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03 POWER ELECTRONICS AND CABINET FEATURES

3BHS799208 E01 REV E

ACS5000 WATER-COOLED

USER MANUAL

3.10.3

Input grounding studs in a PCU

The converter input grounding studs (Fig. 3-27: 1L1, 1L2, and 1L3; Frame
sizes 3 and 4 also have 2L1, 2L2, and 2L3) and the protective earth
grounding studs (Fig. 3-27: PE) are at the back of each PCU.

Figure 3-27 Connection studs for the 4-way grounding set in a PCU

▲

DANGER

⚠

Hazardous voltages!

The steps in the “2.5 The 7 steps that save lives” on page 32 must be
completed before you remove the side and back walls from the drive to
access the grounding studs in a PCU.

PE

1L1

2L1

2L3

2L2

1L2

1L3

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Summary of Contents for ACS5000

Page 1: ... SYSTEM DRIVES ACS5000 water cooled User manual 5 36 MVA 6 6 9 kV ...

Page 2: ... without written permission from ABB Switzerland Ltd System Drives The hardware and software described in this document is provided under a license and may be used copied or disclosed only in accordance with the terms of such license Document owner ABB Switzerland Ltd System Drives CH 5300 Turgi Switzerland Document name ACS5000 water cooled user manual Document number 3BHS799208 E01 Rev E Release...

Page 3: ...4 1 6 3 Electrical installation 24 1 6 4 Operation 24 1 6 5 Maintenance 25 1 7 User s responsibilities 25 1 8 Intended use of equipment 25 1 9 Cyber security disclaimer 25 1 10 Quality certificates and applicable standards 27 1 11 Items covered by delivery 28 1 11 1 Identifying the delivery 28 1 12 Tools 28 2 Important safety information 29 2 1 Safety standards 29 2 2 Safety messages 29 2 3 Produc...

Page 4: ...se converter unit 1700 mm and 2100 mm 46 3 4 Control unit COU 47 3 4 1 Main components 48 3 4 1 1 AMC circuit board 49 3 5 Transformer and motor cable terminals 54 3 5 1 Transformer cable terminals 54 3 5 2 Motor cable terminals 54 3 6 Water cooling unit WCU 56 3 7 EXU Excitation unit optional 57 3 8 Door interlocking system 59 3 9 Grounding switches 60 3 9 1 Locking bars 61 3 10 Grounding studs 6...

Page 5: ...andling of spare parts 71 4 7 1 Warranty information 71 4 8 Disposal of packaging materials and components 72 5 Mechanical installation 73 5 1 Safety 73 5 2 Overview on installation work 73 5 3 General notes on installation 74 5 4 Dimensions and clearances 74 5 4 1 Rear and top access to the cabinet 74 5 4 2 Cabinet roof 74 5 4 3 Fire protection 74 5 4 4 Cable duct material 74 5 4 5 Installation m...

Page 6: ...sbars 87 5 14 Connecting the heating cable 89 5 15 Connecting raw water pipes 90 5 16 Fixing the drive to the floor 90 6 Electrical installation 91 6 1 Safety 91 6 2 Overview 91 6 3 Cable requirements 92 6 3 1 Power cables 92 6 3 2 Auxiliary and control cables 92 6 4 Grounding 93 6 4 1 Grounding the transformer and the drive 93 6 4 2 Grounding the drive and the motor multi point bonding 94 6 4 3 G...

Page 7: ...necting the cables 108 6 7 2 1 Checking the cable insulation 108 6 7 2 2 Connecting the cables 109 6 7 2 3 Bolted connections 111 6 8 Auxiliary power cables and control cables 112 6 8 1 Preparing the cable entry and the cables 112 6 8 1 1 Preparing cables for cable entries with sealing modules 114 6 8 1 2 Preparing cables for cable entries with cable glands 115 6 8 2 Connecting the cables 115 6 8 ...

Page 8: ... Miscellaneous checklist 122 8 Operation 123 8 1 Operating conditions 123 8 2 Safety 123 8 3 Overview 123 8 4 Local operator panel 123 8 5 Lamp test function 125 8 6 Status messages 125 8 6 1 Start sequence of the drive 127 8 6 2 Stop sequence of the drive 128 8 6 3 Emergency off sequence 129 8 7 Starting the drive 129 8 7 1 Checks before starting the drive 130 8 7 2 Starting the drive from remote...

Page 9: ...ctions 140 9 2 Modes 140 9 2 1 Identification mode 140 9 2 2 Actual signals mode 142 9 2 2 1 Overview 142 9 2 2 2 Selecting the actual signals display 143 9 2 2 3 Toggling between actual signals display and fault memory 144 9 2 2 4 Displaying three actual signals 144 9 2 2 5 Selecting actual signals 144 9 2 2 6 Displaying a fault and resetting the fault memory 146 9 2 2 7 Displaying and resetting ...

Page 10: ...ntive and corrective maintenance 161 10 1 General information 161 10 1 1 Required qualification 161 10 1 2 Maintenance schedule 161 10 1 3 Logbook 161 10 1 4 Spare parts 161 10 2 Identifying electrical equipment 161 10 2 1 Device designation 161 10 2 2 Cables and wires 162 10 2 3 Understanding wiring diagrams 162 10 3 Alarm fault indications 163 10 3 1 Messages 163 10 3 2 Error message levels 163 ...

Page 11: ...g switch is not released 176 10 6 5 Emergency release of a door safety switch 177 10 6 5 1 Location of safety switches 177 10 6 5 2 Safety switch settings 178 10 6 6 Visual checks on the drive 179 10 6 7 Cleaning 180 10 6 7 1 Cleaning the drive cabinet 180 10 6 8 Checking wire and cable connections 181 10 6 9 Checking and replacing filter mats 181 10 6 9 1 Location 181 10 6 9 2 Replacing filter ma...

Page 12: ......

Page 13: ...side view right B 43 Figure 3 8 Primary PCU 2100 mm 44 Figure 3 9 Primary PCU 2100 mm side view left A and side view right B 45 Figure 3 10 Secondary PCU 1700 mm A and 2100 mm B 46 Figure 3 11 Block diagram of control system 47 Figure 3 12 COU control section 48 Figure 3 13 DTC torque control 50 Figure 3 14 Local control panel 52 Figure 3 15 COU customer interface section 53 Figure 3 16 Motor term...

Page 14: ... and lift spreader 69 Figure 5 1 Floor inclination 75 Figure 5 2 Connection points on side of transport units PCU example 77 Figure 5 3 Applying silicone 78 Figure 5 4 Roof joint 78 Figure 5 5 Lifting a cooling unit example with IP54 unit 79 Figure 5 6 Cable duct openings example with 1700 mm PCU 81 Figure 5 7 Water inlet outlet and drain outlet back view 83 Figure 5 8 Roof attachment 84 Figure 5 ...

Page 15: ... 1 103 Figure 6 11 Cable entry with cable gland 103 Figure 6 12 Cable entry with EMC plates 104 Figure 6 13 Preparing power cables for cable glands 106 Figure 6 14 Preparing power cables for sealing modules 107 Figure 6 15 PCU cable terminals top and bottom entry back view 109 Figure 6 16 COU cable terminals top and bottom entry back view frame sizes 1 and 2 A and 3 and 4 B 110 Figure 6 17 Bolted ...

Page 16: ...de 149 Figure 9 4 Control panel functions for Functions mode 154 Figure 10 1 Device identification 162 Figure 10 2 Cable and wire designation 162 Figure 10 3 LEDs of AMC circuit board 167 Figure 10 4 TB820 bus modem 168 Figure 10 5 Example of S800 I O station 169 Figure 10 6 Location of safety switches 177 Figure 10 7 Safety switch 178 Figure 10 8 Filter mat replacement for PCU A and WCU B 182 Fig...

