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3BHS842007 E01 REV C

ACS6080

USER MANUAL

09 PREVENTIVE AND CORRECTIVE MAINTENANCE

9.4.16

Testing and replacing air-to-air heat exchangers

• Inspection intervals:

see the "ACS6080 preventive maintenance

schedule" (3BHS838899 E01).

• Service during operation:

not possible

Figure 9-25 Air-to-air heat exchanger overview (type LT-5-5165-UL)

(1) Ambient fan 2
(2) Ambient fan 1
(3) Internal fan 1
(4) Circuit board location
(5) Internal fan 2
(6) Miniature circuit breaker

(7) Red LED off and green LED on:
(8) Heat exchanger is healthy
(9) Red LED on and green LED off:
(10) Alarm condition
(11) Red LED off and green LED off:
(12) Auxiliary voltage missing

Table 9-2 Air-to-air heat exchanger specifications

Thermostat location

Identification

Weight

~65 kg

Length

1025 mm

Width

750 mm

Height

316 mm

1

2

3

4

5

6

7

8

9

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Summary of Contents for ACS6080

Page 1: ... SYSTEM DRIVES ACS6080 User manual ...

Page 2: ...purpose 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 ACS6080 user manual Document number 3BHS842007 E01 Rev C Release date ...

Page 3: ...ualification 35 1 7 1 Handling 35 1 7 2 Mechanical installation 35 1 7 3 Electrical installation 35 1 7 4 Operation 35 1 7 5 Maintenance 35 1 8 User s responsibilities 36 1 9 Intended use of equipment 36 1 10 Cyber security disclaimer 36 1 11 Quality certificates and applicable standards 37 1 12 Identifying the delivery 38 1 13 Tools 38 2 Important safety information 39 2 1 Safety standards 39 2 2...

Page 4: ...net units 51 3 1 1 2 Final drive configuration 51 3 1 2 Motor 51 3 2 Standard cabinet units 51 3 2 1 Active rectifier unit ARU inverter unit INU 51 3 2 2 Line supply unit LSU 53 3 2 3 Capacitor bank unit CBU 56 3 2 4 Terminal unit TEU 57 3 2 5 Control unit COU 58 3 2 5 1 Main circuit breaker 59 3 2 5 2 Speed and torque control 59 3 2 5 3 Peripheral I O devices 59 3 2 5 4 S500 I O system 60 3 2 5 5...

Page 5: ...omer interface unit CIU 73 3 3 6 1 Arc detection with Arc Guard optional 74 3 4 Air cooling 74 3 4 1 Air to air heat exchangers 74 3 4 2 Auxiliary fan units 75 3 5 Cabinet design 76 3 6 Door locking system 77 3 7 Arc resistant design 77 3 7 1 Internal arc classification 77 3 8 Busbars and grounding 78 3 8 1 AC busbars 78 3 8 2 DC busbars 79 3 8 3 PE busbar 79 3 8 4 PG busbar 79 4 Transportation st...

Page 6: ... 5 2 Overview 89 5 3 General notes on installation 90 5 3 1 Dimensions and clearances 90 5 3 2 Access to the cabinets 90 5 3 3 Cabinet roof 90 5 3 4 Fire protection 90 5 3 5 Cable duct material 91 5 3 6 Installation material 91 5 3 7 Tools 91 5 3 8 Floor preparation 91 5 3 9 Floor fixation 91 5 3 10 Raw water circuit 91 5 4 Aligning transport units 92 5 5 Joining transport units 94 5 6 Joining wat...

Page 7: ...s 111 5 8 2 1 Removing an air to air heat exchanger 112 5 8 2 2 Reinstalling an air to air heat exchanger 113 5 8 3 Installing the transformers of air to air heat exchangers 114 5 9 Installing the pressure relief vents 115 5 10 Attaching the sealing tapes 117 5 11 Installing the roof joints and the roof attachments 118 5 11 1 Installing roof joints 118 5 11 2 Installing roof attachments 119 6 Elec...

Page 8: ...C plates with sealing grommets 132 6 6 Preparing cable entry systems for TEU ARU and EXU cabinets 132 6 6 1 TEU cable entry frames with type 1 sealing modules 133 6 6 2 ARU cable entry frames with type 1 sealing modules 134 6 6 3 EXU cable entry with EMC plate and sealing grommets 135 6 7 Power ground and equipotential bonding conductor cables 136 6 7 1 Determining the cable length 136 6 7 2 Prepa...

Page 9: ...binet 150 6 8 7 1 Auxiliary power and control cables 150 6 8 7 2 Optical fiber cables 152 6 8 7 3 Routing optical fiber cables in an EXU cabinet with an ED5V EB5R EB5S EB7P and EB7Q type DCS880 DCT880 converter 153 6 8 7 4 Routing cables in an EXU cabinet with an ED7Y type DCS880 DCT880 converter 155 6 9 Heating cable 157 6 10 Final checks 158 7 Commissioning 159 7 1 Required qualification 159 7 2...

Page 10: ...rol panels for drives with an ARU 165 8 5 1 1 Lamp test 167 8 5 2 Control panels for drives with an LSU 167 8 5 2 1 Lamp test 168 8 6 EXU control panel 168 8 6 1 Operational settings 168 8 6 2 Resetting alarm and fault messages 169 8 6 3 Parameter settings 169 8 7 Grounding switch and door locking system 170 8 7 1 Lamp test 171 8 7 2 Door locking system 171 8 8 Optional switchgear and controlgear ...

Page 11: ...ency off function 181 8 11 3 Initiating an emergency off 181 8 11 4 Starting the drive system after an emergency off 182 8 12 Arc detection with the Arc Guard System optional 183 8 12 1 Action after the Arc Guard System has been triggered 183 9 Preventive and corrective maintenance 185 9 1 General information 185 9 1 1 Required qualification 185 9 1 2 Maintenance schedule 185 9 1 3 Logbook 185 9 1...

Page 12: ... 4 3 Grounding the drive when the grounding switch is not released 196 9 4 4 Unlocking and opening the doors 198 9 4 5 Closing and locking the doors 199 9 4 6 Testing the white lamp 200 9 4 7 Emergency release of a door safety switch 202 9 4 7 1 Location of safety switches 202 9 4 7 2 Safety switch settings 203 9 4 7 3 Unlocking a safety switch 203 9 4 8 Connecting a grounding set 204 9 4 8 1 Driv...

Page 13: ...5 2 Replacing auxiliary fan units 220 9 4 16 Testing and replacing air to air heat exchangers 221 9 4 16 1 Testing the fan units 222 9 4 16 2 Replacing the complete heat exchanger 223 9 4 16 3 Replacing the circuit board 223 9 4 16 4 Replacing internal fan 1 left side 225 9 4 16 5 Replacing internal fan 2 right side 226 9 4 16 6 Replacing the ambient fans 229 9 4 17 Replacing the fan unit in an EX...

Page 14: ......

Page 15: ... A and phase modules with IGCTs B 53 Figure 3 6 LSU block diagram 54 Figure 3 7 LSU 12 pulse circuit diagram 54 Figure 3 8 LSU 12 pulse 55 Figure 3 9 CBU 56 Figure 3 10 TEU 1000 mm 57 Figure 3 11 Master COU 1000 mm and control equipment 58 Figure 3 12 Control panel 60 Figure 3 13 Location of control panels on master COU A and slave COU B 61 Figure 3 14 WCU1400 A and WCU800 B cabinet and system com...

Page 16: ... A 1000 mm COU B and WCU800 C 75 Figure 3 31 Basic cabinet design 76 Figure 3 32 IAC label example 78 Figure 3 33 Busbars 78 Figure 4 1 Lifting bracket 1 on base frame of a drive safety hook 2 secured to lifting bracket and eye bolt 3 84 Figure 4 2 Lift frame A and lift spreader B 85 Figure 5 1 Connection point locations on transport units 94 Figure 5 2 Minimum distances and locking bolt orientati...

Page 17: ...nal block 115 Figure 5 18 Pressure relief vents 115 Figure 5 19 Tools required to fasten the pressure relief vent to the roof 116 Figure 5 20 Installation example of pressure relief vents 116 Figure 5 21 Attach sealing tape to the joining crossbar 1 117 Figure 5 22 Roof joints 1 118 Figure 5 23 Roof attachment parts 119 Figure 5 24 Recommended ceiling and wall fixings 120 Figure 6 1 Phase module o...

Page 18: ... modules 137 Figure 6 19 Prepare power cables for cable glands 138 Figure 6 20 Preparing cables for EMC plates A cables with an outer screen or shield B cables without an outer screen or shield or C cables in an EXU cabinet 139 Figure 6 21 Cable connections in an EXU cabinet 140 Figure 6 22 Minimum distance between bolted joints of different phases in an EXU 141 Figure 6 23 Bolted busbar connectio...

Page 19: ... Figure 6 37 Cable routing example in an EXU cabinet with an ED5V EB5R EB5S EB7P and EB7Q type DCS880 DCT880 converter 154 Figure 6 38 DCS880 DCT880 converter ED7Y 155 Figure 6 39 1 Control unit SDCS CON H01 155 Figure 6 40 Cable routing example in an EXU cabinet with an ED7Y type DCS880 DCT880 converter 156 Figure 6 41 Heating cable connection 157 Figure 8 1 Assistant control panel 163 Figure 8 2...

Page 20: ...98 Figure 9 10 Testing the white lamp 200 Figure 9 11 Safety switch on an ARU INU cabinet door 202 Figure 9 12 Safety switch settings 203 Figure 9 13 Four way grounding set 204 Figure 9 14 TEU ground ball stud locations 205 Figure 9 15 ARU INU ground ball stud locations 206 Figure 9 16 Manual output isolation overview 207 Figure 9 17 Tools for removing the busbar connectors 208 Figure 9 18 Overvie...

Page 21: ...x 220 Figure 9 25 Air to air heat exchanger overview type LT 5 5165 UL 221 Figure 9 26 Wire connection points on the circuit board 224 Figure 9 27 DCS880 controller size H4 230 Figure 9 28 DCS880 controller size H6 232 Figure 9 29 Air to water heat connections 235 Figure 9 30 Lift heat exchanger out of EXU cabinet 235 ...

Page 22: ......

