Page 1 — SYSTEM DRIVES ACS6080 User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL System Drives, ABB Switzerland Ltd. 2023-06-14 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS842007 E01 1/211 © Copyright 2018 ABB All rights reserved.
Page 2 This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document include all the features of the described or referenced standard.
Page 3: Table Of Contents
Maintenance recommendation.....................32 3. Power electronics and cabinet features ................33 3.1. Drive system topology ........................33 3.1.1. Drive............................33 3.1.1.1. ACS6080 cabinet units ..................35 3.1.1.2. Final drive configuration ..................35 3.1.2. Motor ............................35 3.2. Standard cabinet units ........................36 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 4 CONTENTS 3.2.1. Active rectifier unit (ARU)/inverter unit (INU) .............. 36 3.2.2. Line supply unit (LSU) ......................38 3.2.3. Capacitor bank unit (CBU) ....................40 3.2.4. Terminal unit (TEU)......................41 3.2.5. Control unit (COU)....................... 42 3.2.5.1. Main circuit breaker ....................43 3.2.5.2. Speed and torque control ..................
Page 5 CONTENTS 4.6.2. Storing the drive........................70 4.6.3. Storage and handling of spare parts ................71 4.6.3.1. Warranty information ....................71 4.7. Disposing package materials and components ..............71 5. Mechanical installation ......................72 5.1. Safety..............................72 5.2. Overview .............................72 5.3. General notes on installation ......................72 5.3.1.
Page 6 CONTENTS 6.3.3. Cable shield ground connection ..................107 6.3.4. EXU cabinet ground connections ................. 108 6.4. Internal wiring ..........................109 6.4.1. Optical fiber cables......................109 6.4.1.1. Installing the standard optical fibers............... 109 6.4.2. Optical fiber cables for the optional Arc Guard System™ ........110 6.4.2.1.
Page 7 CONTENTS 7.6.2. Electrical installation checklist..................141 7.6.3. Main circuit breaker (MCB) checklist ................142 7.6.4. Input transformer checklist .....................142 7.6.5. Motor checklist ........................142 7.6.6. Insulation tests checklist....................142 7.6.7. Power checklist ........................143 7.6.8. Water Cooling unit checklist ....................143 7.6.9. Miscellaneous checklist ....................143 8.
Page 8 CONTENTS 9.2.2. Cables and wires ........................163 9.2.2.1. Understanding wiring diagrams................163 9.3. Status indicators ..........................164 9.3.1. Alarm / fault indications....................164 9.3.2. Error message levels......................164 9.3.2.1. Alarm and fault messages ...................165 9.3.2.2. Fault handling ......................165 9.3.2.3. Standard troubleshooting procedure...............165 9.3.3. LEDs and switches on PCBs and I/O modules............166 9.3.3.1.
Page 9 (A) EXU H4/T4 frame cabinet and (B) EXU H6 frame cabinet ......54 Fig. 24. (A) CIU cabinet and (B) WCU800 cabinet ............56 Fig. 25. ACS6080 example drive with air-to-air heat exchanger ........57 Fig. 26. Auxiliary fan unit ....................58 Fig. 27.
Page 10 FIGURES Fig. 36. Bolted busbar connection ..................79 Fig. 37. Top view of DC busbar configuration 1 ............... 80 Fig. 38. Top view (A) DC busbar configuration 2, (B) configuration 3, and (C) configuration 4 ....................81 Fig. 39. Ground busbar joints .................... 82 Fig.
Page 11 FIGURES Fig. 73. Short busbar removal in ARU ................118 Fig. 74. (A) EXU with top cable entry and (B) EXU with bottom cable entry ....119 Fig. 75. EXU cabinet ......................119 Fig. 76. Preparing power cables for sealing modules ............ 121 Fig.
Page 12 FIGURES Fig. 106. Cable and wire designation ................. 163 Fig. 107. (A) Assistant control panel and UCU-26: (B) top (C) front and (D) rear ......................... 166 Fig. 108. S500 I/O modules in a COU ................. 167 Fig. 109. Status LEDs on optional air-to-air heat exchangers ........168 Fig.
Page 13 Table 5 BCU braking power......................... 51 Table 6 RBU braking power ......................... 51 Table 7 ABB arc resistant classes......................60 Table 8 Lifting attachment specifications ..................... 68 Table 9 Installation material for AC busbars (COU/TEU – ARU/INU) ..........85 Table 10 Installation material for roof joints...................
Page 14: About This Manual
The ACS6080 is a medium voltage drive that can control any type of AC motor, including high- power induction, synchronous, and permanent magnet motors. The ACS6080 covers a power range of 3 – 36 MVA and delivers output frequencies of 0 – 75 Hz in the voltage range up to 3.3 kV.
Page 15: Structure Of The User Documentation
1.4. 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.
Page 16 Deutsches Institut für Normung (German Institute for Standardization) Digital Output Drive Synonym for ACS6080 frequency converter Drive Composer Windows application for commissioning and maintaining ABB drives. The drive system includes all equipment for converting electrical into mechanical Drive system power to give motion to the machine. Direct-to-line...
Page 17 Term ABB’s S500 I/O system. An I/O device consists of a module termination unit I/O device (MTU) and one I/O module. Term of ABB’s S500 I/O system. The I/O module is an active input or output device I/O module for digital or analog signals.
Page 18 PPCS unit for branching software running on an INT circuit board that is used for data branching PUPA Pulse pattern Pulse width modulation German color standard PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 18/211...
Page 19: Related Documents
Receive Data Register Rolling Mill Drive Revolutions Per Minute The S500 I/O is a distributed process input output system that can be connected S500 I/O 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 20: Technical Data
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 Power cable specification 3BHS125090 E01 Power cables engineering guideline 3BHS542290 E01...
