User’s manual for ACS 6000

Medium voltage AC drives

ACS 6000, 3 - 27 MVA
ABB
ABB

Table of contents

List of figures 1

List of tables 1

Terms, abbreviations, trademarks 1

Terms and abbreviations 1

Trademarks 4

General information on manual and equipment 1

Copyright notice 1
Document identification 1
Equipment covered by the manual 1
Contact information 2
Structure of the user documentation 2
Target groups and required qualifications 3
Relevant chapters of the manual 4
User’s responsibilities 4
Intended equipment use 4
Quality certificates and applicable standards 5
Writing conventions 5
Meaning of icons 5
Text conventions 6
Related documentation 6
Identifying the delivery 7
Tools 7

Chapter 1 - Safety 1-1

1.1 Meaning of safety instructions 1-1

1.2 General safety information 1-2
1.3 Possible residual risks 1-3
1.4 Safety labels and signs 1-4
1.4.1 Safety labels 1-4
1.4.2 Safety signs 1-4
1.5 Important note on main circuit breaker design 1-5
1.5.1 Safety and protection requirements 1-7

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (8)

Table of contents ABB
1.5.2 Minimum requirements for MCB and MCB control 1-7
1.5.3 Maintenance recommendation 1-8

Chapter 2 - Features and hardware of the drive 2-1

2.1 Drive overview 2-1

2.2 Main features of the drive 2-1
2.3 Major components of the drive 2-4
2.3.1 Active rectifier unit (ARU) 2-4
2.3.2 Line supply unit (LSU) 2-8
2.3.3 Inverter unit (INU) 2-14
2.3.4 Capacitor bank unit (CBU) 2-16
2.3.5 Terminal units (TEU) 2-18
2.3.6 Control unit (COU) 2-20
2.3.7 Cooling system 2-27
2.3.8 Customer interface unit (CIU/CIW) 2-29
2.3.9 Input filter unit (IFU) 2-31
2.3.10 Voltage limiter unit (VLU) 2-33
2.3.11 Resistor braking unit (RBU) 2-35
2.3.12 Braking chopper unit (BCU) 2-37
2.4 Overview of busbars and ground connections 2-39
2.4.1 Grounding switch 2-39
2.5 Control switch for DC link isolator 2-41
2.5.1 Excitation unit (EXU) 2-41
2.6 Door interlocking 2-42

Chapter 3 - Transportation, storage and disposal 3-1

3.1 Safety 3-1

3.2 Transport conditions 3-1
3.3 Unpacking and inspection 3-1
3.4 Identifying drive units 3-1
3.4.1 Packing list 3-2
3.4.2 Packing label 3-3
3.5 Lifting and transportation 3-4
3.5.1 General notes on transportation 3-4
3.6 Storage 3-5
3.6.1 Storage conditions 3-5
3.6.2 Storage 3-6
3.7 Storage and handling instructions for spare parts 3-6
3.8 Disposal of packaging materials and components 3-7

2 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB Table of contents

Chapter 4 - Mechanical installation 4-1

4.1 Safety 4-1

4.2 Overview on installation work 4-1
4.3 General notes on installation 4-2
4.3.1 Dimensions and clearances 4-2
4.3.2 Ambient operation conditions 4-2
4.3.3 Foundation and floor surface requirements 4-3
4.3.4 Cable ducts 4-3
4.3.5 Fire protection 4-3
4.3.6 Cabinet roof 4-3
4.3.7 Floor fixings 4-3
4.4 Mechanical door interlock 4-4
4.5 Tools 4-5
4.6 Drive Installation 4-6
4.6.1 Installing transport units 4-6
4.6.2 Aligning the transport units 4-9
4.6.3 Attaching the sealing tape 4-10
4.6.4 Installing roof joints 4-11
4.6.5 Installing roof attachments 4-12
4.6.6 Installing roof-mounted heat exchangers 4-15
4.6.7 Joining water pipes 4-19
4.6.8 Joining DC busbars 4-21
4.6.9 Joining ground busbars 4-25
4.6.10 Joining AC busbars in ARU, INU, IFU 4-25
4.6.11 Joining AC busbars in LSU 4-29
4.6.12 Raw water circuit 4-33

Chapter 5 - Electrical installation 5-1

5.1 Safety 5-1

5.2 Overview on installation work 5-1
5.3 Tools 5-1
5.4 Understanding electrical drawings 5-1
5.5 Cables and wires 5-2
5.5.1 Power cables 5-2
5.5.2 Ground cable 5-2
5.5.3 Equipotential bonding conductor 5-2
5.5.4 Auxiliary power cables 5-2
5.5.5 Control cables 5-2
5.5.6 Synchronization cables 5-3
5.6 Internal wiring 5-3
5.7 Cable entry 5-5
5.7.1 Power cables 5-5
5.7.2 Power cable entry with Roxtec sealing modules 5-7
5.7.3 Cabel entry for auxiliary and control cables in WCU 5-11

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3 (8)

Table of contents ABB
5.8 Ground connections 5-12
5.8.1 Protective earth 5-12
5.8.2 Grounding of drive, transformer and motor 5-14
5.9 External power cabling 5-16
5.9.1 Connecting incoming feeder, motor cables and braking resistor cables 5-16
5.10 Connecting auxiliary power and control cables 5-19
5.10.1 Further information 5-19
5.10.2 Cable preparation and connection 5-20
5.10.3 Connecting auxiliary power cable 5-21
5.10.4 Connecting control cables in WCU 5-21
5.11 Connecting cables for serial communication and encoders 5-25
5.11.1 Further information 5-25
5.11.2 Cable preparation and connection 5-25
5.12 Connecting position encoder cables in marine drives 5-36
5.12.1 Handling and installation guidelines 5-37
5.12.2 Routing cables through WCU 5-37
5.12.3 Routing cables through COU 5-39
5.13 Connecting the heating cable 5-39

Chapter 6 - Information for commissioning 6-1

6.1 Required qualification 6-1

6.2 Commissioning procedure 6-1
6.3 Commissioning check list 6-1
6.4 Customer assistance 6-1
6.5 Customer acceptance 6-1

Commissioning check list 1

Mechanical installation 1
Electrical installation 2
Main circuit breaker (MCB) 2
Input transformer 3
Motor 3
Megger tests 4
Power 4
Miscellaneous 4

Chapter 7 - Operating instructions 7-1

7.1 Overview 8-1

7.1.1 Safety 8-1
7.2 Local control elements 8-1
7.2.1 Control panels 8-1

4 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB Table of contents

7.2.2 Switches 8-1

7.3 Control panels 8-3
7.3.1 Control panel on COU 1 or COU 0 8-3
7.3.2 Control panel on additional control units 8-6
7.4 Status messages 8-7
7.4.1 Overview on status messages 8-7
7.4.2 Start sequence of the drive 8-9
7.4.3 Stop sequence of the drive 8-10
7.4.4 Emergency off sequence 8-11
7.5 Starting the drive 8-11
7.5.1 Checks before starting the drive system 8-12
7.5.2 Starting the drive system from remote 8-13
7.5.3 Starting the drive system locally 8-13
7.6 Stopping the drive 8-17
7.7 Emergency off 8-18
7.7.1 Function 8-18
7.7.2 Initiating an emergency shutdown 8-18
7.7.3 Starting the drive system after an emergency shutdown 8-18

Chapter 8 - CDP control panel 8-1

8.1 Overview 9-1

8.1.1 CDP control panel details 9-1
8.1.2 Display and keypad 9-2
8.2 Overview on CDP control panel functions 9-3
8.3 Overview on CDP control panel modes 9-3
8.4 Identification mode 9-4
8.5 Actual signal display mode 9-5
8.5.1 Overview 9-5
8.5.2 Displaying three actual signals 9-7
8.5.3 Selecting actual signals 9-8
8.5.4 Displaying a fault and resetting the fault history 9-10
8.5.5 Displaying and resetting an active fault 9-12
8.6 Parameter mode 9-12
8.6.1 Overview 9-12
8.6.2 Procedure 9-14
8.6.3 Parameter Lock 9-17
8.7 Function mode 9-17
8.7.1 Overview 9-17
8.7.2 Procedure 9-18
8.8 Operational commands 9-20
8.8.1 Local remote control location 9-20
8.8.2 Locking local or remote control mode 9-21
8.8.3 Setting the direction of rotation 9-22
8.8.4 Entering a setpoint 9-23
8.8.5 Run status indication 9-24

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5 (8)

Table of contents ABB
Chapter 9 - Troubleshooting and maintenance 9-1

9.1 General information 10-1

9.1.1 Required qualification 10-1
9.1.2 Warranty period 10-1
9.1.3 Training courses 10-1
9.1.4 Maintenance schedule 10-1
9.1.5 Log book 10-1
9.1.6 Spare parts 10-1
9.2 Identifying electrical equipment 10-2
9.2.1 Device designation 10-2
9.2.2 Cables and wires 10-2
9.2.3 Understanding wiring diagrams 10-3
9.3 Troubleshooting 10-3
9.3.1 Alarm and fault messages 10-3
9.3.2 Error message levels 10-3
9.3.3 Standard troubleshooting procedure 10-5
9.4 Malfunctioning grounding switch 10-5
9.5 Panel removal 10-6
9.5.1 Communication link 10-7
9.6 LEDs and switches on PCBs and I/O devices 10-8
9.6.1 AMC circuit board 10-8
9.6.2 S800 I/O - TB820 bus modem 10-9
9.6.3 S800 I/O bus modem address 10-10
9.6.4 S800 I/O modules 10-10
9.7 Maintenance and service 10-11
9.7.1 Overview on maintenance and service tasks 10-11
9.7.2 Safety 10-12
9.7.3 De-energizing the drive 10-13
9.7.4 Visual checks on the drive 10-15
9.7.5 Cleaning 10-15
9.7.6 Checking wire and cable connections 10-16
9.7.7 Checking and replacing filter mats 10-16
9.7.8 Replacing door-mounted fans 10-19
9.7.9 Replacing the heat exchanger 10-20
9.7.10 Replacing and initializing delay timer relays 10-20
9.7.11 Grounding the drive with a 4-way grounding set 10-22

Maintenance schedule 1

Appendix A - Additional manuals

Appendix B - Technical data

6 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB Table of contents

Appendix C - Mechanical drawings

Appendix D - Electrical diagrams

Appendix E - Parts list

Appendix F - Test reports

Appendix G - Signal and parameter table

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7 (8)

Table of contents ABB

8 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

List of figures

Figure 1-1 Safety labels 1-4

Figure 2-1 Drive overview (with Line supply unit) 2-1
Figure 2-2 Typical block diagram of a 12-pulse LSU 2-2
Figure 2-3 Typical block diagram of a 6-pulse ARU 2-2
Figure 2-4 DTC principle 2-3
Figure 2-5 IGCT 2-3
Figure 2-6 ARU cabinet layout 2-5
Figure 2-7 Phase module with IGCTs 2-6
Figure 2-8 ARU local control and monitoring equipment 2-7
Figure 2-9 ARU circuit diagram 2-8
Figure 2-10 Cabinet layout of 12-pulse LSU 2-9
Figure 2-11 Circuit diagram of 12-pulse LSU 2-11
Figure 2-12 Cabinet layout of 6-pulse LSU with IRU 2-12
Figure 2-13 Circuit diagram of 6-pulse LSU with IRU 2-13
Figure 2-14 3 and 5 MVA Units 2-14
Figure 2-15 7, 9 and 11 MVA INUs 2-15
Figure 2-16 Circuit diagram of 7, 9 and 11 MVA INUs 2-15
Figure 2-17 Circuit diagram of 3 and 5 MVA units 2-16
Figure 2-18 CBU cabinet layout 2-17
Figure 2-19 CBU circuit diagram 2-18
Figure 2-20 TEU (1000 mm wide), swing frame of COU open 2-19
Figure 2-21 COU control swing frame installed in a TEU (typical configuration) 2-20
Figure 2-22 Reverse side of COU doors (typical configuration) 2-22
Figure 2-23 Local operator panel 2-25
Figure 2-24 Single-motor drive with LSU 2-26
Figure 2-25 Roof heat exchangers 2-27
Figure 2-26 Air-to-air heat exchanger 2-28
Figure 2-27 Air inlet and outlet in TEU, COU and WCU 2-29
Figure 2-28 WCU 029 or 052 with CIW box 2-30
Figure 2-29 CIU, typical cabinet layout 2-31
Figure 2-30 IFU cabinet layout 2-32
Figure 2-31 IFU, circuit diagram 2-33
Figure 2-32 VLU cabinet layout 2-34
Figure 2-33 VLU circuit diagram 2-35
Figure 2-34 RBU cabinet layout 2-36
Figure 2-35 RBU circuit diagram 2-37
Figure 2-36 BCU circuit diagram 2-38
Figure 2-37 Principal busbar arrangements 2-39
Figure 2-38 Grounding switch on CBU 2-40
Figure 2-39 Grounding the drive 2-40
Figure 2-40 Control switch for DC link isolator 2-41
Figure 2-41 ACS 6000 with EXU lineup 2-42
Figure 3-1 Identifying the drive on the packing list 3-2

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (4)

List of figures ABB
Figure 3-2 Identifying the drive on the accessories packing list 3-3
Figure 3-3 Identifying the drive on the packing label 3-3
Figure 4-2 Location of name plates 4-4
Figure 4-12 Installing roof joints 4-11
Figure 4-13 Roof-side steel bracket 4-13
Figure 4-14 Installing the roof attachments 4-14
Figure 4-16 Recommended ceiling and wall fixings 4-15
Figure 4-17 Required tools 4-16
Figure 4-18 Heat exchanger top view 4-16
Figure 4-21 Adjusting pipe joints 4-20
Figure 4-23 Busbar configuration 1, polarity and bolt orientation 4-23
Figure 4-24 Busbar configuration 2, polarity and bolt orientation 4-23
Figure 4-25 Busbar configuration 3, polarity and bolt orientation 4-24
Figure 4-26 Busbar configuration 4, polarity and bolt orientation 4-24
Figure 4-27 Connecting ground busbars 4-25
Figure 4-28 Connecting points of AC busbars in ARU, INU, IFU 4-27
Figure 4-29 Connecting points of ac busbars in ARU, INU, IFU 4-28
Figure 4-30 Connecting points of AC busbars in LSU on the right (7 and 9 MVA) 4-30
Figure 4-31 Connecting points of AC busbars in LSU on the right 14 MVA) 4-31
Figure 4-32 Connecting points of AC busbars in LSU on the left (7 and 9 MVA) 4-32
Figure 4-33 Connecting points of AC busbars in LSU on the left (14 MVA) 4-33
Figure 5-1 Location of cable duct 5-4
Figure 5-2 Cable duct sections 5-4
Figure 5-3 Power cable entry with Roxtec sealing system (typical example) 5-6
Figure 5-4 Cable entry with EMC cable gland 5-7
Figure 5-5 Roxtec frame with sealing modules and cables 5-8
Figure 5-6 Cable entry for auxiliary power and control cables 5-11
Figure 5-7 Pre-compression wedge 5-11
Figure 5-8 Bottom connecting point of system ground in TEU 600 mm 5-12
Figure 5-9 Bottom connecting point of system ground in TEU 1000 mm 5-13
Figure 5-10 Top connecting point of system ground in TEU 1000 mm 5-13
Figure 5-11 Cable installation between drive and motor 5-14
Figure 5-12 Cable installation between transformer and drive with ARU 5-15
Figure 5-13 Cable installation between transformer and drive with LSU 5-16
Figure 5-14 Cable entry for power cables with EMC ROX modules 5-18
Figure 5-15 Connection with spring and flat washers 5-19
Figure 5-16 Cable transit inside cabinet 5-20
Figure 5-18 WCU top cable entry (800 mm unit) 5-22
Figure 5-19 WCU top cable entry (2000 mm unit) 5-22
Figure 5-21 WCU bottom cable entry - cable routing 5-24
Figure 5-22 COU, top cable entry 5-26
Figure 5-35 Shield grounding points 5-35
Figure 5-36 Shield grounding clamps 5-36
Figure 5-37 WCU 800 mm, pulse encoder receiver 5-38
Figure 5-38 Heating cable connector 5-39
Figure 7-1 ARU control panel on COU 1 or COU 0 depending on the drive
configuration 8-3

2 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB List of figures

Figure 7-2 Local operator panel 8-4

Figure 7-3 INU control panel 8-6
Figure 8-1 CDP control panel 9-2
Figure 9-1 Device designation 10-2
Figure 9-2 Cable and wire identification 10-2
Figure 9-3 AMC circuit board 10-8
Figure 9-4 TB820 bus modem 10-9
Figure 9-5 S800 I/O station 10-10
Figure 9-6 Location of filter mat 10-17
Figure 9-7 Removing the louvered panel 10-19
Figure 9-8 Four-fan unit 10-19
Figure 9-9 Thermostat on the control swing frame in the COU and in the WCU 10-20
Figure 9-10 Location of timer relays in control units 10-21
Figure 9-11 Earthing tool set with 4-way grounding set and telescope
earthing rod 10-22
Figure 9-12 Grounding the three phase conductors in the INU 10-23
Figure 9-13 Detailed view of connection to the grounding bolt 10-24
Figure 9-14 The four connection points 10-24
Figure 9-15 Grounding bolt with connected grounding set 10-25

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3 (4)

List of figures ABB

4 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

List of tables

Table 4-1 Installation material 4-9

Table 4-2 Installation material 4-12
Table 4-3 Installation material 4-12
Table 4-4 Installation material 4-22
Table 4-5 Installation material 4-25
Table 4-6 Installation material 4-26
Table 4-7 Installation material 4-29
Table 5-1 Control cable requirements 5-3

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (2)

List of tables ABB

2 (2) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

Terms, abbreviations, trademarks

Terms and abbreviations

The following table lists terms and abbreviations you should be familiar with when using the manual.
Some of the terms and abbreviations used in the manual are unique to ABB and might differ from the
normal usage.

Term / Abbreviation Meaning

aEXU Air-cooled Excitation Unit

AMC Application and Motor Controller

The digital signal processor is the heart of the drive control system.

ANSI American National Standards Institute

ARU Active Rectifier Unit

ASE Anti-saturation Equipment

BCU Braking Chopper Unit

CBU Capacitor Bank Unit

CCB Converter Control Board

CIU Customer Interface Unit

CIW Customer Interface Unit inside the WCU

Converter Short form for ACS 6000 frequency converter

COU The control unit consist of the control compartment and the customer interface
compartment.
The control compartment incorporates the hardware for control, monitoring
and protection functions of the drive and the communication interface to the
door-mounted CDP control panel.

CVMI Current and Voltage Measuring Interface

DDCS Distributed Drive Control System

DIN Deutsches Institut für Normung

Drive ACS 6000 frequency converter

DriveDebug DriveDebug is part of ABB’s DriveWare® software tools for devices using the
DDCS communications protocol. DriveDebug runs on computers with
Windows® operating systems. DriveDebug is a specialist’s tool used to
diagnose, tune and troubleshoot frequency converters.

DriveMonitor DriveMonitor is a monitoring and diagnostics system that allows secure

access to the frequency converter via the internet from a remote location.
DriveMonitor provides long-term monitoring functions that allow to infer
equipment status and improve equipment performance.

DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows®

application for commissioning and maintaining ABB drives equipped with fiber-
optic communication.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (4)

Terms, abbreviations, trademarks ABB

Term / Abbreviation Meaning

DTC Direct Torque Control

EAF Earth Fault monitoring equipment

EMC Electromagnetic Compatibility

Equipment Frequency converter and related equipment

EXU The excitation unit is delivered as part of the drive when a synchronous motor
has to be supplied with excitation power.

FSCD Fast Short Circuit Detection

Ground Earth.

To ground The conducting path (e.g. conductor) between the electric equipment (e.g.
frequency converter) and the earth. The electric equipment is connected to the
earth e.g. by a grounding set or a grounding switch.

GTO Gate Turn Off Thyristor

GUSP Gate Unit Power Supply

HVD High Voltage Divider

IFU Input Filter Unit

IGBT Insulated Gate Bipolar Transistor

IGCT Integrated Gate Commutated Thyristor

IM Induction Motor

INT Interface

INU The inverter unit converts the three DC voltages to the required AC motor
voltage. The unit is designed as a self-commutated, 9-level voltage source
inverter consisting of three identical power cells.

I/O device Term of ABB’s S800 I/O system. An I/O device consists of a module
termination unit (MTU) and one I/O module.

I/O module Term of ABB’s S800 I/O system. The I/O module is an active input or output
device for digital or analog signals.

I/O station Term of ABB’s S800 I/O system. The I/O station typically consists of a bus
modem and several input and output devices.

LSU The line supply unit rectifies the AC line voltage and supplies the electrical
energy to the DC link capacitors.

MCB Main circuit breaker

The MCB is a major protection device of the drive system and connects /
disconnects the main power supply to the drive.

MSM Main State Machine

NP Neutral Point
The neutral point in the DC link in a 3-level inverter

NTAC Pulse Encoder Interface Module

PCB Printed Circuit Board

2 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB Terms, abbreviations, trademarks

Term / Abbreviation Meaning

PE Protective Earth (ground bus)

PFF Power Feed Forward

PG Power Ground (ground bus)

PINT Pulse Interface

PPCS Power Plate Communication System

PUB PPCS Unit for Branching

PWM Pulse Width Modulation

RBU Resistor Braking Unit

RPM Revolutions per Minute

S800 I/O The S800 I/O is a distributed process input output system that can be
connected to various process controllers from ABB and other companies.

SM Synchronous Motor

TEU The terminal unit provides the terminals for the trans-former cables, the
grounding frame for the cable screens and the grounding cable, and the
grounding accessories.

THD Total Harmonic Distortion

VLSCD Voltage Limiting Short Circuit Detection

VLU Voltage Limiter Unit

VSI Voltage Source Inverter

WCU The water cooling unit removes the heat from the power electronics
components of the drive.

wEXU Water-cooled Excitation Unit

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3 (4)

Terms, abbreviations, trademarks ABB
Trademarks
Names that are believed to be trademarks of other companies and organizations are designated as
such. The absence or presence of such a designation should however not be regarded as an offence
of the legal status of any trademark. The following registrations and trademarks are used in this
manual:

Term / Abbreviation Meaning

Advant® Registered trademark of ABB

Advant FieldbusTM Trademark of ABB

DeviceNet® Registered trademark of the Open DeviceNet Vendor Association

DriveMonitorTM Trademark of ABB

DriveWare® Registered trademark of ABB

Ethernet® Registered trademark of Xerox Corporation

Industrial ITTM Trademark of ABB

Modbus® Registered trademark of the Modbus IDA organization

Profibus® Registered trademark of Profibus International (P.I.)

Windows® Registered trademark of Microsoft Corporation

4 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

General information on manual and equipment

Copyright notice
The information in this manual is subject to change without notice.
This manual and parts thereof must not be reproduced or copied, or
disclosed to third parties, nor used for any unauthorized purpose without
written permission from ABB Switzerland Ltd, Medium Voltage Drives.
The hardware and software described in this manual is provided under a
license and may be used, copied, or disclosed only in accordance with the
terms of such license.

Document identification
Ownership ABB Switzerland Ltd
Medium Voltage Drives

Document number 3BHS212794 ZAB E01

Revision B

Issue date 31.8.2011

Equipment covered by the manual

This manual covers standard equipment and provides generic information
on the equipment. The manual does not claim to cover all variations and
details of the equipment, nor to consider all eventualities that may arise
during installation, commissioning, operation and maintenance of the
equipment.
If the equipment is adapted to specific customer needs or applications,
and handling, installation, and operation of the equipment are affected by
these modifications, information on these modifications is provided in the
appropriate documentation (e.g. layout drawings, wiring diagrams,
technical data, engineering notes).
If information is required beyond the instructions in this manual refer the
matter to ABB.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (8)

General information on manual and equipment ABB
Contact information
Address ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi, Switzerland

Phone +41 844 845 845

Fax +41 58 589 2984

Mail [email protected]

Structure of the user documentation

The complete set of user documentation of a standard drive consists of
this manual and supplementary documentation that is provided in the
following appendices:
• Appendix A - Additional manuals
The appendix provides manuals about additional equipment deliv-
ered with the drive (e.g. project specific options such as pulse
encoder or fieldbus interfaces), or information on modifications of the
standard equipment.
• Appendix B - Technical data
The appendix contains the technical data sheets of the drive.
• Appendix C - Mechanical drawings
The appendix provides the Layout drawing(s) of the equipment. The
drawings are generated according to the customer specific project.
• Appendix D - Wiring diagrams
• The appendix contains the circuit diagrams with information on
device designation, cross-reference and device-identification
conventions. The diagrams are generated according to the
customer specific project.
• The Utility consumption list lists the auxiliary power consumption
of the drive
• Setting of protective devices, generated according to the
customer specific project.
• Appendix E - Parts list
The parts list of electrical devices is produced for each project and
contains all information to identify a component.
• Appendix F - Test reports and certificates
The appendix provides the test reports of the equipment. Quality
certificates, and codes and standards the drive complies with are
added if required for the project.
• Appendix G - Signal and parameter table

2 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB General information on manual and equipment

The Signal and parameter table includes descriptions of actual

signals, control and status words, and control parameters and their
default settings.

