supply.
If it has a separate coolant supply (such as a chiller unit), 1" flanges N4
and N5 are provided on the right sidewall of the drive. Otherwise, the
connections are on the left sidewall of the cooling unit.

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4.2 Drain connections

4.2.1 Drain connector / hose

The connector is used to drain coolant that has collected in the drip tray of
the cooling compartment.

Included in delivery The drain connector is part of the cooling compartment if the drive is not
equipped with a drain flange.

Not included in delivery Hose, hose clamp

Connection 1 Cut the hose to the appropriate length.

2 To access the drain connector, remove the cover (1 in Fig. 4-3) at the
base of the cabinet.
3 Connect the hose to the drain connector.
4 If necessary, guide the hose through the base frame to the exterior
(2 in Fig. 4-3).

31

13.5
12.1

1 2
8.9

Fig. 4-3 Drain connector

4.2.2 Drain flange (option)

The drain flange N3 is located under the water cooling compartment.

For details, see outline drawing of the drive.

Connection The same principles apply as in 4.1.2 Water supply flanges (option).

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Chapter 5 - Commissioning

Commissioning of drive equipment must only be performed by or in the

presence of qualified and certified personnel.
Preconditions for commissioning of the cooling system:
■ Drive is ready as per Commissioning check list

NOTICE
Damage to pump seals.
If a pump is running without coolant in it, the pump seals are damaged
immediately.
As long as the cooling system is empty:
• Do not switch on the auxiliary power supply.
• Do not switch on the pump(s).

5.1 Overview
Commissioning of the cooling unit includes the following items:
1 Preparing the coolant for the internal cooling circuit
2 Filling the internal cooling circuit
3 Venting the internal cooling circuit
4 Final settings and adjustments

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5.2 Preparing the coolant for the internal cooling circuit
The cooling unit uses either coolant or a coolant-glycol mixture. The
following sections explain the coolant and glycol requirements and how to
mix the coolant-glycol mixture if applicable.

5.2.1 Requirements

NOTICE
Inhibitors or other chemicals in the coolant significantly reduce the lifetime
of the ion exchange resin and can damage the internal coolant circuit.
Use deionized or distilled coolant. If deionized or distilled coolant is not
available, use water that meets the water specification.

Tab. 5-1 Water specification

Parameter Value

pH 7 -8.5

Specific conductivity < 300 S/cm

Hardness 3 - 10° dH

Chloride (Cl) < 300 mg/l

Copper (Cu) < 0.1 mg/l

Total dissolved salt < 1000 mg/l

Undissolved particles <5 mg/l

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5.2.2 Mixing glycol into the coolant

Glycol requirements

NOTICE
Glycol as used in cars is not suitable as antifreeze. Due to its high conduc-
tivity, it prevents the drive from starting.
Use one of the following types of glycol:
■ Monoethylene glycol (CAS: 107-21-1)
■ Propylene glycol (CAS: 57-55-6)
Make sure that the glycol does not contain additives.

Tab. 5-2 Glycol specification

Parameter Monoethylene glycol Propylene glycol

Content >99.8% >99.8%

Density at 20°C (68°F) 1.115 g/cm3 1.036 g/cm3

Viscosity at 20°C (68°F) 20 mm2/s 56 mm2/s

Specific heat capacity at 20°C (68 °F) 2.3 kJ/kgK 2.5 kJ/kgK

Thermal conductivity 0.29 W/mK 0.21 W/mK

pH-Value Neutral Neutral

Mixing

CAUTION
Hazardous chemical!
Glycol used as antifreeze is a health hazard.
• To prevent direct contact, inhalation or ingestion, wear rubber gloves,
goggles and respiratory protection.
• Observe the safety data sheet of the supplier.
• Before mixing the glycol and the coolant, make sure that any person
involved in the process has read and fully understood all safety and
mixing instructions.

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Chapter 5 - Commissioning ABB
Requirements • For mixing or storing the coolant-glycol mixture, use clean containers
that are designated specifically and labeled appropriately.
• When handling the coolant and the glycol, ensure that chips, grease,
remnants or any other impurities cannot infiltrate the coolant-glycol
mixture
• The ideal temperature for mixing the glycol and the coolant is at
+ 5 °C to + 30 °C.

Mixing ratios Depending on the required freezing point and the glycol used, the coolant-
glycol mixture needs to have a specific concentration. For details, see Tab.
5-3 and Tab. 5-4.
Tab. 5-3 Water-monoethylene glycol concentration

Distilled coolant
Freezing point Pure monoethylene glycol
(volume percent)

- 10 °C 20% 80%

- 20 °C 34% 66%

- 30 °C 44% 56%

- 40 °C 52% 48%

Tab. 5-4 Water-propylene glycol concentration

Distilled coolant
Freezing point Pure propylene glycol
(volume percent)

- 10 °C 23% 77%

- 20 °C 37% 63%

- 30 °C 46% 54%

- 40 °C 52% 48%

How to mix it 1 If the glycol has been ordered from ABB, verify
that the glycol container contains the amount of
glycol ordered and specified on the container
label.
The last two digits of the item number stand for
the amount of glycol in liters (eg,
3BHL001483P0021 contains 21 liters of
glycol).
2 Add 75% of the coolant required to reach the
correct concentration into the glycol container.
3 Thoroughly mix the glycol and the coolant.

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ABB Chapter 5 - Commissioning

NOTICE
If you do not mix the glycol and the coolant, it has a negative effect on the
thermal and hydraulic behavior of the coolant.

4 To reach the correct concentration, add the remaining 25% of the

coolant required to the container.
5 Thoroughly mix the glycol and the coolant again.
To store any remainders of the coolant-glycol mixture for further use,
use the container and close it.
6 Continue with 5.3 Filling the internal cooling circuit.

5.3 Filling the internal cooling circuit

5.3.1 Tools and equipment

5 mm 19 mm

1/2"

500 mm

Pump output pressure: 2 bar

Inner diameter. 20 mm

1/2" female pipe

Container to collect coolant

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Chapter 5 - Commissioning ABB
5.3.2 Preparatory steps
1 In the control compartment of the drive, disconnect the following
devices from the power supply:
• Pump 1: switch off circuit breaker Q5021.
> Pump 2: switch off circuit breaker Q5023.
> Water heater: switch off circuit breaker Q5033.

For ON / OFF position of the circuit breaker, see Fig. 2-8.

