Page 1 SYSTEM DRIVES ACS5000 water-cooled (generation 2) User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL System Drives, ABB Switzerland Ltd. 2023-11-22 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS799208 E01 1/186 © Copyright 2009 ABB All rights reserved.
Page 2 This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document include all the features of the described or referenced standard.
Page 3: Table Of Contents
CONTENTS — CONTENTS 1. About this manual......................... 13 1.1. Equipment covered by this manual ..................... 13 1.2. Structure of the user documentation ..................13 1.3. Related documents..........................14 1.3.1. Maintenance ..........................14 1.3.2. Technical data ........................14 1.3.3. Schematics..........................14 1.3.4. Specifications and guidelines...................14 1.3.5.
Page 4 CONTENTS 3.4.2. AMC circuit board........................ 42 3.4.2.1. Control tasks ......................42 3.4.2.2. Direct torque control....................43 3.4.2.3. Parameters........................ 44 3.4.2.4. Main circuit breaker ....................44 3.4.2.5. Peripheral I/O devices.................... 44 3.4.2.6. Local control panel....................45 3.4.2.7. Customer interface....................46 3.4.2.8. S800 I/O system......................
Page 5 CONTENTS 5.4.5. Installation material......................67 5.4.6. Tools ............................67 5.5. Preparing the installation site...................... 68 5.6. Aligning transport units ........................ 69 5.7. Joining transport units ........................71 5.8. Applying silicone..........................72 5.9. Installing roof joints.........................72 5.10. Installing roof-mounted cooling units ..................73 5.10.1. Lifting a cooling unit with a crane ...................73 5.10.2.
Page 6 CONTENTS 6.8. Auxiliary power cables and control cables................106 6.8.1. Preparing the cable entry and the cables ..............106 6.8.1.1. Determining the cable length ................106 6.8.1.2. Routing the cables ....................106 6.8.1.3. Preparing cables for EMC plates - only top cable entry ......106 6.8.1.4.
Page 7 CONTENTS 8.8.3. Starting the drive locally ....................130 8.9. Stopping the drive..........................132 8.9.1. Stopping the drive in an emergency ................133 8.9.2. Starting the drive system after an emergency-off ............134 8.10. Arc resistant design ........................135 8.10.1. Internal arc classification (IAC) ..................135 8.10.2.
Page 8 CONTENTS 10.3.2. Error message levels......................161 10.3.2.1. Alarm ......................... 161 10.3.2.2. Fault........................... 161 10.3.2.3. Alarm / fault messages ..................162 10.3.3. Fault handling ........................162 10.3.4. Standard troubleshooting procedure................163 10.4. Removing the CDP control panel....................164 10.4.1. Communication with AMC circuit board..............164 10.5. LEDs and switches on circuit boards and I/O devices ............165 10.5.1.
Page 9 FIGURES — FIGURES Fig. 1. Typical delivery....................... 20 Fig. 2. Product warning label examples (label placement depends on the drive) ......................... 23 Fig. 3. Drive system overview ................... 28 Fig. 4. Typical block diagram of the drive ..............30 Fig. 5. Switching levels ......................
Page 10 FIGURES Fig. 34. Floor inclination ..................... 68 Fig. 35. Connection points on side of transport units (PCU example) ......71 Fig. 36. Base frame connection points ................71 Fig. 37. Applying silicone ..................... 72 Fig. 38. Roof joint ......................... 72 Fig.
Page 11 FIGURES Fig. 73. Cable routing options to WCU800 control compartment ........ 109 Fig. 74. Top and bottom cable routing in (A and B) WCU800 and (C and D) WCU1400 cabinets ................... 110 Fig. 75. Shield grounding clamp ..................111 Fig. 76. COU customer interface section ................
Page 12 Table 9 Maximum number of cables per frame opening – 3 core............ 96 Table 10 Maximum number of cables per frame opening – single core........... 96 Table 11 ABB arc resistant classes......................135 Table 12 Filter mat specifications......................177 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 13: About This Manual
(such as layout drawings, wiring diagrams, project-specific data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB. 1.2. Structure of the user documentation The documentation for a standard drive consists of this document and the following project- specific appendices.
Page 14: Related Documents
3BHS813742 E01 Customer interface 3BHS347034 E03 1.3.5. Manuals Title ABB ID ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01 ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 15: Serial Communications Interfaces
1.4. Terms and abbreviations The following table lists terms and abbreviations you should be familiar with when using this user manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might differ from the normal usage.
Page 16 Term of ABB’s S800 I/O process system. An I/O device consists of a module I/O device termination unit (MTU) and one I/O module. Term of ABB’s S800 I/O process system. The I/O module is an active input or I/O module output device for digital or analog signals.
Page 17: Target Groups And Required Qualification
The S800 I/O is a distributed process input / output system that can be S800 I/O connected to various process controllers from ABB and other companies. The synchronized bypass unit (SBU) is a control cabinet that provides control to the startup motor and then synchronizes the motor to the supply network to start...
Page 18: Operation
ABB. Use of the drive outside the scope of the specifications is not permitted.
Page 19: Quality Certificates And Applicable Standards
1.8. Quality certificates and applicable standards The following certificates and conformity declarations are available with ABB: – ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and maintains a management system which fulfills the requirements of the normative standards –...
Page 20: Items Covered By Delivery
1.10. Tools ABB offers various tool sets containing all necessary tools and equipment for installation, commissioning and maintenance of the drive. The content of the tool sets is described in the manual Service equipment.
Page 21: Document Conventions
ABOUT THIS MANUAL 1.11. Document conventions The document uses the following font formats and symbols. See also Section 2.1, “Safety messages and safety signs in this document”, page 22. Font formats Convention Description  Prerequisite for a task Sequential procedural steps in a task –...
Page 22: Important Safety Information
IMPORTANT SAFETY INFORMATION 2. Important safety information Read this material carefully before working on or around the equipment. Failure to do so can result in serious Injury or DEATH! Keep for future reference. 2.1. Safety messages and safety signs in this document This document uses ANSI Z535.6 signal words, ISO 7010 safety signs, and ISO 3864-2 colors to highlight safety-related information.
Page 23: Product Safety Labels
IMPORTANT SAFETY INFORMATION 2.2. Product safety labels Product safety labels on the equipment alert you to the hazards that can occur when you work on or operate the equipment. – Always follow the instructions on the labels to avoid the hazard –...
Page 24: Electrical Safety
IMPORTANT SAFETY INFORMATION 2.3. Electrical safety The following electrical safety instructions are based on EN 50110. 2.3.1. General safety instructions 1) Minimize hazards 2) Before energizing the drive: • Remove all foreign objects are from the drive • Fasten all internal and external covers securely •...
Page 25: The 7 Steps That Save Lives
IMPORTANT SAFETY INFORMATION 2.3.2. The 7 steps that save lives ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. 1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash.
Page 26 IMPORTANT SAFETY INFORMATION 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 busbar shutters. • If working within the restricted approach boundary or vicinity zone where inadvertent movement could cause contact with live parts, special precautions must be employed, such as the use of the properly rated insulated gloves and tools.
Page 27: Possible Residual Risks
IMPORTANT SAFETY INFORMATION 2.3.3. Possible residual risks Residual risks must be considered by the drive system integrator and/or plant owner when assessing the hazards of the equipment to personnel. The following risks can pose a hazard to drive system personnel: 1) Electric power equipment generates electro-magnetic fields which can cause a hazard to people with metal implants and / or a pacemaker.