Target groups and required qualifications

The equipment presented in this manual is part of an industrial environ-
ment where voltages are present that contain a potential hazard of electric
shock and/or burn. For this reason, only personnel who have a thorough
knowledge of the equipment and the industrial environment and have
obtained the required qualification must handle, install, operate, or
maintain the equipment.
The manual addresses personnel who are responsible for unpacking,
transportation, installation, operation and maintenance of the equipment.
The personnel must carry out the below listed tasks in a manner that does
not cause physical harm or danger, and to ensure the safe and reliable
functioning of the equipment.
Note: Commissioning of drive equipment must only be performed by
qualified and certified ABB personnel.

Handling Personnel must be skilled and experienced in unpacking and transporting

heavy equipment.

Mechanical installation Personnel must be qualified to prepare the installation site according to
the site and equipment requirements and to perform the installation
accordingly.

Electrical installation Personnel must have a sound knowledge of the relevant electrical codes
and specifications covering low and medium voltage equipment, and be
experienced with electrical wiring principles and know the electrical
symbols typically used in wiring diagrams.

Operation The personnel include all persons who operate the equipment from the
local operating panel of the drive. The personnel must know the functions
of the operating panel, be adequately trained for the equipment, and know
the driven process. Special knowledge of frequency converter technology
is not required.

Maintenance The personnel includes all persons who

• are qualified to carry out preventive and corrective maintenance on
equipment as described in this manual,
• are thoroughly familiar with the equipment,
• have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment,
• are able to assess the hazards associated with the energy sources of
the equipment and act correspondingly,
• know the safe shutdown and grounding procedures for the
equipment.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3 (8)

General information on manual and equipment ABB
Relevant chapters of the manual

Chapter Handling Installation Operation Maintenance

General information x x x x
Safety x x x x
Overview x x
Transport x
Mechanical installation x x
Electrical installation x
Operation x
Troubleshooting and x
maintenance

User’s responsibilities
It is the responsibility of those in charge of the equipment to ensure that
each person involved in the installation, operation or maintenance of the
equipment has received the appropriate training and has thoroughly read
and clearly understood the instructions in this manual and the relevant
safety instructions.

Intended equipment use

Those in charge of the equipment must ensure that the equipment is only
used as specified in the contractual documents, operated under the
conditions stipulated in the technical specifications and on the rating plate
of the equipment, and serviced in the intervals as specified by ABB.
Use of the equipment outside the scope of the specifications is not
permitted.
Intended equipment use also implies that only spare parts recommended
and approved by ABB must be used.
Unauthorized modifications and constructional changes of the equipment
are not permitted.

4 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB General information on manual and equipment

Quality certificates and applicable standards

The following certificates and conformity declarations are available with
ABB:
• ISO 9001 / ISO 14001 certificates stating that ABB Switzerland Ltd
has implemented and maintains a management system which fulfills
the requirements of the normative standards
• EC Conformity Declaration
• List of standards the drive complies with

Writing conventions
The following icons and text conventions are used in the manual.

Meaning of icons

Illustrates an illuminated lamp or pushbutton.

Illustrates a button or key to be pressed.

Arrows indicate an alternating display message.

Used to highlight text in Chapter 7 - Operating instructions that only

refers to drives with ARU.

Refers to further information in another chapter of this manual or in a

separate document.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5 (8)

General information on manual and equipment ABB
Text conventions
• Bulleted list
Used to list items or steps in a procedure, where the sequence does
not matter.
• Bulleted list of a subsection following a main paragraph
Used to list items or for procedures, where the sequence does
not matter
1 Steps of a procedure, to be followed in the specified order (e.g. 1, 2,
3...)
1 Figure legend identifies the items referred to in illustrations (e.g. 1, 2,
3.....)
Arial Bold is used to highlight switches to be operated, status messages
shown in a display and special terms.
UPPERCASE letters refer to a parameter.
Italic is used for references to illustrations, chapters and supplementary
documentation.

Related documentation
The following documents are available for supplementary information:

Title Document number

AF 100 fieldbus - NAFA-01 installation and start-up guide 3BFE58919837

ARU Main Transformer Specification 3BHS125092

Asynchronous Motor Specification 3BHS125088

CI858 DriveBus - user’s manual 3AFE68237432

DeviceNet - NDNA-02 installation and start-up guide 3AFY58919829

TM user
DriveMonitor manual 3BHS268039

Emergency Off/Stop Modes and Prevention of Operation 3BHS196243

Ethernet - user’s manual ethernet adapter module NETA-01 3AFE64605062

LSU Main Transformer Specification 3BHS125150

Main Circuit Breaker Specification 3BHS125149

Modbus - NMBA-01 installation and start-up guide 3AFY58919772

Power Cable Specification 3BHS125090

Profibus - NPBA-12 installation and start-up guide 3BFE64341588

Recycling instructions 3BHS122085

S800 I/O - General information and installation, user’s guide 3BSE020923

S800 I/O - Modules and termination units, user’s guide 3BSE020924

6 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB General information on manual and equipment

Title Document number

Synchronous Motor Specification 3BHS125093

Tool Sets for Installation, Commissioning and Maintenance 3BHS130246

Voltage Transformer Requirement Specification 3BHS125393

Identifying the delivery

The drive and accessories are identified by the type code printed on the
rating plate.
Besides information on equipment identification, the label provides
important information on rated voltage, frequency and current of the main
and the auxiliary power supply.

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.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7 (8)

General information on manual and equipment ABB

8 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

Chapter 1 - Safety

1.1 Meaning of safety instructions

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

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to personal injury.

The safety instructions are derived from the following standards:

• ISO 3864-2:2004 (E)
Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
• ANSI Z535.6
American National Standard for Product Safety Information in
Product Manuals, Instructions, and Other Collateral Materials

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1-1 (8)
Chapter 1 - Safety ABB
1.2 General safety information
To maintain safety and minimize hazards observe the following:
• Before the drive is energized, make sure that:
• all foreign objects are removed from the drive.
• all internal and external covers are securely fastened and all
doors are closed, locked and / or bolted.
• Before starting to work on the drive, make sure that:
• the main and auxiliary power supply to the drive is switched off,
locked out, and tagged out,
• the drive is dead,
• safety ground connections are in place,
• appropriate personal protective equipment is provided and used
when required,
• everyone involved is informed.
• Use appropriate personal protective equipment and observe the
safety data sheet of the used ion exchange resin and of the used
glycol when working on the water cooling unit.
• When working near the running drive protective earmuffs should be
worn.
• Before work is carried out simultaneously on the drive and on other
drive system equipment, make sure that:
• the relevant safety codes and standards are observed,
• all energy sources of the equipment are turned off,
• lockout and tagout devices are in place,
• barriers and appropriate covers are used on equipment which is
still live,
• everyone involved is informed.
• In case of fire in the drive room:
• Observe the established rules and regulations for fire protection.
• Only firemen with appropriate protective equipment are allowed
to enter the drive room.

1-2 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 1 - Safety

1.3 Possible residual risks

The following risks can arise from a drive system and pose a hazard to
people. These risks must therefore be taken into account by the system
integrator and / or the plant owner when assessing the risks of the
machinery.
• Electric power equipment generates electro-magnetic fields which
can cause a hazard to people with metal implants and / or a
pacemaker.
• Drive system components can move unintentionally when being
commissioned, operated, or serviced due to, for example:
• Operation of the equipment outside the scope of the specifica-
tions
• Incorrectly assembled or installed equipment
• Wrongly connected cables
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware
• Hazardous touch voltages can be present on drive system
components caused by, for example:
• Operation of the equipment outside the scope of the specifica-
tions
• External influence on, or damage of the equipment
• Induced voltages by external equipment
• Condensation on equipment components, or pollution
• Faulty hardware
• High temperatures, noise, particles, or gases can be emitted from
drive system components caused by, for example:
• Operation of the equipment outside the scope of the specifica-
tions
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware
• Hazardous substances can be emitted from drive system
components due to, for example:
• Incorrect disposal of components

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1-3 (8)
Chapter 1 - Safety ABB
1.4 Safety labels and signs

1.4.1 Safety labels

Safety labels are attached to the cabinet where necessary to alert
personnel of potential hazards when working on the equipment. The
instructions on the safety labels must always be followed, and the labels
must be kept in a perfectly legible condition.

Figure 1-1 Safety labels

1.4.2 Safety signs

Depending on the delivery, the following additional safety signs may be
provided:

Fire fighting The sign explains the procedure when fighting fire in electrical equipment.
The sign should be installed well visible near the drive.

Dimensions: 50 x 30 cm

1-4 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 1 - Safety

Pacemaker The magnetic field of the drive can influence the functioning of
pacemakers. The sign should be installed at the entrance to the drive
room or at a minimum distance of 6 meters from the drive to stop
personnel with pacemakers approaching the drive.

Diameter: 32 cm

High voltage The sign should be installed clearly visible at the main circuit breaker in
the switchgear room. The sign alerts personnel to the high voltage which
can be present on the secondary side of the input transformer until the
main circuit breaker has been opened and secured and the drive has been
de-energized and grounded.

Dimensions: 20 x 10 cm

1.5 Important note on main circuit breaker design

The main circuit breaker (MCB) is a major protection device of the drive.
If a serious fault occurs in the drive, the MCB must disconnect the main
power supply to the drive immediately. The main power supply must be
disconnected without delay on an open or trip command from the drive to
prevent hazard to the personnel and further damage to the equipment.
Depending on the main power supply configuration of the drive system,
the MCB is either located on the primary side of the converter transformer
or on the primary side of the drive if the drive is connected directly to the
line (DTL).

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1-5 (8)
Chapter 1 - Safety ABB

Main power supply

MCB

Protection CT

relay

MCB control interface

Converter
transformer

Higher-level
Drive control system
Local MCB control

Motor M

Figure 1 Drive system overview

Figure 1 shows the conceptual single-line diagram of a typical drive

system, including main power supply, MCB, converter transformer, drive
and electrical motor.
The MCB is defined as a switching device to disconnect the power supply
whenever required by the process or when a fault occurs. Typical devices
used as MCBs are:
• Vacuum circuit breakers
• SF6 circuit breakers
• Fused contactors or motor control centers
A dedicated protection relay is used for:
• Transformer or converter primary cable protection (DTL)
• Transformer protection (if applicable)

1-6 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 1 - Safety

• 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.

1.5.1 Safety and protection requirements

For safety and protection reasons, the MCB must meet the stipulated
minimum requirements of the specifications of ABB MV Drives. It is the
system integrator's responsibility to ensure that the minimum require-
ments are met. The minimum requirements for the MCB are stated in this
note and in the respective MCB specifications, which are available for
each medium voltage drive from ABB.
The safety requirements for the drive are based on the following
standards:
• ISO 13849-1 Safety of machinery - Safety-related parts of control
systems - Part 1: General principles for design, section 6.2.6
Category 3
• IEC 60204-1 Safety of machinery - Electrical equipment of machines
- Part 1: General requirements

1.5.2 Minimum requirements for MCB and MCB control

• The MCB open and / or trip command has to be wired directly from
the drive to the MCB. It is not permitted to wire the trip command
through any PLC or DCS system if it is not certified to meet SIL 3 level
requirements and to fulfill the timing requirements outlined below.
• The maximum opening time of the MCB shall never exceed the
product or project-specific maximum time defined in the MCB
specifications. Typical maximum values for the drive are defined as
follows:
• Maximum protection trip time: 75 ms
The maximum protection trip time is the maximum allowed
breaking time (open and arcing) of the breaking device after the
open command has been initiated to prevent further damage to
the drive, e.g. diode failures.
• Maximum safety trip time: 500 ms
The maximum safety trip time is the maximum allowed time to
ensure safe disconnection of the main power supply to prevent
any hazard to personnel.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1-7 (8)
Chapter 1 - Safety ABB

Short-circuit occurs

Open and or trip command is set at the

drive control output

No further damage to drive No hazard to personnel

Max. protection trip time

Max. safety trip time

Figure 2 MCB opening timing diagram

In order to meet the stipulated safety requirements, it is recommended

that:
• the MCB is equipped with two independent opening coils, or
• the MCB is equipped with one opening coil and an undervoltage coil
for monitoring of the control voltage, or
• an upstream 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. The upstream
breaker must open within the maximum safety trip time after a failure
has occurred.

1.5.3 Maintenance recommendation

The MCB trip circuits should be checked yearly.

1-8 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 2 - Features and hardware of the drive

This chapter describes the main design features and introduces the major
components of the drive.

2.1 Drive overview

1 2, 3 4 5 6 7

Figure 2-1 Drive overview (with Line supply unit)

1 LSU - Line Supply Unit, see 2.3.2 Line supply unit (LSU)
2 TEU - Terminal Unit, see 2.3.5 Terminal units (TEU)
3 COU - Control Unit, see 2.3.6 Control unit (COU)
4 INU - Inverter Unit, see 2.3.3 Inverter unit (INU)
5 CBU - Capacitor Bank Unit, see 2.3.4 Capacitor bank unit (CBU)
6 RBU - Resistor Braking Unit, see 2.3.11 Resistor braking unit (RBU)
7 WCU - Water Cooling Unit, see 2.3.7 Cooling system

2.2 Main features of the drive

The ACS 6000 is a medium voltage frequency converter for high power
induction and synchronous motors. The ACS 6000 covers a power range
from 3 to 27 MVA and delivers output frequencies from 0 to 75 Hz.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-1 (42)
Chapter 2 - Features and hardware of the drive ABB
The drive features several proven ABB technologies including:
• Direct torque control (DTC)
• Integrated gate commutated thyristor (IGCT)
• Active rectifier unit (ARU)
• Line supply unit (LSU)
• Common DC bus

Transformer Rectifier DC link Inverter

Figure 2-2 Typical block diagram of a 12-pulse LSU

Transformer Active rectifier DC link Inverter

Figure 2-3 Typical block diagram of a 6-pulse ARU

DTC The motor control method DTC (Direct Torque Control) developed by ABB
and proven in all frequency converters of the ACS product range is used
to control the speed and torque of the motor.
DTC offers:
• Accurate speed and torque control
• Minimized torque ripples
• Ten times faster torque response times than with control methods
such as flux vector or pulse width modulation

2-2 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

Torque reference Torque

Torque- Switching
reference flux logic
controller comparator
Speed reference
Speed
controller
Actual speed Switch
positions
Motor Voltage
model
Current
M

Figure 2-4 DTC principle

Switching of the inverter is directly controlled in accordance with the motor

core variables flux and torque.
The measured motor currents and DC link voltages 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 which are produced by the torque
and flux reference controllers.
Depending on the outputs from the hysteresis controllers, the switching
logic directly determines the optimum inverter switch positions every
50 microseconds. Switching takes place whenever required.

IGCT IGCTs (Integrated Gate Commutated Thyristors) are used as switching

devices in the inverter (see Figure 2-5). The IGCT combines fast switching
with low losses and enables a drive design with a low parts count.

Figure 2-5 IGCT

Active rectifier unit The ARU allows four-quadrant operation. Thus regenerative braking is
possible in both rotating directions of the motor over the whole power
range.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-3 (42)
Chapter 2 - Features and hardware of the drive ABB
The ARU controls the power factor to unity in the whole operating range
even at very low speeds. Optionally the ARU compensates reactive power
generated by other loads connected to the same network.
The ARU reduces and eliminates harmonics in the voltage applied to the
mains by using pre-defined, optimized pulse patterns.

LSU The LSU designed for two-quadrant operation maintains the power factor
at 0.95 in the whole operating range.

Common DC bus Multiple rectifiers and motor inverters can be connected to the same DC
bus. This allows several drives to be combined into one converter unit.
Braking energy generated in one motor can be transferred to other
inverters via the common DC bus without loading the rectifier.

2.3 Major components of the drive

This section provides an overview of a typical drive and its major
components.

See Appendix D - Electrical diagrams for further information on the

interconnection of the components.

2.3.1 Active rectifier unit (ARU)

2.3.1.1 Overview
The ARU controls the energy flow to the DC link and keeps the DC link
voltage at a constant level irrespective of changes in the supply network.
The ARU is designed as a self-commutated VSI in 6-pulse, 3-level
topology for the following power ratings:
• 7 MVA
• 9 MVA
• 9 MVA continuous / 11 MVA peak power
• 11 MVA continuous
The units differ in their electrical ratings but have the same mechanical
dimensions.
A maximum of three ARUs can be connected in parallel for higher drive
power ratings resulting in 12-pulse or 18-pulse rectifier configurations.

2-4 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

Figure 2-6 ARU cabinet layout

1 Gate unit supply

2 Voltage measurement
3 Phase modules
4 Water tubes
5 Anti-saturation equipment
6 Safety ground bar

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-5 (42)
Chapter 2 - Features and hardware of the drive ABB
2.3.1.2 Main components
The ARU consists of the following main components (refer also to Figure
2-8 and Figure 2-9):
• Phase modules consisting of integrated gate commutated thyristors,
diodes and clamp capacitors
The phase modules for all power ratings are identical in construction.
The types of semiconductors used vary depending on the power
rating. For this reason, phase modules for different power ratings
cannot be mixed in the same ARU or INU.

Figure 2-7 Phase module with IGCTs

1 Cooling water outlet

2 IGCTs
3 Antiparallel diodes
4 Rear busbar stubs
5 Cooling water inlet
• GUSP, an electrically isolated unit mainly supplying the IGCTs with
auxiliary power
• Clamping circuit with di/dt chokes and freewheeling diodes protecting
the circuit from excessive rises in current
• EMC filter protecting the transformer from excessive voltage slopes

2-6 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

• Interface circuit board (INT) serving as a communication interface to

the control system in the COU. The pulse firing logic for the IGCTs
and fast protection functions are integrated on the circuit board as
well. Fiber optic cables are used for transmission of data between the
interface circuit board and the control system and for the gate firing
signals of the IGCTs.
• FSCD monitoring the main power circuit for short circuits
• Anti-saturation equipment (ASE) preventing the converter
transformer from saturation
• Voltage and current measurement devices
• The DC voltage is scaled on the HVD circuit board. The resulting
signal and the signals from the AC current transducers are converted
to digital signals on the CVMI circuit board and transmitted to the
Interface circuit board via fiber optic cables.

FSCD
circuit
board

di/dt choke
DC (+)
Rclamp

L1,2,3 DC (NP)

EMC Rclamp
filters

DC (-)
di/dt choke
FSCD HVD
circuit circuit
board board
Gate firing pulses

L1,2,3

ASE CMVI
GUSP
circuit board circuit board

INT circuit board COU

Other INT

Figure 2-8 ARU local control and monitoring equipment

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-7 (42)
Chapter 2 - Features and hardware of the drive ABB
2.3.1.3 Circuit diagram

DC (+)

L1
L2
L3
DC (NP)

DC (-)

EMC filter Phase modules Clamping circuit

Figure 2-9 ARU circuit diagram

2.3.2 Line supply unit (LSU)

2.3.2.1 Overview
The LSU rectifies the AC line voltage and supplies electrical energy to the
DC link capacitors of the CBU (see section 2.3.4 Capacitor bank unit
(CBU). The available LSUs can be distinguished by pulse number and
power rating.

2-8 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.3.2.2 12-pulse LSU

The 12-pulse LSUs as illustrated in Figure 2-10 are used in combination
with a line-side converter transformer.

Figure 2-10 Cabinet layout of 12-pulse LSU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-9 (42)
Chapter 2 - Features and hardware of the drive ABB
1 Cable duct and control unit
2 di/dt limiting reactors
3 Rectifier monitoring unit
4 Snubber capacitor
5 Diode stacks of 12-pulse rectifier (including crowbar)
6 Pulse transformer
7 Snubber resistor
8 Water inlet tube
9 Safety ground busbar
12-pulse LSUs are available for the following power ratings:
• 3 MVA
• 5 MVA
• 7 MVA
• 9 MVA
• 14 MVA
Using the configuration rules for the ACS 6000, LSUs with the same power
rating can be operated in parallel to achieve 24-pulse rectification and/or
to increase the drive power.

Main components The LSU consists of the following main components (refer also to Figure
2-11):
• 12-pulse diode rectifier
• Snubber circuit limiting the rate of the voltage rise (dv/dt) across the
diodes and the crowbar thyristors
• di/dt limiting reactors defining the current rise in the thyristor crowbar
• Thyristor crowbar, a protection circuit which is activated should a
short circuit occur in the drive. By applying protection firing the
rectifier is shorted to prevent further damage of the drive.
• Pulse interface circuit board generating the firing pulses sent to the
crowbar thyristors via the pulse transmitters
• Diode rectifier monitoring unit for short circuit detection in the rectifier
(indirect method to detect faulty rectifier diodes)

2-10 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

Circuit diagram
Thyristor
crowbar
di/dt choke
DC (+)

1L1
1L2
1L3

Rnp
DC (NP)

2L1
2L2
2L3

di/dt choke
DC (-)
Diode rectifier Snubber circuit

Diode rectifier
monitoring unit
To / from
Pulse interface circuit board INU

Figure 2-11 Circuit diagram of 12-pulse LSU

2.3.2.3 6-pulse LSU

The 6-pulse LSUs are designed for applications without converter
transformer and are always operated with a line-side IRU as illustrated in
Figure 2-12. The main purpose of the IRU is to limit the input current and
to improve the Total Harmonic Distortion (THD) of the supply voltage.
IRU and 6-pulse LSU are available for the following power ratings:
• 3 MVA
• 5 MVA
• 7 MVA

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-11 (42)
Chapter 2 - Features and hardware of the drive ABB

1
2
3

7
8
9
10

Figure 2-12 Cabinet layout of 6-pulse LSU with IRU

1 IRU
2 LSU
3 Terminal unit
4 di/dt limiting reactors
5 Diode stacks of 6-pulse rectifier (including crowbar)
6 Snubber resistors
7 Pulse transformer
8 3-phase reactor
9 Water inlet tube
10 Safety ground busbar

Main components The IRU/LSU consists of the following main components (refer also to
Figure 2-13):
• IRU
• 3-phase input reactor
• Terminal unit for input cables

2-12 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

• LSU
• 6-pulse diode rectifier
• Snubber circuit limiting the rate of the voltage rise (dv/dt) across
the diodes and the crowbar thyristors
• di/dt reactors limiting the current rise in the thyristor crowbar
• Thyristor crowbar, a protection circuit which is activated should a
short circuit occur in the drive. The rectifier is shorted to prevent
further damage of the drive by applying protection firing.
• Pulse interface circuit board generating the firing pulses sent to
the crowbar thyristors via the pulse transmitters
• Rectifier monitoring unit for short circuit detection in the rectifier
(indirect method to detect faulty rectifier diodes)

Circuit diagram
Thyristor
1 2 crowbar di/dt choke
DC (+)

1L1
1L2
1L3

di/dt choke
DC (-)

Diode rectifier with snubber circuit

Diode rectifier
Monitoring unit
To / from
Pulse interface circuit board INU

Figure 2-13 Circuit diagram of 6-pulse LSU with IRU

1 IRU
2 LSU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-13 (42)
Chapter 2 - Features and hardware of the drive ABB
2.3.3 Inverter unit (INU)

2.3.3.1 Overview
The INU converts the DC voltage to the AC motor voltage. The self-
commutated, 6-pulse, 3-level VSI allows four-quadrant operation.
The available INUs are distinguished by their power rating and design.
The compact 3 and 5 MVA units as illustrated in Figure 2-14 with the
vertical alignment of the inverter phase modules have their COU and the
TEU for the motor cables incorporated in different sections of the same
cabinet.
See sections 2.3.6 Control unit (COU) and 2.3.5 Terminal units (TEU) for
further information on COU and TEU.

