ABB ACS5000 User Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Air Conditioner
  5. ACS5000
  6. User manual

ABB ACS5000 User Manual

Medium voltage ac drive air-cooled, 2 - 7 mva
Hide thumbs Also See for ACS5000:
Table of Contents

Quick Links

User manual
Medium voltage AC drive
ACS5000 air-cooled, 2 - 7 MVA
Table of Contents
loading

Related Manuals for ABB ACS5000

Summary of Contents for ABB ACS5000

  • Page 1 User manual Medium voltage AC drive ACS5000 air-cooled, 2 - 7 MVA...

  • Page 3: Table Of Contents

    Table of contents General information on manual and equipment Copyright notice Document identification Contact information Equipment covered by the manual Structure of the user documentation Target groups and required qualifications Responsibilities of the user Intended use of equipment Cyber security disclaimer Quality certificates and applicable standards Items covered by delivery Identifying the delivery...
  • Page 4 Table of contents 2.2.1 Main power supply with input transformer configurations 2.2.2 Auxiliary power supply configurations Drive topology 2.3.1 Front end 2.3.2 DC link 2.3.3 INU - Inverter unit Terminal compartment 2.4.1 Cable entry Input transformer 2-10 2.5.1 Installation solutions 2-10 2.5.2 Control equipment...
  • Page 5 Table of contents Chapter 5 - Mechanical installation Safety Overview on installation work General notes on installation 5.3.1 Dimensions, clearances 5.3.2 Cabinet roof 5.3.3 Fire protection 5.3.4 Cable duct material Preparing the floor Fixing the cabinet to the floor Installing the cabinet Installing the fan units Chapter 6 - Electrical installation Safety...
  • Page 6 Table of contents Required qualification Commissioning procedure Commissioning check list Customer assistance Customer acceptance Commissioning check list Mechanical installation Electrical installation Main circuit breaker (MCB) Input transformer (if applicable) Motor Insulation tests Power supply Miscellaneous Chapter 8 - Operation Operating conditions Safety Overview Overview of local operator panel...
  • Page 7 Table of contents CDP control panel modes Identification mode Actual signals mode 9.5.1 Overview 9.5.2 Selecting the actual signals display 9.5.3 Toggle between actual signals display and fault history 9.5.4 Displaying three actual signals 9.5.5 Selecting actual signals 9.5.6 Displaying a fault and resetting the fault history 9.5.7 Displaying and resetting an active fault 9-11...
  • Page 8 Table of contents 10.5.4 Serial communication interfaces 10-11 10.6 Corrective maintenance 10-15 10.6.1 Overview on maintenance tasks 10-15 10.6.2 Safety 10-15 10.6.3 De-energizing the drive locally 10-16 10.6.4 Grounding switches are not released 10-18 10.6.5 Connecting a grounding set 10-20 10.6.6 Emergency release of the door safety switch 10-21...
  • Page 9 Table of figures Fig. 1 Delivered items Fig. 1-1 Safety labels Fig. 2-1 Drive overview Fig. 2-2 Overview Fig. 2-3 DC link Fig. 2-4 Grounding switch Fig. 2-5 Grounding the drive Fig. 2-6 Terminal compartment Fig. 2-7 Control compartment of the transformer 2-12 Fig.
  • Page 10 Table of figures Fig. 10-3 TB820 bus modem 10-9 Fig. 10-4 Example of S800 I/O station 10-10 Fig. 10-5 Ethernet interface 10-12 Fig. 10-6 Modbus interface 10-13 Fig. 10-7 Profibus interface 10-14 Fig. 10-8 Four-way grounding set (option) 10-20 Fig. 10-9 Location of the door safety switch 10-22 Fig.
  • Page 11 List of tables Tab. 3-1 Fieldbus adapters 3-11 5k A UM 3BHS221906 ZAB E01 Rev. D 1 (2)
  • Page 12 List of tables 2 (2) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 13: General Information On Manual And Equipment

    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 Switzerland Ltd, Medium Voltage Drives. 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 14: Structure Of The User Documentation

    General information on manual and equipment If information is required beyond the instructions in this manual, refer the matter to ABB. Structure of the user documentation The complete set of user documentation of a standard drive consists of this manual and supplementary documentation that is provided in the following appendices: ■...

  • Page 15: Target Groups And Required Qualifications

    Commissioning of the drive must only be performed by qualified and certified ABB personnel. Handling The personnel must be skilled and experienced in unpacking and transporting heavy equipment.

  • Page 16: Responsibilities Of The User

    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 17: Items Covered By Delivery

    General information on manual and equipment Items covered by delivery Delivery typically comprises the following items: ■ Drive and transformer ■ Triangular nut driver ■ Door keys The transformer is either an integrated or a non- integrated type. The cabinets are either shipped in seafreight or airfreight packaging.

  • Page 18: Identifying The Delivery

    Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG shown on this packing list. ABB item Qty.
  • Page 19 General information on manual and equipment the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG shown on this packing list. ABB item Qty. Unit. Identnumber Commodity description Customer item 001221 cross wiring...

  • Page 20: Writing Conventions

    General information on manual and equipment Writing conventions The following icons and text conventions are used in the manual. Meaning of icons Illustrates an illuminated lamp or pushbutton. Illustrates a button or key to be pressed. Indicates an alternating display message. Refers to further information in a separate document.

  • Page 21: Important Note On Main Circuit Breaker

    Important note on main circuit breaker The main circuit breaker (MCB) is a major protection device of the drive. If a serious fault occurs in the drive, the MCB must disconnect the main power supply to the drive immediately. The main power supply must be disconnected without delay on an open or trip command from the drive to prevent hazard to the personnel and further damage to the equipment.

  • Page 22: Safety And Protection Requirements

    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 specifications, which are available for each medium voltage drive from ABB.

  • Page 23: Maintenance Recommendation

    ■ The maximum opening time of the MCB must never exceed the product or project-specific maximum time defined in the MCB specifications. Typical maximum values for the drive are defined as follows: ■ Maximum protection trip time: 75 ms The maximum protection trip time is the maximum permitted breaking time (open and arcing) of the breaking device after the open command has been initiated to prevent further damage to the drive, eg, diode failures.
  • Page 24 4 (4) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 25: Chapter 1 - Safety

    Chapter 1 - Safety Meaning of safety instructions Safety instructions are used to highlight a potential hazard when working on the equipment. Safety instructions must be strictly followed! Non- compliance can jeopardize the safety of personnel, the equipment and the environment.

