ABB ACS580MV Hardware Manual
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ABB ACS580MV Hardware Manual

ABB ACS580MV Hardware Manual

200 kw to 6300 kw, 6 kv to 11 kv
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ABB industrial drives
Hardware manual
ACS580MV drives
(200 kW to 6300 kW, 6 kV to 11 kV)
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Summary of Contents for ABB ACS580MV

  • Page 1 ABB industrial drives Hardware manual ACS580MV drives (200 kW to 6300 kW, 6 kV to 11 kV)
  • Page 2 You can find manuals and other product documents in PDF format on the Internet. See http://www.abb.com/motors&drives. For manuals not available in the Document library, contact your local ABB representative. For more information, please refer to ACS580 MV Hardware Manual which can be found by scanning the QR code below.
  • Page 3 200 kW to 6300 kW 6 kV to 11 kV Table of contents Safety instructions Transportation, storage and disposal Mechanical installation Electrical installation Operation Maintenance  2019 ABB Beijing Drive Systems Com- 2UBB004520 Rev E pany Ltd, All Rights Reserved. EFFECTIVE:2019-06-27...

  • Page 5: Table Of Contents

    Table of contents Terms ............. . . 11 Trademarks .
  • Page 6 Power module ............30 Charging circuit .
  • Page 7 Storage conditions ........... 57 Preparing cabinets for storage .
  • Page 8 Connecting the cables ..........82 Control and power supply cables for fan units .
  • Page 9 Unlocking ............110 Cleaning the interior of the cabinet .

  • Page 11: Terms

    The following table lists the terms and abbreviations you should be familiar with when using the manual. Some of the terms and abbreviations used in the manual are unique to ABB and might differ from the normal usage. Term / Abbreviation...

  • Page 12: Trademarks

    The power module is a compact assembly of electronic components including power semiconductors and circuit boards that serves as a standardized building block for the INU of the drive. Safeline ABB synonym for uninterruptible power supply. Terminal Unit Short form for terminal compartment of the drive. Transformer unit Short form for transformer compartment of the drive.

  • Page 13: Safety Instructions

    Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Safety instructions are used to highlight a potential hazard when working on the equipment.

  • Page 14: User's Responsibilities

    14 Safety instructions • ANSI Z535.6 American National Standard for Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials User’s responsibilities It is the responsibility of those in charge of the drive to ensure that each person involved in the installation, operation or maintenance of the drive has received the appropriate training and has thoroughly read and clearly understood the instructions in this manual and the relevant safety instructions.

  • Page 15: Possible Residual Risks

    Safety instructions 15 Possible residual risks The following risks can arise from a drive system and pose a hazard to people. These risks must therefore be taken into account by the system integrator and / or the plant owner when assessing the risks of the machinery. •...

  • Page 16: Safety Labels

    16 Safety instructions Safety labels Safety labels are attached to the cabinet where necessary to alert personnel of potential hazards when working on the equipment. The instructions on the safety labels must always be followed, and the labels must be kept in a perfectly legible condition. DANGER NOTICE Hazardous voltage inside!

  • Page 17: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 17 Electrical safety in installation, start-up and maintenance Precautions before electrical work  These warnings are for all personnel who do work on the drive, motor cable or motor. DANGER High voltage! Before starting to work on the drive, make sure: •...

  • Page 18: Additional Instructions And Notes

    This is necessary for the personnel safety. Proper grounding also reduces electromagnetic emission and interference. • Make sure that the cross-section of the grounding conductors is sufficient. See the ACS580MV Engineering Guideline. Obey the local regulations.

  • Page 19: Introduction To The Manual

    ACS580MV medium voltage drive. This manual and parts thereof must not be reproduced or copied, or disclosed to third parties, nor used for any unauthorized purpose without written permission from ABB Beijing Drive Systems Company Ltd. The hardware and software described in this manual is provided under a license and may be used, copied, or disclosed only in accordance with the terms of such license.

  • Page 20: Target Groups And Required Qualifications

    (e.g. outline drawings, wiring diagrams, technical data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB. Target groups and required qualifications 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 21: Maintenance

    Introduction to the manual 21 Maintenance  The personnel include all persons who • are qualified to carry out preventive and corrective maintenance on drive as described in this manual • are thoroughly familiar with the drive • have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment •...

  • Page 22: Intended Equipment Use

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 23: Function And Hardware Description

    Product overview The air-cooled ACS580MV is a general purpose frequency converter for the control of standard induction motors. It is used for a wide variety of applications in different industries with a voltage of 6 kV to 11 kV and a power range of 200kW to 6300 kW.

