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ABB ACS5000 User Manual

ABB ACS5000 User Manual

Water-cooled (generation 3)
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SYSTEM DRIVES
ACS5000 water-cooled (generation 3)
User manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DOCUMENT KIND
User manual
© Copyright 2024 ABB All rights reserved.
DATE
STATUS
2024-11-20
Approved
DOCUMENT ID.
3BHS904690 E01
SECURITY LEVEL
Public
REV.
LANG.
PAGE
C
en
1/153

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  • Page 1 SYSTEM DRIVES ACS5000 water-cooled (generation 3) User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL System Drives, ABB Switzerland Ltd. 2024-11-20 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS904690 E01 1/153 © Copyright 2024 ABB All rights reserved.
  • Page 2 ABB is in no event liable for the security of the network used by buyer.

  • Page 3: Table Of Contents

    CONTENTS — CONTENTS 1. About this manual..........................12 1.1. Equipment covered by this manual ......................12 1.2. Structure of the user documentation....................12 1.3. Related documents..........................13 1.3.1. Maintenance ..........................13 1.3.2. Technical data..........................13 1.3.3. Schematics............................ 13 1.3.4. Specifications and guidelines ....................13 1.3.5.
  • Page 4 CONTENTS 3.4.3. Main circuit breaker ........................38 3.4.4. Peripheral I/O devices ........................38 3.4.5. Local operator panel........................39 3.4.6. Customer interface ........................40 3.5. Water cooling unit (WCU) ........................41 3.6. Excitation unit (EXU - optional) ......................42 3.6.1. DCS880/DCT880 control panel ....................43 3.6.2. Output disconnector ........................43 3.7.
  • Page 5 CONTENTS 5.10. Installing roof-mounted cooling units....................67 5.10.1. Installing IP42 roof-mounted cooling units................67 5.10.2. Installing IP54 roof-mounted cooling units................69 5.11. Installing roof attachments on marine drives ...................71 5.12. Joining water pipes ..........................73 5.12.1. Removing a pipe joint......................... 73 5.13.
  • Page 6 CONTENTS 6.8.2.3. EXU - auxiliary and control cables ................106 7. Commissioning...........................112 7.1. Required qualification..........................112 7.2. Commissioning procedure ........................112 7.3. Commissioning checklist ........................112 7.4. Customer assistance..........................112 7.5. Customer acceptance ..........................112 7.6. Commissioning checklists ........................113 7.6.1. Mechanical installation checklist ....................113 7.6.2. Electrical installation checklist....................113 7.6.4.
  • Page 7 CONTENTS 9.1.2. Maintenance schedule......................129 9.1.3. Logbook............................129 9.1.4. Spare parts..........................129 9.2. Identifying electrical equipment ......................130 9.2.1. Device designation........................130 9.2.2. Cables and wires........................130 9.2.3. Understanding wiring diagrams ...................130 9.3. Drive status indicators...........................131 9.3.1. Alarm and fault indicators......................131 9.3.2. Error message levels........................131 9.3.2.1.
  • Page 8 FIGURES — FIGURES Figure 1 – Typical delivery............................18 Figure 2 – Product warning label examples (label placement depends on the equipment) .....21 Figure 3 – Drive system overview..........................25 Figure 4 – Typical block diagram of the drive....................... 27 Figure 5 –...
  • Page 9 FIGURES Figure 32 – Sling configurations ..........................57 Figure 33 – Floor inclination ............................62 Figure 34 – Connection points on side of transport units (PCU example) ...........65 Figure 35 – Base frame connection points......................65 Figure 36 – Applying silicone.............................66 Figure 37 –...
  • Page 10 FIGURES Figure 68 – Bolted busbar connection ........................98 Figure 69 – Preparing control cables for sealing modules................100 Figure 70 – Preparing control cables for cable glands ..................101 Figure 71 – Cable routing options to WCU800 control compartment............102 Figure 72 – Top and bottom cable routing in WCU800 and WCU1400 cabinets ........103 Figure 73 –...
  • Page 11 Table 9 – Maximum number of cables per frame opening - 3 core ..............90 Table 10 – Maximum number of cables per frame opening - single core............90 Table 11 – ABB arc resistant classes........................127 Table 12 – Filter mat specifications ........................143...

  • Page 12: 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 13: Related Documents

    Field wiring terminals 3BHS500316 E01 1.3.5. Manuals Title ABB ID ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 Generic spare parts package 3BHS909701 E01 1.3.6.

  • Page 14: Terms And Abbreviations

    Frame sizes 1 to 4 give the different power ranges. The higher the frame size, the greater the output power capability. Gateway to ABB Ability™ Monitoring and diagnostics tool that allows access to the drive from any location in the world via a secure Internet connection.
  • Page 15 Term of ABB’s S500 I/O process system. An I/O device consists of a module termination unit (MTU) and one I/O module. I/O module Term of ABB’s S500 I/O process system. The I/O module is an active input or output device for digital or analog signals. IGCT...

  • Page 16: Target Groups And Required Qualification

    The personnel must carry out the below listed tasks in a manner that does not cause physical harm or danger, and ensures the safe and reliable functioning of the drive. IMPORTANT! Commissioning of the drive must only be performed by qualified and certified ABB personnel 1.5.1. Handling Personnel must be skilled and experienced in unpacking and transporting heavy equipment.

  • Page 17: User's Responsibilities

    ABB. 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.

  • Page 18: Items Covered By 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 manual Service equipment.

  • Page 19: Document Conventions

    ABOUT THIS MANUAL 1.11. Document conventions The document uses the following font formats and symbols. See also 2.1 Safety messages and safety signs in this document on page Font formats Convention Description  Prerequisite for a task Sequential procedural steps in a task ▶...

  • Page 20: Important Safety Information

    IMPORTANT SAFETY INFORMATION 2. Important safety information Read this material carefully before working on or around the equipment. Failure to do so can result in serious Injury or DEATH! Keep for future reference. 2.1. Safety messages and safety signs in this document This document uses ANSI Z535.6 signal words, ISO 7010 safety signs, and ISO 3864-2 colors to highlight safety-related information.

  • Page 21: Product Safety Labels

    IMPORTANT SAFETY INFORMATION 2.2. Product safety labels Product safety labels on the equipment alert you to the hazards that can occur when you work on or operate the equipment. – Always follow the instructions on the labels to avoid the hazard –...