2 Switch on the auxiliary power supply.

3 Open the following valves:
• V5
> V9
4 Close valve V1.
5 Close the following valves:
• V11
> If V11 is not installed: V21 and V23
6 Close valves V15 and V80.
7 Close the drain valve (3 in Fig. 5-1) inside the inverter compartment
of the drive.
To get to the drain valve, do the following:
1 Unscrew and remove the center post (1 in Fig. 5-1).
2 Remove the fastening screws (2 in Fig. 5-1) of the swing frame.
3 Pull out the swing fame.

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ABB Chapter 5 - Commissioning

PZ3
2 1

1/2"

500 mm
19 mm
2

Fig. 5-1 Location of drain valve in inverter compartment

> Cooling units with pump 2:

Close valve V81.
> Pressurized cooling unit:
1 Open valve V50 and V56.
2 Close valve V71.
> Cooling units with enclosure cooler:
Close valve V82.

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Chapter 5 - Commissioning ABB
> Cooling units with external heat exchanger:
1 Unplug connector X23 of the I/O module A5211 in the
control compartment of the drive.
This step prevents that the control system of the drive opens
or closes the control valve.
2 Completely open valve B14 (Fig. 5-2) so that all the coolant
flows through the valve.

5 mm

Fig. 5-2 Adjusting the control valve

The valve is fully open when the LED of DI14 on the I/O
module A5211 is on. Do not use the indicator on the valve.
3 Open all shut-off valves in the pipe to the heat exchanger.
8 Close valve V83.
9 Close all drain plugs.

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ABB Chapter 5 - Commissioning

10 Connect the filling pump to valve V14 according to Fig. 5-3.

1 2 ISO-R1/2"

3 4

5 6

Fig. 5-3 Connecting the filling pump to valve V14

11 Open the following valves:

> Open cooling unit: V12
> Pressurized cooling unit: V50
> Cooling units with external heat exchanger:
1> Open all vent valves of the pipes to the heat exchanger.
2> Close all drain plugs of the pipes to the heat exchanger.
12 Continue with 5.3.3 Filling the internal cooling circuit.

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Chapter 5 - Commissioning ABB
5.3.3 Filling the internal cooling circuit

CAUTION
Hazardous chemical!
If a coolant-glycol mixture is used, do the following:
• To prevent direct contact, inhalation or ingestion, wear rubber gloves,
goggles and respiratory protection.
• Observe the safety data sheet of the supplier.

1 Open valve V14.

2 Pump in coolant at a rate of ≤ 15 l/min.
> Cooling units with external heat exchanger:
Close all vent valves of the pipes to the heat exchanger when
coolant starts to flow out.
3 Stop the filling pump, when the following is indicated:
> Open cooling unit:
The level in the expansion vessel reaches ~80% of the maximum
level.
> Pressurized cooling unit:
B16 indicates a pressure of ~1.2 bar (or the pressure specified
on the cooling unit).
4 Close valve V14.
5 Continue with 5.4 Venting the internal cooling circuit.

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ABB Chapter 5 - Commissioning

5.4 Venting the internal cooling circuit

CAUTION
Pressurized coolant can cause injuries.
To prevent coolant ejecting from the pipes, do not completely remove the
cap or screw of a vent.

The pressure values used in this chapter are valid for a coolant
temperature of approximately 24°C.

When you vent the cooling system, check the coolant level regularly. If
necessary, add coolant. Make sure that all air escapes through the vents.

5.4.1 Venting pump 1

Applies to cooling units with one or two pumps.

If the cooling unit has two pumps, vent the pumps in the following
sequence:
1 Pump 1
2 Pump 2

1 Do not switch on the pump.

2 Open the following valves:
1 V1
> V7
2 V11
> If V11 is not installed: V21 and V23
3 V15
> Pressurized cooling unit:
Open vent V71 of the deionizer.

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Chapter 5 - Commissioning ABB
3 To switch on the pump, do the following:
1 In the junction box of the cooling unit, close the disconnect termi-
nals X2:22, X2:23 and X2:24 (1).

Open Closed

2 In the control compartment of the drive, unplug connector X21

from I/O module A5191.
3 Connect a jumper with a cross-section of 1 mm2 between
terminal X21:1 and X21:3 of connector X21.

4 Plug connector X21 into I/O module A5191.

5 To start the pump, switch on circuit breaker Q5021.
6 When starting the pump for the first time, check if the pump
rotates in the correct direction, and change it if necessary. For
instructions, see 12.2 Changing the rotation during commis-
sioning.

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ABB Chapter 5 - Commissioning

4 Depending on the type of cooling unit, continue with:

> Open cooling unit
or
> Pressurized cooling unit

Open cooling unit

1 While the pump is running for 10 min, check the level indicator of the
expansion vessel (Fig. 5-4).
2 If the level has dropped to the minimum mark, do the following:
1 To stop the pump, switch off circuit breaker Q5021.
2 Close the following valves:
• V11
> V21 and V23 if V11 is not installed
3 Open valve V14 and pump in coolant at a rate of ≤ 15 l/min. Stop
the filling pump when the level it is ~50 mm below the maximum
mark of the level indicator.

Maximum level

Minimum level

Fig. 5-4 Level indication

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Chapter 5 - Commissioning ABB
4 Open the following valves:
• V11
> If V11 is not installed: V21 and V23
5 To vent the cooling circuit, let the pump run for 10 minutes.
While the pump is running, check the level indicator of the expan-
sion vessel:
• If the level drops to the minimum mark again, repeat above
steps.
• If the level stays at about 50 mm below the maximum mark,
switch off circuit breaker Q5021 to stop the pump.
3 Continue with:
> 5.4.2 Venting pump 2 (option)
or
> 5.5 Final settings and adjustments

Pressurized cooling unit

1 While the pump is running for 10 min, check the pressure at pressure
gauge B16.
2 If the pressure has dropped below 0.5 bar, do the following:
1 To stop the pump, switch off circuit breaker Q5021.
> Cooling units with external heat exchanger:
Release air through all vent valves of the pipes to the exter-
nal heat exchanger.
2 Close the following valves:
• V11
> If V11 is not installed: V21 and V23

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ABB Chapter 5 - Commissioning

3 Open valve V14 and pump in coolant at a rate of ≤ 15 l/min.

Stop the filling pump when a pressure of ~1.2 bar is indicated on
pressure gauge B16.