Page 23: ...Main components in a 12 pulse LSU cabinet 54 Table 3 3 Main components in a CBU cabinet 56 Table 3 4 Main components in a WCU cabinet 61 Table 3 5 BCU braking power 68 Table 3 6 RBU braking power 68 Table 3 7 ABB arc resistant classes 77 Table 5 1 Installation material for AC busbars COU TEU ARU INU 103 Table 5 2 Installation material for roof joints 118 Table 6 1 Cable entry frames for type 1 sea...

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Page 25: ...ed according to the required output power motor configuration and process needs 1 1 1 Standard applications Typical fields of applications for the ACS6080 include 1 2 Equipment covered by this manual This manual covers standard drive and provides generic information on the drive The manual does not claim to cover all variations and details of the drive nor to consider all eventualities that may ar...

Page 26: ...s 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 generated according to the customer specific project Appendix D Wiring diagrams contains the circuit diagrams with information on device identification cross reference ...

Page 27: ... unit is designed as a self commutated 3 level voltage source inverter consisting of three identical phase modules The unit allows regenerative braking ASE Anti Saturation Equipment Azipod ABB s electric propulsion system for ships BCON Application and motor controller BCU Braking Chopper Unit CBU Capacitor Bank Unit CCB Converter Control Board Control panel Serves as the basic user interface for ...

Page 28: ... ACS6080 frequency converter Drive Composer Windows application for commissioning and maintaining ABB drives Drive system The drive system includes all equipment for converting electrical into mechanical power to give motion to the machine DTL Direct to line EAF Earth Fault monitoring device ECB Excitation Circuit Breaker EIC Excitation Input Contactor EMC Electromagnetic Compatibility EOB Excitat...

Page 29: ...put Filter Unit IGBT Insulated Gate Bipolar Transistor IGCT Integrated Gate Commutated Thyristor ISU Isolation Unit IM Induction Motor INT Interface circuit board INU Inverter Unit The INU converts the three DC voltages to the required AC motor voltage The unit is designed as a self commutated 3 level voltage source inverter consisting of three identical power modules I O device Term ABB s S500 I ...

Page 30: ...ve from any location in the world via a secure Internet connection NP Neutral Point The term refers to the neutral point of the DC link NTAC Pulse encoder interface module PAI Pulse Amplifier Interface board PCB Printed Circuit Board PE Protective Earth Ground bus for the connection of the ground cable PFF Power Feed Forward PF Power Failure PG Power Ground Ground bus for the connection of cable s...

Page 31: ...Redundant Drive SSI Synchronous Serial Interface The SSI is a point to point serial communication interface for digital data transmission between a master eg drive and a slave eg sensor TEU Terminal Unit The TEU provides the terminals for the transformer and motor cables the ground frame for the cable screens and the ground cable and the grounding accessories THD Total Harmonic Distortion TT Tempe...

Page 32: ...pm Table 1 1 Terms and abbreviations continued Term Abbreviation Definition Table 1 2 Trademarks Trademark Description ABB Ability Registered trademark of ABB Arc Guard System Registered trademark of ABB Azipod Registered trademark of ABB Carboweld Registered trademark of ABB DriveWare Registered trademark of ABB Ethernet Registered trademark of Xerox Corporation Industrial IT Trademark of ABB Mod...

Page 33: ...Auxiliary power and control cables guideline 3BHS813742 E01 13 Voltage transformer requirement specification 3BHS125393 E01 14 Emergency off and stop modes and prevention of operation 3BHS196243 E01 15 Recycling instructions 3BHS122085 E01 16 Environmental information material declaration 3BHS360175 E01 17 Roxtec CF16EMC installation instructions 3BHS820829 E01 18 ACS6000 ACS6080 label placement 3...

Page 34: ... manual 3AUA0000096939 29 PLC Automation PLCs Control Panels Engineering Suite AC500 CP600 Automation Builder 3ADR020077C0204 30 I O configuration S500 BCON for ACS6080 3BHS830984 E01 31 System Assembly and Device Specifications for AC500 V2 Products 3ADR010121 Table 1 9 User manuals related to drive units Title Document number 32 ACS6080 technical catalog 3BHS852904 E01 33 ACS6080 spare part pack...

Page 35: ...d in unpacking and transporting heavy equipment 1 7 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 7 3 Electrical installation Personnel must have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment be...

Page 36: ...ations is not permitted Intended equipment use also implies that only spare parts recommended and approved by ABB must be used Unauthorized modifications and constructional changes of the drive are not permitted 1 10 Cyber security disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is the customer s sole responsibility to provi...

Page 37: ... related parts of control systems Part 1 General principles for design section 6 2 6 Category 3 42 IEC 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements 43 IEC 60721 3 1 Classification of environmental conditions Classification of groups of environmental parameters and their severities Storage 44 IEC 60721 3 2 Classification of environmental conditions Classi...

Page 38: ...ated on the back of the control compartment 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 13 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 Service Equipm...

Page 39: ... 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 if not a...

Page 40: ... sign can also have additional text below it eg High voltage Hot surface Crushing of hands 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...

Page 41: ...earing protection when a drive is running 4 While working on the drive Do not step on the roof Do not install foreign objects on the roof 5 Before working on a water cooling unit WCU In addition to the safety instructions for working on a drive always read the WCU safety data sheet for relevant safety information eg the type of ion exchange resin and glycol 6 Before working simultaneously on the d...

Page 42: ...e 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 phone 3a ...

Page 43: ... 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 and bus...

Page 44: ...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 equipment Co...

Page 45: ...equipment The MCB is located on the primary side of the converter transformer Figure 2 2 Drive system overview Note MCBs and protection relays are not included in the drive supply Typical MCBs devices Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor control centers Dedicated protection relay Transformer or drive primary cable protection DTL Transformer protection if applicabl...

Page 46: ...he MCB at any time It is not permitted to interrupt the open and or trip command eg with a local remote switch in the MCB Closing control of the MCB when the MCB is in service position the drive must have exclusive control over closing the MCB ie local closing of the MCB is not permitted MCB maximum opening time cannot exceed the maximum time that is defined in the product or project specific MCB ...

Page 47: ...m protection coordination scheme is provided which uses the breaker failure ANSI 50BF signal to automatically trip the upstream breaker in case the MCB does not open IMPORTANT The upstream breaker must open within the maximum safety trip time after a failure has occurred 2 8 Maintenance recommendation The MCB trip circuits should be checked annually 1 Short circuit occurs 2 Open and or trip comman...

Page 48: ......

Page 49: ...ired if the line voltage must be adapted to the motor voltage For more information see the Main transformer specification Drive Motor 3 1 1 Drive The ACS6080 is a voltage source frequency converter for high power induction and synchronous motors The drive features a common DC bus permitting the configuration of single motor or multi motor solutions Figure 3 1 Common DC bus principle for single mot...

Page 50: ...e source inverter with IGCT technology 2 Drive control panel for local operation Keypad with multi language display main supply on off pushbuttons and emergency off push button 3 Inverter unit INU Self commutated 6 pulse 3 level voltage source inverter with IGCT technology 4 Capacitor bank unit CBU DC capacitors for smoothing the intermediate DC voltage 5 Water cooling unit WCU Supplies deionized ...

Page 51: ...a 6 pulse self commutated voltage source inverter that rectifies the line voltage of the supply network and maintains the DC link voltage at a constant level irrespective of changes in the supply network The active 6 pulse rectifier allows for regenerative braking INU The INU controls the 3 phase motor voltage and converts the DC link voltage to the required AC motor voltage and frequency The INU ...

Page 52: ... gate commutated thyristors IGCTs diodes and clamp capacitors The phase modules are identical in construction for all power ratings However the types of semiconductors vary depending on the power rating For this reason it is not possible to mix phase modules for different power ratings in one unit Clamping circuit Protects the circuit from excessive rises in current with di dt reactors and freewhe...

Page 53: ...nergy An LSU is used with input transformers and is available in various power ratings The LSU allows two quadrant operation and maintains the power factor at 0 95 in the whole operating range To achieve 24 pulse rectification or to increase the drive power units with the same power rating can be operated in parallel 1 EMC filter 2 Control interface 3 Gate unit power supply 4 Phase module 5 Diode ...

Page 54: ...2 pulse LSU cabinet Component Description 12 pulse diode rectifier Snubber circuit Limits the rate of the voltage rise dv dt across the diodes and the crowbar thyristors di dt limiting reactors Define the current rise in the thyristor crowbar Thyristor crowbar Protection circuit that activates when a short circuit occurs By applying protection firing the thyristor crowbar short circuits the rectif...

Page 55: ... C ACS6080 USER MANUAL 55 238 03 POWER ELECTRONICS AND CABINET FEATURES Figure 3 8 LSU 12 pulse 1 Snubber resistor 2 Snubber capacitor 3 Rectifier monitoring unit 4 di dt limiting reactors 5 Diode stacks 1 2 3 4 5 5 5 5 ...

Page 56: ... 9 CBU Table 3 3 Main components in a CBU cabinet Component Description Liquid cooled DC link capacitors Charging unit To avoid excessive inrush currents after the main circuit breaker has been closed the capacitors are charged before the drive is connected to the main power source Discharging unit This optional unit discharges the DC link capacitors if the drive is not equipped with a voltage lim...

Page 57: ...are designed for top or bottom cable entry The terminal units are available either as individual units or are integrated into a master COU or ARU The width of the unit 600 mm or 1000 mm depends of the number of line supply units or active rectifier units and or the motors supplied via one terminal unit Figure 3 10 TEU 1000 mm 1 DC busbars 2 AC busbars 3 Cable entry frame 4 PE ground busbars 1 2 3 ...

Page 58: ...or they share one control unit Note For information on the number of control units and their location in the drive see Appendix C Mechanical drawings Figure 3 11 Master COU 1000 mm and control equipment 1 Insulation monitoring device optional 2 24 VDC power supply unit 3 Safety relays for emergency off circuit 4 Main controller for ARU 5 Main circuit breaker control 6 Redundant encoders in slot ex...

Page 59: ...s flux and torque The measured motor currents and DC link voltage are inputs to an adaptive motor model The model produces exact values of torque and flux every 25 microseconds Motor torque and flux comparators compare the actual values to reference values produced by the torque and flux reference controllers Depending on the outputs from the hysteresis controllers the switching logic directly det...

Page 60: ...control system External I O signals connect to the terminals inside the water cooling unit WCU and are wired internally to their I O modules 3 2 5 5 Local control panels Each control unit COU is equipped with a local control panel Fig 3 13 The control panel serves as the basic user interface for monitoring control and operation of the drive and setting of parameters Figure 3 12 Control panel ...

