Page 1 — SYSTEM DRIVES ACS6000 User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL ABB Switzerland Ltd. 2020-11-18 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS212794 E01 1/266 © Copyright 2005 ABB All rights reserved.
Page 2 It is the sole responsibility of the buyer of the products to provide and continuously ensure a secure connection between the product and the system network and/or any other networks that may be connected to the product. ABB is in no event liable for the security of the network used by buyer.
Page 3: Table Of Contents
3. Power electronics and cabinet features ..........41 3.1. Drive system topology ............... 41 3.1.1. Drive ................... 41 3.1.1.1. ACS6000 cabinet units ..........43 3.1.1.2. Final drive configuration ..........43 3.1.2. Motor ..................43 3.2. Standard cabinet units ..............44 3.2.1.
Page 4 Dimensions and clearances ............ 86 5.3.2. Access to the cabinets ............86 5.3.3. Cabinet roof ................86 5.3.4. Fire protection ................. 86 5.3.5. Cable duct material ..............87 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 4/266...
Page 5 Connecting the detector cables to the arc monitor device .............. 124 6.5. Cable entry systems ................. 125 6.5.1. Frames with type 1 sealing modules ........125 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 5/266...
Page 6 Required qualification ..............157 7.2. Commissioning procedure ............157 7.3. Commissioning checklist ............... 157 7.4. Customer assistance ..............157 7.5. Customer acceptance ..............157 7.6. Commissioning checklists............... 158 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 6/266...
Page 7 Action after the Arc Guard System™ has been triggered ................. 183 9. CDP control panel ................185 9.1. Overview .................... 185 9.1.1. Display and keypad ..............185 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 7/266...
Page 8 S800 I/O bus modem TB820 ........213 10.3.3.3. S800 I/O modules ............213 10.3.3.4. Serial communication interfaces ........ 214 10.3.3.5. LEDs on optional heat exchangers ......214 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 8/266...
Page 9 DCS800 D4 size controller ............ 258 10.4.18. Replacing the fan unit in an EXU with DCS800 size D5 controller ..............260 10.4.19. Replacing the air-to-water heat exchanger of the EXU ...................262 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 9/266...
Page 11 Figure 3-18 WCU1400 (A) and WCU800 (B) cabinet and system components ........................59 Figure 3-19 Cooling circuit in an ACS6000 drive ............60 Figure 3-20 IRU cabinet (A) and circuit diagram (B) ..........61 Figure 3-21 IFU cabinet (A) and circuit diagram (B) ........... 62 Figure 3-22 VLU cabinet (A) and circuit diagram (B) ..........
Page 12 FIGURES Figure 3-27 ACS6000 example drive with air-to-air heat exchanger ......70 Figure 3-28 Auxiliary fan unit ..................71 Figure 3-29 Air circulation through ventilation grids in 600 mm COU (A), 1000 mm COU (B) and WCU800 (C) ................71 Figure 3-30 Basic cabinet design .................
Page 13 Figure 6-32 Cable route in COU (1000 mm) top cable entry ........145 Figure 6-33 Cable route in COU (600 mm) bottom cable entry ......145 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 13/266...
Page 14 Figure 10-4 TB820 bus modem .................. 213 Figure 10-5 Example of S800 I/O station ..............214 Figure 10-6 Status LEDs on optional air-to-air heat exchangers ......215 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 14/266...
Page 15 Figure 10-29 DCS800 controller - size D5 ..............260 Figure 10-30 Air-to-water heat connections ............. 263 Figure 10-31 Lift heat exchanger out of EXU cabinet ..........263 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 15/266...
Page 17 Table 3-4 Main components in a WCU cabinet ................... 58 Table 3-5 BCU braking power........................64 Table 3-6 RBU braking power........................64 Table 3-7 ABB arc resistant classes......................74 Table 5-1 Installation material for AC busbars (COU/TEU – ARU/INU) ........99 Table 5-2 Installation material for roof joints..................114 Table 6-1 Cable entry frames for type 1 sealing modules ..............
Page 19: About This Manual
(such as layout drawings, wiring diagrams, project-specific data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB. 1.2. Structure of the user documentation The documentation for a standard drive consists of this document and the following project-specific appendices.
Page 20: Terms And Abbreviations
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 21 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 22 Gray-coded interface for determining the absolute position of a rotor. Gate Turn-Off thyristor High Voltage Divider Input / Output Induced Draft fan International Electrotechnical Commission Input Filter Unit IGBT Insulated-Gate Bipolar Transistor PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 22/266...
Page 23 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. I/O station Term of ABB’s S800 I/O system.
Page 24 Receive Data Register Rolling Mill Drive Revolutions Per Minute 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 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 25 “zero speed” that is set in a parameter. The value can be set in the range of 0 and maximum speed (the unit for the speed is rpm). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 25/266...
Page 26: Related Documents
ABB MVD ACS Transformer Specification 3BHS356582 E01 ABB MVD ACS Motor Specification 3BHS824803 E01 Technical project Specification Motor 3BHS824804 E01 ABB MVD ACS High Performance Motor Specification 3BHS824805 E01 ABB MVD ACS High Speed Motor Specification 3BHS824806 E01 Power cable specification 3BHS125090 E01...
