Page 1 — SYSTEM DRIVES ACS5000 water-cooled User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL ABB Switzerland Ltd. 2020-11-18 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS799208 E01 1/178 © Copyright 2009 ABB. All rights reserved.
Page 2 It is the sole responsibility of the buyer of the products to provide and continuously ensure a secure connection between the product and the system network and/or any other networks that may be connected to the product. ABB is in no event liable for the security of the network used by buyer.
Page 3: Table Of Contents
CONTENTS — Contents 1. About this manual ................15 1.1. Equipment covered by this manual ..........15 1.2. Structure of the user documentation ..........15 1.3. Related documents ................16 1.4. Terms and abbreviations ..............17 1.5. Target groups and required qualification ........19 1.5.1.
Page 4 CONTENTS 3.9.1. Locking bars ................54 3.10. Grounding studs ................56 3.10.1. Grounding set ................ 56 3.10.2. Output grounding studs in COU ..........57 3.10.3. Input grounding studs in a PCU ........... 58 4. Transportation, storage and disposal ..........59 4.1.
Page 5 CONTENTS 6.2. Overview ..................... 85 6.3. Cable requirements ................85 6.3.1. Power cables ................85 6.3.2. Auxiliary and control cables ..........85 6.4. Grounding ..................86 6.4.1. Grounding the transformer and an 18-pulse drive ....86 6.4.2. Grounding the transformer and a 36-pulse drive ....87 6.4.3.
Page 6 CONTENTS 7.6.4. Main circuit breaker (MCB) ............ 115 7.6.5. Input transformer checklist ........... 115 7.6.6. Motor checklist ............... 116 7.6.7. Insulation tests checklist ............116 7.6.8. Power checklist ............... 116 7.6.9. Miscellaneous checklist ............116 8. Operation ..................117 8.1. Operating conditions ................
Page 7 CONTENTS 9.2.3.3. User lock ............... 147 9.2.4. Functions mode ..............148 9.2.4.1. Adjusting the display contrast ........148 9.2.5. Local and remote control mode ..........150 9.2.5.1. Local control ..............150 9.2.5.2. Disabling / enabling local lock function ....150 9.2.5.3.
Page 8 CONTENTS 10.6.9.2. Replacing filter mats ............ 174 10.6.10. Replacing a door-mounted fan ..........175 10.6.11. Replacing a fan of an IP42 roof-mounted cooling unit ..................176 10.6.11.1. Replacing a fan .............. 176 10.6.12. Replacing a fan of an IP54 roof-mounted cooling unit ..................
Page 9 FIGURES — Figures Figure 1-1 Typical delivery ..................... 22 Figure 2-1 Product warning label examples (label placement depends on the drive) ........................... 24 Figure 2-2 Drive system overview ................... 29 Figure 3-1 Typical block diagram of the drive ............. 31 Figure 3-2 Switching levels .....................
Page 10 FIGURES Figure 3-27 Connection studs for the 4-way grounding set in an 18-pulse ACS5000WPCU (A) and a 36-pulse ACS5000W PCU (B) ..........58 Figure 4-1 Lifting bracket on base frame of a drive and safety hook secured to lifting bracket ....................62 Figure 4-2 Lift frame and lift spreader ................
Page 11 FIGURES Figure 6-17 PCU 18-pulse top and bottom entry (back view) ........103 Figure 6-18 COU cable terminals, top and bottom entry (back view) - frame sizes 1 and 2 (A) and 3 and 4 (B) ..............104 Figure 6-19 Bolted busbar connection ................ 105 Figure 6-20 Preparing control cables for EMC plates ..........
Page 13 Table 6-3 Maximum number of cables per frame opening - 3 core ..........96 Table 6-4 Maximum number of cables per frame opening - single core........96 Table 8-1 ABB arc resistant classes ...................... 130 Table 10-1 Filter mat specifications ...................... 174...
Page 15: 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 16: Related Documents
3BHS252500 E01 Table 1-6 I/O interface Title Document number 3BSE020923 S800 I/O Getting started 3BSE020924 S800 I/O Modules and Termination Units Also available online in the ABB Library (https://library.abb.com) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W User manual...
Page 17: Terms And Abbreviations
The following table lists terms and abbreviations you should be familiar with when using this user manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might differ from the normal usage. Table 1-8 Terms and abbreviations...
Page 18 To connect the electrical equipment to the earth, eg, by a grounding set or a grounding switch. I/O device Term of ABB’s S800 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 S800 I/O process system.
Page 19: Target Groups And Required Qualification
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 20: Maintenance
Use of the drive outside the scope of the specifications is not permitted. Intended equipment use also implies that only spare parts recommended and approved by ABB must be used. Unauthorized modifications and constructional changes of the drive are not permitted.
Page 21: Quality Certificates And Applicable Standards
1.8. Quality certificates and applicable standards The following certificates and conformity declarations are available with ABB: – ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and maintains a management system which fulfills the requirements of the normative standards –...
Page 22: 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 23: 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 standards The following industry standards are observed: –...
Page 24: Product Safety Labels
IMPORTANT SAFETY INFORMATION 2.3. Product safety labels Safety labels are affixed to the drive components to alert personnel of potential hazards when working on the equipment. For more information, see the label placement document for the drive. The instructions on the safety labels must always be followed and the labels must be kept in a perfectly legible condition.
Page 25: General Safety Instructions
IMPORTANT SAFETY INFORMATION 2.4. General safety instructions Minimize hazards Before energizing the drive: • Remove all foreign objects are from the drive • Fasten all internal and external covers securely • Close, lock, and/or bolt all doors • Move the release dial of the door safety switches into the locked position Before working on the drive: •...
Page 26: The 7 Steps That Save Lives
IMPORTANT SAFETY INFORMATION 2.5. The 7 steps that save lives ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash.
Page 27 IMPORTANT SAFETY INFORMATION 4) Verify the absence of operating voltage: always test before you touch! Only use properly rated and inspected voltage detection devices and wear proper PPE identified in step 1: • Test voltage detection device • Test for voltage •...
Page 28: Possible Residual Risks
IMPORTANT SAFETY INFORMATION 2.6. 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: Electric power equipment generates electro-magnetic fields which can cause a hazard to people with metal implants and / or a pacemaker.
Page 29: Important Note - Main Circuit Breaker
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...