Figure 2-14 3 and 5 MVA Units

1 Phase module of the inverter

2 COU
3 TEU (behind COU)
The bigger 7, 9 and 11 MVA units as presented in Figure 2-15 have the
same layout and components as the ARU except for the anti-saturation
equipment which is not needed for motor operation. See 2.3.1 Active
rectifier unit (ARU) for further information.
Depending on the application, up to five INUs with different power ratings
can be connected to the same DC bus.

2-14 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

Figure 2-15 7, 9 and 11 MVA INUs

1 Gate unit supply

2 Voltage measurement
3 Phase modules
4 Water tubes
5 Safety ground bar

2.3.3.2 Circuit diagram

DC (+)

L1
L2
L3
DC (NP)

DC (-)

Clamping circuit Phase modules EMC filter

Figure 2-16 Circuit diagram of 7, 9 and 11 MVA INUs

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-15 (42)
Chapter 2 - Features and hardware of the drive ABB

DC (+)

L1
L2
L3
DC (NP)

DC (-)

Clamping circuit Phase modules EMC filter

Figure 2-17 Circuit diagram of 3 and 5 MVA units

2.3.4 Capacitor bank unit (CBU)

2.3.4.1 Overview
The CBU smoothes the intermediate DC voltage and decouples the
rectifier from the inverter. The CBU contains DC link capacitors, a charging
unit and a grounding switch.
The CBU is available in two different sizes depending on the power rating
of the drive (size 1 for drives up to 9 MVA and size 2 for drives rated for 9
to 14 MVA).
For high power drives, two CBUs of the same size can be installed on the
same DC link.

2.3.4.2 Main components

The CBU consists of the following main components (refer also to Figure
2-18):
• Water-cooled DC link capacitors
• Charging unit for the DC link capacitors consisting of an auxiliary
transformer and a small diode rectifier
• The capacitors are charged before the drive is connected to the main
power source to avoid excessive inrush currents after the MCB has
been closed.
• Optional discharging unit, needed to discharge the DC link capacitors
when the drive is shut-down and none of the following units are part
of the ACS 6000:
• VLU
• RBU
• BCU

2-16 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

• Grounding switch, a safety switch to ground the DC bus of the drive

The grounding switch can only be closed if the DC link capacitors
have been discharged.
• Optional coupling device for monitoring the insulation resistance

2
3

7
8

Figure 2-18 CBU cabinet layout

1 Cable duct
2 Grounding switch
3 DC busbars
4 DC link capacitors
5 Charging unit
6 Dummy capacitor
7 Connection PE - PG
8 Water inlet tube
9 Safety ground busbar

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-17 (42)
Chapter 2 - Features and hardware of the drive ABB
2.3.4.3 Circuit diagram

Capacitors Charging unit

DC(+)
DC(NP)
DC(-)

Grounding switch

PE

Figure 2-19 CBU circuit diagram

2.3.5 Terminal units (TEU)

2.3.5.1 Overview
Mains and motor cables of the ACS 6000 are connected to their
corresponding busbars inside TEUs. TEUs are designed for top or bottom
cable entry.
TEUs are available either as separate cabinets or they are integrated into
other cabinets. The number and type of TEUs present in a line-up depend
on the type and the power ratings of the line rectifier (LSU or ARU) and the
power ratings of the motor inverter (INU):
• The TEU for the 3, 5 and 7 MVA 6-pulse LSU is combined in the IRU
cabinet (see Figure 2-12).
• The TEU for the 3 and 5 MVA INUs is combined in the INU cabinet
(see Figure 2-14).
• A common TEU can be used in combination with 3, 5, 7 and 9 MVA
12-pulse LSUs and 7, 9 and 11 MVA peak INUs.
• 14 MVA LSUs always require a separate TEU. See Figure 2-20 and
Figure 2-21 (Figure 2-20 shows the TEU with the swing frame of the
COU opened).
• 11 MVA continuous INUs/ARUs always require a separate TEU. See
Figure 2-20.
The width of the cabinet (600 mm or 1000 mm) is determined by the
number of line rectifiers and/or motors to be supplied via one TEU. If
required by the configuration of the ACS 6000, cabinets without a
COU can also be present in the line-up.

2-18 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

7
8

Figure 2-20 TEU (1000 mm wide), swing frame of COU open

1 Ground terminals for grounding set

2 AC busbars
3 Phase designation
4 Roxtec frame
5 Power cable entry section (bottom)
6 Power ground busbar
7 Safety ground busbar
8 Ground terminals for grounding set

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-19 (42)
Chapter 2 - Features and hardware of the drive ABB
2.3.6 Control unit (COU)

2.3.6.1 Overview
The COU incorporates the hardware for control, monitoring and protection
functions of the line rectifier or the inverter it is assigned to. The COU also
includes the interfaces to the local control panel on the front door and to a
higher-level process control system.

9
2

3
10
4

11 5

12 6
13 7

14

15

16 8
17

18

Figure 2-21 COU control swing frame installed in a TEU (typical configuration)

2-20 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

1 Position (gray) encoder interface1(either one or two encoders

possible)
2 Speed encoder interface1
3 Main circuit breaker control circuit board
4 24 VDC distribution terminals
5 Auxiliary relays for main circuit breaker control
6 Insulation monitor1
7 230 VAC distribution terminals
8 Synchronizing equipment for ARU2
9 24 VDC power supply units
10 S800 I/O modules
11 Safety relays of emergency off circuit
12 INU operation prevention devices1
13 Timer relays1
14 Auxiliary relays1
15 Circuit breaker for charging transformer
16 Miniature circuit breakers1
17 230 VAC socket
18 Auxiliary power supply equipment1

1.option, depends on the configuration of the drive

2.only drives with ARU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-21 (42)
Chapter 2 - Features and hardware of the drive ABB

A B A B

A B

4
1

2
6

7
6

9
10

3
11
12

Figure 2-22 Reverse side of COU doors (typical configuration)

1 Fan unit
2 Redundant drive interface1
3 Pocket for documentation
1.option, depends on the configuration of the drive

2-22 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

4 Fan unit
5 Branching unit1
6 Local control panel
7 24 VDC distribution terminals
8 Branching unit1
9 INT circuit board2
10 AMC circuit board3
11 INT circuit board4
12 AMC circuit board
The hardware components of a COU are mounted on a swing frame. The
type and number of the fitted components are determined by the
configuration of the ACS 6000. The size of the swing frame and the
mounting position of the components depend on the cabinet the swing
frame is installed in. See Figure 2-14 for the illustration of the swing frame
in 3 and 5 MVA INUs and Figure 2-21 for the illustration of the swing frame
in a TEU.
The number of COUs in a line-up depends on the configuration of the
ACS 6000:
• A separate COU is assigned to an ARU in combination with 3 and
5 MVA INUs.
As a standard, an ARU in combination with 7, 9 and 11 MVA INUs
shares the COU of the first INU. Depending on the selected options
and the configuration of the drive, a separate COU is used for the
ARU.
When a LSU is part of the drive, all rectifier and line related functions
are implemented in the COU of the first INU.
• A separate COU is assigned to each INU supplying its own motor.
Several INUs supplying one motor share the same COU.

2.3.6.2 Main components

The COU consists of the following main components (refer also to
Figure 2-21 and Figure 2-22):

AMC circuit board The AMC controller is a digital signal processor for general drive and
motor control, and closed loop functions.

1.option, depends on the configuration of the drive

2.only drives with parallel ARUs
3.only drives with ARU
4.only drives with two INUs supplying a motor

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-23 (42)
Chapter 2 - Features and hardware of the drive ABB
The control system is based on ABB’s Application and Motor Controller
(AMC), see Figure 2-22. Fitted with a Motorola DSP processor, the
controller features two PPCS and eight DDCS communication channels.
PPCS (Power Plate Communication System) and DDCS (Distributed
Drive Control System) are acronyms for serial communication protocols
tailored for high speed data transfer via fiber-optic cables, namely with:
• Drive and excitation control interfaces
• Higher-level process control systems via Advant or Fieldbus adapters
• S800 I/O process system, see section below
• Service tools (e.g. DriveWindow, DriveMonitorTM)

S800 I/O process S800 I/O process system with digital and analog I/Os transferring drive
system related hardwired signals to the AMC controller.
Internal and external digital and analog I/O signals are connected to the
control system of the drive by standard ABB Advant S800 I/O modules.
The I/O station consists of a bus modem serving as an interface to the
AMC controller and the I/O modules. Each I/O module is plugged into a
termination unit which is wired to separate terminals where the external
signals are connected to.

Local operator panel The local operator panel on the door of the COU provides all control
devices to operate the drive, e.g. for test purposes or when the higher-
level control system is out of operation. See Chapter 8 - CDP control panel
for further information on the functions of the local operator panel.

CDP Control panel The CDP control panel is a door-mounted user interface for local
operation. The CDP control panel is the same panel as used on all
frequency converters of the ACS family. It is an intelligent digital control
panel with function keypad and LCD display and provides full control of the
drive and allows adjustment of the drive parameters.
The AMC controller communicates with the CDP control panel (see Figure
2-22) which is mounted on the door of the control unit. The CDP control
panel serves as a basic user interface for monitoring, control and
operation of the drive and changing of parameters. The communication of
the AMC controller with the CDP control panel is accomplished via a RS-
485 link.
The key features of the CDP control panel are:
• 4-line display for easy monitoring,
• user selectable display of actual values, such as motor speed,
current, voltage, torque, power,
• fault memory to support maintenance.
The CDP control panel allows the operator:
• to enter startup data into the drive,
• to control the drive by setting reference values and by giving start,
stop and direction commands,

2-24 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

• to display three actual values at a time,

• to display and set parameters,
• to display information on the last 64 fault events.
See Chapter 7 - Operating instructions, 7.3 Control panels for further
information.

CDP control panel

SUPPLY
OFF ON

ALARM RESET Local control buttons

FAULT EMERGENCY OFF

EMERGENCY OFF

Figure 2-23 Local operator panel

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-25 (42)
Chapter 2 - Features and hardware of the drive ABB

COU Inverter control

PC tool or DriveMonitorTM

Process I/O
Process control
system Control panel

ABB
Fieldbus S800
advant
adapter
control

Rotor speed (optional)

AMC
NTAC

LSU INU
FT-link
INT
PPCS
PPCS

IOC

PINT

HVD + CVMI
VNP to ground

Diode
monitoring
VDC-
FSCD
FSCD

EAF
IA...IC
VDC+

IM

To NTAC (optional)
PG
(optional)

Figure 2-24 Single-motor drive with LSU

See Appendix D - Electrical diagrams for details on the configuration of the

control system of the drive.

2-26 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.3.7 Cooling system

2.3.7.1 Water cooling units

The water cooling unit is available in five different versions:
• Types 029 and 052 with horizontal pumps
• Types 080, 106 and 120 with vertical pumps
The type of the WCU present in a drive depends on the required cooling
capacity.

See the two documents in Appendix A - Additional manuals for further

information:
• User’s manual for water cooling unit for types 029 and 052
• User’s manual for water cooling unit for types 080, 106 and 120

2.3.7.2 Air-to-air heat exchangers

Drives with high output power demand are additionally equipped with roof-
mounted heat exchangers, which ensure a constant air flow through the
power units thus transferring the heat from non-water-cooled components
to the exterior. The fans of the heat exchangers are controlled by
thermostats and are switched on when the air temperature exceeds the
adjusted starting threshold of the fans.
Two LEDs on the front of the heat exchanger inform about the status of the
unit (see Figure 2-26). Alarm signals are also shown on the CDP control
panel.
The auxiliary transformer on the roof is installed only if the drive is
equipped with heat exchangers (see Figure 2-25).

Figure 2-25 Roof heat exchangers

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-27 (42)
Chapter 2 - Features and hardware of the drive ABB

Red LED off, green LED on:

Heat exchanger is healthy

Red LED on, green LED off:

Alarm condition

Red LED off, green LED off:

Auxiliary voltage missing

Figure 2-26 Air-to-air heat exchanger

Fan unit in COU A thermostat-controlled fan unit in the upper part of the door of the COU
circulates the air inside the control unit. The air is drawn in through an inlet
at the bottom of the door and leaves the cabinet through the outlet at the
top (see Figure 2-27).

Fan unit in WCU Like the COU, the WCU is equipped with a thermostat-controlled fan unit.
The fan unit is installed in the upper section of the door and transfers the
heat from the components in the control compartment of the cabinet to the
exterior.

2-28 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

TEU and COU WCU 080,

106 and 120

Figure 2-27 Air inlet and outlet in TEU, COU and WCU

2.3.8 Customer interface unit (CIU/CIW)

2.3.8.1 Overview
The Customer Interface Unit houses optional I/Os to monitor transformer
and motors of multi-motor drives. The following units are available:
• CIU1/CIW1 provides a set of predefined I/Os. The I/O modules are
connected to an AMC circuit board.
• CIUe provides engineered project specific interfaces.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-29 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-28 WCU 029 or 052 with CIW box

1 CIW

2-30 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

Figure 2-29 CIU, typical cabinet layout

2.3.8.2 Main components

The CIU/CIW consists of the following main components:

CIU1/CIW1 • Five additional I/O modules (S800 modules) with predefined I/Os for
auxiliaries of each motor
• Predefined I/Os for transformer auxiliaries

CIUe • Customer specific I/O configuration

• Application controller with customer specific application software

2.3.9 Input filter unit (IFU)

2.3.9.1 Overview
The IFU reduces harmonic voltages injected to the supply network and is
used in combination with 6-pulse ARUs connected to a weak supply
network. The IFU is a tuned filter located between the converter
transformer and the ARU.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-31 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-30 IFU cabinet layout

1 Filter resistors
2 Filter capacitors
3 Filter reactor

2.3.9.2 Main components

The IFU consists of the following main components:
• Decoupling reactors in the main circuit
• Filter reactor
• Filter capacitors
• Damping resistors

2-32 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.3.9.3 Circuit diagram

1 2 3
1a 3a

1b 3b
1c 3c

Figure 2-31 IFU, circuit diagram

1 TEU: 1a = L1 TEU, 1b = L2 TEU, 1c = L3 TEU

2 IFU
3 ARU: 3a = L1 ARU, 3b = L2 ARU, 3c = L3 ARU

2.3.10 Voltage limiter unit (VLU)

2.3.10.1 Overview
The VLU dynamically discharges the DC link capacitors to the normal level
should an overvoltage occur. Discharging takes place by a set of resistors
which are switched on by IGCTs (see Figure 2-33).
The VLU is used in applications (typically metals and mining) requiring
dynamic changes between motoring and braking modes.
The ratings of the VLU depend on the size of the drive.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-33 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-32 VLU cabinet layout

1 Air-cooled resistors
2 IGCTs

2.3.10.2 Main components

The VLU consists of the following main components:
• Resistors, protected against overload by means of a software based
thermal model.
• VLU short circuit detection (VLSCD). Feedback signals from the
VLSCD are used to monitor the correct switching of the IGCTs.

2-34 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.3.10.3 Circuit diagram

1 DC(+)
2

DC(NP)

2
DC(-)

Figure 2-33 VLU circuit diagram

1 VLU
2 VLSCD circuit board
3 INU
4 INT circuit board

2.3.11 Resistor braking unit (RBU)

2.3.11.1 Overview
The RBU is used in drive applications where fast braking is required but
regenerative braking is not possible (e.g. marine applications). Typically,
the RBU is part of an ACS 6000 with a LSU.
The RBU is available for a braking power of 0.5 to 0.8 MW and a total
energy dissipation of 10 MW per braking cycle. The energy generated
during braking is dissipated in a set of water-cooled resistors which are
switched on and off by IGCTs (see Figure 2-35). When utilizing the full
braking capability, a cool-down phase of 20 minutes between two braking
cycles is necessary. The braking power can be doubled by adding a
cabinet with another set of resistors.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-35 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-34 RBU cabinet layout

1 IGCTs
2 Water-cooled resistor

2.3.11.2 Main components

The RBU consists of the following main components:
• Water-cooled resistors, protected against overload by means of a
software based thermal model
• RBU short circuit detection (VLSCD). Feedback signals from the
VLSCD are used to monitor the correct switching of the IGCTs.

2-36 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.3.11.3 Circuit diagram

1 DC(+)
2

DC(NP)

2
DC(-)

Figure 2-35 RBU circuit diagram

1 RBU
2 VLSCD circuit board
3 INU
4 INT circuit board

2.3.12 Braking chopper unit (BCU)

2.3.12.1 Overview
An ACS 6000 can be equipped with a BCU when effective motor braking
and short deceleration times are required but regenerative braking is not
possible (e.g. ACS 6000 with LSU).
The BCU houses the braking chopper hardware and the busbar
termination for the braking resistor cables and is connected to the DC bus.
The BCU is available for various sizes and types of external braking
resistors. The resistors are dimensioned based on the required braking
power (up to 2.3 MW) and energy. The resistors connected to the positive
(a in Figure 2-36) and negative DC voltage (b in Figure 2-36) must have
identical electrical ratings.

2.3.12.2 Main components

The BCU consists of the following main components:
• Braking chopper with IGCTs, diodes and snubber circuit
• Terminals for external braking resistors

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-37 (42)
Chapter 2 - Features and hardware of the drive ABB
• BCU short circuit detection (VLSCD). Feedback signals from the
VLSCD are used to monitor the correct switching of the IGCTs.

2.3.12.3 Circuit diagram

1 DC(+)

a
5 DC(NP)
b

DC(-)

Figure 2-36 BCU circuit diagram

1 BCU
2 VLSCD circuit board
3 INU
4 INT circuit board
5 External braking resistors

2-38 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.4 Overview of busbars and ground connections

Cable entry from top

LSU TEU INU CBU WCU EXU (CIU)

DC (-)
DC (NP)
DC (+)
1L1
1L2
1L3

L3
L2
L1
2L3
2L2
2L1
PG
PE

Cable entry from bottom PG to PE connection in CBU

Connecting point of system ground

Figure 2-37 Principal busbar arrangements

AC Busbars 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 line-up.

See the Converter hardware diagram in Appendix D - Electrical diagrams

to assign incoming feeder and motor cables to their corresponding TEU.
The incoming busbars are interconnected with the line rectifier unit (ARU
or LSU) and the outgoing busbars with the motor inverter(s) (INU). The
busbars can be identified by their phase designations.

DC Busbars The DC busbars connect the line rectifiers (ARU or LSU) with motor
inverter(s) (INU) and CBU. In multi-motor configurations up to four DC
busbar arrangements can be installed (see Chapter 4 - Mechanical
installation, 4.6.8 Joining DC busbars). The busbars are mounted in the
upper part of the drive and are marked with DC (+), DC (-) and DC (NP).

2.4.1 Grounding switch

The grounding switch is a safety switch to ground the DC bus of the drive.
The grounding switch can only be closed if the DC link capacitors have
been discharged.
The grounding switch is installed on the capacitor bank unit (CBU). The
switch can only be actuated if released by the drive (see Figure 2-38).
When the grounding switch is released, the indicator lamp on the door of
the CBU lights up. The indicator lamp has an integrated momentary
pushbutton to test the lamp. The lamp lights up when the pushbutton is
pressed.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-39 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-38 Grounding switch on CBU

1 Indicator lamp with lamp test function

signals when grounding switch can be turned into position "grounded"
2 Grounding switch, grounds the drive

See Appendix D - Electrical diagrams for further information.

Capacitors Charging unit

DC(+)
DC(NP)
DC(-)

Grounding switch

PE

Figure 2-39 Grounding the drive

2-40 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 2 - Features and hardware of the drive

2.5 Control switch for DC link isolator

Figure 2-40 shows the control switch for the optional DC link isolator. The
switch is used to open and close the DC link isolator.
Indicates open position of DC link
isolator

Indicates closed position of DC link

isolator

Opens/closes DC link isolator

Figure 2-40 Control switch for DC link isolator

Opening and closing of the DC link isolator is only possible after the DC
link has been de-energized. When the drive is in operation, it must first be
stopped and the DC link be discharged. Discharging of the DC link is
initiated by opening the main circuit breaker. The discharged condition of
the DC link is indicated with the lamp Grounding Switch Unlocked. As
soon as the lamp lights up, the grounding switch of the drive (located on
the door of the CBU) can be turned into the grounded position and
operation of the DC link isolator is released. When the signal is present,
the isolator moves to the position which has been selected.

2.5.1 Excitation unit (EXU)

The EXU is delivered as part of the frequency converter when a
synchronous motor has to be supplied with excitation power.
Communication between drive and excitation unit is achieved via optical
fibers.
EXUs are available in an air-cooled and a water-cooled version for the two
excitation methods of the synchronous motor:
• Brush excitation (DC excitation)
• Brushless excitation (AC excitation)
Air-cooled EXUs (aEXU) can either be integrated in the converter line-up
or supplied separately as a stand-alone unit. Water-cooled EXUs (wEXU)
are always integrated in the converter line-up.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 2-41 (42)
Chapter 2 - Features and hardware of the drive ABB

Figure 2-41 ACS 6000 with EXU lineup

1 aEXU or wEXU integrated in lineup

2 aEXU separate (grouped) lineup
3 aEXU standalone lineup

See the User’s manual for Brush and brushless excitation units for further
information on the various types of excitation units, their installation,
operation and maintenance.

2.6 Door interlocking

The medium voltage cabinets are equipped with an electromechanical
interlocking system. The door locks are released if the safety grounding
switch is closed and the auxiliary voltage is on. The doors are equipped
with position switches. The safety grounding switch is only released for
opening if all the doors are closed.
The doors of CIU, COU, EXU and WCU are not part of the interlocking
system and may also be opened during drive operation.

2-42 (42) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 3 - Transportation, storage and disposal

3.1 Safety
The drive must only be handled by personnel who are skilled and
experienced in unpacking and transporting heavy equipment.

3.2 Transport conditions

The transport conditions for the drive are based on IEC 60721-3-2
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Transportation'.
Classification: 2K4 / 2B1 / 2M1
Transport time: max. 2 months

See Appendix B - Technical data for further information.

3.3 Unpacking and inspection

Proceed as follows:
1 Remove all packaging material carefully.
2 Check the drive and accompanying equipment for damages.
3 Compare the complete delivery with the purchase order and the
packing list.
4 If parts are missing or damaged, immediately inform the shipping
company and the ABB service organization.
It is recommended to photograph the damages and send the photo-
graphs to ABB.

3.4 Identifying drive units

If a delivery comprises transport units for several drives, the transport units
need to be identified and assigned to the drive to which they belong. For
this purpose, the drives have been numbered on the accompanying
papers (e.g. drive 1, drive 2 etc.). The corresponding information is
provided on:
• the packing list, attached to the packaging of each transport unit
and
• the packing label on the back wall of each drive unit (LSU, INU etc.).
The packing label is only visible after the packaging has been
removed.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3-1 (8)
Chapter 3 - Transportation, storage and disposal ABB
3.4.1 Packing list
Transport units which belong to a particular drive are identified with the
help of the commodity description on the packing lists. The identical
column of the packing list states the number of the drive to which the
transport unit belongs (see section of packing list in Figure 3-1).

the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
shown on this packing list.

ABB item Qty. Unit. Identnumber Commodity description

Customer item

001201 1 PC Converter 1: Transport Unit 1

ABB Switzerland Ltd

Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zürich/Switzerland
CH-5401 Baden/Schweiz +41 58 589 27 95 755749 abb ch +41 58 589 29 84

Transport units where packing lists have the same number

in this place belong to one drive
Figure 3-1 Identifying the drive on the packing list

Separately delivered crates with accessories such as tools and installation

material are also assigned to a drive by means of the packing list. The item
number in column "ABB Item / Customer item" provides the necessary
information (see section of packing list in Figure 3-2).

3-2 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 3 - Transportation, storage and disposal

the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
shown on this packing list.