Page 21: Communication Interfaces
ACS6080 spare part packages 3BHS844005 E01 UCU-26 control unit hardware manual 3BHS897436 E01 ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 1.6. Target groups and required qualification The drive presented in this manual is part of an industrial environment where voltages are present that contain a potential hazard of electric shock and / or burn.
Page 22: Electrical Installation
ABB. Use of the drive outside the scope of the specifications is not permitted.
Page 23: Quality Certificates And Applicable Standards
1.9. 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 24: Tools
ABOUT THIS MANUAL 1.11. 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. 1.12. Document conventions The document uses the following font formats and symbols.
Page 25: Important Safety Information
Refer to the instruction Electrotechnical Arc flash warning manual expertise Hazardous voltage Falling objects Elapsed time warning warning Automatic start-up Overhead load warning warning Electrostatic Tipping hazard discharge susceptibility PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 25/211...
Page 26: Product Safety Labels
Ensure that the appropriate personal protective equipment (PPE) is available and used when required • Inform the involved personnel about the potential safety hazards • Wear hearing protection when a drive is running. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 26/211...
Page 27: The 7 Steps That Save Lives
Only allow firefighters with the appropriate PPE to enter the drive room 2.3.2. 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.
Page 28 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 ACS6080 User manual 3BHS842007 E01 28/211...
Page 29: Possible Residual Risks
Incorrect parameter settings • Software errors • Faulty hardware 5) Hazardous substances can be emitted from drive system components, eg, due to incorrect disposal of components PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 29/211...
Page 30: Main Circuit Breaker Protection Device
– 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 ACS6080 User manual 3BHS842007 E01 30/211...
Page 31: Safety And Protection Requirements
Open and or trip command is set at the drive control output No further damage to the drive No hazard to personnel Maximum protection trip time Maximum safety trip time Fig. 3. MCB opening timing diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 31/211...
Page 32: Maintenance Recommendation
IMPORTANT SAFETY INFORMATION 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 33: Power Electronics And Cabinet Features
– Drive – Motor 3.1.1. Drive The ACS6080 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. Key: Motor Fig. 4. Common DC-bus principle for (A) single motor drive and (B) multi-motor drive...
Page 34: Fig. 5. Acs6080 Drive Example
Optional cabinet unit that supplies a synchronous motor with Excitation unit (EXU) excitation Fig. 5. ACS6080 drive example The drive is assembled from standard and optional cabinet units. Each unit is dedicated to a specific function. For more information on the cabinet units in your drive, see the layout drawing in “Appendix C - Mechanical drawings”.
Page 35: Acs6080 Cabinet Units
POWER ELECTRONICS AND CABINET FEATURES 3.1.1.1. ACS6080 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 36: Standard Cabinet Units
Key: DC-link Motor Fig. 6. ARU/INU block diagram DC (+) DC (NP) DC (-) Key: Clamping circuit Phase modules EMC filter Fig. 7. ARU/INU circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 36/211...
Page 37: Fig. 8. (A) Aru/Inu And (B) Phase Module With Igcts
(EMC) filter Key: EMC filter Coolant outlet Control interface IGCT Coolant inlet Phase module Clamp capacitor Diode Fig. 8. (A) ARU/INU and (B) phase module with IGCTs PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 37/211...
Page 38: Line Supply Unit (Lsu)
DC-link Motor Fig. 9. LSU block diagram DC (-) DC (+) Key: Thyristor crowbar Snubber circuit Diode rectifier di/dt choke Fig. 10. LSU (12-pulse) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 38/211...
Page 39: Fig. 11. Lsu (12-Pulse)
Key: Snubber resistor di/dt limiting reactors Snubber capacitor Diode stacks Rectifier monitoring unit Fig. 11. LSU (12-pulse) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 39/211...
Page 40: Capacitor Bank Unit (Cbu)
These can only be closed if the DC-link capacitors have been discharged. Grounding switch For more information, see Section 8.4.4, “EXU control panel”, page 149. Key: Grounding switch DC-link capacitor Fig. 12. CBU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 40/211...
Page 41: Terminal Unit (Teu)
Key: DC busbars Cable entry frame AC busbars PE ground busbars Fig. 13. TEU (1000 mm) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 41/211...
Page 42: Control Unit (Cou)
For information on the number of control units and their location in the drive, see “Appendix C - Mechanical drawings”. Key: Insulation monitoring device (optional) I/O modules 24 VDC power supply unit NETA-21 gateway to enable ABB Ability™ digital services Safety relays for emergency-off circuit Main circuit breaker relays Main controller for ARU (10) (Optional) Fieldbus modules...
Page 43: Main Circuit Breaker
The speed and torque of the motor is controlled by Model Predictive Pulse Pattern Control C). The MP C motor control platform is unique to ABB and has been proven in all variable speed drives of the ACS product range. MP C provides accurate speed and torque control, and high dynamic speed response.
Page 44: Local Control Panels
Fig. 15. Location of (1) control panels on master (A) COU and (B) follower COU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 44/211...
Page 45: 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”, 3BHS835714 E01.
Page 46: Fig. 16. (A) Wcu1400 And (B) Wcu800 Cabinet And System Components
Warm water Motor for 3-way valve Expansion vessel Water-to-water heat exchanger Pump 1 (10) Deionizer Fig. 16. (A) WCU1400 and (B) WCU800 cabinet and system components PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 46/211...
Page 47: Cooling Circuit
Heat exchanger External cooling circuit Internal cooling circuit Feeding pipes Fig. 17. Cooling circuit in an ACS6080 drive The water cooling system distinguishes two circuits for dissipating heat losses: – Internal cooling circuit: circulates coolant (distilled/deionized cooling liquid) and transfers the heat losses of the main power components to the exterior.