Page 30: Safety And Protection Requirements
2.7.1. 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 31: 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 32: Figure 3-2 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 - 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 33: Figure 3-4 Igct
POWER ELECTRONICS AND CABINET FEATURES IGCT Integrated gate-commutated thyristors (IGCT) are used as switching devices in the inverter section of the phase converter units. IGCTs combine fast switching capabilities with low losses and enable a drive design with a low parts count. Figure 3-4 IGCT Fuseless protection concept The drive does not require any power fuses.
Page 34: Frame Sizes
POWER ELECTRONICS AND CABINET FEATURES 3.2. Frame sizes The drive comes in four frame sizes. Depending on the frame size, the drive has the following line-up specifications. Table 3-1 Line-up specifications by frame size Frame Rating Primary Secondary Total size PCUs width width...
Page 35: Phase Converter Unit (Pcu)
POWER ELECTRONICS AND CABINET FEATURES 3.3. Phase converter unit (PCU) All frame sizes use three primary phase converter units, each supplying one motor phase. In frame size 1 and 2, one primary phase converter unit represents a complete functional assembly. In frame size 3 and 4, one primary and one secondary phase converter unit (connected via DC link) represent a complete functional assembly.
Page 36: 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) Primary PCU (1700) Primary phase converter units of 1700 mm are used in frame size 1 and 3. Figure 3-6 Primary PCU, 1700 mm 1) Roof-mounted cooling unit 7) PE ground busbar 2) HVD circuit board 8) Main INT circuit board...
Page 37: Figure 3-7 Primary Pcu, 1700 Mm: Side View Left (A) And Side View Right (B)
POWER ELECTRONICS AND CABINET FEATURES Figure 3-7 Primary PCU, 1700 mm: side view left (A) and side view right (B) 1) Roof-mounted cooling unit 6) Water pipe 2) Terminal compartment for transformer 7) AC busbars for adjacent PCU and motor cables phase 3) LSU snubber plate (18-pulse only)
Page 38: Figure 3-8 Primary Pcu, 2100 Mm
POWER ELECTRONICS AND CABINET FEATURES Primary PCU (2100) Primary phase converter units of 2100 mm are used in frame size 2 and 4. Figure 3-8 Primary PCU, 2100 mm 1) Roof-mounted cooling unit 7) PE ground busbar 2) HVD circuit board 8) Main INT circuit board 3) Crowbar circuit board or PINT circuit board 9) IPS (Integrated Power Supply)
Page 39: Figure 3-9 Primary Pcu, 2100 Mm: Side View Left (A) And Side View Right (B)
POWER ELECTRONICS AND CABINET FEATURES Figure 3-9 Primary PCU, 2100 mm: side view left (A) and side view right (B) 1) Roof-mounted cooling unit 6) Water pipe 2) Terminal compartment for transformer 7) AC busbars for adjacent PCU and motor cables phase 3) LSU snubber plate (18-pulse only)
Page 40: Secondary Phase Converter Unit (1700 Mm And 2100 Mm)
POWER ELECTRONICS AND CABINET FEATURES 3.3.2. Secondary phase converter unit (1700 mm and 2100 mm) The secondary phase converter unit has the same design as the primary unit, except that the rectifier stack and the transformer terminal section are missing. Secondary PCU (1700 and 2100) Secondary phase converter units of 1700 mm are used in frame size 3.
Page 41: Control Unit (Cou)
1) Customer interface 9) Main INT interface 2) Control unit 10) Phase INT interface 3) Inverter 11) s800 I/O process system 4) ABB Ability™ 12) Process I/O 5) Higher-level control system 13) CDP control panel 6) DDCS 14) RS485 7) AMC circuit board...
Page 42: Main Components
POWER ELECTRONICS AND CABINET FEATURES 3.4.1. Main components Figure 3-12 COU control section 1) Arc Guard System™ 12) Isolating transformers for customer UPS – T1011, T1012, and step-down transformer for 2) NETA-21 internal buffer T1021 (optional) 3) AMC and main INT circuit board 13) S800 I/O process system 4) Terminals for customer UPS and PCU 14) Customer terminals...
Page 43: Amc Circuit Board
POWER ELECTRONICS AND CABINET FEATURES 3.4.1.1. AMC circuit board The AMC circuit board is the major component of the drive’s control system and performs general drive, motor control, and closed loop functions. The main internal control devices and the peripheral input and output interfaces to the customer communicate with the AMC circuit board via optical fibers.
Page 44: Figure 3-13 Dtc Torque Control
The speed and torque of the motor is controlled by DTC (Direct Torque Control). The DTC motor control platform is unique to ABB and has been proven in all variable speed drives of the ACS product range. DTC provides accurate speed and torque control, and high dynamic speed response.
Page 45 PC-based service tools comprising: DriveWare® software tools: includes software tools such as the • commissioning and maintenance tools DriveWindow and DriveDebug, and DriveOPC for data transfer between ABB drives and Windows®-based applications. DriveMonitor (option): a monitoring and diagnostics tool that allows access •...
Page 46: Figure 3-14 Local Control Panel
POWER ELECTRONICS AND CABINET FEATURES Figure 3-14 Local control panel 1) Local control panel 2) Local control pushbuttons Customer interface The devices present in the customer interface depend on the options ordered, such as: – Serial communications interface to a higher-level control system –...
Page 47: Figure 3-15 Cou Customer Interface Section
The S800 I/O station with digital and analog I/O interfaces transfers drive-related hardwired signals to the AMC circuit board. Standard ABB Advant S800 I/O modules interconnect internal and external digital and analog I/O signals with the control system of the drive. The I/O station consists of a bus modem serving as an interface to the AMC circuit board and the I/O modules.
Page 48: Transformer And Motor Cable Terminals
POWER ELECTRONICS AND CABINET FEATURES 3.5. Transformer and motor cable terminals 3.5.1. Transformer cable terminals For information on the location of the terminals, see Fig. 3-7. 3.5.2. Motor cable terminals The motor terminals are in the back of the COU compartment. To access them, open the swing frame of the control unit.
Page 49: Figure 3-17 Motor Terminal Section Of Frame Size 3 And 4: Top Entry (A) And Bottom Entry (B)
POWER ELECTRONICS AND CABINET FEATURES Figure 3-17 Motor terminal section of frame size 3 and 4: top entry (A) and bottom entry (B) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W User manual 3BHS799208 E01 49/178...