  • Page 26: General Safety Information

    Chapter 1 - Safety General safety information To maintain safety and minimize hazards observe the following: • Before the drive is energized, make sure that: • all foreign objects are removed from the drive, • all internal and external covers are securely fastened and all doors are closed, locked and / or bolted.

  • Page 27: Possible Residual Risks

    Chapter 1 - Safety 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 28: Safety Labels And Signs

    Chapter 1 - Safety Safety labels and signs 1.4.1 Safety labels Safety labels are attached to the cabinet 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.

  • Page 29: Safety Signs

    Chapter 1 - Safety 1.4.2 Safety signs Depending on the delivery, the following additional safety signs are provided: Fire fighting The sign explains the procedure when fighting fire in electrical equipment. The sign should be installed well visible near the drive. Dimensions: 50 x 30 cm Pacemaker The magnetic field of the drive can influence the functioning of...
  • Page 30 Chapter 1 - Safety 1-6 (6) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 31: Chapter 2 - Power Electronics And Cabinet Features

    Chapter 2 - Power electronics and cabinet features Overview The air-cooled ACS5000 is a general-purpose frequency converter for the control of standard induction and synchronous motors. For information on the power and voltage range of the drive, see the Technical specifications...

  • Page 32: Power Supply Configurations

    Charging voltage I >> Main power supply Motor Transformer ACS5000 Fig. 2-1 Drive overview 2.2.1 Main power supply with input transformer configurations The main power is fed to the drive by the input transformer which adapts the line voltage to the required voltage for the drive. The input transformer is always part of the drive system.

  • Page 33: Auxiliary Power Supply Configurations

    Chapter 2 - Power electronics and cabinet features 2.2.2 Auxiliary power supply configurations The drive needs auxiliary power for: ■ the cooling system and a short-time power demand for the charging unit of the drive. ■ the control hardware. One single-phase power supply or two single-phase power supplies feed the power to the drive.

  • Page 34: Drive Topology

    Chapter 2 - Power electronics and cabinet features Drive topology Control compartment Rectifier/inverter compartment Power cell DC-link capacitors Rectifier Inverter Grounding switch Fig. 2-2 Overview 2-4 (16) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 35: Front End

    Chapter 2 - Power electronics and cabinet features 2.3.1 Front end The front end of the drive consists of three 12-pulse diode rectifiers. The three rectifiers add up to a network-friendly 36-pulse system. The front end rectifies the AC line voltage of the supply network and connects its output to the minus, neutral point, and plus of the DC link.

  • Page 36: Fig. 2-4 Grounding Switch

    Chapter 2 - Power electronics and cabinet features Grounding switches The grounding switches are safety devices that enable safe access to the medium voltage compartments of the drive. There is a grounding switch in each power cell. Fig. 2-4 Grounding switch When all three switches are in position grounded, the rectifier, the DC link and the inverter in each power cell are connected to the PE ground busbar.

  • Page 37: Fig. 2-5 Grounding The Drive

    Chapter 2 - Power electronics and cabinet features Lamp "Grounding switch released" Storage place of grounding switch lever Grounding switch lever inserted Grounding switch position: drive is grounded Grounding switch position: drive is not grounded Fig. 2-5 Grounding the drive 5k A UM 3BHS221906 ZAB E01 Rev.

  • Page 38: Inu - Inverter Unit

    Chapter 2 - Power electronics and cabinet features 2.3.3 INU - Inverter unit The three inverters convert the DC-link voltage to the required AC motor voltage and frequency. The inverters are self-commutated, 5-level voltage source inverters. As a result of the multi-level topology, the drive produces a total of nine switching levels.

  • Page 39: Terminal Compartment

    Chapter 2 - Power electronics and cabinet features Terminal compartment The terminal compartment provides the terminals for the feeder and motor cables and the ground busbar for the termination of the ground cable and the cable screens. The terminal compartment is accessible when the swing frame of the control compartment is open.

  • Page 40: Input Transformer

    Chapter 2 - Power electronics and cabinet features Input transformer The transformer supplies the three 12-pulse rectifier bridges with the required phase-shifted voltages, and voltage levels. This configuration results in a network-friendly 36-pulse system. 2.5.1 Installation solutions Depending on the ordered configuration, the drive and the transformer are prepared for the following installation solutions: ■...

  • Page 41: Control Equipment

    Chapter 2 - Power electronics and cabinet features ■ Non-integrated The drive and the transformer are installed in different locations. The maximum permitted length for the secondary transformer cables determines the distance between drive and transformer. The transformer is equipped with an additional compartment (1). The compartment is divided into the control compartment (2), and the terminal compartment for the power cables.

  • Page 42: Cabinet Design

    Chapter 2 - Power electronics and cabinet features Control compartment If the non-integrated transformer is supplied by ABB, the transformer cabinet contains a control compartment. Circuit breaker for auxiliary voltage Starters for the fan units Auxiliary contactors for the fan units...

  • Page 43: Door Locking System

    Chapter 2 - Power electronics and cabinet features Door locking system The doors of the drive are either lockable or bolted. Additionally, the door of the rectifier/inverter compartment of the drive is electromechanically secured. The lockable doors have locks with different inserts than the control compartment door.

  • Page 44: Cooling System

    Chapter 2 - Power electronics and cabinet features Cooling system 2.8.1 Configurations The standard drive, the integrated transformer, and the non-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 one of the standard fan units fails.

  • Page 45: Function

    Chapter 2 - Power electronics and cabinet features 2.8.2 Function Operation The standard fan unit is switched on by the control system of the drive when the DC link has been charged. The fan unit continuous to run for a preset time after the main power has been switched off to remove the heat from the interior of the cabinet.

  • Page 46: Fig. 2-10 Location Of Air Pressure Switch In The Drive

    Chapter 2 - Power electronics and cabinet features Air flow monitoring Air pressure switches monitor the air flow through the cabinet of the drive and the cabinet of the integrated transformer. Fig. 2-10 Location of air pressure switch in the drive Fig.