Page 27: Target Groups And Required Qualification
S800 I/O Modules and termination units 3BSE020924 Table 1-8 User manuals related to drive units Title Document ID. ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 3BHS821937 E01 user manual ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 3BHS835714 E01 user manual 1.5.
Page 28: Mechanical Installation
Use of the drive outside the scope of the specifications is not permitted. Intended equipment use also implies that only spare parts recommended and approved by ABB must be used. Unauthorized modifications and constructional changes of the drive are not permitted.
Page 29: Quality Certificates And Applicable Standards
1.8. 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 30: Identifying The Delivery
1.10. 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 31: Important Safety Information
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 31/266...
Page 32: Product Safety Labels
PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 32/266...
Page 33: General Safety Instructions
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 33/266...
Page 34: The 7 Steps That Save Lives
IMPORTANT SAFETY INFORMATION 2.5. 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. 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 35 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” PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 35/266...
Page 36: Possible Residual Risks
• Wrong parameter settings • Software errors • Faulty hardware Hazardous substances can be emitted from drive system components, eg, due to Incorrect disposal of components PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 36/266...
Page 37: Important Note - Main Circuit Breaker
– Transformer or drive primary cable protection (DTL) – Transformer protection (if applicable) – Transformer secondary cable protection (if applicable) – Backing up the drive protection PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 37/266...
Page 38: Safety And Protection Requirements
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 38/266...
Page 39: Maintenance Recommendation
3) No further damage to the drive 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 –...
Page 41: Power Electronics And Cabinet Features
– 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...
Page 42: Figure 3-2 Acs6000 Drive Example
POWER ELECTRONICS AND CABINET FEATURES The drive 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 43: Acs6000 Cabinet Units
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 44: Standard Cabinet Units
3) INU 2) DC-link 4) Motor DC (+) DC (NP) DC (-) Figure 3-4 ARU/INU circuit diagram 1) Clamping circuit 3) EMC filter 2) Phase modules PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 44/266...
Page 45: Figure 3-5 Aru/Inu (A) And Phase Modules With Igcts (B)
Figure 3-5 ARU/INU (A) and phase modules with IGCTs (B) 1) EMC filter 6) Coolant outlet 2) Control interface 7) IGCT 3) IPS 8) Coolant inlet 4) Phase module 9) Clamp capacitor 5) Diode PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 45/266...
Page 46: Line Supply Unit (Lsu)
2) DC-link 4) Motor DC (-) DC (+) Figure 3-7 LSU (12-pulse) circuit diagram 1) Thyristor crowbar 3) Snubber circuit 2) Diode rectifier 4) di/dt choke PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 46/266...
Page 47: Figure 3-8 Lsu (12-Pulse)
Figure 3-8 LSU (12-pulse) 1) Snubber resistor 4) di/dt limiting reactors 2) Snubber capacitor 5) Diode stacks 3) Rectifier monitoring unit PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 47/266...
Page 48: Capacitor Bank Unit (Cbu)
These can only be closed if the DC-link capacitors have been discharged. For more information, see “8.5 EXU control panel” on page 166. Figure 3-9 CBU 1) Grounding switch 2) DC-link capacitor PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 48/266...
Page 49: Terminal Unit (Teu)
Figure 3-10 TEU (1000 mm) 1) DC busbars 3) Cable entry frame 2) AC busbars 4) PE ground busbars PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 49/266...
Page 50: Control Unit (Cou)
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 50/266...
Page 51: Figure 3-11 Control Units: 1000 Mm Cou (A) And 600 Mm Cou (B)
POWER ELECTRONICS AND CABINET FEATURES Figure 3-11 Control units: 1000 mm COU (A) and 600 mm COU (B) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 51/266...
Page 52: Control System Configuration
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 52/266...
Page 53: Amc Circuit Board
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 1) AMC circuit board PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 53/266...
Page 54: Main Circuit Breaker
Therefore it must only be controlled and monitored by the drive. For more information, see: – “Main circuit breaker specification” (3BHS125149 E60) – “2.7 Important note - main circuit breaker” on page 37. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 54/266...
Page 55: 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 56: Peripheral I/O Devices
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 57: S800 I/O System
2) I/O modules For more information, see: – S800 I/O - General information and installation, user’s guide – S800 I/O - Modules and termination unit, user’s guide PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 57/266...
Page 58: Water Cooling Unit (Wcu)
The water cooling units are accessible for maintenance even when the drive is in operation. For more information, see: – “ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual” (3BHS821937 E01) – “ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual”...
Page 59: Figure 3-18 Wcu1400 (A) And Wcu800 (B) Cabinet And System Components
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 59/266...
Page 60: Cooling Circuit
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 61: Optional Cabinet Units
Figure 3-20 IRU cabinet (A) and circuit diagram (B) 1) Three-phase reactor 5) Diode rectifier 2) IRU 6) Snubber circuit 3) LSU 7) di/dt choke 4) Thyristor crowbar PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 61/266...
Page 62: Input Filter Unit (Ifu)
ARU and reduces harmonic voltages injected to the supply network. Figure 3-21 IFU cabinet (A) and circuit diagram (B) 1) Resistor 4) TEU 2) Capacitor 5) IFU 3) Reactor 6) ARU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 62/266...