Page 50: Water Cooling Unit (Wcu)
POWER ELECTRONICS AND CABINET FEATURES 3.6. Water cooling unit (WCU) Depending on the frame size, the water cooling unit comes as one of the following two models: – 800 mm (frame size 1 and 2) – 1400 mm (frame size 3 and 4) Fig.
Page 51: Exu - Excitation Unit (Optional)
POWER ELECTRONICS AND CABINET FEATURES 3.7. EXU – Excitation unit (optional) The EXU supplies a synchronous motor with excitation power. The EXU is available for the following excitation methods: – Brush excitation (DC excitation): Brush excitation uses a DCS800 AC-to-DC converter (see figure below) which is supplied by the mains.
Page 52: Figure 3-20 Exu Control Panel
POWER ELECTRONICS AND CABINET FEATURES DCS800 control panel The control panel of the DCS800 unit enables the user to control, read the status messages and set the parameters of the DCS800 unit. The panel can also be used to copy parameters from one DCS800 unit to another DCS800. Figure 3-20 EXU control panel For more information, see “8 Operation”...
Page 53: Door Interlocking System
POWER ELECTRONICS AND CABINET FEATURES 3.8. Door interlocking system The doors of each PCU compartment are secured with an electromechanical interlocking mechanism to prevent them from being opened during operation. The main protection features of the interlocking system are: – Grounding switches (Fig.
Page 54: Grounding Switches
POWER ELECTRONICS AND CABINET FEATURES 3.9. Grounding switches There is one grounding switch (Fig. 3-22: 1) on each primary PCU. Turning a grounding switch to the grounded position (horizontal) is only possible once the yellow lamp (Fig. 3-22: 2) lights up. The yellow lamp indicates that the main power supply is disconnected and the DC link has discharged.
Page 55: Figure 3-23 Locking Bar And White Lamp
POWER ELECTRONICS AND CABINET FEATURES Figure 3-23 Locking bar and white lamp 1) White lamp: Lights up to indicate that the drive is grounded and you can slide the locking bar to the unlocked or locked position. 2) Locking bar: Unlocks or locks the door handles of a PCU compartment. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 56: Grounding Studs
POWER ELECTRONICS AND CABINET FEATURES 3.10. Grounding studs The COU and each PCU has grounding studs that are designed for use with the 4- way grounding set (Fig. 3-25). Figure 3-24 Grounding stud 3.10.1. Grounding set DANGER Hazardous voltages! The steps in the “2.5 The 7 steps that save lives” on page 26 must be completed before you access the grounding studs in the PCU.
Page 57: Output Grounding Studs In Cou
POWER ELECTRONICS AND CABINET FEATURES 3.10.2. Output grounding studs in COU The converter output grounding studs (Fig. 3-26: 1L1, 1L2, 1L3, and PE) are behind the swing frame in the COU. Figure 3-26 Connection studs for the 4-way grounding set in the COU PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 58: Input Grounding Studs In A Pcu
POWER ELECTRONICS AND CABINET FEATURES 3.10.3. Input grounding studs in a PCU DANGER Hazardous voltages! The steps in the “2.5 The 7 steps that save lives” on page 26 must be completed before you remove the side and back walls from the drive to access the grounding studs in a PCU.
Page 59: Transportation, Storage And Disposal
3. Compare the complete delivery with the purchase order and the packing list. 4. If parts are missing or damaged, immediately inform the shipping company and the ABB service organization. It is recommended to photograph the damages and send the photographs to ABB.
Page 60: 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 61: Lifting And Transportation
If the transport units are joined but not yet on the base frame, DO NOT lift and move them with a crane. Instead, use appropriate transport means, such as heavy load hydraulics rollers or air cushions. If in doubt, contact ABB for instructions. –...
Page 62: Using A Crane To Lift A Transport Unit Or The Drive By The Base Frame
Only use a crane to lift single transport units or the drive by the base frame. – Always observe the center of gravity! Refer to Fig. 4-1 and Fig. 4-2 when following these ABB recommendations: – Use a lift frame or a lift spreader with the crane. –...
Page 63: Figure 4-2 Lift Frame And Lift Spreader
TRANSPORTATION, STORAGE AND DISPOSAL 15° max Figure 4-2 Lift frame and lift spreader 3) Lift frame 7) Safety hook or shackle 4) Protect the edges 8) Lifting bracket 5) Protect door handles and levers 9) Slope angle 6) Extra sling 10) Lift spreader PRODUCT DOCUMENT KIND...
Page 64: 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. 4.6.2. Storage If the drive is taken out of service for a longer time proceed as follows: 1.
Page 65: Storage And Handling Of Spare Parts
4.7.1. Warranty information IMPORTANT! Check the spare parts immediately after receipt for damages. Report any damage to the shipping company and the ABB service organization. Observe the following to maintain spare parts in good condition and to keep the warranty valid during the warranty period: –...
Page 66: Disposal Of Packaging Materials And Components
TRANSPORTATION, STORAGE AND DISPOSAL 4.8. Disposal of packaging materials and components Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W User manual 3BHS799208 E01...
Page 67: Mechanical Installation
MECHANICAL INSTALLATION 5. Mechanical installation 5.1. Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations. 5.2. Overview of installation work The drive is delivered in transport units that must be joined and fixed to the floor at the installation site.
Page 68: General Notes On Installation
MECHANICAL INSTALLATION 5.3. General notes on installation NOTICE Risk of component damage, Observe the following during installation: – Ensure that no dirt enters the drive. Always close the doors when work is discontinued and completely cover openings. Metallic dust in particular may cause failures when the drive is powered up and cause damage.
Page 69: 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 (min. 1500 kg/m – The overall incline of the floor across 5 m must not exceed 5 mm. 5 mm 1 mm 1 mm...
Page 70: 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”. The units can be lined up either beginning from the left or the right.
Page 71: Joining Transport Units
MECHANICAL INSTALLATION 7. Screw holes are exactly aligned. 8. Cabinet doors are not misaligned and that there are no gaps between cabinet walls and cabinet frame 9. Adjoining surfaces of transport units meet perfectly all around 5.7. Joining transport units Join the transport units with the supplied installation material.
Page 72: 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 (Fig. 5-3). Gaps within a transport unit are factory-sealed. Figure 5-3 Applying silicone 5.9. Installing roof joints Install the roof joints across shipping splits at the following locations: –...