ABB item Qty. Unit. Identnumber Commodity description

Customer item

001221 1 PC cross wiring

001222 1 PC WCU accessory
001223 1 PC crank for isolator
001500 1 PC 3BHB013202R0001 6
ACS5000 Max-SL LOSE TEILE konfig.
ABB Switzerland Ltd
Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zürich/Switzerland
CH-5401 Baden/Schweiz +41 58 589 27 95 755749 abb ch +41 58 589 29 84

The number in this place (4th digit from right) states the drive to which
the accessories belong. In this example they belong to drive 1.

Figure 3-2 Identifying the drive on the accessories packing list

3.4.2 Packing label

The packing labels on the back walls of drive units can also be used for
identification (see Figure 3-3).

ABB Packing Label 0000

Material no 3BHB009964R1500 1 ST
Material Schrank kpl. LSU konfig
Order no/positions 11027727 001241 Project CBA
Material Document
004902892300012004

001241

The number in this place (4th digit from right) identifies

the drive to which the transport unit belongs.

Figure 3-3 Identifying the drive on the packing label

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3-3 (8)
Chapter 3 - Transportation, storage and disposal ABB
3.5 Lifting and transportation
It is recommended to have the following information at hand before
transporting the drive:
• Appendix C - Mechanical drawings provides details on dimensions,
weight, and of center of gravity of the drive.

3.5.1 General notes on transportation

NOTICE
The drive or parts of the drive could be damaged while moving and/or
unpacking the drive.
Observe the following points when transporting the drive:

• Do not lift and move the drive or a transport unit using a forklift. The
frame of the cabinets could be damaged.
After the transport units have been joined, the drive must not be lifted
and moved by crane. Appropriate transport means such as heavy
load hydraulics rollers or air cushions must be used instead. If in
doubt, contact ABB for instructions.
• The drive must be transported in an upright position.
• When transporting the drive, ensure that no dirt enters. Keep doors
closed. Metallic dust in particular may cause damage and lead to
malfunction when the drive is powered up.
• When lifting a drive always use the lifting lugs which are attached to
the base frame. It is recommended to remove the lugs after the drive
has been installed at its final location to prevent people from
stumbling.
• Do not pass a cable or sling through the fastening hole of a lug.
Use a safety hook or a shackle to attach a cable or a sling to a lug.
• Connect a cable or sling to each lug.
• Observe the center of gravity.
• It is recommended to use lift frames or lift spreaders (as shown in
Figure 3-4) with the crane.

3-4 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 3 - Transportation, storage and disposal

Protect
edges!

Figure 3-4 Lift spreader

If lift frames or lift spreaders are not available, make sure that the
cables or slings are at the appropriate angle to ensure a balanced lift.
• Protect the roof edges of the cabinets using appropriate means.
• Lift the drive slowly and steadily to the required clearance height
maintaining the drive in upright position.
• Check the horizontal position of the drive. Reposition the cables if
necessary.
• If a delivery comprises transport units for several drives see 3.4
Identifying drive units, for information how transport units belonging
to a particular drive are identified.

3.6 Storage

3.6.1 Storage conditions

The minimum requirements for storage are based on IEC 60721-3-1
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage'.
Classification: 1K4 / 1Z3 / 1B1 / 1M3

See Appendix B - Technical data for further information.

The drive can be stored for up to 1 year in the original packaging as long
as it is not damaged or opened. For information on longer storage periods
contact the ABB service organization.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3-5 (8)
Chapter 3 - Transportation, storage and disposal ABB
3.6.2 Storage
If the drive is taken out of service for a longer time proceed as follows:
1 Drain the cooling circuit completely or add the appropriate amount of
glycol for frost proofing, if the drive is to be stored in ambient temper-
atures below 0 °C (32 °F).

See Appendix A - Additional manuals, Water cooling manual for infor-

mation on drainage and frost proofing.
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:
• 1 unit desiccant (30 g) absorbs 6 g water vapor.
The following quantity is needed when using a polyethylene foil:
• 10 units/m2 foil
4 Close and lock the doors of the drive.
5 Use polyethylene or equivalent for packaging:
• 0,3 g/sqm/24 h water vapor diffusion
6 Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly.
Any damages which occur during the storage period should be repaired
immediately.

3.7 Storage and handling instructions for spare parts

NOTICE
Static electricity can damage printed circuit boards.
Apply static-sensitive precautions when handling these components.

Check the spare parts immediately after receipt for damages. Report any
damage to the shipping company and the ABB service organization.
Observe the following to maintain spare parts in good condition and to
keep the warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in antistatic bags or boxes.
• Storage temperature range: -5 °C to + 55 °C (23 °F to 131 °F)
• Storage place requirements:
• Free of vibration and shock
• Protected against dust, sand, vermin and insects

3-6 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 3 - Transportation, storage and disposal

• Free of corrosive gases, salt or other impurities that could

damage electronic equipment
• Dry, no condensation
Relative air humidity: 5 to 85%
If in doubt whether the maximum allowed humidity is exceeded,
protect spare parts by an external heater.
• Do not touch a circuit board without wearing a wrist grounding
strap.
• Put the component on a grounded working surface protected
against electrostatic discharges.
• Hold the component only at the edge.

3.8 Disposal of packaging materials and components

Dispose of the packaging materials and the components at the end of the
lifetime of the drive according to local regulations.

See the document 3BHS122085 Recycling instructions for further

information on disposal of packaging materials and components of the
ACS 6000.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3-7 (8)
Chapter 3 - Transportation, storage and disposal ABB

3-8 (8) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 4 - Mechanical installation

4.1 Safety
All installation work must be carried out by qualified personnel according
to the site and equipment requirements and in compliance with local
regulations.

4.2 Overview on installation work

The installation includes the following items:
• Aligning and joining transport units
See section 4.6.2 Aligning the transport units.
• Attaching sealing tape
See section 4.6.3 Attaching the sealing tape.
• Installing roof joints
See section 4.6.4 Installing roof joints.
• Installing roof attachments
See section 4.6.5 Installing roof attachments.
• Installing the air-to-air heat exchangers
See section 4.6.6 Installing roof-mounted heat exchangers.
• Joining internal water pipes
See section 4.6.7 Joining water pipes.
• Joining DC busbar
See section 4.6.8 Joining DC busbars.
• Joining ground busbars
See section 4.6.9 Joining ground busbars.
• Joining AC busbars in ARU, INU and IFU
See section 4.6.10 Joining AC busbars in ARU, INU, IFU.
• Joining AC busbars in LSU
See section 4.6.11 Joining AC busbars in LSU.
• Fitting raw water pipes
See section 4.6.12 Raw water circuit.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-1 (34)
Chapter 4 - Mechanical installation ABB
4.3 General notes on installation

NOTICE
When installing the drive ensure that no dirt enters. Always close the doors
when work is discontinued and completely cover openings. Metallic dust
in particular may cause malfunction when the drive is energized and cause
damage.

NOTICE
When joining two cabinets do not damage or dislocate the EMC sealing
strip which is glued onto the outer joining surface of the cabinet frame.

NOTICE
Do not weld cabinets without base frame to the floor. The corrosion protec-
tion will become ineffective.

NOTICE
The roof plates of the cabinets are not designed as a mounting base for
foreign devices, cable ducts etc. Therefore, it is not permitted to install any
foreign devices on the cabinet roofs.

4.3.1 Dimensions and clearances

See Layout drawing in Appendix C - Mechanical drawings for information

on:
• Cabinet dimensions
• Clearances to be observed
• Mounting hole sizes

4.3.2 Ambient operation conditions

Ambient factors for the operation of the drive, such as temperature,
relative humidity, air contamination, shock and vibration must be in
compliance with the stated maximum permissible levels.
Contact the ABB service organization if the condition of the installation site
is not within the specifications or if the transportation or the installation
require special measures.

4-2 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

See:
• Rating label of drive for maximum ambient temperature
• Appendix B - Technical data for information on climatic and
environmental conditions is based on IEC 60721-3.
Classification: 3K3 / 3B1 / 3C2 / 3S2 / 3M3

4.3.3 Foundation and floor surface requirements

To ensure proper alignment and installation, it is imperative that the
following requirements are adhered to:
• The floor must be able to support the weight of the cabinets
(min. 1’100 kg/m2).
• The overall incline of the floor across 5 m must not exceed 10 mm.
• The floor must be even.
• The adjoining surfaces of the transport units must meet perfectly all
around.
• The cabinets must not be off-center after the alignment.

4.3.4 Cable ducts

Cable ducts should be of non-flammable material with non-abrasive
surface.
All cable entries and exits should be protected to prevent dust, humidity
and animals from entering into the drive.

4.3.5 Fire protection

Suitable fire protection measures should be applied to prevent fire from
spreading into the drive.

4.3.6 Cabinet roof

The cabinet roof is not designed as a mounting base for foreign devices,
cable ducts etc. Therefore, it is not permitted to install any foreign devices
on the roof.

4.3.7 Floor fixings

Floor fixings are not supplied. Screws and nuts of size M20 (3/4") are
recommended.

See Appendix C - Mechanical drawings to locate the fixing holes in the

base frame.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-3 (34)
Chapter 4 - Mechanical installation ABB
4.4 Mechanical door interlock
The doors of the medium voltage units (units with names plates: LSU,
ARU, IFU, IRU, CBU, INU, BCU, RBU, VLU, TEU, ISU) are equipped with
a solenoid interlock which ensures that a door cannot be opened when the
converter is energized. The doors can also not be opened, when the
converter is disconnected from the auxiliary power and the solenoid
interlock is in “locked” position. To be able to open the doors for the
installation of the converter, the solenoid interlocks are unlocked before
the converter leaves the factory. If a door cannot be opened, however, the
solenoid interlock must be manually unlocked as described below.

Required tools • A small cross-slot screwdriver

• Triangular door key

Figure 4-1 Triangular door key

DANGER
Hazardous voltages!
The following procedure is allowed only during the installation process and
must never be applied during operation of the drive in order to prevent
unintentional contact with energized components.

Procedure The solenoid interlocks are mounted behind the name plate on the doors
of the medium voltage units (see arrows in Figure 4-2).

Figure 4-2 Location of name plates

4-4 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

1 Remove the name plate of the door to be opened and insert the key
through the opening in the door (see Figure 4-3) into the triangular
counterpart of the solenoid interlock (see Figure 4-4).

Figure 4-3 Door opening

2 Turn the key from the “locked” to the “unlocked” position to release
the interlock (when looking through the opening at an angle the
symbols are visible). The door can now be opened.

Unlocked position

Locked position

Figure 4-4 Manual release of the interlock

3 Remount the name plate.

IMPORTANT
After the mechanical and electrical installation has been finished, it is the
task of the commissioning engineer to check that the manual release of all
solenoid interlocks is in the “locked” position. Otherwise, the converter
cannot be started up.

4.5 Tools
See General information on manual and equipment, Tools for further
information.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-5 (34)
Chapter 4 - Mechanical installation ABB
4.6 Drive Installation
Depending on the configuration, the drive is delivered in one unit or in
several transport units, which are joined and fixed to the floor at the
installation site. See Chapter 3 - Transportation, storage and disposal, 3.4
Identifying drive units and Appendix C - Mechanical drawings to identify
the units and their position in the line-up. Transport units must be lined-up
as shown on the Layout drawing. The units can be lined-up either
beginning from the left or the right.
Parts needed for the installation (bolts, washers, joining pieces etc.) are
supplied with the drive in a separate box.
Observe the following points when installing the drive:
• Drill the floor fixing holes before moving the converter unit(s) to the
final location.
• See Chapter 3 - Transportation, storage and disposal, 3.2 Transport
conditions for information to be observed when transporting the units.
• After a transport unit has been positioned in the final location, check
that it is on a level surface.
Check the cabinets for misaligned doors and any gaps between
cabinet walls and cabinet frame. Use a spirit level to check the hori-
zontal and vertical position of the transport unit.
If the floor proves to be not level and the unevenness cannot be
corrected, place shims or leveling plates under the base frame to
adjust the position of the transport unit.
See 4.6.2 Aligning the transport units for further information.

4.6.1 Installing transport units

Proceed as follows:
1 Lift the first transport unit to its installation position.
2 If the transport unit has water pipes, remove the protective covers
from each water pipe end (see arrows in Figure 4-5).

4-6 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Figure 4-5 Water pipe covers

3 Align the transport unit and fix it to the floor.

• Floor fixings are not part of the delivery.
Recommended size of bolts and nuts: M20.
4 Before aligning the following transport units make sure that:
• the protective covers are removed from the water pipe ends on
both sides (see Figure 4-5)
• the water pipe joints are in place. The pipe joints have been slid
onto the water pipes in the factory.
See 4.6.7 Joining water pipes for further information on joining
water pipes.

IMPORTANT
When aligning a transport unit make sure that two joining water pipes have
an axial misalignment of a maximum of +/- 3 mm and an angular deflec-
tion of 5° (see Figure 4-6 and Figure 4-7).

Figure 4-6 Axial misalignment

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-7 (34)
Chapter 4 - Mechanical installation ABB

Figure 4-7 Angular deflection

5 Join the transport units using the supplied M6 screws, item 1 in

Table 4-1. Position of connecting points are illustrated in Figure 4-8.

Connecting points

Figure 4-8 Cabinet connecting points

6 Connect the wiring ducts using the supplied M6 screws and nuts,
washers and spring washers, items 1, 2, 3 and 4 in Table 4-1.

4-8 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Figure 4-9 Connecting points of wiring duct

Table 4-1 Installation material

Item Type Ident. Number Use

1 Hex-head screw M6x20 3BHE004520R0003 Connection of transport unit

2 Hex-head bolt M6x20 NB 312350P0260 Connection of wiring duct

3 Washer A 6.4/12.5 NB 335050P0607 Connection of wiring duct

4 Spring washer NB 335805P0509 Connection of wiring duct

5 Hex-head nut M6 A2-70 HZN 452198P0016 Connection of wiring duct

4.6.2 Aligning the transport units

Drives consisting of transport units which must be properly aligned and
joined. To achieve this, the requirements for the foundation and the floor
surface as stated in 4.3.3 Foundation and floor surface requirements must
be met.
When aligning the transport units, it must be ensured that:
• the transport units can be joined around the shipping split. Make sure
the holes are exactly aligned (see Figure 4-10),

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-9 (34)
Chapter 4 - Mechanical installation ABB

Figure 4-10 Aligning drill holes

• the roof connection plates can be mounted.

Procedure It is recommended to check the evenness and incline of the mounting

surface well in advance so that work to improve the surface is completed
before the installation of the drive. When checking the floor surface, a spirit
level or flooring rule with a vial can be used for example. The tool should
be of sufficient length (1 to 2 m).
If the floor surface cannot be improved, shims or levelling plates must be
placed under the base frame at appropriate points to adjust the position of
the transport units to the above stated requirement regarding the
maximum displacement of the transport units.
Levelling plates of the following size are recommended:
• 65 mm x 50 mm
Depending on the unevenness and incline of the floor, the levelling plates
should be placed at appropriate distances to prevent that the base frame
bends under the weight of the drive (i.e. every 1 m). They should be
placed at least in the corners of the shipping split.

4.6.3 Attaching the sealing tape

This section is applicable for drives with insulation protection IP 54.
The self-adhesive sealing tape (40 mm), which is supplied with the drive,
prevents water entering into the gap between two joining roof plates. The
tape has to be installed where two transport units have been joined. Gaps
within a transport unit have been sealed with a tape in the factory already.

Procedure 1 Remove the roof plates of two joining transport units.

2 Cut the sealing tape to the required length.

4-10 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

3 Attach the tape on the whole length of the joining crossbars.

1 2 1

Figure 4-11 Attaching the sealing tape

4 Remount the roof plates again.

4.6.4 Installing roof joints

The joints (1) are mounted at the front and the back of the roof and connect
two joining transport units. The joints within a transport unit have been
mounted in the factory already.

Figure 4-12 Installing roof joints

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-11 (34)
Chapter 4 - Mechanical installation ABB
Table 4-2 Installation material

Item Type Ident. number

Joint 8 x 80 x 220 mm 3BHB011552R0001

Bolt M16 x 45 NB 312350P0465

Washer A17/30 NB 335050P0611

4.6.5 Installing roof attachments

Note: This section is applicable for marine drives only.
To prevent tilting, the cabinets are fixed to the ceiling or the back wall of
the drive room by means of roof attachments which also serve as vibration
dampers. All parts of a complete roof attachment assembly are listed in
Table 4-3.

See Appendix C - Mechanical drawings for:

• number and location of roof attachments
• hole center distances and dimensions.

Table 4-3 Installation material

Item Type Ident. number

1 Steel bracket, roof-side 120 x 80 x 8 mm, L=120 mm 3BHB11553R0001

with 14 mm mounting holes

2 Steel bracket, wall-side 120 x 80 x 8 mm, L=120 mm 3BHB11553R0002

with 30 mm mounting holes

3 Rubber pad 80 x 220 mm 3BHB12579R0001

4 2 damping connectors - 3BHB012580R0001

5 2 bolts M12x80 NB 312450P8127

6 2 washers 13 x 45 x 4 3BHL001710P0001

7 2 nuts M12 3BHB011779R0002

8 2 washers A13/24 NB 335050P0610

Normally, roof-side steel brackets (item 1 in Table 4-3) within a transport

unit have been mounted in the factory already (see Figure 4-13). If the
brackets are not mounted for transport reasons (e.g. between transport
units) they are part of the separate installation material delivered with the
drive.
The steel brackets can be distinguished by their mounting holes:
• The roof-side brackets have holes with a diameter of 14 mm
(see Figure 4-13).

4-12 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

• The wall-side brackets have holes with a diameter of 30 mm

(see Figure 4-14).

14 mm

Figure 4-13 Roof-side steel bracket

Before starting assembling have all parts of a roof attachment ready at

hand.
A roof attachment can be assembled by one person but depending on the
site conditions the assistance of a second person is helpful.
Proceed as follows:

1 Check that the roof-side steel brackets have been mounted according
to Appendix C - Mechanical drawings.
2 Align the rubber pad and the wall-side steel bracket with the roof-side
steel bracket (see Figure 4-14).
3 Insert one of the sleeves into a mounting hole until the sleeve is flush
with the surface of the second bracket.
4 Join the parts with one set of the supplied bolts, nuts and washers,
with the nut on the roof-side bracket and the bolt on the wall-side
bracket (see Figure 4-14). Tighten the bolted connection by hand.
5 Insert the second sleeve and join the parts with the remaining bolt, nut
and washers. Tighten the bolted connection by hand.
6 Finally, tighten the bolted connections until the rubber of the sleeves
starts to bulge (see Figure 4-14).

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-13 (34)
Chapter 4 - Mechanical installation ABB

Nut Bolt
Damping connector

2nd steel bracket

Rubber pad
Steel bracket

Figure 4-14 Installing the roof attachments

Figure 4-15 Roof attachment assembled

7 Fix the cabinets to the ceiling or the back wall with suitable struts. The
struts are not part of the delivery.
When fixing the cabinets to the ceiling, it is recommended to use two
struts per roof attachment as illustrated in Figure 4-16 a.
Struts connecting the cabinet to the wall should be mounted in a 90°
angle to the drive as illustrated in Figure 4-16 b.

4-14 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

IMPORTANT
When fixing the struts to the ceiling, do not mount the struts in a 90° angle
to the cabinet roof as illustrated in Figure 4-16 c.

45° 45°

90°

a Recommended! b Recommended! c Not recommended!

Figure 4-16 Recommended ceiling and wall fixings

4.6.6 Installing roof-mounted heat exchangers

The air-to-air heat exchangers are already mounted on the drive roof.
However, they have to be removed when two transport units have to be
joined together and then remounted again.

Dimensions and weight Dimensions (L x W x H): 1025 x 750 x 310 mm

Weight: 49 kg

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-15 (34)
Chapter 4 - Mechanical installation ABB
Required tools and
accessories

Figure 4-17 Required tools

Removing the heat

exchangers

Figure 4-18 Heat exchanger top view

The heat exchangers (at least one, depending on the drive alignment)
have to be removed in order to gain access to the DC busbars. This is
necessary in order to join the DC busbars of two adjacent transport units.

4-16 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

CAUTION
Observe the installation height of the heat exchanger, its dimensions and
weight.
Take appropriate measures in order to safely remove and install the heat
exchanger.

1 Loosen the screws of the heat exchanger that has to be removed

using a Phillips bit with extension as shown in Figure 4-17.
The screws do not have to be removed.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-17 (34)
Chapter 4 - Mechanical installation ABB
2 Remove the cable ties using a side cutter.

3 Lift the heat exchanger by crane and move it to the back (approx.
20 cm) and secure it with a piece of squared timber.
4 Push the cables upwards.
5 Pull the cables out, but leave them connected.

4-18 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

6 Place the heat exchanger on top of the other supporting it with two
pieces of squared timber.

7 Screw the DC busbars together. Connecting piece as well as the

screws are part of the scope of supply.

Re-installing the heat 1 Place the heat exchanger to its original position.
exchangers
2 Pull the cables down towards the cable box.
3 Move the heat exchanger to its exact position.
4 Retighten the cables (approx. 20 cm).
5 Tighten all screws of the heat exchanger.
6 Fix the cables inside the cable box with cable ties.

4.6.7 Joining water pipes

The pipe joints connecting the water pipes of two joining transport units
have been slid onto the water pipes in the factory with the bolts showing
in the direction where they can be reached best with a wrench. On the
installation site, they have to be slid over two joining pipe ends, centered,
adjusted and fastened after the cabinets have been aligned.
Proceed as follows:
1 Connect the pipe ends by sliding the pipe joint over the two joining
pipe ends.
2 Center the pipe joint.
Mark the length of a pipe joint on one end of a water pipe as a fitting
guide (see Figure 4-19).

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-19 (34)
Chapter 4 - Mechanical installation ABB

Figure 4-19 Marker for centering a pipe joint

Slide the pipe joint over two pipe ends as shown in Figure 4-20.

47
mm
Figure 4-20 Centering a pipe joint

3 Adjust the pipe joint.

IMPORTANT
When adjusting a pipe joint make sure that the locking part of the pipe joint
is installed according to Figure 4-21.

Cabinet front

min. 40 mm

Locking part of
pipe joint

min. 40 mm

Figure 4-21 Adjusting pipe joints

4-20 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

4 After adjusting a pipe joint, alternately tighten the bolts only lightly.
5 Tighten the bolts with a torque wrench to the final torque rate indi-
cated on the pipe joints outer surface.

Torque rate

Figure 4-22 Torque rate

IMPORTANT
Do not tighten bolts above indicated torque rate.

6 If a pipe joint has to be removed, proceed as follows:

• Loosen bolts alternately but do not remove them completely.
• Slide pipe joint to the side.

IMPORTANT
Sealing lip may touch pipe end. Turn and move pipe joint smoothly.

• Clean pipe joint and treat bolts with an appropriate lubricant

before refitting.

4.6.8 Joining DC busbars

DC busbars must be connected with joining pieces between two transport
units. Busbar joining pieces within a transport unit have already been
mounted in the factory. The DC busbars are reached best from behind and
from the top.
Remove top plates and rear walls if necessary.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-21 (34)
Chapter 4 - Mechanical installation ABB

IMPORTANT
All joining pieces and bolts must be orientated exactly as shown in
Figure 4-23 to Figure 4-26 to maintain the required distance between
busbars of different polarity.
When fitting the joining pieces make sure that the bolt head is on the
busbar side and the nut is on the side of the joining piece.
Only the items listed in Table 4-4 must be used when joining the busbars.

IMPORTANT
Tightening torque for bolted busbar connections: 40 Nm.

Table 4-4 Installation material

Item Type Ident. number

Hex-head bolt M12x35 NB 312350P8118

Strain washer GZN 490084P0111

Hex-head nut M12 A2-70 3BHB019342R0012

Joining piece 3BHB009410R0001

4-22 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Cabinet top Strain washer on each side Cabinet front

of a connection!

Joining piece

- +
NP

Figure 4-23 Busbar configuration 1, polarity and bolt orientation

Cabinet top Strain washer on each side Cabinet front

of a connection!

Joining piece

+ - - +
NP NP

Figure 4-24 Busbar configuration 2, polarity and bolt orientation

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-23 (34)
Chapter 4 - Mechanical installation ABB

Cabinet top Strain washer on each side Cabinet front

of a connection!