  • Page 22: Electrical Safety

    • 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 23 3) Disconnect all sources of supply and secure against reconnection by applying Lockout/Tagout. • If ABB is responsible for switching and it cannot be done remotely, then the person performing the switching must be properly trained and wearing the proper PPE identified in step 1.

  • Page 24: Possible Residual Risks

    IMPORTANT SAFETY INFORMATION 2.3.3. Possible residual risks Residual risks must be considered by the drive system integrator and/or plant owner when assessing the hazards of the equipment to personnel. The following risks can pose a hazard to drive system personnel: 1) Electric power equipment generates electro-magnetic fields which can cause a hazard to people with metal implants and / or a pacemaker.

  • Page 25: Main Circuit Breaker Protection Device

    – Transformer protection (if applicable) – Transformer secondary cable protection (if applicable) – Backing up the drive protection In general, these protective measures are not included in the drive as provided by ABB. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG.

  • Page 26: Safety And Protection Requirements

    For safety and protection reasons, the MCB must meet the stipulated minimum requirements of the specifications of ABB MV Drives. It is the system integrator's responsibility to ensure that the minimum requirements are met. The minimum requirements for the MCB are stated in this note and in the respective MCB engineering guideline, which are available for each medium voltage drive from ABB.

  • Page 27: Power Electronics And Cabinet Features

    3. Power electronics and cabinet features 3.1. Main features of the drive The water-cooled ACS5000 is a voltage source frequency converter of the ACS product range. It is available for up to 36 MVA and for standard motors with voltages up to 6.9 kV.

  • Page 28: Figure 5 - Switching Levels

    POWER ELECTRONICS AND CABINET FEATURES VSI-MF The VSI design employs DC-link capacitors and provides a switched voltage waveform. As a result of the multilevel topology, the drive produces an optimum number of switching levels, ie, 9 levels, phase to phase. The resulting output waveform permits the application of standard motors without decreasing the reliability and efficiency of the motor.

  • Page 29: Drive Frame Sizes And Configurations

    POWER ELECTRONICS AND CABINET FEATURES 3.2. Drive frame sizes and configurations The drive is available in four frame sizes (FS), ie, FS1 to FS4 (see Figure 8 for typical drive configurations). For information on a project-specific configuration, see the layout drawing in “Appendix C –...

  • Page 30: Phase Converter Unit (Pcu)

    POWER ELECTRONICS AND CABINET FEATURES 3.3. Phase converter unit (PCU) PCUs are available as 6-pulse and 12-pulse rectifiers (Table 2). All drive configurations (FS1, FS2, FS3, and FS4, Figure 8) have three primary PCUs, where each PCU supplies a different motor phase. A complete functional PCU assembly is: –...

  • Page 31: Primary Phase Converter Unit (1700 Mm And 2100 Mm)

    POWER ELECTRONICS AND CABINET FEATURES 3.3.1. Primary phase converter unit (1700 mm and 2100 mm) 3.3.1.1. Primary PCU (1700 mm) - FS1 and FS3 For the location of these PCUs in typical FS1 and FS3 drive configurations, see Figure 8. (1) Roof-mounted cooling unit (presence depends on drive (7) 2 di/dt chokes and 2 VLSCD circuit boards configuration)

  • Page 32: Figure 10 - Primary Pcu, 1700 Mm - Side Views

    POWER ELECTRONICS AND CABINET FEATURES a) Left side b) Right side (1) Terminal compartment (PCU 6-pulse only) for transformer cables (2) LSU snubber plate (PCU 6-pulse only) (3) Rectifier stacks consisting of diodes and thyristors (4) DC-link connection (5) Water pipe (6) AC busbars for adjacent PCU and motor phase (7) Inverter stacks consisting of diodes and IGCTs (8) Gate unit...

  • Page 33: Primary Pcu (2100 Mm) - Fs2 And Fs4

    POWER ELECTRONICS AND CABINET FEATURES 3.3.1.2. Primary PCU (2100 mm) - FS2 and FS4 (1) Roof-mounted cooling unit (2) HVD circuit board (3) Crowbar circuit board or PINT circuit board (4) CVMI circuit board for voltage and current measurement (5) 2 di/dt chokes and 2 VLSCD circuit boards (6) DC-link capacitors (7) PE ground busbar (8) INT interface circuit board...

  • Page 34: Figure 12 - Primary Pcu, 2100 Mm - Side Views

    POWER ELECTRONICS AND CABINET FEATURES a) Left side b) Right side (1) Terminal compartment for transformer cables (2) LSU snubber plate (PCU 6-pulse only) (3) Rectifier stacks consisting of diodes and thyristors (4) DC-link connection (5) Water pipe (6) AC busbars for adjacent PCU and motor phase (7) Inverter stacks consisting of diodes and IGCTs (8) Gate unit (9) Back oscillation damping circuit...

  • Page 35: Secondary Phase Converter Unit (1700 Mm And 2100 Mm) - Fs3 And Fs4

    POWER ELECTRONICS AND CABINET FEATURES 3.3.2. Secondary phase converter unit (1700 mm and 2100 mm) – FS3 and FS4 A secondary PCU has the same design as a primary PCU, but without the rectifier stack and the transformer terminal compartment. Drive FS3 uses 1700 mm secondary PCUs and FS4 uses 2100 mm secondary PCUs.

  • Page 36: Control Unit (Cou)

    COU - WCU - Internal Internal processing processing PCU (Inverter) (1) ABB Ability™ cloud connectivity (7) Control panel on COU door (2) Higher-level control system (8) PC tool (Drive Composer) (3) Customer terminals (9) Main controller (4) Ethernet TCP/IP (10)Internal I/Os (5) Gateway to ABB Ability™...

  • Page 37: Main Components

    (11) DC buffer capacitors (optional) (24)1-phase/ 3-phase auxiliary transformers (optional) (12) EMC filter (25)Transformer for unbuffered auxiliary power supply (T1111) (13) Gateway to enable ABB Ability™ digital services (optional) Figure 15 – COU control section PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 38: Parameters

    POWER ELECTRONICS AND CABINET FEATURES 3.4.2. Parameters The control system is configured, customized, and tuned with a set of application parameters. The application parameters are organized in functional groups and have factory-set default values. The default parameter values are adjusted during commissioning to the specific application of the drive in order to activate the specific control, monitoring and protection functions for the driven process, and to define the signals and data transferred between drive and external equipment.