Page 73: Installing Roof-Mounted Cooling Units
MECHANICAL INSTALLATION 5.10. Installing roof-mounted cooling units This section applies only if the units are not preinstalled. 5.10.1. Lifting a unit with a crane CAUTION Heavy objects! An IP42 cooling unit weighs 40 kg. – An IP54 cooling unit weighs 98 kg. –...
Page 74: Installing Ip42 Roof-Mounted Cooling Units
MECHANICAL INSTALLATION 5.10.2. Installing IP42 roof-mounted cooling units One by one, install the IP42 roof-mounted cooling units on top of the PCU compartments that have the designated openings. Table 5-2 Installation material per IP42 unit Item Quantity Details Self-tapping Torx screws M6x16 Washers with sealing 6.8x1 (4.8x2.8)
Page 75: Figure 5-6 Cable Duct Openings (Example With 1700 Mm Pcu)
MECHANICAL INSTALLATION 5. Route the cables along the pre-installed white cable brackets and through the designated openings (1) into the front of the cable duct. Use cable binders to fix the cables to the cable brackets. Figure 5-6 Cable duct openings (example with 1700 mm PCU) 6.
Page 76: Installing Ip54 Roof-Mounted Cooling Units
MECHANICAL INSTALLATION 5.10.3. Installing IP54 roof-mounted cooling units One by one, install the IP54 roof-mounted cooling units on top of the PCU compartments that have the designated openings. Table 5-3 Installation material per IP54 unit Item Quantity Details Self-tapping Torx screws M6x16 Washers with sealing 6.8x1 (4.8x2.8)
Page 77: Figure 5-7 Water Inlet / Outlet And Drain Outlet (Back View)
MECHANICAL INSTALLATION 5. Connect the tube from the return pipe (Fig. 5-7: 5) to the water outlet (Fig. 5-7: 1). The tubes are transparent. The colors used in Fig. 5-7 are for illustration only. 6. Seen from the back, the water outlet is on the left. Seen from the front, the water outlet is on the right.
Page 78: Installing Roof Attachments
MECHANICAL INSTALLATION 5.11. Installing roof attachments This section applies to 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 79: Figure 5-9 Recommended Ceiling And Wall Fixings
MECHANICAL INSTALLATION 1. Assemble the roof attachment. 2. Tighten the bolts firmly. 3. To fix the drive to the ceiling or the back wall, use two suitable struts per roof attachment (the struts are not part of the scope of delivery). WARNING! DO NOT install the struts at a 90°...
Page 80: 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. 47 mm 4.
Page 81: Joining Busbars
MECHANICAL INSTALLATION 5.13. Joining busbars There are three types of busbars that need to be joined: – AC busbars (Fig. 5-10: 1) – PE ground busbar (Fig. 5-10: 2) – DC busbars (Fig. 5-10: 3) Figure 5-10 Busbar connections 1. Before installing the joining pieces, grease the bolts to maintain the required contact pressure.
Page 82: Figure 5-11 Ac Busbar Connection
MECHANICAL INSTALLATION 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 5-11 AC busbar connection 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 83: Connecting The Heating Cable
MECHANICAL INSTALLATION 5.14. Connecting the heating cable This section applies to drives that are delivered in several transport units and are equipped with a heating cable. – Connect the heating cables of two adjoining transport units with each other. – Fasten the connectors with cable ties.
Page 84: 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. Installation material such as counter flanges, bolts, nuts and seals are supplied. For dimensions of the raw water entry and the flanges, see “Appendix C - Mechanical drawings”.
Page 85: 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 the main and auxiliary power supply from being switched on during installation.
Page 86: Grounding
ELECTRICAL INSTALLATION 6.4. Grounding 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 “Appendix C - Mechanical drawings”. 6.4.1.
Page 87: Grounding The Transformer And A 36-Pulse Drive
ELECTRICAL INSTALLATION 6.4.2. Grounding the transformer and a 36-pulse drive Fig. 6-2 shows the grounding connections of a drive and an input transformer in the PCU compartments. -20° +20° -20° +20° 0° 0° Figure 6-2 Grounding the transformer and a 36-pulse drive (in PCU) 1) Input transformer 5) Cable screen 2) Drive...
Page 88: Grounding The Drive And The Motor (Multi-Point Bonding)
ELECTRICAL INSTALLATION 6.4.3. Grounding the drive and the motor (multi-point bonding) Fig. 6-3 shows the multi-point connections to ground a drive and a motor in the COU compartment. For more information see the “Power cables engineering guideline” (3BHS542290 E01). Figure 6-3 Grounding the drive and the motor (multi-point bonding) 1) Drive 5) Cable screen 2) Motor...
Page 89: Grounding The Drive And The Motor (Single-Point Bonding)
ELECTRICAL INSTALLATION 6.4.4. Grounding the drive and the motor (single-point bonding) Fig. 6-4 shows the single-point bonding connections to ground a drive and a motor in the COU compartment. For more information see the “Power cables engineering guideline” document. Figure 6-4 Grounding the drive and the motor (single-point bonding) 1) Drive 4) Ground cable 2) Motor...
Page 90: 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 (Fig. 6-5, Fig. 6-6). The connection must be in compliance with local regulations.
Page 91: Internal Wiring
ELECTRICAL INSTALLATION 6.5. Internal wiring For information on each individual connection, see the Converter hardware diagram in “Appendix D - Wiring diagrams”. Internal wiring comprises all cabling and wiring across shipping splits, and includes: – Signal cable connection – Auxiliary power supply cable connection –...
Page 92: Optical Fibers
ELECTRICAL INSTALLATION 6.5.1. Optical fibers 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 93: Figure 6-7 Wiring Across Shipping Splits, Frame Size 1 (A) And 2 (B)
ELECTRICAL INSTALLATION Figure 6-7 Wiring across shipping splits, frame size 1 (A) and 2 (B) 1) Shipping split PCUx1 – PCUx1 4) Charging cable behind water pipe (not illustrated), laid on the brackets and 2) Cable ducts on each side of the shipping connected to the busbar split for: 5) PCUx1...