Page 28: Main Circuit Breaker Protection Device
– Transformer protection (if applicable) – Transformer secondary cable protection (if applicable) – Backing up the drive protection In general, these protective measures are not included in the drive as provided by ABB. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG.
Page 29: Safety And Protection Requirements
For safety and protection reasons, the MCB must meet the stipulated minimum requirements of the specifications of ABB MV Drives. It is the system integrator's responsibility to ensure that the minimum requirements are met. The minimum requirements for the MCB are stated in this note and in the respective MCB engineering guideline, which are available for each medium voltage drive from ABB.
Page 30: Power Electronics And Cabinet Features
3. Power electronics and cabinet features 3.1. Main features of the drive The water-cooled ACS5000 is a voltage source frequency converter of the ACS product range. It is available for up to 36 MVA and for standard motors with voltages up to 6.9 kV.
Page 31: Fig. 5. Switching Levels
POWER ELECTRONICS AND CABINET FEATURES VSI-MF The VSI design employs DC-link capacitors and provides a switched voltage waveform. As a result of the multilevel topology, the drive produces an optimum number of switching levels, ie, 9 levels, phase to phase. The resulting output waveform permits the application of standard motors without decreasing the reliability and efficiency of the motor.
Page 32: Drive Frame Sizes And Configurations
POWER ELECTRONICS AND CABINET FEATURES Fuseless protection concept The drive does not require any power fuses. Instead, the IGCTs of the inverter are used for protection. If an overcurrent occurs, protection firing is triggered and fault clearing is initialized in less than 25 µs. 3.2.
Page 33: Fig. 8. Typical Drive Configurations For Fs 1, Fs 2, Fs 3, And Fs 4
POWER ELECTRONICS AND CABINET FEATURES FS 1 PCU11 PCU21 PCU31 COU1 WCU1 primary primary primary FS 2 PCU11 PCU21 PCU31 COU1 WCU1 PCU primary PCU primary PCU primary FS 3 PCU10 PCU11 PCU20 PCU21 PCU30 PCU31 COU1 WCU1 secondary primary secondary primary secondary...
Page 34: Phase Converter Unit (Pcu)
POWER ELECTRONICS AND CABINET FEATURES 3.3. Phase converter unit (PCU) PCUs are available as 6-pulse and 12-pulse rectifiers (Table 2). All drive configurations (FS 1, FS 2, FS 3, and FS 4, Fig. 8) have three primary PCUs, where each PCU supplies a different motor phase.
Page 35: Primary Phase Converter Unit (1700 Mm And 2100 Mm)
POWER ELECTRONICS AND CABINET FEATURES 3.3.1. Primary phase converter unit (1700 mm and 2100 mm) 3.3.1.1. Primary PCU (1700 mm) – FS 1 and FS 3 For the location of these PCUs in typical FS 1 and FS 3 drive configurations, see Fig. 8. Key: Roof-mounted cooling unit HVD circuit board...
Page 36: Fig. 10. Primary Pcu, 1700 Mm: (A) Side View Left And (B) Side View Right
POWER ELECTRONICS AND CABINET FEATURES Key: Roof-mounted cooling unit Water pipe Terminal compartment for transformer cables AC busbars for adjacent PCU and motor phase LSU snubber plate (PCU 6-pulse only) Inverter stacks consisting of diodes and IGCTs Rectifier stacks consisting of diodes and Gate unit thyristors DC-link connection...
Page 37: Primary Pcu (2100) - Fs 2 And Fs 4
POWER ELECTRONICS AND CABINET FEATURES 3.3.1.2. Primary PCU (2100) – FS 2 and FS 4 For the location of these PCUs in typical FS 2 and FS 4 drive configurations, see Fig. 8. Key: PE ground busbar Roof-mounted cooling unit Main INT circuit board HVD circuit board IPS (Integrated Power Supply)
Page 38: Fig. 12. Primary Pcu, 2100 Mm: (A) Side View Left And (B) Side View Right
POWER ELECTRONICS AND CABINET FEATURES Key: Roof-mounted cooling unit Water pipe Terminal compartment for transformer cables AC busbars for adjacent PCU and motor phase LSU snubber plate (PCU 6-pulse only) Inverter stacks consisting of diodes and IGCTs Rectifier stacks consisting of diodes and Gate unit thyristors DC-link connection...
Page 39: Fig. 13. (A) Secondary Pcu, 1700 Mm And (B) Secondary Pcu 2100 Mm
POWER ELECTRONICS AND CABINET FEATURES 3.3.2. Secondary phase converter unit (1700 mm and 2100 mm) – FS 3 and FS 4 A secondary PCU has the same design as a primary PCU, but without the rectifier stack and the transformer terminal compartment. Drive FS 3 uses 1700 mm secondary PCUs and FS 4 uses 2100 mm secondary PCUs.
Page 40: Control Unit (Cou)
/ or remote operator stations. Key: Customer interface NETA-21 Control unit CDP control panel Inverter (10) PC tools ABB Ability™ (11) RS485 Cloud connectivity (12) AMC circuit board Fieldbus (13) Internal I/Os Higher-level control system (14) Fiber-optic...
Page 41: Main Components
POWER ELECTRONICS AND CABINET FEATURES 3.4.1. Main components Key: Arc Guard System™ (12) Isolating transformers for customer UPS – T1011, T1012, and step-down transformer for NETA-21 internal buffer T1021 (optional) AMC and main INT circuit board (13) S800 I/O process system Terminals for customer UPS and PCU auxiliary (14) Customer terminals power supply –...
Page 42: Amc Circuit Board
POWER ELECTRONICS AND CABINET FEATURES 3.4.2. AMC circuit board The AMC circuit board is the major component of the drive’s control system and performs general drive, motor control, and closed loop functions. The main internal control devices and the peripheral input and output interfaces to the customer communicate with the AMC circuit board via optical fibers.
Page 43: Direct Torque Control
The speed and torque of the motor is controlled by DTC (Direct Torque Control). The DTC motor control platform is unique to ABB and has been proven in all variable speed drives of the ACS product range. DTC provides accurate speed and torque control, and high dynamic speed response.
Page 44: Parameters
PC-based service tools comprising: • DriveWare® software tools: include the commissioning and maintenance tools DriveWindow and DriveDebug, and DriveOPC for data transfer between ABB drives and Windows®-based applications. DriveMonitor (option): a monitoring and diagnostics tool that allows access to the drive •...
Page 45: Local Control Panel
POWER ELECTRONICS AND CABINET FEATURES 3.4.2.6. Local control panel The control panel serves as the basic user interface for monitoring, control and operation of the drive and setting of parameters. For more information on local operation and the CDP control panel, see Chapter 8, “Operation”, page 122 and Chapter 9, “CDP control panel”, page 138.
Page 46: Customer Interface
The S800 I/O station with digital and analog I/O interfaces transfers drive-related hardwired signals to the AMC circuit board. Standard ABB Advant S800 I/O modules interconnect internal and external digital and analog I/O signals with the control system of the drive. The I/O station consists of a bus modem serving as an interface to the AMC circuit board and the I/O modules.
Page 47: Water Cooling Unit (Wcu)
POWER ELECTRONICS AND CABINET FEATURES 3.5. Water cooling unit (WCU) The size of the WCU depends on the drive FS (see Section 3.2, “Drive frame sizes and configurations”, page 32). Both sizes have the same components: – WCU800 has a cabinet width of 800 mm –...