Page 48: Optional Cabinet Units
(THD) of the supply voltage. DC (+) DC (-) Key: Three-phase reactor Diode rectifier Snubber circuit di/dt choke Thyristor crowbar Fig. 18. (A) IRU cabinet and (B) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 48/211...
Page 49: Input Filter Unit (Ifu)
The tuned filter is located between the input transformer and the ARU and reduces harmonic voltages injected to the supply network. Key: Resistor Capacitor Reactor Fig. 19. (A) IFU cabinet and (B) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 49/211...
Page 50: Voltage Limiter Unit (Vlu)
IGCT semiconductors and protected against overload. DC (+) DC (NP) DC (-) Key: Air-cooled resistors ICGT Fig. 20. (A) VLU cabinet and (B) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 50/211...
Page 51: 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 ACS6080. TABLE 5 BCU braking power Braking resistor (ohm) Single braking power (kW) Double braking power (kW)
Page 52: Braking Chopper Unit
DC (+) DC (NP) DC (-) Key: IGCT Resistor (external) Fig. 21. (A) BCU cabinet and (B) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 52/211...
Page 53: Resistor Braking Unit
An RBU, with integrated resistors, is used for smaller braking capabilities. DC (+) DC (NP) DC (-) Key: IGCT Water-cooled resistor Fig. 22. (A) RBU cabinet and (B) circuit diagram PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 53/211...
Page 54: Excitation Unit (Exu)
Overvoltage protection (not shown in A) Control compartment DCS880 H6 unit Fan units Fig. 23. (A) EXU H4/T4 frame cabinet and (B) EXU H6 frame cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 54/211...
Page 55: Dcs880/Dct880 Control Panel
For more information, see Section 8.4.4, “EXU control panel”, page 149. 3.3.5.2. 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 ACS6080 User manual 3BHS842007 E01 55/211...
Page 56: Customer Interface Unit (Ciu)
(maximum 4 modules in the rooftop extension box (REB) of the water cooling unit). For more I/O modules, a CIU is required. Key: Roof extension box (REB) Fig. 24. (A) CIU cabinet and (B) WCU800 cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 56/211...
Page 57: Arc Detection With Arc Guard (Optional)
Mechanical drawings”. The number of installed air-to-air heat exchangers and transformers depends on the configuration of the drive. Key: Air-to-air heat exchanger Additional transformer Fig. 25. ACS6080 example drive with air-to-air heat exchanger PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG.
Page 58: Auxiliary Fan Units
Fig. 27. Air circulation through ventilation grids in (A) 600 mm COU, (B) 1000 mm COU, and (C) WCU800 NOTE – The number of fans varies depending on the cabinet. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 58/211...
Page 59: 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 60: Door Locking System
Section 2.4, “Main circuit breaker protection device”, page 30. Based on the ACS6080 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 61: Busbars And Grounding
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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 61/211...
Page 62: Transportation, Storage, And Disposal
2. Check the drive and accompanying equipment for damages. 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 63: Packing Label
TRANSPORTATION, STORAGE, AND DISPOSAL 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. ABB item Qty. Unit. Identnumber Commodity description...
Page 64: Lifting And Transportation
→ Before use, always check the lifting attachments for damage, eg, corrosion and cracks. DO NOT attempt to lift equipment with a damaged lifting attachment; contact ABB for a replacement before you proceed → Always transport the load in an upright position →...
Page 65: Lifting Attachment Types
Only use the lifting attachments that are included with the delivery, either factory- installed or in the loose parts box for the drive. These lifting attachments are intended exclusively for use with ACS6080 equipment. Any use beyond this is strictly prohibited. ABB ID:...
Page 66: Lifting With Lifting Plates
5. Lift the load slowly and steadily, with no abrupt stops, in an upright position to the required clearance height. CAUTION! Keep an eye on the horizontal position of the load and reposition the slings when necessary. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 66/211...
Page 67: Lifting With Rotating Eyebolts
NOTE – For a permanent installation, tighten the eyebolts to the correct torque (see Section 4.5.4, “Reinstalling lifting attachments”, page 68) with a suitable torque wrench socket (not included in the scope of delivery). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 67/211...
Page 68: Reinstalling Lifting Attachments
NOTE – The torque wrench sockets for the rotating eyebolts are not included in the scope of delivery. TABLE 8 Lifting attachment specifications Type Mounting bolt Torque (Nm) ABB ID Lifting plate 2 × M16 × 40 (A2-70) 3BHB039841R0001 M24 rotating eyebolt 3BHE015753P0024...
Page 69: Sling Configurations For Lift Frames And Spreader Frames
Protect the edges Lifting plate Protect the door handles and levers Slope angle (maximum 15°) Extra sling Spreader frame Fig. 33. (A) Lift frame and (B) lift spreader PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 69/211...
Page 70: 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 ABB. 4.6.1. Storage conditions The minimum requirements for storage are based on IEC 60721-3-1.
Page 71: Storage And Handling Of Spare Parts
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 72: Mechanical Installation
→ Use heavy load hydraulics rollers or air cushions for transport units that are secured to a base frame. DO NOT use a crane; If you are unsure, contact ABB for instructions. → DO NOT damage or dislocate the EMC sealing strips when you join 2 transport units; The strips are glued to the outer surfaces of the cabinet frames.
Page 73: Cabinet Roof
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 ACS6080 User manual 3BHS842007 E01 73/211...
Page 74: 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 ACS6080 User manual 3BHS842007 E01 74/211...
Page 75 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 ACS6080 User manual 3BHS842007 E01 75/211...
Page 76: Joining Transport Units
Key: Connection point locations M6 × 16 (9ABA450093R0259 SCR-CBS-M6X16-8_8-FLZNNC) Fig. 34. Connection point locations on transport units PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 76/211...
Page 77: Joining Water Pipes
1. Mark the length of a pipe joint on one end of a water pipe as a fitting guide. 2. Slide the pipe joint over the two adjoining pipe ends. 3. Center the pipe joint. 47 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 77/211...