Page 63: Voltage Limiter Unit (Vlu)
IGCT semiconductors and protected against overload. DC (+) DC (NP) DC (-) Figure 3-22 VLU cabinet (A) and circuit diagram (B) 1) Air-cooled resistors 2) IGCT PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 63/266...
Page 64: Braking Units
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 (kW) Double braking power (kW)
Page 65: Braking Chopper Unit
DC (+) DC (NP) DC (-) Figure 3-23 BCU cabinet (A) and circuit diagram (B) 1) IGCT 3) BCU 2) Resistor (external) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 65/266...
Page 66: Resistor Braking Unit
An RBU, with integrated resistors, is used for smaller braking capabilities. DC (+) DC (NP) DC (-) Figure 3-24 RBU cabinet (A) and circuit diagram (B) 1) IGCT 2) Water-cooled resistor PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 66/266...
Page 67: Excitation Unit (Exu)
1) Ground fault detection device (optional) 5) DCS800 D4 unit 2) Fuses 6) Overvoltage protection (not shown in A) 3) Control compartment 7) DCS800 D5 unit 4) Fan units PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 67/266...
Page 68: Dcs800 Control Panel
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 68/266...
Page 69: Customer Interface Unit (Ciu)
For more I/O modules, a CIU is required. Figure 3-26 CIU cabinet (A) and WCU800 cabinet (B) 1) CIU 3) WCU800 2) Roof extension box (REB) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 69/266...
Page 70: Arc Detection With Arc Guard (Optional)
For information on number and location of heat exchangers and transformer, see “Appendix C - Mechanical drawings”. The number of installed air-to-air heat exchangers and transformers depends on the configuration of the drive. Figure 3-27 ACS6000 example drive with air-to-air heat exchanger 1) Air-to-air heat exchanger 2) Additional transformer PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 71: Auxiliary Fan Units
Figure 3-29 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 71/266...
Page 72: Cabinet Design
POWER ELECTRONICS AND CABINET FEATURES 3.5. 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 73: Door Locking System
3.6. Door locking system For more information on the door locking system, including grounding switches, locking bars, and safety switches, see “8.5 EXU control panel” on page 166. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 73/266...
Page 74: Arc Resistant Design
MCB requirements are described in “2.7 Important note - main circuit breaker” on page 37. Based on the ACS6000 IAC rating, the minimum approach distance is 0.3 m. Local rules may require additional distance. The user is responsible to determine the correct approach distance considering local rules.
Page 75: Busbars And Grounding
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 75/266...
Page 77: Transportation, Storage And Disposal
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 78 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 79: Lifting And Transportation
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 80: Lifting Recommendations
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 81: Figure 4-2 Lift Frame (A) And Lift Spreader (B)
5) Safety hook or shackle 2) Lift frame 6) Lifting bracket 3) Strap 7) Slope angle (maximum 15°) 4) Protect the edges, door handles and levers 8) Lift spreader PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 81/266...
Page 82: Storage
4.6. Storage The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. 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 83: Warranty Information
4.6.3.1. 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 84: Disposing Package Materials And Components
Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations. For more information on the disposal of packaging materials and drive components, see the recycling instructions. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 84/266...
Page 85: Mechanical Installation
“5.8 Installing and removing air-to-air heat exchangers” on page 102 • “5.9 Installing the pressure relief vents” on page 111 • “5.10 Attaching the sealing tapes” on page 113 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 85/266...
Page 86: General Notes On Installation
DO NOT install any foreign objects on the roof and do not step on roof. 5.3.4. Fire protection To prevent fire from spreading into the drive, apply suitable fire protection measures. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 86/266...
Page 87: Cable Duct Material
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”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 87/266...
Page 88: Aligning Transport Units
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 88/266...
Page 89 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 89/266...
Page 90: Joining Transport Units
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) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 90/266...
Page 91: Joining Water Pipes
Figure 5-2 Minimum distances and locking bolt orientation (A = front) 1) 40 mm minimum 2) Locking bolt orientation PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 91/266...
Page 92: Removing A Pipe Joint
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 92/266...
Page 93: Joining Busbars
Use a conical spring washer on each side of a connection. Figure 5-3 Bolted busbar connection 1) Hex-head bolt 3) Flange nut 2) Conical spring washer PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 93/266...
Page 94: Dc Busbars
4) Hex-head bolt M12 x 30-A2 NB 312350P8117 5) Busbar with positive potential 6) Busbar with neutral potential 7) Busbar with negative potential 8) Front of cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 94/266...
Page 95: Figure 5-5 Top View Dc Busbar Configurations 2 (A), 3 (B) And 4 (C)
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 95/266...
Page 96: Ground Busbars
M12 x 40-A2 NB 312350P8119 3) Hex-head nut M12-A2-70, HZN 452198P1022 coated 4) Conical spring washer 13 x 29 x 3 HAQN400344P0111 5) Water pipe 6) Cabinet front PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 96/266...
Page 97: Ac Busbars Between Cou/Teu And Lsu (5/7/9 Mva)
M12 x 50-A2-70 NB 312450P8121 7) Conical spring washer DIN6796-13 x 29 x 3 HAQN400344P0111 8) Hex-head nut M12-A2-70 HZN 452198P1022 9) Flange nut M12-A2 3BHB038117R0001 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 97/266...