Page 48: Transformer And Motor Cable Terminals
POWER ELECTRONICS AND CABINET FEATURES 3.6. Transformer and motor cable terminals 3.6.1. Transformer cable terminals DANGER Hazardous voltages! → Complete the steps in Section 2.3.2, “The 7 steps that save lives”, page 25 before you remove the side and back walls from the drive to access the grounding studs in a PCU.
Page 49: Exu - Excitation Unit (Optional)
POWER ELECTRONICS AND CABINET FEATURES 3.7. EXU – Excitation unit (optional) The EXU supplies a synchronous motor with excitation power. The EXU is available for the following excitation methods: – Brush excitation (DC excitation): Uses a DCS880 AC-to-DC converter which is supplied by the mains.
Page 50: Dcs880/Dct880 Control Panel
POWER ELECTRONICS AND CABINET FEATURES 3.7.1. DCS880/DCT880 control panel The control panel of the DCS880/DCT880 unit enables the 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.
Page 51: Grounding Switches
POWER ELECTRONICS AND CABINET FEATURES 3.8.1. Grounding switches Each primary PCU in the drive has a grounding switch on the door. You can only turn the grounding switch (1, Fig. 23) to the grounded position (horizontal) when the yellow lamp (2, Fig. 23) is lit, ie, after the drive has been disconnected from the main power supply and the DC-link has been discharged.
Page 52: Locking Bars
POWER ELECTRONICS AND CABINET FEATURES 3.8.2. Locking bars A locking bar is a safety mechanism that locks the doors of the primary and secondary PCUs when the drive is ungrounded. You can only slide the locking bar (1, Fig. 24) to the unlocked position (2, Fig. 24) and open the doors when the drive is grounded, ie, when the white lamp (3, Fig.
Page 53: Grounding Set
POWER ELECTRONICS AND CABINET FEATURES 3.9.1. Grounding set DANGER Hazardous voltages! → Complete the steps in Section 2.3.2, “The 7 steps that save lives”, page 25 before you access the grounding studs in the PCU and COU. Key: Enclosure ground clamp Telescopic insulating pole Busbar ground clamp Fig.
Page 54: Output Grounding Studs In Cou
POWER ELECTRONICS AND CABINET FEATURES 3.9.2. Output grounding studs in COU The converter output grounding studs, ie, 1L1, 1L2, 1L3 and 2L1, 2L2, and 2L3, and the protective earth (PE) busbar are at the back of the COU. Fig. 27. Location of PE busbar and grounding studs (1L1, 1L2, and 1L3) in COU, FS 1 and FS 2 Fig.
Page 55: Input Grounding Studs In A Pcu
POWER ELECTRONICS AND CABINET FEATURES 3.9.3. Input grounding studs in a PCU DANGER Hazardous voltages! → Complete the steps in Section 2.3.2, “The 7 steps that save lives”, page 25 before you remove the side and back walls from the drive to access the grounding studs in a PCU.
Page 56: Transportation, Storage, And Disposal
2. Inspect the drive and accompanying equipment and make note of any damage. • Take a photograph of the damage and inform ABB and the shipping company immediately. 3. Compare the complete delivery with the purchase order and the packing list.
Page 57: Packing List
All of the transport units for a drive have the same converter number, in this case, “Converter 1”. The item number in the “ABB Item / Customer item” column of the packing list provides information about separately delivered crates with accessories such as tools and installation material.
Page 58: Lifting And Transportation
→ Before use, always check the lifting attachments for damage, eg, corrosion and cracks. DO NOT attempt to lift equipment with a damaged lifting attachment; contact ABB for a replacement before you proceed → Always transport the load in an upright position →...
Page 59: Lifting Attachment Types
Only use the lifting attachments that are included with the delivery, either factory- installed or in the loose parts box for the drive. These lifting attachments are intended exclusively for use with ACS5000W gen. 2 equipment. Any use beyond this is strictly prohibited. ABB ID: 3BHE015753P0008 ABB ID: 3BHE015753P0016...
Page 60: Lifting With Lifting Plates
TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.2. Lifting with lifting plates Lifting plates are factory-installed on the base frame of transport units. CAUTION Risk of tipping! The following procedure requires a crane with a lift frame or a spreader frame. If you do not have this equipment: →...
Page 61: Lifting With Rotating Eyebolts
TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.3. Lifting with rotating eyebolts Rotating eyebolts are either installed in the factory or are in the loose parts box for the drive. The following procedure requires a crane with a lift frame or a spreader frame. 1.
Page 62: Reinstalling Lifting Attachments
NOTE – The torque wrench sockets for the rotating eyebolts are not included in the scope of delivery. TABLE 3 Lifting attachment specifications Type Mounting bolt Torque (Nm) ABB ID Lifting plate 2 × M16 × 40 (A2-70) 3BHB039841R0001 M16 rotating eyebolt 3BHE015753P0016...
Page 63: Sling Configurations For Lift Frames And Spreader Frames
TRANSPORTATION, STORAGE, AND DISPOSAL 4.5.5. Sling configurations for lift frames and spreader frames 15° Key: Lift frame Shackle or safety hook Protect the edges Lifting plate Protect door handles and levers Slope angle (maximum 15 °) Extra horizontal sling Spreader frame Fig.
Page 64: Storage
4.6. Storage The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. For information on longer storage periods, contact ABB. 4.6.1. Storage conditions The minimum requirements for storage are based on IEC 60721-3-1.
Page 65: Storage And Handling Of Spare Parts
→ Apply static-sensitive precautions when you handle spare parts. 4.7.1. Warranty information IMPORTANT! Inspect all spare parts upon receipt and make note of any damage. Inform ABB and the shipping company of the damage. To keep spare parts in good condition and to keep the warranty valid during the warranty period: –...
Page 66: Mechanical Installation
→ DO NOT use a crane if the transport units are secured to the base frame; use heavy load hydraulics rollers or air cushions. If you are unsure, contact ABB for instructions. → DO NOT damage or dislocate the EMC sealing strips when you join 2 transports units; The strips are glued to the outer surfaces of the cabinet frames.
Page 67: Dimensions And Clearances
MECHANICAL INSTALLATION 5.4. Dimensions and clearances For information on dimensions, location and size of fixing holes and clearances, see “Appendix C – Mechanical drawings”. 5.4.1. Rear and top access to the cabinet Joining the transport units and DC busbars requires rear and top access. 5.4.2.
Page 68: Preparing The Installation Site
MECHANICAL INSTALLATION 5.5. Preparing the installation site To ensure proper alignment and installation of the drive, prepare the floor as follows: – The floor must be able to support the weight of the drive (minimum 1500 kg/m – The overall incline of the floor across 5 m must not exceed 5 mm. 5 mm 1 mm 1 mm...
Page 69: Aligning Transport Units
MECHANICAL INSTALLATION 5.6. Aligning transport units 1. Remove the protective covers from the water pipe ends on both sides. 2. Check that a pipe joint has been slid on one pipe end of two adjoining water pipes. 3. Line up the transport units as shown in “Appendix C – Mechanical drawings”. The units can be lined up either beginning from the left or the right.
Page 70 MECHANICAL INSTALLATION 5. Verify the following alignment parameters: • Maximum values for the axial misalignment (± 3 mm) and the angular deflection (5°) of two adjoining water pipes are not exceeded ±3 mm 5° • Bolt holes are exactly aligned. M6×16 (9ABA450093R0259) •...