Page 78: Fig. 35. Minimum Distances And Locking Bolt Orientation (A = Front)
Fig. 35. Minimum distances and locking bolt orientation (A = front) 5. After adjusting a pipe joint, alternately tighten the bolts lightly. 6. Tighten the bolts to the torque indicated on the pipe joint. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 78/211...
Page 79: Removing A Pipe Joint
– Use a conical spring washer on the bolt side of the connection. Key: Hex-head bolt Conical spring washer Flange nut Fig. 36. Bolted busbar connection PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 79/211...
Page 80: Dc Busbars
NB 312350P8117 Busbar with positive potential Busbar with neutral potential Busbar with negative potential Front of cabinet Fig. 37. Top view of DC busbar configuration 1 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 80/211...
Page 81: Fig. 38. Top View (A) Dc Busbar Configuration 2, (B) Configuration 3, And
Busbar with positive potential Busbar with neutral potential Front of cabinet Fig. 38. Top view (A) DC busbar configuration 2, (B) configuration 3, and (C) configuration 4 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 81/211...
Page 82: Ground Busbars
NB 312350P8119 Hex-head nut M12-A2-70, coated HZN 452198P1022 Conical spring washer 13 × 29 × 3 HAQN400344P0111 Water pipe Cabinet front Fig. 39. Ground busbar joints PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 82/211...
Page 83: Ac Busbars Between Cou/Teu And Lsu (5/7/9 Mva)
DIN6796-13 × 29 × 3 HAQN400344P0111 Hex-head nut M12-A2-70 HZN 452198P1022 Flange nut M12-A2 3BHB038117R0001 Fig. 40. AC busbar joints between the COU/TEU and LSU (5/7/9 MVA) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 83/211...
Page 84: Ac Busbars Between Cou/Teu And Lsu (14 Mva)
M12 × 65-A2-70 NB 312450P8124 Conical spring washer DIN6796-13×29×3 HAQN400344P0111 Hex-head nut DIN934-M12-A2-70 HZN 452198P1022 Fig. 41. AC busbar joints between the COU/TEU and LSU (14 MVA). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 84/211...
Page 85: 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 ACS6080 User manual 3BHS842007 E01 85/211...
Page 86: 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 ACS6080 User manual 3BHS842007 E01 86/211...
Page 87 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 ACS6080 User manual 3BHS842007 E01 87/211...
Page 88: Installing And Removing Air-To-Air Heat Exchangers
Fig. 42. Air-to-air heat exchanger (type LT-5-5165-UL) Key: Cordless drill M6 × 12 Torx screw Wire cutter Cable tie Torx drill bit Fig. 43. Tools for installing an air-to-air heat exchanger PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 88/211...
Page 89: Installation
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). 2 × PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 89/211...
Page 90: Fig. 44. Correct And Incorrect Cable Installation
Correct cable installation DC busbar Incorrect cable installation Fig. 44. Correct and incorrect cable installation 4. Remove the cover on the roof where the heat exchanger is installed. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 90/211...
Page 91: Fig. 45. M8 Rotating Eyebolt And Heat Exchanger With Mounted Rotating Eyebolts
360° freely. For a permanent installation, tighten the eyebolts to the nominal torque that is specified in Section 4.5.1, “Lifting attachment types”, page 65. 4 × ABB ID: 3BHE015753P0008 Fig. 45. M8 rotating eyebolt and heat exchanger with mounted rotating eyebolts 6.
Page 92: Fig. 46. Aru/Inu/Ifu Cable Routing
Fig. 46. ARU/INU/IFU cable routing Fig. 47. LSU cable routing 11. Connect each wire to terminal block -X1 according to the terminal numbers printed on the marker sleeves (white). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 92/211...
Page 93 14. Check that the cables do not touch the DC busbars. 15. Fasten the heat exchanger to the roof with 14 self-tapping M6×12 screws (HAQN401205P0257). 16. Remove the rotating eyebolts that you installed in step 5. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 93/211...
Page 94: Removing Air-To-Air Heat Exchangers
DC busbars of two adjacent transport units. Key: Cordless drill Torx drill bit Wire cutter Cable tie Fig. 49. Tools for removing an air-to-air heat exchanger PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 94/211...
Page 95: 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 ACS6080 User manual 3BHS842007 E01 95/211...
Page 96: 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 ACS6080 User manual 3BHS842007 E01 96/211...
Page 97: Installing The Transformers Of Air-To-Air Heat Exchangers
1 × 3.5 kVA transformer ~49 kg 1 × 6 kVA transformer ~66 kg 1 × Fig. 50. Installation example of transformers in an air-to-air heat exchanger PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 97/211...
Page 98: Installing The Pressure Relief Vents
For some drives, the pressure relief vents are delivered spearately and must be installed on the roofs of TEU and COU cabinets. Weight Length Width Height ~26 kg 840 mm 520 mm 210 mm Fig. 52. Pressure relief vents PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 98/211...
Page 99: Fig. 54. Installation Example Of Pressure Relief Vents
2. Fasten the pressure relief vent to the roof with the supplied screws (3, Fig. 53). Key: Orientation of baffle blades Center of drive Pressure relief vents Fig. 54. Installation example of pressure relief vents PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 99/211...
Page 100: Attaching The Sealing Tapes
3. Attach the tape on the whole length of the joining crossbars (1, Fig. 55). Fig. 55. Attach sealing tape to the joining crossbar (1) 4. Reinstall the roof plates. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 100/211...
Page 101: 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. Fig. 56. Roof joints (1) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 101/211...
Page 102: Installing Roof Attachments
(11) Washers 2 × 13 / 29 ST / ZN 9ABA450078P0007 (12) Hex-head bolts 2 × M12 × 80 NB 312450P8127 Fig. 57. Roof attachment parts PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 102/211...