Joining
piece

- + + - - +
NP NP NP

Figure 4-25 Busbar configuration 3, polarity and bolt orientation

Cabinet top Cabinet front

Strain washer on each side
Joining piece of a connection!

+ - - + + - - +
NP NP NP NP

Figure 4-26 Busbar configuration 4, polarity and bolt orientation

4-24 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

4.6.9 Joining ground busbars

Ground busbars must be connected with joining pieces between two
transport units. Busbar joining pieces within a transport unit have already
been mounted in the factory.

IMPORTANT
Tightening torque for bolted busbar connections: 40 Nm.

Mount the joining pieces for the ground bus (PE) and (PG) as shown in
Figure 4-27 using the items listed in Table 4-5.
Table 4-5 Installation material

Item Type Ident. number

Hex-head bolt M12x40 NB 312350P8119

Strain washer GZN 490084P0111

Hex-head nut M12 A2-70 3BHB019342R0012

Busbar joint 3BHB009221R0001

Busbar joint

PG ground bus
Strain washer on each side
of a connection!

Pipe joint
Busbar joint
PE ground
bus
Cabinet front

Figure 4-27 Connecting ground busbars

4.6.10 Joining AC busbars in ARU, INU, IFU

If a Terminal Unit (TEU) is joined to an Active Rectifier Unit (ARU), an
Inverter Unit (INU) or an Input Filter Unit (IFU), the AC busbars in these
cabinets must be connected to the corresponding busbars in the TEU.
The busbar joint between two transport units have oblong holes for fine
adjustment.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-25 (34)
Chapter 4 - Mechanical installation ABB

IMPORTANT
Tightening torque for bolted busbar connections: 40 Nm.

Table 4-6 Installation material

Item Type Ident. number

Hex-head bolt M12x45 NB 312350P8120

Strain washer GZN 490084P0111

Hex-head nut M12 A2-70 3BHB019342R0012

Connecting points on Figure 4-28 shows the connecting points of AC busbars of ARU, INU and
the right of TEU IFU when located on the right of a terminal unit.

4-26 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Connecting points for

phase L3 of IFU

Front of TEU cabinet

Connecting points for

phase L3 of ARU/INU/IFU

Connecting points for

phase L2 of ARU/INU

Connecting points for

phase L1 of ARU/INU/IFU

Figure 4-28 Connecting points of AC busbars in ARU, INU, IFU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-27 (34)
Chapter 4 - Mechanical installation ABB
Connecting points on Figure 4-29 shows the connecting points of AC busbars of ARU, INU and
the left of TEU IFU when located on the left of a terminal unit.

Connecting points for IFU

Front of TEU cabinet

Phase L1
Phase L2
Phase L3

L3
Connecting points for
ARU/INU

L1

L2

Figure 4-29 Connecting points of ac busbars in ARU, INU, IFU

4-28 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

4.6.11 Joining AC busbars in LSU

If a Line Supply Unit (LSU) is joined to a Terminal Unit (TEU), the AC
busbars in this cabinet must be connected to the corresponding busbars
in the TEU.

IMPORTANT
Tightening torque for bolted busbar connections: 40 Nm.

Table 4-7 Installation material

Item Type Ident. number Use

Hex-head bolt M12x50 NB 312450P8121 single busbars

Hex-head bolt M12x80 NB 312450P8127 double busbars

Hex-head bolt M12x60 NB 312350P0418

Strain washer GZN 490084P0111

Hex-head nut M12 A2-70 3BHB019342R0012

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-29 (34)
Chapter 4 - Mechanical installation ABB
Connecting points on Figure 4-30 and Figure 4-31 show the connecting points of AC busbars of
the right of TEU LSU when located on the right of a terminal unit.

Connecting points

Front of TEU cabinet

Figure 4-30 Connecting points of AC busbars in LSU on the right (7 and 9 MVA)

4-30 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Connecting points

Front of TEU cabinet

Figure 4-31 Connecting points of AC busbars in LSU on the right 14 MVA)

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-31 (34)
Chapter 4 - Mechanical installation ABB
Connecting points on Figure 4-32 and Figure 4-33 show the connecting points of AC busbars of
the left of TEU LSU when located on the left of a terminal unit.

Connecting points

Front of TEU cabinet

Figure 4-32 Connecting points of AC busbars in LSU on the left (7 and 9 MVA)

4-32 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 4 - Mechanical installation

Connecting points

Front of TEU cabinet

Figure 4-33 Connecting points of AC busbars in LSU on the left (14 MVA)

4.6.12 Raw water circuit

The incoming and outgoing raw water pipes are connected to the flanges
of the water cooling unit. Installation material such as counter flange, bolts,
nuts and seals are supplied.

See Appendix C - Mechanical drawings for information on dimensions of

the raw water entry and the drive-side flanges.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 4-33 (34)
Chapter 4 - Mechanical installation ABB

4-34 (34) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 5 - Electrical installation

5.1 Safety

WARNING
Hazardous voltage!
Improper work could lead to life-threatening injury or death.
The electrical installation must be carried out by qualified personnel
according to the site and equipment requirements and the relevant
electrical codes.
When the electrical installation is completed, the main and auxiliary power
supply to the drive must not be switched on without the consent of the ABB
commissioning personnel.
Take appropriate measures to prevent main and auxiliary power supply
being switched on during installation.

5.2 Overview on installation work

The electrical installation includes the following wire and cable
connections:
• Internal wiring
See section 5.6 Internal wiring.
• Grounding cable
See section 5.8 Ground connections.
• Power cables
See section 5.9 External power cabling.
• Auxiliary voltage and control cables
See section 5.10 Connecting auxiliary power and control cables.

5.3 Tools
See General information on manual and equipment, Tools for further
information.

5.4 Understanding electrical drawings

See Appendix D - Electrical diagrams for definitions on designation, cross-
reference and device-identification conventions.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-1 (40)
Chapter 5 - Electrical installation ABB
5.5 Cables and wires

5.5.1 Power cables

See Power cable specification for further information.

5.5.2 Ground cable

It is important that the drive is properly grounded to maintain safety and to
ensure smooth functioning of the equipment.
The ground cable must be securely tied to the ground system of the
installation site and to the ground bus closest to the cable entry of the
drive. See section 5.8 Ground connections for further information.

5.5.3 Equipotential bonding conductor

If the shielding of the cables between the input transformer and the drive,
or the drive and the motor, is less than half the cross-sectional area of that
cable, an extra bonding conductor is required. The bonding conductor
running in parallel to the power cables is recommended to prevent screen
overloading due to potential differences in the plant. See section 5.8
Ground connections for further information.

Cross-section The cross-section and ampacity rating of the conductor and the
connection must be in compliance with national and local electrical codes.

5.5.4 Auxiliary power cables

A three-core cable is required for the auxiliary power supply. A neutral
connector is not required. Type and rating is to be selected according to
local code.

5.5.5 Control cables

Control cables should be provided in accordance with Table 5-1. Either
single or multiple twisted pair cables may be used.
Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm must be maintained
between control and power cables. Control and power cables should be
crossed at an angle of 90°.

5-2 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Table 5-1 Control cable requirements

Signal type General cable type Cross-section

Analog In Twisted pair(s) - Overall shield 0.5 to 2.5 mm2

Analog Out Twisted pair(s) - Overall shield 0.5 to 2.5 mm2

Digital In Twisted pair(s) - Overall shield 0.5 to 2.5 mm2

Digital Out Twisted pair(s) - Overall shield 0.5 to 2.5 mm2

Speed Encoder Twisted pair cable with separately 0.5 mm2

shielded pairs and overall shield 4 x (2+1)

Position Encoder Twisted pair cable with separately 0.5 mm2

shielded pairs and overall shield 14 x (2+1)

5.5.6 Synchronization cables

Synchronization cables are used in ACS 6000 configurations with ARU. A
three-phase shielded cable without neutral wire is required for the voltage
supply of the synchronization transformer.

5.6 Internal wiring

Cables for internal wiring are delivered separately. All necessary data for
each individual connection, i.e.
• Cable numbers
• Cable type
• Cross-section
• Location of terminals
are specified on the Converter hardware diagram in Appendix D -
Electrical diagrams.
The cables have been connected on one side or they have been rolled up
and delivered as loose items.
All cables to be connected can be identified by their specific number.
Individual strands or wires have been marked with the designation of the
terminal they have to be connected to.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-3 (40)
Chapter 5 - Electrical installation ABB
Proceed as follows:
1 Pull all cables through the cable duct located at the top of the cabi-
nets. Cut-outs in the ducts provide entry into the cabinets.

Cable duct

Figure 5-1 Location of cable duct

2 Lay the cables and wires in their designated trays and cable ducts as
shown in Figure 5-2.

Cabinet front

Figure 5-2 Cable duct sections

5-4 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

1 Cable trays A for:

- Auxiliary cables
- Control cables
2 Cable duct B for optical fiber
3 Mounting rail C for IGCT power supply cable of:
- Discharging unit (DIU)
- Resistor banking unit (RBU)
- Voltage limiter unit (VLU)

IMPORTANT
When fastening IGCT power supply cables on mounting rail C (see Figure
5-2) make sure that the cables are at a minimum distance of 5 mm from
the nearest metal part.

3 Connect all cables and wires according to the Converter hardware

diagram in Appendix D - Electrical diagrams.

IMPORTANT
Handle optical fibers with care. Do not touch the ends of the fibers, they
are extremely sensitive to dirt. When unplugging an optical fiber, always
hold it at the connector not at the fiber.
Observe the maximum long-term tensile load of 1.0 N and the minimum
bend radius of 25 mm.

5.7 Cable entry

5.7.1 Power cables

The cables can be entered either through the roof or the floor of a cabinet.
With respect to EMC sealing and IP protection, the following types of cable
transits are available:
• Roxtec cable transit
• Customized cable entry

The type of cable transit and top or bottom cable entry has been specified
when ordering the drive. Information on dimensions, exact location,
maximum number of cables per transit is stated on the Layout drawings in
Appendix C - Mechanical drawings and in the Power cable specification,
3BHS125090.

Roxtec cable entry The cable entry assembly for the power cables consists of a galvanized
entry frame which holds the adaptable EMC sealing modules. The
modules can be easily adapted to the cable diameter by peeling off the

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-5 (40)
Chapter 5 - Electrical installation ABB
concentric layers of the module. Compression wedges ensure that the
conductive foil of the sealing modules tightly enclose the cable armor or
shield in the area of the cable transit.
• TEU: The entry frame can accommodate a maximum of 30 sealing
modules of type RM120 ES.
• COU: The entry frame can accommodate a maximum of 10 sealing
modules of type RM120 ES.
Possible cable diameters: 67.5 to 99 mm

See the Layout drawings in Appendix C - Mechanical drawings and the

Power cable specification, 3BHS125090 for further information on the
exact location and dimensions of the transformer and motor cable entry.

Figure 5-3 Power cable entry with Roxtec sealing system (typical example)

1 Sealing module
2 Removable layers to adapt the sealing module to the cable diameter
3 Conductive foil
4 Frame
5 Compression wedge
6 Sealing module

5-6 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Customized cable entry An undrilled aluminium plate with a thickness of 5 mm is available for
users who wish to customize the cable entry. The plate is installed in the
factory already.
In this case, all material for cable entry, EMC requirements and IP
protection are to be provided by the customer.
The cable transits must be made according to local regulations (see
example in Figure 5-6).

Figure 5-4 Cable entry with EMC cable gland

1 Cable gland
2 Overall cable shield in contact with cable gland
3 Point of entry
4 Entry plate

5.7.2 Power cable entry with Roxtec sealing modules

Further information See the following documents for further information:

• Appendix C - Mechanical drawings for position and dimensions of the

Roxtec frames.
• Appendix A - Additional manuals, Roxtec Installation manual for
installation instructions of the sealing modules and cables.
Figure 5-5 shows the three sealing module types used and an example of
how cables should be laid into the sealing modules.
The sealing modules in the upper halt of the frame (A, nearer to the back
side of the drive) must be aligned as shown in Figure 5-5. The cables must
be as far as possible from the back wall of the drive in order to maintain
the minimum distance to the high voltage busbars.
Keep three-core cables together in one frame opening, either in one
Roxtec module as shown in Figure 5-5 B or split into three Roxtec modules
as shown in Figure 5-5 C.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-7 (40)
Chapter 5 - Electrical installation ABB

Back wall of the drive

C B

2 x RS90
6 x RS60

L1 L2 L1
L2
L3 1 x RS120
219 mm A
L3 L1
L1
L1 L2
L2
L3 L2 L3 L3

2 x RS90
6 x RS60

L1 L2 L1
L2
L3 1 x RS120

L3
L1
L1 L2
L2
L3 L3

120.5 mm

Figure 5-5 Roxtec frame with sealing modules and cables

Frame version 1 The following number of sealing modules can be inserted in case of frame
(12 openings) for version 1 for INU:
INU (7/9/11 MVA)
• Up to 4 modules of the type RM120
• Up to 8 modules of the type RM 90
• Up to 24 modules of the type RM 60
Frame version 1 can be equipped with the following number of cables:
• Maximum 4 three-core cables with a diameter of 68-99 mm
One cable per ROX-field
• Maximum 8 three-core cables with a diameter of 48-71 mm (only with
cable lengths of less than 100 m)
Two cables per ROX-field
• Maximum 24 single-core cables with a diameter of 28-50 mm (only
with cable lengths of less than 100 m)
Six cables per ROX-field
The frame part belonging to inverter unit (INU) is colored in the picture
below. The white part is the cable entry for the line supply unit (LSU).

5-8 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Frame version 2 The following number of sealing modules can be inserted in case of frame
(4 openings) for version 2:
INU 7/9 MVA and IRU
• Up to 4 modules of the type RM120
• Up to 8 modules of the type RM 90
• Up to 24 modules of the type RM 60
Frame version 2 can be equipped with the following number of cables:
• Maximum 4 three-core cables with a diameter of 68-99 mm
One cable per ROX-field
• Maximum 8 three-core cables with a diameter of 48-71 mm (only with
cable lengths of less than 100 m)
Two cables per ROX-field
• Maximum 24 single-core cables with a diameter of 28-50 mm (only
with cable lengths of less than 100 m)
Six cables per ROX-field

Frame version 3 The following number of sealing modules can be inserted in case of frame
(3 openings) for version 3:
INU (3/5 MVA)
• Up to 3 modules of the type RM120
• Up to 6 modules of the type RM 90
• Up to 18 modules of the type RM 60
Frame version 3 can be equipped with the following number of cables:
• Maximum 3 three-core cables with a diameter of 68-99 mm
One cable per ROX-field
• Maximum 6 three-core cables with a diameter of 48-71 mm
Two cables per ROX-field (only with cable lengths of less than 100 m)
• Maximum 18 single-core cables with a diameter of 28-50 mm
Six cables per ROX-field (only with cable lengths of less than 100 m)

Frame version 1 The following number of sealing modules can be inserted in case of frame
(12 openings) for version 1 for LSU 7/9 MVA:
LSU (7/9 MVA)
• Up to 8 modules of the type RM120
• Up to 16 modules of the type RM 90
• Up to 48 modules of the type RM 60

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-9 (40)
Chapter 5 - Electrical installation ABB
Frame version 1 can be equipped with the following number of cables:
• Maximum 8 three-core cables with a diameter of 68-99 mm (only with
cable lengths of less than 100 m)
one cable per ROX-field
• Maximum 16 three-core cables with a diameter of 48-71 mm (only
with cable lengths of less than 100 m)
two cables per ROX-field
• Maximum 48 single-core cables with a diameter of 28-50 mm (only
with cable lengths of less than 100 m)
six cables per ROX-field
The frame part belonging to line supply unit (LSU) is colored in the picture
below. The white part is the cable entry for the inverter unit (INU).

Frame version 1 The following number of sealing modules can be inserted in case of frame
(12 openings) for version 1 for LSU 14 MVA:
LSU (14 MVA)
• Up to 12 modules of the type RM120 per frame
• Up to 24 modules of the type RM 90 per frame
• Up to 72 modules of the type RM 60 per frame
Frame version 1 can be equipped with the following number of cables:
• Maximum 12 three-core cables with a diameter of 68-99 mm (only
with cable lengths of less than 100 m)
One cable per ROX-field
• Maximum 24 three-core cables with a diameter of 48-71 mm (only
with cable lengths of less than 100 m)
Two cables per ROX-field
• Maximum 72 single-core cables with a diameter of 28-50 mm (only
with cable lengths of less than 100 m)
Six cables per ROX-field

Frame version 4 The following number of sealing modules can be inserted in case of frame
(1 opening) for BCU version 4:
• 1 module of the type RM120
• 1 module of the type RM90
• Up to 4 modules of the type RM60
Frame version 4 can be equipped with the following number of cables:
• Maximum 1 three-core cable with a diameter of 68-99 mm
• Maximum 1 three-core cable with a diameter of 48-71 mm
• Maximum 3 single-core cables with a diameter of 28-50 mm

5-10 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

5.7.3 Cabel entry for auxiliary and control cables in WCU

The cable entry for the auxiliary power and control cables is fitted with a
Roxtec frame, type CS F 16 (1), and EMC sealing inserts (2) that are
adaptable to the cable diameter. The EMC sealing inserts are not supplied
and must be provided by the customer.

1 2

Figure 5-6 Cable entry for auxiliary power and control cables

The sealing modules have to be removed for the cable installation. The re-
installation of the sealing modules requires the pre-compression wedge
(1 in Figure 5-7).
1

Figure 5-7 Pre-compression wedge

See the ROXTEC installation instructions in Appendix A - Additional

manuals for further information on deinstallation and installation of the
sealing inserts.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-11 (40)
Chapter 5 - Electrical installation ABB
5.8 Ground connections

5.8.1 Protective earth

It is important that the drive is properly grounded to maintain safety and to
ensure smooth functioning of the equipment. For this reason, the ground
cable of the drive must be securely tied to the grounding system of the
installation site (system ground).
The drive is equipped with a continuous ground bus (marked PE,
Protective Earth) which is installed in the bottom area of the cabinets.
The ground cable is connected to a busbar which is accessible from the
IMPORTANT
front of the cabinets (see Figure 5-9 to Figure 5-10).

The ground cable must be connected to the ground busbar of the drive at
only one point: at the busbar inside the TEU closest to the CBU. See
Converter hardware diagram in Appendix D - Electrical diagrams for
project-specific illustration.
The connection must be in compliance with local regulations.

See the Layout drawings in Appendix C - Mechanical drawings for

information on the thickness of the busbar and the diameter of the fixing
holes.

Ground bus for

ground cables

Figure 5-8 Bottom connecting point of system ground in TEU 600 mm

Note: If cables are entered from the top, the ground bus is mounted below
the roof.

5-12 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Connecting point
for ground cable

Figure 5-9 Bottom connecting point of system ground in TEU 1000 mm

Connecting point
for ground cable

Figure 5-10 Top connecting point of system ground in TEU 1000 mm

Power ground Cable shields must be connected to the drive to ensure proper operation.
A separate ground bus (Power Ground, PG) is installed for this purpose.
The busbars of “power ground” and “protective earth” are connected with
each other inside the CBU which has the grounding switch mounted on the
front door. The connection has been made in the factory already.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-13 (40)
Chapter 5 - Electrical installation ABB
5.8.2 Grounding of drive, transformer and motor

ACS 6000 INU

L1 L2 L3 PG PE

1 2 3 1 2 3 1 2 3

Armor

Shield

1 2 3 1 2 3 1 2 3

U1 V1 W1

PE
Motor
3

Figure 5-11 Cable installation between drive and motor

5-14 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

ACS 6000 ARU

L1 L2 L3 PG PE

1 2 3 1 2 3 1 2 3

Armor

Shield

1 2 3 1 2 3 1 2 3

2U 2V 2W

PE

Transformer
3

Figure 5-12 Cable installation between transformer and drive with ARU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-15 (40)
Chapter 5 - Electrical installation ABB

ACS 6000 LSU

1L1 1L2 1L3 2L1 2L2 2L3 PG PE

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

Armor
Shield

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

2U1 2V1 2W1 2U2 2V2 2W2

PE

Transformer
2x3

Figure 5-13 Cable installation between transformer and drive with LSU

5.9 External power cabling

Sections 5.9.1 Connecting incoming feeder, motor cables and braking
resistor cables describes cable entry using Roxtec sealing modules.
These modules are not in ABB’s scope of supply.
Information on Roxtec sealing modules can be fond in 5.7.2 Power cable
entry with Roxtec sealing modules.

See the Layout drawing in Appendix C - Mechanical drawings for the

dimensions of Roxtec frame(s).
If Roxtec modules are not used, EMC compatible cable transits in
accordance with local regulations must be installed.

5.9.1 Connecting incoming feeder, motor cables and braking resistor cables

The incoming feeder and motor cables are connected inside a TEU. If
several TEUs are part of the drive, see Appendix D - Electrical diagrams
to assign incoming feeder and motor cables to their corresponding TEU.
Braking resistor cables are connected inside the BCU.

5-16 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Cable entry can either be from the top or from the bottom. Project-specific
cable entry is illustrated on the Layout drawing in Appendix C - Mechanical
drawings.

NOTICE
If possible do not cut cables inside the terminal unit. Make sure that waste
from cable cutting and stripping cannot enter the drive. Any waste which
accidentally dropped into the drive must be retrieved. The waste could
cause damage or malfunction.

NOTICE
High voltages will be present in the terminal compartment. High voltages
can cause flashover between the electric potential of different phase
conductors, and the electric potential of a phase conductor and earth.
Therefore, a minimum clearance of 55 mm must be maintained between
a phase conductor and the terminals of any other phase conductor, and
between a phase conductor and earth.

• The holes of the cable termination bars are suitable for M12 bolts.
Information on hole sizes and distances are stated in Appendix C -
Mechanical drawings.
• Use cable lugs suitable for M12 bolts. Cables must be terminated with
lugs according to the specification of the cable manufacturer.
• When determining the required cable length refer also to Appendix C
- Mechanical drawings for dimensions of distances between point of
entry and the termination bars.
• The transformer and motor cables must be prepared so that the
overall cable armor/shield and the shields of the individual conductors
can be securely connected to the PG ground bus (see Figure 5-14).
It is recommended to ground a shield all around its circumference,
rather than making a pigtail which is only grounded at one point.
• Remove the outer cable insulation in the area where the cable passes
through the entry frame to bring the cable armor / shield into contact
with the conductive foil of the sealing module (see Figure 5-14).

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-17 (40)
Chapter 5 - Electrical installation ABB

Figure 5-14 Cable entry for power cables with EMC ROX modules

1 Sealing module
2 Conductive foil of sealing module
3 Entry frame
4 Cable armor / shield to be connected to PG ground bus
5 Cable armor / shield
6 Individual cable shields to be connected to PG ground bus
• Install the sealing modules following the instructions of the ROX
module supplier.
• It is recommended to leave the cables unconnected at both ends until
the commissioning engineer has given his permission.
• When the cable insulation has been checked and the commissioning
engineer has given his permission connect
• the cable conductors to their corresponding termination bars,
• cable screens of feeder and motor cables of all cables to the PG
ground bus,
• cable screens of breaking chopper cables to the PG ground bus
inside the BCU.
• the ground cable(s) to the PE ground bus of the drive (see
Chapter 2 - Features and hardware of the drive, Figure 2-37),

5-18 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

• the equipotential bonding conductor to the PG ground bus.

5.9.1.1 Bolted busbar connections

Material requirements Use stainless steel bolts and nuts with the appropriate steel grade and
property class for the connection (recommended: A2-70 [designation
according to ISO 3506]). Nuts with bonded coating can be used as an
alternative to uncoated stainless steel nuts.

Connection type The following connection type is recommended when connecting a cable
lug (3) to a busbar:
Spring washer (1) and flat washer (2) on each side of the busbar (4).

1 2 4 3 2 1

Figure 5-15 Connection with spring and flat washers

Other washers may be used, provided they are capable of maintaining the
required contact pressure.

Lubrication If stainless steel bolts and nuts are used, lubricate the thread and head
contact surface of the bolt using recommended pasts, e.g. Molykote D
paste.
Note: If a coated nut (e.g. with bonded molybdenum-disulfide [MoS2]
coating) is used, the connection does not have to be lubricated.

Tightening torque Tighten bolted connections with bolts of sizes M10 and greater with the
recommended nominal torque for the bolt size used.