Page 71: Joining Transport Units
MECHANICAL INSTALLATION 5.7. Joining transport units Join the transport units with the supplied installation material. The installation material is attached to one of the transport units. Fig. 35. Connection points on side of transport units (PCU example) (HZN 452198P1025) (9ABA450078P0008) M16×50 (312350P0466) Fig.
Page 72: Applying Silicone
MECHANICAL INSTALLATION 5.8. Applying silicone Silicone prevents water from entering the gap between two joining roof plates. Apply silicone where two transport units have been joined (Fig. 37). Gaps within a transport unit are factory- sealed. Fig. 37. Applying silicone 5.9.
Page 73: Installing Roof-Mounted Cooling Units
→ Use appropriate slings and shackles Referring to Fig. 39: 1. Install 4 RUD bolt-on lifting points (ABB ID: 3BHE015753P0008) in the 4 top corners of the cooling unit. NOTE – The lifting points are in the loose parts that were delivered with the drive.
Page 74: Installing Ip42 Roof-Mounted Cooling Units
CAUTION Heavy object! An IP42 cooling unit weighs 40 kg. 40 kg → Only use the rotating eyebolts (ABB ID: 3BHE015753P0008) that were delivered with the loose part of the drive → Use appropriate slings and shackles with the eyebolts →...
Page 75: Fig. 41. Cable Duct Openings (Example With 1700 Mm Pcu)
MECHANICAL INSTALLATION 4. Lift the cooling unit above the PCU cabinet with a crane. 5. Align the cooling unit with the opening (2) in the cabinet roof and slowly lower the cooling unit onto the cabinet roof. IMPORTANT! Ensure that the screw holes on the roof and the cooling unit match up. 6.
Page 76: Installing Ip54 Roof-Mounted Cooling Units
CAUTION Heavy object! An IP54 cooling unit weighs 98 kg. 98 kg → Only use the rotating eyebolts (ABB ID: 3BHE015753P0008) that were delivered with the loose part of the drive → Use appropriate slings and shackles with the eyebolts →...
Page 77: Fig. 43. Water Tube Connections (Back View)
MECHANICAL INSTALLATION 4. Lift the cooling unit above the PCU cabinet with a crane. 5. Align the water inlet / outlet (2, Fig. 42), drain outlet (3, Fig. 42), and cables (4, Fig. 42) of the cooling unit with the designated openings in the cabinet roof and then slowly lower the cooling unit onto the cabinet roof.
Page 78: Installing Roof Attachments On Marine Drives
MECHANICAL INSTALLATION 5.11. Installing roof attachments on marine drives Roof attachments are only available on marine drives. To prevent tilting and dampen vibrations, attach the drive to the ceiling or the back wall of the drive room according to the instructions. For information on the fitting location, see “Appendix D –...
Page 79: Fig. 45. Recommended Ceiling And Wall Fixings
MECHANICAL INSTALLATION 3. To fix the drive to the ceiling or the back wall, use two suitable struts per roof attachment (the struts are not part of the scope of delivery). WARNING! DO NOT install the struts at a 90° angle to the cabinet roof (3, Fig. 45). 4.
Page 80: Joining Water Pipes
MECHANICAL INSTALLATION 5.12. Joining water pipes 1. Mark the length of a pipe joint on one end of a water pipe as a fitting guide. 2. Slide the pipe joint over the two adjoining pipe ends. 3. Center the pipe joint. 47 mm 4.
Page 81: Joining Busbars
MECHANICAL INSTALLATION 5.13. Joining busbars There are three types of busbars that need to be joined: – AC busbars (1, Fig. 46) – PE ground busbar (2, Fig. 46) – DC busbars (3, Fig. 46) Fig. 46. Busbar connections 1. Before installing the joining pieces, grease the bolts to maintain the required contact pressure.
Page 82: Ac Busbars
MECHANICAL INSTALLATION 5.13.1. AC busbars The joining pieces of the AC busbars and related installation material are mounted at one of the busbar ends in the transport units. Fig. 47. AC busbar connection 5.13.2. PE ground busbar The joining pieces of the PE ground busbar and related installation material are mounted at one of the busbar ends in the transport units.
Page 83: Connecting The Heating Cable
MECHANICAL INSTALLATION 5.13.3. DC busbars The joining pieces of the DC busbars are deposited inside the transport units. Related installation material is mounted at one of the busbar ends in the transport units. Fig. 49. DC busbar connection 5.14. Connecting the heating cable Some drives have heating cables that you need to connect when you assemble the transport units.
Page 84: Connecting Raw Water Pipes
MECHANICAL INSTALLATION 5.15. Connecting raw water pipes Connect the incoming and outgoing raw water pipes to the flanges of the water cooling unit. Installation material such as counter flanges, bolts, nuts and seals are supplied. For dimensions of the raw water entry and the flanges, see “Appendix C – Mechanical drawings”.
Page 85: Electrical Installation
→ Qualified personnel only, who have a thorough knowledge of relevant electrical codes, site, and equipment requirements. → DO NOT switch on main and auxiliary power supplies without ABB consent. → Take preventive measures to ensure power remains off during the installation.
Page 86: Grounding
ELECTRICAL INSTALLATION 6.4. Grounding The cabinet is equipped with ground buses (marked PE, protective earth) for grounding the armor and shields of the cables, and for the connection of the ground cable. To identify the ground buses, see “Appendix C – Mechanical drawings”. 6.4.1.
Page 87: Grounding The Transformer And A 36-Pulse Drive
ELECTRICAL INSTALLATION 6.4.2. Grounding the transformer and a 36-pulse drive Fig. 52 shows the grounding connections of an ACS5000W drive with an 36-pulse line supply and an input transformer. Input transformer(s) -20° +20° -20° +20° 0° 0° ACS5000W PCU11 PCU21 PCU31 Key: PE busbar...
Page 88: Grounding The Drive And The Motor (Multi-Point Bonding)
ELECTRICAL INSTALLATION 6.4.3. Grounding the drive and the motor (multi-point bonding) Multi-point bonding is the preferred method for voltage source converter applications. NOTE – Multi-point bonding is not allowed for high-speed applications; use single-point bonding instead (see Section 6.4.4, “Grounding the drive and the motor (single-point bonding)”, page 89).
Page 89: Grounding The Drive And The Motor (Single-Point Bonding)
ELECTRICAL INSTALLATION 6.4.4. Grounding the drive and the motor (single-point bonding) Single-point bonding is the preferred method for high-speed applications with fundamental frequencies above 120 Hz. For more information see the “Power cables engineering guideline”, 3BHS542290 E01. Fig. 54 shows the single-point bonding connections to ground a drive and a motor in the COU compartment.
Page 90: Ground Cable Connection
ELECTRICAL INSTALLATION 6.4.5. Ground cable connection The ground cable enters the COU compartment from the top or from the bottom. It connects to the PE ground busbar of the adjoining PCU compartment. The ground busbar spans across the entire length of the drive (Fig. 55). The connection must be in compliance with local regulations. For project-specific illustrations, see “Appendix D –...
Page 91: Exu Cabinet Ground Connections
ELECTRICAL INSTALLATION 6.4.6. EXU cabinet ground connections It is important that the EXU is properly grounded to maintain safety and to ensure smooth functioning of the equipment. – Connect the ground to the ground system of the installation site and to the ground busbar inside the EXU.