Fig. 5-5 Pressure gauge B16

4 Open the following valves:

• V11
> If V11 is not installed: V21 and V23
5 To vent the cooling circuit, let the pump run for 10 minutes.
While the pump is running, check the pressure:
• If the pressure drops below 0.5 bar again, repeat above
steps.
• If the pressure stays at approximately 1.2 bar (or the pres-
sure specified on the unit), switch off circuit breaker Q5021
to stop the pump.
3 When the pump is switched off, check if the pressure stays at approx-
imately 1.2 bar (or the pressure specified on the unit).

An increase in pressure indicates that air is trapped in the external

heat exchanger circuit.
4 Continue with:
> 5.4.2 Venting pump 2 (option)
or
> 5.5 Final settings and adjustments

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Chapter 5 - Commissioning ABB
5.4.2 Venting pump 2 (option)

After completing the instructions in 5.4.1 Venting pump 1, vent pump 2 as

follows.
With the pumps switched off, do the following:
1 Open the following valves:
• V2
> V8
2 To switch on the pump, do the following:
1 In the junction box of the cooling unit, close the disconnect termi-
nals X2:25, X2:26 and X2:27 (1).

Open Closed

2 In the control compartment of the drive, unplug connector X22

from I/O module A5211.
3 Connect a jumper with a cross-section of 1 mm2 between
terminal X22:1 and X22:3 of connector X22.

4 Plug connector X22 into I/O module A5211.

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ABB Chapter 5 - Commissioning

5 To start the pump 2, switch on circuit breaker Q5023.

6 When starting the pump for the first time, check if the pump
rotates in the correct direction, and change it if necessary. For
instructions, see 12.2 Changing the rotation during commis-
sioning.
3 Depending on the type of cooling unit, continue with:
> Open cooling unit
or
> Pressurized cooling unit

Open cooling unit

1 Let pump 2 run for 10 minutes.
While the pump is running, check the level indicator of the expansion
vessel (Fig. 5-4).
2 If the level has dropped to the minimum mark, do the following:
1 To stop the pump, switch off circuit breaker Q5023.
2 Close the following valves
• V11
> If V11 is not installed: V21 and V23
3 Open valve V14 and pump in coolant at a rate of ≤ 15 l/min. Stop
the filling pump when until the level is at the maximum mark of
the level indicator.
4 Open the following valves:
• V11
> If V11 is not installed: V21 and V23
5 To vent the cooling circuit, keep the pump running for 10
minutes.
While the pump is running, check the level indicator of the expan-
sion vessel:
• If the level drops to the minimum mark again, repeat above
steps.
• If the level stays at the maximum mark, switch off the circuit
breaker Q5023 to stop the pump.
3 Continue with 5.5 Final settings and adjustments.

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Chapter 5 - Commissioning ABB
Pressurized cooling unit
1 Let the pump run for 10 minutes.
While the pump is running, check the pressure at the pressure gauge
B16.
2 If the pressure has dropped below 0.5 bar, do the following:
1 To stop the pump, switch off circuit breaker Q5023.
2 Close the following valves:
• V11
> If V11 is not installed: V21 and V23
3 Open valve V14 and pump in coolant at a rate of ≤ 15 l/min. Stop
the filling pump when the pressure gauge B16 indicates a pres-
sure of ~1.2 bar (or the pressure specified on the unit).
4 Open the following valves:
• V11
> If V11 is not installed: V21 and V23
5 To vent the cooling circuit, let the pump run for 10 minutes.
While the pump is running, check the pressure:
• If the pressure drops below 0.5 bar again, repeat above
steps.
• If the pressure stays at approximately 1.2 bar (or the pres-
sure specified on the unit), switch off the circuit breaker
Q5023 to stop the pump.
3 When the pump is switched off, check if the pressure stays at ~1.2 bar
(or the pressure specified on the unit).
An increase in pressure, indicates that air is trapped in the external
heat exchanger circuit.

4 Continue with 5.5 Final settings and adjustments.

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ABB Chapter 5 - Commissioning

5.5 Final settings and adjustments

5.5.1 Adjusting the flow meter (option)

Applies to cooling units with enclosure cooler.

1 To adjust the flow meter, do the following:

• If the enclosure cooler is connected to the internal cooling circuit,
make sure that the pump(s) are running.
• If the enclosure cooler is connected to an external cooling circuit,
make sure that the external cooling circuit is open.
2 Open the shut-off valves:
• V29
> V28
3 Turn the flow adjustment valve (1 in Fig. 5-6) of the flow meter until
the center line of the float (3 in Fig. 5-6) is at the 20 l/min mark (2 in
Fig. 5-6).

Fig. 5-6 Flow meter B15

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Chapter 5 - Commissioning ABB
5.5.2 Adjusting the temperature of the enclosure cooler (option)

Applies to cooling units with an enclosure cooler and a thermostatically

operated valve.

To adjust the temperature of the enclosure cooler, set the adjustment knob
of valve K1 to level 5 (30°C).

K1

°C
5 30

4 23

3 15

2 3

5.5.3 Preparing the cooling system for operation

1 Do the following:
> Open cooling unit:
Make sure that the level in the level indicator is about 50 mm be-
low the maximum mark.
> Pressurized cooling unit:
Make sure that the pressure indicated at the pressure gauge B16
and displayed on the CDP control panel is approximately 1.2 bar
(or the pressure specified on the unit).
2 Close the following valves:
• V14
> V9
3 Disconnect the filling pump.

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ABB Chapter 5 - Commissioning

4 Switch off the auxiliary power supply.

5 To enable secure locking of the compartment door, restore the orig-
inal state of the inverter compartment.
1 Push back the swing frame and fasten it.
2 Install the center post.
6 Remove the jumper from the I/O module connector and check that
the connector is plugged in properly.
• Pump 1: connector X21 of I/O module A5191
> Pump 2: connector X22 of I/O module A5211
> Cooling unit with external heat exchanger:
Plug connector X23 into I/O module A5211.
7 Switch on the auxiliary power supply.
8 Close the following valves:
> Open cooling unit: V12
> Pressurized cooling unit: V50
9 Switch on the circuit breakers:
• Pump 1: Q5021
> Pump 2: Q5023
> Water heater: Q5033
> Cooling unit with the coolant heater:
Set the temperature to the reference temperature of the internal
cooling circuit (parameter RefWtrTemperature).
> Drives with software version MSOH: see parameter 190.13.
> Drives with software version MSOI: see parameter 41.28.
> Cooling unit with an enclosure cooler:
Make sure that the flow meter B15 is set to 20 l/min or adjust it if
necessary.
10 Reset the alarms that are displayed on the CDP control panel.
To reset pump alarms, set parameter 41.10 PumpAlarmReset to 1.