Page 17: ...cifications by frame size 40 Table 5 1 Installation material per roof joint 78 Table 5 2 Installation material per IP42 unit 80 Table 5 3 Installation material per IP54 unit 82 Table 6 1 Type 1 sealing modules and cables per frame opening 102 Table 6 2 Maximum number of type 1 sealing modules per frame opening 102 Table 6 3 Maximum number of cables per frame opening 3 core 102 Table 6 4 Maximum nu...

Page 18: ......

Page 19: ...es Appendix A Additional manuals provides manuals about additional equipment delivered with the drive such as project specific options like pulse encoder or fieldbus interfaces or information on modifications of the standard drive Appendix B Technical data contains the technical data sheets of the drive Appendix C Mechanical drawings provides the outline drawings of the drive The drawings are gene...

Page 20: ...ware for medium voltage drives Table 1 3 Schematics Title Document number 4 Layout drawing Project specific Table 1 4 Specifications and guidelines Title Document number 5 Generic transformer specification 3BHS356582 E01 6 Generic motor specification 3BHS824803 E01 7 Main circuit breaker engineering guideline 3BHS125149 E50 8 ACS5000 power cable specification 3BHS215798 E01 9 Power cables engineer...

Page 21: ...rt up guide 1 3AFY58919772 18 Profibus NPBA 12 installation and start up guide 1 3BFE64341588 1 Also available online in the ABB Library https library abb com Table 1 8 Terms and abbreviations Term Abbreviation Definition AMC The application and motor controller AMC is a digital signal processor and the heart of the drive control system Converter Short form for ACS5000 frequency converter COU The ...

Page 22: ...ompatibility EOI Electrical optical interface Equipment Frequency converter and related equipment EXU The excitation unit EXU is part of the drive when a synchronous motor has to be supplied with excitation power Ground Earth To ground 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...

Page 23: ...se module The phase module is a compact assembly of wired components including power semiconductors and circuit boards that serves as a standardized building block for the inverter and rectifier stack PINT Pulse interface SW Software S800 I O The S800 I O is a distributed process input output system that can be connected to various process controllers from ABB and other companies Transformer termi...

Page 24: ... 1 6 1 Handling Personnel must be skilled and experienced in unpacking and transporting heavy equipment 1 6 2 Mechanical installation The personnel must be qualified to prepare the installation site according to the site and equipment requirements and to perform the installation accordingly 1 6 3 Electrical installation Personnel must have a sound knowledge of the relevant electrical codes and spe...

Page 25: ...d has thoroughly read and clearly understood the instructions in this manual and the relevant safety instructions 1 8 Intended use of equipment Those in charge of the drive must ensure that the drive is only used as specified in the contractual documents operated under the conditions stipulated in the technical specifications and on the rating plate of the drive and serviced in the intervals speci...

Page 26: ...es encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB and its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leak...

Page 27: ...afety labels 21 ISO 7010 2011 E Graphical symbols Safety colours and safety signs Registered safety sign 22 EN 50110 European standard code for electrical work safety 23 ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design section 6 2 6 Category 3 24 IEC 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements ...

Page 28: ...tment door The label provides information on the type of drive the rated voltage the frequency and the current of the main and the auxiliary power supply 1 12 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 1 Drive either frame size S...

Page 29: ...lure to do so can result in serious Injury or DEATH Keep for future reference This is the safety alert symbol It is used to alert you to potential physical injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which i...

Page 30: ...ctricity warning This sign can also have additional text below it eg High voltage No access for people with active implanted cardiac device The magnetic field of the drive can influence the functioning of pacemakers The pacemaker sign should be installed at the entrance to the drive room or at a minimum distance of 6 m from the drive to stop personnel with pacemakers approaching the drive Firefigh...

Page 31: ...nsure that the appropriate personal protective equipment PPE is available and used when required Inform the involved personnel about the potential safety hazards Wear hearing protection when a drive is running 4 Before working simultaneously on the drive and on other drive system equipment Observe the relevant safety codes and standards Turn off all energy sources for the equipment Ensure that all...

Page 32: ...ate the Permit To Work PTW process For an example Permit to Work see Permission for working and permit to work for test work at test stations 3BHS817511 E30 2 Clearly identify the work location and equipment Use your senses sight hearing and smell to identify problem areas Define the work area via barriers and barricading and label equipment Avoid distractions such as talking or texting on the pho...

Page 33: ...ing If this is carried out by the customer then the PICW must ensure that this equipment is properly earthed as a part of the integration verification and during step 7 when the PICW walks the PTW 6 Protect against adjacent live parts and take special precautions when close to bare conductors Determine minimum approach distances apply screening or shrouding and when applicable padlock both cable a...

Page 34: ... or installed equipment Wrongly connected cables External influence on or damage of the equipment Wrong parameter settings Software errors Faulty hardware 3 Hazardous touch voltages can be present on drive system components which can be caused by Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltages by external equipmen...

Page 35: ...rmer Figure 2 2 Drive system overview The MCB is defined as a switching device to disconnect the power supply whenever required by the process or when a fault occurs Typical devices used as MCBs are Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor control centers A dedicated protection relay is used for Transformer primary cable protection Transformer protection if applicable...

Page 36: ...ing of the MCB by the drive must be possible at any time It is not permitted to interrupt the open and or trip command eg by a local remote switch in the MCB When the MCB is in service position the drive must have exclusive control of closing the MCB Local closing of the MCB is not permitted The maximum opening time of the MCB must never exceed the product or project specific maximum time defined ...

Page 37: ...dard motors with voltages up to 6 9 kV The drive features several proven ABB technologies including Multilevel fuseless voltage source inverter VSI MF design Direct torque control DTC platform IGCT power semiconductors Figure 3 1 Typical block diagram of the drive 1 Main power supply 2 Auxiliary power supply 3 I Prot 4 MCB 5 Transformer 6 ACS5000 7 36 pulse rectifier 8 DC link 9 9 level inverter 1...

Page 38: ...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 Figure 3 2 Switching levels Figure 3 3 Principle of 9 level topology 1 Volts 2 Amps 3 50 Hz operation point 4 Voltage 5 Current 1 2 3 4 5 6 7 8 9 10000 V 5000 V 5000 V 10000 V 1 2 3 4 5 15000 10000 5000 0 ...

Page 39: ... 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 Instead the IGCTs of the inverter are used for protection If an overcurrent occurs protection firing is triggered and fault clearing is initialized in less than 25 µs ...

Page 40: ...g on the frame size the drive has the following line up specifications Figure 3 5 Frame sizes 1 4 Table 3 1 Line up specifications by frame size Frame size Rating COU Primary PCU Secondary PCUs PCU width mm WCU width mm Total length mm 1 12 MVA 1 3 0 1700 800 7130 2 18 MVA 1 3 0 2100 1400 8930 3 24 MVA 1 3 3 1700 1400 12830 4 36 MVA 1 3 3 2100 1400 15230 1 2 3 4 ...

Page 41: ...hase converter unit connected via DC link represent a complete functional assembly Transformer cable connection The back left part of the primary phase converter unit contains the terminals for the transformer cables Fig 3 6 1 and Fig 3 8 1 Depending on the cable entry ordered the unit comes with a top or bottom cable entry Note For information on the dimensions and the busbar arrangement see Appe...

Page 42: ...AL 42 186 Figure 3 6 Primary PCU 1700 mm 1 Grounding switch 2 Crowbar circuit board or PINT circuit board 3 2 di dt chokes and 2 VLSCD circuit boards 4 DC link capacitors 5 Roof mounted cooling unit 6 Phase INT circuit board 7 PE ground busbar 8 Back oscillation damping circuit 1 2 3 4 5 6 7 8 ...

Page 43: ... side view left A and side view right B 1 Terminals for transformer cables 2 NP filter unit 3 Rectifier stack consisting of diodes and thyristors 4 DC link connection 5 Roof mounted cooling unit 6 Water pipe 7 Invert stack consisting of diodes sand IGCTs 8 AC busbars for adjacent PCU and motor phase 9 Gate unit 1 2 3 4 5 6 7 8 9 A B ...

