ABB ACS6000 User Manual
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ABB ACS6000 User Manual

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Summary of Contents for ABB ACS6000

  • Page 1 — SYSTEM DRIVES ACS6000 User manual...
  • Page 2 — General information Copyright © 2020 ABB. All rights reserved. The information in this manual is subject to change without notice. This document 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., System Drives.
  • Page 3 — Contents About this manual Equipment covered by this manual Structure of the user documentation Terms and abbreviations Trademarks Related documentation Target groups and required qualification 1.6.1 Handling 1.6.2 Mechanical installation 1.6.3 Electrical installation 1.6.4 Operation 1.6.5 Maintenance User’s responsibilities Intended use of equipment Cyber security disclaimer 1.10...
  • Page 4 2.7.2 Safety and protection requirements for the MCB Maintenance recommendation Power electronics and cabinet features Drive system topology 3.1.1 Drive 3.1.1.1 ACS6000 cabinet units 3.1.1.2 Final drive configuration 3.1.2 Motor Standard cabinet units 3.2.1 Active rectifier unit (ARU)/inverter unit (INU) 3.2.2...
  • Page 5 Optional cabinet units 3.3.1 Input reactor unit (IRU) 3.3.2 Input filter unit (IFU) 3.3.3 Voltage limiter unit (VLU) 3.3.4 Braking units 3.3.4.1 Braking chopper unit 3.3.4.2 Resistor braking unit 3.3.5 Excitation unit (EXU) 3.3.5.1 DCS800 control panel 3.3.5.2 Reversing switch 3.3.5.3 Output disconnector 3.3.6...
  • Page 6 Transport conditions Unpacking and inspection Identifying transport units Lifting and transportation 4.5.1.1 Lifting recommendations Storage Storing and handling of spare parts 4.7.1 Warranty information Disposing package materials and components Mechanical installation Safety Overview General notes on installation 5.3.1 Dimensions and clearances 5.3.2 Access to the cabinets 5.3.3...
  • Page 7 Joining busbars 5.7.1 DC busbars 5.7.2 Ground busbars 5.7.3 AC busbars between COU/TEU and LSU (5/7/9 MVA) 5.7.4 AC busbars between COU/TEU and LSU (14 MVA) 5.7.5 AC busbars between COU/TEU and ARU/INU 5.7.6 AC busbar joints - without disconnector 5.7.7 AC busbar joints - with motorized disconnector Installing and removing air-to-air heat exchangers...
  • Page 8 6.3.1 Grounding diagrams 6.3.2 Ground cable connection 6.3.3 Cable shield ground connection 6.3.4 EXU cabinet ground connections Internal wiring 6.4.1 Optical fiber cables 6.4.1.1 Installing the standard optical fibers 6.4.2 Optical fiber cables for the optional Arc Guard System™ 6.4.2.1 Connecting the detector cables to the arc monitor device Cable entry systems...
  • Page 9 6.7.5.2 EXU cabinet connections 6.7.5.3 Bolted busbar connections – marine drives 6.7.5.4 Bolted busbar connections – non-marine drives Auxiliary power, control and serial communication cables 6.8.1 Determining the cable length 6.8.2 Preparing cables for sealing modules 6.8.3 Preparing cables for cable glands 6.8.4 Preparing cables for EMC plates 6.8.5...
  • Page 10 Commissioning procedure Commissioning checklist Customer assistance Customer acceptance Commissioning checklists 7.6.1 Mechanical installation checklist 7.6.2 Electrical installation checklist 7.6.3 Main circuit breaker (MCB) 7.6.4 Input transformer checklist 7.6.5 Motor checklist 7.6.6 Insulation tests checklist 7.6.7 Power checklist 7.6.8 Miscellaneous checklist Operation Overview Operating conditions...
  • Page 11 Grounding switch and door locking system 8.6.1 Lamp test 8.6.2 Door locking system Optional switchgear and controlgear 8.7.1 DC-link disconnector 8.7.2 Output switches 8.7.3 Manual output isolation Status messages 8.8.1 Start sequence of the drive 8.8.2 Stop sequence of the drive 8.8.3 Emergency-off sequence 8.8.4...
  • Page 12 Modes 9.2.1 Identification mode 9.2.2 Actual signals mode 9.2.2.1 Overview 9.2.2.2 Selecting the actual signals display 9.2.2.3 Toggling between actual signals display and fault memory 9.2.2.4 Displaying three actual signals 9.2.2.5 Selecting actual signals 9.2.2.6 Displaying a fault and resetting the fault memory 9.2.2.7 Displaying and resetting an active fault 9.2.3...
  • Page 13 10.1.1 Required qualification 10.1.2 Maintenance schedule 10.1.3 Logbook 10.1.4 Spare parts 10.2 Identifying electrical equipment 10.2.1 Device designation 10.2.2 Cables and wires 10.2.2.1 Understanding wiring diagrams 10.3 Status indicators 10.3.1 Alarm / fault indications 10.3.2 Error message levels 10.3.2.1 Alarm and fault messages 10.3.2.2 Fault handling 10.3.2.3 Standard troubleshooting procedure 10.3.3...
  • Page 14 10.4.7 Emergency release of a door safety switch 10.4.7.1 Location of safety switches 10.4.7.2 Safety-switch settings 10.4.7.3 Unlocking a safety switch 10.4.8 Connecting a grounding set 10.4.8.1 Drives with LSU 10.4.8.2 Drives with ARU 10.4.9 Drives with the manual output isolation (optional) 10.4.9.1 Removing the busbar connectors 10.4.9.2 Fitting the busbar connectors 10.4.10...
  • Page 15 10.4.16.6 Replacing the ambient fans 10.4.17 Replacing the fan unit in an EXU with a DCS800 D4 size controller 10.4.18 Replacing the fan unit in an EXU with DCS800 size D5 controller 10.4.19 Replacing the air-to-water heat exchanger of the EXU...
  • Page 17 Figure 2-3 MCB opening timing diagram Figure 3-1 Common DC-bus principle for single motor drive (A) and multi-motor drive (B) Figure 3-2 ACS6000 drive example Figure 3-3 ARU/INU block diagram Figure 3-4 ARU/INU circuit diagram Figure 3-5 ARU/INU (A) and phase modules with IGCTs (B)
  • Page 18 EXU D4 frame cabinet (A) and EXU D5 frame cabinet (B) Figure 3-31 CIU cabinet (A) and WCU800 cabinet (B) Figure 3-32 ACS6000 example drive with air-to-air heat exchanger Figure 3-33 Auxiliary fan unit Figure 3-34 Air circulation through ventilation grids in 600 mm...
  • Page 19 Figure 5-4 Top view of DC busbar configuration 1 Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B) and 4 (C) Figure 5-6 Ground busbar joints Figure 5-7 AC busbar joints between the COU/TEU and LSU (5/7/9 MVA). Figure 5-8 AC busbar joints between the COU/TEU and LSU (14 MVA).
  • Page 20 Figure 6-4 Grounding the EXU Figure 6-5 Cable tray and cable ducts in an LSU (A = front) Figure 6-6 Arc Guard System™ in an optional roof extension box (REB) Figure 6-7 Location of Arc Guard sensors in a TEU Figure 6-8 Cable tray and cable ducts in an LSU (A = front)
  • Page 21 Figure 6-26 Preparing control cables for sealing modules Figure 6-27 Preparing auxiliary control cables for cable glands Figure 6-28 Preparing the screens of control cables for EMC plates Figure 6-29 Preparing control cables for EMC plates Figure 6-30 Top cable entry of 600 mm COU Figure 6-31 Cable route in COU (600 mm) top cable entry Figure 6-32...
  • Page 22 Figure 6-43 REB cable entry Figure 6-44 Heating cable connection Figure 8-1 ARU control panel Figure 8-2 INU control panel for motor 1 (A) and additional motors (B) Figure 8-3 Typical semi-redundant drive configuration Figure 8-4 Typical full-power (A) and half-power (B) drive modes Figure 8-5 DCS800 control panel...
  • Page 23 Figure 10-10 Testing the white lamp Figure 10-11 Safety switch on an ARU/INU cabinet door Figure 10-12 Safety switch settings Figure 10-13 Four-way grounding set Figure 10-14 TEU ground ball stud locations Figure 10-15 ARU/INU ground ball stud locations Figure 10-16 Manual output isolation overview Figure 10-17 Input module A2511...
  • Page 25 Main components in a WCU cabinet Table 3-5 BCU braking power Table 3-6 RBU braking power Table 3-7 ABB arc resistant classes Table 5-1 Installation material for AC busbars (COU/TEU – ARU/INU) Table 5-2 Installation material for roof joints Table 6-1...
  • Page 27 • Appendix G - Signal and parameter table: includes descriptions of actual signals, control and status words, and control parameters and their default settings. 3BHS212794 E01 REV M ACS6000 USER MANUAL 27/278...
  • Page 28 The following table lists terms and abbreviations you should be familiar with when using this user manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might differ from the normal usage. Table 1-1 Terms and abbreviations...
  • Page 29 Drivebus Communication link dedicated for ABB drives DriveDebug DriveDebug is part of ABB’s DriveWare® software tools for devices using the DDCS communications protocol. DriveDebug runs on computers with Windows® operating systems. DriveDebug is a specialist tool used to diagnose, tune and troubleshoot frequency converters.
  • Page 30 Table 1-1 Terms and abbreviations (continued) Term/Abbreviation Definition DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows® application for commissioning and maintaining ABB drives equipped with fiber- optic communication. Direct Torque Control Direct-to-line Earth Fault monitoring device Excitation Circuit Breaker...