  • Page 24: Rating Plate

    For information on the power and voltage range of your drive, see the Technical data Rating plate of the drive. For further information on the general drive characteristics, refer to the ACS580MV catalog. Drive unit Transformer unit (TRU) Local control panel (rear side)
  • Page 25 (1 in figure below). An example label is shown below. Description Location of rating plate Type designation, see ACS580MV catalog. Ratings Compliance information Serial number. Label with MV full typecode for ABB internal use is pasted below the rating plate.

  • Page 26: System Overview

    (option: 10 Min internal UPS) Command: MCB close, MCB open Cabinet heater 220-240 V AC System overview and single line diagram The ACS580MV drive consists of the following parts: • integrated input transformer with multiple secondary windings (TRU) • power modules connected in cascaded h-bridge technology (INU) •...

  • Page 27: Auxiliary Power Supply

    The power feed for the auxiliary supply must be protected with a suitable circuit protection rated for the inrush current. For information on the type dependent auxiliary power consumption figures, see ACS580MV power supply consumption of the drive in the ACS580MV Engineering Guideline.

  • Page 28: Terminal Unit

    28 Function and hardware description Terminal unit  Voltage dividers Motor side terminals Input terminals Cable entry plate Cabinet grounding busbar Terminal compartment with cover plate removed The terminal unit (TEU) is located behind the control unit (COU). A bolted protection plate separates the two compartments.The plate is integrated into the protection loop to prevent access when the drive is energized.

  • Page 29: Transformer Unit

    Function and hardware description 29 For further information on the cable entry, see • ACS580MV Base frame & TEU layout design • Chapter Electrical installation, Cable entries for external connections. Transformer unit  The integrated input transformer is placed on the right side of the drive. It is delivered as a separate unit (TRU) and joint with the converter unit at the final installation location.

  • Page 30: Power Module

    30 Function and hardware description   Fan unit Control hub Power modules phase A Power modules phase B Power modules phase C Inverter unit (drive type 11R6) Power module  Three types of power modules are used: • Power module 0 (frame sizes R1, R2, R3) •...
  • Page 31 Function and hardware description 31 Input cables (3 phases) Power cable terminals Input fuses Fiber optic terminal Output busbar (behind cable terminals) Power module 0/1(frame size R1 - R6) F1, F2 Input fuses D1 - D6 Diode rectifier bridge DC circuit capacitor S1 - S4 Inverter IGBTs Charging resistor...

  • Page 32: Charging Circuit

    32 Function and hardware description Each power module integrates in one single housing a • 6 pulse diode rectifier bridge • DC circuit • inverter IGBTs • gate driver electronics. The active 3-phase unit is designed as a self-commutated, multi-level voltage source inverter.

  • Page 33: Control Unit

    Function and hardware description 33 during the DC link capacitors discharge. After the DC link capacitors have discharged completely the cabinet doors of the power compartments unlock and the SUPPLY OFF pushbutton changes to a permanent light. The power modules can the be grounded with the supplied grounding hook (for details see Shutting down the drive for maintenance).
  • Page 34 34 Function and hardware description   CVMI2 board Cabinet heater (optional) Control compartment with swing frame closed Local control panel and pushbuttons Sealing grommets for cable top entry Control compartment with front door closed...

  • Page 35: Cabinet Design

    Cabinet design The cabinet has been designed using the MNS cabinet system of ABB. The design consists of a skeletal frame to which the outer panels are bolted to. Corrosion resistant materials are used to protect the cabinet from corrosion.
  • Page 36 36 Function and hardware description Door of control compartment: lockable Cover plates to TEU with safety contact: bolted. The main power cannot be switched on when the plate is removed. Doors of INU compartment: electromechanically locked Doors of transformer unit: bolted  ...

  • Page 37: Cooling System

    Function and hardware description 37 Cooling system The drive unit and the transformer unit are each equipped with one or several fan units, depending on the drive type. Optionally, the drive and the integrated transformer can each be equipped with a redundant fan configuration. This configuration ensures that the operation of the drive system is not interrupted if a fan fails.

  • Page 38: Temperature Monitoring

    38 Function and hardware description Air flow through the drive When a fan of the drive or a fan of the integrated transformer fails, the control system of the drive switches on the stand-by fan automatically in case of redundant fans. The failure of a fan is indicated on the control panel of the drive.

  • Page 39: Control System And Interfaces

    Control system and interfaces 39 Control system and interfaces Contents of this chapter This chapter contains an overview of the control system, the default I/O connection diagram, descriptions of the terminals and contains references to related manuals and documentation. Main components The control compartment incorporates the hardware for the control, monitoring and protection functions of the drive, and the communication interfaces to the local control panel and to the remote control devices.