5.10 Connecting auxiliary power and control cables

5.10.1 Further information

See Layout Drawing in Appendix C - Mechanical drawings for information

on:
• Project specific cable entry
• Dimensions between point of cable entry and terminals

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-19 (40)
Chapter 5 - Electrical installation ABB
• Dimensions of the EMC ROX frame(s)
See Appendix D - Electrical diagrams for information on:
• Designation, cross-reference and device-identification conventions.

Information on Roxtec modules can be obtained from www.roxtec.com

and from 5.7.2 Power cable entry with Roxtec sealing modules.

5.10.2 Cable preparation and connection

The auxiliary power cable and the control cables are connected inside the
WCU.

Determining the cable Determine the required length of a cable between the point of entry and
length the connection point inside the cabinet. Cut the cable to the required
length before connection to avoid excess cable to be stored in the cable
ducts.
The following section describes cable entry using EMC ROX modules
(type CS-EMV). These modules are not in ABB’s scope of supply.
If EMC ROX modules are not used, cable transits in accordance with local
regulations must be installed.

2 3

4
Figure 5-16 Cable transit inside cabinet

1 Individual cable screens to be connected to the PE ground bus

2 Sealing module
3 Cable shield
4 Conductive foil of sealing module

5-20 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

5.10.3 Connecting auxiliary power cable

Proceed as follows:
1 Enter the auxiliary power cable into the WCU.

2 Connect the cable according to the Converter hardware diagram in

Appendix D - Electrical diagrams.
• Shielded cables: Remove the outer cable sheath in the area of
the cable transit. The conductive parts of the EMC ROX module
must be in contact with the cable shield (see Figure 5-16). The
cable screen is connected to PE.

5.10.4 Connecting control cables in WCU

Top cable entry Proceed as follows:

1 Enter the control cables into the WCU through the entry plate (see
Figure 5-18 and Figure 5-19).
• Remove the rubber grommets from the entry plate and cut them
to adequate diameter for the auxiliary power cable. To ensure
proper sealing, cut along the diameter marking that corresponds
to the cable diameter (see Figure 5-17). Slide the grommet onto
the cable. The grommet must fit tight to prevent water from
entering the cabinet. If necessary, seal the junctions with silicone
rubber.

Figure 5-17 Cutting rubber grommets to size

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-21 (40)
Chapter 5 - Electrical installation ABB

1 2 3

Figure 5-18 WCU top cable entry (800 mm unit)

1 Cable routing
2 Cable transit
3 Top entry plate

1 2 3

Figure 5-19 WCU top cable entry (2000 mm unit)

1 Cable transit
2 Cable routing
3 Top entry plate

5-22 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

2 Pull the cables through the cable transit (see Figure 5-18 and Figure
5-19).
• Shielded cables are prepared as illustrated in Figure 5-16.
Remove the cable insulation in the area of the cable transit to
bring the conductive parts of the EMC ROX module in contact
with the cable shield.
3 Connect the end of the cable screen to PE.

4 Connect the cables to the terminals below the cable transit according
to the Converter hardware diagram in Appendix D - Electrical
diagrams.

Bottom cable entry Proceed as follows:

1 Remove the cover (if present) of the cable entry. The cover can either
be discarded or used as an entry plate.

Figure 5-20 WCU bottom cable entry

2 Enter the cables through the floor and run them up the side wall as
illustrated in Figure 5-21.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-23 (40)
Chapter 5 - Electrical installation ABB
3 Fix the cables to the C-rails on the side of the cabinet.
• The cables can be fixed using a screw base with a cable tie or
cable clamps.
4 Pull the cables through the cable transit (see Figure 5-21).
• Shielded cables are prepared as illustrated in Figure 5-16.
Remove the cable insulation in the area of the cable transit to
bring the conductive parts of the EMC ROX module in contact
with the cable shield.
5 Connect the end of the cable screen to PE.

6 Connect the cables to the terminals below the cable transit according
to the Converter hardware diagram in Appendix D - Electrical
diagrams.

Figure 5-21 WCU bottom cable entry - cable routing

5-24 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

1 Cable transit
2 C-rail
3 Cable routing
4 Bottom cable entry

5.11 Connecting cables for serial communication and encoders

5.11.1 Further information

Information on cable termination and on the device terminals where the

conductors are connected can be found on the Converter hardware
diagram in Appendix D - Electrical diagrams.

5.11.2 Cable preparation and connection

The serial communications and encoder cables are entered into a COU
either from the top or from the bottom.
The cable from the encoder to the drive has to be a single cable and must
not be cut.
Top and bottom cable entry are covered by plates. Holes for cable glands
have to be drilled on site.
It is recommended to properly determine the required length of a cable
between the point of entry and the connection point inside a cabinet and
to cut the cable to the required length before connection to avoid excess
cable to be stored in the cable ducts.

Top cable entry When cables are entered through the roof, EMC cable glands have to be
used. These cable glands are not part of the delivery.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-25 (40)
Chapter 5 - Electrical installation ABB

Top entry plate

Figure 5-22 COU, top cable entry

5-26 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Proceed as follows:
1 Remove the entry plate and drill a hole adequate for the diameter of
the cable gland.
2 Cut off the cable sheath on the length of cable between the cable
gland and the connection point.
Prepare the cable in the area of the cable gland according to
Figure 5-23.

Figure 5-23 Cable entry with EMC cable gland

1 Overall cable shield in contact with cable gland

2 Point of entry
3 Entry plate

3 Pull the cable through the cable gland, attach the cable gland to the
entry plate and fasten the entry plate to the roof.
4 Lay the cable along cable tray A (see Figure 5-24).

Cabinet front
1
2

Figure 5-24 Control cable trays

1 Cable routing
2 Cable trays A for control cables

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-27 (40)
Chapter 5 - Electrical installation ABB
5 At the end of cable tray A run the cable down into the cable duct to its
destination inside the COU (see Figure 5-25 regarding COU 800 mm,
Figure 5-26 regarding COU 600 mm or Figure 5-27 regarding COU
1000 mm).

Cable trays A for control

cables

Figure 5-25 Front view of COU 800 mm

5-28 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Cable trays A for

control cables

Figure 5-26 Front view of COU 600 mm

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-29 (40)
Chapter 5 - Electrical installation ABB

Figure 5-27 Front view of COU 1000 mm

1 Cable trays A for control cables

2 Cable routing

6 If twisted pair cable is used, leave the unshielded cable ends twisted
up to the device terminals.
Connect the cable shields as described in section Bottom cable entry.

5-30 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Bottom cable entry If control cables are entered through the bottom, rubber grommets must
be used to seal the entry plate. The rubber grommets are not part of the
delivery.
Proceed as follows:
1 Remove the entry plate and drill a hole adequate for the diameter of
the rubber grommet.
2 Enter the cable through the bottom entry plate. Depending on the
type of COU, run the cable to the duct on the right (see Figure 5-28
regarding COU 800 mm) or to the duct on the left (see Figure 5-29
regarding COU 1000 mm and Figure 5-30 regarding COU 600 mm).

Figure 5-28 Bottom cable entry in COU 800 mm

1 Entry plate
2 Cable routing

Figure 5-29 Bottom cable entry COU 1000 mm

1 Entry plate
2 Cable routing
Inside a COU 1000 mm without cable duct, fasten the cable to the
water pipe with suitable cable ties.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-31 (40)
Chapter 5 - Electrical installation ABB

Figure 5-30 Bottom cable entry COU 600 mm

1 Entry plate
2 Routing cable along water pipe

3 Run the cable up the cable duct and lead the cable through the cable
transit as illustrated in Figure 5-31.
Cable transit through the frame is the same for all three types of
COUs. Figure 5-32 illustrates the cable transit through the frame
inside a COU 1000 mm.
• Cut the rubber grommet(s) to the correct size.
• Remove the cable shield in the area of the grounding bracket.
• Ground the overall cable shield.
• Fix the cable to the side wall.

5-32 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

Cabinet front

Cable routing

Side wall removed for

illustration purposes

Figure 5-31 Cable routing in COU

Cabinet
front

Figure 5-32 Cable transit in COU 1000 mm

1 Control cable fixing

2 Cable transit
3 Grounding brackets for overall cable shield
4 Cable duct

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-33 (40)
Chapter 5 - Electrical installation ABB
4 Run the cable along the horizontal cable duct and down through the
vertical duct to its destination inside the COU (see Figure 5-33
regarding COU 600 mm and Figure 5-34 regarding COU 1000 mm).

Figure 5-33 Routing control cable in COU 800 mm

1 Cable routing
2 Rubber grommets
3 Encoder or fieldbus interface

Figure 5-34 Routing control cable in COU 1000 mm

1 Cable routing

5-34 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

2 Encoder or fieldbus interface

3 Rubber grommets

5 If twisted pair cable is used, leave the unshielded cable ends twisted
up to the device terminals.
6 Connect the cable shields as described in section Bottom cable
entry.

Grounding cable
shields

IMPORTANT
The individual shields and the overall shield of encoder cables must not
be connected to the terminals of the encoder adapter but to the separate
shield grounding point next to it (see Figure 5-35).
The unshielded cable ends must be as short as possible. The shield ends
which are fixed to the grounding clamp must be not longer than 50 mm.

The shields of serial communications cables, however, are terminated at

the fieldbus adapter as shown on the Converter hardware diagram in
Appendix D - Electrical diagrams.

Figure 5-35 Shield grounding points

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-35 (40)
Chapter 5 - Electrical installation ABB
A shield grounding point consists of a slotted mounting bracket which has
been mounted in the factory, and a grounding clamp.
Depending on the layout of the COU, the shield grounding points can be
mounted at a different place than shown in Figure 5-35.
Three grounding clamps of different sizes (see Figure 5-36) are supplied
for each connection to accommodate encoder cables of different diameter.
The clamps are tied to each mounting bracket.
SK 20
SK 14
SK 8

Figure 5-36 Shield grounding clamps

5.12 Connecting position encoder cables in marine drives

IMPORTANT
This section is only applicable for marine drives used for Azipod propul-
sion.

Optical fibers are used for signal transmission between position

encoder(s) and the associated receiver(s) in the drive in applications for
azipod propulsion. The number of the pulse encoders and the location of
the receiver(s) in the drive depends on the application. The receiver(s) can
either be installed in the WCU or a Control Unit (COU). See Converter
hardware diagram in Appendix D - Electrical diagrams for project specific
details.

NOTICE
If a fiber-optic cable is damaged or improperly installed, data transmission
can be affected and the equipment can malfunction. To prevent such prob-
lems always follow the handling and installation guidelines.

5-36 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

5.12.1 Handling and installation guidelines

• Lay the fiber-optic cables in a steel or plastic conduit to protect the
cables against damages. The conduit shall only be used for encoder
cables.
• The conduit starts at the Azipod Information Unit (AIU) and ends
inside the drive.
On the AIU side, the conduit starts at the rubber cable penetrations
through which the fiber-optic cable is entered into the cabinet.
On the drive side, the conduit enters through the entry plate with
about 10 to 20 mm of conduit extending from the entry plate.
• Cover the cable end with a cap to protect the tip of the fiber against
scratches before pulling the cable through the conduit.
• Do not exceed the maximum tensile load and the minimum bend
radius of the cable. See cable specification for information.
• When using cable ties be careful not to deform the fiber-optic cable.
Do not use tie guns.
• Connect/unplug a fiber-optic cable by holding the connector and not
the fiber.

5.12.2 Routing cables through WCU

Proceed as follows when routing cables through the WCU:
1 Route the cables through the WCU as described in section 5.10.4
Connecting control cables in WCU.
2 After the cables have been pulled through the cable transit inside the
WCU run the cables through the WCU as indicated with the dashed
line in Figure 5-37.
3 Connect the cable to the receiving connector of the receiver (see
Figure 5-37).
The supplied connectors must be used if the cable has not been
equipped with connectors.
Redundant cables should be stored appropriately for later use.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-37 (40)
Chapter 5 - Electrical installation ABB

Figure 5-37 WCU 800 mm, pulse encoder receiver

1 Receiving connector
2 Cable transit
3 Dual supply

5-38 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 5 - Electrical installation

5.12.3 Routing cables through COU

When routing cables through a COU proceed as illustrated in section 5.11
Connecting cables for serial communication and encoders.

5.13 Connecting the heating cable

See the Converter hardware diagram in Appendix D - Electrical diagrams
for further information on power supply connections.
When the drive has been ordered with a heating cable, the heating cable
has been readily installed along the bottom water pipe (see Figure 5-38).
The following connections have to be made:
• The power supply
• The heating cables of two adjoining transport units have to be
connected with each other.

Figure 5-38 Heating cable connector

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 5-39 (40)
Chapter 5 - Electrical installation ABB

5-40 (40) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 6 - Information for commissioning

6.1 Required qualification

Commissioning, parameter adjustments and functional tests are to be
carried out only by qualified commissioning personnel certified by ABB.

6.2 Commissioning procedure

Information on the commissioning procedure and the start conditions for
commissioning can be obtained from ABB.
See section General information on manual and equipment for address.

6.3 Commissioning check list

In order to ensure uncomplicated and speedy commissioning, it is
important that drive and associated equipment are ready for
commissioning. Reviewing and completing the items in the
Commissioning check list before the commissioning personnel arrive on
site will help to achieve this.

6.4 Customer assistance

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 medium and low voltage equipment
(main circuit breaker, other low and medium voltage switchgear etc.),
• authorized to operate the driven process for functional tests.

6.5 Customer acceptance

When commissioning has been completed, the commissioning report is
signed by the responsible commissioning personnel and by the customer
as a sign of acceptance. A copy of the report and a copy of the actual
parameter settings are handed out to the customer.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 6-1 (2)
Chapter 6 - Information for commissioning ABB

6-2 (2) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB
Commissioning check list

Mechanical installation

1 The drive is aligned according to the drive layout drawing (if delivered in several
transport units) and installed according to the instructions in the User’s manual

2 The drive is securely fixed to the floor

3 The roof fixings are mounted (if applicable)

4 The pipe joints are correctly orientated and torqued

5 The DC link and ground busbar joining pieces are installed and correctly torqued

6 The insulation panel across the shipping split at the back of the drive is installed

7 The insulation shields across the shipping split at the front of the drive are installed

8 The roof-mounted fan units are installed

9 The customer-side raw water piping is completed and pipes are flanged to the drive

10 The raw water supply is ready

11 Visual inspection:
- no badly affixed or damaged components
- no foreign objects left in the cabinet
- no dirt, dust or moisture in the cabinet

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 1 (4)

Commissioning check list ABB
Electrical installation

1 The types and cross sections of control cables are suitable for the signal type and
signal level

2 The types and cross sections of power cables are selected according to the “ABB
power cable specification”

3 The pulse encoder cable shields are connected to the “shield earthing point” and not
connected directly to the pulse encoder interface (only drives with pulse encoder
interface)
4 The cable entry is made according to the instructions in the User’s manual

5 All control cable screens and conductors are connected according to the instructions in
the User’s manual, appropriately labelled, and the customer side connections are
completed
6 The heating cable (if supplied) is installed according to the instructions in the User’s
manual

7 The wiring across the shipping split at the front of the drive is made according to the
information in the User’s manual and completed

8 The ground cable of drive is securely connected at both ends

9 The cable armor and screens of power cables are connected to FE / PE ground bus

10 The transformer and motor cables are installed but the conductors are not connected at
both ends (cables and drive must be meggered before connection)

Main circuit breaker (MCB)

1 The type of MCB is selected as per “ABB MCB specification”a

2 High voltage power connections are completed

3 The MCB is ready to be tested with the drive

2 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB Commissioning check list

4 The MCB protection relay settings are tested

5 The safety devices (door locks etc.) are tested and in operation

6 Local operation of MCB is disabled

7 Emergency off loop is tested

a.attention must be paid to MCB opening time and installation of undervoltage coil or 2nd opening coil

Input transformer

1 The grounding is completed

2 Transformer auxiliaries (dehydrating breathers, cooling, protection devices) are ready

3 The safety devices (door looks etc.) are tested and in operation

Motor

1 The motor is installed, aligned and alignment protocol is available

2 The motor is not coupled to the driven load

3 The grounding is completed

4 The motor auxiliaries (bearing lubrication, heater cooling etc.) are ready

5 The control and monitoring signals are connected

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 3 (4)

Commissioning check list ABB
Megger tests

1 All power cables to input transformer, between input transformer and drive and from
drive to motor are meggered and the measured values are within the required limits.

2 The test report of the megger test is available

If the test is carried out by the commissioning engineer of the drive, an additional day
per drive-motor combination needs to be reserved. After the test, the mains cables can
be connected, except at the drive end. Test must comply with the specification.

Power

1 Medium voltage is available for start-up of the drive

2 Low voltage auxiliary power is available for start-up of the drive

Miscellaneous

1 Sufficient number and correct type of spare parts is available

2 Sufficient quantity of deionized water according to the information on the Converter

layout drawing is available

3 Air conditioning of drive room is ready for load run of drive

4 Optional equipment (chiller unit etc.) is ready

4 (4) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual

ABB

Chapter 7 - Operating instructions

7.1 Overview
This manual outlines the local operation using the CDP control panel and
the control switches as illustrated in section 7.3 Control panels after the
drive has been installed and commissioned.
Control of the drive via a PLC or higher-level control systems is not
described in this chapter. If the drive is controlled from remote, see the
appropriate manuals for information.
Note: The panel messages and parameter settings used in this chapter
are typical examples to illustrate the related instructions and display
functions and may therefore differ from the actual messages and
parameter settings in your drive.

7.1.1 Safety
The drive system must only be operated by qualified and authorized
personnel, i.e. personnel who are familiar with the operation of the drive
system and the hazards involved.

7.2 Local control elements

7.2.1 Control panels

The following control panels are provided for local operation of a drive
which is equipped with a line supply unit (LSU) and one or several inverter
units (INU):
• INU control panel(s)
The control panel for the first inverter unit (INU1) is located on the
door of control unit COU 1. The number and location of additional
control panels depends on the configuration of the drive (single or
multi-motor drive, drive for motors with double windings) (see Figure
7-2 and Figure 7-3).

7.2.2 Switches

Main supply The on/off switches for the main supply are installed on the door of COU 1
(see Figure 7-2).

Emergency off An emergency off switch is installed on each control unit with a CDP
control panel. The emergency off switches affect the whole drive when
activated (see Figure 7-2 and Figure 7-3).

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-1 (20)
Chapter 7 - Operating instructions ABB
Grounding switch The grounding switch is installed on the capacitor bank unit (CBU) (see
Chapter 2 - Features and hardware of the drive, Figure 2-38). The switch
can only be actuated if released by the drive.

DC link isolator Drives can optionally be equipped with a manual controlled DC link
isolator. The installation location of the control switch for opening and
closing depends on the configuration of the drive (see Chapter 2 -
Features and hardware of the drive, Figure 2-40). Actuation of the control
switch is released by the drive.

Output switches Drives can optionally be equipped with motorized output isolators or
output grounding switches which are installed between inverter and motor.
The open and closed position of the switches is monitored by the drive.
The switches for actuating the manual output switches are installed inside
the drive cabinets. The installation 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.

IMPORTANT
The user of the drive system must ensure that the motor does not rotate
before the switch is actuated.

The motorized switches are opened or closed automatically by the drive

depending on the operating status of the drive and the settings of the
parameters provided for this function. The possible parameter settings are
shown in Appendix G - Signal and parameter table.

IMPORTANT
The operating personnel must be informed about the types of output
switches present in the drive and the parameter settings for opening and
closing.

Lamp test The bulbs of lamps and illuminated pushbuttons on the doors of control
units (see Figure 7-2 and Figure 7-3) can be tested with the lamp test
function.
The lamp test is activated via the CDP control panel by setting control
parameter 16.7 to lamp test. The lamp-test function resets itself after a set
time.
The indicator lamp for the grounding switch (see Chapter 2 - Features and
hardware of the drive, Figure 2-38) has an integrated momentary
pushbutton. The lamp lights up when the lamp cap is pressed.

7-2 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

7.3 Control panels

7.3.1 Control panel on COU 1 or COU 0

Control panel:
- displays ARU status messages
- displays ARU alarm and fault messages
- resets alarm and fault messages

Figure 7-1 ARU control panel on COU 1 or COU 0 depending on the

drive configuration

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-3 (20)
Chapter 7 - Operating instructions ABB

SUPPLY
OFF ON

2 3

4 5

ALARM EMERGENCY OFF

FAULT RESET

EMERGENCY OFF

Figure 7-2 Local operator panel

7-4 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

1 CDP control panel

Main functions:
Starts and stops the motor
Displays status messages of the INU
Displays alarm and fault messages of the drive and monitored foreign
equipment
Resets alarm and fault messages
2 Main power supply off
Illuminated pushbutton opens the main circuit breaker
3 Main power supply on
Illuminated pushbutton charges the CD link and closes the main
circuit breaker
4 Alarm / Fault lamp
Alarm: flashing light
Fault: permanent light
5 Emergency off reset pushbutton
Resets the emergency off relay in the drive control system
Flashes when the auxiliary voltage is switched on, or when an
emergency off switch is pressed
6 Emergency off latching pushbutton
Prevents starting when pressed at standstill of the drive
Main circuit breaker opens and DC link discharges when pressed
during operation of the drive
See Chapter 8 - CDP control panel for further information on the CDP
control panel.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-5 (20)
Chapter 7 - Operating instructions ABB
7.3.2 Control panel on additional control units

Figure 7-3 INU control panel

1 CDP control panel

- starts and stops the motor
- displays status messages of the drive

7-6 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

- displays alarm and fault messages

- resets alarm and fault messages
2 Alarm / fault lamp
- ALARM: flashing light
- FAULT: permanent light
3 Emergency off latching pushbutton
- prevents starting when pressed at standstill of the drive
- main circuit breaker opens and DC link discharges when pressed
..during operation of the drive

7.4 Status messages

7.4.1 Overview on status messages

The following section lists the messages of the main operating states of
the drive, the drive passes through, when it is put into operation (see 7.4.2
Start sequence of the drive), when it is stopped (see 7.4.3 Stop sequence
of the drive), or when a fault condition has occurred. The messages are
sent to the higher-level control system and are displayed on the CDP
control panel of the drive.

See the status words in Appendix G - Signal and parameter table for
information on other status messages, such as fault status messages in
particular.

NotReadyOn means that the DC link cannot be charged and the drive
Not ready on cannot be connected to the main power supply, i.e. the main circuit
breaker cannot be closed. The status message is displayed, e.g. 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 etc.

The status message signals that the drive is healthy and ready for the ON
Ready 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 pushbutton
on the control compartment of the drive.

The status message ReadyOn changes to Charging when the DC link

Charging capacitors of the drive are being charged.

The message ReadyRun tells the operator that the drive is energized and
Ready run ready for operation. As soon as the start command is initiated, the motor
is magnetized and the drive starts to modulate.

When the drive is in ReadyRef state, it is running and operating according

Ready ref to the set speed or torque reference value. When in remote control mode,

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-7 (20)
Chapter 7 - Operating instructions ABB
the reference value is set at the remote control system. When in local
control mode, the value is entered into the CDP control panel.

Stopping indicates that the drive has received a stop command and that
Stopping a ramp or coast stop has been initiated. The stopping mode depends on
the parameter setting. The status indication changes to ReadyRun when
the zero speed threshold is reached.
When a start command is given while the drive is stopping, the drive
resumes operation and the status indication changes to ReadyRef again.