  • Page 31 3-level voltage source inverter consisting of three identical power modules. I/O device Term of ABB’s S800 I/O system. An I/O device consists of a module termination unit (MTU) and one I/O module. I/O module Term of ABB’s S800 I/O system. The I/O module is an active input or output device for digital or analog signals.
  • Page 32 PUPA Pulse pattern Pulse width modulation German color standard Resistor Braking Unit Redundant Drive Control Redundant Drive Interface Receive Data Register Rolling Mill Drive Revolutions Per Minute 3BHS212794 E01 REV M ACS6000 USER MANUAL 32/278...
  • Page 33 Term/Abbreviation Definition S800 I/O The S800 I/O is a distributed process input output system that can be connected to various process controllers from ABB and other companies. Short-Circuit Synchronous Motor Semi-Redundant Drive Synchronous Serial Interface The SSI is a point-to-point, serial communication interface for digital data transmission between a master (eg, drive) and a slave (eg, sensor).
  • Page 34 Registered trademark of Microsoft Corporation Related documentation The following documents are available for supplementary information: Table 1-3 Maintenance Title Document number ACS6000 preventive maintenance schedule 3BHS855273 E01 Table 1-4 Technical data Title Document number Technical data from drive smart (configuration...
  • Page 35 Technical project Specification Motor 3BHS824804 E01 [10] ABB MVD ACS High Performance 3BHS824805 E01 Motor Specification [11] ABB MVD ACS High Speed Motor Specification 3BHS824806 E01 [12] Power cable specification 3BHS125090 E01 [13] Power cables engineering guideline 3BHS542290 E01 [14] Auxiliary power and control cables guideline...
  • Page 36 [32] S800 I/O Modules and Termination Units 3BSE020924 Table 1-9 User manuals related to drive units Title Document number [33] ACS5000, ACS6000 and ACS6080 water 3BHS821937 E01 cooling unit WCU800 user manual [34] ACS5000, ACS6000 and ACS6080 water 3BHS835714 E01...
  • Page 37 IMPORTANT! Commissioning of the drive must only be performed by qualified and certified ABB personnel. 1.6.1 Handling Personnel must be skilled and experienced in unpacking and transporting heavy equipment.
  • Page 38 ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
  • Page 39 Quality certificates and applicable standards The following certificates and conformity declarations are available with ABB: • ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and maintains a management system which fulfills the requirements of the normative standards •...
  • Page 40 1.12 Tools ABB offers various tool sets containing all necessary tools and equipment for installation, commissioning and maintenance of the drive. The content of the tool sets is described in the Service Equipment manual.
  • Page 41 Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. ▲ NOTICE Is used to address practices not related to physical injury, but which can result in equipment damage. 3BHS212794 E01 REV M ACS6000 USER MANUAL 41/278...
  • Page 42 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 de- energized and grounded. 3BHS212794 E01 REV M ACS6000 USER MANUAL 42/278...
  • Page 43 7) In case of fire in the drive room: • Observe the established rules and regulations for fire safety • Only allow firefighters with the appropriate PPE to enter the drive room 3BHS212794 E01 REV M ACS6000 USER MANUAL 43/278...
  • Page 44 02 IMPORTANT SAFETY INFORMATION 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. 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.
  • Page 45 • 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” 3BHS212794 E01 REV M ACS6000 USER MANUAL 45/278...
  • Page 46 • External influence on or damage of the equipment • Wrong parameter settings • Software errors • Faulty hardware 5) Hazardous substances can be emitted from drive system components, eg, due to Incorrect disposal of components 3BHS212794 E01 REV M ACS6000 USER MANUAL 46/278...
  • Page 47 • Fused contactors or motor control centers Dedicated protection relay • Transformer or drive primary cable protection (DTL) • Transformer protection (if applicable) • Transformer secondary cable protection (if applicable) • Backing up the drive protection 3BHS212794 E01 REV M ACS6000 USER MANUAL 47/278...
  • Page 48 • 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. 3BHS212794 E01 REV M ACS6000 USER MANUAL 48/278...
  • Page 49 (4) No hazard to personnel (5) Maximum protection trip time (6) Maximum safety trip time In order to meet the stipulated safety requirements, ABB recommends one of the following: • MCB is equipped with 2 independent opening coils • MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage •...
  • Page 51 • Motor 3.1.1 Drive The ACS6000 is a voltage source frequency converter for high-power induction and synchronous motors. The drive features a common DC bus permitting the configuration of single-motor or multi-motor solutions. Figure 3-1 Common DC-bus principle for single motor drive (A) and multi-...
  • Page 52 03 POWER ELECTRONICS AND CABINET FEATURES The ACS6000 has a flexible modular design with standard and optional cabinet units. Each cabinet unit is dedicated to a specific function. Figure 3-2 ACS6000 drive example (1) Active rectifier unit (ARU): (5) Water cooling unit (WCU):...
  • Page 53 03 POWER ELECTRONICS AND CABINET FEATURES 3.1.1.1 ACS6000 cabinet units Standard cabinet units Optional cabinet units • Active rectifier unit (ARU) • Input reactor unit (IRU) • Inverter unit (INU) • Input filter unit (IFU) • Line supply unit (LSU) •...
  • Page 54 Clamping circuit Protects the circuit from excessive rises in current with di/dt reactors and freewheeling diodes. Electromagnetic Protects the transformer from excessive compatibility (EMC) filter voltage slopes 3BHS212794 E01 REV M ACS6000 USER MANUAL 54/278...
  • Page 55 The LSU allows two-quadrant operation and maintains the power factor at 0.95 in the whole operating range. To achieve 24-pulse rectification or to increase the drive power, units with the same power rating can be operated in parallel. 3BHS212794 E01 REV M ACS6000 USER MANUAL 55/278...
  • Page 56 Define the current rise in the thyristor crowbar. reactors Thyristor crowbar Protection circuit that activates when a short- circuit occurs. By applying protection firing, the thyristor crowbar short-circuits the rectifier to prevent further damage of the drive. 3BHS212794 E01 REV M ACS6000 USER MANUAL 56/278...
  • Page 57 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3-8 LSU (12-pulse) (1) Snubber resistor (4) di/dt limiting reactors (2) Snubber capacitor (5) Diode stacks (3) Rectifier monitoring unit 3BHS212794 E01 REV M ACS6000 USER MANUAL 57/278...
  • Page 58 These can only be closed if the DC-link capacitors have been discharged. For more information, see “8.5 EXU control panel” on page 178. Figure 3-9 CBU (1) Grounding switch (2) DC-link capacitor 3BHS212794 E01 REV M ACS6000 USER MANUAL 58/278...
  • Page 59 Figure 3-10 TEU (1000 mm) (1) DC busbars (3) Cable entry frame (2) AC busbars (4) PE ground busbars 3BHS212794 E01 REV M ACS6000 USER MANUAL 59/278...
  • Page 60 The hardware components of a COU are fitted on a swing frame. The size of the swing frame and the mounting position of the components depend on the cabinet version where the swing frame is installed in Fig. 3-11. 3BHS212794 E01 REV M ACS6000 USER MANUAL 60/278...
  • Page 61 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3-11 Control units: 1000 mm COU (A) and 600 mm COU (B) 3BHS212794 E01 REV M ACS6000 USER MANUAL 61/278...
  • Page 62 (9) NETA-21 (3) DriveWare (10) DDCS (4) Cloud connectivity (11) AMC circuit board (5) CDP control panel (12) PPCS (6) RS485 (13) Pulse encoder (option) (7) Fieldbus adapter (14) INT circuit board 3BHS212794 E01 REV M ACS6000 USER MANUAL 62/278...
  • Page 63 INT circuit boards inside the ARU and INU (Fig. 3-12). Figure 3-13 Examples of AMC circuit boards in 1000 mm COU (A) and 600 mm COU (B) (1) AMC circuit board 3BHS212794 E01 REV M ACS6000 USER MANUAL 63/278...
  • Page 64 Therefore it must only be controlled and monitored by the drive. Note: For more information, see: • "Main circuit breaker specification" (3BHS125149 E60) • “2.7 Important note - main circuit breaker” on page 47. 3BHS212794 E01 REV M ACS6000 USER MANUAL 64/278...
  • Page 65 Speed and torque control The speed and torque of the motor is controlled by DTC (direct torque control). The DTC motor control platform is unique to ABB and has been proven in all variable speed drives of the ACS product range. DTC provides accurate speed and torque control, and high dynamic speed response.
  • Page 66 • DriveWare® software tools:• includes software tools such as the commissioning and maintenance tools DriveWindow and DriveDebug, and DriveOPC for data transfer between ABB drives and Windows®-based applications. • NETA-21: monitoring and diagnostics tool that allows access to the drive from any location in the world via a secure Internet connection.
  • Page 67 The water cooling units are accessible for maintenance even when the drive is in operation. Note: For more information, see "ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual" (3BHS821937 E01) and "ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual"...
  • Page 68 The ion exchange vessel in the water treatment circuit deionizes the coolant of the internal cooling circuit and maintains the conductivity. 3-way valve The three-way valve controls the flow of the external cooling liquid through the water-to-water heat exchanger. 3BHS212794 E01 REV M ACS6000 USER MANUAL 68/278...
  • Page 69 (7) Cool water swing frame (8) Expansion vessel (2) Pump circuit breakers (9) Three-way valve (3) Warm water (10) Water-to-water heat exchanger (4) Expansion vessel (11) Deionizer (5) Pump 1 (6) Pump 2 3BHS212794 E01 REV M ACS6000 USER MANUAL 69/278...
  • Page 70 • External cooling circuit: transfers the heat losses from the water-to- water heat exchanger to the exterior. The water cooling units are pressurized and not open to atmospheric pressure. Figure 3-19 Cooling circuit in an ACS6000 drive (1) Return pipes (6) Heat exchanger (2) LSU...