Page 92: Fig. 57. Wiring Across Shipping Splits, (A) Fs 1 And (B) Fs 2
ELECTRICAL INSTALLATION PCU×1 PCU×1 Explanation Key: Shipping split PCUx1 – PCUx1 Cable ducts on each side of the For auxiliary power supply cables, optical fibers, and signal cables shipping split For charging cable Connection point Charging cable behind water Laid on the brackets and connected to the busbar pipe (not illustrated) Fig.
Page 93: Fig. 58. Wiring Across Shipping Splits, Fs 3 And Fs 4
ELECTRICAL INSTALLATION PCU×0 PCU×1 PCU×1 PCU×0 Key: Explanation Shipping split PCUx0 – PCUx1 and PCUx1 – PCUxo Cable ducts on each side of the For auxiliary power supply cables, optical fibers, and signal cables shipping split For charging cable Connection point Charging cable behind water Laid on the brackets and connected to the busbar pipe (not illustrated)
Page 94: Optical Fibers
ELECTRICAL INSTALLATION 6.5.1. Optical fibers NOTICE Risk of equipment failure! A damaged or incorrectly installed optical fiber cable can degrade data transmission and cause equipment failure. → Handle optical fibers with care. → Only use the designated encoder cable conduit that passes through the drive to the EXU; The conduit extends 10 to 20 mm from the entry plate of the drive.
Page 95: Cable Entries
ELECTRICAL INSTALLATION 6.6. Cable entries The drive is prepared for top or bottom cable entry with one or a combination of the following cable entries: – Cable entry with sealing modules, type 1 – Cable entry with cable glands For information on the location and the dimensions of the cable entry, see “Appendix C – Mechanical drawings”.
Page 96: Fig. 60. Cable Entry Frame Sizes (Top) For Type 1 Sealing Modules (Bottom)
ELECTRICAL INSTALLATION L1 L2 L1 L2 RM120 RM69 RM60 Fig. 60. Cable entry frame sizes (top) for type 1 sealing modules (bottom) TABLE 7 Type 1 sealing modules and cables per frame opening Frame Location Top entry FS1 to FS6 FS2_6p FS1_6p FS1_12p...
Page 97: Cable Entry With Sealing Modules, Type 2
ELECTRICAL INSTALLATION 6.6.2. Cable entry with sealing modules, type 2 Usage Included in delivery Not included in delivery Supplier – Auxiliary power Frame (1, Fig. 61) – Type 2 sealing Roxtec AB cables modules (2, Fig. 61) (www.roxtec.com) – Control cables –...
Page 98: Cable Entry With Emc Plates
ELECTRICAL INSTALLATION 6.6.4. Cable entry with EMC plates Usage Included in delivery – Power cables – Galvanized plate with EMC mesh (1, Fig. 64) – Ground cables – Sealing grommets (2, Fig. 64) – Bonding conductors – Auxiliary power cables –...
Page 99: Power Cables, Ground Cables, Equipotential Bonding Conductor
ELECTRICAL INSTALLATION 6.7. Power cables, ground cables, equipotential bonding conductor See “Appendix A – Additional manuals” for information on: – Project-specific cable entry – Distance between point of cable entry and terminals – Busbar and fastening hole dimensions – Installation instructions for sealing modules See “Appendix D –...
Page 100: Fig. 65. Preparing Power Cables For Cable Glands
ELECTRICAL INSTALLATION Key: Conductor insulation removed to expose Cable gland cable shield/armor Plate Cable screen extension (pigtail) for PE ground Heat-shrinkable termination busbar connection Outer cable sheath Sheath seal Fig. 65. Preparing power cables for cable glands PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 101: Preparing Cables For Cable Entries With Sealing Modules
ELECTRICAL INSTALLATION 6.7.1.3. Preparing cables for cable entries with sealing modules Prepare cables with an outer cable screen or shield for EMC bonding with the metal enclosure of the cabinet as illustrated. Install the sealing modules according to the instructions of the sealing module supplier.
Page 102: Connecting The Cables
ELECTRICAL INSTALLATION 6.7.2. Connecting the cables CAUTION Risk of flashover! High voltages in the terminal unit can cause flashover between the electric potential of different conductors and the electric potential of a conductor and earth. When you route and connect the cables, maintain the following minimum clearances: →...
Page 103: Fig. 67. Pcu 12-Pulse Top And Bottom Entry (Back View)
ELECTRICAL INSTALLATION 6.7.2.2.1. Transformer cables ACS5000W, 36-pulse Key: Top cable entry Bottom cable entry Busbars for transformer cables Fig. 67. PCU 12-pulse top and bottom entry (back view) 6.7.2.2.2. Transformer cables ACS5000W, 18-pulse Key: Top cable entry Bottom cable entry Busbars for transformer cables Fig.
Page 104: Fig. 69. Cou Cable Terminals, Top And Bottom Entry (Back View) - (A) Fs
ELECTRICAL INSTALLATION 6.7.2.2.3. Motor cables Key: Top cable entry Bottom cable entry Busbars for motor cables (FS 1 and FS 2) Fig. 69. COU cable terminals, top and bottom entry (back view) - (A) FS 1 and FS 2, and (B) FS 3 and FS 4 PRODUCT DOCUMENT KIND...
Page 105: Bolted Connections
If a coated nut (eg, with bonded molybdenum-disulfide [MoS ] coating) is used, the connection does not have to be lubricated. 6.7.2.3.4. Tightening torque ABB recommends a tightening torque of 40 Nm for M10 bolts. For other sizes, follow the manufacturer’s recommendations. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 106: Auxiliary Power Cables And Control Cables
ELECTRICAL INSTALLATION 6.8. Auxiliary power cables and control cables See “Appendix C – Mechanical drawings” for information on: – Project-specific cable entry – Dimensions between point of cable entry and terminals See “Appendix D – Wiring diagrams” for information on: –...
Page 107: Preparing Cables For Cable Entries With Sealing Modules
ELECTRICAL INSTALLATION 9. Pull the cable (1) through the entry plate (2). 10. To prevent water from entering the cabinet, fit the grommet (3) tightly and seal any gaps with silicone. 11. If you removed the entry plate, reinstall the plate, and fasten it properly.
Page 108: Preparing Cables For Cable Entries With Cable Glands
ELECTRICAL INSTALLATION 6.8.1.5. Preparing cables for cable entries with cable glands Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated (Fig. 72). Key: Outer cable sheath Cable gland Conductor insulation removed to expose cable shield Plate Conductor screen extension to be connected to PE terminal Fig.
Page 109: Routing And Connecting Low Voltage Cables
ELECTRICAL INSTALLATION 6.8.2. Routing and connecting low voltage cables For the project-specific cable connections, see “Appendix D – Wiring diagrams”. For a description of the different cable entry types, see Section 6.6, “Cable entries”, page 95. 6.8.2.1. WCU - auxiliary power and space heater cable For an overview of the components in a WCU cabinet, see Section 3.5, “Water cooling unit (WCU)”, page 47.
Page 110: Fig. 74. Top And Bottom Cable Routing In (A And B) Wcu800 And (C And D) Wcu1400 Cabinets
ELECTRICAL INSTALLATION 6.8.2.1.1. Top and bottom cable entries Referring to Fig. 74: 1. Route the cables to the terminal compartment (1). • Top cable entry: via (2) or (4) • Bottom cable entry: via (3) or (6) NOTE – Use cable ties to attach the cables to the cable ladder (7) or cable duct (5). 2.