Page 44: ...PCU 2100 mm 1 Roof mounted cooling unit 2 EAF circuit board 3 Pulse transformers for crowbar thyristors 4 PINT circuit board 5 2 di dt chokes and 2 VLSCD circuit boards 6 DC link capacitors 7 Main INT circuit board 8 2 IPS 9 Grounding switch 10 HVD and CVMI circuit board for voltage and current measurement 11 Clamp resistor 12 PE ground busbar 13 Back oscillation damping circuit 1 2 3 3 4 5 6 7 8 ...

Page 45: ...side view right B 1 Terminal compartment for transformer cables 2 VLSCD circuit board 3 Discharging circuit 4 Rectifier stacks consisting of diodes and thyristors 5 DC link connection 6 Roof mounted cooling unit 7 Inverter stacks consisting of diodes and IGCTs 8 Gate unit 9 Water pipe 10 AC busbars for adjacent PCU and motor phase 1 2 3 4 5 6 7 8 9 10 A B ...

Page 46: ...condary 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 Secondary phase converter units of 2100 mm are used in frame size 4 Figure 3 10 Secondary PCU 1700 mm A and 2100 mm B A B ...

Page 47: ...s Depending on the control concept of the drive system the remote control devices include a higher level control system and or remote operator stations Figure 3 11 Block diagram of control system 1 Customer interface 2 Control unit 3 Inverter 4 DriveMonitor 5 Higher level control system 6 DDCS 7 AMC circuit board 8 Fiber optic 9 Main INT interface 10 Phase INT interface 11 s800 I O process system ...

Page 48: ...or circuit breakers 8 Auxiliary contactors 9 Charging contactor 10 Switched mode power supplies 11 Electrolytic capacitors optional 12 Isolating transformers for customer UPS T1011 T1012 and step down transformer for internal buffer T1021 optional 13 S800 I O process system 14 Customer terminals 15 Thermostat for internal temperature 16 EOI circuit board 17 Thermostat for door mounted cooling fan ...

Page 49: ...rds inside the phase modules Control tasks The AMC circuit board has specific control and closed loop tasks assigned to it It processes drive and status information performs the speed and torque control tasks and monitors the operation of the drive All relevant drive variables eg speed torque current voltage are continuously monitored by the control system Pre programmed protection functions ensur...

Page 50: ...the actual values to reference values which are produced by the torque and flux reference controllers Depending on the outputs from the hysteresis controllers the switching logic directly determines the optimum switch positions every 50 ms and initiates switching whenever required Parameters The control system is configured customized and tuned with a set of application parameters The application ...

Page 51: ...include Local control panel on page 51 Customer interface on page 52 S800 I O system for parallel signal transfer to external devices Fieldbus adapters for serial data transfer to a higher level control system 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 b...

Page 52: ...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 The modules of the S800 I O system for monitoring of external equipment such as transformer and motor DriveMonitor 1 Local control panel 2 Local control pushbuttons 1 2 ...

Page 53: ...l 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 Each I O module is plugged into a termination unit that is wired to separate terminals to which the external signals are connected 1 Arc Guard System 2 Remote condition monitoring NETA 21 and fieldbus interface 3 Customer...

Page 54: ...hem open the swing frame of the control unit Besides of the busbars for motor cable terminations this unit also includes the charging transformer for the DC link the EMC filter and the EAF filter The layout of the motor terminal section depends on the following Frame size single or double busbars Cable entry from top or from bottom of the cabinet Note For information on the dimensions and the busb...

Page 55: ...3BHS799208 E01 REV E ACS5000 WATER COOLED USER MANUAL 55 186 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3 17 Motor terminal section of frame size 3 and 4 bottom entry A and top entry B A B 3 4 ...

Page 56: ...e 1 and 2 1400 mm frame size 3 and 4 Fig 3 18 shows the water cooling unit of frame size 3 type WCU1400 It allows you to identify the components of other models as well Figure 3 18 WCU 1400 mm frame size 3 Note For more information on the water cooling unit see Appendix A Additional manuals 1 Deaeration valve 2 Expansion vessels 3 Water pump 1 4 Filter 5 Ion exchange vessel 6 Water to water heat e...

Page 57: ...ns The converter controls the direct current for generating the magnetic field Brushes and slip rings feed the DC current to the rotor Brushless excitation AC excitation Brushless excitation uses a three phase DCS800 AC power controller see figure below The power controller feeds an exciter which is mounted on the shaft of the main motor The rotating armature of the exciter supplies a rectifier wh...

Page 58: ...her DCS800 Figure 3 20 EXU control panel Note For more information see 8 Operation on page 123 Reversing switch The EXU for brushless excitation is equipped with a reversing switch for changing the sense of rotation The switch is actuated by the drive The switch changes the sense of rotation via the optical communication link When the drive is in state ReadyOn or NotReadyOn the switch is opened Ou...

Page 59: ...e closed and locked and the grounding switches are in ungrounded position The interlocking system also ensures that you cannot open the doors of PCU compartments until the main power supply is disconnected the DC link capacitors are discharged and the grounding switches are in grounded position The doors of the COU compartment control unit and motor terminal section and the WCU compartment are not...

Page 60: ... 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 Figure 3 22 Grounding switch 1 Grounding switch Horizontal position drive is grounded Vertical position drive is not grounded 2 Yellow lamp grounding switch released Lights up to indicate that you can turn the grounding switch to...

Page 61: ...osition is only possible once the white lamp Fig 3 23 2 lights up The white lamp indicates that the drive is grounded In addition sliding a locking bar to the locked position is only possible once all doors of a PCU 2 doors in 1700 mm PCUs 3 doors in 2100 mm PCUs are closed 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 lo...

Page 62: ... designed for use with the 4 way grounding set Fig 3 25 Figure 3 24 Grounding stud 3 10 1 Grounding set Figure 3 25 4 way grounding set DANGER Hazardous voltages The steps in the 2 5 The 7 steps that save lives on page 32 must be completed before you access the grounding studs in the PCU 1 Enclosure ground clamp 2 Telescopic insulating pole 3 Busbar ground clamp 1 2 3 3 3 ...

Page 63: ...3 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 PE 1L1 1L2 1L3 ...

Page 64: ...zes 3 and 4 also have 2L1 2L2 and 2L3 and the protective earth grounding studs Fig 3 27 PE are at the back of each PCU Figure 3 27 Connection studs for the 4 way grounding set in a PCU DANGER Hazardous voltages The steps in the 2 5 The 7 steps that save lives on page 32 must be completed before you remove the side and back walls from the drive to access the grounding studs in a PCU PE 1L1 2L1 2L3 ...

Page 65: ...ve all packaging material carefully 2 Check the drive and accompanying equipment for damages 3 Compare the complete delivery with the purchase order and the packing list 4 If parts are missing or damaged immediately inform the shipping company and the ABB service organization It is recommended to photograph the damages and send the photographs to ABB The drive must only be handled by personnel who...

Page 66: ...ly delivered crates with accessories such as tools and installation material ABB item Customer item Qty Unit Identnumber Commodity description 001201 1 PC Converter 1 1 Transport Unit 1 1 All of the transport units for a drive have the same converter number in this case Converter 1 ABB Switzerland Ltd Drives Mailing address CH 5401 Baden Switzerland Phone 41 58 589 27 95 Telex 755749 abb ch Facsim...

Page 67: ...pendix C Mechanical drawings before transporting the drive This appendix provides details on dimensions weight and center of gravity of the drive To prevent distortions DO NOT lift and move the drive or a transport unit with a forklift 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 hy...

Page 68: ...et for stabilization Use appropriate safety hooks or shackles to attach a sling Do not pass a sling through the hole of the bracket If the slings are too close to the cabinet protect the edges and the door handles or levers Lift the drive or a transport unit slowly and steadily to the required clearance height maintaining it in upright position Check the horizontal position and reposition the slin...