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

7-8 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

7.4.2 Start sequence of the drive

Not ready on

Ready on conditions:
Auxiliary supply on (400 VAC)
doors of medium voltage units
*ARU Ready on & closed and locked
Drive not grounded
No emergency off
No fault
WCU ready
Ready on

On command

Charging

DC link charges
MCB closes
Cooling system switches on

*ARU Ready ref

Ready run

START command

**INU starts magnetizing

INU starts to modulate

Ready ref

Operation

*only drives with ARU

** only drives for asynchronous drives

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-9 (20)
Chapter 7 - Operating instructions ABB
7.4.3 Stop sequence of the drive

Operation

Ready ref

Stop command

Stopping

Speed ramps down

INU stops to modulate

Ready run

Off command
*Stop command to ARU

MCB opens
DC link discharges
Cooling system switches off
after a delay

*ARU Ready on

Ready on Actions:
Drive is grounded
doors of medium voltage units
are released for opening
Auxiliary supply is switched off
(400 VAC)
Not ready on

*only drives with ARU

7-10 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

7.4.4 Emergency off sequence

Operation

Ready Ref

Emergency off command

*Stop command to ARU

MCB opens
INU stops to modulate
Speed coasts down

Emergency Off

*only drives with ARU

7.5 Starting the drive

It is recommended to have the following documents at hand when starting
the drive system locally for the first time after commissioning:
• Appendix D - Electrical diagrams to identify the circuit breakers to be
switched on
• Appendix A - Additional manuals, Water cooling unit to check that the
water cooling unit is ready for operation
• Chapter 8 - CDP control panel for information on functions and
features of the CDP control panel.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-11 (20)
Chapter 7 - Operating instructions ABB
7.5.1 Checks before starting the drive system

DANGER
Hazardous voltages!
All covers must be screwed in place to prevent unintentional contact with
energized components.

When the drive system 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:
• Check that no tools and foreign objects are left inside the drive.

NOTICE
The cooling system may start automatically as soon as the auxiliary
voltage has been switched on.

• Check that all auxiliary power supplies from external sources are
switched on.
• Check that all internal circuit breakers of the drive are closed.
• Check that all covers are mounted and the doors are closed, locked
and / or bolted.
• Check that the grounding switch is in position not grounded.

Figure 7-4 Grounding switch in position not grounded

• Check that the main circuit breaker is in operating position.

• If the drive is equipped with a DC link isolator, check that the control
switch for the DC link isolator is in the desired position.

7-12 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

7.5.2 Starting the drive system from remote

When the drive system is operated from remote through a higher-level
control system or an operator control desk, follow the instructions in the
appropriate manuals.

7.5.3 Starting the drive system locally

1 Set the CDP control panel to LOCAL mode.

2 If the emergency off reset pushbutton is flashing, press the push-

button to cancel flashing.
Each time the auxiliary voltage is switched off and on again, the emer-
gency off safety relay of the drive is actuated and lets the emergency
off reset pushbutton flash.
The pushbutton also flashes if the emergency off pushbutton on the
control compartment door, or any other emergency off switch linked
to the drive, is pressed. If the pushbutton continuous flashing, verify
that there is no emergency off command active.
See section 7.7 Emergency off for further information.
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
ARU control panel displays ReadyOn:

1 L -> 4840.0 V
StateARU ReadyOn
DC VOLT 0.00 V
PRI VOLT 0V

When no alarms and faults are present and the drive is ready, the INU
control panel displays ReadyOn:

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-13 (20)
Chapter 7 - Operating instructions ABB

1 L -> 0.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

4 Press the SUPPLY ON pushbutton on the door of the control unit to

charge the DC link. The pushbutton flashes during charging.
The status line of the CDP control panel alternates between
Charging and AuxiliaryOn.

1 L -> 0.0 rpm Charging

StateINU Charging
MOTOR SP 0.00 rpm AuxiliaryOn
POWER 0.0 kW

After charging has been finished, the following takes place:

• The main circuit breaker closes automatically.
• The SUPPLY ON pushbutton lights up permanently.

1 L -> 0.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

7-14 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

The ARU control panel changes to ReadyRun:

1 L -> 4840.0 V 0
StateARU ReadyRun
DC Voltage 4400.0 V
COS PHI 0.2

First INU and additional INU(s) (if present) are now in status
ARU NotRun:

1 L -> 0.0 rpm 0

StateINU ARU NotRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

5
Press the start key on the ARU control panel:

The ARU starts modulating and the control panel displays

Modulating.
The status of the ARU changes to Modulating.
When the ARU has reached the status READY REF the status of
the first INU and the additional INU(s) change to READY RUN:

1 L -> 0.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-15 (20)
Chapter 7 - Operating instructions ABB
6 Enter the setpoint.

1 L -> [600.0 rpm] 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

7 Start the motor.

1 L -> 600.0 rpm

StateINU Magnetizing
MOTOR SP 0.00 rpm
POWER 0.0 kW

After the motor has been magnetized, the motor speed ramps up to
the setpoint.
While the motor is magnetizing, the run status indication on the
display blinks. When the motor has finished magnetizing, the run
status indication lights up permanently.
The display shows ReadyRef to indicate that the drive system is
operating:

1 L -> 600.0 rpm

StateINU ReadyRef
MOTOR SP 0.00 rpm
POWER 1000.0 kW

7-16 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

7.6 Stopping the drive

Press the stop key on the CDP control panel.

The motor stops according to the preset stop function. While the motor
stops, the status line of the display shows Stopping and ReadyRef. The
run status indication blinks during the stop sequence.

1 L -> 600.0 rpm

StateINU ReadyRef
MOTOR SP 300.00 rpm
POWER 20.0 kW

As long as the stop sequence is in progress, the drive can always be

restarted by pressing the start key on the CDP control panel.

1 L -> 600.0 rpm 0

StateINU Stopping
MOTOR SP 0.00 rpm
POWER 0.0 kW

When the drive has stopped modulating, the CDP control panel displays
ReadyRun:

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, the motor can be started again.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-17 (20)
Chapter 7 - Operating instructions ABB
7.7 Emergency off

7.7.1 Function
The drive is equipped with a hardwired emergency off circuit. If an
emergency situation occurs during operation, this safety feature ensures
that the drive system can be disconnected without delay from the main
power supply. When the emergency off pushbutton has been pressed
while the drive is discharged, the main power supply cannot be connected
to the drive, hence the drive cannot be started up.
The emergency off pushbutton of the drive is part of the local operator
panel (see Figure 7-2) and features a latching switch action.
Note: Pressing the emergency off pushbutton does not disconnect the
auxiliary power supply from the drive.

7.7.2 Initiating an emergency shutdown

An emergency shutdown is initiated by pressing the emergency off
pushbutton on the door of the drive control unit or an external emergency
off pushbutton (if present) linked to the emergency off circuit.
When an emergency shutdown is initiated during operation, the following
takes place:
• The MCB opens
• The drive system coasts down
• The DC link of the drive discharges
• The status line of the CDP control panel alternates between the mes-
sage EmergencyOff, NotReadyOn.

1 L -> 600.0 rpm

StateINU EmergeOff EmergencyOff
NotReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

• The EMERGENCY OFF RESET button flashes

• The SUPPLY-OFF pushbutton flashes

7.7.3 Starting the drive system after an emergency shutdown

To start up the drive system after an emergency shutdown, the emergency
off pushbutton must be unlatched. The emergency off pushbutton returns
to its initial position when turned into the direction indicated by the arrows
on the pushbutton. Then, the emergency off reset button must be pressed

7-18 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 7 - Operating instructions

in order to reset the emergency off memory in the control system of the
drive.
Note: The drive remains in Emergency Off state until the DC link voltage
has dropped to < 50 V (discharged).
The status line of the CDP control panel alternates between the messages
EmergencyOff and EOFF<DCVolt.

1 L -> 600.0 rpm

StateINU EmergencyOff EmergencyOff
EOFF<DCVolt
MOTOR SP 0.00 rpm
POWER 0.0 kW

After resetting, the status indication of the drive changes to ReadyOn.

1 L -> 0.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

Now, the main power supply can be connected to the drive again and the
drive system can be started up.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 7-19 (20)
Chapter 7 - Operating instructions ABB

7-20 (20) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 8 - CDP control panel

8.1 Overview
Note: The CDP control panel messages and parameter settings used in
this chapter are typical examples to illustrate the related instructions and
display functions and may therefore differ from the actual messages and
parameter settings in your drive.

8.1.1 CDP control panel details

The CDP control panel is located on the front of the control compartment
door. The CDP control panel can be removed from its mounting cradle.
The reaction of the drive when the CDP control panel is removed during
operation depends on the setting of parameter 31.01 PANEL LOSS
SUPERVISION. If the setting is NOT USED, the CDP control panel can be
removed without interrupting drive operation.
See Chapter 9 - Troubleshooting and maintenance, 9.5 Panel removal for
removal instructions.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-1 (24)
Chapter 8 - CDP control panel ABB
8.1.2 Display and keypad

1 L -> 1242,0 rpm

StateINU ReadyOn
Display
MOTOR SP 1242 rpm
POWER 86.0 kW

3
2 4
Keypad
7
5 8
6
9 11
10

Figure 8-1 CDP control panel

1 Mode selection keys

2 Fast navigation keys, select and / or change a value fast
3 Slow navigation keys, select and / or change a value slowly
4 Enter key,
Terminates a procedure
5 Local / remote selection key
6 Reset key
7 Reference key
8 Start key
9 Forward key
10 Reverse key
11 Stop key

8-2 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

8.2 Overview on CDP control panel functions

The CDP control panel serves as the basic user interface for operating
and monitoring the drive when the local operating mode has been
selected.
The CDP control panel can be attached to or detached from the drive
without having to switch off the auxiliary power supply first.
Using the CDP control panel it is possible to:
• enter start-up data,
• control the drive with a reference value and start, stop and direction
commands,
• display actual values (three values can be read simultaneously),
• display and adjust parameters,
• display information on the most recent forty fault events,

8.3 Overview on CDP control panel modes

The CDP control panel provides the following modes:
• Identification mode
See section 8.4 Identification mode for further information.
• Actual signal display mode
See section 8.5 Actual signal display mode for further information.
• Parameter mode, selected by the PAR key
See section 8.6 Parameter mode for further information.
• Function mode, selected by the FUNC key
See section 8.7 Function mode for further information.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-3 (24)
Chapter 8 - CDP control panel ABB
8.4 Identification mode
When the drive is energized or the CDP control panel is connected to the
drive and the auxiliary voltage has been switched on already, the
identification display appears showing the CDP control panel version
and then the ID-number of the drive. When the CDP control panel is
initialized, the display changes as follows:

CDP312 PANEL V5.30

........

After 2-3 seconds information on the drive (1 and 2), the application
software in use (3), and the drive identification (4) is displayed.

ACS 6000 xxxx 1

< Device Name > 2
LXAH44xx 3
ID-NUMBER 1 4

After another few seconds:

1 L -> 0.0 rpm

StateINU InitSeq....
MOTOR SP 0.00 rpm
POWER 0.0 kW

8-4 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

After another few seconds, the display changes to the actual signal
display mode. The status line of the display alternates between DCGnd
NOpen, NotReadyOn:

1 L -> 0.0 rpm

StateINU DCGndNopen DCGnd Nopen
NotReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

8.5 Actual signal display mode

8.5.1 Overview
Two displays can be selected in the actual signal display mode:
• Actual signal display
• Fault history display
The actual signal display appears first when the actual signal display
mode has been selected. However, when the drive is in a fault condition,
the fault display will be shown instead.
The actual signal display is used to monitor the drive without interfering
its operation. Three selectable actual values are shown continuously on
the display.
The CDP control panel will automatically return to the actual signal
display mode from other modes within one minute when no keys are
pressed (exceptions: status display and common reference display
when in drive selection and fault display mode).

Actual values

Group 01 Measured or calculated motor values

Group 02 Measured or calculated drive values

Group 03 Reference values

Group 04 Status signals of S800 I/O system

Group 05 Communication link and MCB status signals

Group 06 Software version, drive and motor nominal values

Group 07 Control words

Group 08 Status words

Group 09 Fault and alarm words

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-5 (24)
Chapter 8 - CDP control panel ABB
See Appendix G - Signal and parameter table for the complete list of
selectable actual signals.

Control panel overview

1 L -> 600.0 rpm 1

StateINU ReadyOn
MOTOR SP 0.00 rpm 2
POWER 0.0 kW

4
5
6

1 Status line
2 Actual signal names and values
3 Selects the function mode
4 Selects actual signal / fault
5 Scrolls through signal / fault message
6 Enters the selection mode; acknowledges the selection

Fault memory The fault memory includes information on the 64 most recent fault events
that occurred in the drive. The name of the fault and the actual time are
displayed. The procedure for selecting and clearing the fault history is
described in section 8.5.5 Displaying and resetting an active fault.
When a fault or warning is generated in the drive, the message will be
displayed immediately.
Changing from the fault display mode to other display modes is possible
without resetting the fault first. When no keys are pressed, the fault or
warning text is displayed as long as the fault is pending.

8-6 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

Selecting the actual The actual signal display mode is selected by pressing the ACT key.
signal display

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

Toggle between actual When in actual signal display mode, the fast up / down keys allow to
signal display and fault toggle between actual signal display and fault history display.
history

1 L -> 600.0 rpm

1 LAST FAULT
+Overspeed
070730 12:30:02.3256

8.5.2 Displaying three actual signals

1 To display the full name of three actual signals, press and hold the
ACT key:

1 L -> 600.0 rpm

StateINU
MOTOR SPEED
POWER

2 To return to the actual signal display, release the ACT key.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-7 (24)
Chapter 8 - CDP control panel ABB
8.5.3 Selecting actual signals
1 To select the actual signal display, press the ACT key.:

1 L -> 600.0 rpm

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

2 To select a row where the actual signal is to be displayed, press the

corresponding slow navigation key. A blinking cursor indicates the
selected row.

1 L -> 600.0 rpm

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

3 To enter the actual signal selection function, press the ENTER key:

1 L -> 600.0 rpm

1 ACTUAL SIGNALS
15 POWER
0.0 kW

8-8 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

4 To select a parameter group, press the corresponding fast naviga-

tion key:

1 L -> 600.0 rpm

2 ACTUAL SIGNALS
01 DC VOLTAGE
1000 V

5 To select an actual signal, press the corresponding slow navigation

key:

1 L -> 600.0 rpm

2 ACTUAL SIGNALS
05 NP VOLTAGE
1000 V

6 To accept the selection and to return to the actual signal display

mode, press the ENTER key:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
NP VOLT 0V

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-9 (24)
Chapter 8 - CDP control panel ABB
7 To cancel the selection and keep the original selection, press any of
the mode keys:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

The selected keypad mode is entered.

8.5.4 Displaying a fault and resetting the fault history

1 To enter the actual signal display mode, press the ACT key:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

2 To enter the fault history display, press any of the fast navigation
keys:

1 L -> 600.0 rpm

1 LAST FAULT
+ PANEL LOST
0707730 12:30:02.3256

8-10 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

3 To select the previous or next fault, press the corresponding slow

navigation key. The up key selects the previous, the down key the
next fault.

1 L -> 600.0 rpm

2 LAST FAULT
+ AMC: Fault Class 1
0707730 12:30:02.3256

4 To clear the fault history, press the RESET key:

1 L -> 600.0 rpm

1 LAST FAULT

H MIN S

5 To return to the actual signal display mode, press any of the fast
navigation keys:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-11 (24)
Chapter 8 - CDP control panel ABB
8.5.5 Displaying and resetting an active fault
1 To display an active fault, press the ACT key:

1 L -> 600.0 rpm

ACS 6000
*** FAULT ***
CW1 NoWtrPumpOn

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

8.6 Parameter mode

NOTICE
Running the drive system with incorrect data can result in improper oper-
ation, reduction of control accuracy and damage of equipment. Do not
change any parameter, if the meaning of the parameter and the effects of
the change are not fully understood.

8.6.1 Overview
Parameters allow the drive to be configured and set-up specifically for an
application. Parameters are organized in functional groups. All control
functions are represented by a parameter group and can be activated and
set-up individually by the parameter mode.

8-12 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

Group 07 Control words 21.01 Start function

Group 08 Status words 21.02 Stop function

Group 09 Fault & alarm words 21.03 Off1 stop mode

Group 11 Start/stop/direction/MCB control 21.04 Process stop selection

Group 12 Reference selection 21.05 Process stop signal

Group 16 System control inputs 21.06 Process stop reaction

Group 17 DC link control 21.07 Process stop mode

Group 18 Utility .

Group 19 Data storage .

Group 20 Limits .

Group 21 Start/stop/process stop 21.17 MCB control signal

Group 22 Ramp functions 21.18 MCB feedback signal

Group 23 Speed reference 21.19 MCB presignal trip

See Appendix G - Signal and parameter table for further information on the
parameters, their settings and functions.
When the parameter mode is entered for the first time after the auxiliary
voltage of the drive has been switched on, the display will show the first
parameter of parameter group 11. The next time the parameter mode is
entered, the previously selected parameter is shown.
Some parameter values cannot be changed while the drive is running. If
tried, the following warning will be displayed:

** WARNING **
WRITE ACCESS DENIED
PARAMETER SETTING
NOT POSSIBLE

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-13 (24)
Chapter 8 - CDP control panel ABB

1 L -> 600.0 rpm Status line

77 SYSTEM CONFIG Group number and name
01 INU IdentifySel Parameter number and name
INU1 (MASTER) Parameter value

Selects the parameter mode

Selects the parameter number and
name
Selects the parameter value

Enters change mode

Acknowledges the selection

8.6.2 Procedure
1 To enter the parameter mode, press the PAR key:

1 L -> 600.0 rpm

77 SYSTEM CONFIG
01 INU IdentifySel
INU1 (MASTER)

8-14 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

2 To select a different group, press the corresponding fast navigation

key:

1 L -> 600.0 rpm

75 OPTION MODULES
06 C3P1/AI820 Module
DISABLED

3 To select a parameter, press the corresponding slow navigation key:

1 L -> 600.0 rpm

75 OPTION MODULES
07 C3P2/DI81x Module
DISABLED

4 to enter the parameter setting function, press the ENTER key:

1 L -> 600.0 rpm

75 OPTION MODULES
07 C3P2/DI81x Module
[DISABLED]

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-15 (24)
Chapter 8 - CDP control panel ABB
5 To change the parameter value, press
• the corresponding slow navigation key for numbers and text
• the corresponding fast navigation key for numbers only.

1 L -> 600.0 rpm

75 OPTION MODULES
07 C3P2/DI81x Module
[DI810 24VDC]

6 To accept the selection and to return to the actual signal display

mode, press the ENTER key:

1 L -> 600.0 rpm

75 OPTION MODULES
07 C3P2/DI81x Module
DI810 24VDC

7 To cancel the setting and keep the original selection, press any of the
mode keys. The selected keypad mode is entered.

1 L -> 600.0 rpm

75 OPTION MODULES
07 C3P2/DI81x Module
DISABLED

8-16 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

8.6.3 Parameter Lock

Unwanted parameter entry can be prevented by activating the
ParameterLock function which is part of parameter group 16 SYSTEM
CTRL INPUTS.
The ParameterLock is activated by setting parameter 16.02.

Activating the 1 Select parameter 16.02 PARAMETER LOCK.

ParameterLock:
2 Set parameter 16.02 to LOCKED.
3 Save the setting and exit the parameter mode.

Opening the Parame- 1 Select parameter 16.03 PASSCODE.

terLock:
2 Set the pass code 358.
3 Save the setting and exit the parameter mode.

See Appendix G - Signal and parameter table for further information.

8.7 Function mode

8.7.1 Overview
The function mode is used to set the display contrast.

1 L -> 0.0 rpm Status line

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4 Selectable function

Selects the function mode

Selects the line

Acknowledges the selection

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-17 (24)
Chapter 8 - CDP control panel ABB
8.7.2 Procedure
1 To enter the function mode, press the FUNC key:

1 L -> 0.0 rpm

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4

2 To select a function (a blinking cursor indicates the selected function),

press the corresponding slow navigation key:

1 L -> 0.0 rpm

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4

3 To enter the contrast setting function, press the ENTER key:

1 L -> 0.0 rpm

CONTRAST [4]

8-18 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

4 To change the contrast value, press the corresponding slow naviga-

tion key:

1 L -> 0.0 rpm

CONTRAST [6]

5 To accept the selection and to return to the actual signal display

mode, press the ENTER key:

1 L -> 0.0 rpm

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6

6 To cancel the setting and keep the original selection, press any of the
mode keys. The selected keypad mode is entered:

1 L -> 0.0 rpm

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-19 (24)
Chapter 8 - CDP control panel ABB
8.8 Operational commands

8.8.1 Local remote control location

The local / remote feature of the CDP
control panel allows the operator to select
the control location of the drive:
• Local control
• Remote control
The control location is selected by
pressing the LOC / REM key on the CDP
control panel.

Local control When the CDP control panel is switched to local, operation via the
pushbuttons on the control compartment door and the CDP control panel
is possible. Control commands from remote have no effect.

Remote control When the CDP control panel is switched to remote, the pushbuttons on
the control compartment door and the operational keys of the CDP control
panel are normally disabled. Operational commands and reference value
from a remote control station are transmitted via fieldbus or remote I/O to
the drive. The control panel can also be used as a remote control place if
selected (see section Selecting remote).

Selecting local To select local control, press the LOC / REM key. The local control location
is indicated by the letter L.

1L 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

8-20 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

Selecting remote To select remote control, press the LOC / REM key. The remote control
location is normally indicated by a blank (see arrow).

1 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

The letter R (see arrow) is indicated if the control panel is used as a remote
control place. In this case the parameter 11.01 or 11.02 or 12.03 or 12.06
is set to KEYPAD and the START/STOP command can be given and the
reference value can be set from the CDP control panel.

1R 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

8.8.2 Locking local or remote control mode

Accidental switching from remote control to local control can be prevented
with the lock function of parameter 16.04.
The parameter 16.04 LOCAL LOCK locks or unlocks the LOC / REM key
of the CDP control panel and determines the control place where the lock
function is activated (CDP control panel or remote control place).

Disable lock function The lock function is disabled if the parameter 16.04 is set to 1 (= OPEN).
Switching from local to remote and vice versa is possible.

Enable lock function The lock function is enabled if the parameter 16.04 is set to 2 (= LOCKED).
In this case local cannot be selected on the CDP control panel. However,
the CDP control panel or the Drive Window PC remain in local mode if they
had already been in local mode when the parameter was set to locked,
until the CDP control panel is switched to remote.
The letter L remains on the display until the LOC / REM key has been
pressed.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-21 (24)
Chapter 8 - CDP control panel ABB
8.8.3 Setting the direction of rotation
The direction of rotation is selected using the forward (I) or reverse (0)
key of the CDP control panel. Both keys can be used if the CDP control
panel is in local mode. The function is released with parameter 11.03
DIRECTION (REQUEST).

1 L -> 600.0 rpm

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

1 L <- 600.0 rpm

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

The arrow on the display indicates the direction:

• When the motor is running, the arrow indicates the actual sense of
rotation.
• When the motor is not running, the arrow indicates the preselected
sense of rotation.
When the direction of rotation is changed while the motor is running, the
speed will automatically ramp to zero and the motor will accelerate in
opposite direction to the preset speed. The direction of the arrow on the
display changes to the new direction when the motor has reached zero
speed.

8-22 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 8 - CDP control panel

8.8.4 Entering a setpoint

The setpoint can be changed at any time if the CDP control panel has
been set to local.
1 To enter a keypad mode displaying the status row, press ACT mode
key:

1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

2 To enter the setpoint setting function, press the REF key:

1 L -> [600.0 rpm] 0

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

3 To change the setpoint, press either the corresponding fast or slow

navigation key:

1 L -> [550.0 rpm] 0

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 8-23 (24)
Chapter 8 - CDP control panel ABB
4 To exit the setpoint setting mode, press any of the mode keys:

1 L -> 550.0 rpm 0

StateINU ReadyRun
MOTOR SP 550.00 rpm
POWER 75.0 kW

8.8.5 Run status indication

The run status indication on the display (see arrows) changes depending
on the state the inverter is in:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 600.00 rpm
POWER 0.0 kW

1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 600.00 rpm
POWER 75.0 kW

1 L -> 600.0 rpm

StateINU ReadyRef
MOTOR SP 600.00 rpm
POWER 75.0 kW

8-24 (24) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB

Chapter 9 - Troubleshooting and maintenance

9.1 General information

9.1.1 Required qualification

Maintenance and parts replacement on the drive must only be carried out
by qualified personnel, and in compliance with local regulations.

9.1.2 Warranty period

During the warranty period of the drive, any repair work must be carried
out exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by qualified personnel.

9.1.3 Training courses

ABB offers maintenance and service training courses. Customer staff
having successfully attended such courses, will be certified to do
maintenance and repair work on the drive. To maintain safe and reliable
operation of the drive, ABB recommends taking out a service contract with
the ABB service organization.
For more information contact the ABB service organization. See section
General information on manual and equipment for address.