  • Page 47: Chapter 3 - Control System

    INT circuit board PPCS PPCS PPCS Phase-INT Phase-INT Phase-INT circuit board circuit board circuit board Power cell Power cell Power cell ACS5000 * option Fig. 3-1 Block diagram of control system 5k A UM 3BHS221906 ZAB E01 Rev. D 3-1 (14)

  • Page 48: Main Components

    Chapter 3 - Control system Main components Optional I/O station Customer terminals Circuit breaker for auxiliary voltage Circuit breaker for charging transformer AMC circuit board and main modulator Starters for fan units Standard I/O station Charging transformer for DC link 24 V power supply units 230 V (AC) transformer Fig.

  • Page 49: Local Control Panel

    Chapter 3 - Control system 3.2.1 Local control panel The local control panel on the door of the control compartment serves as the basic user interface for monitoring, control, operation of the drive, and setting of parameters. For further information, see Chapter 8 - Operation Chapter 9 - CDP control...
  • Page 50 Chapter 3 - Control system Control tasks The AMC circuit board has specific control and closed-loop tasks assigned to it. The AMC circuit board processes drive and status information, performs the speed and torque control tasks, and monitors the operation of the drive.

  • Page 51: Fig. 3-4 Dtc Torque Control

    Direct 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 52: I/O Modules

    DriveWare 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) DriveMonitor is a monitoring and diagnostics tool that allows ac- cess to the drive from any location in the world via a secure In- ternet connection.
  • Page 53 S800 I/O system Overview Internal and external, analog and binary I/O signals are connected to the control system by standard S800 I/O from the ABB Advant control system. The S800 I/O system is configured from the following interface packages: Standard package The standard interface package is always part of the drive.
  • Page 54 Chapter 3 - Control system I/O modules A complete I/O station comprises the I/O modules and the TB 820 bus modem. An I/O module consists of an I/O module and a module terminal unit (MTU). No. of I/O module type I/O rating channels Digital input...

  • Page 55: Fig. 3-5 S800 I/O Stations

    Chapter 3 - Control system I/O stations Optional I/O station TB820 bus modem (A5301) AI820 analog input (A5311) DI810 digital input (A5321) AO810 analog output (A5331) DO820 digital output (A5341) AI830 analog input (A5351) DI810 digital input (A5361) AI830 analog input (A5371) Standard I/O station TB820 bus modem (A2501) DI810 digital input (A2511)
  • Page 56 Chapter 3 - Control system I/O module identification The I/O modules are identified in the drive and in the wiring diagrams by their technical designation (eg, A2511). Additionally, a cluster-position designation is used in the wiring diagrams and in the software. This designation has no relevance to the connection of the control cables but is used to help identify a device in the software and the Signal and...

  • Page 57: Fieldbus Communication Interfaces (Option)

    Chapter 3 - Control system 3.3.2 Fieldbus communication interfaces (option) Overview Fieldbus communication interfaces are used for the bidirectional communication between the drive and a higher-level process control system. Typically, operational commands, status messages of the drive, speed or torque reference values, and actual values are transmitted. For further information on data transmission and on data and signal allocation to the transmitted datasets, see ■...
  • Page 58 Chapter 3 - Control system Modbus Terminal assignment X2:1 D(P) Data positive X2:2 D(N) Data negative Customer connections X2:3 Data ground X2:4 Shield AC ground via RC filter X2:5 Shield ground direct X2:6 Power supply (24 V (DC) +/- 10 %) X2:7 +24 V X2:8...
  • Page 59 Chapter 3 - Control system AMC circuit board DDCS Fieldbus adapter Higher-level control system Location The fieldbus adapter is DIN rail-mounted inside the control compartment (Fig. 3-6: The indicated mounting position can vary depending on the number of optional devices present in the control compartment. Fig.

  • Page 60: Pulse Encoder Interface Ntac (Option)

    Chapter 3 - Control system 3.3.3 Pulse encoder interface NTAC (option) Overview The NTAC interface is part of the control system of the drive if pulse encoder feedback is used to control the motor. Terminals X1 Terminals X2 Channel A 24 V Channel B 24 / 25...

  • Page 61: Chapter 4 - Transportation, Storage And Disposal

    Chapter 4 - Transportation, storage and disposal Safety The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment. Transport conditions The transport conditions for the drive are based on IEC 60721-3-2 'Classification of environmental conditions: Classification of groups of environmental parameters and their severities;...

  • Page 62: Unpacking And Inspection

    Compare the complete delivery with the purchase order and the packing list. 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 photo- graphs to ABB.

  • Page 63: Using A Crane

    Chapter 4 - Transportation, storage and disposal 4.4.2 Using a crane • Use lifting equipment (eg, web slings, chain slings, round slings, safety hooks, shackles) that corresponds to the weight of the cabinet. • Attach slings to the lifting brackets on the front and on the back of the base frame (Fig.

  • Page 64: Storage

    (9 – 200 Hz) 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. 4.5.2 Storage...

  • Page 65: Storage And Handling Of Spare Parts

    To maintain spare parts in good condition and to keep the warranty valid during the warranty period, observe the following: • Check the spare parts immediately after receipt for damages. Report any damage to the shipping company and the ABB service organization. • Keep spare parts in their original packaging.
  • Page 66 Chapter 4 - Transportation, storage and disposal 4-6 (6) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 67: Chapter 5 - Mechanical Installation

    Chapter 5 - Mechanical installation Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations. Overview on installation work The installation includes the following work: ■ Preparing the floor ■...

  • Page 68: Cable Duct Material

    Chapter 5 - Mechanical installation 5.3.4 Cable duct material Cable ducts should be of non-flammable material with non-abrasive surface. All cable entries and exits should be protected to prevent dust, humidity and animals entering into the drive. Preparing the floor Condition of the floor ■...

  • Page 69: Installing The Cabinet

    Chapter 5 - Mechanical installation Installing the cabinet The drive and integrated transformer are delivered in separate transport units. The units are joined and fixed to the floor at the installation place. After a transport unit has been positioned in the final location, do the following: •...

  • Page 70: Installing The Fan Units

    Chapter 5 - Mechanical installation Installing the fan units For information on the number of fan units to be installed, their location on the cabinet roof and the dimensions and weight, see Appendix C – Mechanical drawings. To lift the fan unit onto the roof, use a crane. To attach the lifting gear, use the supplied lifting eyes.

  • Page 71: Chapter 6 - 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 being switched on during installation.

  • Page 72: Ground Cable Connection And Cable Shield Connections

    Chapter 6 - Electrical installation Ground cable connection and cable shield connections Cable shields and cable armor are connected to the FE ground busbar (FE, protective earth) inside the drive. The ground cable is connected to the PE ground busbar of the drive. Transformer Drive Motor...