  • Page 39: Local Operator Panel

    POWER ELECTRONICS AND CABINET FEATURES 3.4.5. Local operator panel The local operator panel serves as the basic user interface for monitoring, control and operation of the drive and setting of parameters. For more information on local operation and the control panel, see 8 Operation on page 116.

  • Page 40: Customer Interface

    Optional control I/O extension, eg, to monitor external equipment such a transformer or motor (1) Arc Guard System™ (2) S500 I/O process system (customer- specific configuration) (3) ABB Ability™ (NETA-21) (4) Speed and position encoder interface (5) Customer terminals for control I/O extension (optional)

  • Page 41: Water Cooling Unit (Wcu)

    POWER ELECTRONICS AND CABINET FEATURES 3.5. Water cooling unit (WCU) The size of the WCU depends on the drive FS (see 3.2 Drive frame sizes and configurations on page 29). Both sizes have the same components: – WCU800 has a cabinet width of 800 mm –...

  • Page 42: Excitation Unit (Exu - Optional)

    POWER ELECTRONICS AND CABINET FEATURES 3.6. Excitation unit (EXU - optional) The EXU supplies a synchronous motor with excitation power and is available for the following excitation methods: Brush excitation (DC excitation): Uses a DCS880 AC-to-DC converter which is supplied by the –...

  • Page 43: Dcs880/Dct880 Control Panel

    POWER ELECTRONICS AND CABINET FEATURES 3.6.1. DCS880/DCT880 control panel The control panel of the DCS880/DCT880 unit enables the user to control, read the status messages and set the parameters of the DCS880/DCT880 unit. The panel can also be used to copy parameters from one DCS880/DCT880 unit to another DCS880/DCT880.

  • Page 44: Transformer And Motor Cable Terminals

    POWER ELECTRONICS AND CABINET FEATURES 3.7. Transformer and motor cable terminals 3.7.1. Transformer cable terminals DANGER Hazardous voltages! → Complete the steps in 2.3.2 The 7 steps that save lives on page 22 before you remove the side and back walls from the drive to access the grounding studs in a PCU. To access the transformer cable terminals (busbars), remove the back wall of the primary PCU (see Figure 8 for PCU location).

  • Page 45: Grounding Switches

    POWER ELECTRONICS AND CABINET FEATURES You can only connect the main power supply to the drive when all of the locking bars are in the locked position and the grounding switches in the ungrounded position. Similarly, you can only open the PCU doors after the main power supply has been disconnected, the DC-link capacitors have been discharged, and the grounding switches are in grounded position.

  • Page 46: Locking Bars

    POWER ELECTRONICS AND CABINET FEATURES 3.8.2. Locking bars A locking bar is a safety mechanism that locks the doors of the primary and secondary PCUs when the drive is ungrounded. You can only slide the locking bar (1) to the unlocked position (2) and open the doors when the drive is grounded, ie, when the white lamp (3) is lit.

  • Page 47: Grounding Studs

    POWER ELECTRONICS AND CABINET FEATURES 3.9. Grounding studs The COU and each PCU has grounding studs that are designed for use with the 4-way grounding set (Figure 25). Figure 24 – Grounding stud 3.9.1. Grounding set DANGER Hazardous voltages! → Complete the steps in 2.3.2 The 7 steps that save lives on page 22 before you access the grounding studs in the PCU and COU.

  • Page 48: Output Grounding Studs In Cou

    POWER ELECTRONICS AND CABINET FEATURES 3.9.2. Output grounding studs in COU The converter output grounding studs, ie, 1L1, 1L2, 1L3 and 2L1, 2L2, and 2L3, and the protective earth (PE) busbar are at the back of the COU. Figure 26 – Location of PE busbar and grounding studs (1L1, 1L2, and 1L3) in COU, FS1 and FS2 Figure 27 –...

  • Page 49: Input Grounding Studs In A Pcu

    POWER ELECTRONICS AND CABINET FEATURES 3.9.3. Input grounding studs in a PCU DANGER Hazardous voltages! → Complete the steps in 2.3.2 The 7 steps that save lives on page 22 before you remove the side and back walls from the drive to access the grounding studs in a PCU. The converter input grounding studs, ie, 1L1, 1L2, and 1L3 and 2L1, 2L2, and 2L3 and the protective earth busbar are at the back of each PCU.

  • Page 50: Transportation, Storage, And Disposal

    2. Inspect the drive and accompanying equipment and make note of any damage. • Take a photograph of the damage and inform ABB and the shipping company immediately. 3. Compare the complete delivery with the purchase order and the packing list.

  • Page 51: Packing List

    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 52: 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 53: 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 ACS5000W gen. 3 equipment. Any use beyond this is strictly prohibited. ABB ID: 3BHE015753P0008 ABB ID: 3BHE015753P0016...

  • Page 54: Lifting With Lifting Plates

    TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.2. Lifting with lifting plates Lifting plates are factory-installed on the base frame of transport units. CAUTION Risk of tipping! The following procedure requires a crane with a lift frame or a spreader frame. If you do not have this equipment: →...

  • Page 55: Lifting With Rotating Eyebolts

    TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.3. Lifting with rotating eyebolts Rotating eyebolts are either installed in the factory or are in the loose parts box for the drive. The following procedure requires a crane with a lift frame or a spreader frame. 1.

  • Page 56: Reinstalling Lifting Attachments

    NOTE – The torque wrench sockets for the rotating eyebolts are not included in the scope of delivery. Table 3 – Lifting attachment specifications Type Mounting bolt Torque (Nm) ABB ID Lifting plate 2 × M16 × 40 (A2-70) 3BHB039841R0001 M16 rotating eyebolt 3BHE015753P0016...

  • Page 57: Sling Configurations For Lift Frames And Spreader Frames

    TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.5. Sling configurations for lift frames and spreader frames a) Lift frame 15° b) Spreader frame (1) Lift frame (5) Safety hook or shackle (2) Protect the edges (6) Lifting plate (3) Protect door handles and levers (7) Slope angle (maximum 15 °) (4) Extra horizontal sling (8) Lift spreader...