  • Page 71 DC (+) DC (-) Figure 3-20 IRU circuit diagram (1) IRU (4) Diode rectifier (2) LSU (5) Snubber circuit (3) Thyristor crowbar (6) di/dt choke Figure 3-21 IRU cabinet (1) Three-phase reactor 3BHS212794 E01 REV M ACS6000 USER MANUAL 71/278...
  • Page 72 ARU and reduces harmonic voltages injected to the supply network. Figure 3-22 IFU circuit diagram (1) TEU (3) ARU (2) IFU Figure 3-23 IFU cabinet (1) Resistor (3) Reactor (2) Capacitor 3BHS212794 E01 REV M ACS6000 USER MANUAL 72/278...
  • Page 73 During braking, the energy is dissipated in liquid-cooled resistors. The resistors are controlled by IGCT semiconductors and protected against overload. DC (+) DC (NP) DC (-) Figure 3-24 VLU circuit diagram Figure 3-25 VLU cabinet (1) Air-cooled resistors (2) IGCT 3BHS212794 E01 REV M ACS6000 USER MANUAL 73/278...
  • Page 74 03 POWER ELECTRONICS AND CABINET FEATURES 3.3.4 Braking units A braking chopper unit (BCU) and a resistor braking unit (RBU) are available for the ACS6000. Table 3-5 BCU braking power Braking resistor (ohm) Single braking power Double braking power (kW)
  • Page 75 The energy generated during braking is dissipated in external water-cooled resistors, which are not part of the drive. DC (+) DC (NP) DC (-) Figure 3-26 BCU circuit diagram (1) Resistor (external) (2) BCU Figure 3-27 BCU cabinet (1) IGCT 3BHS212794 E01 REV M ACS6000 USER MANUAL 75/278...
  • Page 76 Resistor braking unit An RBU, with integrated resistors, is used for smaller braking capabilities. DC (+) DC (NP) DC (-) Figure 3-28 RBU circuit diagram Figure 3-29 RBU cabinet (1) IGCT (2) Water-cooled resistor 3BHS212794 E01 REV M ACS6000 USER MANUAL 76/278...
  • Page 77 Figure 3-30 EXU D4 frame cabinet (A) and EXU D5 frame cabinet (B) (1) Ground fault detection device (5) DCS800 D4 unit (optional) (6) Overvoltage protection (not (2) Fuses shown in A) (3) Control compartment (7) DCS800 D5 unit (4) Fan units 3BHS212794 E01 REV M ACS6000 USER MANUAL 77/278...
  • Page 78 When the drive is in state ReadyOn or NotReadyOn, the switch is opened. 3.3.5.3 Output disconnector The optional output disconnector is used to disconnect the EXU from the motor for maintenance purposes. 3BHS212794 E01 REV M ACS6000 USER MANUAL 78/278...
  • Page 79 (REB) of the water cooling unit. For more I/O modules, a CIU is required. Figure 3-31 CIU cabinet (A) and WCU800 cabinet (B) (1) CIU (3) WCU800 (2) Roof extension box (REB) 3BHS212794 E01 REV M ACS6000 USER MANUAL 79/278...
  • Page 80 “Appendix C – Mechanical drawings”. The number of installed air-to-air heat exchangers and transformers depends on the configuration of the drive. Figure 3-32 ACS6000 example drive with air-to-air heat exchanger (1) Air-to-air heat exchanger (2) Additional transformer 3BHS212794 E01 REV M...
  • Page 81 Figure 3-33 Auxiliary fan unit Figure 3-34 Air circulation through ventilation grids in 600 mm COU (A), 1000 mm COU (B) and WCU800 (C) Note: The number of fans varies depending on the cabinet. 3BHS212794 E01 REV M ACS6000 USER MANUAL 81/278...
  • Page 82 03 POWER ELECTRONICS AND CABINET FEATURES Cabinet design The cabinet has been designed using the modular cabinet system of ABB and fulls the requirements of international standards. The design consists of a skeletal frame made of galvanized steel where the outer panels made of 1.5 mm thick painted galvanized steel are bolted to.
  • Page 83 178. Arc resistant design The optional “Arc Resistant Design” provides the drive with arc fault protection (see Table 3-7) in accordance with IEC 62477-2. Table 3-7 ABB arc resistant classes ABB class Description Class I Protection based on arc prevention (NOT certified according to...
  • Page 84 (Associated Protection Requirement) without the need for additional devices. The MCB requirements are described in “2.7 Important note - main circuit breaker” on page 47. Busbars and grounding The ACS6000 drive contains busbars for various types of connections. Figure 3-37 Busbars 3.8.1 AC busbars The incoming feeder and motor cables are connected to their corresponding busbars inside a TEU.
  • Page 85 To ensure proper operation, cable shields are connected to the PG ground busbar. The PE and PG busbar connect inside the capacitor bank unit, which has the grounding switch on the front door. The connection is made in the factory. 3BHS212794 E01 REV M ACS6000 USER MANUAL 85/278...
  • Page 87 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 photographs to ABB.
  • Page 88 All of the transport units for a drive have the same converter number, in this case, “Converter 1”. The item number in the “ABB Item / Customer item” column of the packing list provides information about separately delivered crates with accessories such as tools and installation material.
  • Page 89 NOT lift and move them with a crane. - Use appropriate transport means, such as heavy load hydraulics rollers or air cushions. If in doubt, contact ABB for instructions. • To prevent damage to drive components, transport and move the drive or a transport unit only in upright position.
  • Page 90 04 TRANSPORTATION, STORAGE AND DISPOSAL 4.5.1.1 Lifting recommendations Refer to Fig. 4-1 and Fig. 4-2 when following these ABB recommendations: • Use a lift frame or a lift spreader with the crane. • Use lifting equipment (eg, web slings, chain slings, round slings, safety hooks, shackles) that corresponds to the weight that is to be lifted.
  • Page 91 (1) Safety hook (5) Safety hook or shackle (2) Lift frame (6) Lifting bracket (3) Strap (7) Slope angle (maximum 15°) (4) Protect the edges, door handles (8) Lift spreader and levers 3BHS212794 E01 REV M ACS6000 USER MANUAL 91/278...
  • Page 92 04 TRANSPORTATION, STORAGE AND DISPOSAL Storage The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. Note: For information on longer storage periods, contact the ABB service organization. 4.6.1 Storage conditions The minimum requirements for storage are based on IEC 60721-3-1.
  • Page 93 4.7.1 Warranty information IMPORTANT! Check the spare parts immediately after receipt for damages and 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: •...
  • Page 94 Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations. Note: For more information on the disposal of packaging materials and drive components, see the recycling instructions. 3BHS212794 E01 REV M ACS6000 USER MANUAL 94/278...
  • Page 95 • Only for optional components - “5.8 Installing and removing air-to-air heat exchangers” on page 112 - “5.9 Installing the pressure relief vents” on page 121 - “5.10 Attaching the sealing tapes” on page 123 3BHS212794 E01 REV M ACS6000 USER MANUAL 95/278...
  • Page 96 • DO NOT install any foreign objects on the roof and do not step on roof. 5.3.4 Fire protection ⚠ CAUTION • To prevent fire from spreading into the drive, apply suitable fire protection measures. 3BHS212794 E01 REV M ACS6000 USER MANUAL 96/278...
  • Page 97 WCU. Installation material such as counter-flanges, bolts, nuts and seals are supplied. For information on dimensions of the raw water entry and the flanges, see “Appendix C – Mechanical drawings”. 3BHS212794 E01 REV M ACS6000 USER MANUAL 97/278...
  • Page 98 2. Check that a pipe joint (1) has been slid on one pipe end of two adjoining water pipes. 3. Line-up the transport units as shown in “Appendix C – Mechanical drawings”. Note: The units can be lined-up either beginning from the left or the right. 3BHS212794 E01 REV M ACS6000 USER MANUAL 98/278...
  • Page 99 Fig. 5-1) • Cabinet doors are not misaligned and that there are no gaps between cabinet walls and cabinet frame • Adjoining surfaces of transport units meet perfectly all around 3BHS212794 E01 REV M ACS6000 USER MANUAL 99/278...
  • Page 100 In such cases, you only need to join the connection points that you can access. Figure 5-1 Connection point locations on transport units (1) Connection point locations (2) M6 x 16 (9ABA450093R0259 SCR-CBS-M6X16-8_8-FLZNNC) 3BHS212794 E01 REV M ACS6000 USER MANUAL 100/278...
  • Page 101 Figure 5-2 Minimum distances and locking bolt orientation (A = front) (1) 40 mm minimum (2) Locking bolt orientation 3BHS212794 E01 REV M ACS6000 USER MANUAL 101/278...
  • Page 102 Note: The sealing lip can touch the pipe end. 3. Turn and move the pipe joint smoothly. 4. Clean the pipe joint and treat the bolts with an appropriate lubricant before refitting. 3BHS212794 E01 REV M ACS6000 USER MANUAL 102/278...
  • Page 103 • Orientate the parts of a joint (plates, bolts, and nuts) as shown. • Use a conical spring washer on each side of a connection. Figure 5-3 Bolted busbar connection (1) Conical spring washer 3BHS212794 E01 REV M ACS6000 USER MANUAL 103/278...
  • Page 104 HZN 452198P1022 coated (4) Conical spring 13 x 29 x 3 HAQN400344P0111 washer (5) Busbar with positive potential (6) Busbar with neutral potential (7) Busbar with negative potential (8) Front of cabinet 3BHS212794 E01 REV M ACS6000 USER MANUAL 104/278...