  • Page 40: Control Block Diagram

    40 Control system and interfaces Control block diagram  Higher level control system Customer IO Drive Tool ACS-AP-S panel PC Drive Motor Composer protection AX5x1 DX5x1 USB-RS485-WE-1800-BT relay AC500eco (IO controller) NETA-21 DDCS PC Drive Startup FSCA-01 FDCO-02 BIOC-01 ZMU-02 CVMI2 Control hub PEBB control board...

  • Page 41: Control Unit (Bcu)

    The actual configuration of the I/O extensions and fieldbus adapters can be derived from the option codes in the ordering code of the drive (for identification refer to the ACS580MV catalog). Typical configuration includes one I/O extension adapter plus one fieldbus...

  • Page 42: Control Tasks

    42 Control system and interfaces For the related manuals refer to the project documentation, containing the relevant Manuals and quick guides for I/O extension modules, fieldbus adapters, etc. Control tasks  The BCU has specific control and closed-loop tasks assigned to it. It processes drive and status information, performs the speed and torque control tasks, and monitors the operation of the drive.

  • Page 43: Control Locations And Operating Modes

    ACS580MV primary control program firmware manual Control locations and operating modes The ACS580MV has two main control locations: external and local. The control location is selected with the Loc/Rem key on the control panel or in the PC tool. Refer to ACS580MV primary control program firmware manual.

  • Page 44: Supply Off/On Pushbuttons

    44 Control system and interfaces Control panel Supply OFF/ON pushbuttons and indication lamps Alarm (flashing) / Fault (on) indication light Emergency Reset button (optional for SIL3) Emergency off button Local operating elements Supply OFF/ON pushbuttons  The SUPPLY OFF pushbutton is used to disconnect the drive from the main power supply. It is illuminated when the MCB is open and the drive is discharged.

  • Page 45: Alarm And Fault Indications

    I/O interfaces Customer control and process I/Os  This chapter provides an overview of the hardwired I/Os. For details refer to ACS580MV Engineering Guideline and ACS580MV Catalog. Please note that this I/O interface only available in standard option, if Synchronized...
  • Page 46 46 Control system and interfaces XPOW External power input +24VI 24 VDC, 2 A (internally used) XA I Reference voltage and analog inputs +VREF 10 VDC, R 1…10 kohm -VREF -10 VDC, R 1…10 kohm AGND Ground AI1+ Speed reference AI1- 0(2)…10 V, R >200 kohm...
  • Page 47 Control system and interfaces 47 Customer Interface Terminal Block Customer Interface Terminal Block floating contacts to customer MCB close cmd making capability: 40 A thermal current: Ith = 6 A @40°C breaking capability: MCB open cmd AC-15 50 Hz Ie(240 V)=4 A, Ie(500 V)=2 A DC-13 Ie(24 V)=2.5 A, Ie(110 V)=0.7 A, Ie(240 V)=0.4 A minimum load: 17 V, 5 mA MCB trip/unlock cmd 1...
  • Page 48 48 Control system and interfaces Reference voltage and analog inputs AI1+ Speed reference (Hand) AI1- 0(2)…10 V, R >200 kohm AI2+ Speed reference (AuTO) AI2- 0(4)…20 mA, R >100 ohm Digital inputs Stop (0) / Start (1) - Hand Forward (0) / Reverse (1) - Hand Hand (0) / Auto (1) Constant speed 1 (1 = On) Forward (0) / Reverse (1) - Auto...

  • Page 49: I/O Signal Requirements

    Control system and interfaces 49 I/O signal requirements  See the Technical data. Communication interfaces  See the ACS580MV primary control program firmware manual and the Technical data.
  • Page 50 50 Control system and interfaces...

  • Page 51: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
  • Page 52 52 Guidelines for planning the electrical installation...

  • Page 53: Transportation, Storage And Disposal

    Transportation, storage and disposal 53 Transportation, storage and disposal Contents of this chapter This chapter provides information and instructions for transportation, storage and disposal of the drive. Safety The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment.

  • Page 54: Unpacking And Inspection

    Check the drive and accompanying equipment for damages. Compare the complete delivery with the purchase order and the packing list. If parts are missing or damaged, immediately inform the shipping company and ABB. It is recommended to photograph the damages and send the photographs to ABB.

  • Page 55: Using A Crane

    Transportation, storage and disposal 55 Drive unit Transformer unit Type Height Depth Width Weight Height Depth Width Weight (mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg) 6.6R3 2571 1176 1815 1250 2571 1176 2215 2450 6.6R4 2571 1176 1815 1350 2571 1176 2215...