Page 61: ...electronics components and transfer the heat losses through the return pipes and the water to water heat exchanger The water cooling units are accessible for maintenance even when the drive is in operation Note For more information see ACS5000 ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 and ACS5000 ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E...

Page 62: ... pumps is always on standby and starts automatically if the running pump fails An alternative solution based on one pump is also available Water to water heat exchanger Transfers the heat from the internal cooling circuit to the external cooling circuit Expansion vessel Used for pressure compensations Ion exchange vessel The ion exchange vessel in the water treatment circuit deionizes the coolant ...

Page 63: ... A and WCU800 B cabinet and system components 1 Control equipment mounted on a swing frame 2 Pump circuit breakers 3 Warm water 4 Expansion vessel 5 Pump 1 6 Pump 2 7 Cool water 8 Expansion vessel 9 Three way valve 10 Water to water heat exchanger 11 Deionizer A 1 2 3 4 5 6 7 8 9 10 11 B 1 3 4 5 6 8 10 2 7 11 ...

Page 64: ... to keep conductivity at a low level External cooling circuit transfers the heat losses from the water to water heat exchanger to the exterior The water cooling units are pressurized and not open to atmospheric pressure Figure 3 15 Cooling circuit in an ACS6080 drive 3 2 6 2 External cooling connection Two flanges connect the external cooling circuit water pipes to the cooling unit They are part o...

Page 65: ... 1 Input reactor unit IRU The IRU is used with the 6 pulse LSU for applications without an input transformer The IRU limits the input current and improves the total harmonic distortion THD of the supply voltage Figure 3 16 IRU circuit diagram Figure 3 17 IRU cabinet 1 IRU 2 LSU 3 Thyristor crowbar 4 Diode rectifier 5 Snubber circuit 6 di dt choke 1 Three phase reactor DC DC 1L1 1L2 1L3 1 2 3 4 5 6...

Page 66: ...ion with 6 pulse active rectifier units connected to a weak supply network The tuned filter is located between the input transformer and the ARU and reduces harmonic voltages injected to the supply network Figure 3 18 IFU circuit diagram Figure 3 19 IFU cabinet 1 TEU 2 IFU 3 ARU 1 Resistor 2 Capacitor 3 Reactor L1 L2 L3 L1 L2 L3 1 2 3 1 2 1 2 3 ...

Page 67: ...sed for applications that require dynamic changes between driving and braking mode During braking the energy is dissipated in liquid cooled resistors The resistors are controlled by IGCT semiconductors and protected against overload Figure 3 20 VLU circuit diagram Figure 3 21 VLU cabinet 1 Air cooled resistors 2 IGCT DC DC NP DC 1 2 ...

Page 68: ...ctive motor braking However BCUs and RBUs can also be used in combination with ARUs eg mine hoists and other special applications that require emergency braking in the event of a power outage During braking the BCU limits the DC link voltage and converts the braking energy into heat that is dissipated in resistors IGCT semiconductors switch the braking energy to the resistors Table 3 5 BCU braking...

Page 69: ...per unit A BCU is used when the braking scenario requires consistent energy dissipation The energy generated during braking is dissipated in external water cooled resistors which are not part of the drive Figure 3 22 BCU circuit diagram Figure 3 23 BCU cabinet 1 Resistor external 2 BCU 1 IGCT DC DC NP DC 1 2 1 ...

Page 70: ...42007 E01 REV C ACS6080 USER MANUAL 70 238 3 3 4 2 Resistor braking unit An RBU with integrated resistors is used for smaller braking capabilities Figure 3 24 RBU circuit diagram Figure 3 25 RBU cabinet 1 IGCT 2 Water cooled resistor DC DC NP DC 1 2 ...

Page 71: ...n AC excitation Uses a three phase DCT880 AC power controller 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 which generates the DC current for producing the magnetic field in the synchronous motor Note For more information see the Air cooled excitation units brush brushless excitation technical data p...

Page 72: ...user to control read the status messages and set the parameters of the DCS880 DCT880 unit The panel can also be used to copy parameters from one DCS880 DCT880 unit to another DCS880 DCT880 Note For more information see 8 6 EXU control panel on page 168 3 3 5 2 Output disconnector The optional output disconnector is used to disconnect the EXU from the motor for maintenance purposes ...

Page 73: ...ing the auxiliaries of motors and the transformers The I O module modules are connected to the drive controller CIUe provides engineered project specific interfaces and an application controller with customer specific software As an option for single motor drives it is possible to integrate the predefined I O modules maximum 4 modules in the rooftop extension box REB of the water cooling unit For ...

Page 74: ...1 Air to air heat exchangers Drives for high power applications are equipped with air to air heat exchangers They ensure a constant air flow through the medium voltage units and transfer the heat losses of non water cooled components to the exterior The fans of the air to air heat exchangers are controlled by the drive The auxiliary power for the heat exchangers is supplied by an additional transf...

Page 75: ...units circulate the air in the control unit cabinet s and in the WCU cabinet If installed additional fan units are available in the optional WCU roof box Figure 3 29 Auxiliary fan unit Figure 3 30 Air circulation through ventilation grids in 600 mm COU A 1000 mm COU B and WCU800 C Note The number of fans varies depending on the cabinet A B C ...

Page 76: ... The inside panels of the compartments are not painted because paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC The joining surfaces of two transport units are equipped with EMC sealing strips The cabinet doors and the internal cable ducts are also equipped with EMC sealing Degree of protection The standard cabinets are rated for IP 32 Ratings for IP...

Page 77: ...ormation on the door locking system including grounding switches locking bars and safety switches see 8 6 EXU control panel on page 168 3 7 Arc resistant design The optional Arc Resistant Design provides the drive with arc fault protection see Table 3 7 in accordance with IEC 62477 2 3 7 1 Internal arc classification The arc fault rating which is based on arc fault tests is on the label underneath...

Page 78: ...ns busbars for various types of connections Figure 3 33 Busbars 3 8 1 AC busbars The incoming feeder and motor cables are connected to their corresponding busbars inside a TEU In multi motor drives several TEUs are part of the drive lineup Depending on drive configuration the incoming busbars are interconnected with the ARU or the LSU The outgoing busbars are interconnected with the inverter unit ...

Page 79: ... safety and to ensure smooth functioning of the equipment it is important to ground the drive properly For this reason the ground cable of the drive is connected to the grounding system of the installation site The drive is equipped with a continuous PE ground busbar that stretches across the bottom part of the entire cabinet 3 8 4 PG busbar To ensure proper operation cable shields are connected t...

Page 80: ......

Page 81: ... It is recommended to photograph the damages and send the photographs to ABB 4 4 Identifying transport units A delivery can consist of transport units for several drives To identify the transport units and assign them to a particular drive see the following accompanying papers for information Packing list that is attached to the packaging of each transport unit Packing label on the back wall of ea...

Page 82: ...and Ltd Drives Mailing address CH 5401 Baden Switzerland Phone 41 58 589 27 95 Telex 755749 abb ch Facsimile 41 58 580 20 84 Bank Credit Suisse CH 8070 Zurich Switzerland ABB item Customer item Qty Unit Identnumber Commodity description 001221 1 1 The third digit from the right identifies the drive that the accessories belong to ie drive 1 1 PC cross wiring 001222 1 PC WCU accessory 001223 1 PC cr...

Page 83: ... NOT lift and move them with a crane Use appropriate transport means such as heavy load hydraulics rollers or air cushions If in doubt contact ABB for instructions To prevent damage to drive components transport and move the drive or a transport unit only in upright position To prevent dirt from entering the drive keep the doors of the drive or a transport unit closed Metallic dust in particular c...

Page 84: ...s of the cabinet roof Use appropriate safety hooks or shackles to attach a sling DO NOT pass a sling through the hole of the bracket Protect the edges and the door handles if the slings are too close to the cabinet If a lift frame or lift spreader is not available make sure that the slope angle is a maximum of 15 see Fig 4 2 Observe the center of gravity Lift the drive or a transport unit slowly a...

Page 85: ...ON STORAGE AND DISPOSAL Figure 4 2 Lift frame A and lift spreader B 1 Safety hook 2 Lift frame 3 Strap 4 Protect the edges door handles and levers 5 Safety hook or shackle 6 Lifting bracket 7 Slope angle maximum 15 8 Lift spreader A 1 2 2 3 4 5 6 B 1 3 4 5 6 7 8 8 ...

Page 86: ... 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 4 1 unit desiccant 30 g absorbs 6 g water vapor IMPORTANT If you use polyethylene foil to cover the cabinets use...

Page 87: ... boards in antistatic bags or boxes Storage temperature range 5 C to 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 humidity 5 85 DO NOT touch a circuit board without wearing a wrist grounding strap Put the component on a g...

Page 88: ...8 4 8 Disposing package materials and components Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations Note For more information on the disposal of packaging materials and drive components see the recycling instructions ...

Page 89: ...nits on page 92 5 5 Joining transport units on page 94 5 6 Joining water pipes on page 95 Joining the busbars 5 11 Installing the roof joints and the roof attachments on page 118 Only for optional components 5 8 Installing and removing air to air heat exchangers on page 106 5 9 Installing the pressure relief vents on page 115 5 10 Attaching the sealing tapes on page 117 All installation work must ...

Page 90: ...k is discontinued and completely cover openings Metallic dust in particular could cause failures when the drive is powered up and cause damage When joining two transport units do not damage or dislocate the EMC sealing strip that is glued onto the outer joining surfaces of the cabinet frame If the transport units are joined but not yet on the base frame do not lift and move them with a crane Inste...

Page 91: ...ter circuit The incoming and outgoing raw water pipes are connected to the flanges of the WCU Installation material such as counter flanges bolts nuts and seals are supplied For information on dimensions of the raw water entry and the flanges see Appendix C Mechanical drawings NOTICE Risk of component damage Use cable ducts of non flammable material with non abrasive surface To prevent dust humidi...

Page 92: ...ral transport units 1 If a transport unit has water pipes remove the protective covers from the water pipe ends on both sides 2 Check that a pipe joint 1 has been slid on one pipe end of two adjoining water pipes 3 Line up the transport units as shown in Appendix C Mechanical drawings Note The units can be lined up either beginning from the left or the right 1 ...