Page 103: Fig. 58. Recommended Ceiling And Wall Fixings
One strut at 90° to wall DO NOT install the struts at a 90° angle to the cabinet roof Fig. 58. Recommended ceiling and wall fixings PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 103/211...
Page 104: 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 you switch on the main and auxiliary power supplies.
Page 105: 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 ACS6080 User manual 3BHS842007 E01 105/211...
Page 106: Grounding The Drive System
(10) LSU Equipotential bonding conductor (11) INU Ground cable (12) Motor Fig. 60. Grounding the (A) input side and (B) output side of the drive system PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 106/211...
Page 107: 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 ACS6080 User manual 3BHS842007 E01 107/211...
Page 108: Exu Cabinet Ground Connections
– At the EXU, ground the cable screen via the conductive sleeve of the entry plate. Key: Transformer Motor Ground cable Fig. 62. Grounding the EXU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 108/211...
Page 109: Internal Wiring
Cable duct for optical fibers Rail for IGCT power supply cables of RBU, BCU and VLU Fig. 63. Cable tray and cable ducts in an LSU (A = front) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 109/211...
Page 110: Optical Fiber Cables For The Optional Arc Guard System
2 detectors in ARU with bottom cable entry (option) – 1 detector in BCU The excess optical fibers are coiled up beside the detectors (Fig. 65). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 110/211...
Page 111: Connecting The Detector Cables To The Arc Monitor Device
Cable duct for optical fibers Rail for IGCT power supply cables of RBU, BCU and VLU Fig. 66. Cable tray and cable ducts in an LSU (A = front) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 111/211...
Page 112: Cable Entry Systems
NOTICE Risk of component damage! Handling excessively large single core power cables inside ACS6080 modules can damage components. → DO NOT use a single core power cable with a cross-sectional area larger than 500 mm → Use a cable lug that is small enough for M12 bolts to connect the power cable to the busbar...
Page 113: Frames With Type 1 Sealing Modules
Included in delivery Not included in delivery – Power cables – Cable entry frame – Sealing modules – Ground cables – Accessories – Equipotential bonding – Tools conductors PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 113/211...
Page 114: Fig. 68. Cable Entry Frame With Type 1 Sealing Modules
Maximum number of entry frame modules/openings cables/openings RM120 RM90 RM60 Single-core Three-core Ø28 - 50 mm Ø68 - 99 mm TEU 1000 mm TEU 600 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 114/211...
Page 115: Frame With Type 2 Sealing Modules
Not included in delivery – Power cables, ground cables, – Undrilled gland plate – Cable glands bonding conductors – Tools – Auxiliary power cables, control – Accessories cables PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 115/211...
Page 116: Emc Plates With Sealing Grommets
– Power cables – Galvanized plate with net-like EMC sleeves – Ground cables – Sealing grommets – Bonding conductors – Auxiliary power cables – Control cables PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 116/211...
Page 117: Preparing Cable Entry Systems For Teu, Aru And Exu Cabinets
High-voltage busbars Compression wedge RM90 sealing module with 3-core cable Fig. 72. TEU 1000 mm cabinet (A = back) with (1) top and (2) bottom cable entries PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 117/211...
Page 118: Aru Cable Entry Frames With Type 1 Sealing Modules
17 mm and 19 mm Fig. 73. Short busbar removal in ARU 4. After you have routed the cables, install the busbars in the reverse order of removal. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 118/211...
Page 119: Exu Cable Entry With Emc Plate And Sealing Grommets
DCS880 H4/DCT880 T4 unit”, page 204. 4. Unplug the fan power supply cables and the tube from the air pressure switch. Key: Front cover Pull relief Fig. 75. EXU cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 119/211...
Page 120: 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 ACS6080 User manual 3BHS842007 E01 120/211...
Page 121: Preparing Cables For Sealing Modules
(11) Cable lug as specified by the cable supplier and suitable for M12 bolt (12) Sheath seal Fig. 76. Preparing power cables for sealing modules 2. Install the sealing modules according to the instructions of the sealing module supplier. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 121/211...
Page 122: Preparing Cables For Cable Glands
Conductor insulation removed to expose cable shield Cable screen extension to be connected to PG busbar Sheath seal Fig. 77. Prepare power cables for cable glands PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 122/211...
Page 123: Preparing Cables For Emc Plates
6. Prepare EXU cables according to Fig. 78. The orientation of the EMC plates in both scenarios is the same for top and bottom cable entries, ie, the sealing grommets face upwards. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 123/211...
Page 124: Connecting The Cables
→ Maintain the following minimum clearance between two different potentials (phase-to-phase and ground-to-phase) in the TEU: • Marine applications: 55 mm • Other applications: 25 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 124/211...
Page 125: Checking The Cable Insulation
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. 25 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 125/211...
Page 126: Bolted Busbar Connections - Marine Drives
(recommended: A2-70 - designation according to ISO 3506-1). NOTE – Nuts with a bonded coating can be used as an alternative to uncoated stainless steel nuts. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 126/211...
Page 127: Auxiliary Power, Control And Serial Communication Cables
] 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. 6.8. Auxiliary power, control and serial communication cables The following sections describe how to prepare and route cables.
Page 128: Preparing Cables For Sealing Modules
Sealing module Conductive foil Cable sheath removed to expose cable shield Conductor screen extension to connect to PE terminal Fig. 83. Preparing control cables for sealing modules PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 128/211...
Page 129: Preparing Cables For Cable Glands
Cable gland Plate Conductor insulation removed to expose shield Conductor screen extension to connect to PE terminal Fig. 84. Preparing auxiliary control cables for cable glands PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 129/211...