  • Page 73: Cabling Between Drive And Transformer

    Chapter 6 - Electrical installation Cabling between drive and transformer 6.5.1 Drive with integrated transformer Transformer Terminal compartment Drive Fig. 6-2 Drive with integrated transformer Cabling of a standard drive configuration includes the following connections between the drive and the transformer: ■...

  • Page 74: Drive With Non-Integrated Transformer

    Chapter 6 - Electrical installation 6.5.2 Drive with non-integrated transformer Transformer Terminal compartment Drive Fig. 6-3 Drive with non-integrated transformer Cabling includes the following connections between the drive and the transformer: ■ Transformer secondary cables ■ Cable from the PT100 temperature sensor in the transformer cabinet ■...

  • Page 75: Cable Entries

    Chapter 6 - Electrical installation 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 ■...

  • Page 76: Cable Entry With Cable Glands

    Chapter 6 - Electrical installation 6.6.2 Cable entry with sealing modules, type 2 Usage Auxiliary power cables, control cables Included in delivery Frame Supplier Roxtec AB (www.roxtec.com) Not included in delivery EMC sealing inserts (2), installation tools and accessories 6.6.3 Cable entry with cable glands Usage Power cables, ground cables, bonding conductors...

  • Page 77: Power Cables, Ground Cables, Equipotential Bonding Conductor

    Chapter 6 - Electrical installation Power cables, ground cables, equipotential bonding conductor 6.7.1 Further information See layout drawing in Appendix C – Mechanical drawings for information ■ Project-specific cable entry ■ Distance between point of cable entry and termination busbars ■...

  • Page 78: Fig. 6-4 Preparing Power Cables For Sealing Modules

    Chapter 6 - Electrical installation 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 in Fig. 6-5. • Install the sealing modules according to the instructions of the sealing module supplier.
  • Page 79 Chapter 6 - Electrical installation Preparing cables for EMC plates The orientation of the EMC plates is the same for top and bottom cable entry: the sealing grommets always face upwards. Remove the grommets from the entry plate. To ensure proper sealing, cut along the marking that corresponds to the cable diameter.

  • Page 80: Fig. 6-5 Preparing Power Cables For Emc Plates

    Chapter 6 - Electrical installation Outer cable sheath Grommet Entry plate EMC sleeve Conductor insulation removed to expose cable shield Cable tie Conductor screen extension to be connected to PE ground busbar Heat-shrinkable termination Fig. 6-5 Preparing power cables for EMC plates 6-10 (22) 3BHS221906 ZAB E01 Rev.

  • Page 81: Fig. 6-6 Preparing Power Cables For Cable Glands

    Chapter 6 - Electrical installation 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 in Fig. 6-6. Outer cable sheath Cable gland Conductor insulation removed to expose cable shield Plate...

  • Page 82: Connecting The Cables

    Chapter 6 - Electrical installation 6.7.3 Connecting the cables Connecting the cables NOTICE Risk of flashover! High voltages will be present in the terminal compartment. High voltages can cause a flashover between conductors with different electric potential, and between a conductor and earth. Therefore, maintain a minimum clearance of 55 mm between a conductor and the terminals of any other conductor, and between a conductor and earth.

  • Page 83: Fig. 6-8 Cable Connection And Bolt Orientation

    Chapter 6 - Electrical installation Drive and non-integrated transformer Drive • Connect the secondary cables of the transformer, and the motor cables to their corresponding busbars. • Connect the secondary cables of the transformer to the side of the busbars where the arrows point to in Fig.
  • Page 84 Chapter 6 - Electrical installation Ground connection to the grounding network • Connect the ground cable to the ground busbars (marked PE, Protective Earth) inside the terminal compartment of the drive and / or the transformer (arrows). Cabinet back Fig. 6-10 Ground busbar inside drive cabinet Cabinet front Fig.
  • Page 85 Chapter 6 - Electrical installation 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 86: Auxiliary Power, Control And Serial Communication Cables

    Chapter 6 - Electrical installation Auxiliary power, control and serial communication cables 6.8.1 Further information See Outline drawing in Appendix C – Mechanical drawings for information ■ Project-specific cable entry ■ Distance between point of cable entry and terminals Appendix D – Wiring diagrams for information on: ■...

  • Page 87: Routing The Cables

    Chapter 6 - Electrical installation 6.8.3 Routing the cables • Route the auxiliary power and the control cables through the cable duct on the left side of the control compartment as indicated in Fig. 6- Fig. 6-14 Routing control cables 6.8.4 Determining the cable length •...

  • Page 88: Connecting The Cables

    Chapter 6 - Electrical installation 6.8.6 Connecting the cables I/O stations • Connect the cables for the standard I/O station (Fig. 6-15: 1) to the intermediate terminals (Fig. 6-15: • Connect the cables for the optional I/O station (Fig. 6-15: 3) directly to the terminals of the I/O modules.
  • Page 89 Chapter 6 - Electrical installation Encoder module • Connect the overall shield and the individual shields of the encoder (option) cable to the separate shield grounding point (Fig. 6-16: 2). Do not connect the cable directly to the encoder (Fig. 6-16: The unshielded cable ends must be as short as possible.

  • Page 90: Final Checks

    Chapter 6 - Electrical installation 6.8.7 Final checks • Check that the entry plates are fastened properly. • Check that the cable glands fit tightly. • If EMC entry plates with rubber grommets are used, check that the grommets fit tightly. If necessary, seal the gaps with silicone rubber. Power supply cables for fan units •...

  • Page 91: Transformer Heating Cable

    Chapter 6 - Electrical installation 6.10 Transformer heating cable The heating cable inside the terminal compartment of the drive and the extension into the cabinet of the integrated transformer have been installed in the factory. The heating cable inside the drive cabinet has been installed in the factory and does not require any installation work.
  • Page 92 Chapter 6 - Electrical installation 6-22 (22) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 93: Chapter 7 - Commissioning

    Chapter 7 - Commissioning Required qualification Commissioning, parameter settings and functional tests of the drive must be carried out only by commissioning personnel certified by ABB. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.
  • Page 94 Chapter 7 - Commissioning 7-2 (2) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 95: Commissioning Check List

    Commissioning check list Mechanical installation Drive installed according to the instructions in the User manual Drive securely fastened to the floor (if applicable) Fan unit or fan units installed Visual inspection: - no badly affixed or damaged components - no foreign objects inside cabinet - no dirt, dust and humidity inside cabinet Electrical installation Types and cross-sections of control cables suitable for the signal type and signal level...