Page 69: ... TRANSPORTATION STORAGE AND DISPOSAL Figure 4 2 Lift frame and lift spreader 3 Lift frame 4 Protect the edges 5 Protect door handles and levers 6 Extra sling 7 Safety hook or shackle 8 Lifting bracket 9 Slope angle 10 Lift spreader 1 2 3 4 5 6 2 3 4 5 6 7 8 15 max ...

Page 70: ...col for frost proofing if the drive is to be stored in ambient temperatures below 0 C Note For information about draining and frost proofing see the manual of the water cooling unit in Appendix A Additional manuals 2 Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil and a wooden panel 3 Add a desiccant of the appropriate quality One unit desiccant 30 g absor...

Page 71: ...ags or boxes Storage temperature range 5 C 55 C Storage place requirements Free of vibration and shock Protected against dust sand vermin and insects Free of corrosive gases salt or other impurities that could damage electronic equipment Dry no condensation relative air humidity 5 95 If in doubt whether the maximum allowed humidity is exceeded protect spare parts by an external heater Do not touch...

Page 72: ...SAL 3BHS799208 E01 REV E ACS5000 WATER COOLED USER MANUAL 72 186 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 ...

Page 73: ...oining transport units on page 77 5 8 Applying silicone on page 78 5 9 Installing roof joints on page 78 5 10 Installing roof mounted cooling units on page 79 option 5 11 Installing roof attachments on page 84 option 5 12 Joining water pipes on page 86 5 13 Joining busbars on page 87 5 14 Connecting the heating cable on page 89 option 5 15 Connecting raw water pipes on page 90 5 16 Fixing the driv...

Page 74: ...aterial with non abrasive surface To prevent dust humidity and animals from entering the drive protect all cable entries and exits of cable ducts 5 4 5 Installation material Installation material is supplied with the drive in a separate box 5 4 6 Tools See 1 12 Tools on page 28 NOTICE Risk of component damage Observe the following during installation Ensure that no dirt enters the drive Always clo...

Page 75: ...work for improving the surface is completed before the installation of the drive Use a spirit level or flooring rule with a vial for checking Recommended length 1 2 m If the surface cannot be improved place shims or leveling plates under the base frame at appropriate distances every 1 m for adjustment Leveling plates of the following size are recommended 10 mm x 10 mm Drill the fixing holes before...

Page 76: ...nsport units as shown in Appendix C Mechanical drawings The units can be lined up either beginning from the left or the right 4 Align the transport units 5 Verify the following alignment parameters 6 Maximum values for the axial misalignment and the angular deflection of two adjoining water pipes are not exceeded Axial misalignment 3 mm Axial deflection 5 7 Screw holes are exactly aligned ...

Page 77: ... 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 The installation material is mounted at one of the transport units Figure 5 2 Connection points on side of transport units PCU example ...

Page 78: ...stall the roof joints across shipping splits at the following locations Marine drives at the front of the roof the back is reserved for roof attachments see 5 11 Installing roof attachments on page 84 Standard drives at the front and the back of the roof Note For the exact number and fitting location of roof joints see Appendix C Mechanical drawings Figure 5 4 Roof joint Table 5 1 Installation mat...

Page 79: ...f the units are not preinstalled 5 10 1 Lifting a unit with a crane Procedure 1 Attach appropriate slings and shackles to the lifting brackets of a cooling unit 2 Using a crane lift the cooling units above the cabinet Figure 5 5 Lifting a cooling unit example with IP54 unit CAUTION Heavy objects An IP42 cooling unit weighs 40 kg An IP54 cooling unit weighs 98 kg ...

Page 80: ... 1 Align the unit with the opening 1 in the cabinet roof 2 Slowly lower the cooling unit onto the cabinet roof IMPORTANT Make sure that the screw holes fit 3 Screw the cooling unit to the cabinet roof 4 To get to the cable inside the cabinet remove the back wall if necessary to reach them from the back Table 5 2 Installation material per IP42 unit Item Quantity Details Self tapping Torx screws 18 ...

Page 81: ...he 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 In the cable duct at the front connect the cables according to Appendix D Wiring diagrams 1 ...

Page 82: ...the cabinet roof 2 Slowly lower the cooling unit onto the cabinet Make sure that the water inlet outlet the drain outlet the cables and the screw holes fit 3 Screw the cooling unit to the cabinet roof 4 To get to the water inlet outlet and the drain outlet from inside the cabinet Try to reach them from underneath the cable duct at the front Remove the back wall if necessary to reach them from the ...

Page 83: ...ct the tube from the feed pipe at bottom of cabinet to the water inlet Fig 5 7 2 8 Seen from the back the water inlet is on the right Seen from the front the water inlet is on the left 9 Connect the drain tube to the drain outlet Fig 5 7 3 The drain tube guides condensation water to the cabinet floor Figure 5 7 Water inlet outlet and drain outlet back view 10 Install the two white spacers Fig 5 7 ...

Page 84: ...see Appendix D Wiring diagrams Figure 5 8 Roof attachment Item Details ID number 1 2 x nuts M12 HZN 452198P1022 2 2 x washers 13 29 ST ZN 9ABA450078P0007 3 2 x washers 17x30x3 9ABA450078P0008 4 2 x hex head bolts M16x40 NB 312350P0464 5 1 x bracket 3BHB035997R0002 6 2 x spacers 3BHB032466R0001 7 1 x damping pad 3BHB035998R0001 8 1 x bracket 3BHB035997R0001 9 2 x damping connectors 3BHB033405R0001 ...

Page 85: ... of the scope of delivery WARNING Do not install the struts at a 90 angle to the cabinet roof Fig 5 9 4 If you fix the drive to the ceiling use two struts per roof attachment 1 in Fig 5 9 5 If you fix the drive to the back wall install one strut in a 90 angle to the drive 2 in Fig 5 9 Figure 5 9 Recommended ceiling and wall fixings 1 Two struts at 45 to ceiling 2 One strut at 90 to wall 3 Do not i...

Page 86: ...adjusting a pipe joint alternately tighten the bolts lightly 5 Tighten the bolts to the torque indicated on the pipe joint 5 12 1 Removing a pipe joint If you need to remove a pipe joint proceed as follows 1 Loosen the bolts alternately but do not remove them completely 2 Slide the pipe joint to the side 3 The sealing lip may touch the pipe end 4 Turn and move the pipe joint smoothly 5 Clean the p...

Page 87: ...re 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 2 Join the busbars 3 Tighten the bolts to the torque of 40 Nm 1 2 3 ...

Page 88: ...ure 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 Figure 5 12 PE ground busbar connection DC busbars The joining pieces of the DC busbars are deposited inside the transport units Related installation material is mounted at one of the busbar ends in the transport un...

Page 89: ...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 Figure 5 14 Heating cable connection ...

Page 90: ...langes of the water cooling unit Installation material such as counter flanges bolts nuts and seals are supplied Note For dimensions of the raw water entry and the flanges see Appendix C Mechanical drawings 5 16 Fixing the drive to the floor The base frame provides holes for fixing the drive to the floor Floor fixings are not supplied Bolts and nuts of size M16 are recommended ...

Page 91: ...trol cables on page 112 DANGER Hazardous voltage Improper work could lead to life threatening injury or death The electrical installation must be carried out by qualified personnel according to the site and equipment requirements and the relevant electrical codes When the electrical installation is completed the main and auxiliary power supply to the drive must not be switched on without the conse...

Page 92: ...wer cables engineering guideline 6 3 2 Auxiliary and control cables Note For information on the requirements for the auxiliary power cable and the control cables see Auxiliary power and control cables guideline NOTICE Risk of false signals DO NOT lay control cables in parallel to the power supply cables If this cannot be avoided a minimum distance of 30 cm must be maintained between control and po...