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Chapter 5 - Commissioning ABB

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ABB

Chapter 6 - Preventive maintenance

6.1 Inspection checklist

Perform the inspections regularly and keep a record of the results and
measurements. ABB recommends recording all troubleshooting and
maintenance in a logbook including:
■ Date and time
■ Detailed description of work carried out
■ Measured values
Depending on the cooling unit, not all of the inspections may apply.
For information on how to inspect a pump, see Chapter 7 - Inspecting and
replacing a pump.
Checking the actual operating conditions is possible on the control
terminal of the drive via fieldbus devices and on the corresponding sensor.

For information on the control terminal of the drive, see the user manual
of the drive.

1 Components in general Checked

1 Check if the pipes, hoses or other components leak. Look for coolant on the floor.

2 Check for dust or dirt on components and clean the components.

2 Pump(s) Checked

1 Check if pump 1 leaks.

2 Check pump 1 and its bearings for unusual noise and vibrations.

3 Check if pump 2 (option) leaks.

4 Check pump 2 (option) and its bearings for unusual noise and vibrations.

3 Coolant conductivity Checked

Check if the conductivity (parameter 4.04 InvWtrConductivity) is 0.05 - 0.4 µS/cm. Compare the
value to previous measurements taken at the same temperature.
The conductivity rises approximately 0.05 µS/cm with every 10°C coolant temperature increase in
the internal cooling circuit.

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Chapter 6 - Preventive maintenance ABB

4a Coolant pressure (monthly inspection, drive in operation) Checked

1 With the open water cooling unit (option) and the pump(s) running, check if the differential
pressure 1 (4.03 InvWtrCoolPress1) is approximately 2.3 bar. Compare the value to previous
measurements.

2 With the pressurized water cooling unit (option) and the pump(s) running, check if the differential
pressure 2 (parameter 80.20 WtrCoolPressDiff) is approximately 2.3 bar (or the pressure specified
on the unit). Compare the value to previous measurements.

3 With the pressurized water cooling unit (option) and the pump(s) running, check if pressure 2
(80.19 WtrCoolPress2 or indicated on the pressure gauge B16) is approximately 1.2 bar (or the
pressure specified on the unit). Compare the value to previous measurements taken at the same
temperature.

4b Coolant pressure (annual inspection, drive shut down for general maintenance) Checked

1 With the open water cooling unit (option) and the pump(s) stopped, check if pressure 1 (parameter
4.03 InvWtrCoolPress1) is approximately 0 bar. Compare the value to previous measurements.

2 With the pressuirzed water cooling unit (option) and the pump(s) stopped, check if the differential
pressure (parameter 80.20 WtrCoolPressDiff) is approximately 0 bar. Compare the value to
previous measurements.

3 With the pressurized water cooling unit (option) and the pump(s) stopped, check if pressure 2
(parameter 80.19 WtrCoolPress2 or indicated on the pressure gauge B16) is approximately 1.2 bar
(or the pressure specified on the unit). Compare the value to previous measurements taken at the
same temperature).

5 Coolant temperature Checked

Check if the temperature (parameter 4.02 InvWtrCoolTemp) meets the customer-specific nominal
value. Compare the value to previous measurements.

6 Coolant level Checked

With the open water cooling unit (option), check if the water level is between the minimum and the
maximum mark on the water level indicator of the expansion vessel. Compare to previous
measurements taken at the same temperature.

7 Coolant flow Checked

Check if flow meter B15 indicates 20 l/min.

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ABB Chapter 6 - Preventive maintenance

6.2 Checking actual values

For detailed navigation instructions for the CDP control panel, see the
ACS1000W user manual, Chapter 9 – CDP control panel.

1 To check actual values on the CDP control panel, select the actual
signals display (ACT).
2 Select parameter group 4 ACTUAL SIGNALS.
• To check the water temperature, select signal 02 InvWtrCool-
Temp.
• To check the water conductivity, select signal 04 InvWtrConduc-
tivity.
• To check the water pressure 1, select signal 03 InvWtrCool-
Press1.
3> Select parameter group 80 ACTUAL SIGNALS OF IOEC3.
> To check the water pressure 2, select signal 19 WtrCoolPress2.
> To check the differential pressure, select signal 20 WtrCool-
PressDiff.

Coolant level
> Open cooling unit:
Check the level on the level indicator of the expansion vessel (see
Fig. 5-4).
> Pressurized cooling unit:
The coolant level is determined according to water pressure 2.

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Chapter 6 - Preventive maintenance ABB

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ABB
Chapter 7 - Inspecting and replacing a pump

7.1 General information

Replacement intervals See maintenance schedule.

Maintenance Replace a pump when it leaks or when it develops vibrations and / or

indications unusual noise.

Maintenance during Possible if cooling unit has two pumps.

operation

Lubrication The internal parts of the pump are maintenance-free.

7.2 Inspection

DANGER
Hazardous voltage!
When the drive is in operation, voltages of up to 690 V (AC) are present in
the cooling unit.
Use personal protective equipment.

7.3 Removal

DANGER
Hazardous voltage!
Observe the following, when you work on the cooling unit:
• Units with a single pump: make sure that the drive is de-energized
and grounded.
For information, see ACS1000W user manual of the drive.
> Units with two pumps: when a pump is replaced while the drive is in
operation, voltages of up to 690 V (AC) are present in the cooling unit.
Use personal protective equipment.

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Chapter 7 - Inspecting and replacing a pump ABB
7.3.1 Isolating the pump
1 In the control compartment of the drive, disconnect the pump from the
power supply.
• Pump 1: switch off circuit breaker Q5021.
> Pump 2: switch off circuit breaker Q5023.
2 In the junction box of the cooling unit, open the disconnect terminals
of the pump:
• Pump 1: disconnect terminals X2:22, X2:23 and X2:24 (1).
> Pump 2: disconnect terminals X2:25, X2.26 and X2:27 (2).