  • Page 96: Main Circuit Breaker (Mcb)

    Commissioning check list Main circuit breaker (MCB) Type of MCB selected as per MCB specification High-voltage connections completed MCB ready to be tested with drive MCB protection relay settings tested Safety devices (eg, door locks) tested and in operation Input transformer (if applicable) Ground connection completed Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) ready Safety devices (eg, door locks) tested and in operation...

  • Page 97: Insulation Tests

    Commissioning check list Insulation tests All power cables to input transformer, between input transformer and drive, and from drive to motor measured, measured values within the required limits. Test report of the megger test available If the test is carried out by the commissioning personnel of the drive, an additional day per drive-motor combination needs to be reserved.
  • Page 98 Commissioning check list 4 (4) 3BHS221906 ZAB E01 Rev. D 5k A UM...
  • Page 99 40 m/s 5 – 95% in the absence of condensation 5 – 60% in the presence of corrosive gases If the operating conditions are not within the specifications, contact ABB. 5k A UM 3BHS221906 ZAB E01 Rev. D 8-1 (14)

  • Page 100: Chapter 8 - Operation

    Chapter 8 - Operation For the maximum ambient temperature, see the Rating plate of the drive. Safety The drive must only be operated by qualified and authorized personnel, ie, personnel who are familiar with the operation of the drive and the hazards involved.

  • Page 101: Lamp Test

    Chapter 8 - Operation CDP control panel Main functions: ■ Starts and stops the motor ■ Displays status messages of the drive Displays alarm and fault messages of the drive and monitored foreign equipment. Resets alarm and fault messages Main power supply on When pressed, the illuminated pushbutton charges the DC link, and closes the main circuit breaker.

  • Page 102: Status Messages

    Chapter 8 - Operation Status messages 8.5.1 Overview on status messages The following section lists the status messages of the main operating states of the drive, the drive passes through, when it is put into operation (see section 8.5.2 Start sequence of the drive), when it is stopped (see section 8.5.3 Stop sequence of the...

  • Page 103: Start Sequence Of The Drive

    Chapter 8 - Operation The status message indicates that a fault condition has occurred that Tripped requires a shutdown of the drive. The status message always alternates with the specific fault message. The type of shutdown depends on the fault class the fault condition is assigned to in the drive software.

  • Page 104: Stop Sequence Of The Drive

    Chapter 8 - Operation 8.5.3 Stop sequence of the drive Operation Ready ref Stop command Stopping Speed ramps down INU stops to modulate Ready run Off command MCB opens DC link discharges Fan switches off after a delay Ready on Actions: Drive is grounded Door with electro-mechanical lock...

  • Page 105: Emergency-Off Sequence Of The Drive

    Chapter 8 - Operation 8.5.4 Emergency-off sequence of the drive Operation Ready ref Emergency-off command MCB opens INU stops to modulate Speed coasts down Cooling fan stops Not ready on Starting the drive It is recommended to have the following documents at hand when starting the drive system locally for the first time after commissioning: ■...

  • Page 106: Checks Before Starting The Drive

    Chapter 8 - Operation 8.6.1 Checks before starting the drive DANGER Hazardous voltages! All covers must be screwed in place to prevent unintentional contact with energized components. The manual release of the safety switch must be in the locked position to prevent the door of the medium voltage compartment being opened unintentionally during operation.

  • Page 107: Starting The Drive Locally

    Chapter 8 - Operation 8.6.3 Starting the drive locally Enable the local control mode of the CDP control panel. This step only applies to drives which are equipped with the optional safety relay. If the EMERGENCY-OFF RESET pushbutton is flashing, press the EMERGENCY-OFF RESET pushbutton to cancel flashing.
  • Page 108 Chapter 8 - Operation The status line of the CDP control panel alternates between Charging and AuxiliaryOn. 0.0 rpm 1 L -> Charging Charging StateINU AuxiliaryOn MOTOR SP 0.00 rpm POWER 0.0 kW When charging has been finished, the following takes place: ■...
  • Page 109 Chapter 8 - Operation To indicate that the drive system is operating, the display shows ReadyRef. 1 L -> 600.0 rpm StateINU ReadyRef MOTOR SP 0.00 rpm POWER 1000.0 kW 5k A UM 3BHS221906 ZAB E01 Rev. D 8-11 (14)

  • Page 110: Stopping The Drive

    Chapter 8 - Operation Stopping the drive Press the STOP key on the CDP control panel. The motor stops according to the preset stop function and the drive stops modulating. While the motor stops, the status line of the display shows ReadyRef.

  • Page 111: Emergency-Off

    Chapter 8 - Operation Emergency-off 8.8.1 Function The drive is equipped with a hard-wired emergency-off circuit. When an emergency situation occurs during operation, this safety feature ensures that the drive can be disconnected without delay from the main power supply. When the EMERGENCY-OFF pushbutton has been pressed while the drive is at standstill, the main power supply cannot be connected to the drive, hence the drive cannot be started up.

  • Page 112: Starting The Drive After An Emergency-Off

    Chapter 8 - Operation 8.8.3 Starting the drive after an emergency-off To start the drive after an emergency-off reference value, unlatch the EMERGENCY-OFF pushbutton. Turn the EMERGENCY-OFF pushbutton into the direction indicated by the arrows on the pushbutton to return the pushbutton to its initial position.

  • Page 113: Chapter 9 - Cdp Control Panel

    Chapter 9 - CDP control panel Overview The panel messages and parameter settings used in this chapter are typical examples to illustrate the related instructions and display functions and may therefore differ from the actual messages and parameter settings in the drive. 9.1.1 Display and keypad Display...

  • Page 114: Cdp Control Panel Functions

    Chapter 9 - CDP control panel CDP control panel 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 115: Identification Mode

    Chapter 9 - CDP control panel Identification mode When the power supply is switched on, or the CDP control panel is connected to the drive and the auxiliary voltage has been switched on already, the identification display appears showing the CDP control panel version and then the ID number of the drive.