Page 98: Ac Busbars Between Cou/Teu And Lsu (14 Mva)
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 washer DIN6796-13x29x3 HAQN400344P0111 7) Hex-head nut DIN934-M12-A2-70 HZN 452198P1022 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 98/266...
Page 99: Ac Busbars Between Cou/Teu And Aru/Inu
• 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 99/266...
Page 100: Ac Busbar Joints - With Motorized Disconnector
5, 7, 9, 13 peak MVA • COU/TEU: 1000 mm • COU/TEU - ARU/INU • ARU/INU: 5, 7, 9, 13 peak MVA • COU/TEU: 1000 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 100/266...
Page 101 Busbar joints • ARU/INU - COU/TEU • ARU/INU: 12 MVA • COU/TEU: 1000 mm • COU/TEU - ARU/INU • ARU/INU: 12 MVA • COU/TEU: 1000 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 101/266...
Page 102: Installing And Removing Air-To-Air Heat Exchangers
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 102/266...
Page 103: Installation
2. Loop the cables as illustrated and fasten them to the cable tie mounts (circles). 3. Loop a length of the cables and fasten them to the cable tie mount (circle). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 103/266...
Page 104: Figure 5-11 Correct And Incorrect Cable Installation
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 104/266...
Page 105 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 105/266...
Page 106: Figure 5-12 Aru/Inu/Ifu Cable Routing
15 x 11. In the lower part (2), tie the cables together at regular distances. 12. Check that the cables do not touch the DC busbars. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 106/266...
Page 107: Removing Air-To-Air Heat Exchangers
Air-to-air heat exchangers must be removed and refitted where two transport units are joined. Depending on the drive configuration, at least one heat exchanger must be removed for joining the DC busbars of two adjacent transport units. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 107/266...
Page 108: Removing An Air-To-Air Heat Exchanger
2. Remove the cable ties. 3. Lift the heat exchanger by crane and move it approximately 20 cm to the back and place it on pieces of square timber. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 108/266...
Page 109: Reinstalling An Air-To-Air Heat Exchanger
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 109/266...
Page 110: Installing The Transformers Of Air-To-Air Heat Exchangers
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 110/266...
Page 111: Installing The Pressure Relief Vents
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 111/266...
Page 112: Figure 5-19 Tools Required To Fasten The Pressure Relief Vent To The Roof
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). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 112/266...
Page 113: Attaching The Sealing Tapes
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 113/266...
Page 114: Installing The Roof Joints And The Roof Attachments
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) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 114/266...
Page 115: Installing Roof Attachments
2 x damping connectors 3BHB033405R0001 2 x plates 3BHB035999R0001 2 x washers 13 / 29 ST / ZN 9ABA450078P0007 2 x hex-head bolts M12 x 80 NB 312450P8127 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 115/266...
Page 116: 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 116/266...
Page 117: Electrical Installation
– DO NOT switch on the main and auxiliary power supplies during the installation. – After the installation, obtain permission from the ABB commissioning personnel BEFORE switching on the the main and auxiliary power supplies. Overview The installation includes the following items: –...
Page 118: Cable Requirements
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 118/266...
Page 119: Grounding The Drive System
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 119/266...
Page 120: Ground Cable Connection
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 120/266...
Page 121: Exu Cabinet Ground Connections
Wiring list in “Appendix D - Wiring diagrams”. The data provide information on: – Cable identification – Cable type – Cross-sectional area – Location of terminals PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 121/266...
Page 122: Optical Fiber Cables
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 122/266...
Page 123: Optical Fiber Cables For The Optional Arc Guard System
Arc Guard unit TVOC-2 with HMI panel – Optical fiber detectors: pre-installed in the relevant cabinets with the corresponding optical fibers coiled up beside the detectors (Fig. 6-7). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 123/266...
Page 124: Connecting The Detector Cables To The Arc Monitor Device
2. Lay the cables into their designated trays and cable ducts as seen in Fig. 6-8. 3. Connect the cables to the arc monitor located in the REB according to the drawings. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 124/266...
Page 125: Cable Entry Systems
Power cables – Ground cables – Equipotential bonding conductors Included in delivery – Cable entry frame Not included in – Sealing modules delivery – Accessories – Tools PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 125/266...
Page 126: Figure 6-10 Cable Entry Frame With Type 1 Sealing Modules
RM120 RM90 RM60 Single-core Three-core Single-core Ø28 - 50 Ø68 - 99 Ø48 - 71 TEU 1000 mm TEU 600 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 126/266...
Page 127: Frame With Type 2 Sealing Modules
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 127/266...
Page 128: Emc Plates With Sealing Grommets
In the openings facing the back wall of the TEU, place the compression wedge (4) between the frame (1) and the sealing module (5). This ensures that the minimum distance to the high-voltage busbars is maintained. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 128/266...
Page 129: Figure 6-14 Teu 1000 Mm Cabinet (A = Back) With Top (1) And Bottom (2
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 129/266...
Page 130: Aru Cable Entry Frames With Type 1 Sealing Modules
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 130/266...
Page 131: Exu Cable Entry With Emc Plate And Sealing Grommets
DCS800 D4 size controller” on page 258. 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 131/266...
Page 132: Power, Ground And Equipotential Bonding Conductor Cables
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 132/266...