  • Page 56: Using A Forklift

    56 Transportation, storage and disposal • Observe the center of gravity (see the ACS580MV Gravity Center for Packing). • Lift the cabinet slowly and steadily to the required clearance height maintaining the cabinet in upright position. • Check the horizontal position of the cabinet. Reposition the slings, if necessary.

  • Page 57: Storage

    5 to 85 %, no condensation Cabinets can be stored for up to one year in the original packaging as long as they are not damaged or opened. For information on longer storage periods, contact the ABB service organization. Preparing cabinets for storage ...

  • Page 58: Reforming Capacitors Of The Power Modules

    Printed circuit boards and capacitors need selective treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers.

  • Page 59: Mechanical Installation

    • There is enough free space above the drive to enable cooling air flow, service and maintenance. See the ACS580MV Base frame & TEU layout design. • The floor that the unit is installed on is of non-flammable material, as smooth as possible, and strong enough to support the weight of the unit.

  • Page 60: Necessary Tools

    60 Mechanical installation Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below: • crane, fork-lift (check load capacity!), iron bar, jack and rollers •...

  • Page 61: Cabinet Roof

    AC fans are already mounted when delivered from works. EC fans need to be installed with fan box in the field. For information on the number of fan units to be installed, see ACS580MV Base frame & TEU layout design.

  • Page 62: Bolting Together The Units

    62 Mechanical installation Bolting together the units  Required bolts are attached to the drive unit side wall adjoining the transformer unit. Align the units. Then bolt the units together using the 12 hexagonal bolts with 5N·M(see figure below). Fixing units to the floor ...

  • Page 63: Location Of Tool Kit And Accessories

    Mechanical installation 63 Fixing the base to the floor Location of tool kit and accessories 1. COU Key Key for control unit fix on the door of COU. 2. Combination screws Screws for combining converter and transformer are fixed on the door of control unit. 3.
  • Page 64 64 Mechanical installation driver which is used for open the transformer cabinet is in this box, it should be kept by authorized person, actions without authorization are dangerous. 4. Absorbing material in cabinet - Desiccant Place Desiccant in the cabinet, one bag for per door, position them on the bottom plate uniformly distributed.

  • Page 65: Electrical Installation

    When the electrical installation is completed, the main and auxiliary power supply to the drive must not be switched on without the consent of the ABB commissioning personnel. Take appropriate measures to prevent main and auxiliary power supply from being switched on during installation.

  • Page 66: Cable Requirements

    Cable requirements For information on the requirements for power cables and the ground cable see the ACS580MV Engineering Guideline For information on the requirements for the auxiliary power cable and the control cables, see Auxiliary power and control cables guideline.

  • Page 67: Ground Cable And Cable Shield Connections

    The cabinet is equipped with ground buses (marked PE, Protective Earth) for grounding the armor and shields of the cables, and for the connection of the ground cable. To identify the ground buses, see ACS580MV Wiring Diagram. Grounding of the drive system ...
  • Page 68 68 Electrical installation Input transformer (TRU) Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor Grounding drive system and integrated transformer...

  • Page 69: Cables And Pe Busbar Between Integrated Transformer And Drive

    Electrical installation 69 Cables and PE busbar between integrated transformer and drive   Transformer unit Drive unit Control cable lead-through PE busbar Drive with integrated transformer Cables and PE busbar between drive and integrated transformer includes the following connections: • Transformer primary and secondary cables •...
  • Page 70 70 Electrical installation M8 bolt Dished washers (4 pcs. per terminal) Flat washers (4 pcs. per terminal) M8 nuts (2 pcs. per terminal) Cable shoes Support plate Transformer terminal connections The supply cables for the fan units of the transformer and the control cables are routed through the cable lead-through in the side wall.

  • Page 71: Cable Entries For External Connections

    Cable entry with EMC plates, EMC cushions and sealing grommets for auxiliary and control cables For detailed information e.g. location and dimensions, see ACS580MV Base frame & TEU layout design. Power cable entry via holes in cable entry plate ...
  • Page 72 72 Electrical installation • Galvanized plate (1 in figure below) with EMC cushions (2, 3, 4) and sealing grommets (5). See ACS580MV Base frame & TEU layout design for details and for the possible mounting variants. Lead through plate Bracket...

  • Page 73: Installing Power And Ground Cables

    Electrical installation 73 Installing power and ground cables Further information  ACS580MV Base frame & TEU layout design for information on: • Project-specific cable entry • Distance between the point of cable entry and the termination bars • Busbar and fastening hole dimensions •...
  • Page 74 74 Electrical installation Outer cable sheath Outer cable sheath Entry plate Entry plate Conductor screen extension to be connected to PE Conductor screen extension to be connected to PE ground busbar ground busbar Heat-shrinkable termination Heat-shrinkable termination Sealing compound Sealing compound Power cable termination...