  • Page 116: Actual Signals Mode

    Chapter 9 - CDP control panel After another few seconds, the display changes to the actual signals mode. The status line of the display alternates between DCGnd NOpen, NotReadyOn. 0.0 rpm 1 L -> DCGnd Nopen DCGndNopen StateINU NotReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW...
  • Page 117 Chapter 9 - CDP control panel For the complete list of selectable actual signals, see Signal and parameter table. Fault memory The fault memory display provides information on the 64 most recent fault events that occurred in the drive. It displays the name of the fault and the time it occurred.

  • Page 118: Selecting The Actual Signals Display

    Chapter 9 - CDP control panel 9.5.2 Selecting the actual signals display To open the actual signals display, press the ACT key. 1 L -> 600.0 rpm ReadyOn StateINU MOTOR SP 0.00 rpm POWER 0.0 kW 9.5.3 Toggle between actual signals display and fault history To toggle between actual signals display and fault history display, press a fast navigation key.

  • Page 119: Selecting Actual Signals

    Chapter 9 - CDP control panel 9.5.5 Selecting actual signals To select the actual signals display, press the ACT key. 1 L -> 600.0 rpm ReadyRun StateINU 600.00 rpm MOTOR SP POWER 75.0 kW To select a line where the actual signal is to be displayed, press the corresponding slow navigation key.
  • Page 120 Chapter 9 - CDP control panel To select a parameter group, press a fast navigation key. 600.0 rpm 1 L -> 1 ACTUAL SIGNALS 01 DC VOLTAGE 1000 V To select an actual signal, press a slow navigation key. 600.0 rpm 1 L ->...

  • Page 121: Displaying A Fault And Resetting The Fault History

    Chapter 9 - CDP control panel To cancel the selection and keep the original selection, press any of the mode selection keys. The selected CDP control panel mode is entered. 1 L -> 600.0 rpm ReadyOn StateINU MOTOR SP 0.00 rpm POWER 0.0 kW 9.5.6...
  • Page 122 Chapter 9 - CDP control panel To display a specific fault, press the slow navigation keys. The UP key selects the previous, the DOWN key the next fault. 1 L -> 600.0 rpm LAST FAULT + AMC: Fault Class 1 9 H 38 MIN 48 S To clear the fault history, press the RESET key.

  • Page 123: Displaying And Resetting An Active Fault

    Chapter 9 - CDP control panel 9.5.7 Displaying and resetting an active fault To display an active fault, press the ACT key. 600.0 rpm 1 L -> ACS 2000 FAULT MCB CloseControl To reset the fault, press the RESET key. 600.0 rpm 1 L ->...
  • Page 124 Chapter 9 - CDP control panel Group 07 Control words 21.01 Start function Group 08 Status words 21.02 Start function Group 09 Fault and alarm words 21.03 Off1 stop mode Group 11 Start / stop / direction / MCB control 21.04 Process stop selection Group 12...

  • Page 125: Selecting And Changing Parameters

    Chapter 9 - CDP control panel Control panel overview Status line Group number and name Parameter number and name Parameter value Selects the parameters mode Selects the parameter number 1 L -> 600.0 rpm and name 77 SYSTEM CONFIG 01 INU IdentifySel Selects the parameter value INU1 (MASTER) Enters change mode...
  • Page 126 Chapter 9 - CDP control panel To select a different group, press a fast navigation key. 600.0 rpm 1 L -> 75 OPTION MODULES 06 C3P1/AI820 Module DISABLED To select a parameter, press a slow navigation key. 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module...
  • Page 127 Chapter 9 - CDP control panel To change the parameter value, press: • a slow navigation key for numbers and text, • a fast navigation key for numbers only. 600.0 rpm 1 L -> 75 OPTION MODULES 07 C3P1/AI820 Module [DI810 24VDC] To confirm the setting and to return to the actual signals mode, press the ENTER key.

  • Page 128: Enabling / Unlocking A Parameter Lock

    Chapter 9 - CDP control panel 9.6.3 Enabling / unlocking a parameter lock Unwanted parameter entry can be prevented by activating the parameter lock function. The corresponding parameters are 16.02 PARAMETER LOCK and 16.03 PASSCODE and belong to parameter group 16 SYSTEM CTRL INPUTS. Enabling the Select parameter 16.02.

  • Page 129: Adjusting The Display Contrast

    Chapter 9 - CDP control panel 9.7.2 Adjusting the display contrast To enter the functions mode, press the FUNC key. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST To select the contrast adjustment function, press the slow navigation keys until the blinking cursor reaches the CONTRAST line.
  • Page 130 Chapter 9 - CDP control panel To change the contrast value, press a slow navigation key. 0.0 rpm 1 L -> CONTRAST To confirm the selection and to return to the actual signals display, press the ENTER key. 1 L -> 0.0 rpm UPLOAD <= <=...

  • Page 131: Local And Remote Control

    Chapter 9 - CDP control panel Local and remote control The local-remote feature of the CDP control panel allows selecting the control location of the drive. Possible are: ■ Local control ■ Remote control In this context, remote control is not necessarily equivalent to higher- level control.

  • Page 132: Remote Control

    Chapter 9 - CDP control panel 9.8.2 Remote control In remote control mode, operational commands or reference values usually come from a higher-level control system via fieldbus or remote I/O. However, with the following parameter settings it is possible to start and stop the drive, to set the motor’s direction of rotation, and to enter reference values from the CDP control panel.

  • Page 133: Disabling / Enabling Local Lock Function

    Chapter 9 - CDP control panel 9.8.3 Disabling / enabling local lock function Accidental switching from remote control to local control can be prevented with the local lock function. The corresponding parameter is 16.04 LOCAL LOCK and belongs to the parameter group 16 SYSTEM CTRL INPUTS.

  • Page 134: Operational Commands

    Chapter 9 - CDP control panel Operational commands For instructions on how to start and stop the drive system from the CDP control panel, see 8.6 Starting the drive 8.7 Stopping the drive. 9.9.1 Setting the direction of rotation Setting the direction of rotation from the CDP control panel is possible in: ■...

  • Page 135: Entering A Reference Value

    Chapter 9 - CDP control panel 9.9.2 Entering a reference value Entering a reference value from the CDP control panel is possible in: ■ Local control mode L ■ Remote control mode R Press a mode selection key. 1 L -> 600.0 rpm ReadyRun StateINU...
  • Page 136 Chapter 9 - CDP control panel To exit the reference value setting mode, press any of the mode selection keys. 550.0 rpm 1 L -> ReadyRun StateINU MOTOR SP 550.00 rpm POWER 75.0 kW 9-24 (24) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 137: Chapter 10 - Preventive And Corrective Maintenance

    ABB service personnel. After the warranty period, maintenance must only be carried out by certified personnel. To maintain safe and reliable operation of the drive, ABB recommends taking out a service contract with the ABB service organization.