  • Page 58: 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 59: Storage And Handling Of Spare Parts

    → Apply static-sensitive precautions when you handle spare parts. 4.7.1. Warranty information IMPORTANT! Inspect all spare parts upon receipt and make note of any damage. Inform ABB and the shipping company of the damage. To keep spare parts in good condition and to keep the warranty valid during the warranty period: –...

  • Page 60: Mechanical Installation

    → DO NOT use a crane if the transport units are secured to the base frame; use heavy load hydraulics rollers or air cushions. If you are unsure, contact ABB for instructions. → DO NOT damage or dislocate the EMC sealing strips when you join 2 transports units;...

  • Page 61: Dimensions And Clearances

    MECHANICAL INSTALLATION 5.4. Dimensions and clearances For information on dimensions, location and size of fixing holes and clearances, see “Appendix C – Mechanical drawings”. 5.4.1. Rear and top access to the cabinet Joining the transport units and DC busbars requires rear and top access. 5.4.2.

  • Page 62: Preparing The Installation Site

    MECHANICAL INSTALLATION 5.5. Preparing the installation site To ensure proper alignment and installation of the drive, prepare the floor as follows: – The floor must be able to support the weight of the drive (minimum 1500 kg/m – The overall incline of the floor across 5 m must not exceed 5 mm. 5 mm 1 mm 1 mm...

  • Page 63: Aligning Transport Units

    MECHANICAL INSTALLATION 5.6. Aligning transport units 1. Remove the protective covers from the water pipe ends on both sides. 2. Check that a pipe joint has been slid on one pipe end of two adjoining water pipes. 3. Line up the transport units as shown in “Appendix C – Mechanical drawings”. NOTE –...
  • Page 64 MECHANICAL INSTALLATION • Bolt holes are exactly aligned. M6×16 (9ABA450093R0259) • 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.

  • Page 65: Joining Transport Units

    MECHANICAL INSTALLATION 5.7. Joining transport units Join the transport units with the supplied installation material. The installation material is attached to one of the transport units. Figure 34 – Connection points on side of transport units (PCU example) (HZN 452198P1025) (9ABA450078P0008) M16×50 (312350P0466)

  • Page 66: Applying Silicone

    MECHANICAL INSTALLATION 5.8. Applying silicone Silicone prevents water from entering the gap between two joining roof plates. Apply silicone where two transport units have been joined (Figure 36). Gaps within a transport unit are factory-sealed. Figure 36 – Applying silicone 5.9.

  • Page 67: Installing Roof-Mounted Cooling Units

    MECHANICAL INSTALLATION 5.10. Installing roof-mounted cooling units You need a crane to install a roof-mounted cooling unit. Each PCU has a designated roof opening for a cooling unit. These instructions are only for PCU that were not delivered with pre-installed cooling units.

  • Page 68: Figure 39 - Cable Duct Openings (Example With 1700 Mm Pcu)

    MECHANICAL INSTALLATION 4. Lift the cooling unit above the PCU cabinet with a crane. 5. Align the cooling unit with the opening (3, Figure 38) in the cabinet roof and slowly lower the cooling unit onto the cabinet roof. IMPORTANT! Ensure that the screw holes on the roof and the cooling unit match up. 6.

  • Page 69: Installing Ip54 Roof-Mounted Cooling Units

    MECHANICAL INSTALLATION 5.10.2. Installing IP54 roof-mounted cooling units CAUTION Heavy object! An IP54 cooling unit weighs 98 kg. 98 kg → Use appropriate slings and shackles → Before you begin, read 4.5.3 Lifting with rotating eyebolts on page 55 Table 6 – Installation material per IP54 unit Item Quantity Details...

  • Page 70: Figure 41 - Water Tube Connections (Back View)

    MECHANICAL INSTALLATION 5. Align the water inlet / outlet (3, Figure 40), drain outlet (4, Figure 40), and cables (5, Figure 40) of the cooling unit with the designated openings in the cabinet roof and then slowly lower the cooling unit onto the cabinet roof. IMPORTANT! Ensure that the screw holes on the roof and the cooling unit match up.

  • Page 71: Installing Roof Attachments On Marine Drives

    MECHANICAL INSTALLATION 5.11. Installing roof attachments on marine drives Roof attachments are only available for marine drives. To prevent tilting and dampen vibrations, attach the drive to the ceiling or the back wall of the drive room according to the instructions. For information on the fitting location, see “Appendix D – Wiring diagrams”.

  • Page 72: Figure 43 - Recommended Ceiling And Wall Fixings

    MECHANICAL INSTALLATION 5. If you fix the drive to the back wall, install one strut at a 90° angle to the drive (2, Figure 43). ~45° ~45° ~90° (1) Two struts at 45° to ceiling (2) One strut at 90° to wall (3) DO NOT install the struts at a 90°...

  • Page 73: Joining Water Pipes

    MECHANICAL INSTALLATION 5.12. 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. Dimensions in mm 4.

  • Page 74: Joining Busbars

    MECHANICAL INSTALLATION 5.13. Joining busbars There are three types of busbars that need to be joined: – AC busbars (1, Figure 44) – PE ground busbar (2, Figure 44) – DC busbars (3, Figure 44) (1) AC busbars (2) PE ground busbar (3) DC busbars Figure 44 –...

  • Page 75: Ac Busbars

    MECHANICAL INSTALLATION 5.13.1. AC busbars The joining pieces of the AC busbars and related installation material are mounted at one of the busbar ends in the transport units. Figure 45 – AC busbar connection 5.13.2. PE ground busbar The joining pieces of the PE ground busbar and related installation material are mounted at one of the busbar ends in the transport units.

  • Page 76: Dc Busbars

    MECHANICAL INSTALLATION 5.13.3. DC busbars The joining pieces of the DC busbars are deposited inside the transport units. Related installation material is mounted at one of the busbar ends in the transport units. Figure 47 – DC busbar connection 5.14. Connecting the heating cable Some drives have heating cables that you need to connect when you assemble the transport units.

  • Page 77: Connecting Raw Water Pipes

    MECHANICAL INSTALLATION 5.15. Connecting raw water pipes Connect the incoming and outgoing raw water pipes to the flanges of the water cooling unit. NOTE – Installation material such as counter flanges, bolts, nuts and seals are in the loose parts box that was delivered with the drive.