Page 130: Preparing Cables For Emc Plates
6.8.5. Routing cables in a WCU For the available cable routing options in WCU800 and WCU1400, such as top entry and bottom entry, see “Appendix C - Mechanical drawings”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 130/211...
Page 131: Routing Cables In A Cou Cabinet
Fig. 86. Blanking plates on 600 mm COU and 1000 mm COU 2. Prepare the length of cable that passes through the cable entry according to Section 6.8.3, “Preparing cables for cable glands”, page 129. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 131/211...
Page 132: Connecting The Cables
If a twisted pair cable is used, leave the unshielded cable ends twisted until they reach the terminals. – Leave unshielded conductor ends as short as possible (< 50 mm). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 132/211...
Page 133: Routing Cables In An Exu Cabinet
Cable entries with cable glands: Section 6.8.3, “Preparing cables for cable glands”, page 129. NOTE – Materials for cable fitting, EMC requirements and sealing are not supplied for undrilled plates. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 133/211...
Page 134: Fig. 89. Cable Routing Examples In An Exu Cabinet With An (A) Ed5V, Eb5R
DCS880/DCT880 converter and in an (B) EXU cabinet with an ED7Y type DCS880 converter 4. Connect the cables to the terminals inside the terminal compartment of the cabinet. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 134/211...
Page 135: Optical Fiber Cables
4. Gently press down the latch tab with the tip of the screwdriver and pull the corner of the cover forward and repeat for the other side. 5. Slide the removable cover up and then remove the cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 135/211...
Page 136: Fig. 91. 1 Control Unit Sdcs-Con-H01
Fig. 92. Cable routing example in an EXU cabinet with an ED5V, EB5R, EB5S, EB7P and EB7Q type DCS880/DCT880 converter 8. Reattach the front cover of the DCS880/DCT880. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 136/211...
Page 137: Routing Cables In An Exu Cabinet With An Ed7Y Type Dcs880/Dct880 Converter
2. Connect the two optical fibers to the receptacles of slot 1 according to the terminal numbers printed on the marker sleeves. Key: Slot 1 (FDCO-01 module Control panel Fig. 94. 1 Control unit SDCS-CON-H01 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 137/211...
Page 138: Connecting The Heating Cable
“Appendix D - Wiring diagrams”. 2. Connect the heating cables (1) of two adjoining transport units 3. Fasten the connectors with cable ties (2). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 138/211...
Page 139: Final Checks
If you used EMC entry plates check that the grommets fit tightly (arrows) to prevent water entering the cabinet. – If required, seal gaps with silicone. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 139/211...
Page 140: Commissioning
7. Commissioning 7.1. Required qualification Commissioning, parameter adjustments and functional tests must be carried out only by qualified commissioning personnel that have been certified by ABB. 7.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.
Page 141: Commissioning Checklists
 1) Types and cross sections of control cables suitable for the signal type and signal level.  2) Types and cross sections of power cables selected according to the 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 142: Main Circuit Breaker (Mcb) Checklist
If the commissioning personnel carry out the test, an additional day per drive-motor combination must be reserved. After the test, the mains cables can be connected, except at the drive end. Test must comply with the specification. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 142/211...
Page 143: Power Checklist
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 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 143/211...
Page 144: Operation
OPERATION 8. Operation 8.1. Overview The following sections describe how to operate an ACS6080 drive from an assistant control panel on a control unit of the drive, ie, local operation. Fig. 96. Assistant control panel NOTE – Control of the drive via a PLC or higher-level control system is not described in this document.
Page 145: Control Panels
The user can also select the drive to operate in the panel network. The PC tool can be easily connected to the drive through the USB connector on the control panel. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 145/211...
Page 146: Navigating The Home View
(visible in the top right corner) (Menu) to open the main Menu – Press (Options) to open the Options menu – Press – Press (Help) for a context-sensitive help page PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 146/211...
Page 147: Control Panels For Drives With An Aru
– Displays the status messages of the INU Fig. 98. Master control panel on (A) COU1 and (B) slave control panel for a drive with an ARU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 147/211...
Page 148: Control Panels For Drives With An Lsu
– Displays the status messages of the INU Fig. 99. (A) Master control panel on COU1 and (B) slave control panel for a drive with an LSU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 148/211...
Page 149: Exu Control Panel
– Motor current in A – Armature voltage in V Converter current in A (rectified AC current value) – PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 149/211...
Page 150: Resetting Alarm And Fault Messages
→ DO NOT change a parameter if you do not understand the parameter and the effects of the change → Contact ABB if you want to modify a parameter 8.5. Lamp test The illuminated push buttons on the doors can be tested with the lamp test function as described in the firmware manual, see “Appendix G - Signal and parameter table”.
Page 151: Grounding Switch And Door Locking System
The indicator lamp for the grounding switch and the white lamp (1, Fig. 101), have an integrated momentary push button. The lamps light up when the lamp cap is pressed. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 151/211...
Page 152: Door Locking System
TABLE 12 Medium voltage units with safety switches and locking bars Standard cabinet units Optional cabinet units Key: Locking bar in locked position Locking bar in unlocked position Safety switch Fig. 102. Safety switches PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 152/211...
Page 153: Optional Switchgear And Controlgear
For more information, see Section 9.4.9, “Drives with the manual output isolation (optional)”, page 180. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 153/211...
Page 154: Status Messages
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 ACS6080 User manual 3BHS842007 E01 154/211...
Page 155: Start Sequence Of The Drive
7) Ready run • INU starts magnetizing (only in drives with an ARU) • INU starts to modulate 8) Start command 9) Ready ref 10) Operation PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 155/211...
Page 156: Stop Sequence Of The Drive
3) Emergency-off command Stop command to ARU (only in drives with an ARU) • • MCB opens • INU stops modulating • Speed coasts down 4) Emergency-off PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 156/211...