  • Page 138: Identifying Electrical Equipment

    Chapter 10 - Preventive and corrective maintenance 10.2 Identifying electrical equipment 10.2.1 Device identification To facilitate the identification in wiring diagrams and parts lists, all devices are labeled in accordance with IEC 81346-1. Fig. 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 identification number as in the wiring diagrams.

  • Page 139: Alarm / Fault Indications

    Chapter 10 - Preventive and corrective maintenance 10.3 Alarm / fault indications 10.3.1 Messages When a failure occurs in the drive or in the equipment monitored by the drive (eg, MCB, transformer, cooling system), the CDP control panel displays a corresponding alarm or fault message and the alarm / fault lamp on the control compartment door lights up: ■...
  • Page 140 Chapter 10 - Preventive and corrective maintenance The message can be saved and viewed in the fault logger of the drive when a PC with the DriveWindow, DriveDebug or DriveMonitor is connected to the drive. The fault logger can also be called up on the CDP control panel.

  • Page 141: Error Message Levels

    Chapter 10 - Preventive and corrective maintenance 10.3.2 Error message levels Two error message levels are used in the drive: Alarm An alarm does not shut down the drive. If the condition causing the alarm is not corrected, a persisting alarm can often lead to a fault. An alarm cannot be reset manually.

  • Page 142: Troubleshooting Procedure

    The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. If a fault cannot be rectified, contact ABB service. When calling ABB service, it is recommended to have the following data available at the time when the fault occurred: ■...

  • Page 143: Removing The Cdp Control Panel

    Chapter 10 - Preventive and corrective maintenance 10.4 Removing the CDP control panel When the panel is removed while the drive is in operation, check the setting of parameter 31.01 PANEL LOSS SUPERVISION first. If the parameter is set to NOT USED, the panel can be removed without interrupting drive operation.
  • Page 144 Chapter 10 - Preventive and corrective maintenance Communication with The CDP control panel is connected to the AMC circuit board via an AMC circuit board RS485-Interface. 1 L -> 1242,0 rpm StateINU ReadyOn MOTOR SP 1242 rpm POWER 86.0 kW 10-8 (36) 3BHS221906 ZAB E01 Rev.

  • Page 145: Leds And Switches On Circuit Boards And I/O Modules

    Chapter 10 - Preventive and corrective maintenance 10.5 LEDs and switches on circuit boards and I/O modules The following section provides an overview on 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 146: S800 I/O - Tb820 Bus Modem

    Chapter 10 - Preventive and corrective maintenance 10.5.2 S800 I/O - TB820 bus modem Color Meaning Fault Fault in module Green Device in operation Green Power Power supply is healthy Green Traffic on optical ModuleBus Green Traffic on optical ModuleBus Green Traffic on electrical ModuleBus Fig.

  • Page 147: S800 I/O Modules

    Chapter 10 - 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 located at the topmost position on each module (Fig.

  • Page 148: Serial Communication Interfaces

    Chapter 10 - Preventive and corrective maintenance 10.5.4 Serial communication interfaces To identify the serial communication interface in the drive, see Appendix D – Wiring diagrams. For further information on the device, select the appropriate manual from the list below: ■...
  • Page 149 Chapter 10 - Preventive and corrective maintenance Ethernet interface NETA-21 remote monitoring tool NEXA-21 extension module Fiber-optic connectors for communication cable to the drive ■ TXD = transmitter ■ RXD = receiver RJ-45 connector for Ethernet cable Power supply connection on underside Fig.
  • Page 150 Chapter 10 - Preventive and corrective maintenance Name Color Function No NEXA-21 connected Green NEXA-21 found and initialized Blinking green NEXA-21 support is being initialized (when the remote monitoring tool boots up) NEXA-21 malfunctions Blinking red NEXA-21 not supported No SD/SDHC card Green Card attached and taken into use Blinking green...
  • Page 151 Chapter 10 - Preventive and corrective maintenance Name Color Function PC ETH 1 PC not connected. If an Ethernet cable is connected to the PC ETH 1 port but no one uses the tool, the LED remains blank. Green Connection set up and in operation, for example, DHCP is active and at least one PC has got an IP-address 1/2-second DHCP server is active.
  • Page 152 Chapter 10 - Preventive and corrective maintenance LED indications of the NEXA-21 Name Color Function NEXA-21 not controlled by the NETA-21 or the NETA-21 boots up Green NEXA-21 detected by the NETA-21 and the NEXA-21 turned on STAT Green System in operation, OK. DDCS drives (/converters/inverters) commissioned.
  • Page 153 Chapter 10 - Preventive and corrective maintenance Modbus interface Bus-cable terminals Fiber-optic connectors for communication cable to the drive ■ TXD = transmitter ■ RXD = receiver Status LEDs Switch for bus termination Meaning XMIT Flashing Interface transmits a response or an exception Flashing Interface receives a command from the Modbus network ERROR...
  • Page 154 Chapter 10 - Preventive and corrective maintenance Profibus interface Fiber-optic connectors for communication cable to the drive ■ TXD = transmitter ■ RXD = receiver Reset button for initialization of module Status LEDs Bus-cable terminals During start-up Master DDCS Power-on Green then red then off Green then red then off Green then red then off...

  • Page 155: Corrective Maintenance

    Chapter 10 - Preventive and corrective maintenance 10.6 Corrective maintenance 10.6.1 Overview on maintenance tasks ■ Visual checks on the drive ■ Cleaning ■ Checking wire and cable connections ■ Replacing the filter mats ■ Replacing a fan 10.6.2 Safety DANGER Hazardous voltages! Before starting to work on the drive, make sure that:...

  • Page 156: De-Energizing The Drive Locally

    Chapter 10 - Preventive and corrective maintenance NOTICE Foreign matter and particularly metallic dust can cause failure and damage when the drive is energized. Ensure that foreign matter cannot enter the cabinet: • Close the doors and cover openings completely when work is discontinued.
  • Page 157 Chapter 10 - Preventive and corrective maintenance De-energizing the drive To disconnect the drive from the main power supply, press the MAIN SUPPLY OFF pushbutton. The following takes place: ■ The MCB opens. ■ The DC link discharges. While the DC link discharges, the display shows the following. 600.0 rpm 1 L ->...