Page 133: Preparing Cables For Sealing Modules
M12 bolt 7) Outer cable sheath 12) Sheath seal 2. Install the sealing modules according to the instructions of the sealing module supplier. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 133/266...
Page 134: Preparing Cables For Cable Glands
EXU. 1. Remove the grommets from the entry plate. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 134/266...
Page 135: Figure 6-20 Preparing Cables For Emc Plates: (A) Cables With An Outer Screen Or Shield, (B) Cables Without An Outer Screen Or Shield Or (C) Cables In An Exu Cabinet
7) Conductor insulation removed to expose cable shield 3) Cable tie 8) Cable screen extension to connect to 4) Heat-shrinkable termination the PE busbar 5) Outer cable sheath 9) Cable clamp PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 135/266...
Page 136: Connecting The Cables
3. Choose the length and the orientation of the bolts so that the distance between bolted joints of different phases is not less than 25 mm. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 136/266...
Page 137: Bolted Busbar Connections - Marine Drives
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 137/266...
Page 138: Bolted Busbar Connections - Non-Marine Drives
If a coated nut (eg, with bonded molybdenum-disulfide [MoS ] 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. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 139: Auxiliary Power, Control And Serial Communication Cables
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 139/266...
Page 140: Preparing Cables For Sealing Modules
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 140/266...
Page 141: Preparing Cables For Cable Glands
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 141/266...
Page 142: Figure 6-28 Preparing The Screens Of Control Cables For Emc Plates
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 142/266...
Page 143: Routing Cables In A Wcu
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 143/266...
Page 144: Top Cable Entry
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 144/266...
Page 145: Bottom Cable Entry
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 145/266...
Page 146: Connecting The Cables
IMPORTANT! DO NOT connect the shields to the terminals of the interface. NOTE – Different-sized ground clamps are supplied. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 146/266...
Page 147: Routing Cables In An Exu Cabinet
Cable entries with cable glands: “6.8.3 Preparing cables for cable glands” on page 141. NOTE – Materials for cable fitting, EMC requirements and sealing are not supplied for undrilled plates. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 147/266...
Page 148: Optical Fiber Cables
When you tighten the cable ties DO NOT deform the optical fibers and DO NOT use a cable tie gun. – Hold the connector when you connect or disconnect an optical fiber. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 148/266...
Page 149: Routing Optical Fiber Cables In An Exu Cabinet With An Ed5V, Eb5R, Eb5S, Eb7P Or Eb7Q Type Dcs800 Converter
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 149/266...
Page 150: Figure 6-39 Cable Routing Example In An Exu Cabinet With An Ed5V, Eb5R, Eb5S, Eb7P Or Eb7Q Type Dcs800 Converter
3) Cable enters through the floor 7) Optical fibers to DCS800 D4 converter 4) Terminal strip for auxiliary power and control cables 8. Reattach the DCS800 cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 150/266...
Page 151: Routing Cables In An Exu Cabinet With An Ed7Y Type Dcs800 Converter
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 151/266...
Page 152: Figure 6-42 Cable Routing Example In An Exu Cabinet With An Ed5V, Eb5R Or Eb5S Type Dcs800 Converter
3) Cable enters through the floor 7) Optical fibers to DCS800 D4 converter 4) Terminal strip for auxiliary power and control cables 4. Reattach the DCS800 cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 152/266...
Page 153: Routing Azipod® Encoder Cables
When you tighten the cable ties DO NOT deform the optical fibers and DO NOT use a cable tie gun. – Hold the connector when you connect or disconnect an optical fiber. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 153/266...
Page 154: Routing Cables Through The Reb (Wcu)
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) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 154/266...
Page 155: Heating Cable
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 155/266...
Page 156: Final Checks
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 156/266...
Page 157: Commissioning
ABB. 7.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB. 7.3. Commissioning checklist In order to ensure uncomplicated and speedy commissioning, it is important that drive and associated equipment are ready for commissioning.
Page 158: Commissioning Checklists
Types and cross sections of control cables suitable for the signal type and signal level. □ Types and cross sections of power cables selected according to the ABB power cable specification. □ 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 159: Main Circuit Breaker (Mcb)
7.6.4. Input transformer checklist □ Grounding is completed □ Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are ready. □ Protection devices are tested and in operation. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 159/266...
Page 160: Motor Checklist
Sufficient quantity of deionized water according is available. (see “Appendix C - Mechanical drawings”). □ Air conditioning of drive room ready for load run of drive □ 4) Optional equipment (eg, chiller) ready PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 160/266...
Page 161: Operation
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 161/266...
Page 162: Aru Control Panel
– Displays status messages of the INU – Displays alarm and fault messages of the drive and monitored foreign equipment – Resets alarm and fault messages PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 162/266...
Page 163: Inu Control Panels
DC link and closes the main circuit breaker 4) Alarm / fault lamp • Alarm: flashing light • Fault: permanent light PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 163/266...
Page 164: Lamp Test
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 164/266...
Page 165: Operating Modes
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 165/266...
Page 166: Exu Control Panel
DCS800 unit at any time. – Context-sensitive help menu – Fault and alarm text messages including fault history For more information, see “DCS800 drives firmware manual” (3ADW000193R0801). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 166/266...