  • Page 75: Connecting The Cables

    Electrical installation 75 Connecting the cables  NOTICE Risk of flashover High voltages will be present in the terminal compartment. High voltages can cause flashover between the electric potential of different conductors, and the electric potential of a conductor and earth. Therefore, a minimum clearance of 59.5 mm must be maintained between a conductor and earth, and 90 mm between a conductor and the terminals of any other conductor.
  • Page 76 76 Electrical installation Voltage dividers Motor side terminals Input terminals Cable entry plate (bottom plate) Terminal compartment with cover plate removed, view from front...
  • Page 77 Electrical installation 77 Power cable entry from top ((1) screen extensions to ground)

  • Page 78: Connections

    78 Electrical installation Power cable entry from bottom ((1) screen extensions to ground) Checking the cable insulation • Check the insulation of each cable before connection and verify that the results are within the specification of the cable manufacturer. • Leave the cables unconnected at both ends until the commissioning personnel has given permission to connect them.

  • Page 79: Installing Auxiliary, Control And Serial Communication Cables

    Tighten bolted connections with bolts of sizes M10 and greater with the recommended nominal torque for the bolt size used. Installing auxiliary, control and serial communication cables Further information  ACS580MV Base frame & TEU layout design for information on: • Project-specific cable entry...

  • Page 80: Preparing The Cable Entry And The Cables

    80 Electrical installation • Dimensions between point of cable entry and terminals ACS580MV Wiring Diagram for information on: • Conventions for cross-references and device identification • Terminal designations Preparing the cable entry and the cables  Determining the cable length Determine the required length of a cable between the point of entry and the connection point inside the cabinet.

  • Page 81: Preparing The Cables

    Electrical installation 81 Preparing the cables  1. Remove the grommets. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter. Slide the grommet onto the cable. The grommet must fit tightly to prevent water from entering the cabinet. 3.

  • Page 82: Connecting The Cables

    82 Electrical installation Preparing control cables for EMC plates 6. Pull the cables through the EMC cushions. 7. Push the cushions together so they fit tightly around the bare screen and tighten the screws. Connecting the cables  • Connect the cables for digital and analog input and output signals to the corresponding terminals / modules.

  • Page 83: Control And Power Supply Cables For Fan Units

    Front cable entry Rear cable entry Fan cable connectors For information on connection details, see ACS580MV Wiring Diagram. Sealing holes in entry plates • Seal the gap between cable and entry plate with the supplied two component sealant. For mixing and applying the sealing compound, follow the instructions on the...

  • Page 84: Final Checks

    84 Electrical installation Final checks • Check that the entry plates are properly fastened and cable entries are correctly sealed.

  • Page 85: Installation Checklist

    Installation checklist 85 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before commissioning can take place. Safety DANGER High voltage! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 86: Checklist

    86 Installation checklist WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. NOTICE! The field engineer should confirm that the power cables are connected to the correct bus bars before switching on the main power. Once the main power direct reach the output bus bars by wrong connections, the power modules would be irreversible damaged.
  • Page 87 - recommended in case of long storage time, humid environment or visible transportation damages) Door interlocking Door locks tested and in operation The manual release of the door safety switch(es) is in the locked position. Main circuit breaker (MCB) Type of MCB selected as per ACS580MV Engineering Guideline...
  • Page 88 88 Installation checklist High voltage connections completed MCB ready to be tested with drive MCB interposing relay settings tested Local close order is disabled, and the connection to switch or button is canceled. The wiring of the control & signal cables connecting with the converter is finished. Safety devices checked and in operation The user manual and technical specification is available.
  • Page 89 Installation checklist 89 Grounding cables of transformer, converter and motor are connected and tighten. Types and cross sections of power cables are selected according to the “ABB power cable specification”. Type of cable Transformer and motor cables are not fastened at both ends (cables and converter must be meggered before connection).
  • Page 90 90 Installation checklist...

  • Page 91: Operation

    (if any) are given in brackets after the name, for example “main switch-disconnector (Q1)”. The same device designations are also used in the , typically. ACS580MV Wiring Diagram Operating conditions The operating conditions for the drive are according to IEC 60721-3-3 ’Stationary use at weather-protected locations’...

  • Page 92: Overview On Drive Status And Sequences

    Stop sequence of the drive), or when a fault condition has occurred. For information on other status messages, such as fault status messages in particular, see ACS580MV primary control program firmware manual. Status indications  The drive status is indicated with a status icon on the control panel.