  • Page 78: Electrical Installation

    → Qualified personnel only, who have a thorough knowledge of relevant electrical codes, site, and equipment requirements. → DO NOT switch on main and auxiliary power supplies without ABB consent. → Take preventive measures to ensure power remains off during the installation.

  • Page 79: Auxiliary And Control Cables

    ELECTRICAL INSTALLATION 6.3.3. Auxiliary and control cables NOTICE Risk of false signals! Power supply cables can disrupt signals in control cables. → DO NOT lay control cables in parallel to the power supply cables. If this cannot be avoided, a minimum distance of 30 cm must be maintained between control and power supply cables.

  • Page 80: Grounding The Transformer And An 18-Pulse Drive

    ELECTRICAL INSTALLATION 6.4.1. Grounding the transformer and an 18-pulse drive Figure 49 shows the grounding connections of an ACS5000W drive with an 18-pulse line supply and an input transformer. Input transformer +20° -20° 0° ACS5000W PCU11 PCU21 PCU31 (1) PE busbar (2) Cable screen (3) Cable shield/armor (4) Equipotential bonding conductor (optional)

  • Page 81: Grounding The Transformer And A 36-Pulse Drive

    ELECTRICAL INSTALLATION 6.4.2. Grounding the transformer and a 36-pulse drive Figure 50 shows the grounding connections of an ACS5000W drive with an 36-pulse line supply and an input transformer. Input transformer(s) -20° +20° -20° +20° 0° 0° ACS5000W PCU11 PCU21 PCU31 (1) PE busbar (2) Cable screen...

  • Page 82: Grounding The Drive And The Motor (Multi-Point Bonding)

    ELECTRICAL INSTALLATION 6.4.3. Grounding the drive and the motor (multi-point bonding) Multi-point bonding is the preferred method for voltage source converter applications. NOTE – Multi-point bonding is not allowed for high-speed applications; use single-point bonding instead (see 6.4.3 Grounding the drive and the motor (multi-point bonding) on page 82).

  • Page 83: Grounding The Drive And The Motor (Single-Point Bonding)

    ELECTRICAL INSTALLATION 6.4.4. Grounding the drive and the motor (single-point bonding) Single-point bonding is the preferred method for high-speed applications with fundamental frequencies above 120 Hz. For more information see the “Power cables engineering guideline”, 3BHS542290 E01. Figure 52 shows the single-point bonding connections to ground a drive and a motor in the COU compartment.

  • Page 84: Ground Cable Connection

    ELECTRICAL INSTALLATION 6.4.5. Ground cable connection The ground cable enters the COU compartment from the top or from the bottom. It connects to the PE ground busbar of the adjoining PCU compartment. The ground busbar spans across the entire length of the drive (Figure 53). The connection must be in compliance with local regulations. For project-specific illustrations, see “Appendix D –...

  • Page 85: Exu Cabinet Ground Connections

    ELECTRICAL INSTALLATION 6.4.6. EXU cabinet ground connections For safe operation, the EXU cabinet must be properly grounded: – Connect the ground to the ground system of the installation site and to the ground busbar inside the EXU – Minimum cross-sectional area of the ground conductor must be 16 mm or ½...

  • Page 86: Figure 55 - Wiring Across Shipping Splits, Fs1 And Fs2

    ELECTRICAL INSTALLATION PCU×1 PCU×1 Explanation PCUx1 – PCUx1 (1) Shipping split (2) Cable ducts on each side of the For auxiliary power supply cables, optical fibers, and signal cables shipping split For charging cable (3) Connection point (4) Charging cable behind water pipe (not Laid on the brackets and connected to the busbar illustrated) Figure 55 –...

  • Page 87: Figure 56 - Wiring Across Shipping Splits, Fs3 And Fs4

    ELECTRICAL INSTALLATION PCU×0 PCU×1 PCU×1 PCU×0 Explanation (1) Shipping split PCUx0 – PCUx1 and PCUx1 – PCUxo For auxiliary power supply cables, optical fibers, and signal cables (2) Cable ducts on each side of the shipping split (3) Connection point For charging cable Laid on the brackets and connected to the busbar (4) Charging cable behind water pipe (not...

  • Page 88: Optical Fibers

    ELECTRICAL INSTALLATION 6.5.1. Optical fibers NOTICE Risk of equipment failure! A damaged or incorrectly installed optical fiber cable can degrade data transmission and cause equipment failure. → Handle optical fibers with care. → Only use the designated encoder cable conduit that passes through the drive to the EXU;...

  • Page 89: Cable Entries

    ELECTRICAL INSTALLATION 6.6. Cable entries The drive is prepared for top or bottom cable entry with one or a combination of the following cable entries: – Cable entry with sealing modules, type 1 – Cable entry with cable glands For information on the location and the dimensions of the cable entry, see “Appendix C – Mechanical drawings”.

  • Page 90: Figure 58 - Cable Entry Frame Sizes (Top) For Type 1 Sealing Modules (Bottom)

    ELECTRICAL INSTALLATION L1 L2 L1 L2 RM 120 RM 90 RM 60 Figure 58 – Cable entry frame sizes (top) for type 1 sealing modules (bottom) Table 7 – Type 1 sealing modules and cables per frame opening Frame Location FS1 to FS6 FS1_6p FS2_6p...

  • Page 91: Cable Entry With Sealing Modules, Type 2

    ELECTRICAL INSTALLATION 6.6.2. Cable entry with sealing modules, type 2 Usage Included in delivery Not included in delivery Supplier – Auxiliary power cables Frame (1, Figure 59) – Type 2 sealing modules Roxtec AB (www.roxtec.com) – Control cables (2, Figure 59) –...

  • Page 92: Cable Entry With Emc Plates

    ELECTRICAL INSTALLATION 6.6.4. Cable entry with EMC plates Usage Included in delivery – Power cables – Galvanized plate with EMC mesh (1, Figure 62) – Ground cables – Sealing grommets (2, Figure 62) – Bonding conductors – Auxiliary power cables –...

  • Page 93: Preparing Cables For Cable Entries With Cable Glands

    ELECTRICAL INSTALLATION 6.7.1.2. Preparing cables for cable entries with cable glands Prepare cables with an outer cable screen or shield for EMC bonding with the metal enclosure of the cabinet as illustrated. NOTICE Risk of cable damage! Incorrectly connected pigtails (6, Figure 63) can create unwanted current loops that can damage the cables.