Page 93: ...nd the drive Fig 6 1 shows the grounding connections of a drive and an input transformer in the PCU compartments Figure 6 1 Grounding the transformer and the drive in PCU 1 Input transformer 2 Drive 3 Grounding network of installation site 4 Ground cable 5 Cable screen 6 Cable shield 7 Equipotential bonding conductor 1 L2 20 0 20 20 0 20 20 0 20 20 0 20 1 2 3 U V W 1 2 3 U V W 1 2 3 U V W 1 2 3 U ...

Page 94: ...o ground a drive and a motor in the COU compartment Note For more information see the Power cables engineering guideline document Figure 6 2 Grounding the drive and the motor multi point bonding 1 Drive 2 Motor 3 Grounding network of installation site 4 Ground cable 5 Cable screen 6 Cable shield 7 Equipotential bonding conductor 1 2 3 1 2 3 1 2 3 1 2 3 PE 1L1 1L2 1L3 PE U V W 1 2 3 4 5 6 7 ...

Page 95: ...t bonding connections to ground a drive and a motor in the COU compartment Note For more information see the Power cables engineering guideline document Figure 6 3 Grounding the drive and the motor single point bonding 1 Drive 2 Motor 3 Grounding network of installation site 4 Ground cable 5 Cable screen 6 Cable shield 1 2 3 1 2 3 1 2 3 1 2 3 PE 1L1 1L2 1L3 PE U V W 1 2 3 4 5 6 ...

Page 96: ...ent The ground busbar spans across the entire length of the drive Fig 6 4 Fig 6 5 The connection must be in compliance with local regulations For project specific illustrations see Appendix D Wiring diagrams Figure 6 4 PE ground busbar in COU back view Figure 6 5 PE ground busbar in PCU back view 1 Bottom entry 2 PE ground busbar 3 Top entry 1 Bottom entry frame sizes 1 and 3 example 2 PE ground b...

Page 97: ...ion Auxiliary power supply cable connection Optical fiber connections Arc Guard sensor cabling Make the above mentioned connections through the cable duct in the upper part of the drive cabinet Fig 6 6 Fig 6 7 Additionally there is one charging cable to be connected The charging cable is located at the bottom of the drive cabinet behind the water pipe The cables and wires can be identified by thei...

Page 98: ...up beside the detectors must be routed from the detectors to the Arc Guard unit in the COU NOTICE Risk of equipment failure Handle optical fibers with care DO NOT touch the ends of the fibers they are sensitive to dirt When unplugging hold the connector and not the fiber If an optical fiber is damaged or improperly installed data transmission can be affected and the equipment can fail To prevent s...

Page 99: ...s frame size 1 A and 2 B 1 Shipping split PCUx1 PCUx1 2 Cable ducts on each side of the shipping split for Auxiliary power supply cables Optical fibers Signal cables 3 Connection point for charging cable 4 Charging cable behind water pipe not illustrated laid on the brackets and connected to the busbar 5 PCUx1 1 2 2 3 4 5 5 A B ...

Page 100: ...ize 3 and 4 1 Shipping split 2 Cable ducts on each side of the shipping split for Auxiliary power supply cables Optical fibers Signal cables 3 Connection point for charging cable 4 Charging cable behind water pipe not illustrated laid on the brackets and connected to the busbar 5 PCUx0 6 PCUx1 1 1 2 2 3 3 4 4 A B PCUx0 PCUx0 PCUx1 PCUx1 ...

Page 101: ...ry with cable glands Note For information on the location and the dimensions of the cable entry see Appendix C Mechanical drawings 6 6 1 Cable entry with sealing modules type 1 Usage power cables ground cables bonding conductors Included in delivery cable entry frame Fig 6 8 1 Not included in delivery sealing modules Fig 6 8 2 accessories tools Figure 6 8 Cable entry with sealing modules type 1 1 ...

Page 102: ... 4 6 FS 1 3 5 Cable entry bottom FS 2 4 6 FS 2 4 FS 1 3 FS 6 FS 5 Table 6 2 Maximum number of type 1 sealing modules per frame opening Frame 1 1 2 3 4 5 6A 6B RM120 2 2 2 1 1 1 2 1 RM90 2 2 1 RM60 8 8 8 4 4 6 8 4 Table 6 3 Maximum number of cables per frame opening 3 core Frame 1 1 2 3 4 5 6A 6B 68 99 mm 2 2 2 1 1 1 2 1 48 71 mm 2 2 1 Table 6 4 Maximum number of cables per frame opening single cor...

Page 103: ... 1 Figure 6 10 Cable entry with sealing modules type 1 Supplier Roxtec AB roxtec com Not included in delivery EMC sealing inserts Fig 6 8 2 installation tools accessories 6 6 3 Cable entry with cable glands Usage power cables ground cables bonding conductors auxiliary power cables control cables Included in delivery undrilled plate for cable glands Figure 6 11 Cable entry with cable gland Cable st...

Page 104: ... 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 12 1 and sealing grommets Fig 6 12 1 Figure 6 12 Cable entry with EMC plates Ø45 mm 1 2 ...

Page 105: ...n on Designation cross reference and device identification conventions Transformer cables and motor cables and their corresponding connections 6 7 1 Preparing the cable entry and the cables 6 7 1 1 Determining the cable length 1 Determine the required length of a cable between the point of entry and the connection point inside the cabinet 2 Cut the cable to the required length before connection NO...

Page 106: ... an outer cable screen or shield for EMC bonding with the metal enclosure of the cabinet as illustrated Figure 6 13 Preparing power cables for cable glands 1 Cable gland 2 Plate 3 Heat shrinkable termination 4 Outer cable sheath 5 Conductor insulation removed to expose cable shield 6 Cable screen extension to be connected to PE ground busbar 7 Sheath seal 1 2 3 4 5 6 7 ...

Page 107: ...ing modules Install the sealing modules according to the instructions of the sealing module supplier 1 Sealing module 2 Frame 3 Conductive foil of sealing module 4 Cable clamp 5 Shrinkable sheath seal 6 Heat shrinkable termination 7 Outer cable sheath 8 Cable sheath removed to expose cable shield 9 Shield extension to be connected to PG busbar 10 Cable screen extension to be connected to the PG bu...

Page 108: ...sioning personnel has given permission to connect them CAUTION Risk of flashover High voltages will be present in the terminal compartment High voltages can cause flashover between conductors with different electric potential and between a conductor and earth Therefore route and connect the cables in such a way that the following minimum clearances are maintained 70 mm between cable lugs of conduc...

Page 109: ...ponding busbars Transformer cables to the busbars inside the primary PCU Fig 6 15 Motor cables to the busbars inside the COU Fig 6 16 Ground cable to the PE ground busbar 6 7 2 2 1 Transformer cables Figure 6 15 PCU cable terminals top and bottom entry back view 1 Busbars for transformer cables 2 Top cable entry 3 Bottom cable entry 1 1 2 2 2 2 3 3 3 3 ...

Page 110: ...nals top and bottom entry back view frame sizes 1 and 2 A and 3 and 4 B 1 Top cable entry frame sizes 1 and 2 2 Busbars for motor cables frame sizes 1 and 2 3 Bottom cable entry frame sizes 1 and 2 4 Top cable entry frame sizes 3 and 4 5 Busbars for motor cables frame sizes 3 and 4 6 Bottom cable entry frame sizes 3 and 4 1 2 2 3 4 5 6 A B ...

Page 111: ...d to a busbar Spring washer Fig 6 17 1 and flat washer Fig 6 17 2 on each side of the busbar Fig 6 17 3 Other washers can be used provided they maintain the required contact pressure Use cable lugs suitable for M12 bolts Figure 6 17 Bolted busbar connection Lubrication If stainless steel bolts and nuts are used lubricate the thread and head contact surface of the bolt using recommended pasts eg Mo...

Page 112: ...uired length of a cable between the point of entry and the connection point inside the cabinet 2 Cut the cable to the required length before connection Routing the cables The auxiliary power supply cables enter the WCU compartment The control cables enter the COU compartment Preparing cables for EMC plates only top cable entry 1 Remove the grommets 2 To ensure proper sealing cut along the marking ...