  • Page 105 Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B) and 4 (C) (1) Busbar with negative potential (3) Busbar with positive potential (2) Busbar with neutral potential (4) Front of cabinet 3BHS212794 E01 REV M ACS6000 USER MANUAL 105/278...
  • Page 106 3BHB010246R0001/R0051 (2) Hex-head bolt M12 x 40-A2 NB 312350P8119 (3) Hex-head nut M12-A2-70, HZN 452198P1022 coated (4) Conical spring 13 x 29 x 3 HAQN400344P0111 washer (5) Water pipe (6) Cabinet front 3BHS212794 E01 REV M ACS6000 USER MANUAL 106/278...
  • Page 107 M12 x 45-A2-70 NB 312450P8120 (6) Hex-head bolt M12 x 50-A2-70 NB 312450P8121 (7) Conical spring DIN6796-13 x 29 x 3 HAQN400344P0111 washer (8) Hex-head nut M12-A2-70 HZN 452198P1022 (9) Flange nut M12-A2 3BHB038117R0001 3BHS212794 E01 REV M ACS6000 USER MANUAL 107/278...
  • Page 108 (3) Connection bu bar LSU-TEU 3a 3BHB045558R0001 (4) Hex-head bolt M12 x 45-A2-70 NB 312450P8120 (5) Hex-head bolt M12 x 65-A2-70 NB 312450P8124 (6) Conical spring DIN6796-13x29x3 HAQN400344P0111 washer (7) Hex-head nut DIN934-M12-A2-70 HZN 452198P1022 3BHS212794 E01 REV M ACS6000 USER MANUAL 108/278...
  • Page 109 • ARU/INU: 5 MVA (without MOI) • COU/TEU: 600 mm 1000 mm • ARU/INU - COU/TEU • ARU/INU: 7, 9, 13 peak MVA 5 MVA (with MOI) • COU/TEU: 600 mm 1000 mm 3BHS212794 E01 REV M ACS6000 USER MANUAL 109/278...
  • Page 110 12 MVA • COU/TEU: 1000 mm 5.7.7 AC busbar joints - with motorized disconnector Module Busbar joints • ARU/INU - COU/TEU • ARU/INU: 5, 7, 9, 13 peak MVA • COU/TEU: 1000 mm 3BHS212794 E01 REV M ACS6000 USER MANUAL 110/278...
  • Page 111 5, 7, 9, 13 peak MVA • COU/TEU: 1000 mm • ARU/INU - COU/TEU • ARU/INU: 12 MVA • COU/TEU: 1000 mm • COU/TEU - ARU/INU • ARU/INU: 12 MVA • COU/TEU: 1000 mm 3BHS212794 E01 REV M ACS6000 USER MANUAL 111/278...
  • Page 112 • Height: 316 mm Figure 5-10 Tools for installing an air-to-air heat exchanger (1) Cordless drill (4) M6 x 12 Torx screw (2) Wire cutter (5) Cable tie (3) Torx drill bit 3BHS212794 E01 REV M ACS6000 USER MANUAL 112/278...
  • Page 113 • Damage to the heat exchanger Procedure: 1. Before lifting the heat exchanger onto the roof, cut off the cable ties. 2. Loop the cables as illustrated and fasten them to the cable tie mounts (circles). 3BHS212794 E01 REV M ACS6000 USER MANUAL 113/278...
  • Page 114 4. Remove the cover on the roof where the heat exchanger is installed. 5. Lift the heat exchanger above the opening in the roof and orientate the heat exchanger with the LEDs (circle) pointing to the front of the cabinet. 3BHS212794 E01 REV M ACS6000 USER MANUAL 114/278...
  • Page 115 05 MECHANICAL INSTALLATION 6. Route the cables through the designated openings (circle) at the front of the cabinet. 7. While lowering the heat exchanger onto the roof, pull the cables through the openings. 3BHS212794 E01 REV M ACS6000 USER MANUAL 115/278...
  • Page 116 10. In the upper part of the cable duct (1), fasten the cables to the cabinet frame. 15 x 11. In the lower part (2), tie the cables together at regular distances. 3BHS212794 E01 REV M ACS6000 USER MANUAL 116/278...
  • Page 117 • Take appropriate measures for removing and installing the heat exchanger safely. Figure 5-14 Air-to-air heat exchangers (type LT-5-5165-UL) Air-to-air heat exchangers must be removed and refitted where two transport units are joined. 3BHS212794 E01 REV M ACS6000 USER MANUAL 117/278...
  • Page 118 (2) Wire cutter (4) Cable tie 5.8.2.1 Removing an air-to-air heat exchanger 1. Loosen the 4 self-tapping M6x12 screws (HAQN401205P0257) that fasten the heat exchanger to the roof. 2. Remove the cable ties. 3BHS212794 E01 REV M ACS6000 USER MANUAL 118/278...
  • Page 119 4. Fix the cables with cable ties at regular distances of approximately 20 cm. 5. Tighten all screws of the heat exchanger. 6. Fix the cables inside the terminal box with cable ties. 3BHS212794 E01 REV M ACS6000 USER MANUAL 119/278...
  • Page 120 (5) 1.5 kVA transformer: ~17 kg (2) Transformer hood (6) 2.8 kVA transformer: ~49 kg (3) 4 x M8x20 (9ABA450093R0310) (7) 3.5 kVA transformer: ~49 kg (4) Transformer connection plate (8) 6 kVA transformer: ~66 kg 3BHS212794 E01 REV M ACS6000 USER MANUAL 120/278...
  • Page 121 Pressure relief vents are installed on the roofs of TEUs and COUs. Figure 5-18 Pressure relief vents • Weight: ~26 kg • Length: 840 mm • Width: 520 mm • Height: 210 mm 3BHS212794 E01 REV M ACS6000 USER MANUAL 121/278...
  • Page 122 Figure 5-20 Installation example of pressure relief vents (1) Orientation of baffle blades (3) Pressure relief vents (2) Center of drive 2. Fasten the pressure relief vent to the roof with the supplied screws (Fig. 5-20). 3BHS212794 E01 REV M ACS6000 USER MANUAL 122/278...
  • Page 123 2. Cut the sealing tape to the required length. 3. Attach the tape on the whole length of the joining crossbars (1). Figure 5-21 Attach sealing tape to the joining crossbar (1) 4. Reinstall the roof plates. 3BHS212794 E01 REV M ACS6000 USER MANUAL 123/278...
  • Page 124 • Install the joints at the front and the back of the roof of two adjoining transport units using the supplied installation material. Note: The joints (1) within a transport unit are factory-installed. Figure 5-22 Roof joints (1) 3BHS212794 E01 REV M ACS6000 USER MANUAL 124/278...
  • Page 125 3BHB035997R0001 2 x damping 3BHB033405R0001 connectors (10) 2 x plates 3BHB035999R0001 (11) 2 x washers 13 / 29 ST / ZN 9ABA450078P0007 (12) 2 x hex-head bolts M12 x 80 NB 312450P8127 3BHS212794 E01 REV M ACS6000 USER MANUAL 125/278...
  • Page 126 Figure 5-24 Recommended ceiling and wall fixings (1) Two struts at 45° to ceiling (3) Do not install the struts at a 90° angle to the cabinet roof (2) One strut at 90° to wall 3BHS212794 E01 REV M ACS6000 USER MANUAL 126/278...
  • Page 127 • 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 ABB commissioning personnel. • To prevent main and auxiliary power supply being switched on during installation, take appropriate measures.
  • Page 128 "Auxiliary power and control cables guideline" (3BHS813742 E01). 6.2.3 Synchronization cables Synchronization cables are used in drives with an ARU. A shielded, 3-phase cable without neutral wire is required for the supply voltage of the synchronization transformer. 3BHS212794 E01 REV M ACS6000 USER MANUAL 128/278...
  • Page 129 (1) Transformer or busbar (7) TEU (2) System ground (8) ARU (3) Cable shield (9) Transformer (4) Cable armor (10) LSU (5) Equipotential bonding conductor (11) INU (6) Ground cable (12) Motor 3BHS212794 E01 REV M ACS6000 USER MANUAL 129/278...
  • Page 130 Cable shields are connected to the separate PG ground busbar. The connection between the PE and PG ground busbars inside the CBU is made in the factory. The CBU has a grounding switch on the door. 3BHS212794 E01 REV M ACS6000 USER MANUAL 130/278...
  • Page 131 All necessary data for each individual connection are specified on the “Converter hardware diagram” and the Wiring list in “Appendix D – Wiring diagrams”. The data provide information on: • Cable identification • Cable type • Cross-sectional area • Location of terminals 3BHS212794 E01 REV M ACS6000 USER MANUAL 131/278...
  • Page 132 RBU, BCU and VLU, make sure that the cables are at a minimum distance of 5 mm from the closest metal part. 3. Connect all cables and wires according to the “Converter Hardware” diagram. 3BHS212794 E01 REV M ACS6000 USER MANUAL 132/278...
  • Page 133 • Arc Guard unit TVOC-2 with HMI panel • Optical fiber detectors The detectors are pre-installed in the relevant cabinets with the corresponding optical fibers coiled up beside the detectors (Fig. 6-7). 3BHS212794 E01 REV M ACS6000 USER MANUAL 133/278...
  • Page 134 2. Lay the cables into their designated trays and cable ducts as illustrated in Fig. 6-8. 3. Connect the cables to the arc monitor located in the REB according to the drawings. 3BHS212794 E01 REV M ACS6000 USER MANUAL 134/278...
  • Page 135 (2) Sealing module (RM120) Usage • Power cables • Ground cables • Equipotential bonding conductors Included in delivery • Cable entry frame Not included in • Sealing modules delivery • Accessories • Tools 3BHS212794 E01 REV M ACS6000 USER MANUAL 135/278...