  • Page 94: Preparing Cables For Cable Entries With Sealing Modules

    ELECTRICAL INSTALLATION 6.7.1.3. Preparing cables for cable entries with sealing modules Prepare cables with an outer cable screen or shield for EMC bonding with the metal enclosure of the cabinet as illustrated. Install the sealing modules according to the instructions of the sealing module supplier.

  • Page 95: Connecting The Cables

    ELECTRICAL INSTALLATION 6.7.2. Connecting the cables CAUTION Risk of flashover! High voltages in the terminal unit can cause flashover between the electric potential of different conductors and the electric potential of a conductor and earth. When you route and connect the cables, maintain the following minimum clearances: →...

  • Page 96: Figure 65 - Pcu 12-Pulse Top And Bottom Entry (Back View)

    ELECTRICAL INSTALLATION 6.7.2.2.1. Transformer cables ACS5000W, 36-pulse (1) Top cable entry (4) Bottom cable entry (2) Top cable entry – second opening (FS3/FS4 only) (5) Bottom cable entry – second opening (FS3/FS4 only) (3) Busbars for transformer cables Figure 65 – PCU 12-pulse top and bottom cable entry (back view) 6.7.2.2.2.

  • Page 97: Motor Cables

    ELECTRICAL INSTALLATION 6.7.2.2.3. Motor cables a) COU FS1/FS2 b) COU FS3/FS4 (1) Top cable entry (2) Busbars for motor cables (FS1 and FS2) (3) Bottom cable entry Figure 67 – COU cable terminals PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W gen.

  • Page 98: Bolted Connections

    If a coated nut (eg, with bonded molybdenum-disulfide [MoS ] coating) is used, the connection does not have to be lubricated. 6.7.2.3.4. Tightening torque ABB recommends a tightening torque of 40 Nm for M10 bolts. For other sizes, follow the manufacturer’s recommendations. PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 99: Auxiliary Power Cables And Control Cables

    ELECTRICAL INSTALLATION 6.8. Auxiliary power cables and control cables See “Appendix C – Mechanical drawings” for information on: – Project-specific cable entry – Dimensions between point of cable entry and terminals See “Appendix D – Wiring diagrams” for information on: –...

  • Page 100: Preparing Cables For Cable Entries With Sealing Modules

    ELECTRICAL INSTALLATION 9. Pull the cable (1) through the entry plate (2). 10. To prevent water from entering the cabinet, fit the grommet (3) tightly and seal any gaps with silicone. 11. If you removed the entry plate, reinstall the plate, and fasten it properly.

  • Page 101: Preparing Cables For Cable Entries With Cable Glands

    ELECTRICAL INSTALLATION 6.8.1.5. Preparing cables for cable entries with cable glands Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated (Figure 70). (1) Outer cable sheath (2) Cable gland (3) Conductor insulation removed to expose cable shield (4) Plate (5) Conductor screen extension to be connected to PE terminal...

  • Page 102: Routing And Connecting Low Voltage Cables

    ELECTRICAL INSTALLATION 6.8.2. Routing and connecting low voltage cables For the project-specific cable connections, see “Appendix D – Wiring diagrams”. For a description of the different cable entry types, see 6.6 Cable entries on page 6.8.2.1. WCU - auxiliary power and space heater cable For an overview of the components in a WCU cabinet, see 3.5 Water cooling unit (WCU) on page The following cables are typically connected to the WCU.

  • Page 103: Figure 72 - Top And Bottom Cable Routing In Wcu800 And Wcu1400 Cabinets

    ELECTRICAL INSTALLATION 6.8.2.1.1. Top and bottom cable entries Referring to Figure 72: 1. Route the cables to the terminal compartment (1). • Top cable entry: via (2) or (4) • Bottom cable entry: via (3) or (6) NOTE – Use cable ties to attach the cables to the cable ladder (7) or cable duct (5). 2.

  • Page 104: Cou - Ups Supply And Control Signal Cable

    (11) Shield grounding busbar (for process and encoder (4) S500 I/O process system cabling) (customer- specific configuration) (12) Cable route (5) ABB Ability™ (13) Customer terminal for standard process interface (6) Customer terminals for control I/O extension (optional) (14)Fieldbus (7) Speed and position encoder interface...

  • Page 105: Figure 74 - Cable Routing In Cou Cabinet

    ELECTRICAL INSTALLATION (1) Top cable entry (2) Bottom cable entry Figure 74 – Cable routing in COU cabinet 6.8.2.2.1. Shielded cables – Keep the unshielded ends of twisted pair cables twisted until they reach the terminals. – Keep unshielded conductor ends as short as possible. –...

  • Page 106: Fieldbus Interface

    • Shield grounding busbar (11, Figure 73) 6.8.2.2.5. Fieldbus interface 1. Connect the fieldbus cable to the module (13, Figure 73). 2. Connect the shield of fieldbus cables to the fieldbus adapter. 6.8.2.2.6. ABB Ability™ gateway (NETA-21) – Connect the Ethernet cable to the ETH2 port.

  • Page 107: Figure 75 - Exu Cable Routing Examples

    ELECTRICAL INSTALLATION a) EXU cabinet with ED5V, EB5R, EB5S, EB7P or EB7Q type b) EXU cabinet with an ED7Y type DCS880 converter DCS880/DCT880 converter (1) Cable enters through roof (2) PE ground busbar (3) Cable enters through the floor (4) Terminal strip for auxiliary power and control cables (5) Auxiliary supply cable (6) Terminal for optical fibers behind cover (7) Optical fibers to DCS880 H4 converter...

  • Page 108: Figure 76 - Dcs880/Dct880 H4 Converter (Ed5V, Eb5R, Eb5S, Eb7P And Eb7Q Types)

    ELECTRICAL INSTALLATION 6.8.2.3.2. Optical fiber cables NOTICE Risk of equipment failure! Handle optical fibers with care. A damaged or incorrectly installed optical fiber cable can degrade data transmission and cause equipment failure. → Only use the designated encoder cable conduit that passes through the drive to the EXU.

  • Page 109: Figure 77 - 1 Control Unit Sdcs-Con-H01

    ELECTRICAL INSTALLATION 6. Connect the two optical fibers to the receptacles of slot 1 according to the terminal numbers printed on the marker sleeves. (1) Slot 1 (FDCO-01 module (2) Control panel Figure 77 – 1 Control unit SDCS-CON-H01 7. Route the cables through the designated cable ducts as illustrated in Figure 78. (1) Cable enters through roof (2) PE ground busbar (3) Cable enters through the floor...