Page 111: Connecting Cables In Cou
ELECTRICAL INSTALLATION 6.8.2.2. Connecting cables in COU 6.8.2.2.1. Shielded cables – If you use twisted pair cables, leave the unshielded cable ends twisted until they reach the terminals. – Leave unshielded conductor ends as short as possible. – Use a shield grounding clamp (Fig. 75) to fasten the overall shield and the individual shields to the ground busbar (8, Fig.
Page 112: Fig. 77. Cable Routing In Cou Cabinet
ELECTRICAL INSTALLATION Key: Top cable entry Bottom cable entry Fig. 77. Cable routing in COU cabinet 6.8.2.2.2. Control power supply – Connect the cable for the control power to terminal X2 (11, Fig. 76). 6.8.2.2.3. Control signals – Connect the cables to the following terminals: •...
Page 113: Routing Cables In A Stand-Alone Exu Cabinet
ELECTRICAL INSTALLATION 6.8.3. Routing cables in a stand-alone EXU cabinet 6.8.3.1. 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: •...
Page 114: Optical Fiber Cables
ELECTRICAL INSTALLATION 6.8.3.2. Optical fiber cables NOTICE Risk of equipment failure! Handle optical fibers with care. A damaged or incorrectly installed optical fiber cable can degrade data transmission and cause equipment failure. → Only use the designated encoder cable conduit that passes through the drive to the EXU; the conduit extends 10 to 20 mm from the entry plate of the drive.
Page 115: Fig. 81. Cable Routing Example In An Exu Cabinet With An Ed5V, Eb5R, Eb5S, Eb7P And Eb7Q Type Dcs880/Dct880 Converter
ELECTRICAL INSTALLATION Key: Slot 1 (FDCO-01 module Control panel Fig. 80. 1 Control unit SDCS-CON-H01 7. Route the cables through the designated cable ducts as illustrated in Fig. 81. Key: Cable enters through roof PE ground busbar Cable enters through the floor Terminal strip for auxiliary power and control cables Auxiliary supply cable...
Page 116: Routing Cables In An Exu Cabinet With An Ed7Y Type Dcs880/Dct880 Converter
ELECTRICAL INSTALLATION 6.8.3.4. Routing cables in an EXU cabinet with an ED7Y type DCS880/DCT880 converter 1. Unscrew the rectangular cover from the DCS880/DCT880 unit. Key: Control panel Removable cover Fig. 82. 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.
Page 117: Fig. 84. Cable Routing Example In An Exu Cabinet With An Ed7Y Type Dcs880/Dct880 Converter
ELECTRICAL INSTALLATION 3. Route the cables through the designated cable ducts as illustrated in Fig. 84. Key: Cable enters through roof PE ground busbar Cable enters through the floor Terminal strip for auxiliary power and control cables Auxiliary supply cable Terminal for optical fibers behind cover Optical fibers to DCS880/DCT880 converter Fig.
Page 118: Commissioning
7. Commissioning 7.1. Required qualification Commissioning, parameter adjustments and functional tests must be carried out only by qualified commissioning personnel that have been certified by ABB. 7.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.
Page 119: Commissioning Checklists
 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) Pulse encoder cable shields are connected to the shield earthing point and not connected directly to the pulse encoder interface (applies only to drives with pulse encoder interface).
Page 120: Door Interlocking Checklist
COMMISSIONING 7.6.3. Door interlocking checklist   1) The release dial of the safety switches in the locked position. 7.6.4. Main circuit breaker (MCB) checklist   1) MCB selected as per “Main circuit breaker specification” Pay attention to MCB opening time and installation of undervoltage coil or second opening coil ...
Page 121: Power Checklist
COMMISSIONING 7.6.8. Power checklist   1) Medium voltage available for startup of drive.  2) Low voltage is available for startup of drive. 7.6.9. Miscellaneous checklist   1) Sufficient number and correct type of spare parts available  2) Sufficient quantity of deionized water according is available.
Page 122: Operation
OPERATION 8. Operation 8.1. Operating conditions The operating conditions for the drive are according to IEC 60721-3-3. – Classification: 3K22 / 3B1 / 3S6 / 3M11 8.2. Safety WARNING Risk of electric shock The IPXXB/IP20 rating of the low voltage compartment is not fulfilled by live parts with voltages >...
Page 123: Local Operator Panel
OPERATION 8.4. Local operator panel The operator panel on the control compartment enables the operator to control the drive without restrictions, provided that all requirements for normal operation are met. The functions of the local operator panel include: – Connecting and disconnecting the main power supply –...
Page 124: Exu Control Panel
OPERATION 8.5. EXU control panel The EXU assistant control panel (ACP) allows you to control the operation of the DCS880 or DCT880 unit in the EXU cabinet as well as set the parameters and view the status data of the EXU.
Page 125: Display Values
OPERATION 8.5.1.1. Display values The actual values shown on the display can be freely selected. The following default values are shown on the display when the panel is in local control mode: – Motor current in percent (%) – Actual armature voltage in V –...
Page 126 OPERATION NotReadyOn The DC link cannot be charged and the drive cannot be connected to the main power supply, ie, the main circuit breaker cannot be closed. The status message is displayed, eg, when the doors of medium voltage compartments are still open, the grounding switch of the drive is in the grounded position, or the motor starter of the fan unit is switched off.
Page 127: Start Sequence Of The Drive
OPERATION 8.7.1. Start sequence of the drive 1) NotReadyOn 2) ReadyOn • Auxiliary power supply on • PCU doors closed and locked • Drive not grounded • No emergency-off • No fault • WCU ready 3) On command 4) Charging •...
Page 128: Stop Sequence Of The Drive
OPERATION 8.7.2. Stop sequence of the drive 1) Operation 2) ReadyRef 3) Stop command 4) Stopping • Speed ramps down • Inverter stops modulating 5) ReadyRun 6) Off command • MCB opens • DC link discharges • Cooling system switches off after a delay 7) ReadyOn •...
Page 129: Starting The Drive
OPERATION 8.8. Starting the drive DANGER Hazardous voltages! Accidental contact with energized components can cause serious injury or DEATH. All doors and openings must be secured before operation. → Remove all foreign objects from the drive → Secure and fasten all covers. →...
Page 130: Checks Before Starting The Drive
OPERATION 8.8.1. Checks before starting the drive When the drive is put into service after it has been commissioned, or after it has been taken out of service for a longer period, check the drive according to the following list: –...
Page 131 OPERATION 3. Check that no alarm or fault messages are displayed on the CDP control panel. When a fault message is displayed on the CDP control panel, reset the fault. If a fault cannot be reset, it must be rectified by the responsible personnel. When no alarms and faults are present and the drive is ready, the CDP control panel displays ReadyOn.
Page 132: Stopping The Drive
OPERATION 6. To start the motor, press the START key. After the motor has been magnetized, the motor speed ramps up to the reference value. While the motor is accelerating, the run status message in the display blinks. When the motor speed has reached the reference value, the run status message lights up permanently.
Page 133: Stopping The Drive In An Emergency
OPERATION 1 L -> 600.0 rpm 0 StateINU ReadyRun MOTOR SP 0.00 rpm POWER 0.0 kW As long as the MCB has not been opened, you can restart the motor at any time. 8.9.1. Stopping the drive in an emergency The EMERGENCY OFF push button (Fig.
Page 134: Starting The Drive System After An Emergency-Off
OPERATION SUPPLY Key: SUPPLY OFF push button ALARM RESET FAULT EMERGENCY OFF RESET EMERGENCY OFF push button EMERGENCY OFF latching push button EMERGENCY OFF Fig. 87. Detail of local control panel 8.9.2. Starting the drive system after an emergency-off You need to reset the EMERGENCY OFF button after each use, ie, when the RESET EMERGENCY OFF button is flashing.