Page 94: Figure 6-8 Wiring Across Shipping Splits, Frame Size 3 And 4
ELECTRICAL INSTALLATION PCUx0 PCUx1 PCUx1 PCUx0 Figure 6-8 Wiring across shipping splits, frame size 3 and 4 1) Shipping split 4) Charging cable behind water pipe (not illustrated), laid on the brackets and 2) Cable ducts on each side of the shipping connected to the busbar split for: 5) PCUx0...
Page 95: 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 96: Figure 6-10 Cable Entry Frame Sizes (Top) For Type 1 Sealing Modules (Bottom)
ELECTRICAL INSTALLATION Frame sizes (FS) L1 L2 L1 L2 RM120 RM69 RM60 Figure 6-10 Cable entry frame sizes (top) for type 1 sealing modules (bottom) Table 6-1 Type 1 sealing modules and cables per frame opening Frame Location Cable entry FS 2/4/6 FS 2/4/6 FS 1/3/5...
Page 97: Cable Entry With Sealing Modules, Type 2
ELECTRICAL INSTALLATION 6.6.2. Cable entry with sealing modules, type 2 – Usage: auxiliary power cables and control cables – Included in delivery: frame (Fig. 6-11: 1) Figure 6-11 Cable entry with sealing modules – type 1 – Supplier: Roxtec AB (roxtec.com) Not included in delivery: EMC sealing inserts (Fig.
Page 98: Cable Entry With Emc Plates
ELECTRICAL INSTALLATION Not included in delivery: cable glands, tools, cable clamps, accessories – 6.6.4. Cable entry with EMC plates Usage: power cables, ground cables, bonding conductors, auxiliary power – cables, control cables Included in delivery: galvanized plate with EMC mesh (Fig. 6-13: 1) and sealing –...
Page 99: Power Cables, Ground Cables, Equipotential Bonding Conductor
ELECTRICAL INSTALLATION 6.7. Power cables, ground cables, equipotential bonding conductor See “Appendix A - Additional manuals” for information on: – Project-specific cable entry – Distance between point of cable entry and terminals – Busbar and fastening hole dimensions – Installation instructions for sealing modules See “Appendix D - Wiring diagrams”...
Page 100: 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. Figure 6-14 Preparing power cables for cable glands 1) Cable gland 5) Conductor insulation removed to expose cable shield...
Page 101: 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. Figure 6-15 Preparing power cables for sealing modules 1) Sealing module 8) Cable sheath removed to expose cable shield...
Page 102: 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 103: Figure 6-16 Pcu 36-Pulse Top And Bottom Entry (Back View)
ELECTRICAL INSTALLATION Transformer cables ACS5000W 36-pulse Figure 6-16 PCU 36-pulse top and bottom entry (back view) 1) Top cable entry 3) Bottom cable entry 2) Busbars for transformer cables Transformer cables ACS5000W 18-pulse Figure 6-17 PCU 18-pulse top and bottom entry (back view) 1) Top cable entry 3) Bottom cable entry 2) Busbars for transformer cables...
Page 104: Figure 6-18 Cou Cable Terminals, Top And Bottom Entry (Back View)
ELECTRICAL INSTALLATION Motor cables Figure 6-18 COU cable terminals, top and bottom entry (back view) - frame sizes 1 and 2 (A) and 3 and 4 (B) 1) Top cable entry 3) Bottom cable entry 2) Busbars for motor cables 4) Busbars for motor cables (frame sizes 1 and 2) (frame sizes 3 and 4)
Page 105: Bolted Connections
ELECTRICAL INSTALLATION 6.7.2.3. Bolted connections Material requirements Use stainless steel bolts and nuts with the appropriate steel grade and property class for the connection (recommended: A2-70 [designation according to ISO 3506]). Nuts with bonded coating can be used as an alternative to uncoated stainless steel nuts.
Page 106: 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 107: Figure 6-20 Preparing Control Cables For Emc Plates
ELECTRICAL INSTALLATION 5. Remove the cable insulation at the point of entry (Fig. 6-20: 1). If the outer cable screen is non-conductive, cut open the cable screen in the middle of the stripped area (Fig. 6-20: 1). To turn the conductive side inside out, pull the cable screen ends over the cable insulation (Fig.
Page 108: Preparing Cables For Cable Entries With Sealing Modules
ELECTRICAL INSTALLATION 6.8.1.1. Preparing cables for cable entries with sealing modules 1. Unscrew the frame and remove the sealing modules. For information on removing and installing the sealing modules and using the compression wedge, see “Appendix A - Additional manuals”. 2.
Page 109: Preparing Cables For Cable Entries With Cable Glands
ELECTRICAL INSTALLATION 6.8.1.2. 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 6-22 Preparing control cables for cable glands 1) Outer cable sheath 4) Plate 2) Cable gland 5) Conductor screen extension to be...
Page 110: Connecting Auxiliary Power Cables And Space Heater Cables In Wcu
ELECTRICAL INSTALLATION 6.8.2.1. Connecting auxiliary power cables and space heater cables in WCU Top cable entry 1. Route the cables through the cable transit into the terminal compartment (Fig. 6-23: 1) of the WCU. 2. Connect the cables to the relevant terminals. Bottom entry 1.
Page 111: Connecting Cables In Cou
ELECTRICAL INSTALLATION 6.8.2.2. Connecting cables in COU Shielded cables – If you use twisted pair cables, leave the unshielded cable ends twisted until they reach the terminals. – Leave unshielded conductor ends as short as possible. – Use a shield grounding clamp (Fig. 6-24) to fasten the overall shield and the individual shields to the ground busbar (Fig.
Page 112 ELECTRICAL INSTALLATION Control power supply – Connect the cable for the control power to terminal X2 (Fig. 6-25: 11). Control signals – Connect the cables to the following terminals: • X10, X11 (Fig. 6-25: 10) Main circuit breaker signals and emergency off signals •...
Page 113: Commissioning
ABB. 7.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB. 7.3. Commissioning checklist In order to ensure uncomplicated and speedy commissioning, it is important that drive and associated equipment are ready for commissioning.
Page 114: Commissioning Checklists
Types and cross sections of control cables suitable for the signal type and signal level. □ Types and cross sections of power cables selected according to the ABB power cable specification. □ Pulse encoder cable shields are connected to the shield earthing point and not connected directly to the pulse encoder interface (applies only to drives with pulse encoder interface).