9.1.4 Maintenance schedule

It is strongly recommended to carry out all maintenance tasks according
to the maintenance schedule and the applicable service instructions, on
time and at the stated intervals.

9.1.5 Log book

It is recommended to record all maintenance activities in the maintenance
log book including:
• Date and time
• Detailed description

9.1.6 Spare parts

To ensure safe and reliable operation, it is important to use only spare
parts recommended and approved by ABB.

See Appendix E - Parts list for information on types and identification

codes.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-1 (26)
Chapter 9 - Troubleshooting and maintenance ABB
9.2 Identifying electrical equipment

9.2.1 Device designation

All devices are labelled as per DIN for easy identification of the
components in wiring diagrams and parts lists.

Figure 9-1 Device designation

9.2.2 Cables and wires

Cables and wires in the drive are equipped with marker sleeves which
carry the same identification number as in the wiring diagrams.

Terminal number

Wire number
Figure 9-2 Cable and wire identification

9-2 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

9.2.3 Understanding wiring diagrams

See Appendix D - Electrical diagrams for information on item designation

and cross-reference conventions.

9.3 Troubleshooting

9.3.1 Alarm and fault messages

When a malfunction occurs in the drive or in the equipment monitored by
the drive (e.g. MCB, transformer, cooling system), the CDP control panel
displays a corresponding alarm or fault message and the alarm / fault lamp
on the control compartment door lights up:
• Alarm: flashing light
• Fault: permanent light

SUPPLY
OFF ON

1 L -> 600.0 rpm

ACS 6000
*** FAULT ***
CW1 NoWtrPumpOn
ALARM EMERGENCY OFF
FAULT RESET

EMERGENCY OFF

The display message can be saved and viewed in the fault logger of the
drive when a PC with the DriveWindow, DriveDebug or DriveMonitorTM
tool is connected to the drive. The fault logger can also be called up on the
CDP control panel.

9.3.2 Error message levels

Two error message levels are used in the drive:

Alarm / warning An alarm does not shut-down the drive. However, a persisting alarm
condition can often lead to a fault if the condition causing the alarm is not
corrected. An alarm cannot be reset manually. The alarm message will be

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-3 (26)
Chapter 9 - Troubleshooting and maintenance ABB
deleted from the display as soon as the alarm condition has been
corrected.

Fault A fault always shuts down the drive. The type of shutdown depends on the
origin of the fault.
Depending on the type of fault, the main circuit breaker (MCB) is opened
by the drive or stays closed:
• Class 1 faults (FC 1) open the MCB
• Class 2 faults (FC 2) do not open the MCB
Since the MCB is controlled and monitored entirely by the drive, no
external opening command must be given to the MCB when a fault
condition occurs.
In general, a fault condition must be corrected and the fault be manually
reset before the drive can be started again.

Alarm / fault handling In the event of an alarm or a fault, a specific message is saved in the fault
logger of the drive. Information on the 64 most recent fault and alarm
events are saved.
The faults are entered into the fault buffer as they occur and are
numbered; the last fault entered always has number 1 assigned to it and
the first fault always has the highest number in the fault buffer.
Information of the fault classification (e.g. FC 1 or FC 2) is also saved
when the first fault of the fault class is active. Date and time stamps
facilitate fault tracing, especially when a fault leads to several subsequent
faults.
Example:
1. +Fault AMC: Fault Class 2 2008-01-08 16:58:24.3770
2. +Fault PPCS Communication 2008-01-08 16:58:24.3760
3. +Fault AMC: Fault Class 1 2008-01-08 16:56:02.1170
4. +Fault DC Undervoltage 2008-01-08 16:56:02.1170
In the above example:
• 4. +Fault DC Undervoltage is the reason for the failure of the drive
system as it occurred first.
• The message 3. +Fault AMC: Fault Class 1 classifies the fault.
• The message 2. +Fault PPCS Communication occurred 2 min. 22 s
later than the first fault due to another fault in the drive system.
• The message 1. +Fault AMC: Fault Class 2 informs about the
pending fault class.

See Appendix G - Signal and parameter table for further information.

9-4 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

9.3.3 Standard troubleshooting procedure

In the event that a malfunction shuts down the drive, it is recommended to
proceed as follows:
1 Do not switch off the auxiliary voltage or try to reset a fault message
before all essential information at the time of the occurrence of the
fault condition has been saved.
2 Call up the Fault History Display on the CDP control panel.
See Chapter 7 - Operating instructions for further information.
Do not clear the fault buffer now!
3 Identify the fault and make a log book entry.
4 Save the content of the data logger when a PC is available which has
the DriveWindow or DriveDebug tool installed.
The data logger provides useful information (e.g. waveforms of
voltage, current, torque etc.) 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:
• Operating, ambient and load conditions
• Unusual events
After the fault has been rectified, start the drive as described in Chapter 7
- Operating instructions.

9.4 Malfunctioning grounding switch

When the DC link of the drive has been de-energized, 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 and there is reason to assume that the
grounding circuit is malfunctioning, proceed as follows:
1 Do not try with force to turn the grounding switch in any direction.
The switch could be damaged if tried.
2 Verify that the MCB is in the open position.
3 Check the drive status from the CDP control panel.
The message ReadyOn is displayed when the DC link of the drive
has been discharged.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-5 (26)
Chapter 9 - Troubleshooting and maintenance ABB

1 L -> 0.0 rpm 0

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

4 Verify that the DC link has been discharged.

The discharging level can be viewed in parameter 2.01 DC
VOLTAGE. The value should be below 50 V.
5 Check if there are any alarm and fault messages on the display.
6 Try to rectify the reason for the alarms and faults, and then press the
reset key on the CDP control panel.

7 Call ABB service if the cause for the malfunctioning grounding switch
cannot be rectified.
See section General information on manual and equipment for
address.

9.5 Panel removal

Procedure 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.
If the parameter is set to NOT USED, the panel can be removed
without interrupting drive operation.
See Signal and parameter table if information on setting parameters
is required.
Note: When the CDP control panel has been removed during opera-
tion, the drive can only be stopped by pressing the emergency off
button.

9-6 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

2 Proceed as illustrated below.

1 2 3

Meaning of the LEDs The green LED (see arrow in 3) is illuminated when the control voltage has
been switched on.
The red LED is not used.

Dimensions and weight Dimensions (L x W x H): 170 x 80 x 21 mm

Weight: 0.2 kg

9.5.1 Communication link

The CDP control panel (1) is connected to the AMC controller of the INU
(2). Communication between the devices is accomplished via an RS485
interface.

See Appendix G - Signal and parameter table for further information on

parameter settings.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-7 (26)
Chapter 9 - Troubleshooting and maintenance ABB

2
1 L -> 1242,0 rpm
StateINU ReadyOn
MOTOR SP 1242 rpm
POWER 86.0 kW

9.6 LEDs and switches on PCBs and I/O devices

The following section provides an overview on the meaning of LEDs and
switches of the main circuit boards and I/O devices. The LEDs presented
in the following section can be checked easily while the auxiliary voltage
is switched on without having to remove covers first. The LEDs provide
information on the status of the devices and can be used for diagnostic
purposes.

9.6.1 AMC circuit board

F R

M P

T1 T2

S3 S1

S4 S0

Cover removed for illustration purposes

Figure 9-3 AMC circuit board

9-8 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

LED Color Function

F red Fault, not used (ON when booting)

R green Run, always OFF

M green Not used (ON when booting)

P green Supply OK

T1 yellow ON = receiving data on DDCS channel 0

T2 yellow ON = receiving data on DDCS channel 3

S3 yellow Always OFF

S1 yellow Always OFF

S4 yellow Always OFF

S0 yellow Always OFF

9.6.2 S800 I/O - TB820 bus modem

Figure 9-4 TB820 bus modem

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-9 (26)
Chapter 9 - Troubleshooting and maintenance ABB

LED Color Function

F Red Fault in module

R Green Run, device in operation

P Green Power supply is healthy

Rx1 Green Traffic on optical ModuleBus

Rx2 Green Traffic on optical ModuleBus

ERx Green Traffic on electrical ModuleBus

9.6.3 S800 I/O bus modem address

The TB820 bus modem has a unique cluster address that identifies the
module in the software and links it to a parameter.
The address is set with the rotary switch on the module (see arrow in
Figure 9-4). The factory set value must not be changed.

9.6.4 S800 I/O modules

LEDs on I/O modules having the same meaning on all types of I/O
modules are always at the same position. The LEDs are always located at
the topmost position on each module (see arrows in Figure 9-5) and can
be identified as follows:
• F: fault
• R: run
• W: warning
• O or OSP (only output modules)

Figure 9-5 S800 I/O station

9-10 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

LED Color Meaning

F Red Fault Indicates malfunction

R Green Run Device is operating normally

W Yellow Warning External fault or minor fault in the module

O (OSP) Yellow - (Output Set as Predetermined)

Indicates an active signal

- Yellow - Indicates an active signal

See the following manuals for further information:

• S800 I/O - General information and installation, user’s guide
• S800 I/O - Modules and termination unit, user’s guide

9.7 Maintenance and service

9.7.1 Overview on maintenance and service tasks

• Visual checks on the drive
See section 9.7.4 Visual checks on the drive.
• Checking wire and cable connections
See section 9.7.6 Checking wire and cable connections.
• Checking and replacing filter mats
See section 9.7.7 Checking and replacing filter mats.
• Replacing door-mounted fans
See section 9.7.8 Replacing door-mounted fans.
• Replacing a fan unit
See section 9.7.9 Replacing the heat exchanger.
• Replacing and initializing delay timer relays
See section 9.7.10 Replacing and initializing delay timer relays.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-11 (26)
Chapter 9 - Troubleshooting and maintenance ABB
9.7.2 Safety

DANGER
Hazardous voltages!
Before starting to work on the drive, make sure that:
• the main and auxiliary power supply to the drive is switched off,
locked out, and tagged out,
• the drive is dead,
• safety ground connections are in place,
• personal protective equipment is provided and used when required,
• everyone involved is informed.
Before energizing the drive, make sure that:
• all foreign objects are removed from the drive,
• all internal and external covers are securely fastened and all doors
are closed, locked and / or bolted.

DANGER
Hazardous voltages!
When maintenance on the drive is carried out that includes the removal of
phase modules, the connection of grounding equipment at the appropriate
locations is a must. The grounding equipment ensures that hazardous
voltages cannot be fed into the drive neither from the main power supply
nor the motor.

NOTICE
When working on the drive ensure that foreign matter cannot enter the
cabinet. Close the doors and cover openings completely when work is
discontinued. Any foreign matter which accidentally dropped into the
cabinet must be retrieved. Metallic dust in particular could cause malfunc-
tion and damage when the drive is energized.

9-12 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

WARNING
Depending on the type of auxiliary supply, the drive can be equipped with
buffer capacitors inside the COU.
During operation, the capacitor voltage is 300 VDC over ground. Wait
5 minutes for the capacitors to discharge. Before touching a capacitor,
verify that the capacitors have been completely discharged.

9.7.3 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.

Procedure 1 Stop the motor.

When the motor has reached zero speed, the display shows
ReadyRun:

1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

2 Press the SUPPLY OFF pushbutton to disconnect the drive from the
main power supply. The following takes place:
• The MCB opens
• The DC link discharges
While the DC link discharges, the status line of the display alter-
nates between OffSeqOn/Discharging/AuxiliaryOn:

1 L -> 600.0 rpm

OffSeqOn
StateINU OffSeqOn Discharging
MOTOR SP 0.00 rpm AuxiliaryOn
POWER 0.0 kW

• The SUPPLY OFF pushbutton flashes and changes to a perma-

nent light when the DC link is discharged completely.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-13 (26)
Chapter 9 - Troubleshooting and maintenance ABB
When the DC link is discharged, the display shows ReadyOn:

1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

3 Lockout, ground and tagout the main circuit breaker.

4 Turn the grounding switch to the grounded position.

NOTICE
Do not turn the grounding switch to the grounded position before the light
GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will be
damaged.

If the lamp does not light up and there is reason to believe that the
grounding circuit is malfunctioning, see 9.4 Malfunctioning grounding
switch for further information.
When the grounding switch is in the grounded position, the status
line of the display alternates between DCGnd NOpen, NotReadyOn:

1 L -> 600.0 rpm

StateINU DCGnd NOpen DCGnd Nopen
NotReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

5 Switch off all auxiliary voltages from external sources.

Refer to 9.7.11 Grounding the drive with a 4-way grounding set for
information on grounding the drive with a 4-way grounding set.

9-14 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

9.7.4 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

See Rating label of the drive for information on permitted air temper-
ature range.
• Dust built-up inside the drive room and inside the drive
• Signs for overheated components, wires, cables or busbars
• Corrosion on electronic circuit boards, connectors or busbars
• Appropriate fastening of cables and wires and connections of cable
shields and screens
See Chapter 5 - Electrical installation for further information.
• Integrity of cable insulation
The outer jacket of a cable must not be damaged.
• Correct type of signal and power cables
See applicable cable specifications for reference.

9.7.5 Cleaning
Dust on electrical components and wiring can cause malfunction and
damage the components. Dust and moisture can build up in loose
connections and cause loss of low-level signals.
For these reasons, the cabinet should be checked regularly and cleaned
if necessary.
When cleaning the drive cabinet, mind the following:
• Cover equipment or assemblies to prevent dirt from falling into it.
• The drive contains components which are sensitive to electrostatic
discharge. Therefore, take electrostatic-sensitive precautions and
use suitable tools when cleaning circuit boards and assemblies which
are sensitive to electrostatic discharge.
Circuit boards should be cleaned with special care using antistatic
brushes and a vacuum cleaner with a soft nozzle to prevent compo-
nent damage.
• Dust inside the cabinet (assemblies, busbars etc.) can be removed
with a vacuum cleaner and lint-free cleaning cloths.
• Water, oily or greasy deposits on assemblies, components, busbars
etc. should be removed with water- and oil-absorbing microfibers
such as "3M Scotch Brite".

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-15 (26)
Chapter 9 - Troubleshooting and maintenance ABB
• Use a nylon brush or a vacuum cleaner to remove dust or deposits
from holes.
• The outside of the drive enclosure can be cleaned using a vacuum
cleaner and cleaning cloths.
• Do not use alcohol or solvents.

9.7.6 Checking wire and cable connections

Vibration can loosen electrical connections and cause occasional
malfunction or equipment failure.
Check all power and control cable connections and tighten them if
necessary. Check that all plugs and connectors are tight.

NOTICE
Capacitor bushings will be damaged when excessive force is applied. Do
not exceed the maximum tightening torque when tightening the capacitor
terminals. The tightening torque value is printed on a label which is
attached to the capacitor. If not otherwise specified, the maximum torque
must not exceed 20 Nm.

9.7.7 Checking and replacing filter mats

Location The filter mats are located at the air intake and air outlet panels of the
following sections:
• COU (1)
• WCU (2)

9-16 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

1 2

The filter mat (1) is located between the louvered panel (2) and the woven
wire mesh (3) in drives with insulation protection IP 54. See Figure 9-6 for
illustration. The woven wire mesh (size 1 mm) is always installed,
irrespective of the insulation protection of the drive.

2 1 3

Figure 9-6 Location of filter mat

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-17 (26)
Chapter 9 - Troubleshooting and maintenance ABB
Checking and Filter mats should be checked regularly. The intervals in which the mats
replacement are checked depend on the cleanliness of the cooling air.
indications

Filter mat characteristic Use only replacement filter mats of the same filter class and size as the
original filter mat:
• Filter class: G3 (EN779)
• Thickness: approximately 10 mm

Dimensions
20.5 mm

20.5 mm 24.5 mm

24.5 mm

Replacement

The cooling fans behind the air outlet panels may start automatically when
the temperature rises to a certain level. In order to prevent this the
corresponding protection switch of the cooling fan must be switched off
according to Appendix D - Electrical diagrams.
It is recommended to roll down the filter mat beginning at the top.
To replace a filter mat, the louvered panel of the corresponding unit is
removed.
The panels are secured to the cabinet by hex-head screws. They require
a 7 mm spanner. The screws are accessible when the door is opened as
illustrated in Figure 9-7. (The illustration does not show a filter mat.)

9-18 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

Figure 9-7 Removing the louvered panel

The panel (1), the woven wire mesh (2) and the filter mat (not shown) can
now be removed and the filter mat replaced.

1 2

9.7.8 Replacing door-mounted fans

Location of the fans Four-fan units are installed on the back of the cabinet doors of the COU
and WCU.
1 2 1 1

Figure 9-8 Four-fan unit

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-19 (26)
Chapter 9 - Troubleshooting and maintenance ABB
Location of thermostats

The fans are controlled by thermostats. A thermostat can control a group

of fan units or a single fan. Refer to the wiring diagrams of the above
mentioned units in Appendix D - Electrical diagrams to identify the
thermostat and the fans connected to it.
The thermostat for fans installed in the COU is located on the control swing
frame of a COU (-B2981) (1).
The thermostat controlling the fans in a WCU is installed on the control
swing frame inside the WCU (-B5741) (2).

1 2

Figure 9-9 Thermostat on the control swing frame in the COU and in the
WCU

Replacement instruc- The replacement can be performed on the running drive. Proceed as
tion follows:

1 Switch off the corresponding miniature protection switch (Q2981 for

the fans in the COU and Q5741 for the fans in the WCU).
See Appendix D - Electrical diagrams for further details.
2 Unscrew and remove the cables (2 in Figure 9-8).
3 Unscrew the three fastening screws (1 in Figure 9-8).
4 Replace the four-fan unit.
5 Remount the new fan unit in reverse order.

9.7.9 Replacing the heat exchanger

See the Chapter 4 - Mechanical installation, 4.6.6 Installing roof-mounted
heat exchangers for further information on the heat exchanger
replacement.

9.7.10 Replacing and initializing delay timer relays

If one of the delay timer relays K2831, K2832, K2833, K2834, K2861 and
K2862 has to be replaced it is imperative that the two-way contacts of the
new relay are in the correct position. Otherwise the drive cannot be started
up.

9-20 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

The relays are located in COU 1000 mm (see rectangle in Figure 9-10).
The relays K2861 and K2862 are optional and can also be located in COU
600 and 800 mm. The presence of COU 600 and 800 mm in a line-up
depends on the configuration of the drive.

Typical COU 1000 mm

230 VAC 24 VDC

control voltage control voltage

optional

Figure 9-10 Location of timer relays in control units

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-21 (26)
Chapter 9 - Troubleshooting and maintenance ABB

DANGER
Voltages of up to 690 VAC are present in COU 1000 mm!

A relay is operational again after the time delay set on the relay dial has
elapsed.
When replacing a relay, verify that the dial of the replacement relay is set
to the value of the relay to be replaced.

NOTICE
The relays K2812 and K2814 (see Figure 9-10) must not be powered up.
These relays are supplied with 230 VAC. Connecting them to 24 VDC will
cause a short-circuit.

9.7.11 Grounding the drive with a 4-way grounding set

In case the drive is configured in a way that grounding is not possible in
the TEU, the grounding must be done in the INU. In this case proceed as
explained below.

Required tools

Figure 9-11 Earthing tool set with 4-way grounding set and telescope
earthing rod

9-22 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

Grounding precedure 1 Connect the 4-way grounding set to the PE bus bar.

2 Ground the phase conductors one after the other using the telescope
earthing rod. For a detailed view of the connection between
grounding set and grounding bolt see Figure 9-13.

grounding the 1st phase grounding the 2nd phase grounding the 3rd phase

Figure 9-12 Grounding the three phase conductors in the INU

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-23 (26)
Chapter 9 - Troubleshooting and maintenance ABB

Figure 9-13 Detailed view of connection to the grounding bolt

The INU is now grounded.

Figure 9-14 The four connection points

9-24 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB Chapter 9 - Troubleshooting and maintenance

Figure 9-15 Grounding bolt with connected grounding set

The drive is now dead, and safe access is possible.

ACS 6000 User’s manual 3BHS212794 ZAB E01 Rev. B 9-25 (26)
Chapter 9 - Troubleshooting and maintenance ABB

9-26 (26) 3BHS212794 ZAB E01 Rev. B ACS 6000 User’s manual
ABB
Maintenance schedule
The maintenance schedule applies to all air-cooled and water-cooled medium voltage drives. Please
note the maintenance items in the schedule which only apply to particular drives.
The recommended intervals for maintenance and component replacement are based on the normal
operational conditions of the drive. The drive should be checked at least every two years by qualified
personnel whose recommendations should be followed. Depending on the actual condition of the
drive, the maintenance work can be carried out before or after the recommended interval.

Years from start-up

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Air cooling
- Air filters 1 I R R R R R R R R R R R R R R R R R R R
- Cooling fan (continuous operation) 2, A I I P I R I P I R I P I R I P I R I P I
- Cooling fan (redundant) 2, B I I P I P I P I R I P I P I P I R I P I
Water cooling C
- Deionizer, microfilter and strainer 3 I I R I R I R I R I R I R I R I R I R I
- Cooling pump gasket - - - - R - - - R - - - R - - - R - - -
- Cooling pump (continuous operation) 2 I I P I R I P I R I P I R I P I R I P I
- Cooling pump (redundant) 2 I I P I P I P I R I P I P I P I R I P I
- Hoses I I I I I I I I R I I I I I I I R I I I
- Plastic tubes and connectors I I I I I I I I I I I I I I I I I I I I
Aging
- Capacitors 4 I I I I I I I I P I P I P I P I P I P I
- Printed circuit boards, power supplies - - - - - - - - - - R - - - - - - - - -
- Batteries D I I R I R I R I R I R I R I R I R I R I
Connections and operational conditions
- Optical fibers 5 - - - - - - P - P - P - P - P - P - P -
- Cable connections I I I I I I I I I I I I I I I I I I I I
- Dustiness, corrosion, temperature I I I I I I I I I I I I I I I I I I I I
Improvements and spare parts
- Software, hardware upgrades 6 I - I - I - I - I - P - I - I - I - I -
- Spare parts I - I - P - I - P - I - P - I - P - I -
Measurements and tests
- Measurements with auxiliary voltage I I P I P I P I P I P I P I P I P I P I
- Insulation - - - - P - - - P - - - P - - - P - - -
- Safety circuits P P P P P P P P P P P P P P P P P P P P

R Replacement of the component

I Inspection (visual inspection; corrective measures, repair and/or replacement of component if needed)
P Performance of on-site work (commissioning, tests, measurements, etc.)
- No action

A Applies to ACS 1000i, ACS 1000A, ACS 1000W, ACS 2000, ACS 5000A, ACS 5000W, ACS 6000, MEGADRIVE-LCI
B Applies to ACS 1000i, ACS 1000A, ACS 1000W, ACS 2000, ACS 5000A, ACS 5000W
C Applies to all water-cooled drives
D Applies only to ACS 1000i, ACS 1000A, ACS 1000W

1 Air filters can be replaced or cleaned. The decision to replace or clean a filter depends on the condition of the filter.

User’s manual 3BHS351169 ZAB E01 Rev. - 1 (2)

Maintenance schedule ABB
2 The device can be serviced or be replaced by authorized service personnel. It is recommended to replace the device
after four years of operation.
3 The average lifetime of the deionizer is 2-4 years, depending mainly on the water quality. At the same time the
deionizer is changed, the micro filter should also be replaced and the strainer should be cleaned.
4 The expected lifetime of the capacitors depends mainly on the ambient conditions. The recommended intervals are
based on operation with rated current and maximum permitted temperature. A capacitor should be replaced when
regularly taken measurements show significant deviation from the rated capacitance.
5 The expected lifetime of the optical fibers depends mainly on the ambient conditions. The recommended intervals are
based on operation with rated current and maximum permitted temperature. An optical fiber should be replaced when
regularly taken measurements show significant deterioration of the fiber.
6 Improvements based on further development, software modifications, etc. When printed circuit boards must be
replaced, an upgrade of the control system should be considered as well.

2 (2) 3BHS351169 ZAB E01 Rev. - User’s manual

Contact us
ABB
last page

© Copyright 2009 ABB. All rights reserved. Specifications subject to change without notice. 3BHS212794 ZAB E01 Rev. B.
ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi
Phone: +41 58 589 27 95
Fax: +41 58 589 29 84
E-Mail: [email protected]

www.abb.com/drives