Page 93: ...and the angular deflection of two adjoining water pipes are not exceeded Axial misalignment 3 mm Axial deflection 5 Bolt holes are aligned where transport units are joined see the connection points on Fig 5 1 Cabinet doors are not misaligned and that there are no gaps between cabinet walls and cabinet frame Adjoining surfaces of transport units meet perfectly all around ...

Page 94: ...ote Some of the connection points might not be accessible in certain configurations In such cases you only need to join the connection points that you can access Figure 5 1 Connection point locations on transport units NOTICE Risk of component damage DO NOT move joined transport units with a crane Use transport means such as heavy load hydraulics rollers or air cushions instead 1 Connection point ...

Page 95: ...of a pipe joint on one end of a water pipe as a fitting guide 2 Slide the pipe joint over the two adjoining pipe ends 3 Center the pipe joint 4 Orientate the locking bolts of the pipe joint for the return water pipes Fig 5 2 Figure 5 2 Minimum distances and locking bolt orientation A front WARNING Flashover hazard The locking bolts maintain the required minimum distances between pipe joint and bus...

Page 96: ... the bolts to the torque indicated on the pipe joint 5 6 1 Removing a pipe joint 1 Loosen the bolts alternately but do not remove them completely 2 Slide the pipe joint to the side Note The sealing lip can touch the pipe end 3 Turn and move the pipe joint smoothly 4 Clean the pipe joint and treat the bolts with an appropriate lubricant before refitting ...

Page 97: ...e a conical spring washer on each side of a connection Figure 5 3 Bolted busbar connection CAUTION Flashover hazard Incorrect orientation of the busbar bolts can cause flashover when the drive is energized Orientate the bolts and the nuts of each connection as shown in this section to maintain the required minimal distances between busbars of different polarity NOTICE Risk of component damage Tigh...

Page 98: ...configuration of the drive DC busbar configuration 1 Fig 5 4 DC busbar configuration 2 A in Fig 5 5 DC busbar configuration 3 B in Fig 5 5 DC busbar configuration 4 C in Fig 5 5 Figure 5 4 Top view of DC busbar configuration 1 Item Quantity Technical parameters Identification 1 Connecting plate 3 Flex 3BHB010246R0001 R0051 2 Hex head bolt 6 M12 x 35 A2 NB 312350P8118 3 Hex head nut 6 M12 A2 70 coa...

Page 99: ...8 05 MECHANICAL INSTALLATION Figure 5 5 Top view DC busbar configurations 2 A 3 B and 4 C 1 Busbar with negative potential 2 Busbar with neutral potential 3 Busbar with positive potential 4 Front of cabinet A B C NP NP NP NP NP NP NP NP NP 1 2 3 4 ...

Page 100: ...und busbar joints Item Quantity Technical parameters Identification 1 Connecting plate 2 Flex 3BHB010246R0001 R0051 2 Hex head bolt 4 M12 x 40 A2 NB 312350P8119 3 Hex head nut 4 M12 A2 70 coated HZN 452198P1022 4 Conical spring washer 8 13 x 29 x 3 HAQN400344P0111 5 Water pipe 6 Cabinet front PG PE 1 1 2 3 4 4 5 ...

Page 101: ...een the COU TEU and LSU 5 7 9 MVA Item Quantity Technical parameters Identification 1 Connection bus bar 1 LSU TEU 1b 3BHB045554R0001 2 Connection bus bar 1 LSU TEU 2b 3BHB045556R0001 3 Connection bus bar 4 LSU TEU 3b 3BHB045558R0001 4 Bus bar spacer 4 80 mm spacer 10 mm 3BHB031095R0001 5 Hex head bolt 32 M12 x 45 A2 70 NB 312450P8120 6 Hex head bolt 16 M12 x 50 A2 70 NB 312450P8121 7 Conical spri...

Page 102: ...of this figure Figure 5 8 AC busbar joints between the COU TEU and LSU 14 MVA Item Quantity Technical parameters Identification 1 Connection bus bar 1 LSU TEU 1a 3BHB045554R0001 2 Connection bus bar 1 LSU TEU 2a 3BHB045556R0001 3 Connection bu bar 4 LSU TEU 3a 3BHB045558R0001 4 Hex head bolt 32 M12 x 45 A2 70 NB 312450P8120 5 Hex head bolt 16 M12 x 65 A2 70 NB 312450P8124 6 Conical spring washer 9...

Page 103: ... M12 x 40 A2 70 NB 312350P8119 Single busbar Hex head bolt M12 x 60 A2 70 NB 312450P8123 Double busbars Hex head bolt M12 x 80 A2 70 NB 312450P8127 Triple busbars Conical spring washer 13 x 29 x 3 HAQN400344P0111 Hex head nut M12 A2 70 coated HZN 452198P1022 Modules Busbar joints ARU INU COU TEU ARU INU 5 MVA without MOI COU TEU 600 mm 1000 mm COU TEU ARU INU ARU INU 5 MVA without MOI COU TEU 600 ...

Page 104: ...with motorized disconnector COU TEU ARU INU ARU INU 7 9 13 peak MVA 5 MVA with MOI COU TEU 600 mm 1000 mm ARU INU COU TEU ARU INU 12 MVA COU TEU 1000 mm COU TEU ARU INU ARU INU 12 MVA COU TEU 1000 mm Module Busbar joints ARU INU COU TEU ARU INU 5 7 9 13 peak MVA COU TEU 1000 mm Modules Busbar joints ...

Page 105: ...S6080 USER MANUAL 105 238 05 MECHANICAL INSTALLATION COU TEU ARU INU ARU INU 5 7 9 13 peak MVA COU TEU 1000 mm ARU INU COU TEU ARU INU 12 MVA COU TEU 1000 mm COU TEU ARU INU ARU INU 12 MVA COU TEU 1000 mm Module Busbar joints ...

Page 106: ...lling air to air heat exchangers For information on the number of air to air heat exchangers to be installed and their fitting position see Appendix C Mechanical drawings Figure 5 9 Air to air heat exchanger type LT 5 5165 UL Figure 5 10 Tools for installing an air to air heat exchanger Weight 65 kg Length 1025 mm Width 750 mm Height 316 mm 1 Cordless drill 2 Wire cutter 3 Torx drill bit 4 M6 x 12...

Page 107: ...fore lifting the heat exchanger onto the roof cut off the cable ties 2 Loop the cables as illustrated and fasten them to the cable tie mounts circles NOTICE Risk of damage Incorrect installation of the heat exchanger cables can cause Ground fault Unexpected shutdown of the drive Damage to the heat exchanger 2 x ...

Page 108: ... cover on the roof where the heat exchanger is installed 5 Lift the heat exchanger above the opening in the roof and orientate the heat exchanger with the LEDs circle pointing to the front of the cabinet CAUTION Hazardous voltage Make sure that the heat exchanger cables do not touch the high voltage carrying DC busbars 2 in Fig 5 11 1 Correct cable installation 2 DC busbar 3 Incorrect cable instal...

Page 109: ...S6080 USER MANUAL 109 238 05 MECHANICAL INSTALLATION 6 Route the cables through the designated openings circle at the front of the cabinet 7 While lowering the heat exchanger onto the roof pull the cables through the openings ...

Page 110: ...RU INU IFU 9 MVA and LSU Figure 5 12 ARU INU IFU cable routing Figure 5 13 LSU cable routing 9 Connect each wire to terminal block X1 according to the terminal numbers printed on the marker sleeves white 10 In the upper part of the cable duct 1 fasten the cables to the cabinet frame 11 In the lower part 2 tie the cables together at regular distances 1 1 2 1 2 15 x 1 1 2 ...

Page 111: ...lies to drives that are delivered in several transport units Figure 5 14 Air to air heat exchangers type LT 5 5165 UL Air to air heat exchangers must be removed and refitted where two transport units are joined CAUTION Heavy object An air air height exchanger weighs approximately 65 kg Observe the installation height of the heat exchanger as well as the dimensions and weight of the heat exchanger ...

Page 112: ... for joining the DC busbars of two adjacent transport units Figure 5 15 Tools for removing an air to air heat exchanger 5 8 2 1 Removing an air to air heat exchanger 1 Loosen the 4 self tapping M6x12 screws HAQN401205P0257 that fasten the heat exchanger to the roof 2 Remove the cable ties 1 Cordless drill 2 Wire cutter 3 Torx drill bit 4 Cable tie 1 2 3 4 ...

Page 113: ... exchanger and place the removed heat exchanger on the timber 6 Join the DC busbars with the supplied installation material 5 8 2 2 Reinstalling an air to air heat exchanger 1 Move the heat exchanger to its original position 2 Pull the cables down towards the terminal box 3 Move the heat exchanger to its exact position 4 Fix the cables with cable ties at regular distances of approximately 20 cm 5 ...

Page 114: ...r of transformers to be installed and their fitting position see Appendix C Mechanical drawings 1 Install the transformer and hood as illustrated Figure 5 16 Installation example of transformers in an air to air heat exchanger 1 8 x M6x12 HAQN401205P0257 2 Transformer hood 3 4 x M8x20 9ABA450093R0310 4 Transformer connection plate 5 1 5 kVA transformer 17 kg 6 2 8 kVA transformer 49 kg 7 3 5 kVA t...

Page 115: ...rs printed on the marker sleeves Figure 5 17 Connect wires to terminal block 5 9 Installing the pressure relief vents This section applies to drives with separately delivered pressure relief vents Pressure relief vents are installed on the roofs of TEUs and COUs Figure 5 18 Pressure relief vents Weight 26 kg Length 840 mm Width 520 mm Height 210 mm ...

Page 116: ...ows pointing to the center of the drive Note The orientation of the baffle blades can be seen through the grille on the underside Figure 5 20 Installation example of pressure relief vents 2 Fasten the pressure relief vent to the roof with the supplied screws Fig 5 20 1 Cordless drill 2 Torx bit 3 24 x M6x20 Self tapping HAQN40105P0260 1 Orientation of baffle blades 2 Center of drive 3 Pressure rel...

Page 117: ...it prevents water entering the gap between two adjoining roof plates The tape is installed where two transport units have been joined Gaps within a transport unit have been sealed with a tape in the factory Procedure 1 Remove the roof plates of two adjoining transport units 2 Cut the sealing tape to the required length 3 Attach the tape on the whole length of the joining crossbars 1 Figure 5 21 At...