Page 113: ...Fig 6 18 1 To turn the conductive side inside out pull the cable screen ends over the cable insulation Fig 6 18 2 Connect the screens ends with a continuous conducting foil Fig 6 18 3 Figure 6 18 Preparing control cables for EMC plates 6 Pull the cable through the entry plate 7 To prevent water from entering the cabinet fit the grommet tightly and seal any gaps with silicone 8 If you had removed t...

Page 114: ...ving and installing the sealing modules and using the compression wedge see Appendix A Additional manuals 2 Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated Figure 6 19 Preparing control cables for sealing modules 1 Sealing module 2 Conductive foil 3 Cable sheath removed to expose cable shield 4 Conductor screen extension to be co...

Page 115: ...closure of the cabinet as illustrated Figure 6 20 Preparing control cables for cable glands 6 8 2 Connecting the cables For information on project specific connections see Appendix D Wiring diagrams For information on terminal sizes see document Customer interface 1 Outer cable sheath 2 Cable gland 3 Conductor insulation removed to expose cable shield 4 Plate 5 Conductor screen extension to be con...

Page 116: ... relevant terminals Bottom entry 1 Route the cables through the floor or the top of the WCU up the cable duct 4 in Fig 6 21 on the right side wall and then into the terminal compartment 3 in Fig 6 21 of the WCU 2 Connect the cable to the bottom of the relevant terminals according to the converter wiring diagram Figure 6 21 Cable routing in WCU800 A and WCU1400 B cabinets 1 Terminal compartment 2 W...

Page 117: ...ds as short as possible Use a shield grounding clamp Fig 6 22 to fasten the overall shield and the individual shields to the ground busbar Fig 6 22 8 Figure 6 22 Shield grounding clamp Figure 6 23 COU customer interface section 1 Arc Guard 2 Remote condition monitoring NETA 21 and fieldbus interface 3 Customer terminals 4 S800 I O process system customer specific configuration 5 Grey encoder optio...

Page 118: ... X10 X11 Fig 6 23 10 Main circuit breaker signals and emergency off signals X20 X27 Fig 6 23 7 Control signals of monitored equipment Fieldbus interface Connect the cable directly to the fieldbus adapter Encoder interface 1 Connect the cable directly to the encoder adapter 2 Connect the overall shield and the individual shields of the encoder cable to the copper busbar IMPORTANT DO NOT connect the...

Page 119: ...ing and completing the items in the commissioning checklist before the commissioning personnel arrive on site will help to achieve this During the commissioning period the customer is requested to provide qualified personnel for assistance who are Experienced with medium and low voltage equipment and with the local safety regulations Familiar with the driven process Authorized to operate associate...

Page 120: ...nged to the drive if applicable 8 Raw water supply is ready 9 Visual inspection No badly affixed or damaged components No foreign objects left in the cabinet No dirt dust or moisture in the cabinet 7 6 2 Electrical installation checklist 1 Types and cross sections of control cables suitable for the signal type and signal level 2 Types and cross sections of power cables selected according to the AB...

Page 121: ... 1 The release dial of the safety switches in the locked position 7 6 4 Main circuit breaker MCB 1 MCB selected as per Main circuit breaker specification 1 2 High voltage power connections completed 3 MCB is ready to be tested with drive 4 MCB protection relay settings are tested 5 Protection devices eg door locks are tested and in operation 6 Local operation of MCB is disabled 7 Emergency off loo...

Page 122: ...alues within required limits 2 Test report is available If the commissioning personnel carry out the test an additional day per drive motor combination must be reserved After the test the mains cables can be connected except at the drive end Test must comply with the specification 7 6 8 Power checklist 1 Medium voltage available for startup of drive 2 Low voltage is available for startup of drive ...

Page 123: ...ore differ from the actual status messages and parameter settings in the drive 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 Setting the reference valu...

Page 124: ...n equipment Resets alarm and fault messages Note For more information see 9 CDP control panel on page 139 Main power supply off Illuminated pushbutton opens the main circuit breaker Main power supply on Illuminated pushbutton charges the DC link and closes the main circuit breaker 1 CDP control panel 2 Main power supply off 3 Main power supply on 4 Alarm fault lamp 5 Emergency off reset pushbutton...

Page 125: ...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 Status messages The following section lists the status messages of the main operating states that the drive passes through when Drive is put into operation see 8 6 1 Start sequence...

Page 126: ...On changes to Charging when the DC link capacitors of the drive are being charged The drive is energized and ready for operation As soon as the start command is initiated the motor is magnetized and the drive starts to modulate The drive is running and operating according to the set speed or torque reference value When in remote control mode the reference value is set at the higher level control s...

Page 127: ...f the drive 1 NotReadyOn 2 ReadyOn Auxiliary power supply on PCU doors closed and locked Drive not grounded No emergency off No fault WCU ready 3 On command 4 Charging DC link charges MCB closes Cooling system switches on 5 ReadyRun 6 Start Command Inverter starts to modulate 7 ReadyRef 8 Operation ...

Page 128: ...he drive 1 Operation 2 ReadyRef 3 Stop command 4 Stopping Speed ramps down Inverter stops modulating 5 ReadyRun 6 Off command MCB opens DC link discharges Cooling system switches off after a delay 7 ReadyOn Ground drive PCU doors are released for opening Switch off auxiliary power supply 8 NotReadyOn ...

Page 129: ...oors of the medium voltage compartments from being opened unintentionally during operation CAUTION Cooling system starts automatically The cooling system can start automatically as soon as the auxiliary voltage has been switched on NOTICE When you start the drive system locally for the first time after commissioning have the following documents at hand Appendix D Wiring diagrams to identify the ci...

Page 130: ... interlock active 8 7 2 Starting the drive from remote When the drive system is operated from a higher level control system or an operator control desk follow the instructions in the applicable manuals 8 7 3 Starting the drive locally 1 Set the CDP control panel to local control mode 2 If the EMERGENCY OFF RESET pushbutton is flashing press the pushbutton to cancel flashing Each time the auxiliary...

Page 131: ...ntrol panel alternates between Charging and AuxiliaryOn After charging has been finished the following takes place The main circuit breaker closes automatically The SUPPLY ON pushbutton lights up permanently 5 Enter the reference value Note For more information see 9 3 2 Entering a reference value on page 159 1 L 0 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW 1 L 0 0 rpm StateINU Charging...

Page 132: ...d 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 The display shows ReadyRef to indicate that the drive system is operating LOC RESET REF REM 1 L 600 0 rpm I StateINU ReadyRef MOTOR SP 0 00 rpm POWER 1000 0 kW ...

Page 133: ...in progress you can always restart the drive by pressing the START key Just before the motor comes to a standstill the status line shortly displays Stopping When the motor has reached zero speed the status line displays ReadyRun As long as the MCB has not been opened you can restart the motor at any time I 0 1 L 600 0 rpm I StateINU ReadyRef MOTOR SP 300 00 rpm POWER 20 0 kW LOC RESET REF REM 1 L ...

Page 134: ...al EMERGENCY OFF pushbutton that is linked to the emergency off circuit When an emergency off is initiated during operation the following takes place Main circuit breaker opens Drive coasts down DC link of the drive discharges Status line indication of the CDP control panel alternates between EmergencyOff and NotReadyOn EMERGENCY OFF RESET pushbutton flashes SUPPLY OFF pushbutton flashes 8 9 2 Sta...

Page 135: ...D USER MANUAL 135 186 08 OPERATION After resetting the drive status message changes to ReadyOn The main power supply can be connected to the drive and the drive can be started again 1 L 0 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW ...

Page 136: ...hout the need for additional devices The MCB requirements are described in 2 7 Important note main circuit breaker on page 35 Table 8 1 ABB arc resistant classes ABB class Description Class I Protection based on arc prevention NOT certified according to IEC 62477 2 Class II Protection based on arc resistant cabinet structure 1 1 IAC certified by 3rd body according to IEC 62477 2 Class III Protecti...