Page 167: Operational Settings
The message on the display can be reset either by pressing the reset soft key on the EXU control panel, or by pressing the reset button on the control panel of the drive. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 167/266...
Page 168: Parameter Settings
Figure 8-6 CBU grounding switch in ungrounded (A) and grounded (B) The switch is electromechanically interlocked with a discharge monitoring circuit that prevents the switch from closing when the DC-link capacitors are still charged. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 168/266...
Page 169: Lamp Test
Table 8-1 Medium voltage units with safety switches and locking bars Standard cabinet units Optional cabinet units NOTE – For more information, see “10.4.4 Unlocking and opening the doors” on page 221. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 169/266...
Page 170: Optional Switchgear And Controlgear
The control switch can be actuated when released by the drive. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 170/266...
Page 171: Output Switches
For information on other status messages (eg, fault status messages), see the status words in “Appendix G - Signal and parameter table”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 171/266...
Page 172 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 172/266...
Page 173: Start Sequence Of The Drive
Only in drives with an ARU ReadyRun • INU starts magnetizing (only in drives with an ARU) • INU starts to modulate 8) Start command 9) ReadyRef 10) Operation PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 173/266...
Page 174: Stop Sequence Of The Drive
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 174/266...
Page 175: Emergency-Off Sequence
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 175/266...
Page 176: Starting The Drive
– If the drive is equipped with a DC link disconnector, check that the control switch for the DC link disconnector is in the correct position. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 176/266...
Page 177: Starting The Drive Remotely
When alarms and faults are not present and the drive is ready, the INU CDP control panel displays ReadyOn. 1 L -> 0.0 rpm StateINU ReadyOn DC VOLT 0.00 rpm PRI VOLT 0 kW PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 177/266...
Page 178 INU 1 and other INUs (if present) are now in status “ARU NotRun” 1 L -> 0.0 rpm StateINU ARU NotRun MOTOR SP 0.00 rpm POWER 0.0 kW PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 178/266...
Page 179 The drive is now in “ReadyRef” to indicate that the drive system is operating. 1 L -> 600.0 rpm I StateINU ReadyRef MOTOR SP 0.00 rpm POWER 1000.0 kW PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 179/266...
Page 180: Stopping The Drive
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 180/266...
Page 181: Stopping The Drive With The Emergency-Off Function
1 L -> 600.0 rpm StateINU EmergencyOff – EmergencyOff MOTOR SP 0.00 rpm – NotReadyOn POWER 0.0 kW EMERGENCY-OFF RESET button flashes SUPPLY OFF push button flashes PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 181/266...
Page 182: Starting The Drive System After An Emergency-Off
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 182/266...
Page 183: Arc Detection With The Arc Guard System™ (Optional)
8.11. 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 185: Cdp Control Panel
6) Fast navigation key for selecting the actual signals display or the fault memory display 13) Reference key 7) Local / remote selection key 14) Start key 15) Stop key PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 185/266...
Page 186: Functions
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 186/266...
Page 187 CDP CONTROL PANEL ACS6000 xxxx <Device Name> LXHH44xx ID-NUMBER 1 After another few seconds. 1 L -> 0.0 rpm StateINU InitSeq..MOTOR SP 0.00 rpm POWER 0.0 kW After another few seconds, the display changes to the actual signals display. The status line of the display alternates between DCGndNOpen and NotReadyOn.
Page 188: Actual Signals Mode
9.2.2.1. Overview Two displays can be selected in the actual signals mode: – Actual signals display – Fault memory display PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 188/266...
Page 189: Selecting The Actual Signals Display
If no key is actuated, the fault or alarm message displays as long as the fault is active. 9.2.2.2. Selecting the actual signals display To select the actual signals display, press the ACT key. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 189/266...
Page 190: Toggling Between Actual Signals Display And Fault Memory
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 190/266...
Page 191 4. To select a parameter group, press a fast navigation keys. 1 L -> 600.0 rpm 1 ACTUAL SIGNALS 01 DC VOLTAGE 1000 V 5. To select an actual signal, press a slow navigation keys. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 191/266...
Page 192: Displaying A Fault And Resetting The Fault Memory
MOTOR SP 0.00 rpm POWER 0.0 kW 9.2.2.6. Displaying a fault and resetting the fault memory 1. To open the actual signals display, press the ACT key. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 192/266...
Page 193 4. To clear the fault memory, press the RESET key. 1 L -> 600.0 rpm LAST FAULT 5. To return to the actual signals display, press a fast navigation key. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 193/266...
Page 194: Displaying And Resetting An Active Fault
9.2.2.7. Displaying and resetting an active fault 1. To display an active fault, press the ACT key. 1 L -> 600.0 rpm ACS6000 *** FAULT *** CW1 NoWtrPumpOn 2. To reset the fault, press the RESET key. 1 L ->...
Page 195: Parameters Mode
3) Parameter number and name parameter (and a parameter value) 4) Parameter value 8) Enter key for confirming the selection 5) Selection key for parameters mode PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 195/266...
Page 196: Overview
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 196/266...
Page 197: Changing A Parameter Setting
06 C3P1/AI820 Module DISABLED 4. To enter the parameter setting function, press the ENTER key. 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module [DISABLED] PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 197/266...
Page 198 7. 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 198/266...