1 2

Open Closed

3 Unhook the fixing belts (1) and lift the deionizer out of the cooling unit.

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ABB Chapter 7 - Inspecting and replacing a pump

4 Isolate the pump. Continue with:

> Unit with one pump
or
> Unit with two pumps

Unit with one pump

1 Close the following valves:
• V1 on the suction side
• V15
> V7 on the discharge side
> If V7 is not installed: V5 and V11
> If V11 is not installed: V21 and V23 (conductivity sensors)
> Cooling units with external heat exchanger if valve V7 is not
installed:
Valves in the supply and discharge pipe of the heat exchanger
2 Continue with 7.3.2 Draining the pump.

Unit with two pumps

• If pump 1 is replaced, close the following valves:
• V1 on the suction side
> V7 on the discharge side
The check valve V3 additionally isolates the pump on the discharge
side.

• If pump 2 is replaced, close the following valves:

• V2 on the suction side
> V8 on the discharge side
The check valve V4 additionally isolates the pump on the discharge
side.

Continue with 7.3.2 Draining the pump.

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Chapter 7 - Inspecting and replacing a pump ABB
7.3.2 Draining the pump
1 To drain the pump, remove the drain plug at the bottom of the pump
housing.
Approximate coolant quantities that drain from the cooling circuit:
> Unit with one pump and internal heat exchanger: 6 l
> Unit with one pump and external heat exchanger:
Quantity depends on the location of the shut-off valves
> Unit with two pumps: 3 l per pump
2 Insert the drain plug again.
3 Continue with 7.3.3 Removing the pump.

7.3.3 Removing the pump

1 Unscrew the lid of the terminal box of the pump motor.
2 Verify that the terminals of the pump motor are de-energized.
3 Note how the power supply cable is connected.
4 Disconnect the power supply cable.

front view

5 Remove the coupling at the supply (1) and discharge (2) pipe of the
pump.

side view
6 Push the rubber gasket of each coupling onto the corresponding pipe.
7 Remove the fastening bolts at the pump foot.

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ABB Chapter 7 - Inspecting and replacing a pump

8 Place a lift truck or a height-adjustable table in front of the pump and

pull the pump onto it.

7.4 Installing the pump

1 Put the new pump into the cooling unit.
2 Tighten the bolts at the pump foot by hand.
3 Align the pump with the pipes.
4 Push the rubber gasket of each coupling back over the two joining
pipes.
Make sure that each pipe is covered by the same length of gasket.
5 Depending on the number of pumps and the accessibility of the
pumps, do the following:
> Water cooling unit with one pump:
1 Install the coupling at the supply pipe and discharge pipe.
2 Tighten the screws alternately.
3 Tighten the fastening bolts at the pump foot.
> Water cooling unit with two pumps – front access:
1 Install the coupling at the supply pipe:
2 Tighten the screws alternately.

Do not yet install the coupling at the discharge pipe. The

discharge pipe will be used for venting.
Do not tighten the fastening bolts at the pump foot.
> Water cooling unit with two pumps – front / side access:
1 Install the coupling at the supply pipe and the discharge
pipe.
2 Tighten the screws alternately.
3 Tighten the fastening bolts at the pump foot.
6 Connect the power supply cable in the terminal box in the correct
order and screw the lid back on.
7 To fill and vent the cooling unit, continue with the appropriate section:
> 7.5 Filling / venting – unit with one pump
or
> 7.6 Filling – unit with two pumps – front access
or
> 7.7 Filling – unit with two pumps – side / rear access

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Chapter 7 - Inspecting and replacing a pump ABB
7.5 Filling / venting – unit with one pump
1 To fill the pump with coolant, open the following valves:
1 V1
2> V7
3 V11
> If V11 is not installed: V21 and V23
2 Depending on the type of cooling unit, release the air as follows.
> Open cooling unit:
1 Open valve V14 just a little.
2 As soon as coolant runs out, close valve V14 again.
3 Open valve V12
4> If valve V7 is not installed: open valve V5 and V15
> Pressurized cooling unit:
1 Open valve V71.
2 As soon as coolant runs out, close valve V71.
3 Open valve V50.
4> If valve V7 is not installed: open valve V5 and V15
3> Cooling units with external heat exchanger and if valve V7 is not
installed:
Open the valves in the supply pipe and discharge pipe again.
4 Check for leakages.
5 Switch on the pump.
1 In the control compartment of the drive, unplug connector X21
from I/O module A5191.
2 Connect a jumper with a cross-section of 1 mm2 between
terminal X21:1 and X21:3 of connector X21.

3 Plug connector X21 into I/O module A5191.

4 In the junction box of the cooling unit, close the disconnect termi-
nals.

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ABB Chapter 7 - Inspecting and replacing a pump

5 Switch on circuit breaker Q5021 to start the pump.

6 Check if the pump rotates in the correct direction.
If necessary, continue with 12.3 Changing the rotation after a
pump replacement.
6 To vent the cooling system, the pump running for 30 min.
7 Switch off the pump.
8 Check for leakages.
9 Continue with 7.8 Final settings – unit with one pump.

7.6 Filling – unit with two pumps – front access

1 To fill the pump with coolant, slightly open the following valve and
close it when coolant starts running out of the discharge pipe:
• If pump 1 was replaced:
• V1
> V7
• If pump 2 was replaced:
• V2
> V8
While the pump fills with coolant, the air inside the pump escapes
through the discharge pipe socket.
2 Install the coupling at the discharge pipe.
3 Tighten the screws alternately.
4 Tighten the fastening bolts at the pump foot.
5 Continue with 7.9 Venting / final settings – unit with two pumps.

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Chapter 7 - Inspecting and replacing a pump ABB
7.7 Filling – unit with two pumps – side / rear access
1 To release air, remove the vent plug on the pump housing.

rear view

2 To fill the pump with coolant, open the following valves a little and
close them when coolant starts running out of the discharge pipe.
• If pump 1 was replaced:
• V1
> V7
• If pump 2 was replaced:
• V2
> V8
While the pump fills with coolant, the air inside the pump escapes
through the vent hole.
3 Insert the vent plug.
4 Connect the pump to the coolant supply.
• If pump 1 was replaced, open the following valves:
• V1
> V7
• If pump 2 was replaced, open the following valves:
• V2
> V8
5 Continue with 7.9 Venting / final settings – unit with two pumps.