Page 118: ...tion see Appendix C Mechanical drawings Install the joints at the front and the back of the roof of two adjoining transport units using the supplied installation material Note The joints 1 within a transport unit are factory installed Figure 5 22 Roof joints 1 Table 5 2 Installation material for roof joints Item Technical parameter Identification Connecting plate 8 x 80 x 220 mm 3BHB011552R0001 He...

Page 119: ...ppendix C Mechanical drawings Figure 5 23 Roof attachment parts Item Details ID number 1 2 x nuts M12 HZN 452198P1022 2 2 x washers 13 29 ST ZN 9ABA450078P0007 3 2 x washers 17 x 30 x 3 9ABA450078P0008 4 2 x hex head bolts M16 x 40 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 3BHB...

Page 120: ...ot supplied WARNING Do not install the struts at a 90 angle to the cabinet roof Fig 5 24 4 If you fix the drive to the ceiling use two struts per roof attachment 1 in Fig 5 24 5 If you fix the drive to the back wall install one strut in a 90 angle to the drive 2 in Fig 5 24 Figure 5 24 Recommended ceiling and wall fixings 1 Two struts at 45 to ceiling 2 One strut at 90 to wall 3 Do not install the...

Page 121: ... 6 1 Phase module on lift table 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 t...

Page 122: ...te For information on the requirements for the auxiliary power cable and the control cables see Auxiliary power and control cables guideline 3BHS813742 E01 6 2 3 Synchronization cables Synchronization cables are used in drives with an ARU A shielded 3 phase cable without neutral wire is required for the supply voltage of the synchronization transformer NOTICE Risk of false signals DO NOT lay contr...

Page 123: ...e B of the drive system 1 Transformer or busbar 2 System ground 3 Cable shield 4 Cable armor 5 Equipotential bonding conductor 6 Ground cable 7 TEU 8 ARU 9 Transformer 10 LSU 11 INU 12 Motor L1 L2 L3 PE U1 V1 W1 PG PE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 L1 L2 L3 PE 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 L1 L2 L3 PG PE L1 L2 L3 2L1 2L2 2L3 PG PE U1 V1 W1 PE U2 V2 W2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3...

Page 124: ... ground busbar is fitted below the roof Figure 6 3 System ground connection 1 in a 600 mm TEU Note For project specific information see Appendix D Wiring diagrams For information on busbar thickness and fastening hole diameter see Appendix C Mechanical drawings 6 3 3 Cable shield ground connection Cable shields are connected to the separate PG ground busbar The connection between the PE and PG gro...

Page 125: ...a cable At the EXU ground the cable screen via the conductive sleeve of the entry plate Figure 6 4 Grounding the EXU 6 4 Internal wiring This section applies to a drive that is delivered as multiple transport units Cables for internal wiring are delivered separately The pre assembled cables are fitted with terminal identifications at each end All necessary data for each individual connection are s...

Page 126: ... minimum distance of 5 mm from the closest metal part 3 Connect all cables and wires according to the Converter Hardware diagram 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 a...

Page 127: ...ed for arc faults by the Arc Guard System with optical detectors 2 detectors in COU TEU 2 detectors in ARU with bottom cable entry option 1 detector in BCU Figure 6 6 Arc Guard System in an optional roof extension box REB The Arc Guard System consists of the following Arc Guard unit TVOC 2 with HMI panel Optical fiber detectors The detectors are pre installed in the relevant cabinets with the corr...

Page 128: ...through the cable duct 3 in Fig 6 8 at the top of the cabinets Note Cut outs in the ducts provide entry into the cabinets Figure 6 8 Cable tray and cable ducts in an LSU A front 2 Lay the cables into their designated trays and cable ducts as illustrated in Fig 6 8 3 Connect the cables to the arc monitor located in the REB according to the drawings 1 Cable tray for auxiliary power supply cable 2 Ca...

Page 129: ...top and or bottom cable entry 6 5 1 Frames with type 1 sealing modules on page 129 6 5 2 Frame with type 2 sealing modules on page 131 6 5 3 Plates with cable glands on page 131 6 5 4 EMC plates with sealing grommets on page 132 Note For information on the location and the dimensions of the cable entry see Appendix C Mechanical drawings 6 5 1 Frames with type 1 sealing modules Figure 6 9 Cable ent...

Page 130: ...ngle core cable Table 6 1 Cable entry frames for type 1 sealing modules Cabinet entry frame Cabinet Maximum number of sealing modules openings Maximum number of cables openings RM12 0 RM9 0 RM6 0 Single core Ø28 50 mm Three core Ø68 99 mm Single core Ø48 71 mm 1 TEU 1000 mm 1 2 6 6 1 2 2 TEU 600 mm 1 2 6 6 1 2 3 ARU 1 2 6 6 1 2 4 BCU 1 1 4 3 1 1 5 EXU 1 2 6 6 1 2 L1 L2 L3 L1 L2 L3 L1 L2 L3 L3 L1 L...

Page 131: ...land 1 EMC sealing modules 2 Frame Usage Auxiliary power cables Control cables Included in delivery Cable entry frame Supplier Roxtec AB www roxtec com Not included in delivery EMC sealing inserts Installation tools Accessories 1 2 Usage Power cables ground cables bonding conductors Auxiliary power cables control cables Included in delivery Undrilled gland plate Not included in delivery Cable glan...

Page 132: ...ble entry systems for TEU ARU and EXU cabinets This section describes how to prepare cable entry systems for the following cabinets TEU ARU EXU 1 EMC sleeves 2 Sealing grommets 3 45 mm 4 1 5 mm Usage Power cables Ground cables Bonding conductors Auxiliary power cables Control cables Included in delivery Galvanized plate with net like EMC sleeves Sealing grommets 1 2 3 4 ...

Page 133: ...ompression wedge 4 between the frame 1 and the sealing module 5 This ensures that the minimum distance to the high voltage busbars is maintained Figure 6 14 TEU 1000 mm cabinet A back with top 1 and bottom 2 cable entries 1 Top cable entry frame 2 Bottom cable entry 3 High voltage busbars 4 Compression wedge 5 RM90 sealing module with 3 core cable L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2...

Page 134: ...s well 6 6 2 0 1 Removing the short busbars on page 134 6 6 2 0 1 Removing the short busbars 1 Remove the phase module according to 9 4 10 Removing and installing a phase module on page 213 2 If necessary remove the short busbars boxes to facilitate entering the cables 3 To remove a busbar unscrew the bottom bracket and the bolts and then move the busbar downward and away from the cabinet Figure 6...

Page 135: ...e 6 16 EXU with top cable entry A and EXU with bottom cable entry B If the cabinet is only accessible from the front and the cables are entered through the bottom proceed as follows 1 Remove the front cover and if present unplug the heating cable and remove the cross brace with the heating cable 2 Remove the cover above the fan unit 3 Remove the fan unit as explained in 9 4 17 Replacing the fan un...

Page 136: ...point of cable entry and terminals or busbars Busbar and fastening hole dimensions Busbar designations See Appendix D Wiring diagrams for information on Conventions for cross reference and device identification 6 7 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 b...

Page 137: ...dules 2 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 connect to PG busbar 10 Cable screen extension to connect to the PG busbar 11 Cable ...

Page 138: ...le glands 6 7 4 Preparing cables for EMC plates This section describes how to prepare standard cables for EMC plates as well as cables for an EXU 1 Remove the grommets from the entry plate 2 To ensure proper sealing cut along the marking that corresponds to the cable diameter 1 Cable gland 2 Plate 3 Heat shrinkable termination 4 Outer cable sheath 5 Conductor insulation removed to expose cable shi...

Page 139: ... Fig 6 20 6 Prepare EXU cables according to Fig 6 20 The orientation of the EMC plates in both scenarios is the same for top and bottom cable entries ie the sealing grommets face upwards Figure 6 20 Preparing cables for EMC plates A cables with an outer screen or shield B cables without an outer screen or shield or C cables in an EXU cabinet 1 Grommet 2 EMC sleeve 3 Cable tie 4 Heat shrinkable ter...

Page 140: ...are connected to a busbar attach the cable lugs of the cables on each side of the busbar 2 Fasten the cables to the strain relief rails with suitable cable clamps Figure 6 21 Cable connections in an EXU cabinet WARNING Risk of flashover High voltages will be present in the terminal compartment High voltages can cause flashover between the electric potential of different conductors and the electric...

Page 141: ...m distance between bolted joints of different phases in an EXU 6 7 5 3 Bolted busbar connections marine drives The following bolts washers and nuts are supplied and fixed to the busbars in marine drives Figure 6 23 Bolted busbar connection marine drives 1 25 mm 1 Part Quantity Identification Hex head bolt M12x40 A2 NB 312350P8119 Coated hex head nut M12 A2 70 HZN 452198P1022 Conical spring washer ...

Page 142: ...o a busbar Spring washer and flat washer on each side of the busbar The spring washer and flat washer can be replaced by a conical spring washer Fig 6 23 Other washers can be used provided they maintain the required contact pressure Use cable lugs suitable for M12 bolts 6 7 5 4 3 Lubrication If stainless steel bolts and nuts are used lubricate the thread and head contact surface of the bolt using ...

Page 143: ...U and EXU cabinets on page 132 See Appendix C Mechanical drawings for information on Project specific cable entry Dimensions between point of cable entry and terminals See Appendix D Wiring diagrams for information on Conventions for cross references and device identification Terminal designations 6 8 1 Determining the cable length 1 Determine the required length of a cable between the point of en...

Page 144: ...A Additional manuals Figure 6 25 Cable entry with sealing modules 1 Unscrew the frame 2 Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig 6 26 Figure 6 26 Preparing control cables for sealing modules 1 Sealing modules 2 Compression wedge 1 Sealing module 2 Conductive foil 3 Cable sheath removed to expose cable shield 4 Condu...

Page 145: ...he grommets from the entry plate 2 To ensure proper sealing cut along the marking that corresponds to the cable diameter 3 Slide the grommet onto the cable and ensure that the grommet fits tightly to prevent water from entering the cabinet Note If cables are routed through the cabinet floor the grommets can be discarded 4 If necessary remove the entry plate and pull the cable through the entry hol...

Page 146: ... is non conductive 1 Cut open the cable screen in the middle of the stripped area 1 in Fig 6 28 2 Pull the cable screen ends over the cable insulation to turn the conductive side inside out 2 in Fig 6 28 3 Connect the screens ends with a continuous conducting foil 3 in Fig 6 28 Figure 6 28 Preparing the screens of control cables for EMC plates 1 Cable screen 2 Cable screen ends 3 Conductive foil 1...