  • Page 136 Maximum number Maximum number of cables/ entry of sealing openings frame modules/openings RM12 Single- Three- Single- core core core Ø28 - 50 Ø68 - 99 Ø48 - 71 1000 mm 600 mm 3BHS212794 E01 REV M ACS6000 USER MANUAL 136/278...
  • Page 137 Usage • Power cables, ground cables, bonding conductors • Auxiliary power cables, control cables Included in delivery • Undrilled gland plate Not included in • Cable glands delivery • Tools • Accessories 3BHS212794 E01 REV M ACS6000 USER MANUAL 137/278...
  • Page 138 • Sealing grommets Preparing cable entry systems for TEU, ARU and EXU cabinets This section describes how to prepare cable entry systems for the following cabinets: • TEU • ARU • EXU 3BHS212794 E01 REV M ACS6000 USER MANUAL 138/278...
  • Page 139 Figure 6-14 TEU 1000 mm cabinet (A = back) with top (1) and bottom (2) cable entries (1) Top cable entry frame (4) Compression wedge (2) Bottom cable entry (5) RM90 sealing module with 3-core cable (3) High-voltage busbars 3BHS212794 E01 REV M ACS6000 USER MANUAL 139/278...
  • Page 140 (4) 1/2” wrench (2) Remove these bolts (5) 17 mm and 19 mm (3) Bottom bracket 4. After you have routed the cables, install the busbars in the reverse order of removal. 3BHS212794 E01 REV M ACS6000 USER MANUAL 140/278...
  • Page 141 EXU with a DCS800 D4 size controller” on page 270. 4. Unplug the fan power supply cables and the tube from the air pressure switch. Figure 6-17 EXU cabinet (1) Front cover (2) Pull relief 3BHS212794 E01 REV M ACS6000 USER MANUAL 141/278...
  • Page 142 Determining the cable length 1. Determine the required length of a cable between the point of entry and the connection point inside the cabinet. 2. Cut the cable to the required length before connection. 3BHS212794 E01 REV M ACS6000 USER MANUAL 142/278...
  • Page 143 (6) Heat shrinkable termination cable supplier and suitable for M12 bolt (7) Outer cable sheath (12) Sheath seal 2. Install the sealing modules according to the instructions of the sealing module supplier. 3BHS212794 E01 REV M ACS6000 USER MANUAL 143/278...
  • Page 144 This section describes how to prepare standard cables for EMC plates as well as cables for an EXU. 1. Remove the grommets from the entry plate. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter. 3BHS212794 E01 REV M ACS6000 USER MANUAL 144/278...
  • Page 145 (2) EMC sleeve (7) Conductor insulation removed to expose cable shield (3) Cable tie (8) Cable screen extension to connect (4) Heat-shrinkable termination to the PE busbar (5) Outer cable sheath (9) Cable clamp 3BHS212794 E01 REV M ACS6000 USER MANUAL 145/278...
  • Page 146 2. Fasten the cables to the strain relief rails with suitable cable clamps. Figure 6-21 Cable connections in an EXU cabinet (1) Cable clamp (3) Strain relief rail (2) Cable lugs on each side of busbar 3BHS212794 E01 REV M ACS6000 USER MANUAL 146/278...
  • Page 147 Figure 6-23 Bolted busbar connection - marine drives Part Quantity Identification Hex-head bolt M12x40-A2 NB 312350P8119 Coated hex-head nut M12-A2-70 HZN 452198P1022 Conical spring washer 13 x 29 x 3 HAQN400344P0111 3BHS212794 E01 REV M ACS6000 USER MANUAL 147/278...
  • Page 148 ] coating) is used, the connection does not need to be lubricated. 6.7.5.4.4 Tightening torque ABB recommends a tightening torque of 40 Nm for M12 bolts. For other sizes, follow the manufacturer’s recommendations. 3BHS212794 E01 REV M ACS6000 USER MANUAL...
  • Page 149 Determining the cable length 1. Determine the required length of a cable between the point of entry and the connection point inside the cabinet. 2. Cut the cable to the required length before connection. 3BHS212794 E01 REV M ACS6000 USER MANUAL 149/278...
  • Page 150 Fig. 6-26. Figure 6-26 Preparing control cables for sealing modules (1) Sealing module (4) Conductor screen extension to connect to PE terminal (2) Conductive foil (3) Cable sheath removed to expose cable shield 3BHS212794 E01 REV M ACS6000 USER MANUAL 150/278...
  • Page 151 Note: If cables are routed through the cabinet floor, the grommets can be discarded. 4. If necessary, remove the entry plate and pull the cable through the entry holes. 3BHS212794 E01 REV M ACS6000 USER MANUAL 151/278...
  • Page 152 3. Connect the screens ends with a continuous conducting foil (3 in Fig. 6-28). Figure 6-28 Preparing the screens of control cables for EMC plates (1) Cable screen (3) Conductive foil (2) Cable screen ends 3BHS212794 E01 REV M ACS6000 USER MANUAL 152/278...
  • Page 153 The serial communications and encoder cables are connected inside a COU. Top and bottom cable entries are covered with blanking plates. Materials for cable fitting, EMC requirements and sealing are not supplied. 3BHS212794 E01 REV M ACS6000 USER MANUAL 153/278...
  • Page 154 3. Route the cable to its destination as illustrated in: • Fig. 6-31 (COU 600 mm) • Fig. 6-32 (COU 1000 mm) Figure 6-31 Cable route in COU (600 mm) top cable entry 3BHS212794 E01 REV M ACS6000 USER MANUAL 154/278...
  • Page 155 1. Insert and route the cables as illustrated in Fig. 6-33 and Fig. 6-34. Figure 6-33 Cable route in COU (600 mm) bottom cable entry (1) Cable entry bottom (3) Detail (2) Side view 3BHS212794 E01 REV M ACS6000 USER MANUAL 155/278...
  • Page 156 • Connect the individual shields and the overall shield (if present) of encoder cables to the separate shield grounding point. IMPORTANT! DO NOT connect the shields to the terminals of the interface. • Different-sized ground clamps are supplied. 3BHS212794 E01 REV M ACS6000 USER MANUAL 156/278...
  • Page 157 151 • Cable entries with cable glands: “6.8.3 Preparing cables for cable glands” on page 151. Note: Materials for cable fitting, EMC requirements and sealing are not supplied for undrilled plates. 3BHS212794 E01 REV M ACS6000 USER MANUAL 157/278...
  • Page 158 (6) Terminal for optical fibers behind cover (3) Cable enters through the floor (7) Optical fibers to DCS800 D4 (4) Terminal strip for auxiliary power converter and control cables (8) Optical fibers to DCS800 D5 converter 3BHS212794 E01 REV M ACS6000 USER MANUAL 158/278...
  • Page 159 • When using cable ties, be careful not to deform the optical fibers and do not use a cable tie gun. • When connecting or unplugging an optical fiber, hold it at the connector and not at the fiber. 3BHS212794 E01 REV M ACS6000 USER MANUAL 159/278...
  • Page 160 COM-8x circuit board (A) according to the terminal numbers printed on the marker sleeves. Figure 6-38 COM-8x circuit board (A) in a DCS800 converter (ED5V, EB5R and EB5S types) and a detail of channel CH0 (B) on the board. 3BHS212794 E01 REV M ACS6000 USER MANUAL 160/278...
  • Page 161 (6) Terminal for optical fibers behind cover (3) Cable enters through the floor (7) Optical fibers to DCS800 D4 (4) Terminal strip for auxiliary power converter and control cables 8. Reattach the DCS800 cover. 3BHS212794 E01 REV M ACS6000 USER MANUAL 161/278...
  • Page 162 COM-8x circuit board (A) according to the terminal numbers printed on the marker sleeves. Figure 6-41 COM-8x circuit board (A) in a DCS800 converter (ED7Y type) and a detail of channel CH0 (B) on the board 3BHS212794 E01 REV M ACS6000 USER MANUAL 162/278...
  • Page 163 (6) Terminal for optical fibers behind cover (3) Cable enters through the floor (7) Optical fibers to DCS800 D4 (4) Terminal strip for auxiliary power converter and control cables 4. Reattach the DCS800 cover. 3BHS212794 E01 REV M ACS6000 USER MANUAL 163/278...
  • Page 164 • When using cable ties, be careful not to deform the optical fibers and DO NOT use a cable tie gun. • When connecting or unplugging an optical fiber, hold it at the connector and not at the fiber. 3BHS212794 E01 REV M ACS6000 USER MANUAL 164/278...
  • Page 165 4. To seal the cable entry, use appropriate sealing inserts for the cable entry frames. Figure 6-43 REB cable entry (1) Blanking plate (removed) 3BHS212794 E01 REV M ACS6000 USER MANUAL 165/278...
  • Page 166 2. Connect the heating cables of two adjoining transport units with each other. 3. Fasten the connectors with cable ties. Figure 6-44 Heating cable connection (1) Heating cable plug (2) Cable tie 3BHS212794 E01 REV M ACS6000 USER MANUAL 166/278...
  • Page 167 • Check that the entry plates are properly fastened. • If EMC entry plates with grommets are used, check that the grommets fit tightly (arrows) to prevent water entering the cabinet. - If necessary, seal gaps with silicone. 3BHS212794 E01 REV M ACS6000 USER MANUAL 167/278...
  • Page 169 ABB. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB. Commissioning checklist In order to ensure uncomplicated and speedy commissioning, it is important that drive and associated equipment are ready for commissioning.