Page 115: Door Interlocking Checklist
COMMISSIONING 7.6.2. Electrical installation checklist (continued) □ Wiring across shipping splits is completed according to the instructions in the user manual (3BHS799208 E01 F). □ 8) Ground cable of the drive is securely connected at both ends. □ Cable armor and screens of power supply cables are connected to PE ground busbar.
Page 116: Motor Checklist
COMMISSIONING 7.6.6. Motor checklist □ Motor is installed, aligned and alignment protocol available. □ Motor is not coupled to driven load. □ Grounding is completed □ 4) Motor auxiliaries (eg, bearing lubrication) are ready □ Control and monitoring signals are connected. 7.6.7.
Page 117: Operation
OPERATION 8. Operation 8.1. Operating conditions The operating conditions for the drive are according to IEC 60721-3-3. – Classification: 3K22 / 3B1 / 3S6 / 3M11 8.2. Safety The drive system must only be operated by qualified and authorized personnel, ie, personnel who are familiar with the operation of the drive system and the hazards involved.
Page 118: Local Operator Panel
OPERATION 8.4. Local operator panel The operator panel on the control compartment enables the operator to control the drive without restrictions, provided that all requirements for normal operation are met. The functions of the local operator panel include: – Connecting and disconnecting the main power supply –...
Page 119: Lamp-Test Function
OPERATION 8.5. Lamp-test function The lights and illuminated push buttons on the control compartment can be tested with the lamp-test function. The lamp test is activated via the CDP control panel by setting control parameter 16.7 to LAMP TEST. The lamp-test function resets itself after a set time. 8.6.
Page 120 OPERATION NotReadyOn The DC link cannot be charged and the drive cannot be connected to the main power supply, ie, the main circuit breaker cannot be closed. The status message is displayed, eg, when the doors of medium voltage compartments are still open, the grounding switch of the drive is in the grounded position, or the motor starter of the fan unit is switched off.
Page 121: Start Sequence Of The Drive
OPERATION 8.6.1. Start sequence of the drive NotReadyOn ReadyOn • Auxiliary power supply on • PCU doors closed and locked • Drive not grounded • No emergency-off • No fault • WCU ready On command 4) Charging • DC link charges •...
Page 122: Stop Sequence Of The Drive
OPERATION 8.6.2. Stop sequence of the drive Operation ReadyRef Stop command 4) Stopping • Speed ramps down • Inverter stops modulating ReadyRun 6) Off command • MCB opens • DC link discharges • Cooling system switches off after a delay ReadyOn •...
Page 123: Starting The Drive
OPERATION 8.7. Starting the drive DANGER Hazardous voltages! – To prevent unintentional contact with energized components, all covers must be screwed in place. – The release dial of the door safety switches must be in the locked position to prevent the doors of the medium voltage compartments from being opened unintentionally during operation.
Page 124: Checks Before Starting The Drive
OPERATION 8.7.1. 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, check the drive according to the following list: –...
Page 125 OPERATION When no alarms and faults are present and the drive is ready, the CDP control panel displays ReadyOn. 1 L -> 0.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 4. Press the SUPPLY ON push button on the control compartment door to charge the DC link.
Page 126 OPERATION 6. To start the motor, press the START key. After the motor has been magnetized, the motor speed ramps up to the reference value. While the motor is accelerating, the run status message in the display blinks. When the motor speed has reached the reference value, the run status message lights up permanently.
Page 127: Stopping The Drive
OPERATION 8.8. Stopping the drive – To stop the motor, press the STOP key. The motor stops according to the preset stop function. While the motor stops, the status line of the display shows ReadyRef and the run status message blinks.
Page 128: Emergency-Off
OPERATION 8.9. Emergency-off CAUTION Hazardous voltage! Pressing the EMERGENCY-OFF push button DOES NOT disconnect the auxiliary power supply from the drive. The drive is equipped with a hardwired emergency-off circuit. When an emergency situation occurs during operation, this safety feature ensures that the drive system can be disconnected without delay from the main power supply.
Page 129: Starting The Drive System After An Emergency-Off
OPERATION 8.9.2. Starting the drive system after an emergency-off 1. To start up the drive system after an emergency-off, unlatch the EMERGENCY- OFF push button. The EMERGENCY-OFF push button returns to its initial position when turned into the direction indicated by the arrows on the push button. 2.
Page 130: Arc Resistant Design
OPERATION 8.10. Arc resistant design The arc resistant design provides the drive with ABB class IV arc fault protection (see Table 8-1) in accordance with IEC 62477-2. Table 8-1 ABB arc resistant classes ABB class Description Class I Protection based on arc prevention (NOT certified according to...
Page 131: Arc Detection With The Arc Guard System
OPERATION 8.10.2. Arc detection with the Arc Guard System™ The Arc Guard System™ detects fast arc faults in the terminal sections of the drive. When the Arc Guard System detects an arc fault the drive performs protection firing and immediately opens the main circuit breaker. The Arc Guard monitor and HMI panel are located in the COU (Fig.
Page 132: Energizing And Grounding The Drive
OPERATION 8.11. De-energizing and grounding the drive See “10.6.2 De-energizing the drive” on page 165. 8.12. Opening the doors See “10.6.3 Opening and closing the doors” on page 167. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W User manual 3BHS799208 E01 132/178...
Page 133: Cdp Control Panel
CDP CONTROL PANEL 9. CDP control panel 9.1. Overview The panel messages and parameter settings in the following sections are typical examples and might differ from the actual ones. 9.1.1. Display and keypad 1 L -> 1242.0 rpm StateINU ReadyOn MOTOR SP 1242 rpm POWER...
Page 134: Functions
CDP CONTROL PANEL 9.1.2. Functions The CDP control panel serves as the basic user interface for operating and monitoring the drive when the local operating mode has been selected. The CDP control panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first.
Page 135 CDP CONTROL PANEL After 2-3 seconds the display shows the drive name (1, 2), the application software in use (3), and the drive identification (4) is displayed. ACS5000 xxxx LXHH44xx ID-NUMBER 1 After another few seconds. 1 L ->...
Page 136: Actual Signals Mode
CDP CONTROL PANEL 9.2.2. Actual signals mode 1 L -> 600.0 rpm StateINU InitSeq..MOTOR SP 0.00 rpm POWER 0.0 kW FUNC FUNC DRIVE DRIVE Figure 9-2 Control panel functions for Actual signals mode 1) Display 5) Slow navigation key for selecting signals or fault messages 2) Actual signal names and values 6) Enter key for confirming the selection...