7-8 (10) 3BHS204366 ZAB E01 Rev. E 1k W WCU UM

ABB Chapter 7 - Inspecting and replacing a pump

7.8 Final settings – unit with one pump

1 Remove the jumper from the I/O module connector and check that
the connector is plugged in properly.
Pump 1: connector X21 of I/O module A5191
2 Lift the deionizer back into the compartment and fasten it with the two
belts.
3 If necessary, add coolant to the cooling circuit according to Chapter
11 - Adding coolant to the internal cooling circuit.
4 Switch on circuit breaker Q5021.
5 Close the following valve:
> Open cooling unit: V12.
> Pressurized cooling unit: V50.
6 Reset the alarms that are displayed on the CDP control panel.
To reset pump alarms, set parameter 41.10 PumpAlarmReset to 1.

7.9 Venting / final settings – unit with two pumps

1 Check for leakages.
2 If necessary, add coolant to the cooling circuit as described in
Chapter 11 - Adding coolant to the internal cooling circuit.
3 Start the pump as follows:
• Pump 1:
1 In the terminal box of the cooling unit, close the disconnect
terminals X2:22, X2:23 and X2:24.
2 In the control compartment of the drive, unplug connector
X21 from I/O module A5191.
3 Connect a jumper with a cross-section of 1 mm2 between
terminal X21:1 and X21:3 of connector X21.

4 Plug connector X21 into I/O module A5191.

5 To start pump 1, switch on circuit breaker Q5021.
6 Check if the pump rotates in the correct direction and
change it if necessary. For instructions, see 12.3 Changing
the rotation after a pump replacement.

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Chapter 7 - Inspecting and replacing a pump ABB
• Pump 2:
1 In the terminal box of the cooling unit, close the disconnect
terminals X2:25, X2:26 and X2:27.
2 In the control compartment of the drive, unplug connector
X22 from I/O module A5211.
3 Connect a jumper with a cross-section of 1 mm2 between
terminal X22:1 and X22:3 of connector X22.
4 Plug connector X22 into I/O module A5211.
5 To start pump 2, switch on circuit breaker Q5023.
6 Check if the pump rotates in the correct direction, and
change it if necessary. For instructions, see 12.3 Changing
the rotation after a pump replacement.
4 To vent the cooling system, let the pump run for 10 min.
5 Remove the jumper from the I/O module connector and check that
the connector is plugged in properly.
• Pump 1: connector X21 of I/O module A5191
• Pump 2: connector X22 of I/O module A5211
6 Lift the deionizer back into the compartment and fasten it with the two
belts.
7 Reset the alarms that are displayed on the CDP control panel.
To reset pump alarms, set parameter 41.10 PumpAlarmReset to 1.

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ABB

Chapter 8 - Replacing deionizer and filter

8.1 General information

Replacement intervals See maintenance schedule.

Maintenance Replace the deionizer and filter when the coolant conductivity has
indications increased above the nominal value.

Maintenance during Make sure that the replacement does not take longer than 30 minutes. If
operation the time is exceeded, the coolant conductivity rises above the trip level
and the drive shuts down.

8.2 Removal

DANGER
Hazardous voltage!
When you work while the drive is in operation, voltages up to 690 V (AC)
are present in the cooling unit.
If necessary, use personal protective equipment.

WARNING
Hazardous chemicals!
The ion exchange resin can seriously injure your eyes! To prevent injury,
do the following:
• To prevent eye contact, wear safety goggles and gloves.
• Observe the safety data sheet of the supplier.

CAUTION
Hazardous chemical!
If a coolant-glycol mixture is used, do the following:
• To prevent direct contact, inhalation or ingestion, wear rubber gloves,
goggles and respiratory protection.
• Observe the safety data sheet of the supplier.

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 8-1 (4)

Chapter 8 - Replacing deionizer and filter ABB
8.2.1 Preparatory steps
• Isolate the coolant treatment circuit.
• Close valve V11
> If valve V11 is not present, close V21 and V23 (conductivity
sensors)
• If necessary, make provisions to catch the coolant that comes out of
the hoses when they are uncoupled from the deionizer.

8.2.2 Replacing the deionizer

1 Disconnect the hoses from the distributor head.
Some residual coolant may spill out.
Depending on the type of cooling unit, the distributor head has two or
three hose connectors.

2 To prevent dirt entering, cover the hose connectors.

3 Unhook the two belts, and lift the deionizer out of the compartment.
4 Unscrew the distributor head from the deionizer.
5 Slowly pull the distributor head and the tube out of the deionizer.
6 Remove the O-ring of from the distributor head of the deionizer.
7 Rinse the tube.
8 Remove the distributor head from the new deionizer.
9 Mount the O-ring of the new deionizer on the old distributor head.
10 Insert the new distributor head and the tube into the new deionizer
and tighten the distributor head.
11 Lift the new deionizer into the compartment and fasten it.
12 Reconnect the hoses and tighten the union nuts.

Connect the hose that comes from filter Z2 to the OUT socket (1 in
Fig. 8-1) of the distributor head.

Fig. 8-1 Deionizer – distributor head

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ABB Chapter 8 - Replacing deionizer and filter

8.2.3 Replacing the filter

1 Unscrew the filter housing from its socket and remove it.
2 Remove the old filter cartridge from the filter housing.
3 Remove the O-ring from the filter housing groove.

4 Remove the old lubricant from the O-ring.

5 Lubricate the O-ring with clean petroleum jelly or a silicone lubricant.
6 Carefully reinsert the O-ring into the filter housing groove.
7 Insert and center the new filter cartridge.

8 Screw the housing back onto its socket. Do not overtighten it.

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 8-3 (4)

Chapter 8 - Replacing deionizer and filter ABB
8.2.4 Filling and venting the coolant treatment circuit
1 To fill the coolant treatment circuit, slowly open valve V11, or if appli-
cable V21 and V23.

When the drive is in operation and you open the valve too fast, the
coolant pressure may drop below the trip level and the drive shuts
down.
2 Check the distributor head and the filter for leakage.
3 Vent the coolant treatment circuit.
• Pressurized expansion vessel (option):
1 Open valve V71.
2 Open valve V15.
• Open expansion vessel (option):
1 Open valve V12 for 30 min.
2 Open valve V50 for 30 min.
4 If necessary, add coolant according to Chapter 11 - Adding coolant to
the internal cooling circuit.