Page 135: Arc Resistant Design
The optional “Arc Resistant Design” provides the drive with arc fault protection in accordance with IEC 62477-2. The ABB arc resistant classes in Table 11 indicate the type of arc proofing that a drive uses. Depending on the drive configuration, classes I and IV are available for an ACS5000W gen. 2.
Page 136: Arc Detection With The Arc Guard System
OPERATION 8.10.2. Arc detection with the Arc Guard System™ The Arc Guard System™ detects fast arc faults in the terminal sections of the drive. When the Arc Guard System detects an arc fault the drive performs protection firing and immediately opens the main circuit breaker.
Page 137: Energizing And Grounding The Drive
OPERATION 8.11. De-energizing and grounding the drive See Section 10.6.2, “De-energizing the drive”, page 169. 8.12. Opening the doors See Section 10.6.3, “Opening and closing the doors”, page 171. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS5000W gen. 2 User manual 3BHS799208 E01 137/186...
Page 138: Cdp Control Panel
CDP CONTROL PANEL 9. CDP control panel 9.1. Overview The panel messages and parameter settings in the following sections are typical examples and might differ from the actual ones. 9.1.1. Display and keypad Key: Display Forward key Status line (10) Backward key Actual signal names and values (11) Slow navigation key for selecting signals or fault messages...
Page 139: Functions
CDP CONTROL PANEL 9.1.2. Functions The CDP control panel serves as the basic user interface for operating and monitoring the drive when the local operating mode has been selected. The CDP control panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first.
Page 140 CDP CONTROL PANEL After 2 to 3 seconds the display shows the drive name (1 and 2), the application software in use (3), and the drive identification (4) is displayed. ACS5000 xxxx <Device Name> LXHH44xx ID-NUMBER 1 After another few seconds.
Page 141: Actual Signals Mode
CDP CONTROL PANEL 9.2.2. Actual signals mode Key: Display Slow navigation key for selecting signals or fault messages Actual signal names and values Enter key for confirming the selection Selection key for actual signals mode Fast navigation key for selecting the actual signals display or the fault memory display Fig.
Page 142: Selecting The Actual Signals Display
CDP CONTROL PANEL 9.2.2.1.1. Actual values For the complete list of selectable actual signals, see “Appendix G – Signal and parameter table”. The actual values are organized in groups. Group Description Group 01 Measured or calculated motor values Group 02 Measured or calculated drive values Group 03 Reference values...
Page 143: Toggling Between Actual Signals Display And Fault Memory
CDP CONTROL PANEL 9.2.2.3. Toggling between actual signals display and fault memory To toggle between actual signals display and fault history display, press a fast navigation key. 1 L -> 600.0 rpm 1 LAST FAULT +Overspeed 070730 12:30:02.3256 9.2.2.4. Displaying three actual signals 1.
Page 144 CDP CONTROL PANEL 2. To select a line where the actual signal is to be displayed, press the slow navigation keys. blinking cursor indicates the selected line. 1 L -> 600.0 rpm StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 3.
Page 145: Displaying A Fault And Resetting The Fault Memory
CDP CONTROL PANEL 6. To confirm the selection and to return to the actual signals display, press the ENTER key. 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm NP VOLT 7. To cancel the selection and keep the original selection, press any of the mode selection keys.
Page 146: Displaying And Resetting An Active Fault
0.00 rpm POWER 0.0 kW 9.2.2.7. Displaying and resetting an active fault 1. To display an active fault, press the ACT key. 1 L -> 600.0 rpm ACS5000 *** FAULT *** MCB CloseControl PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG.
Page 147: Parameters Mode
CDP CONTROL PANEL 2. To reset the fault, press the RESET key. 1 L -> 600.0 rpm StateINU ReadyOn MOTOR SP 0.00 rpm POWER 0.0 kW 9.2.3. Parameters mode NOTICE Risk of component damage. Incorrect parameter data can reduce control accuracy, interfere with drive operation, and damage equipment.
Page 148: Fig. 93. Control Panel Functions For Parameters Mode
CDP CONTROL PANEL Key: Status line Fast navigation key for selecting a parameter group (and a parameter value) Group number and name Slow navigation key for selecting a parameter Parameter number and name (and a parameter value) Parameter value Enter key for confirming the selection Selection key for parameters mode Fig.
Page 149: Overview
CDP CONTROL PANEL 9.2.3.1. Overview If the parameter lock is disabled or unlocked (see Section 9.2.3.3, “Enabling / unlocking a parameter lock”, page 152) the parameters mode allows entering the parameter settings for the required drive configuration depending on the application. The parameters are organized in functional groups, so called parameter groups.
Page 150: Changing A Parameter Setting
CDP CONTROL PANEL 9.2.3.2. Changing a parameter setting 1. To enter the parameters mode, press the PAR key. 1 L -> 600.0 rpm 77 SYSTEM CONFIG 01 INU IdentifySel INU1 (MASTER) 2. To select a different group, press a fast navigation key. 1 L ->...
Page 151 CDP CONTROL PANEL 5. To change the parameter value, press: • Slow navigation keys for numbers and text • Fast navigation keys for numbers only 1 L -> 600.0 rpm 75 OPTION MODULES 07 C3P1/AI820 Module [DI810 24VDC] 6. To confirm the setting and to return to the actual signals display, press the ENTER key. 1 L ->...
Page 152: Enabling / Unlocking A Parameter Lock
9.2.3.4. User lock NOTICE Risk of component damage. ABB is not liable for damages or losses that are caused by the failure to activate the user lock for the control panel or to change the default pass code for the user lock.
Page 153: Functions Mode
CDP CONTROL PANEL 9.2.4. Functions mode The functions mode is used for adjusting the display contrast. Key: Status line Slow navigation key for selecting a line (and adjusting the contrast) Selectable functions Enter key for confirming the selection Selection key for functions mode Fig.
Page 154 CDP CONTROL PANEL 2. To select the contrast adjustment function, press the slow navigation keys until the blinking cursor reaches the CONTRAST line. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 3. Press the ENTER key. 1 L ->...
Page 155: Local And Remote Control Mode
CDP CONTROL PANEL 6. To cancel the setting and keep the original setting, press any of the mode selection keys. The selected keypad mode is entered. FUNC DRIVE 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 9.2.5.
Page 156: Enabling The Local Lock
CDP CONTROL PANEL 9.2.5.3. Enabling the local lock To enable the local lock, set parameter 16.04 to 2 (LOCKED). – With this parameter setting, local control (including the LOC-REM key) is disabled. If the CDP control panel or a DriveWindow PC is in local control mode at the time that the local lock is enabled, they remain in local control mode until they are switched to remote control mode.
Page 157: Operational Commands
CDP CONTROL PANEL NOTE – To prevent accidental switching from remote control to local control, see Section 9.2.5.2, “Disabling / enabling local lock function”, page 155. 9.3. Operational commands For instructions on how to start and stop the drive system from the CDP control panel, see Section 8.8, “Starting the drive”, page 129 and Section 8.9, “Stopping the drive”, page 132.
Page 158 CDP CONTROL PANEL 1. Press a mode selection key. FUNC DRIVE 1 L -> 600.0 rpm 0 StateINU ReadyRun MOTOR SP 600.00 rpm POWER 75.0 kW 2. To enter the reference value input mode, press the REF key. 1 L -> [600.0 rpm] 0 StateINU ReadyRun...