Page 157: Prevention Of Unexpected Startup Sequence
CAUTION Cooling system starts automatically! The cooling system can start automatically when the auxiliary voltage is switched on. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 157/211...
Page 158: Checks Before Starting The Drive
ARU changes to Modulating. When the ARU has reached the status Ready ref, the status of the first INU and the other INUs change to Ready run. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 158/211...
Page 159: Stopping The Drive
4 Reset Emergency-Off button flashes Supply Off push button flashes For more information, see “Emergency off/stop modes and prevention of operation & safe torque off”, 3BHS196243. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 159/211...
Page 160: Starting The Drive System After An Emergency-Off
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 ACS6080 drive. When the Arc Guard System detects an arc fault the drive performs protection firing and immediately opens the main circuit breaker.4...
Page 161: Action After The Arc Guard System™ Has Been Triggered
WARNING! Only set this parameter after the fault has been identified and corrected. 8. Restart the drive according to Section 8.9, “Starting the drive”, page 157. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 161/211...
Page 162: Preventive And Corrective Maintenance
PREVENTIVE AND CORRECTIVE MAINTENANCE 9. Preventive and corrective maintenance 9.1. General information During the warranty period of the drive, any maintenance must be carried out exclusively by ABB service personnel. After the warranty period, repair work must be carried out by certified personnel.
Page 163: Identifying Electrical Equipment
Terminal number Fig. 106. Cable and wire designation 9.2.2.1. Understanding wiring diagrams For information on item designation and cross-reference conventions, see “Appendix D - Wiring diagrams”. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 163/211...
Page 164: Status Indicators
MCB when a fault condition occurs. A fault condition must be corrected and the fault be manually reset before the drive can be started again. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 164/211...
Page 165: Alarm And Fault Messages
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 166: Leds And Switches On Pcbs And I/O Modules
For more information, see the “UCU-26 control unit hardware manual”, 3BHS897436 E01. Key: Location of LEDs Fig. 107. (A) Assistant control panel and UCU-26: (B) top (C) front and (D) rear PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 166/211...
Page 167: S500 I/O Modules
To identify the serial communication interface in the drive, see “Appendix D - Wiring diagrams”. For more information, see “NETA-21 remote monitoring tool user manual”, 3AUA0000096939. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 167/211...
Page 168: Leds On Optional Heat Exchangers
(A) Red LED on and (B) green LED off Alarm condition (A) Red LED off and (B) green LED off Auxiliary voltage is missing Fig. 109. Status LEDs on optional air-to-air heat exchangers PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 168/211...
Page 169: Maintenance Tasks
→ DO NOT forcibly turn a grounding switch in any direction → Identify and resolve the condition that prevents the switch from turning, eg, switch was not released properly PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 169/211...
Page 170 7. Open the doors of medium voltage units according to Section 9.4.4, “Unlocking and opening the doors”, page 172. NOTE – To open the doors of medium voltage units, auxiliary voltage is required. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 170/211...
Page 171: Grounding The Drive When The Grounding Switch Is Not Released
If the DC link is discharged, the drive is in Ready to switch on status. Ready to Switch ON is enabled in parameter 6.11 Main status word . • Check that PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 171/211...
Page 172: Unlocking And Opening The Doors
(1) to the unlocked (2) position. 3. (Door hinged on the right) Slide the locking bar right from the locked position (1) to the unlocked (2) position. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 172/211...
Page 173: Closing And Locking The Doors
(1) to the locked position (2). 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 ACS6080 User manual 3BHS842007 E01 173/211...
Page 174: Testing The White Lamp
9.4.7.1. Location of safety switches The doors of medium voltage units (LSU, ARU, IFU, IRU, CBU, INU, BCU, RBU, VLU, TEU and ISU) are equipped with safety switches. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 174/211...
Page 175: Safety-Switch Settings
To open the door of a medium voltage unit, the DC link must be discharged and the auxiliary voltage must be switched on. Fig. 111. Safety switch settings PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 175/211...
Page 176: Unlocking A Safety Switch
5. Tighten the locking screw. 6. Seal the locking screw. 7. Refit the screw cap. 8. To ground the drive, continue with Section 9.4.8, “Connecting a grounding set”, page 177. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 176/211...
Page 177: Connecting A Grounding Set
Depending on the type of line-side rectifier, continue with: – Section 9.4.8.1, “Drives with an LSU”, page 178 – Section 9.4.8.2, “Drives with an ARU”, page 179 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 177/211...
Page 178: Drives With An Lsu
Inside TEU: 1L1, 1L2, 1L3, 2L1, 2L2 and 2L3 in Fig. 113 • Inside INU: L1, L2 and L3 in Fig. 114 Key: Ground ball stud example Fig. 113. TEU ground ball stud locations PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 178/211...
Page 179: Drives With An Aru
2. Use the telescopic insulating pole to connect and tighten busbar ground clamps to the ground ball studs of the following busbars inside an ARU and INU: • L1, L2 and L3 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 179/211...
Page 180: Drives With The Manual Output Isolation (Optional)
(11) Busbar connectors (3 ×) in TEU BCU1 (12) Busbar connectors (3 ×) in COU1 INU2 (13) Lever for removing and fitting the busbar connections COU1 Fig. 115. Manual output isolation overview PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 180/211...
Page 181: Removing The Busbar Connectors
Orientation of lever for removing busbar connectors Orientation of lever for fitting the busbar connectors Four-way grounding set Fig. 116. Tools for removing the busbar connectors PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 181/211...
Page 182: Fig. 117. Overview Of Grounding The Drive - (A) Inu1 Is Shut Down, And (B)
Busbars for the cables to the secondary transformer windings (1, Fig. 118) Busbars for the motor cables (2, Fig. 118) Busbars in the INU (3, Fig. 118) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 182/211...