8.2.5 Disposal
Dispose of the deionizer and / or the exhausted resin according to local
regulations and the applicable safety data sheet.

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ABB

Chapter 9 - Cleaning the strainer Z1

9.1 General information

Purpose of the strainer Strainer Z1 (mesh size 0.5 mm) prevents dirt in the external cooling circuit
from entering the cooling unit.

Replacement intervals See maintenance schedule.

Maintenance With the external heat exchanger (option), clean the strainer whenever
indications you replace the ion exchange vessel and the cartridge of filter Z2.
Also clean the strainer if the raw water flow has decreased.

Maintenance during Not possible

operation

9.2 Overview

Fig. 9-1 Strainer Z1

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 9-1 (4)

Chapter 9 - Cleaning the strainer Z1 ABB
9.3 Cleaning
Depending on whether the heat exchanger is internal or external to the
drive, continue with
> 9.3.1 Internal heat exchanger
or
> 9.3.2 External heat exchanger

9.3.1 Internal heat exchanger

1 De-energize the drive.

For information, see the user manual of the drive.

2 Shut off the external cooling circuit.
3> Cooling units with an enclosure cooler connected to the raw water
circuit:
1> Open valve V82 to drain the raw coolant pipe.
2> Close valve V82 when all coolant has drained.
4 Unscrew and remove the strainer from its pipe socket.
5 Remove the strainer screen from the cap.
6 Clean the strainer screen and the cap.
7 Reinsert the strainer screen into the cap.
8 Insert the strainer into its pipe socket and tighten it.
9 Open the raw water supply.
10 Check the strainer for leakage.

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ABB Chapter 9 - Cleaning the strainer Z1

9.3.2 External heat exchanger

1 De-energize the drive.

For information, see the user manual of the drive.

2 Close the following valves:
• V5
• V1 (pump 1)
> V2 (pump 2)
3 Close the following valves in the coolant treatment circuit:
• V11
> If V11 is not installed: V21 and V23 (conductivity sensors)
4> Close valve V29 or V28.
5 Close the valves to the heat exchanger.
6> Water cooling units with an enclosure cooler connected to the internal
cooling circuit that has a three-way valve:
1> Open valve V83.
2> Close valve V83 when all coolant has drained.
7 Unscrew and remove the strainer from its pipe socket.
8 Remove the strainer screen from the cap.
9 Clean the strainer screen and the cap.
10 Reinsert the strainer screen into the cap.
11 Insert the strainer into its pipe socket and tighten it.
12 Open the valves again.
13 Check the strainer for leakage.
14 If necessary, add coolant according to Chapter 11 - Adding coolant to
the internal cooling circuit.

1k W WCU UM 3BHS204366 ZAB E02 Rev. E 9-3 (4)

Chapter 9 - Cleaning the strainer Z1 ABB

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ABB

Chapter 10 - Draining the internal cooling circuit

10.1 General information

This section describes how to drain the internal cooling circuit for repair
purposes. To drain the entire cooling system for storage purposes, contact
your ABB representative.

10.2 Tools and equipment

Container ■ Capacity: ~60 l (to collect coolant)

■ ...........drain valve (ISO G ½) in inverter compartment

■ ...........valve V14 (ISO-R1/2")
■ ...........valve V80 (1/4")
> ...........valve V81 (1/4") – if pump 2 is present
> ...........valve V82 (1/4") – if enclosure cooler is present

Length per hose : ~2 m

1/2"

19 mm

500 mm

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 10-1 (4)

Chapter 10 - Draining the internal cooling circuit ABB
10.3 Location of drain valves

PZ3
1

1/2" V80

500 mm
V14
19 mm
2
V81
1

V82

Fig. 10-1 Location of drain valves

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ABB Chapter 10 - Draining the internal cooling circuit

10.4 Draining

10.4.1 Preparatory steps

1 De-energize the drive.

For instructions, see the ACS1000W user manual.

2 In the control compartment of the drive, disconnect the following
devices from the power supply:
• Pump 1: switch off circuit breaker Q5021.
> Pump 2: switch off circuit breaker Q5023.
> Water heater: switch off circuit breaker Q5033.

For ON / OFF position of the circuit breaker, see Fig. 2-8.

3 In the junction box of the cooling unit, open the disconnect terminals
of the pumps:
• Pump 1: open terminals X2:22, X2:23 and X2:24 (1).
> Pump 2: open terminals X2:25, X2.26 and X2:27 (2).

1 2

Open Closed

4 To access the drain valve in the inverter compartment:

1 Unscrew and remove the center post (1 in Fig. 10-1).
2 Remove the fastening screws (2 in Fig. 10-1) of the swing frame.
3 Pull out the swing fame.

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Chapter 10 - Draining the internal cooling circuit ABB
10.4.2 Draining

CAUTION
Hazardous chemical!
If a coolant-glycol mixture is used, do the following:
• To prevent direct contact, inhalation or ingestion, wear rubber gloves,
goggles and respiratory protection.
• Observe the safety data sheet of the supplier.

> External heat exchanger

To let air into the circuit, open the valve that is at the highest point in
the pipe to the heat exchanger.
Open all drain valves.
• Connect a hose to each of the following valves, lead the hose into the
container, and open the valve:
• Drain valve (ISO G ½) to drain inverter
• Valve V80 (1/4”) to drain pump 1
> Valve V81 (1/4”) to drain pump 2
> Valve V82 (1/4”) to drain enclosure cooler
• V14 (ISO-R 1/2") to drain the rest of the cooling circuit

10.4.3 Final steps

1 When the cooling system is completely drained, do the following:
• Close the valves.
• Remove the hoses.
2 To enable secure locking of the compartment door, do the following.
1 Push back the swing frame.
2 Reattach the center post (1 in Fig. 10-1).
3 Tighten the fastening screws (2 in Fig. 10-1) of the swing frame.
3 If the drained coolant is not intended for reuse, dispose of it according
to local regulations.

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ABB

Chapter 11 - Adding coolant to the internal cooling circuit

11.1 General information

Maintenance indica- Adding coolant to the internal cooling circuit is indicated in the following
tions cases:
> Open cooling unit
Add coolant if the level in the expansion vessel is at the minimum
mark of the level indicator.
> Pressurized cooling unit
Add coolant if the pressure indicated on the pressure gauge B16 or
on the CDP control panel (80.19 WtrCoolPress2) is lower than 0.7
bar.