  • Page 110: Figure 79 - Dcs880/Dct880 Converter (Ed7Y)

    ELECTRICAL INSTALLATION 6.8.2.3.4. Routing cables in an EXU cabinet with an ED7Y type DCS880/DCT880 converter 1. Unscrew the rectangular cover from the DCS880/DCT880 unit. (1) Control panel (2) Removable cover Figure 79 – DCS880/DCT880 converter (ED7Y) 2. Connect the two optical fibers to the receptacles of slot 1 according to the terminal numbers printed on the marker sleeves.

  • Page 111: Figure 81 - Cable Routing Example In An Exu Cabinet With An Ed7Y Type Dcs880/Dct880 Converter

    ELECTRICAL INSTALLATION 3. Route the cables through the designated cable ducts as illustrated in Figure 81. (1) Cable enters through roof (2) PE ground busbar (3) Cable enters through the floor (4) Terminal strip for auxiliary power and control cables (5) Auxiliary supply cable (6) Terminal for optical fibers behind cover (7) Optical fibers to DCS880/DCT880 converter...

  • Page 112: 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 113: Commissioning Checklists

    7.6.2. Electrical installation checklist ☐ 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 114: Main Circuit Breaker (Mcb) Checklist

    COMMISSIONING 7.6.3. Door interlocking checklist ☐ The release dial of the safety switches in the locked position. 7.6.4. Main circuit breaker (MCB) checklist ☐ MCB selected as per “Main circuit breaker specification” ☐ Pay attention to MCB opening time and installation of undervoltage coil or second opening coil ☐...

  • Page 115: Miscellaneous Checklist

    COMMISSIONING 7.6.8. Power checklist ☐ Medium voltage available for startup of drive. ☐ Low voltage is available for startup of drive. 7.6.9. Miscellaneous checklist ☐ Sufficient number and correct type of spare parts available ☐ Sufficient quantity of deionized water according is available. (see “Appendix C – Mechanical drawings”).

  • Page 116: Operation

    8. Operation 8.1. Overview This chapter describes how to locally operate an ACS5000 drive or EXU from an assistant control panel (ACP). The COU and the EXU have separate control panels. NOTE – Control of the drive via a PLC or higher-level control system is not described. If the drive is controlled remotely, see the applicable manuals for more information.

  • Page 117: Navigating The Home View

    OPERATION 8.3.1. Navigating the home view The main view in the control panel display is called Home view. In Home view you can monitor the Home status of the drive, such as drive speed, torque, or power. The view has one or more pages, each of which can display up to three signals.

  • Page 118: Exu Control Panel

    OPERATION 8.3.3. EXU control panel The EXU control panel allows you to control the operation of the DCS880 or DCT880 unit in the EXU cabinet as well as set the parameters and view the status data of the EXU. For an overview of the control panel buttons and usage, see 8.3 Control panels on page 116.

  • Page 119: 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 8.4. Lamp test The illuminated push buttons on the COU and PCU doors can be tested.

  • Page 120: Status Messages

    OPERATION 8.5. Status messages The following section lists the status messages of the main operating states that the drive passes through when: – Drive is put into operation (see 8.5.1 Start sequence of the drive on page 121) – Drive is stopped (see 8.5.2 Stop sequence of the drive on page 122) –...

  • Page 121: Start Sequence Of The Drive

    OPERATION 8.5.1. Start sequence of the drive 1) NotReadyOn 2) ReadyOn • Auxiliary power supply on • PCU doors closed and locked • Drive not grounded • No emergency-off • No fault • WCU ready 3) On command 4) Charging •...

  • Page 122: Stop Sequence Of The Drive

    OPERATION 8.5.2. Stop sequence of the drive 1) Operation 2) ReadyRef 3) Stop command 4) Stopping • Speed ramps down • Inverter stops modulating 5) ReadyRun 6) Off command • MCB opens • DC-link discharges • Cooling system switches off after a delay 7) ReadyOn •...

  • Page 123: Starting The Drive

    OPERATION 8.6. Starting the drive DANGER Hazardous voltages! Accidental contact with energized components can cause serious injury or DEATH. Before operating the drive: → Remove all foreign objects from the drive → Secure and fasten all covers → Close all doors and lock the doors of the medium voltage compartments →...

  • Page 124: Checks Before Starting The Drive

    OPERATION 8.6.1. Checks before starting the drive When the drive is put into service after it has been commissioned, or after it has been taken out of service for a longer period, use the following check list: ☐ Tools and foreign objects are not in the cabinet. ☐...

  • Page 125: Stopping The Drive

    OPERATION 8.7. Stopping the drive 8.7.1. Stopping the drive remotely When the drive system is operated from a higher-level control system or an operator control desk, follow the instructions in the applicable manuals. 8.7.2. Stopping the drive locally You can stop the drive locally with the control panel on the COU. 1.

  • Page 126: Resetting The Emergency Off Push Button

    The optional “Arc Resistant Design” provides the drive with arc fault protection in accordance with IEC 62477-2. The ABB arc resistant classes in Table 11 indicate the type of arc proofing that a drive uses. Depending on the drive configuration, classes I and IV are available for an ACS5000W gen. 3.

  • Page 127: Internal Arc Classification (Iac)

    OPERATION Table 11 – ABB arc resistant classes ABB class Description Class I Protection based on arc prevention (NOT certified according to IEC 62477-2) Class II Protection based on arc resistant cabinet structure, IAC certified by 3rd body according to IEC 62477-2 Class III Protection based on external arc fault limitation and elimination.

  • Page 128: Action After The Arc Guard System™ Has Been Triggered

    OPERATION 8.8.3. Action after the Arc Guard System™ has been triggered 1. De-energize and ground the drive according to 9.4.2 De-energizing the drive on page 135. 2. Search for the location where the arc has been detected. 3. Check the Arc Guard HMI panel messages and use the circuit diagrams. Figure 88 –...

  • Page 129: 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 may only be carried out by certified personnel.

  • Page 130: Identifying Electrical Equipment

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.2. Identifying electrical equipment 9.2.1. Device designation To facilitate the identification in wiring diagrams and parts lists, all devices are labeled in accordance with IEC 81346-1. CONNECTED TO NEXT UNIT -A2521 -A2531 -A2511 -XSHLD3 -A2511 -A2511 TU518 Figure 89 –...