Page 137: ...onsists of the following Arc Guard unit TVOC 2 with HMI panel Optical fiber detector 8 10 3 Action after the Arc Guard System has been triggered 1 De energize and ground the drive according to 10 6 2 De energizing the drive on page 172 2 Search for the location where the arc has been detected 3 Check the Arc Guard HMI panel messages and use the circuit diagrams Figure 8 4 HMI panel 4 Open the powe...

Page 138: ...9208 E01 REV E ACS5000 WATER COOLED USER MANUAL 138 186 8 11 De energizing and grounding the drive See 10 6 2 De energizing the drive on page 172 8 12 Opening the doors See 10 6 3 Opening and closing the doors on page 174 ...

Page 139: ...lay 2 Status line 3 Actual signal names and values 4 Keypad 5 Mode selection keys 6 Fast navigation key for selecting the actual signals display or the fault memory display 7 Local remote selection key 8 Reset key 9 Forward key 10 Backward key 11 Slow navigation key for selecting signals or fault messages 12 Enter key terminates a procedure 13 Reference key 14 Start key 15 Stop key 1 2 3 4 5 6 7 8...

Page 140: ...tion on the most recent 64 fault events 9 2 Modes The CDP control panel provides the following modes 9 2 1 Identification mode on page 140 9 2 2 Actual signals mode on page 142 9 2 3 Parameters mode on page 149 9 2 4 Functions mode on page 154 Drive mode not used 9 2 1 Identification mode The identification mode informs the user about the CDP control panel version and the ID number of the drive Th...

Page 141: ...lay changes to the actual signals display The status line of the display alternates between DCGndNOpen and NotReadyOn ACS6000 xxxx Device Name LXHH44xx ID NUMBER 1 1 2 3 4 1 L 0 0 rpm StateINU InitSeq MOTOR SP 0 00 rpm POWER 0 0 kW 1 L 0 0 rpm StateINU DCGndNopen MOTOR SP 0 00 rpm POWER 0 0 kW Alternating display message DCGndNopen NotReadyOn ...

Page 142: ... the drive is in a fault condition the fault memory display appears instead The actual signals display is used to monitor the drive without interfering with its operation It continuously displays three selectable actual values 1 Display 2 Actual signal names and values 3 Selection key for actual signals mode 4 Fast navigation key for selecting the actual signals display or the fault memory display...

Page 143: ...resetting an active fault on page 148 When the drive generates a fault or alarm the corresponding message displays immediately Changing from the fault memory display to other modes is possible without resetting the fault first If no key is actuated the fault or alarm message displays as long as the fault is active 9 2 2 2 Selecting the actual signals display To select the actual signals display pr...

Page 144: ...e of three actual signals press and hold the ACT key 2 To return to the actual signals display release the ACT key 9 2 2 5 Selecting actual signals 1 To select the actual signals display press the ACT key 1 L 600 0 rpm 1 LAST FAULT Overspeed 070730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU MOTOR SPEED POWER ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 ...

Page 145: ...parameter group press a fast navigation keys 5 To select an actual signal press a slow navigation keys 1 L 600 0 rpm StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 ACTUAL SIGNALS 15 POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 ACTUAL SIGNALS 01 DC VOLTAGE 1000 V ACT PAR FUNC DRIVE LOC I 0 RESET REF E...

Page 146: ...9 2 2 6 Displaying a fault and resetting the fault memory 1 To open the actual signals display press the ACT key 2 To change to the fault memory display press a fast navigation key 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm NP VOLT 0 V ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 ...

Page 147: ...n to the actual signals display press a fast navigation key 1 L 600 0 rpm 1 LAST FAULT PANEL LOST 070730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 2 LAST FAULT AMC Fault Class 1 9H 38 MIN 48 s ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 LAST FAULT H MIN S ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 ...

Page 148: ...etting an active fault 1 To display an active fault press the ACT key 2 To reset the fault press the RESET key 1 L 600 0 rpm ACS5000 FAULT MCB CloseControl ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 0 00 rpm POWER 0 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 149: ...ust only be set by qualified personnel DO NOT change any parameter if the meaning of the parameter and the effects of the change are not fully understood 1 Status line 2 Group number and name 3 Parameter number and name 4 Parameter value 5 Selection key for parameters mode 6 Fast navigation key for selecting a parameter group and a parameter value 7 Slow navigation key for selecting a parameter an...

Page 150: ... of parameter group 11 The next time the parameters mode is entered the previously selected parameter displays Some parameter settings cannot be changed while the drive is running If tried the following warning displays Group Description Paramet er Description 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 ...

Page 151: ...er the parameter setting function press the ENTER key 1 L 600 0 rpm 77 SYSTEM CONFIG 01 INU IdentifySel INU1 MASTER ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 06 C3P1 AI820 Module DISABLED ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DISABLED ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OP...

Page 152: ...y press the ENTER key 9 To cancel the setting and keep the original setting press any of the mode selection keys The selected keypad mode is entered 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DI810 24VDC ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MODULES 07 C3P1 AI820 Module DI810 24 VDC ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 75 OPTION MO...

Page 153: ...formation see Appendix G Signal and parameter table 9 2 3 4 User lock NOTICE ABB is not be liable for damages or losses caused by the failure to activate the user lock with a new pass code For more information see 1 9 Cyber security disclaimer on page 25 For better cyber security it is highly recommended that you set a master pass code for the control panel to prevent the parameter values from bei...

Page 154: ...ns mode 9 2 4 1 Adjusting the display contrast 1 To enter the functions mode press the FUNC key 1 Status line 2 Selectable functions 3 Selection key for functions mode 4 Slow navigation key for selecting a line and adjusting the contrast 5 Enter key for confirming the selection 1 2 3 4 5 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET ...

Page 155: ... the contrast press the slow navigation keys 5 To confirm the setting and to return to the actual signals display press the ENTER key 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm CONTRAST 6 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm UPLOAD DOWNLOAD CONTRAST 6 A...

Page 156: ...ntrol on page 157 9 2 5 1 Local control In local control mode full operational control of the drive is enabled from the local operator panel Commands from remote have no effect To enter the local control mode press the LOC REM key Local control is indicated by the letter L 9 2 5 2 Disabling enabling local lock function Accidental switching from remote control to local control can be prevented with...

Page 157: ... control is enabled 9 2 5 4 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 direction of rotation and to enter reference values from the CDP control panel 11 01 EXT1 START STOP DIR 10 KEYPAD or ...

Page 158: ...3 9 3 1 Setting the direction of rotation Setting the direction of rotation from the CDP control panel is possible in Local control mode L Remote control mode R The arrow on the display indicates the direction of rotation When the motor is running the arrow indicates the actual direction When the motor is not running the arrow indicates the preselected direction To set the direction of rotation pr...

Page 159: ...eference value from the CDP control panel is possible in Local control mode L Remote control mode R 1 Press a mode selection key 2 To enter the reference value input mode press the REF key 1 L 600 0 rpm StateINU ReadyOn MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESE...

Page 160: ...ess the corresponding fast or slow navigation key 4 To exit the mode press a mode selection key 1 L 550 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 550 0 rpm 0 StateINU ReadyRun MOTOR SP 600 00 rpm POWER 75 0 kW ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 161: ...nance schedule Carry out all maintenance tasks according to the maintenance schedule on time and at the stated intervals in the ACS5000 preventive maintenance schedule 3BHS855274 E01 10 1 3 Logbook It is recommended to record all troubleshooting and maintenance work in a logbook including Date and time Detailed description 10 1 4 Spare parts To ensure safe and reliable operation use only spare par...

Page 162: ...nd wires Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams Figure 10 2 Cable and wire designation 10 2 3 Understanding wiring diagrams For information on item designation and cross reference conventions see Appendix D Wiring diagrams A2501 1 Terminal number 2 Wire number 1 2 ...