Page 137: Selecting The Actual Signals Display
CDP CONTROL PANEL If no key is actuated within one minute (an exception from this is the fault memory display), the CDP control panel automatically returns to the actual signals display from other modes. Actual values For the complete list of selectable actual signals, see “Appendix G - Signal and parameter table”.
Page 138: Toggling Between Actual Signals Display And Fault Memory
CDP CONTROL PANEL 9.2.2.3. Toggling between actual signals display and fault memory To toggle between actual signals display and fault history display, press a fast navigation key. 1 L -> 600.0 rpm 1 LAST FAULT +Overspeed 070730 12:30:02.3256 9.2.2.4. Displaying three actual signals 1.
Page 139 CDP CONTROL PANEL 2. To select a line where the actual signal is to be displayed, press the slow navigation keys. blinking cursor indicates the selected line. 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3.
Page 140 CDP CONTROL PANEL 6. To confirm the selection and to return to the actual signals display, press the ENTER key. 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm NP VOLT 7. To cancel the selection and keep the original selection, press any of the mode selection keys.
Page 141: Displaying A Fault And Resetting The Fault Memory
CDP CONTROL PANEL 9.2.2.6. Displaying a fault and resetting the fault memory 1. To open the actual signals display, press the ACT key. 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 2. To change to the fault memory display, press a fast navigation key. 1 L ->...
Page 142: Displaying And Resetting An Active Fault
9.2.2.7. Displaying and resetting an active fault 1. To display an active fault, press the ACT key. 1 L -> 600.0 rpm ACS5000 *** FAULT *** MCB CloseControl 2. To reset the fault, press the RESET key. 1 L ->...
Page 143: Parameters Mode
CDP CONTROL PANEL 9.2.3. Parameters mode NOTICE Risk of component damage. Running the drive system with incorrect data can result in improper operation, reduction of control accuracy and damage of equipment. – Parameters must only be set by qualified personnel. –...
Page 144: Overview
CDP CONTROL PANEL 9.2.3.1. Overview If the parameter lock is disabled or unlocked (see “ Enabling / unlocking a parameter lock” on page 147) the parameters mode allows entering the parameter settings for the required drive configuration depending on the application. The parameters are organized in functional groups, so called parameter groups.
Page 145: Changing A Parameter Setting
CDP CONTROL PANEL 9.2.3.2. Changing a parameter setting 1. To enter the parameters mode, press the PAR key. 1 L -> 600.0 rpm 77 SYSTEM CONFIG 01 INU IdentifySel INU1 (MASTER) 2. To select a different group, press a fast navigation key. 1 L ->...
Page 146 CDP CONTROL PANEL 5. To change the parameter value, press: • Slow navigation keys for numbers and text • Fast navigation keys for numbers only 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module [DI810 24VDC] 6. To confirm the setting and to return to the actual signals display, press the ENTER key.
Page 147: User Lock
For more information, see “Appendix G - Signal and parameter table”. 9.2.3.3. User lock NOTICE Risk of component damage. ABB is not be liable for damages or losses caused by the failure to activate the user lock with a new pass code. – See the “Legal disclaimer” on page 2.
Page 148: Functions Mode
CDP CONTROL PANEL 9.2.4. Functions mode The functions mode is used for adjusting the display contrast. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST FUNC DRIVE DRIVE Figure 9-4 Control panel functions for Functions mode 1) Status line 4) Slow navigation key for selecting a line (and adjusting the contrast) 2) Selectable functions...
Page 149 CDP CONTROL PANEL 2. To select the contrast adjustment function, press the slow navigation keys until the blinking cursor reaches the CONTRAST line. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 3. Press the ENTER key. 1 L ->...
Page 150: Local And Remote Control Mode
CDP CONTROL PANEL 6. To cancel the setting and keep the original setting, press any of the mode selection keys. The selected keypad mode is entered. FUNC DRIVE 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 9.2.5.
Page 151: Enabling The Local Lock
CDP CONTROL PANEL 9.2.5.3. Enabling the local lock – To enable the local lock, set parameter 16.04 to 2 (LOCKED). With this parameter setting, local control (including the LOC-REM key) is disabled. If the CDP control panel or a DriveWindow PC is in local control mode at the time that the local lock is enabled, they remain in local control mode until they are switched to remote control mode.
Page 152: Operational Commands
CDP CONTROL PANEL – To enter the remote control mode, press the LOC-REM key. • A blank space indicates full remote control from a higher-level control system. • The letter indicates partial remote control (some commands are enabled locally). 1 L -> 600.0 rpm 0 StateINU ReadyRun...
Page 153: Entering A Reference Value
CDP CONTROL PANEL To set the direction of rotation, press the forward or backward key. 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 1 L <- 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW If you change the direction while the motor is running, the motor automatically...
Page 154 CDP CONTROL PANEL 2. To enter the reference value input mode, press the REF key. 1 L -> [600.0 rpm] 0 StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3. To enter / change the reference value, press the corresponding fast or slow navigation key.
Page 155: Preventive And Corrective Maintenance
ABB service personnel. After the warranty period, repair work may only be carried out by certified personnel. 10.1.1. Required qualification To maintain safe and reliable operation of the drive, ABB recommends taking out a service contract with the ABB service organization. 10.1.2. Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule, on time and at the stated intervals in the “ACS5000 preventive maintenance schedule”...
Page 156: Identifying Electrical Equipment
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.2. Identifying electrical equipment 10.2.1. Device designation To facilitate the identification in wiring diagrams and parts lists, all devices are labeled in accordance with IEC 81346-1. -A2501 Figure 10-1 Device identification 10.2.2. Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams.
Page 157: Alarm / Fault Indications
– Flashing light: alarm – Light remains on: fault SUPPLY 1 L -> 600.0 rpm ACS5000 ** FAULT ** CW1 NoWtrPumpOn ALARM EMERGENCY OFF FAULT RESET EMERGENCY OFF The message can be saved and viewed in the fault history of the drive when a PC with DriveWindow, DriveDebug or DriveMonitor is connected to the drive.
Page 158: Fault
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.3.2.2. Fault A fault shuts down the drive. The type of shutdown depends on the origin of the fault. Depending on the type of fault, the drive opens the main circuit breaker (MCB) or keeps it closed: –...