  • Page 131: Drive Status Indicators

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.3. Drive status indicators The drive has hardware and software indicators that show the status of the drive, drive component, or equipment that is monitored by the drive, eg, MCB, transformer, or cooling system. 9.3.1. Alarm and fault indicators When a failure occurs in the drive or in the equipment monitored by the drive (eg, main circuit breaker, transformer, cooling system), the control panel displays a corresponding alarm or fault message and the alarm / fault lamp on the control compartment door lights up:...

  • Page 132: 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: • Operating, ambient and load conditions •...

  • Page 133: Leds And Switches On Circuit Boards And I/O Devices

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.3.3. LEDs and switches on circuit boards and I/O devices This section provides an overview of the meaning of LEDs and switches of the main circuit boards and I/O modules. The LEDs can be checked easily while the auxiliary voltage is switched on without having to remove covers first.

  • Page 134: S500 I/O Modules

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.3.3.2. S500 I/O modules The S500 modules have protected outputs and are used for comprehensive diagnosis that covers a wide range of signal types. For more information about diagnostic and LED states, see “System assembly and device specifications for AC500 V2 Products”, 3ADR010121.

  • Page 135: Safety

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.1. Safety DANGER Hazardous voltages! Risk of life-threatening injury or DEATH. → Before you work on the drive, carry out the steps in 2.3.2 The 7 steps that save lives on page After the work is complete and before you energize the drive: →...
  • Page 136 PREVENTIVE AND CORRECTIVE MAINTENANCE 3. Press the SUPPLY OFF push button to disconnect the drive from the main power supply. The following happens: • MCB opens • DC-link discharges SUPPLY OFF • push button flashes and remains on after the DC-link has discharged Ready •...

  • Page 137: Opening And Closing The Doors

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.3. Opening and closing the doors 9.4.3.1. Releasing the doors (1) White lamp: Lights up to indicate that the drive is grounded and you can slide the locking bar to the unlocked / locked position. (2) Yellow lamp: Lights up when the grounding switch has been released.

  • Page 138: Opening The Doors

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.3.2. Opening the doors 1. To release the door handle, insert and turn the key to the right. The door handle pops out. 2. Turn the door handle: • Right if the door is hinged on the right •...

  • Page 139: Grounding The Drive When The Grounding Switch Is Not Released

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.4. Grounding the drive when the grounding switch is not released When the DC link of the drive has been discharged, the lamp GROUNDING SWITCH UNLOCKED lights up to indicate that the grounding switch is released and can be turned to the grounded position. If the lamp does not turn on, take the following steps.

  • Page 140: Emergency Release Of A Door Safety Switch

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.5. Emergency release of a door safety switch DANGER Hazardous voltages! Risk of life-threatening injury or DEATH! → Before you unlock a safety switch, de-energize and ground the drive according to 9.4.2 De-energizing the drive on page 135 →...

  • Page 141: Safety-Switch Settings

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.5.2. Safety-switch settings (1) Release dial (2) Unlocked position: enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off. (3) Locked position: Normal operating setting Figure 93 – Safety switch 9.4.5.2.1.

  • Page 142: Visual Checks On The Drive

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.6. Visual checks on the drive Check the drive and its immediate vicinity visually at the intervals stated on the maintenance schedule and pay attention to the following items: – Humidity inside the drive – Permitted range of ambient air temperature and humidity of the drive –...

  • Page 143: 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. 9.4.9. Checking and replacing filter mats Inspection intervals See the “ACS5000 preventive maintenance schedule”, 3BHS855274 E01. Service during operation Possible Filter mat class...

  • Page 144: Replacing Filter Mats

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.9.1. Replacing filter mats You can replace PCU and WCU filter mats. CAUTION Cooling fans start automatically. Cooling fans start automatically in response to temperature levels. → Switch off the protection switch for the cooling fan according to “Appendix D – Wiring diagrams”.
  • Page 145 PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.9.1.2. Replacing a WCU filter mat Although checking and replacing the filter mats of the WCU compartment is possible during operation of the drive, it is easier to do it when the drive is shut down. 1.

  • Page 146: Replacing A Fan In An Ip42 Roof-Mounted Cooling Unit

    In case of fan failure, the redundant fan begins operating and the red indicator light on the front of the cooling unit turns on. If you need to replace a fan in a roof-mounted cooling unit, contact ABB. DO NOT attempt to replace the fan yourself.

  • Page 147: Replacing A Fan In An Ip54 Roof-Mounted Cooling Unit

    In case of fan failure, the redundant fan begins operating and the red indicator light on the front of the cooling unit turns on. If you need to replace a fan in a roof-mounted cooling unit, contact ABB. DO NOT attempt to replace the fan yourself.

  • Page 148: Replacing A Fan In An Exu With A Dcs880 H4/Dct880 T4 Controller

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.12. Replacing a fan in an EXU with a DCS880 H4/DCT880 T4 controller Figure 96 – DCS880 controller - size H4 1. Switch off the miniature circuit breaker of the fan unit. NOTE – To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 2.
  • Page 149 PREVENTIVE AND CORRECTIVE MAINTENANCE 3. Unplug the fan cables. 4. Remove the 4 fastening screws from the outside panel of the fan unit. 5. Pull the fan out of fan unit in the cabinet. CAUTION! To prevent the fan from falling onto you, place a support (ie, a box) underneath. 6.

  • Page 150: Replacing A Fan In An Exu With A Dcs880 H6 Unit

    PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.13. Replacing a fan in an EXU with a DCS880 H6 unit Figure 97 – DCS880 controller - size H6 1. Switch off the miniature circuit breaker of the fan unit. To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 2.
  • Page 151 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 ACS5000W gen. 3 User manual 3BHS904690 E01 151/153...
  • Page 152 PREVENTIVE AND CORRECTIVE MAINTENANCE 5. Pull the fan out of the fan unit in the cabinet. 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.
  • Page 153 /153 — ABB Switzerland Ltd. Bruggerstrasse 66 CH-5400 Baden Switzerland new.abb.com/drives/medium-voltage-ac-drives — © Copyright 2024 ABB. All rights reserved. The information in this document is subject to change without notice.