Page 147: ...try see Appendix C Mechanical drawings 6 8 6 Routing cables in a COU cabinet The serial communications and encoder cables are connected inside a COU Top and bottom cable entries are covered with blanking plates Materials for cable fitting EMC requirements and sealing are not supplied 1 Outer cable sheath 2 Grommet 3 EMC sleeve 4 Plate 5 Cable sheath removed to expose cable shield 6 Conductor scree...

Page 148: ...lanking plates of 600 mm COU A and 1000 mm COU B Figure 6 31 Location of bottom blanking plates of 600 mm COU A and 1000 mm COU B 2 Prepare the length of cable that passes through the cable entry according to 6 8 3 Preparing cables for cable glands on page 145 1 Top blanking plate 2 Front 1 Bottom blanking plate 2 Front 1 1 2 2 A B 1 1 1 2 2 A B ...

Page 149: ...Absolute encoder SSI and incremental encoder TTL Absolute Encoder Interface FEN 11 user manual 3AFE68784841 Incremental encoder HTL HTL Encoder Interface FEN 31 user manual 3AUA0000031044 Conductors If a twisted pair cable is used leave the unshielded cable ends twisted until they reach the terminals Leave unshielded conductor ends as short as possible not longer than 50 mm Cable shields Connect t...

Page 150: ...tion applies to a stand alone EXU 6 8 7 1 Auxiliary power and control cables 1 Enter the cables through a free hole of the EMC plate 2 On the length of cable that passes through the cable transit prepare the cable according to the following instructions Cable entries with EMC plates 6 8 4 Preparing cables for EMC plates on page 145 Cable entries with cable glands 6 8 3 Preparing cables for cable g...

Page 151: ...rter A and in an EXU cabinet with an ED7Y type DCS880 converter 4 Connect the cables to the terminals inside the terminal compartment of the cabinet 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Terminal for optical fibers behind cover 7 Optical fibers to DCS880 H4 converter 8 Optic...

Page 152: ...y used for the encoder cables The conduit starts at the drive and ends inside the EXU At the drive the conduit enters through the entry plate with about 10 20 mm of conduit extending from the entry plate To protect the tip of the optical fiber against scratches cover the cable end with a cap before pulling the cable through the conduit DO NOT exceed the specified maximum tensile load and the minim...

Page 153: ...CT880 control panel Figure 6 35 DCS880 DCT880 H4 converter ED5V EB5R EB5S EB7P and EB7Q types 3 Insert a flat blade screwdriver into one of the indentations at the bottom of the DCS880 DCT880 front cover 4 Gently press down the latch tab with the tip of the screwdriver and pull the corner of the cover forward and repeat for the other side 5 Slide the removable cover up and then remove the cover 1 ...

Page 154: ...as illustrated in Fig 6 37 Figure 6 37 Cable routing example in an EXU cabinet with an ED5V EB5R EB5S EB7P and EB7Q type DCS880 DCT880 converter 8 Reattach the front cover of the DCS880 DCT880 1 Slot 1 FDCO 01 module 2 Control panel 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Term...

Page 155: ...erter 1 Unscrew the rectangular cover from the DCS880 DCT880 unit Figure 6 38 DCS880 DCT880 converter ED7Y 2 Connect the two optical fibers to the receptacles of slot 1 according to the terminal numbers printed on the marker sleeves Figure 6 39 1 Control unit SDCS CON H01 1 Control panel 2 Removable cover 1 Slot 1 FDCO 01 module 2 Control panel 1 2 1 2 ...

Page 156: ... routing example in an EXU cabinet with an ED7Y type DCS880 DCT880 converter 4 Reattach the DCS880 DCT880 cover 1 Cable enters through roof 2 PE ground busbar 3 Cable enters through the floor 4 Terminal strip for auxiliary power and control cables 5 Auxiliary supply cable 6 Terminal for optical fibers behind cover 7 Optical fibers to DCS880 DCT880 D4 converter 1 2 3 4 5 6 7 ...

Page 157: ...ith a heating cable Procedure 1 Connect the power supply of the heating cable Note For more information on power supply connections see the converter hardware diagram in Appendix D Wiring diagrams 2 Connect the heating cables of two adjoining transport units with each other 3 Fasten the connectors with cable ties Figure 6 41 Heating cable connection 1 Heating cable plug 2 Cable tie 1 1 2 2 ...

Page 158: ...6080 USER MANUAL 158 238 6 10 Final checks Check that the entry plates are properly fastened If EMC entry plates with grommets are used check that the grommets fit tightly arrows to prevent water entering the cabinet If necessary seal gaps with silicone ...

Page 159: ... 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 associated mediu...

Page 160: ...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 ABB power cable specification 3 Puls...

Page 161: ... connection 7 6 3 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 loop is tested 1 Pay attention to MCB opening time and in...

Page 162: ...ithin 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 7 Power checklist 1 Medium voltage available for startup of drive 2 Low voltage is available for startup of drive 7 6 8 M...

Page 163: ...e location see the applicable manuals for information The panel messages and parameter settings used in this chapter are typical examples They illustrate the related instructions and display functions and can differ from the actual messages and parameter settings of the drive 8 2 Operating conditions The operating conditions for the drive are according to IEC 60721 3 3 Classification 3K22 3B1 3S6 ...

Page 164: ...any specialized application needed The menus and messages can be customized for specific terminology so that each application can be set up and configured to its optimum performance With the panel s text editor users can also add information customize text and label the drive Powerful backup and restore functions are supported The help key provides context sensitive guidance Faults or warnings can...

Page 165: ...panel 8 5 1 Control panels for drives with an ARU Fig 8 3 shows the control panel configurations are present in drives with an ARU Fig 8 3 The master control unit COU1 has 2 control panels one for the ARU and one to parameterize the INU to control motor 1 Additional motors are controlled by single control panels on slave COUs 2 5 The control panels for the ARU and motor 1 are on the door of contro...

Page 166: ... status messages of the INU 12 Main power supply on 13 Charges the DC link 14 Closes the main circuit breaker 15 Emergency off reset push button 16 Resets the emergency off relay in the drive control system 17 Flashes when the auxiliary voltage is switched on or when an emergency off push button is pressed 18 Emergency off latching push button 19 Prevents starting when pressed at standstill of the...

Page 167: ...8 4 Master control panel on COU1 A and slave control panel B for a drive with an LSU 1 Master control panel INU 2 Starts and stops the INU motor 1 3 Displays the status messages of the INU 4 Main power supply off 5 Opens the main circuit breaker 6 Alarm fault lamp 7 Alarm flashing light 8 Fault permanent light 9 Main power supply on 10 Charges the DC link 11 Closes the main circuit breaker 12 Emer...

Page 168: ...arm or a fault condition must be rectified After commissioning of the EXU the control panel is set to remote and local operation is locked in parameter 16 04 LocLock This setting prevents the control panel being switched to local control unintentionally Remote operation is indicated with the letters REM in the top left corner of the display The actual values shown on the display can be freely sele...

Page 169: ... be reset manually after the reason causing the fault has been resolved The message on the display can be reset either by pressing the reset soft key on the EXU control panel or by pressing the reset button on the control panel of the drive 8 6 3 Parameter settings The parameters are set as required for operation and verified during commissioning and must not be changed afterwards NOTICE Risk of c...

Page 170: ... below 50 V DC When the grounding switch is in position grounded the door safety switches of the medium voltage units are released and the doors can be opened 1 Grounding switch in ungrounded position A 2 Grounding switch in grounded position B When the switch is in grounded position the DC link of the drive is connected to the ground busbar of the drive 3 White illuminated pushbutton DC link is g...

Page 171: ...U EXU and WCU are not part of the interlocking circuit and can be opened when the drive is energized Note For more information see 9 4 4 Unlocking and opening the doors on page 198 Figure 8 7 Location on the safety switches The safety switches are part of an interlocking circuit that prevents the doors being opened as long as the DC link is charged The interlocking circuit ensures that the Table 8...

Page 172: ... grounding switch is in position not grounded and the safety switches are in position locked Doors can only be opened when the main power has been disconnected the DC link capacitors have been discharged and the grounding switch is in position grounded The locking bar locks and unlocks the locking mechanism of the door of a medium voltage unit ...

Page 173: ...es for actuating the manual output switches are installed inside the drive cabinets The location depends on the configuration of the drive The switches are accessible after the DC link has been discharged and the doors have been opened The open and closed position of the switches is monitored by the drive Depending on the operating state of the drive and the settings of the parameters for this fun...

Page 174: ...s healthy and ready for the ON command The ON command initiates charging of the DC link and the closing of the main circuit breaker of the drive Depending on the control place the command can either be sent from the higher level control system to the drive or be initiated by pressing the SUPPLY ON push button on the control compartment of the drive Informs the operator that the drive is energized ...

Page 175: ...in the drive software 1 Not ready to switch on 2 ARU Ready on Only drives with an ARU see the next step Ready to switch on for the conditions 3 Ready to switch on Auxiliary power supply on Doors of medium voltage units closed and locked Drive is not grounded No emergency off No fault WCU ready 4 On command 5 Charging DC link charges MCB closes Cooling system switches on 6 ARU Ready ref Only in dri...

Page 176: ... INU stops modulating 5 Off command Stop command to ARU only in drives with an ARU MCB opens DC link discharges Cooling system switches off after a delay 6 Ready run 7 ARU Ready on Only in drives with an ARU 8 Ready to switch on Drive is grounded Doors in medium voltage units are released for opening Auxiliary power supply switched off 9 Not ready to switch on ...

Page 177: ...off command Stop command to ARU only in drives with an ARU MCB opens INU stops modulating Speed coasts down 4 Emergency off 1 Operation 2 Ready ref 3 Prevention of unexpected startup command Drives stops according to Ramp Torque and Ramp stop modes Open disconnector Prevention of unexpected startup complete Drive remains charged MCB closed 4 INU operation prevention feedback ...

Page 178: ...following list Tools and foreign objects have not been left inside the cabinet All auxiliary power supplies from external sources are switched on All internal circuit breakers of the drive are closed All covers are fitted All locking screws have been removed from the locking bars on the inside of the doors of medium voltage compartments Doors are closed and locked or bolted 8 10 2 Starting the dri...

