ABB PCS6000 PRODUCT FAMLIY

Introduction, terms, trademarks and related documents

Equipment covered by this manual

This manual covers a standard converter and provides generic information on the converter. The manual does not claim to cover all variations and details of the converter, nor to consider all eventualities that may arise during installation, commissioning, operation and maintenance of the converter. If the converter is adapted to specific customer needs or applications, and handling, installation and operation of the converter are affected by these modifications, information on these modifications is provided in the appropriate documentation (eg, layout drawings, wiring diagrams, technical data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB.

Overview

This manual covers the standard PCS6000 equipment and provides generic information. 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 if handling, installation, and operation of the equipment are affected by these modifications, specific information is provided in the appropriate documentation (eg, layout drawings, wiring diagrams, technical data, and engineering notes) in the appendices. Each person responsible for the transportation, installation, operation, commissioning, preventive maintenance or troubleshooting must have read and fully understood the corresponding chapters in this PCS6000 user's manual and in particular chapter 2, Important safety information, page 19. These responsible persons must ensure that all involved personnel follows the relevant instructions from this manual.

Important safety information

Safety standards

The following industry standards are observed:

– ANSIZ535.6

– ISO3864-2

– ISO7010

– EN50110

Safety messages

The following safety messages are provided to help prevent personal injury and damage to the equipment. The indicated hazard level is based on the ANSI Z535.6 standard. This is the safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Product safety labels

Safety labels are affixed to the converter components to alert personnel of potential hazards when working on the equipment. For more information, see the label placement document for the converter. The instructions on the safety labels must always be followed and the labels must be kept in a perfectly legible condition.

Figure 2–1 Product warning label examples (label placement depends on the converter)

Additional safety labels, including the following, might also be provided:

General safety instructions

1) Minimize hazards 2) Before energizing the converter: 

 • Remove all foreign objects from the converter 

 • Fasten all internal and external covers securely 

 • Close, lock, and/or bolt all doors 

 • Move the release dial of the door safety switches into the locked position 3) Before working on the converter: 

 • Turn off, lock out, and tag out the main and auxiliary power supplies to the converter 

 • De-energize the converter 

 • Ensure that the safety ground connections are in place 

 • Ensure that the appropriate personal protective equipment (PPE) is available and used when required 

 • Inform the involved personnel about the potential safety hazards 4) While working on the converter: 

 • Wear hearing protection when a converter is running. 

 • Do not step on the roof. 

 • Do not install foreign objects on the roof. 5) Before working on a water cooling unit (WCU): In addition to the safety instructions for working on a converter, always read the WCU safety data sheet for relevant safety information, eg, the type of ion exchange resin and glycol. 6) Before working simultaneously on the converter and on other converter system equipment: 

 • Observe the relevant safety codes and standards 

 • Turn off all energy sources for the equipment 

 • Ensure that all lockout and tagout devices are in place 

 • Install barriers around and use appropriate covers on the equipment that is still energized 

 • Inform the involved personnel about the potential safety hazards 7) In case of fire in the converter room: 

 • Observe the established rules and regulations for fire safety 

 • Only allow firefighters with the appropriate PPE to enter the converter room

The 7 steps that save lives

ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. PRODUCT PCS6000 1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash. 

 • Be in possession of a clear work order to execute the work. 

 • When required, the access or work permit is to be obtained by a person who is authorized for the specific electrical system. 

 • Engage the person responsible for electrical equipment or system to review single-line diagrams, schematics, switching plans, etc. 

 • Ensure the competence of workers. 

 • Check for proper tools for the job. 

 • Determine and select the proper arc-rated Personal Protective Equipment (PPE). 

 • Decide of the appropriate work methods and initiate the Permit To Work (PTW) process. 2) Clearly identify the work location and equipment. 

 • Use your senses (sight, hearing and smell) to identify problem areas. 

 • Define the work area via barriers and barricading and label equipment. 

 • Avoid distractions such as talking or texting on the phone. 3) Disconnect all sources of supply and secure against reconnection by applying Lockout/Tagout. 

 • If ABB is responsible for switching and it cannot be done remotely, then the person performing the switching must be properly trained and wearing the proper PPE identified in step 1. 

 • The Person in Charge of Work (PICW) must ensure that switching is performed in the proper manner by witnessing it from a safe distance if present on site or by engaging the person responsible for switching to identify all isolation points. 

 • Apply Lockout/Tagout (LOTO) to the energy isolation device and if multiple energy isolation devices are involved, then Group LOTO must be implemented with the PICW serving as the Group LOTO Leader.

4) Verify the absence of operating voltage: always test before you touch! Only use properly rated and inspected voltage detection devices and wear proper PPE identified in step 1: 

 • Test voltage detection device 

 • Test for voltage 

 • Test voltage detection device It is highly important that the voltage detection device is tested on a known voltage source such as a Proving Unit or by performing an internal self-test, according to the manufacturer’s instructions, before and after testing for the absence of operating voltage. 5) Carry out earthing and short-circuiting. 