  • Page 158: Grounding Switches Are Not Released

    Chapter 10 - Preventive and corrective maintenance If the lamp is on, continue with Grounding. If the yellow lamp is not on, continue with 10.6.4 Grounding switches are not released. Grounding If the yellow lamp GROUNDING SWITCH UNLOCKED is on, turn the grounding switches to the grounded position.
  • Page 159 0.00 rpm POWER 0.0 kW If the DC-link voltage does not decrease below 50 V, do not continue but call ABB. To contact the ABB service organization, see Contact information. To test the lamp GROUNDING SWITCH UNLOCKED, activate the lamp test with parameter 16.7.

  • Page 160: Connecting A Grounding Set

    Chapter 10 - Preventive and corrective maintenance Switch off and lockout all auxiliary voltages from external sources. 10 Verify that the drive system is de-energized. 11 Ground the drive with a grounding set (option). 10.6.5 Connecting a grounding set Telescopic insulating pole Enclosure ground clamp Busbar ground clamp Fig.

  • Page 161: Emergency Release Of The Door Safety Switch

    Chapter 10 - Preventive and corrective maintenance 10.6.6 Emergency release of the door safety switch The door of the rectifier/inverter compartment is secured with a safety switch. The safety switch is tied into an interlocking circuit that operates in conjunction with the grounding switches of the drive and the interlocks from the main circuit breaker of the drive.
  • Page 162 Chapter 10 - Preventive and corrective maintenance Location Fig. 10-9 Location of the door safety switch Safety switch settings Release dial Unlocked position The unlocked position enables opening the door of a medium voltage compartment whether the auxiliary voltage is switched on or off. Locked position Locked is the normal operating setting.
  • Page 163 Chapter 10 - Preventive and corrective maintenance Unlocking On the roof of the drive, remove the cap of the access hole to the safety switch. Insert the supplied triangular nut driver into the triangular counterpart of the safety switch. Turn the release dial from the locked to the unlocked position (the symbols on the safety switch are visible when looking through the opening at an angle).

  • Page 164: Door Handles

    Chapter 10 - Preventive and corrective maintenance 10.6.7 Door handles Fig. 10-10 Pivoted door handle To open a door: To release the door handle, insert and turn the key to the right. The door handle pops out. To open the door, turn the door handle •...

  • Page 165: Cleaning

    Chapter 10 - Preventive and corrective maintenance 10.6.9 Cleaning NOTICE Risk of component damage! ■ Dust on electrical components and wiring can cause failure and damage the components. Dust and moisture can build up in loose connections and cause loss of low-level signals. Check the cabinet regularly for signs of dust and humidity and clean if necessary.

  • Page 166: 10.6.10 Checking Wire And Cable Connections

    Chapter 10 - Preventive and corrective maintenance 10.6.10 Checking wire and cable connections Vibration can loosen electrical connections and cause occasional malfunction or equipment failure. • Check all power and control cable connections and tighten them if necessary. • Check that all plugs and connectors are tight. NOTICE Capacitor bushings are damaged when excessive force is applied.

  • Page 167: 10.6.11 Replacing The Filter Mats

    Chapter 10 - Preventive and corrective maintenance 10.6.11 Replacing the filter mats Transformer Drive Filter class G3 (according to EN779) Dimensions (mm) 3.5 MVA drive 230 x 738 1839 x 648 1839 x 698 1839 x 277 7 MVA drive 230 x 738 1839 x 648 1839 x 698...
  • Page 168 Chapter 10 - Preventive and corrective maintenance 10-32 (36) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 169: 10.6.12 Replacing A Fan

    Chapter 10 - Preventive and corrective maintenance 10.6.12 Replacing a fan For information on replacement intervals, see Maintenance schedule. ~22 kg ~50 kg Screen Mounting plate Impeller and motor Flange Housing Motor cable connector Fig. 10-11 Fan – Exploded view Disconnect all power supplies to the drive and ground the drive.
  • Page 170 Chapter 10 - Preventive and corrective maintenance Remove the screen. Remove the fastening screws of the mounting plate (arrows). Disconnect the power supply cable inside the terminal box of the fan motor (arrow). 10-34 (36) 3BHS221906 ZAB E01 Rev. D 5k A UM...
  • Page 171 Chapter 10 - Preventive and corrective maintenance Unscrew the locknut of the cable gland and pull the power supply cable through the cable gland (arrow). Attach lifting gear appropriate for the weight of the impeller and the motor. Lift off the mounting plate with the impeller attached to it. To separate the motor-impeller-assembly from the mounting plate, remove the fastening screws of the motor.
  • Page 172 Chapter 10 - Preventive and corrective maintenance 10-36 (36) 3BHS221906 ZAB E01 Rev. D 5k A UM...

  • Page 173: Terms, Trademarks, Related Documentation

    Terms and abbreviations The following table lists 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.
  • Page 174 Term of ABB’s S800 I/O system. An I/O device consists of a module termination unit (MTU) and one I/O module. I/O module Term of ABB’s S800 I/O system. The I/O module is an active input or output device for digital or analog signals. I/O station Term of ABB’s S800 I/O system.

  • Page 175: Trademarks

    Term / Abbreviation Meaning Windows® Registered trademark of Microsoft Corporation Industrial IT Trademark of ABB DriveWare® Registered trademark of ABB Advant® Registered trademark of ABB Advant Fieldbus Trademark of ABB Ethernet® Registered trademark of Xerox Corporation Profibus® Registered trademark of Profibus International (P.I.) Modbus®...

  • Page 176: Related Documentation

    Technical data Technical data from drive smart Schematics Layout drawing Project-specific Specifications, guidelines Retrofit guideline 3BHS301179 ACS5000 Main circuit breaker specification 3BHS125149 ABB MVD ACS transformer specification 3BHS356582 ABB MVD ACS motor specification 3BHS824803 ACS5000 Power cable specification 3BHS215798 Power cables engineering guideline...
  • Page 178 Contact us ABB Beijing Drives System Company Limited No.1, Block D, A-10 Jiuxianqiao Beilu 100015, Chaoyang District, Beijing, PRC Phone: +86 400 810 8885 E-Mail: [email protected]...

Table of Contents