Page 179: ...e control compartment door or any other EMERGENCY OFF push button linked to the drive is pressed If the EMERGENCY OFF RESET push button continuous flashing verify that there is no emergency off command active See 8 11 2 Stopping the drive with the emergency off function on page 181 3 Check that no alarm or fault messages are displayed on the control panel When a fault message is displayed on the c...

Page 180: ...tatus of the first INU and the other INUs change to Ready run 6 Enter the reference value 7 Start the motor with the INU control panels After the motor has been magnetized the motor speed ramps up to the reference value While the motor is magnetizing the run status message on the display blinks When the motor has finished magnetizing the run status message lights up permanently The drive is now in...

Page 181: ...of the local control panel Figs 8 3 and 8 4 and features a latching switch action IMPORTANT Pressing the EMERGENCY OFF push button does not disconnect the auxiliary power supply from the drive Note For more information see Emergency off stop modes and prevention of operation safe torque off 3BHS196243 8 11 3 Initiating an emergency off When an emergency off is initiated during operation the follow...

Page 182: ...itial position when turned into the direction indicated by the arrows on the push button 2 Press the EMERGENCY OFF RESET button to reset the emergency off safety relay of the drive The drive remains in emergency off state until the DC link voltage has dropped to 50 V discharged After resetting the status message of the drive changes to Ready to switch on 3 The main power supply can be connected to...

Page 183: ...ng and immediately opens the main circuit breaker Figure 8 8 Arc Guard System in a WCU REB 8 12 1 Action after the Arc Guard System has been triggered 1 De energize and ground the drive according to 9 4 2 De energizing and grounding the drive on page 194 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 9 HMI pa...

Page 184: ...e power units and localize the defect 5 Repair the defect or contact support line if needed 6 Reset the fault on Arc Guard HMI panel 7 Acknowledge the firing through with parameter 16 26 on the control panel only when fault was understood and corrected 8 Restart the drive ...

Page 185: ...the ABB service organization 9 1 2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule on time and at the stated intervals in the ACS6080 preventive maintenance schedule 3BHS838899 E01 9 1 3 Logbook ABB recommends recording all troubleshooting and maintenance work in a logbook including Date and time Detailed description 9 1 4 Spare parts To ensure safe and r...

Page 186: ...labeled in accordance with IEC 81346 1 Figure 9 1 Labels on S500 I O modules and associated wiring diagram 9 2 2 Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams Figure 9 2 Cable and wire designation therein Reproduction use or C ABB Switzerland Ltd 2002 TU518 1 6 1 5 1 4 1 3 1 2 1 1 1 0 A2511 240 A7 XC...

Page 187: ... or fault message and the alarm fault lamp on the control compartment door lights up Alarm flashing light Fault permanent light The message can be saved and viewed in the fault logger of the drive when a PC with Drive Composer is connected to the drive The fault history can also be called up on the control panel 9 3 2 Error message levels Two error message levels are used in the drive Alarm An ala...

Page 188: ...manually reset before the drive can be started again 9 3 2 1 Alarm and fault messages When an alarm or a fault occurs a specific message is saved in the fault buffer of the drive Information on the 64 most recent fault and alarm events are saved 9 3 2 2 Fault handling The faults are entered into the fault buffer as they occur and are numbered The last fault entered has number 1 The first fault ent...

Page 189: ... modules to help fault tracing and analysis The data is stored in a secure data card Note For more information see the BCU 55 PP C932 A Technical Description 3BHS813816 E01 1 DO NOT switch off the auxiliary 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 control panel...

Page 190: ... view B 1 LEDs SD CARD WRITE FAULT PWR OK BATT OK XETH X13 V1T V1R V2T I O CONNECTORS V2R V7T V7R V8T V8R V19T V19R V20T V20R V5T V5R V6T V6R V17T V17R V18T V18R V3T V3R V4T V4R V15T V15R V16T V16R XCAN STATUS A B C D E F G H I J K L X12 V9T V9R V10T V10R V11T V11R V12T V12R V13T V13R V14T V14R V24T V24R V25T V25R V26T V26R V22T V22R V23T V23R V21T V21R SAFETY OPTION 1 6 1 A B ...

Page 191: ...ypes Figure 9 5 S500 I O modules in a COU 9 3 3 3 Serial communication interfaces To identify the serial communication interface in the drive see Appendix D Wiring diagrams For more information see Modbus TCP NETA 21 remote monitoring tool user manual 3AUA0000031044 9 3 3 4 LEDs on optional heat exchangers Two LEDs on the front of the heat exchanger indicate the status of the unit Alarm signals ar...

Page 192: ...R MANUAL 192 238 Figure 9 6 Status LEDs on optional air to air heat exchangers 1 Red LED off A and Green LED on B Heat exchanger is healthy 2 Red LED on A and Green LED off B Alarm conditions 3 Red LED off A and Green LED off B Auxiliary voltage is missing 1 2 3 B A B A B A ...

Page 193: ...n objects are removed from the drive All internal and external covers are securely fastened and all doors are closed locked and or secured locking bar in locked position Release dials of safety switches are in locked position Before you remove a phase module from a cabinet Connect the grounding equipment at the appropriate locations When the motor is spinning a HAZARDOUS VOLTAGE appears at the out...

Page 194: ...The motor stops according to the preset stop function When the motor has reached zero speed the drive is in Ready run 3 Press the SUPPLY OFF push button to disconnect the drive from the main power supply NOTICE Risk of component damage 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...

Page 195: ...ed on page 196 otherwise continue with step 6 Figure 9 7 Grounding switch ungrounded 6 If the yellow lamp GROUNDING SWITCH UNLOCKED is on keep the yellow lamp cap pressed while you turn the grounding switch to the grounded position CAUTION If the lamp does not light up DO NOT force the grounding switch in any direction before you know the reason why the lamp has not lit up If you try the following...

Page 196: ...is not released When the DC link of the drive has been discharged the lamp GROUNDING SWITCH UNLOCKED lights up to indicate that the grounding switch is released and can be turned to the grounded position If the lamp does not light up take the following steps 1 Check that the auxiliary voltage is switched on NOTICE DO NOT use force for turning the grounding switch in any direction 2 Press the lamp ...

Page 197: ... the value of the parameter 2 01 DC VOLTAGE is below 50 V the DC link is discharged If the DC link is discharged the drive is in Ready to switch on status Check that the message Ready on is enabled in the main status word 7 Carefully turn the grounding switch to the grounded position on the following conditions Hazardous voltages cannot be fed into the drive from the main power supply or the motor...

Page 198: ...n the CBU to turn on The white lamp indicates that the drive is grounded and that the locking bars are released Note If the white lamp does not turn on continue with 9 4 6 Testing the white lamp on page 200 Figure 9 9 Grounding switch grounded 2 Slide the locking bar from the locked 1 to the unlocked 2 position Door hinged on the left Door hinged on the right 1 White lamp 2 Yellow lamp 1 2 1 2 1 2...

Page 199: ...hinged on the right or to the left if the door is hinged on the left 5 If you cannot open the door continue with 9 4 7 Emergency release of a door safety switch on page 202 9 4 5 Closing and locking the doors 1 Close the doors 2 To lock the door bring the door handle in line with the door plate 1 and press the handle down 2 until it clicks in 3 Slide the locking bar from the unlocked 1 to the lock...

Page 200: ...t circuit is faulty The lamp test circuit and the door releasing circuit are independent of each other From the lamp not lighting up it cannot be concluded that the door releasing circuit is not working Lamp turns on Door releasing circuit is malfunctioning Figure 9 10 Testing the white lamp 2 Check if the LED of digital input 16 input module A1511 in COU1 is lit If the LED is lit the drive contro...

Page 201: ...nue with 9 4 7 Emergency release of a door safety switch on page 202 Note For information on the wiring of the control circuit see Converter hardware diagram Wiring diagram of COU1 For information on the wiring of the discharging circuit and or the grounding circuit see Wiring diagram of COU1 Wiring diagram of CBU ...

Page 202: ...CU RBU VLU TEU and ISU are equipped with safety switches Figure 9 11 Safety switch on an ARU INU cabinet door DANGER Hazardous voltages Touching energized components can be fatal Before you unlock a safety switch verify that the drive is de energized DO NOT unlock the safety switches permanently 1 Screw cap on door 2 Safety switch location behind door 3 Safety switch 4 Unlocked position 5 Locked p...

Page 203: ... the release dial from the locked to the unlocked position You can now actuate the locking bar and open the doors Location Setting Description 1 Unlocked Enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off 2 Release dial Direction of arrow indicates safety switch status ie locked or unlocked 3 Locked Normal operating setting To open the door of a m...

Page 204: ...ecting a grounding set Figure 9 13 Four way grounding set Depending on the type of line side rectifier continue with 9 4 8 1 Drives with LSU on page 205 9 4 8 2 Drives with ARU on page 206 DANGER Hazardous voltages Grounding equipment ensures that FATAL voltages cannot be fed into the drive from the main power supply or the motor during maintenance work eg the removal of phase modules Connect grou...

Page 205: ...ground busbar inside TEU Fig 9 14 2 Use the telescopic insulating pole to connect and tighten the busbar ground clamps to the ground ball studs 1 of the following busbars Inside TEU 1L1 1L2 1L3 2L1 2L2 and 2L3 in Fig 9 14 Inside INU L1 L2 and L3 in Fig 9 15 Figure 9 14 TEU ground ball stud locations 1 Ground ball stud example 2 2L2 3 1L1 4 1L3 5 2L3 6 2L1 7 1L2 8 PE 1 2 3 4 5 6 7 8 8 ...

Page 206: ...and L3 in Fig 9 15 Figure 9 15 ARU INU ground ball stud locations 9 4 9 Drives with the manual output isolation optional The manual output isolation disconnects the output of the drive INU1 or INU2 from the motor and creates a visible isolating distance in the supply line to the motor The option includes the following items Busbar connectors in TEU1 and COU1 Busbar connectors for INU1 are located ...

Page 207: ...MAINTENANCE Figure 9 16 Manual output isolation overview 1 LSU1 2 TEU1 3 INU1 4 CBU1 5 BCU1 6 INU2 7 COU1 8 LSU2 9 WCU1 10 Motor 11 Busbar connectors 3 x in TEU 12 Busbar connectors 3 x in COU1 13 Lever for removing and fitting the busbar connections 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 208: ...ing sets at the locations indicated in Fig 9 19 Be aware of arcing between ground clamp and busbar ground studs when connecting a grounding set to the busbars for the motor cables Arcing can be caused by voltages being fed into the drive when the motor is driven by the propeller of the ship Follow local safety procedures 1 Orientation of lever for removing busbar connectors 2 Orientation of lever ...