Page 199: Enabling / Unlocking A Parameter Lock
NOTE – For more information, see “Appendix G - Signal and parameter table”. 9.2.3.4. User lock NOTICE Risk of component damage. ABB is not be liable for damages or losses caused by the failure to activate the user lock with a new pass code. – See the “Legal disclaimer” on page 2.
Page 200: Functions Mode
4) Slow navigation key for selecting a line (and adjusting the contrast) 2) Selectable functions 5) Enter key for confirming the selection 3) Selection key for functions mode PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 200/266...
Page 201: Adjusting The Display Contrast
3. Press the ENTER key. 1 L -> 0.0 rpm CONTRAST 4. To change the contrast, press the slow navigation keys. 1 L -> 0.0 rpm CONTRAST PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 201/266...
Page 202: Local And Remote Control Mode
Remote control (R) NOTE – In this context, remote control is not necessarily equivalent to higher- level control. For more information, see “9.2.5.4 Remote control” on page 204. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 202/266...
Page 203: Local Control
9.2.5.3.1 Disabling the local lock – To disable the local lock, set parameter 16.04 to 1 (OPEN). With this parameter setting, switching between remote and local control is enabled. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 203/266...
Page 204: Remote Control
POWER 0.0 kW NOTE – To prevent accidental switching from remote control to local control, see “9.2.5.2 Disabling / enabling local lock function” on page 203. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 204/266...
Page 205: Operational Commands
9.3.2. Entering a reference value Entering a reference value from the CDP control panel is possible in: – Local control mode (L) – Remote control mode (R) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 205/266...
Page 206 4. To exit the mode, press a mode selection key. FUNC DRIVE 1 L -> 550.0 rpm 0 StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 206/266...
Page 207: Preventive And Corrective Maintenance
ABB service personnel. After the warranty period, repair work must be carried out by certified personnel. 10.1.1. Required qualification To maintain safe and reliable operation of the drive, ABB recommends taking out a service contract with the 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”...
Page 208: Identifying Electrical Equipment
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 208/266...
Page 209: Understanding Wiring Diagrams
Alarm: flashing light – – Fault: permanent light SUPPLY 1 L -> 600.0 rpm ACS6000 ** FAULT ** CW1 NoWtrPumpOn EMERGENCY-OFF ALARM RESET FAULT EMERGENCY OFF The message can be saved and viewed in the fault logger of the drive when a PC with Drive Composer is connected to the drive.
Page 210: Alarm And Fault Messages
Is the reason for the failure of the drive 4) +Fault DC Undervoltage system as it occurred first For more information on alarms and faults, see “Appendix G - Signal and parameter table”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 210/266...
Page 211: Standard Troubleshooting Procedure
The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. 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 212: Amc Circuit Board
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 212/266...
Page 213: S800 I/O Bus Modem Tb820
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) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 213/266...
Page 214: Serial Communication Interfaces
10.3.3.5. LEDs on optional heat exchangers Two LEDs on the front of the heat exchanger indicate the status of the unit. Alarm signals are also shown on the CDP control panel. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 214/266...
Page 215: Figure 10-6 Status Leds On Optional Air-To-Air Heat Exchangers
3) Red LED off (A) and Green LED off (B): exchanger is healthy Auxiliary voltage is missing 2) Red LED on (A) and Green LED off (B): Alarm conditions PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 215/266...
Page 216: Maintenance Tasks
300 V (DC) over ground. – Wait 5 minutes for the capacitors to discharge. – Before touching a capacitor, verify that the capacitors are discharged. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 216/266...
Page 217: Energizing And Grounding The Drive
POWER 0.0 kW 3. Press the SUPPLY OFF push button to disconnect the drive from the main power supply. The following takes place: • MCB opens. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 217/266...
Page 218 IMPORTANT! If the yellow lamp does not turn on, continue with“10.4.3 Grounding the drive when the grounding switch is not released” on page 220, otherwise continue with step 6. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 218/266...
Page 219: Figure 10-7 Grounding Switch Ungrounded
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. Figure 10-8 Grounding switch grounded 1) White lamp 2) Yellow lamp PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 219/266...
Page 220: Grounding The Drive When The Grounding Switch Is Not Released
4. Verify that hazardous voltages from the motor cannot be fed into the drive. 5. Check if the LED of digital output DO07 (output module A2541 in COU1) is lit. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 220/266...
Page 221: Unlocking And Opening The Doors
The white lamp indicates that the drive is grounded and that the locking bars are released. NOTE – If the white lamp does not turn on, continue with “10.4.6 Testing the white lamp” on page 225. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 221/266...
Page 222: Figure 10-9 Grounding Switch Grounded
Door hinged on the right: 3. To release the door handle, insert and turn the key to the right. The door handle pops out. 8 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 222/266...
Page 223 5. If you cannot open the door, continue with “10.4.7 Emergency release of a door safety switch” on page 227. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 223/266...
Page 224: Closing And Locking The Doors
• Door hinged on the right: IMPORTANT! A limit switch monitors the locked position. If a door is not locked properly, you cannot start the drive. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 224/266...
Page 225: Testing The White Lamp
If the LED is lit, the drive control system receives the feedback signal "grounding switch is closed", but the control system has not released the doors. • If the LED is not lit, the feedback signal is missing. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 225/266...