  • Page 93: Start Sequence Of The Drive

    Operation 93 Start sequence of the drive  Drive not ready Conditions for start: Auxiliary supply on TEU protective plate mounted & TRU / INU door closed and locked Drive not grounded No emergency off active No fault active Drive OFF SUPPLY ON command MCB closes DC link charges...

  • Page 94: Stop Sequence Of The Drive

    94 Operation Stop sequence of the drive  Operation Drive running Stop command Speed ramps down INU stops modulation Drive stopped SUPPLY OFF command MCB opens DC link discharges (15 Min) Fan switches off after a delay Drive OFF Actions: TRU / INU door released for opening Switch off auxiliary supply Drive not ready...

  • Page 95: Emergency Stop Sequence

    Energizing and starting the drive It is recommended to have the following documents at hand when starting the drive locally for the first time after commissioning: • ACS580MV Wiring Diagram to identify the circuit breakers • User’s Manual “ACS-AP-X assistant control panels user’s manual”...

  • Page 96: Starting The Drive From Remote

    96 Operation When the drive is put into service after it has been commissioned, or after it has been taken out of service for maintenance or troubleshooting, check the drive according to the following list: • Check that no tools and foreign objects are left inside the cabinets. •...

  • Page 97: Stopping The Drive

    Operation 97 1. Enable the local control mode of the control panel by pressing the Loc/Rem key (1). The drive is in state Stopped and the display shows 2. Enter the setpoint. See “ACS-AP-X assistant control panels user’s manual” 3. Press the Start key (2) to start the motor. After the motor has been magnetized, the motor speed ramps up to the setpoint.
  • Page 98 DANGER Hazardous voltages! The ACS580MV is not de-energized in the state Stopped. Before doors are opened / removed or work is begun on the drive, the system must first be de-energized (see Chapter Maintenance, Shutting down the drive for...

  • Page 99: Fault Tracing

    Fault tracing 99 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Alarm and fault indications When a failure occurs in the drive or in the equipment monitored by the drive, the control panel displays a corresponding alarm or fault message and the red Fault / Alarm button on the control compartment door lights up: •...

  • Page 100: Warning And Fault Messages

    Alarm pending Drive in fault state. Warning and fault messages In case of an alarm or fault refer to the ACS580MV primary control program firmware manual for the descriptions, causes and remedies of the drive control program warning and fault messages.

  • Page 101: Maintenance

    Maintenance 101 Maintenance Contents of this chapter This chapter contains instructions for preventive maintenance and component replacements and the Maintenance schedule with recommended maintenance intervals. Safety DANGER High voltage! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 102: Preparation For Maintenance Work

    To ensure safe and reliable operation, it is important to use only spare parts recommended and approved by ABB. For information on types and identification codes, see the spare part kits or contact ABB service organization. Shutting down the drive for maintenance...

  • Page 103: De-Energizing The Drive

    Maintenance 103 For details on using the local control panel, see User’s Manual “ACS-AP-X assistant control panels user’s manual”. DANGER Hazardous voltages! For work in the medium voltage circuit of the drive the connection of grounding equipment at the appropriate locations is a must. The grounding equipment ensures that hazardous voltages cannot be fed into the drive neither from the main power supply nor the motor.

  • Page 104: Unlocking And Locking The Doors

    104 Maintenance After the DC link capacitors have discharged completely, the cabinet doors of the power compartments unlock, the SUPPLY OFF pushbutton changes to a permanent light and the status line displays 4. Rack-out, lock-out, ground and tag-out the main power feeder. 5.
  • Page 105 (consisting of two grounding harnesses plus a telescopic insulating pole) for the 3-phase power input. Notice: To adapt grounding harness ordered from ABB, ball type grounding studs are provided as option. Telescopic insulating pole...
  • Page 106 106 Maintenance Voltage dividers Motor side terminals Input terminals Cable entry plate Cabinet grounding busbar Terminal compartment with cover plate removed 4. Use the telescopic insulating pole to connect the busbar grounding clamps to the busbars in the Terminal Unit, and to tighten each connection.

  • Page 107: Grounding Power Module With Grounding Hook

    Maintenance 107 Grounding power module with grounding hook  Since the power modules are on a floating potential, one must check at the module terminals for residual voltages before starting work at the modules. Required tools • Voltmeter or multimeter with impedance of >=10 Mohm (not part of supply) •...

  • Page 108: Procedure

    108 Maintenance Procedure: 1. Open the INU door. 2. Connect the voltage divider probe to the volt-/multimeter and select the appropriate metering range (see the instruction manuals of the devices). 3. Connect the grounding clip of the voltage divider probe to the cabinet (PE busbar, see the instruction manual of the probe).