Page 163: ...rive when a PC with DriveWindow DriveDebug or DriveMonitor is connected to the drive The fault history can also be called up on the CDP control panel 10 3 2 Error message levels Two error message levels are used in the drive Alarm does not shut down the drive Fault shuts down the drive 10 3 2 1 Alarm An alarm does not shut down the drive If the condition causing the alarm is not corrected a persis...

Page 164: ...the fault buffer as they occur and are numbered The last fault entered has number 1 The first fault entered has the highest number Information of the fault classification eg FC 1 or FC 2 is also saved when the first fault of the fault class is active Date and time stamps facilitate fault tracing especially when a fault leads to several subsequent faults Example In the above example 4 Fault DC Unde...

Page 165: ...liary supply voltage or try to reset a fault message before all information at the time of the occurrence of the fault condition has been saved 2 Select the fault history display on the CDP control panel but do not clear the buffer now For more information see 9 CDP control panel on page 139 3 Identify the fault and make a logbook entry 4 Save the content of the data logger when a PC is available ...

Page 166: ...MC circuit board The CDP control panel 1 is connected to the AMC circuit board 2 via an RS485 interface 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 ...

Page 167: ...not loaded Booting ON Booting ON F Red Fault ON OFF ON ON R Green Run OFF OFF OFF OFF M Green ON OFF ON ON P Green Supply OK ON ON ON ON T1 Yellow Receiving data on DDCS channel 0 Flashing ON OFF Flashing ON OFF T2 Yellow Receiving data on DDCS channel 3 Flashing ON OFF Flashing ON OFF S3 Yellow OFF OFF OFF OFF S1 Yellow Flashing OFF Flashing OFF S2 Yellow Flashing OFF Flashing OFF S0 Yellow Flash...

Page 168: ...uster address that identifies the module in the software and links it to a parameter The address is set with the rotary switch on the module Fig 10 4 1 The factory set value must not be changed LED Color Indication F Red Fault in module R Green Device in operation P Green Power supply is healthy Rx1 Yellow Traffic on optical module bus Rx2 Yellow Traffic on optical module bus ERx Yellow Traffic on...

Page 169: ...ly output modules Figure 10 5 Example of S800 I O station Note For more information see the following manuals S800 I O General information and installation user s guide S800 I O Modules and termination unit user s guide 10 6 Corrective maintenance Overview on maintenance tasks 10 6 6 Visual checks on the drive on page 179 LED Color Indication F Red Indicates failure R Green Device is operating nor...

Page 170: ...e 180 10 6 8 Checking wire and cable connections on page 181 10 6 9 Checking and replacing filter mats on page 181 10 6 10 Replacing a door mounted fan on page 182 10 6 11 Replacing a fan of an IP42 roof mounted cooling unit on page 183 optional 10 6 12 Replacing a fan of an IP54 roof mounted cooling unit on page 184 optional ...

Page 171: ...d position When maintenance on the drive is carried out such as changing of semiconductors grounding equipment must be connected at the appropriate locations The grounding equipment ensures that hazardous voltages cannot be fed into the drive from the main power supply or the motor WARNING Hazardous DC voltage Depending on the type of auxiliary supply the drive can be equipped with buffer capacito...

Page 172: ...r 1 Enable the local control mode of the CDP control panel 2 To stop the motor press the STOP key When the motor has reached zero speed the display shows ReadyRun 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 co...

Page 173: ...unding circuit is malfunctioning Note For more information 10 4 Removing the CDP control panel on page 165 6 Once the yellow lamp GROUNDING SWITCH UNLOCKED is lit turn the grounding switch to the grounded position 7 When the grounding switch is in the grounded position the status line alternates between DCGnd NOpen NotReadyOn StateINU NotRdy 8 If necessary open the doors of medium voltage compartm...

Page 174: ... link is discharged If the yellow lamp does not light up see 10 4 Removing the CDP control panel on page 165 4 Once the yellow lamp lights up turn the grounding switch to the grounded position The white lamp lights up to indicate that the drive is grounded 1 White lamp Lights up to indicate that the drive is grounded and you can slide the locking bar to the unlocked locked position 2 Yellow lamp L...

Page 175: ...oor turn the door handle 3 To the right if the door is hinged on the right 4 To the left if the door is hinged on the left Closing and locking the doors Once maintenance of medium voltage compartments is complete proceed as follows 1 To close a door bring the door handle in line with the door plate and press the handle down until it clicks in 2 Before actuating the locking bars make sure that the ...

Page 176: ... position IMPORTANT Do not use force for turning the grounding switch in any direction The handle and or the switch could get damaged If the lamp does not light up proceed as follows 1 Verify that the main circuit breaker MCB is in the open position 2 Check the drive status on the CDP control panel The drive status should be ReadyOn indicating that the DC link has discharged and the MCB has opened...

Page 177: ...unded This prevents doors from being opened unintentionally during operation In 1700 mm PCUs the safety switches are on the back of the left door In 2100 mm PCUs the safety switches are on the back of the middle door A screw cap on the front of the door marks the exact position Figure 10 6 Location of safety switches DANGER Hazardous voltages Touching energized components can be fatal Before you u...

Page 178: ... manually 10 6 5 2 Safety switch settings Figure 10 7 Safety switch Unlocking 1 To access the release dial 2 remove the screw cap 1 from the door 2 Turn out the locking screw 1 until the release dial can be turned 1 Release dial 2 Unlocked position enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off 3 Locked position Normal operating setting To ope...

Page 179: ...eck 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 Dust built up inside the drive Appropriate fastening of cables and wires and connections of cable shields and screens Integrity of cable insulation Signs for over...

Page 180: ... on assemblies and busbars inside the cabinet with a vacuum cleaner and lint free cleaning cloths Remove water oily or greasy deposits on assemblies components and busbars with water and oil absorbing microfibers such as 3M Scotch Brite Use a nylon brush or a vacuum cleaner for removing dust or deposits from recesses Clean the outside of the cabinet with a vacuum cleaner and cleaning cloths NOTICE...

Page 181: ...lter mats of the same filter class and size as the original filter mat for replacement Although checking and replacing the filter mats of the WCU compartment is possible during operation of the drive it is easier to do it when the drive is shut down The fans behind the air outlet panels may start automatically when the temperature rises to a certain level NOTICE Risk of component damage Vibration ...

Page 182: ... cooling fans from starting automatically 2 Remove the air outlet panel Fig 10 8 1 3 Roll down the filter mat Fig 10 82 beginning at the top 4 Insert a new filter mat 5 Reattach the air outlet panel Figure 10 8 Filter mat replacement for PCU A and WCU B 10 6 10 Replacing a door mounted fan The WCU compartment has door mounted fans Note For replacement instructions see Assembly instructions for fan...

Page 183: ...n one of the other fans fails If one fan fails the red indicator lights up and replacement is required 10 6 11 1 Replacing a fan For replacement instructions see the Instruction manual in Appendix A Additional manuals Figure 10 9 Roof mounted cooling unit IP42 Dimensions L x W x H 1550 x 550 x 230 mm Weight 40 kg WARNING Hazardous voltage Before starting any work on the fans de energize the coolin...

Page 184: ...her fans fails If one fan fails the red indicator lights up and replacement is required 10 6 12 1 Replacing a fan For replacement instructions see the instruction manual in Appendix A Additional manuals Figure 10 10 Roof mounted cooling unit IP54 Dimensions L x W x H 1550 x 975 x 386 mm Weight 98 kg WARNING Hazardous voltage Before starting any work on the fans de energize the cooling unit 1 Contr...

Page 185: ... Ltd CH 5300 Turgi Switzerland new abb com drives medium voltage ac drives Copyright 2020 ABB All rights reserved The information in this document is subject to change without notice 3BHS799208 E01 Rev E 17 06 2020 186 ...

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