  • Page 170 □ 2) Types and cross sections of power cables selected according to the ABB power cable specification. □ 3) Pulse encoder cable shields are connected to the shield earthing point and not connected directly to the pulse encoder interface (applies only to drives with pulse encoder interface).
  • Page 171 Pay attention to MCB opening time and installation of undervoltage coil or second opening coil 7.6.4 Input transformer checklist □ Grounding is completed □ 2) Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are ready. □ 3) Protection devices are tested and in operation. 3BHS212794 E01 REV M ACS6000 USER MANUAL 171/278...
  • Page 172 2) Sufficient quantity of deionized water according is available. (see “Appendix C – Mechanical drawings”). □ 3) Air conditioning of drive room ready for load run of drive □ 4) Optional equipment (eg, chiller) ready 3BHS212794 E01 REV M ACS6000 USER MANUAL 172/278...
  • Page 173 • Classification: 3K22 / 3B1 / 3S6 / 3M11 Safety The drive system must only be operated by qualified and authorized personnel, ie, personnel who are familiar with the operation of the drive system and the hazards involved. 3BHS212794 E01 REV M ACS6000 USER MANUAL 173/278...
  • Page 174 • Starts and stops the motor • Displays status messages of the INU • Displays alarm and fault messages of the drive and monitored foreign equipment • Resets alarm and fault messages 3BHS212794 E01 REV M ACS6000 USER MANUAL 174/278...
  • Page 175 DC link operation of the drive and closes the main circuit breaker (4) Alarm / fault lamp • Alarm: flashing light • Fault: permanent light 3BHS212794 E01 REV M ACS6000 USER MANUAL 175/278...
  • Page 176 DC link. Figure 8-3 Typical semi-redundant drive configuration (1) Excitation power (7) LSU (2) Mains (8) INU (3) EXU (9) CBU/RBU (4) WCU (10) ISU (5) COU (11) Motor (6) Control 3BHS212794 E01 REV M ACS6000 USER MANUAL 176/278...
  • Page 177 (13) Synchronous motor (7) INU2 8.4.3.2 Semi-redundant drive control panel The semi-redundant drive control panel can be operated in both local and remote mode. For more information, see the appropriate application note. 3BHS212794 E01 REV M ACS6000 USER MANUAL 177/278...
  • Page 178 DCS800 unit at any time. • Context-sensitive help menu • Fault and alarm text messages including fault history Note: For more information, see "DCS800 drives firmware manual" (3ADW000193R0801). 3BHS212794 E01 REV M ACS6000 USER MANUAL 178/278...
  • Page 179 • DO NOT change any parameter if the meaning of the parameter and the effects of the change are not fully understood. The parameters are set as required for operation and verified during commissioning and must not be changed afterwards. 3BHS212794 E01 REV M ACS6000 USER MANUAL 179/278...
  • Page 180 DC-link voltage is below 50 V(DC). When the grounding switch is in position grounded, the door safety switches of the medium voltage units are released and the doors can be opened. 3BHS212794 E01 REV M ACS6000 USER MANUAL 180/278...
  • Page 181 Figure 8-7 Location on the safety switches The safety switches are part of an interlocking circuit that prevents the doors being opened as long as the DC link is charged. The interlocking circuit ensures that the: 3BHS212794 E01 REV M ACS6000 USER MANUAL 181/278...
  • Page 182 DC-link capacitors have been discharged, and the grounding switch is in position grounded. The locking bar locks and unlocks the locking mechanism of the door of a medium voltage unit. 3BHS212794 E01 REV M ACS6000 USER MANUAL 182/278...
  • Page 183 Note: For more information, see “10.4.9 Drives with the manual output isolation (optional)” on page 244. 3BHS212794 E01 REV M ACS6000 USER MANUAL 183/278...
  • Page 184 The drive is running and operating according to the set speed or torque reference value. When in remote control mode, the reference value is set at the remote control system. When in local control mode, the value is entered into the control panel. 3BHS212794 E01 REV M ACS6000 USER MANUAL 184/278...
  • Page 185 The status message always alternates with the specific fault message. The type of shutdown depends on the fault class the fault condition is assigned to in the drive software. 3BHS212794 E01 REV M ACS6000 USER MANUAL 185/278...
  • Page 186 6) ARU ReadyRef • Only in drives with an ARU 7) ReadyRun • INU starts magnetizing (only in drives with an ARU) • INU starts to modulate 8) Start command 9) ReadyRef 10) Operation 3BHS212794 E01 REV M ACS6000 USER MANUAL 186/278...
  • Page 187 7) ARU ReadyOn • Only in drives with an ARU 8) ReadyOn • Drive is grounded • Doors in medium voltage units are released for opening • Auxiliary power supply switched off 9) NotReadyOn 3BHS212794 E01 REV M ACS6000 USER MANUAL 187/278...
  • Page 188 3) Prevention of unexpected startup command • Drives stops according to Ramp, Torque, and Ramp stop modes • Open disconnector • Prevention of unexpected startup complete • Drive remains charged, MCB closed 4) INU operation prevention feedback 3BHS212794 E01 REV M ACS6000 USER MANUAL 188/278...
  • Page 189 • Doors are closed and locked or bolted. • Grounding switch is in position not grounded. Figure 8-8 Grounding switch in ungrounded position • MCB is in operating position. 3BHS212794 E01 REV M ACS6000 USER MANUAL 189/278...
  • Page 190 • If a fault cannot be reset, the responsible personnel must rectify it. • (Drives with an ARU) When faults are present and the drive is ready, the INU is “ReadyOn”. 1 L -> 4840.0 V StateARU ReadyOn DC VOLT 0.00 V PRI VOLT 3BHS212794 E01 REV M ACS6000 USER MANUAL 190/278...
  • Page 191 MOTOR SP 0.00 rpm POWER 0.0 kW • Drives with an ARU: - The ARU is now “ReadyRun”. 1 L -> 4840.0 V 0 StateARU ReadyRun DC Voltage 4400.0 V COS PHI 3BHS212794 E01 REV M ACS6000 USER MANUAL 191/278...
  • Page 192 After the motor has been magnetized, the motor speed ramps up to the reference value. While the motor is magnetizing, the run status message on the display blinks. When the motor has finished magnetizing, the run status message lights up permanently. 3BHS212794 E01 REV M ACS6000 USER MANUAL 192/278...
  • Page 193 Note: During the stop sequence, you can restart the drive by pressing the START key. The drive is now in stopping mode. 1 L -> 600.0 rpm StateINU Stopping MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 193/278...
  • Page 194 2. When the motor has reached zero speed, the drive is “ReadyRun”. 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 0.00 rpm POWER 0.0 kW As long as the MCB has not been opened, you can restart the motor at any time. 3BHS212794 E01 REV M ACS6000 USER MANUAL 194/278...
  • Page 195 Alternating display message: 1 L -> 600.0 rpm StateINU EmergencyOff • EmergencyOff MOTOR SP 0.00 rpm • NotReadyOn POWER 0.0 kW 5) EMERGENCY-OFF RESET button flashes 6) SUPPLY OFF push button flashes 3BHS212794 E01 REV M ACS6000 USER MANUAL 195/278...
  • Page 196 EmergencyOff • EmergencyOff MOTOR SP 0.00 rpm • EOFF<DCVolt POWER 0.0 kW 3. The main power supply can be connected to the drive again and the drive system can be started up. 3BHS212794 E01 REV M ACS6000 USER MANUAL 196/278...
  • Page 197 Arc detection with the Arc Guard System™ (optional) The optional Arc Guard System™ detects fast arc faults in the terminal sections of an ACS6000 drive. When the Arc Guard System detects an arc fault the drive performs protection firing and immediately opens the main circuit breaker.
  • Page 198 6. Reset the fault on Arc Guard HMI panel. 7. Acknowledge the firing through with parameter 16.26 on the control panel (only when fault was understood and corrected). 8. Restart the drive. 3BHS212794 E01 REV M ACS6000 USER MANUAL 198/278...
  • Page 199 (12) Enter key, terminates a procedure (6) Fast navigation key for selecting the actual signals display or the (13) Reference key fault memory display (14) Start key (7) Local / remote selection key (15) Stop key 3BHS212794 E01 REV M ACS6000 USER MANUAL 199/278...
  • Page 200 When the CDP control panel is initialized, the display changes as follows: CDP312 PANEL V5.30 ... After 2-3 seconds the display shows the drive name (1, 2), the application software in use (3), and the drive identification (4) is displayed. 3BHS212794 E01 REV M ACS6000 USER MANUAL 200/278...
  • Page 201 The status line of the display alternates between DCGndNOpen and NotReadyOn. Alternating display message: 1 L -> 0.0 rpm StateINU DCGndNopen • DCGndNopen MOTOR SP 0.00 rpm • NotReadyOn POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 201/278...
  • Page 202 However, when the drive is in a fault condition, the fault memory display appears instead. The actual signals display is used to monitor the drive without interfering with its operation. It continuously displays three selectable actual values. 3BHS212794 E01 REV M ACS6000 USER MANUAL 202/278...
  • Page 203 9.2.2.2 Selecting the actual signals display To select the actual signals display, press the ACT key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 203/278...
  • Page 204 2. To return to the actual signals display, release the ACT key. 9.2.2.5 Selecting actual signals 1. To select the actual signals display, press the ACT key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 204/278...
  • Page 205 1 ACTUAL SIGNALS 01 DC VOLTAGE 1000 V 5. To select an actual signal, press a slow navigation keys. FUNC DRIVE 1 L -> 600.0 rpm 2 ACTUAL SIGNALS 05 NP VOLTAGE 1000 V 3BHS212794 E01 REV M ACS6000 USER MANUAL 205/278...