Page 159: Preventive And Corrective Maintenance
10. Preventive and corrective maintenance 10.1. General information During the warranty period of the drive, any maintenance must be carried out exclusively by ABB service personnel. After the warranty period, repair work may only be carried out by certified personnel.
Page 160: Cables And Wires
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.2.2. Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams. Key: Terminal number Wire number Fig. 96. Cable and wire designation 10.2.3.
Page 161: Messages
– Flashing light: alarm – Light remains on: fault SUPPLY 1 L -> 600.0 rpm ACS5000 ** FAULT ** CW1 NoWtrPumpOn ALARM EMERGENCY OFF FAULT RESET EMERGENCY OFF The message can be saved and viewed in the fault history of the drive when a PC with DriveWindow, DriveDebug or DriveMonitor is connected to the drive.
Page 162: Alarm / Fault Messages
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.3.2.3. Alarm / fault messages When an alarm or a fault occurs, a specific message is saved in the fault history of the drive. Information on the 64 most recent fault and alarm events are saved. 10.3.3.
Page 163: Standard Troubleshooting Procedure
The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. 5) Contact ABB service if a fault cannot be rectified. When calling ABB service, it is recommended to have the following data available at the time when the fault occurred: •...
Page 164: Removing The Cdp Control Panel
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.4. Removing the CDP control panel When the CDP control panel must be removed from its mounting cradle, follow the instructions below. 1. When the panel is removed while the drive is in operation, check the setting of parameter 31.01 PANEL LOSS SUPERVISION first.
Page 165: Leds And Switches On Circuit Boards And I/O Devices
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5. LEDs and switches on circuit boards and I/O devices The following section provides an overview of the meaning of LEDs and switches of the main circuit boards and I/O modules. The LEDs presented in the following section can be checked easily while the auxiliary voltage is switched on without having to remove covers first.
Page 166: S800 I/O Bus Modem Tb820
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5.2. S800 I/O bus modem TB820 Color Indication Fault in module Green Device in operation Green Power supply is healthy Yellow Traffic on optical module bus Yellow Traffic on optical module bus Yellow Traffic on electrical module bus Fig.
Page 167: S800 I/O Modules
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5.3. S800 I/O modules LEDs on I/O modules having the same meaning on all types of I/O modules are always at the same position. The LEDs are always at the topmost position on each module (1, Fig. 99) and are identified as follows: –...
Page 168: Corrective Maintenance
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6. Corrective maintenance Overview on maintenance tasks: – Visual checks on the drive – Cleaning – Checking wire and cable connections – Checking and replacing filter mats – Replacing a fan in an IP42 roof-mounted cooling unit (optional) –...
Page 169: Energizing The Drive
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.2. De-energizing the drive The following section describes how to de-energize the drive using the local operator panel of the drive. If the drive is controlled from remote, follow the established shutdown procedures. For instructions on how to use the CDP control panel, see Chapter 9, “CDP control panel”, page 138.
Page 170 PREVENTIVE AND CORRECTIVE MAINTENANCE • DC link discharges While the DC link discharges, the CDP control panel shows the following: Alternating display message: 1 L -> 600.0 rpm – OffSeqOn StateINU OffSeqOn – Discharging MOTOR SP 0.00 rpm POWER 0.0 kW –...
Page 171: Opening And Closing The Doors
PREVENTIVE AND CORRECTIVE MAINTENANCE 7. Switch off and lock-out all auxiliary supply voltages from external sources. The drive is now de-energized, but not grounded. DANGER! FATAL voltages can still be fed into an ungrounded drive from the main power supply or motor during maintenance work. Connect grounding equipment to the designated locations before you work on the drive (see Section 3.9, “Grounding studs”, page 52).
Page 172: Opening The Doors
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.3.2. Opening the doors 1. To release the door handle, insert and turn the key to the right. The door handle pops out. 2. Turn the door handle: • Right if the door is hinged on the right •...
Page 173: Grounding The Drive When The Grounding Switch Is Not Released
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.4. Grounding the drive when the grounding switch 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.
Page 174: Emergency Release Of A Door Safety Switch
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.5. Emergency release of a door safety switch DANGER Hazardous voltages! Risk of life-threatening injury or DEATH! → Before you unlock a safety switch, de-energize and ground the drive according to Section 10.6.2, “De-energizing the drive”, page 169. →...
Page 175: Safety-Switch Settings
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.5.2. Safety-switch settings Key: Release dial Unlocked position: enables opening the door of a medium voltage unit whether the auxiliary voltage is switched on or off. Locked position: Normal operating setting Fig. 101. Safety switch 10.6.5.2.1. Unlocking a door ...
Page 176: Visual Checks On The Drive
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.6. Visual checks on the drive Check the drive and its immediate vicinity visually at the intervals stated on the maintenance schedule and pay attention to the following items: – Humidity inside the drive – Permitted range of ambient air temperature and humidity of the drive –...
Page 177: Checking Wire And Cable Connections
→ Check all power and control cable connections and tighten them if necessary. → Check that all plugs and connectors are tight. 10.6.9. Checking and replacing filter mats Inspection intervals See the “ACS5000 preventive maintenance schedule”, 3BHS855274 E01. Service during operation Possible Filter mat class...
Page 178: Replacing Filter Mats
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.9.1. Replacing filter mats You can replace PCU and WCU filter mats. CAUTION Cooling fans start automatically. Cooling fans start automatically in response to temperature levels. → Switch off the protection switch for the cooling fan according to “Appendix D – Wiring diagrams”.
Page 179 PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.9.1.2. Replacing a WCU filter mat Although checking and replacing the filter mats of the WCU compartment is possible during operation of the drive, it is easier to do it when the drive is shut down. 1.
Page 180: Replacing A Fan In An Ip42 Roof-Mounted Cooling Unit
If you need to replace a fan in a roof-mounted cooling unit, contact ABB. DO NOT attempt to replace the fan yourself.
Page 181: Replacing A Fan In An Ip54 Roof-Mounted Cooling Unit
In case of fan failure, the redundant fan begins operating and the red indicator light on the front of the cooling unit turns on. If you need to replace a fan in a roof-mounted cooling unit, contact ABB. DO NOT attempt to replace the fan yourself.
Page 182: Replacing A Fan In An Exu With A Dcs880 H4/Dct880 T4 Controller
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.12. Replacing a fan in an EXU with a DCS880 H4/DCT880 T4 controller Fig. 104. DCS880 controller - size H4 1. Switch off the miniature circuit breaker of the fan unit. NOTE – To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 2.
Page 183 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 out of fan unit in the cabinet. CAUTION! To prevent the fan from falling onto you, place a support (ie, a box) underneath. 6.
Page 184: Replacing A Fan In An Exu With A Dcs880 H6 Unit
PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.13. Replacing a fan in an EXU with a DCS880 H6 unit Fig. 105. DCS880 controller - size H6 1. Switch off the miniature circuit breaker of the fan unit. To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 2.
Page 185 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 out of the fan unit in the cabinet. CAUTION! To prevent the fan from falling onto you, put a support (ie, a box) underneath. 6.
Page 186 /186 — ABB Switzerland Ltd. Bruggerstrasse 66 CH-5400 Baden Switzerland new.abb.com/drives/medium-voltage-ac-drives — © Copyright 2009 ABB. All rights reserved. The information in this document is subject to change without notice.

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