  • Page 109: Safety-Switch Settings

    If the release dial is in the locked position, unlock the safety switch as described in Safety-switch settings on page 109. ABB can also provide thicker air cassette as optional for high level protection. Safety-switch settings ...

  • Page 110: Unlocking

    110 Maintenance Release dial Unlocked position The unlocked position enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off. Locked position Locked is the normal operating setting. To open the door of a medium  ...

  • Page 111: Cleaning The Interior Of The Cabinet

    Operation, Energizing and starting the drive. Replacing the door air filters Inspect filter mat condition, replace if necessary. Replace filter mat regularly according to PM schedule. see ACS580MV Preventive Maintenance Schedule. ABB also provide air filter cassette as option for higher level protection.

  • Page 112: Cleaning Heat Sinks Of Power Modules

    112 Maintenance Filter 1. Lift the grating and pull it away from the door. 2. Remove the air filter. 3. Place the new filter into the grating. 4. Reinstall the filter and grating in reverse order. Cleaning heat sinks of power modules The heat sink fins of the power modules pick up dust from the cooling air.

  • Page 113: Replacing Roof Ac Fans

    2. Switch off the motor starter of the fan unit to isolate the fan unit from the auxiliary power supply. To identify the motor starter, see the ACS580MV Wiring Diagram. 3. Remove the hex-head combination screws (M6x16) that attach the top cover to the fan box.
  • Page 114 14. Check visually the direction of fan rotation when starting the drive. The correct rotation direction please refer to arrow direction posted on fan box. * Depends on site situation, ACS580MV fan box can be mounted backward, the screw positions are compatible between fan box and cabinet top plate. The procedure can refer to instruction above.

  • Page 115: Required Tools And Equipment

    Maintenance 115 Required tools and equipment  • Screwdriver for M6 and M10 screw • Lifting eye: M8, 2 pieces The fans can be lifted by crane or by hand.

  • Page 116: Replacing Roof Ec Fans

    2. Switch off the motor starter of the fan unit to isolate the fan unit from the auxiliary power supply. To identify the motor starter, see the ACS580MV Wiring Diagram. 3. Remove the hex-head combination screws that attach the top cover to the fan box. Lift the top cover and pull it away from the fan box.
  • Page 117 * depends on site situation, ACS580MV fan box can be mounted backward, the screw positions are compatible between fan box and cabinet top plate. The procedure can refer to instruction above. For details of the EC fan box outline see ACS580MV Air duct interface Outline Drawing of EC Fan Box.

  • Page 118: Replacing The Power Modules

    118 Maintenance Replacing the power modules WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Required manpower and tools  Two persons are required for replacing a power module. The following tools are needed: •...

  • Page 119: Dismounting

    Maintenance 119 Dismounting 1. Stop, de-energize and ground the drive following the steps in section Shutting down the drive for maintenance before you start the work. 2. Switch off all miniature circuit breakers in the control compartment. 3. Ground the power modules according to Grounding power module with grounding hook on page 107.

  • Page 120: Mounting

    Operation, Energizing and starting the drive. Converter module testing and repair Testing and repair of a defective power module is done at ABB works. Send the module in for repair. Replacing the power module fuse R1 - R3 1. Stop, de-energize and ground the drive following the steps in section...

  • Page 121: Replacement Of A Power Module Frame Size R4 - R6

    Maintenance 121 Replacing power module fuse on a module of frame size R1 - R3 Replacement of a power module frame size R4 - R6  The replacement procedure is basically the same for power modules of frame size R1-R3. The main difference is the weight of the module types.
  • Page 122 122 Maintenance Busbar connections Power cable terminals Fixation screws Terminals for fiber optic cables 6. Loosen and detach the two fixation screws in the front of power module. 7. Slide out the power module by hand • Weight of power module: max.

  • Page 123: Mounting

    Operation, Energizing and starting the drive. Converter module testing and repair Testing and repair of a defective power module is done at ABB works. Send the module in for repair. Replacing the power module fuse R4 - R6 1. Stop, de-energize and ground the drive following the steps in section...

  • Page 124: Replacement Of A Power Module Frame Size R7 - R9

    124 Maintenance Replacement of a power module frame size R7 - R9  The replacement procedure is basically as for power module of frame size R4-R6. The main difference is the weight of the module types. Replacement power modules must always be of the same type.
  • Page 125 Maintenance 125 Hoist screw M8X20 5. Disconnect the fiber optic links from the power module.
  • Page 126 126 Maintenance 6. Loosen and detach the three power cables and the two busbars in front of the power module. Busbar connections Power cable terminals Fixation screws Terminals for fiber optic cables 7. Loosen and detach the three fixation screws (M6X16) that attach the power module to the front lock.
  • Page 127 Maintenance 127 stops it again. 10. Connect the second lifting belts to the lifting eyes provided on the power module.
  • Page 128 128 Maintenance 11. Lift again the blocking bar of the front lock, pull the power module completely out of the support module beam and lower it.