  • Page 206 1. To open the actual signals display, press the ACT key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 2. To change to the fault memory display, press a fast navigation key. 3BHS212794 E01 REV M ACS6000 USER MANUAL 206/278...
  • Page 207 600.0 rpm LAST FAULT 5. To return to the actual signals display, press a fast navigation key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 207/278...
  • Page 208 600.0 rpm ACS5000 *** FAULT *** MCB CloseControl 2. To reset the fault, press the RESET key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 208/278...
  • Page 209 (3) Parameter number and name (7) Slow navigation key for selecting a (4) Parameter value parameter (and a parameter value) (5) Selection key for (8) Enter key for confirming parameters mode the selection 3BHS212794 E01 REV M ACS6000 USER MANUAL 209/278...
  • Page 210 Some parameter settings cannot be changed while the drive is running. If tried, the following warning displays. ** WARNING ** WRITE ACCESS DENIED PARAMETER SETTING NOT POSSIBLE 3BHS212794 E01 REV M ACS6000 USER MANUAL 210/278...
  • Page 211 75 OPTION MODULES 07 C3P1/AI820 Module DISABLED 4. To enter the parameter setting function, press the ENTER key. FUNC DRIVE 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module [DISABLED] 3BHS212794 E01 REV M ACS6000 USER MANUAL 211/278...
  • Page 212 9. To cancel the setting and keep the original setting, press any of the mode selection keys. The selected keypad mode is entered. FUNC DRIVE 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module DISABLED 3BHS212794 E01 REV M ACS6000 USER MANUAL 212/278...
  • Page 213 User lock ▲ NOTICE ABB is not be liable for damages or losses caused by the failure to activate the user lock with a new pass code. For more information, see “1.9 Cyber security disclaimer” on page 38. For better cyber security, it is highly recommended that you set a master pass code for the control panel to prevent the parameter values from being changed.
  • Page 214 (3) Selection key for functions mode the selection 9.2.4.1 Adjusting the display contrast 1. To enter the functions mode, press the FUNC key. FUNC DRIVE 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 3BHS212794 E01 REV M ACS6000 USER MANUAL 214/278...
  • Page 215 CONTRAST 5. To confirm the setting and to return to the actual signals display, press the ENTER key. FUNC DRIVE 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 3BHS212794 E01 REV M ACS6000 USER MANUAL 215/278...
  • Page 216 Accidental switching from remote control to local control can be prevented with the local lock function. The corresponding parameter is 16.04 LOCAL LOCK and belongs to the parameter group 16 SYSTEM CTRL INPUTS. 3BHS212794 E01 REV M ACS6000 USER MANUAL 216/278...
  • Page 217 - A blank space indicates full remote control from a higher-level control system. - The letter R indicates partial remote control (some commands are enabled locally). FUNC DRIVE 600.0 rpm StateINU ReadyRun MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 217/278...
  • Page 218 • When the motor is not running, the arrow indicates the preselected direction. To set the direction of rotation, press the forward or backward key. FUNC DRIVE 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 218/278...
  • Page 219 600.00 rpm POWER 75.0 kW 2. To enter the reference value input mode, press the REF key. FUNC DRIVE 1 L -> [600.0 rpm] StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 219/278...
  • Page 220 MOTOR SP 600.00 rpm POWER 75.0 kW 4. To exit the mode, press a mode selection key. FUNC DRIVE 1 L -> 550.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 220/278...
  • Page 221 ABB service organization. 10.1.2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule, on time and at the stated intervals in the "ACS6000 preventive maintenance schedule" (3BHS855273 E01). 10.1.3 Logbook...
  • Page 222 Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams. Figure 10-2 Cable and wire designation (1) Wire number (2) Terminal number 3BHS212794 E01 REV M ACS6000 USER MANUAL 222/278...
  • Page 223 • Fault: A fault shuts down the drive. The type of shutdown depends on the origin of the fault. 3BHS212794 E01 REV M ACS6000 USER MANUAL 223/278...
  • Page 224 2 min. 22 s than the first fault. +Fa u lt AM C: Fault Class 2 classifies the fault. Note: For more information on alarms and faults, see “Appendix G – Signal and parameter table”. 3BHS212794 E01 REV M ACS6000 USER MANUAL 224/278...
  • Page 225 The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. 5) Contact ABB service if a fault cannot be rectified. When calling ABB service, it is recommended to have the following data available at the time when the fault occurred: •...
  • Page 226 Flashing ON / OFF DDCS channel 0 Yellow Receiving data on Flashing ON / OFF Flashing ON / OFF DDCS channel 3 Yellow Yellow Flashing Flashing Yellow Flashing Flashing Yellow Flashing Flashing 3BHS212794 E01 REV M ACS6000 USER MANUAL 226/278...
  • Page 227 The LEDs are always at the topmost position on each module (Fig. 10-5: 1) and are identified as follows: • F: fault • R: run • W: warning • O or OSP (only output modules) 3BHS212794 E01 REV M ACS6000 USER MANUAL 227/278...
  • Page 228 • "AF 100 fieldbus - NAFA-01 installation and start-up guide" (3BFE58919837) • "Modbus TCP - NETA-21 remote monitoring tool user manual" (3AUA0000096939) • "Modbus RTU - NMBA-01 installation and startup guide" (3AFY58919772) • "Profibus - NPBA-12 installation and startup guide" (3BFE64341588) 3BHS212794 E01 REV M ACS6000 USER MANUAL 228/278...
  • Page 229 (1) Red LED off (A) and Green LED on (3) Red LED off (A) and Green LED off (B): Heat exchanger is healthy (B): Auxiliary voltage is missing (2) Red LED on (A) and Green LED off (B): Alarm conditions 3BHS212794 E01 REV M ACS6000 USER MANUAL 229/278...
  • Page 230 IOI switch in the RDC unit, even if the switch is open and the drive is grounded. - See the local safety procedures on how to isolate and ground the equipment. 3BHS212794 E01 REV M ACS6000 USER MANUAL 230/278...
  • Page 231 The motor stops according to the preset stop function. When the motor has reached zero speed, the drive is in “ReadyRun. 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 0.00 rpm POWER 0.0 kW 3BHS212794 E01 REV M ACS6000 USER MANUAL 231/278...
  • Page 232 When the DC link is discharged, the drive is “ReadyOn”. 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 4. Rack-out, lock-out, ground and tag-out the main power feeder. 3BHS212794 E01 REV M ACS6000 USER MANUAL 232/278...
  • Page 233 Ungrounded position 6. If the yellow lamp GROUNDING SWITCH UNLOCKED is on, keep the yellow lamp cap pressed while you turn the grounding switch to the grounded position. 3BHS212794 E01 REV M ACS6000 USER MANUAL 233/278...
  • Page 234 1. Check that the auxiliary voltage is switched on. NOTICE DO NOT use force for turning the grounding switch in any direction 2. Press the lamp cap to test the lamp. 3BHS212794 E01 REV M ACS6000 USER MANUAL 234/278...
  • Page 235 • Hazardous voltages cannot be fed into the drive from the main power supply or the motor • DC link is discharged • Grounding switch is released (DO07 is energized) • Drive status is “ReadyOn” 3BHS212794 E01 REV M ACS6000 USER MANUAL 235/278...
  • Page 236 238. Figure 10-9 Grounding switch grounded (1) White lamp (2) Yellow lamp 2. Slide the locking bar from the locked (1) to the unlocked (2) position. • Door hinged on the left: 3BHS212794 E01 REV M ACS6000 USER MANUAL 236/278...
  • Page 237 Closing and locking the doors 1. Close the doors. 2. To lock the door, bring the door handle in line with the door plate (1) and press the handle down (2) until it clicks in. 3BHS212794 E01 REV M ACS6000 USER MANUAL 237/278...
  • Page 238 From the lamp not lighting up, it cannot be concluded that the door releasing circuit is not working. • Lamp turns on: - Door releasing circuit is malfunctioning. 3BHS212794 E01 REV M ACS6000 USER MANUAL 238/278...
  • Page 239 • Converter hardware diagram • Wiring diagram of COU1 For information on the wiring of the discharging circuit and / or the grounding circuit, see: • Wiring diagram of COU1 • Wiring diagram of CBU 3BHS212794 E01 REV M ACS6000 USER MANUAL 239/278...
  • Page 240 Figure 10-11 Safety switch on an ARU/INU cabinet door (1) Screw cap on door (4) Unlocked position (2) Safety switch location (5) Locked position (behind door) (6) Release dial (3) Safety switch 3BHS212794 E01 REV M ACS6000 USER MANUAL 240/278...
  • Page 241 2. Loosen the locking screw (1) until the release dial can be turned. 3. Turn the release dial from the locked to the unlocked position. 5 mm You can now actuate the locking bar and open the doors. 3BHS212794 E01 REV M ACS6000 USER MANUAL 241/278...
  • Page 242 (3) Telescopic insulating pole (2) Enclosure ground clamp Depending on the type of line-side rectifier, continue with: • “10.4.8.1 Drives with LSU” on page 243 • “10.4.8.2 Drives with ARU” on page 244 3BHS212794 E01 REV M ACS6000 USER MANUAL 242/278...
  • Page 243 • Inside INU: L1, L2 and L3 in Fig. 10-15 Figure 10-14 TEU ground ball stud locations (1) Ground ball stud example (5) 2L3 (2) 2L2 (6) 2L1 (3) 1L1 (7) 1L2 (4) 1L3 (8) PE 3BHS212794 E01 REV M ACS6000 USER MANUAL 243/278...
  • Page 244 • Busbar connectors in TEU1 and COU1 - Busbar connectors for INU1 are located in TEU1. - Busbar connectors for INU2 are located in the terminal compartment inside COU1. • Lever for removing and fitting the busbar connectors 3BHS212794 E01 REV M ACS6000 USER MANUAL 244/278...