Page 226 For information on the wiring of the discharging circuit and / or the grounding circuit, see: • Wiring diagram of COU1 • Wiring diagram of CBU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 226/266...
Page 227: Emergency Release Of A Door Safety Switch
Figure 10-11 Safety switch on an ARU/INU cabinet door 1) Screw cap on door 4) Unlocked position 2) Safety switch location (behind door) 5) Locked position 3) Safety switch 6) Release dial PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 227/266...
Page 228: Safety-Switch Settings
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 228/266...
Page 229: Connecting A Grounding Set
2) Enclosure ground clamp Depending on the type of line-side rectifier, continue with: – “10.4.8.1 Drives with LSU” on page 230 – “10.4.8.2 Drives with ARU” on page 231 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 229/266...
Page 230: Drives With Lsu
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 230/266...
Page 231: Drives With Aru
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 231/266...
Page 232: Figure 10-16 Manual Output Isolation Overview
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 232/266...
Page 233: Figure 10-17 Input Module A2511
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 233/266...
Page 234: Removing The Busbar Connectors
Figure 10-18 Tools for removing the busbar connectors 1) Orientation of lever for removing busbar 3) Four-way grounding set (4x) connectors 2) Orientation of lever for fitting the busbar connectors PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 234/266...
Page 235: Figure 10-19 Overview Of Grounding The Drive - Inu1 Is Shut Down (A) And Inu2 Is Shut Down (B). Numbers Indicate The Connection Sequence
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 235/266...
Page 236: Figure 10-20 Connect The Grounding Sets In Cou1 (A And C), Teu1 (B), Inu1 (D) And Inu2 (E)
Figure 10-20 Connect the grounding sets in COU1 (A and C), TEU1 (B), INU1 (D) and INU2 (E) 1) Busbars for secondary transformer 4) PE windings 5) Ground ball stud 2) Busbars for motor cables 3) INU busbars PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 236/266...
Page 237: Figure 10-21 Busbar Connector Removal Sequence In Teu1 Or Cou1
4. Inside TEU1 or COU1 remove the busbar connectors in the sequence shown in Fig. 10-21. CAUTION! A busbar connector weighs approximately 10 kg. Figure 10-21 Busbar connector removal sequence in TEU1 or COU1 5. Remove the grounding sets. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 237/266...
Page 238: 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 238/266...
Page 239 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 239/266...
Page 240: Removing And Installing A Phase Module
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). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 240/266...
Page 241: Figure 10-23 Phase Module Removal
CAUTION! A 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 241/266...
Page 242: Installing A Phase Module
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 242/266...
Page 243: Visual Checks On The Drive
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 244: Checking Wire And Cable Connections
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 245: Figure 10-24 Cou Filter
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 245/266...
Page 246: Testing And Replacing Auxiliary Fan Units
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 247: Replacing Auxiliary Fan Units
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 247/266...
Page 248: Testing And Replacing Air-To-Air Heat Exchangers
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 249: Testing The Fan Units
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 249/266...
Page 250: Replacing The Complete Heat Exchanger
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). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 250/266...
Page 251: Figure 10-27 Wire Connection Points On The Circuit Board
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 251/266...
Page 252: Replacing Internal Fan 1 - Left Side
8. Reconnect the ground wire to the front cover. 9. Fasten the covers. 10.4.16.4. Replacing internal fan 1 - left side Procedure 1. Unscrew the front top cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 252/266...
Page 253 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 253/266...
Page 254: Replacing Internal Fan 2 - Right Side
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4.16.5. Replacing internal fan 2 - right side Procedure 1. Unscrew the front top cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 254/266...
Page 255 3. Unscrew the circuit board mounting bracket (1, 2 and 3). 4. Take out the circuit board mounting bracket and place it on the heat exchanger housing. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 255/266...
Page 256 6. Remove the fan from the housing, and unscrew the fan from the mounting bracket. 7. Replace the fan and reassemble the unit in reverse order of removal. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 256/266...
Page 257: Replacing The Ambient Fans
PREVENTIVE AND CORRECTIVE MAINTENANCE 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). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 257/266...
Page 258: Replacing The Fan Unit In An Exu With A Dcs800 D4 Size Controller
Figure 10-28 DCS800 controller - size D4 Procedure 1. Switch off the miniature circuit breaker of the fan unit. To identify the miniature circuit breaker, see “Appendix D - Wiring diagrams”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 258/266...
Page 259 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 259/266...
Page 260: Replacing The Fan Unit In An Exu With Dcs800 Size D5 Controller
10.4.18. Replacing the fan unit in an EXU with DCS800 size D5 controller Figure 10-29 DCS800 controller - size D5 Procedure 1. Switch off the miniature circuit breaker of the fan unit. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 260/266...
Page 261 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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 261/266...
Page 262: Exu
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 262/266...
Page 263: Figure 10-30 Air-To-Water Heat Connections
CAUTION! The 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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6000 User manual 3BHS212794 E01 263/266...
Page 264 7. To install the new heat exchanger, proceed in reverse order of removal. 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”...
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Acs6080

ABB ACS6000 User Manual

1 About this Manual

2 Important Safety Information

3 Power Electronics and Cabinet Features

4 Transportation, Storage and Disposal

5 Mechanical Installation

6 Electrical Installation

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