Page 159: Standard Troubleshooting Procedure
The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. Contact ABB service if a fault cannot be rectified. When calling ABB service, it is recommended to have the following data available at the time when the fault occurred: •...
Page 160: Removing The Cdp Control Panel
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4. Removing the CDP control panel When the CDP control panel must be removed from its mounting cradle, follow the instructions below. 1. When the panel is removed while the drive is in operation, check the setting of parameter 31.01 PANEL LOSS SUPERVISION first.
Page 161: Leds And Switches On Circuit Boards And I/O Devices
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5. LEDs and switches on circuit boards and I/O devices The following section provides an overview of the meaning of LEDs and switches of the main circuit boards and I/O modules. The LEDs presented in the following section can be checked easily while the auxiliary voltage is switched on without having to remove covers first.
Page 162: S800 I/O Bus Modem Tb820
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5.2. S800 I/O bus modem TB820 Figure 10-4 TB820 bus modem Color Indication Fault in module Green Device in operation Green Power supply is healthy Yellow Traffic on optical module bus Yellow Traffic on optical module bus Yellow Traffic on electrical module bus 10.5.2.1.
Page 163: S800 I/O Modules
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5.3. S800 I/O modules LEDs on I/O modules having the same meaning on all types of I/O modules are always at the same position. The LEDs are always at the topmost position on each module (Fig. 10-5: 1) and are identified as follows: –...
Page 164: Corrective Maintenance
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6. Corrective maintenance Overview on maintenance tasks: – “10.6.6 Visual checks on the drive” on page 173 – “10.6.7 Cleaning” on page 173 – “10.6.8 Checking wire and cable connections” on page 174 – “10.6.9 Checking and replacing filter mats” on page 174 –...
Page 165: Energizing The Drive
PREVENTIVE AND CORRECTIVE MAINTENANCE WARNING Hazardous DC voltage! Depending on the type of auxiliary supply, the drive can be equipped with buffer capacitors inside the control unit. During operation, the capacitor voltage is 300 V (DC). – Wait 5 minutes for the capacitors to discharge. –...
Page 166: Energizing The Drive
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.2.2. De-energizing the drive 1. To disconnect the drive from the main power supply, press the SUPPLY OFF pushbutton. The following takes place: 2. Main circuit breaker (MCB) opens 3. DC link discharges While the DC link discharges, the CDP control panel shows the following: Alternating display message: 1 L ->...
Page 167: Opening And Closing The Doors
PREVENTIVE AND CORRECTIVE MAINTENANCE 8. If necessary, open the doors of medium voltage compartments according to “10.6.3 Opening and closing the doors” on page 167 9. Switch off and lock-out all auxiliary supply voltages from external sources. The drive is now de-energized, and safe access is possible. 10.6.3.
Page 168 PREVENTIVE AND CORRECTIVE MAINTENANCE Opening the doors 1. To release the door handle, insert and turn the key to the right. The door handle pops out. 2. To open the door, turn the door handle: 3. To the right if the door is hinged on the right 4.
Page 169: Grounding Switch Is Not Released
The actual value (parameter 2.30 DC Volt 1-3 MaxVal) must be < 50 V (discharged). Check if there are any alarm and fault messages on the display. If there are alarms / faults, contact the ABB service organization PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 170: Emergency Release Of A Door Safety Switch
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.5. Emergency release of a door safety switch DANGER Hazardous voltages! Touching energized components can be fatal. – Before you unlock a safety switch, de-energize and ground the drive according to“10.6.2 De-energizing the drive” on page 165. –...
Page 171: Safety-Switch Settings
PREVENTIVE AND CORRECTIVE MAINTENANCE If the auxiliary power supply is unavailable and the doors are closed, you can only open them by unlocking the safety switch manually. 10.6.5.2. 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.
Page 172 PREVENTIVE AND CORRECTIVE MAINTENANCE 3. Turn the release dial from the locked to the unlocked position. You can now actuate the locking bar and open the doors. 5 mm 4. When the door is open, turn the release dial to the locked position and screw in the locking screw.
Page 173: Visual Checks On The Drive
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.6. 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 174: Checking Wire And Cable Connections
– Check that all plugs and connectors are tight. 10.6.9. Checking and replacing filter mats For the filter mat replacement interval, see the “ACS5000 preventive maintenance schedule” (3BHS855274 E01). 10.6.9.1. Location Drives with IP54 cabinet, have filter mats in the following compartment doors: –...
Page 175: Replacing A Door-Mounted Fan
PREVENTIVE AND CORRECTIVE MAINTENANCE Replacing both types of WCU filter mats 1. Switch off the protection switch of the cooling fan according to “Appendix D - Wiring diagrams” in order to prevent the cooling fans from starting automatically. 2. Remove the air outlet panel (Fig. 10-8:1). 3.
Page 176: Replacing A Fan Of An Ip42 Roof-Mounted Cooling Unit
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.11. Replacing a fan of an IP42 roof-mounted cooling unit WARNING Hazardous voltage! Before starting any work on the fans, de-energize the cooling unit. The roof-mounted cooling unit as used with IP42 cabinets consists of three fans. One fan is redundant and takes over when one of the other fans fails.
Page 177: Replacing A Fan Of An Ip54 Roof-Mounted Cooling Unit
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.12. Replacing a fan of an IP54 roof-mounted cooling unit WARNING Hazardous voltage! Before starting any work on the fans, de-energize the cooling unit. The roof-mounted cooling unit as used with IP54 cabinets consists of an air-to- water heat exchanger and four fans.
Page 178 PREVENTIVE AND CORRECTIVE MAINTENANCE PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W User manual 3BHS799208 E01 178/178...
Page 180 /180 — ABB Switzerland Ltd. Bruggerstrasse 66 CH-5400 Baden Switzerland new.abb.com/drives/medium-voltage-ac-drives — © Copyright 2009 ABB. All rights reserved. The information in this document is subject to change without notice.

ABB ACS5000 User Manual

1 About this Manual

2 Important Safety Information

3 Power Electronics and Cabinet Features

4 Transportation, Storage and Disposal

5 Mechanical Installation

6 Electrical Installation

7 Commissioning

8 Operation

9 CDP Control Panel

10 Preventive and Corrective Maintenance

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