  • Page 245 (10) Motor (4) CBU1 (11) Busbar connectors (3 x) in TEU (5) BCU1 (12) Busbar connectors (3 x) in COU1 (6) INU2 (13) Lever for removing and fitting the busbar connections (7) COU1 3BHS212794 E01 REV M ACS6000 USER MANUAL 245/278...
  • Page 246 The three busbar connectors are fitted in TEU1. The motor is connected to INU1. The three busbar connectors are not fitted in TEU1. The motor is disconnected from INU1. Invalid configuration. Drive will not start. 3BHS212794 E01 REV M ACS6000 USER MANUAL 246/278...
  • Page 247 • Follow local safety procedures Figure 10-18 Tools for removing the busbar connectors (1) Orientation of lever for removing (3) Four-way grounding set (4x) busbar connectors (2) Orientation of lever for fitting the busbar connectors 3BHS212794 E01 REV M ACS6000 USER MANUAL 247/278...
  • Page 248 • Busbars in the INU (3 in Fig. 10-20) LSU1 TEU1 INU1 INU2 COU1 LSU2 Figure 10-19 Overview of grounding the drive - INU1 is shut down (A) and INU2 is shut down (B). Numbers indicate the connection sequence. 3BHS212794 E01 REV M ACS6000 USER MANUAL 248/278...
  • Page 249 Figure 10-20 Connect the grounding sets in COU1 (A and C), TEU1 (B), INU1 (D) and INU2 (E) (1) Busbars for secondary (4) PE transformer windings (5) Ground ball stud (2) Busbars for motor cables (3) INU busbars 3BHS212794 E01 REV M ACS6000 USER MANUAL 249/278...
  • Page 250 4. Inside TEU1 or COU1 remove the busbar connectors in the sequence shown in Fig. 10-21. CAUTIONA busbar connector weighs approximately 10 kg. Figure 10-21 Busbar connector removal sequence in TEU1 or COU1 5. Remove the grounding sets. 3BHS212794 E01 REV M ACS6000 USER MANUAL 250/278...
  • Page 251 10.4.9.2 Fitting the busbar connectors 1. Shut down the drive according to the established procedures. 2. Fit the busbar connectors in the sequence shown in Fig. 10-22. Figure 10-22 Fitting sequence for busbar connectors 3BHS212794 E01 REV M ACS6000 USER MANUAL 251/278...
  • Page 252 6. Close and lock the doors. 7. Check that the power operating mode (POM) of the drive corresponds to the busbar connectors fitted. 8. Start the drive according to the established procedures. 3BHS212794 E01 REV M ACS6000 USER MANUAL 252/278...
  • Page 253 Note: To disconnect the water hose, pull the locking sleeve of the coupling towards the front of the cabinet (arrow). 2. Cut off the cable ties (1) and disconnect the optical fibers and the power supply leads (2). 3BHS212794 E01 REV M ACS6000 USER MANUAL 253/278...
  • Page 254 6. Pull the phase module onto the table. CAUTIONA phase module weighs approximately 190 kg. When pulling out the phase module, make sure that the disconnected water hoses, optical fibers and power supply leads are out of the way. 3BHS212794 E01 REV M ACS6000 USER MANUAL 254/278...
  • Page 255 NOTICE DO NOT mix up the cables. The identification on the label must correspond to its counterpart on the phase module. Verify the correct connection with the corresponding wiring diagram. 10. Fasten the cables with cable ties. 3BHS212794 E01 REV M ACS6000 USER MANUAL 255/278...
  • Page 256 10 PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4.11 Visual checks on the drive Check the drive and its immediate vicinity visually at the intervals stated in "ACS6000 preventive maintenance schedule" (3BHS855273 E01) and pay attention to the following items: • Humidity inside the drive •...
  • Page 257 • Check all power and control cable connections and tighten them if necessary. • Check that all plugs and connectors are tight. 10.4.14 Checking and replacing filter mats • Inspection intervals: See the "ACS6000 preventive maintenance schedule" (3BHS855273 E01). • Service during operation: possible. • Filter mat class: G3 (EN779) •...
  • Page 258 3. Slide the cover up and pull it out of the slots. 4. Turn the cover over and remove the filter mat. 5. Insert the new filter mat and reinstall the ventilation grid. 3BHS212794 E01 REV M ACS6000 USER MANUAL 258/278...
  • Page 259 10 PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4.15 Testing and replacing auxiliary fan units • Inspection intervals: see the "ACS6000 preventive maintenance schedule" (3BHS855273 E01). • Service during operation: possible • Location:• installed behind the doors of the following cabinets: - COU cabinet (2 fan units)
  • Page 260 Figure 10-25 Accessing the fan units in the WCU roof box 3. Disconnect the wires (1) and unscrew (2) the fan units. 4. Remove the fan unit. 5. Reinstall the new one in reverse order of removal. 3BHS212794 E01 REV M ACS6000 USER MANUAL 260/278...
  • Page 261 10 PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4.16 Testing and replacing air-to-air heat exchangers • Inspection intervals: see the "ACS6000 preventive maintenance schedule" (3BHS855273 E01). • Service during operation: not possible Figure 10-26 Air-to-air heat exchanger overview (type LT-5-5165-UL) (1) Ambient fan 2...
  • Page 262 (arrow). 4. Check that the fans run smoothly and if a fan is defective, replace the complete fan unit. 5. Adjust the setting of the thermostat to its original value. 3BHS212794 E01 REV M ACS6000 USER MANUAL 262/278...
  • Page 263 For information on replacing the complete heat exchanger, see “Mechanical installation” on page 56. 10.4.16.3 Replacing the circuit board 1. Unscrew the front and top cover. 2. Disconnect the ground wire from the front cover (arrow). 3BHS212794 E01 REV M ACS6000 USER MANUAL 263/278...
  • Page 264 4x J9 4x fan power supply 1x J4 2x J6 3x J8 4x J10 4x fan alarm signals 1x J22 2x J23 3x J24 4x J25 LEDs Red J18 Green J19 Alarm 1 3BHS212794 E01 REV M ACS6000 USER MANUAL 264/278...
  • Page 265 10.4.16.4 Replacing internal fan 1 - left side Procedure 1. Unscrew the front top cover. 2. Unplug the plug-in connectors (arrows) and unscrew the screws (1, 2, 3 and 4) which fix the fan mounting bracket to the housing. 3BHS212794 E01 REV M ACS6000 USER MANUAL 265/278...
  • Page 266 3. Remove the fan from the housing and unscrew the fan from the mounting bracket. 4. Replace the fan and reassemble the unit in reverse order of removal. 10.4.16.5 Replacing internal fan 2 - right side 3BHS212794 E01 REV M ACS6000 USER MANUAL 266/278...
  • Page 267 10 PREVENTIVE AND CORRECTIVE MAINTENANCE Procedure 1. Unscrew the front top cover. 2. Remove the front cover and disconnect the ground wire (arrow). 3BHS212794 E01 REV M ACS6000 USER MANUAL 267/278...
  • Page 268 5. Disconnect the ground wire (1), cut off the cable tie (2), unplug the plug-in connectors (arrows), and unscrew the screws (3, 4, 5 and 6) fixing the fan mounting bracket to the housing. 3BHS212794 E01 REV M ACS6000 USER MANUAL 268/278...
  • Page 269 7. Replace the fan and reassemble the unit in reverse order of removal. 10.4.16.6 Replacing the ambient fans 1. Unscrew the rear cover. 2. Lift the hinged cover up a little and disconnect the ground wire (arrow). 3BHS212794 E01 REV M ACS6000 USER MANUAL 269/278...
  • Page 270 Figure 10-28 DCS800 controller - size D4 Procedure 1. Switch off the miniature circuit breaker of the fan unit. Note: To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 3BHS212794 E01 REV M ACS6000 USER MANUAL 270/278...
  • Page 271 2. Remove the 6 screws from the fan cover and then remove the fan cover. 3. Unplug the fan cables. 4. Remove the 4 fastening screws from the outside panel of the fan unit. 3BHS212794 E01 REV M ACS6000 USER MANUAL 271/278...
  • Page 272 Figure 10-29 DCS800 controller - size D5 Procedure 1. Switch off the miniature circuit breaker of the fan unit. Note: To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 3BHS212794 E01 REV M ACS6000 USER MANUAL 272/278...
  • Page 273 2. Remove the 6 screws from the fan cover and then remove the fan cover. 3. Unplug the fan cables. 4. Remove the 4 fastening screws from the outside panel of the fan unit. 3BHS212794 E01 REV M ACS6000 USER MANUAL 273/278...
  • Page 274 2. Close valves V30 and V31 in the water-cooling unit. 3. Disconnect the hose from valve V30 to drain the WCU. NOTICE Expect approximately 5 liters of water. 4. Unscrew the top plate. 3BHS212794 E01 REV M ACS6000 USER MANUAL 274/278...
  • Page 275 6. Lift the heat exchanger out of the cabinet. CAUTIONThe heat exchanger weighs approximately 16 kg and requires a minimum overhead clearance of 85 cm. Figure 10-31 Lift heat exchanger out of EXU cabinet 3BHS212794 E01 REV M ACS6000 USER MANUAL 275/278...
  • Page 276 Note: For information on adding water to the cooling system, see the manual for the "ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual" (3BHS821937 E01) and "ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual" (3BHS835714 E01).
  • Page 277 .com /d r ive s/ me d ium -v ol ta g e -a c- d riv es — © Copyright 2020 ABB. All rights reserved. The information in this document is subject to change without notice.

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