  • Page 129: Mounting

    Maintenance 129 WARNING! Weight of power module: max. 65 kg. Obey local regulations when lifting the power modules. Mounting 1. Loosen and detach the two combination screws (M6X16) from the front lifting bar that attach the power module to be replaced.
  • Page 130 130 Maintenance 2. fix the adapt plate to the new power module with two combination screws (M6X16), but don’t fix tightly. Adapt plate screw M6X16 3. Install the new module in reverse order of removal. 4. Adjust the metal plate to alien the middle three holes with lock holes, fix the connection with five combination screws (M6X16).

  • Page 131: Replacing The Power Module Fuse R7 - R9

    Maintenance 131 5. Switch on all miniature circuit breakers in the control compartment. 6. When the work is completed the drive can be started up again. See Chapter Operation, Energizing and starting the drive Replacing the power module fuse R7 - R9 1.

  • Page 132: Reforming Capacitors Of The Power Modules

    132 Maintenance In order to ensure reliable drive operation, replace the power modules according to the maintenance interval table. Reforming capacitors of the power modules  Power modules that are used as spare parts must be installed and operated in a drive every 2 years in order to reform the capacitors and thus reduce the risk of a potential hazard.
  • Page 133 Maintenance 133 Procedure: 1. Stop, de-energize and ground the drive following the steps in section Shutting down the drive for maintenance before you start the work. 2. Switch off all miniature circuit breakers in the control compartment. 3. Unplug all connectors on the BCU. 4.
  • Page 134 134 Maintenance NOTICE In case of a defective ZMU, the drive needs to be re-parametrized. Please contact ABB service. 6. Remove the ZMU: undo the fastening screw B and pull out the memory unit. Real-time clock battery Fastening screws for ZMU...

  • Page 135: Replacing The Sd Memory Card

    After power-up, the BCU scans the memory unit. If a different control program or different parameter settings are detected, they are copied to the BCU. This can take several minutes. 10. Contact ABB service as soon as possible to obtain a new license before the trial mode expires. NOTICE After a BCU or memory replacement, the license might not match the new hardware.

  • Page 136: High Voltage Divider Board

    136 Maintenance the drive for maintenance before you start the work. 2. Switch off all miniature circuit breakers in the control compartment. 3. Undo the fastening screw and remove the battery (see A in figure Replacement of BCU components above). 4.

  • Page 137: Control Hub Daughter Board

    Maintenance 137 1. Stop, de-energize and ground the drive following the steps in section Shutting down the drive for maintenance before you start the work. 2. Switch off all miniature circuit breakers in the control compartment. 3. Unplug all fiber optic links on the daughter boards and fiber optic links Y1,Y2,Y3,Y4, power supply connector (X1), signal connectors (X2) and the pressure tube.
  • Page 138 138 Maintenance 5. Pick the daughter board to be replaced and withdraw. 6. Install the new daughter board in reverse order. 7. When the work is completed the drive can be started up again. See Chapter Operation, Energizing and starting the drive.

  • Page 139: Maintenance Schedule

    Depending on the actual condition of the drive, the maintenance work can be carried out before or after the recommended interval. For detailed inspect and replacement time interval. See ACS580MV Preventive Maintenance Schedule...

  • Page 140: Drive Seasonal Operation

    PEBBs. If really needed, contact ABB. Air inlet and outlet are clean All air filter mats are clean. Otherwise, replace with new ones from ABB. It is prohibited to wash the filter mats because the tissue structure will be destroyed No dust and corrosion in cabinet No tools and foreign objects are left inside the cabinets.

  • Page 141: Start The Drive Following Chapter Of "Operation

    SUPPLY ON. • Reform DC-link capacitors in Power modules and spare power modules If the stock age more than 1year following 2UBB017371_ACS580MV capacitor reforming instruction. ABB provide standard drive startup service package. 400-810-8885...
  • Page 142 142 Maintenance...

  • Page 143: Technical Data

    For the technical specifications of the drive, e.g. ratings sizes and technical requirements see the following documents: For technical data, drive types and options refer to ACS580MV Catalog. For mechanical layout, dimensions and required free space see ACS580MV Base frame &...

  • Page 145: Product And Service Inquiries

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 146 Contact us www.abb.com/drives www.abb.com/drivespartners 2UBB004520 Rev E(EN) 2019-06-27...

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