Page 183: Fig. 118. Connect The Grounding Sets In (A And C) Cou1, (B) Teu1, (D) Inu1
Busbars for motor cables Ground ball stud INU busbars Fig. 118. Connect the grounding sets in (A and C) COU1, (B) TEU1, (D) INU1, and (E) INU2 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 183/211...
Page 184: Fig. 119. Busbar Connector Removal Sequence In Teu1 Or Cou1
9. Check that the power operating mode (POM) of the drive corresponds to the busbar connectors fitted. 10. Start the drive according to the established procedures. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 184/211...
Page 185: Fitting The Busbar Connectors
7. Check that the power operation 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 ACS6080 User manual 3BHS842007 E01 185/211...
Page 186: Removing And Installing A Phase Module
(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 ACS6080 User manual 3BHS842007 E01 186/211...
Page 187: Fig. 121. Phase Module Removal
7. Pull the phase module onto the table. CAUTION! A phase module weighs approximately 190 kg! PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 187/211...
Page 188: Installing A Phase Module
8. Let go of the locking sleeve and firmly push the female part against the male part until the coupling locks home with a click. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 188/211...
Page 189: Visual Checks On The Drive
10. Fasten the cables with cable ties. 9.4.11. Visual checks on the drive Check the drive and its immediate vicinity visually at the intervals stated in “ACS6080 preventive maintenance schedule” , 3BHS838899 E01 and pay attention to the following items: –...
Page 190: 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. 9.4.14. Checking and replacing filter mats Inspection intervals See the “ACS6080 preventive maintenance schedule” , 3BHS838899 E01. Service during operation Possible Filter mat class...
Page 191: Replacing A Filter Mat
4. Turn the cover over and remove the filter mat. 5. Insert the new filter mat and reinstall the ventilation grid. 9.4.15. Testing and replacing auxiliary fan units Inspection intervals See the “ACS6080 preventive maintenance schedule” , 3BHS838899 E01. Service during operation Possible Location Installed behind the doors of the following cabinets: –...
Page 192: Testing Auxiliary Fan Units
4. Check that the fans run smoothly and if a fan is faulty, replace the complete fan unit. 5. Set the thermostat to the factory-set value. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 192/211...
Page 193: 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 ACS6080 User manual 3BHS842007 E01 193/211...
Page 194: Testing And Replacing Air-To-Air Heat Exchangers
PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.16. Testing and replacing air-to-air heat exchangers Inspection intervals See the “ACS6080 preventive maintenance schedule” , 3BHS838899 E01. Service during operation Not possible Explanation Key: Ambient fan 2 Ambient fan 1 Internal fan 1 Circuit board location...
Page 195: 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 ACS6080 User manual 3BHS842007 E01 195/211...
Page 196: Replacing The Complete Heat Exchanger
88. 9.4.16.3. 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 ACS6080 User manual 3BHS842007 E01 196/211...
Page 197: Fig. 125. Wire Connection Points On The Circuit Board
Green J19 LEDs Alarm 1 Fig. 125. Wire connection points on the circuit board 8. Reconnect the ground wire to the front cover. 9. Fasten the covers. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 197/211...
Page 198: Replacing Internal Fan 1 - Left Side
PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.16.4. Replacing internal fan 1 - left side 1. Unscrew the front top cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 198/211...
Page 199 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 ACS6080 User manual 3BHS842007 E01 199/211...
Page 200: Replacing Internal Fan 2 - Right Side
PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.16.5. Replacing internal fan 2 - right side 1. Unscrew the front top cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 200/211...
Page 201 PREVENTIVE AND CORRECTIVE MAINTENANCE 2. Remove the front cover and disconnect the ground wire (arrow). 3. Unscrew the circuit board mounting bracket (1, 2, and 3). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 201/211...
Page 202 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 ACS6080 User manual 3BHS842007 E01 202/211...
Page 203: Replacing The Ambient Fans
3. Disconnect the plug-in connectors (arrows) and remove the fastening screws (1, 2, 3, and 4). 4. Replace the fan, and reassemble the unit in reverse order of removal. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 203/211...
Page 204: Replacing The Fan Unit In An Exu With A Dcs880 H4/Dct880 T4 Unit
NOTE – To identify the miniature circuit breaker, see “Appendix D - Wiring diagrams”. 2. Remove the 6 screws (circles) from the fan cover and then remove the fan cover. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 204/211...
Page 205 PREVENTIVE AND CORRECTIVE MAINTENANCE 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 ACS6080 User manual 3BHS842007 E01 205/211...
Page 206: Replacing The Fan Unit In An Exu With A Dcs880 H6 Unit
6. Install the new fan in reverse order of removal. 9.4.18. Replacing the fan unit in an EXU with a DCS880 H6 unit Fig. 127. DCS880 controller - size H6 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 206/211...
Page 207 To identify the miniature circuit breaker, see “Appendix D - Wiring diagrams”. 2. Remove the 6 screws (circles) from the fan cover and then remove the fan cover. 3. Unplug the fan cables. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 207/211...
Page 208 CAUTION! To prevent the fan from falling onto you, put a support (ie, a box) underneath. 6. Install the new fan in reverse order of removal. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 208/211...
Page 209: Replacing The Air-To-Water Heat Exchanger Of The Exu
5. Disconnect the water tubes (1) from the air-to-water heat exchanger, unplug the cables (2) and remove the fastening screws. Key: Water tube connection Fastening screw Cable connections Fig. 128. Air-to-water heat connections PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS6080 User manual 3BHS842007 E01 209/211...
Page 210: Fig. 129. Lift Heat Exchanger Out Of Exu Cabinet
Fig. 129. Lift heat exchanger out of EXU cabinet 7. To install the new heat exchanger, proceed in reverse order of removal. For information on adding water to the cooling system, see: “ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual”, 3BHS821937 E01 or “ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual”, 3BHS835714 E01.
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