 • Close and lock the earthing switch if the electrical equipment is designed for this purpose or apply portable equipment for earthing and short circuiting. If this is carried out by the customer, then the PICW must ensure that this equipment is properly earthed as a part of the integration/verification and during step 7 when the PICW walks the PTW. 6) Protect against adjacent live parts and take special precautions when close to bare conductors. 

 • Determine minimum approach distances, apply screening or shrouding, and when applicable, padlock both cable and busbar shutters. 

 • If working within the restricted approach boundary or vicinity zone where inadvertent movement could cause contact with live parts, special precautions must be employed, such as the use of the properly rated insulated gloves and tools. 7) Complete the permit to work and “Walk the Permit”. 

 • Check isolation points 

 • Verify that all circuits are isolated and secured 

 • Ensure all parties are integrated with the Lockout/Tagout 

 • Check the earths are properly applied 

 • Answer specific questions from the working group 

 • Ensure the work can proceed without danger 

 • Complete and verify the “Permit to Work”

Possible residual risks

Residual risks must be considered by the converter system integrator and/or plant owner when assessing the hazards of the equipment to personnel. The following risks can pose a hazard to converter system personnel: PRODUCT PCS6000 1) Electric power equipment generates electro-magnetic fields which can cause a hazard to people with metal implants and / or a pacemaker. 2) Converter system components can move unintentionally when being commissioned, operated, or serviced due to: 

 • Operation of the equipment outside the scope of the specifications 

 • Incorrectly assembled or installed equipment 

 • Wrongly connected cables 

 • External influence on, or damage of the equipment 

 • Wrong parameter settings 

 • Software errors 

 • Faulty hardware 3) Hazardous touch voltages can be present on converter system components, which can be caused by: 

 • Operation of the equipment outside the scope of the specifications 

 • External influence on, or damage of the equipment 

 • Induced voltages by external equipment 

 • Condensation on equipment components, or pollution 

 • Faulty hardware 4) High temperatures, noise, particles, or gases can be emitted from converter system components caused by: 

 • Operation of the equipment outside the scope of the specifications 

 • External influence on or damage of the equipment 

 • Wrong parameter settings 

 • Software errors 

 • Faulty hardware 

 • Hazardous substances can be emitted from converter system components, eg, due to Incorrect disposal of components

PCS6000 User manual 3BHS600000 E40 G en 24/114

5) Control cabinet door: danger of slight injuries, eg, foot crushing as the door of the control cabinet is not fixed to the cabinet when the locks are open.– Support the door with your hand when opening the locks.

– Weight per door: approximately < 20 kg. 6) Generator disconnector: risk of excessive arcing due to undetected arc.

– Risk of injuries from particles, contamination, electric shock, hearing damage, burns, explosion due to hardware failure, operation beyond specified limits, unauthorized access– No access to converter room or platform is allowed when the turbine is idling with open generator disconnectors or a 2CL converter is running in constricted operation 

– Turbine idling speed shall be limited to a maximum of 30% of rated speed

– 2CL converter must not be operated in constricted mode, except in case of converter defect that requires disconnecting the defective converter train

– Operation time in constricted mode and idling with open disconnector must be reduced as far as possible

Important note- main circuit breaker

The main circuit breaker (MCB) is a major protection device of the converter. If a serious fault occurs in the converter, the MCB must disconnect the main power supply to the converter immediately. The main power supply must be disconnected without delay on an open or trip command from the converter to prevent hazard to the personnel and further damage to the equipment. The MCB is located on the primary side of the converter transformer.

Safety and protection requirements

The system integrator must ensure that the following minimum safety and protection requirements for the converter are met.

– ISO13849-1

– IEC60204-1

Safety and protection requirements for the MCB

The following safety requirements are also in the MCB specifications for the converter:

– MCB open and/or trip command:  must be wired directly from the converter to the MCB. If you want to wire the command through a PLC or DCS system, the system must be certified to meet SIL 3 requirements and to fulfill the maximum MCB opening timing requirements. The converter must also be able to open the MCB at any time. It is not permitted to interrupt the open and/or trip command, eg, with a local-remote switch in the MCB.– Closing control of the MCB:  when the MCB is in service position, the converter must have exclusive control over closing the MCB, ie, local closing of the MCB is not permitted.

– MCB maximum opening time:  cannot exceed the maximum time that is defined in the product or project-specific MCB specifications. Typical maximum values for the converter are defined as follows:– Maximum protection trip time:  75 ms The maximum protection trip time is the maximum allowed breaking time (open and arcing) of the breaking device after the open command has been initiated to prevent further damage to the converter.

– 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 prevent any hazard to personnel.

Maintenance recommendation

The MCB trip circuits should be checked annually.

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