Page 209: ...ole Fig 9 17 to connect and tighten the enclosure ground clamp to the ground ball stud of the PE ground busbar 3 Connect the busbar ground clamps to the ground ball studs of the phase busbars in the following sequence Busbars for the cables to the secondary transformer windings 1 in Fig 9 19 Busbars for the motor cables 2 in Fig 9 19 Busbars in the INU 3 in Fig 9 19 Figure 9 18 Overview of groundi...

Page 210: ...ER MANUAL 210 238 Figure 9 19 Connect the grounding sets in COU1 A and C TEU1 B INU1 D and INU2 E 1 Busbars for secondary transformer windings 2 Busbars for motor cables 3 INU busbars 4 PE 5 Ground ball stud B A C D E 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 ...

Page 211: ...TIONA busbar connector weighs approximately 10 kg Figure 9 20 Busbar connector removal sequence in TEU1 or COU1 5 Remove the grounding sets 6 Check that the LEDs are lit 7 Check that tools and foreign objects are not left inside the cabinets 8 Close and lock the doors 9 Check that the power operating mode POM of the drive corresponds to the busbar connectors fitted 1 2 3 4 5 6 ...

Page 212: ...cedures 2 Fit the busbar connectors in the sequence shown in Fig 9 21 Figure 9 21 Fitting sequence for busbar connectors 3 Remove the grounding sets 4 Check that the LEDs are lit 5 Check that tools and foreign objects are not left inside the cabinets 6 Close and lock the doors 7 Check that the power operating mode POM of the drive corresponds to the busbar connectors fitted 8 Start the drive accor...

Page 213: ...removal of phase module from an ARU INU eg to access the back of the cabinet or to work on the phase module 9 4 10 1 Removing a phase module 1 Disconnect the water hoses Note To disconnect the water hose pull the locking sleeve of the coupling towards the front of the cabinet arrow 2 Cut off the cable ties 1 and disconnect the optical fibers and the power supply leads 2 1 1 2 ...

Page 214: ...of the phase module 5 Adjust the height of the table so that it is level with the rails on the underside of the phase module 6 Pull the phase module onto the table CAUTIONA phase module weighs approximately 190 kg When pulling out the phase module make sure that the disconnected water hoses optical fibers and power supply leads are out of the way 1 1 2 2 80 mm 3 17 mm 4 Location of bolts to remove...

Page 215: ... towards the back of the cabinet until the busbars engage with the connectors at the back of the cabinet 5 Screw in and tighten the bolts 6 Pull the locking sleeve of the female half of the water hose coupling back as far as possible 7 While holding it in this position push it over the fixed male half of the coupling until it stops 8 Let go of the locking sleeve and firmly push the female part aga...

Page 216: ...ble cable specifications 9 4 12 Cleaning 9 4 12 1 Cleaning the drive cabinet When cleaning the drive cabinet mind the following To keep dirt out cover the equipment or assemblies Take electrostatic sensitive precautions and use suitable tools to prevent electrostatic discharge To prevent damage use antistatic brushes and a vacuum cleaner with a soft nozzle to carefully clean circuit boards with sp...

Page 217: ...on class IP 54 The filter mats are located between the ventilation grid and the wire mesh The wire mesh is always installed NOTICE Risk of component damage Vibration can loosen electrical connections and cause equipment failure Excessive force damages the capacitor bushings Tighten to the torque value on the label attached to the capacitor IMPORTANT DO NOT exceed 20 Nm if the tightening torque val...

Page 218: ...behind the ventilation grids start automatically when the temperature rises above a preset level 2 Remove the bolt at the top of the fan cover 3 Slide the cover up and pull it out of the slots 4 Turn the cover over and remove the filter mat 5 Insert the new filter mat and reinstall the ventilation grid 1 Ventilation grid 2 Wire mesh 3 Filter mat only for protection class IP 54 10 mm 250 mm 250 mm ...

Page 219: ... auxiliary fan units To switch the fan units on and off for the test use the thermostats of the fan units Procedure 1 Switch on the auxiliary voltage for the fan unit to be tested 2 Take note the setting of the thermostat The factory set value is also stated on the Settings label The label is attached to the inside of the cabinet door 3 To switch on a fan unit turn the dial of the thermostat from ...

Page 220: ...iniature circuit breaker see Appendix D Wiring diagrams 2 Only for fan units of the optional REB Unscrew the ventilation grid circles and flip the grid downward arrow IMPORTANT The ventilation grid is hinged You DO NOT need to remove it Figure 9 24 Accessing the fan units in the WCU roof box 3 Disconnect the wires 1 and unscrew 2 the fan units 4 Remove the fan unit 5 Reinstall the new one in rever...

Page 221: ... heat exchanger overview type LT 5 5165 UL 1 Ambient fan 2 2 Ambient fan 1 3 Internal fan 1 4 Circuit board location 5 Internal fan 2 6 Miniature circuit breaker 7 Red LED off and green LED on 8 Heat exchanger is healthy 9 Red LED on and green LED off 10 Alarm condition 11 Red LED off and green LED off 12 Auxiliary voltage missing Table 9 2 Air to air heat exchanger specifications Thermostat locat...

Page 222: ... the fan units To switch the fan units on and off for the test use the thermostats of the fan units Procedure 1 Switch on the auxiliary voltage for the air to air heat exchanger 2 Take note of the setting of the thermostat The factory set value is also stated on the Settings label The label is attached to the inside of the cabinet door 3 To start a fan or a group of fans adjust the setting of the ...

Page 223: ...AINTENANCE 9 4 16 2 Replacing the complete heat exchanger For information on replacing the complete heat exchanger see Mechanical installation on page 56 9 4 16 3 Replacing the circuit board 1 Unscrew the front and top cover 2 Disconnect the ground wire from the front cover arrow ...

Page 224: ...rcuit board on the spacers and gently push the circuit board onto the spacers until they snap in properly 7 Reconnect the wires to the circuit board Fig 9 26 Figure 9 26 Wire connection points on the circuit board No Description Pin Pin Pin Pin 1 Ground wire J15 2 Supply phase L 3 Supply neutral N 4 4x external capacitors 1x J3 2x J5 3x J7 4x J9 5 4x fan power supply 1x J4 2x J6 3x J8 4x J10 6 4x ...

Page 225: ...NTENANCE 8 Reconnect the ground wire to the front cover 9 Fasten the covers 9 4 16 4 Replacing internal fan 1 left side Procedure 1 Unscrew the front top cover 2 Unplug the plug in connectors arrows and unscrew the screws 1 2 3 and 4 which fix the fan mounting bracket to the housing ...

Page 226: ...HS842007 E01 REV C ACS6080 USER MANUAL 226 238 3 Remove the fan from the housing and unscrew the fan from the mounting bracket 4 Replace the fan and reassemble the unit in reverse order of removal 9 4 16 5 Replacing internal fan 2 right side 1 2 ...

Page 227: ...3BHS842007 E01 REV C ACS6080 USER MANUAL 227 238 09 PREVENTIVE AND CORRECTIVE MAINTENANCE Procedure 1 Unscrew the front top cover 2 Remove the front cover and disconnect the ground wire arrow ...

Page 228: ...board mounting bracket 1 2 and 3 4 Take out the circuit board mounting bracket and place it on the heat exchanger housing 5 Disconnect the ground wire 1 cut off the cable tie 2 unplug the plug in connectors arrows and unscrew the screws 3 4 5 and 6 fixing the fan mounting bracket to the housing 1 2 3 1 2 3 4 5 6 ...

Page 229: ...NCE 6 Remove the fan from the housing and unscrew the fan from the mounting bracket 7 Replace the fan and reassemble the unit in reverse order of removal 9 4 16 6 Replacing the ambient fans 1 Unscrew the rear cover 2 Lift the hinged cover up a little and disconnect the ground wire arrow ...

Page 230: ... and reassemble the unit in reverse order of removal 9 4 17 Replacing the fan unit in an EXU with a DCS880 H4 DCT880 T4 unit Figure 9 27 DCS880 controller size H4 Procedure 1 Switch off the miniature circuit breaker of the fan unit Note To identify the miniature circuit breaker see Appendix D Wiring diagrams 2 Remove the 6 screws from the fan cover and then remove the fan cover 1 2 3 4 1 2 3 4 ...

Page 231: ...PREVENTIVE AND CORRECTIVE MAINTENANCE 3 Unplug the fan cables 4 Remove the 4 fastening screws from the outside panel of the fan unit 5 Pull the fan unit out of the cabinet CAUTION To prevent the fan from falling onto you put a support ie a box underneath ...

Page 232: ...Install the new fan in reverse order of removal 9 4 18 Replacing the fan unit in an EXU with a DCS880 H6 unit Figure 9 28 DCS880 controller size H6 Procedure 1 Switch off the miniature circuit breaker of the fan unit Note To identify the miniature circuit breaker see Appendix D Wiring diagrams ...

Page 233: ...0 USER MANUAL 233 238 09 PREVENTIVE AND CORRECTIVE MAINTENANCE 2 Remove the 6 screws from the fan cover and then remove the fan cover 3 Unplug the fan cables 4 Remove the 4 fastening screws from the outside panel of the fan unit ...

Page 234: ...l the new fan in reverse order of removal 9 4 19 Replacing the air to water heat exchanger of the EXU 1 Switch off the miniature circuit breaker of the heat exchanger Note To identify the miniature circuit breaker see Appendix D Wiring diagrams 2 Close valves V30 and V31 in the water cooling unit 3 Disconnect the hose from valve V30 to drain the WCU NOTICE Expect approximately 5 liters of water 4 ...

Page 235: ...lug the cables 2 and remove the fastening screws Figure 9 29 Air to water heat connections 6 Lift the heat exchanger out of the cabinet CAUTIONThe heat exchanger weighs approximately 16 kg and requires a minimum overhead clearance of 85 cm Figure 9 30 Lift heat exchanger out of EXU cabinet 1 Water tube connections 1 Fastening screw 2 Cable connections 1 1 2 3 3 ...

Page 236: ...he new heat exchanger proceed in reverse order of removal Note For information on adding water to the cooling system see the manual for the ACS5000 ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 and ACS5000 ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 ...

Page 237: ... 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 3BHS842007 E01 Rev C 18 06 2020 238 ...

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