11.2 Tools and equipment

Pump output pressure: 2 bar

Inner diameter. 20 mm

1/2" female pipe

11.3 Preparing the coolant

For information on coolant requirements, preparing the coolant or a
coolant-glycol mixture, see 5.2 Preparing the coolant for the internal
cooling circuit.
If any coolant is left from commissioning or previous top-ups, check if it still
meets the requirements stated.

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 11-1 (4)

Chapter 11 - Adding coolant to the internal cooling circuit ABB
11.4 Adding the coolant
If the coolant conductivity is below 0.4 µS/cm, it is possible to add coolant
to the internal cooling circuit while the drive is in operation.

DANGER
Hazardous voltage!
When the coolant is added while the drive is in operation, voltages up to
690 V (AC) are present in the cooling unit.
Use personal protective equipment.

CAUTION
Hazardous chemical!
If a coolant-glycol mixture is used, do the following:
• To prevent direct contact, inhalation or ingestion, wear rubber gloves,
goggles and respiratory protection.
• Observe the safety data sheet of the supplier.

NOTICE
Drive shuts down if coolant is filled fast!
When coolant is filled into the internal cooling circuit while the drive is in
operation, the coolant conductivity can rise because of the high
conductivity of the added coolant.

To prevent the drive from shutting down, fill in the coolant slowly.

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ABB Chapter 11 - Adding coolant to the internal cooling circuit

1 Connect the filling pump to valve V14 according to Fig. 11-1.

1 2 ISO-R1/2"

3 4

5 6

Fig. 11-1 Adding coolant

2 Close the following valves:

• V11
> If V11 is not installed: V21 and V23 (conductivity sensors)
3 Open valve V14.
4 Pump in approximately 5 l of coolant.
5 Close valve V14.

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 11-3 (4)

Chapter 11 - Adding coolant to the internal cooling circuit ABB
6 Open the following valves:
• V11
> If V11 is not installed: V21 and V23
7 Wait until the coolant conductivity drops to 0.4 µS/cm.
8 Depending on the type of cooling unit, do the following:
> Open cooling unit
Repeat steps 2 – 7 until the level in the expansion vessel is ap-
proximately 50 mm below the maximum mark of the level indica-
tor.
> Pressurized cooling unit
Repeat steps 2 – 7 until the pressure indicated on pressure
gauge B16 or displayed on the CDP control panel (80.19 Wtr-
CoolPress2) is approximately 1.2 bar (or the pressure specified
on the unit).
9 Disconnect the pump.

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ABB

Chapter 12 - Checking and changing the pump rotation

NOTICE
Damage to pump seals.
If a pump is running without coolant in it, the pump seals are damaged
immediately.
As long as the cooling system is empty:
• Do not switch on the auxiliary power supply.
• Do not switch on the pump(s).

12.1 Rotation indicator

1 To check if the pump rotates in the correct direction, check the indi-
cator on the pump (Fig. 12-1):
■ If the indicator is white (1 in Fig. 12-1), the pump rotates in the
correct direction.
■ If the indicator is black (2 in Fig. 12-1), the pump rotates in the
wrong direction.

Fig. 12-1 Rotation indicator

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 12-1 (4)

Chapter 12 - Checking and changing the pump rotation ABB
2 If the rotational direction has to be changed, disconnect the pump
from the power supply:
• To disconnect pump 1, switch off circuit breaker Q5021.
> To disconnect pump 2, switch off circuit breaker Q5023.
3 To change the rotation, continue with
> 12.2 Changing the rotation during commissioning
or
> 12.3 Changing the rotation after a pump replacement

12.2 Changing the rotation during commissioning

1 Switch off the auxiliary power supply.
2 Depending on which of the pumps run in the wrong direction, do the
following:
• Pump 1 rotates in the wrong direction
Interchange any two of the three conductors at terminals X10:1,
X10:2 and X10:3 in the control compartment of the drive.

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ABB Chapter 12 - Checking and changing the pump rotation

• Pump 2 rotates in the wrong direction

Interchange any two of the three conductors at terminals X2:25,
X2:26 and X2:27 (1) in the junction box of the cooling unit.

3 To check if the pump rotates in the correct direction, switch the pump
on again.

12.3 Changing the rotation after a pump replacement

1 For safety reasons open the disconnect terminals in the junction box
of the cooling unit:
• To disconnect pump 1, open terminals X2:22, X2:23 and X2:24
(1).
> To disconnect pump 2, open terminals X2:25, X2.26 and X2:27
(2).

1 2

Open Closed

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 12-3 (4)

Chapter 12 - Checking and changing the pump rotation ABB
2 To change the rotation, interchange any two of the three conductors
in the terminal box of the pump motor.

3 To check if the pump rotates in the correct direction, switch the pump
on again.

12-4 (4) 3BHS204366 ZAB E01 Rev. E 1k W WCU UM

ABB

Terms, abbreviations, trademarks

Terms and abbreviations

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 / Abbreviation Meaning

Coolant Water with or without antifreeze, meeting the requirements stated in this manual.

Corrective maintenance Any number of works that are carried out at any given time to rectify an unwanted
condition discovered during inspection or else.

Drive Short form for the ACS1000W frequency converter.

Inspection Part of preventive maintenance that aims at detecting possible faults in advance.

Preventive maintenance A predefined number of works that are to be carried out at predetermined intervals or
according to prescribed criteria with the intention to reduce the probability of failure or the
degradation of the functioning of an item.

Service Any number of preventive or corrective maintenance tasks that must be carried out
exclusively by ABB service personnel.

WCU Water cooling unit. It dissipates heat produced by power parts of the drive and transfers it
to the exterior.

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

Victualic® Registered trademark of Victualic Company

LoctiteTM Registered trademark of Henkel

1k W WCU UM 3BHS204366 ZAB E01 Rev. E 1 (2)

Terms, abbreviations, trademarks ABB

2 (2) 3BHS204366 ZAB E01 Rev. E 1k W WCU UM

Contact us
ABB

ABB Switzerland Ltd

© Copyright 2009 ABB. All rights reserved. Specifications subject to change without notice. 3BHS204366 ZAB E01 Rev. E
Medium Voltage Drives
CH-5300 Turgi
Phone: +41 58 589 27 95
Fax: +41 58 589 29 84
E-mail: mvdrives@ch.abb.com
www.abb.com/drives