ABB ACS5000 User manual

User manual
Medium voltage AC drive
ACS5000 air-cooled, 2 - 7 MVA

ABB

ABB
5k A UM 3BHS221906 ZAB E01 Rev. D 1 (6)
Table of contents
General information on manual and equipment 1
Copyright notice 1
Document identification 1
Contact information 1
Equipment covered by the manual 1
Structure of the user documentation 2
Target groups and required qualifications 3
3
Responsibilities of the user 4
Intended use of equipment 4
Cyber security disclaimer 4
Quality certificates and applicable standards 4
Items covered by delivery 5
Identifying the delivery 6
Identifying transport units 6
Writing conventions 8
Meaning of icons 8
Text conventions 8
Important note on main circuit breaker 1
Safety and protection requirements 2
Minimum requirements for MCB and MCB control 2
Maintenance recommendation 3
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 1-5
Chapter 2 - Power electronics and cabinet features 2-1
2.1 Overview 2-1
2.2 Power supply configurations 2-2

Table of contents ABB
2 (6) 3BHS221906 ZAB E01 Rev. D 5k A UM
2.2.1 Main power supply with input transformer configurations 2-2
2.2.2 Auxiliary power supply configurations 2-3
2.3 Drive topology 2-4
2.3.1 Front end 2-5
2.3.2 DC link 2-5
2.3.3 INU - Inverter unit 2-8
2.4 Terminal compartment 2-9
2.4.1 Cable entry 2-9
2.5 Input transformer 2-10
2.5.1 Installation solutions 2-10
2.5.2 Control equipment 2-11
2.6 Cabinet design 2-12
2.7 Door locking system 2-13
2.8 Cooling system 2-14
2.8.1 Configurations 2-14
2.8.2 Function 2-15
Chapter 3 - Control system 3-1
3.1 Overview 3-1
3.2 Main components 3-2
3.2.1 Local control panel 3-3
3.2.2 AMC circuit board 3-3
3.3 I/O modules 3-6
3.3.1 S800 I/O system 3-7
3.3.2 Fieldbus communication interfaces (option) 3-11
3.3.3 Pulse encoder interface NTAC (option) 3-14
Chapter 4 - Transportation, storage and disposal 4-1
4.1 Safety 4-1
4.2 Transport conditions 4-1
4.3 Unpacking and inspection 4-2
4.4 Lifting and transportation 4-2
4.4.1 General notes on transportation 4-2
4.4.2 Using a crane 4-3
4.5 Storage 4-4
4.5.1 Storage conditions 4-4
4.5.2 Storage 4-4
4.6 Storage and handling of spare parts 4-5
4.6.1 Storage place conditions 4-5
4.6.2 Handling precautions 4-5
4.7 Disposal of packaging materials and components 4-5

ABB Table of contents
5k A UM 3BHS221906 ZAB E01 Rev. D 3 (6)
Chapter 5 - Mechanical installation 5-1
5.1 Safety 5-1
5.2 Overview on installation work 5-1
5.3 General notes on installation 5-1
5.3.1 Dimensions, clearances 5-1
5.3.2 Cabinet roof 5-1
5.3.3 Fire protection 5-1
5.3.4 Cable duct material 5-2
5.4 Preparing the floor 5-2
5.5 Fixing the cabinet to the floor 5-2
5.6 Installing the cabinet 5-3
5.7 Installing the fan units 5-4
Chapter 6 - Electrical installation 6-1
6.1 Safety 6-1
6.2 Overview of installation work 6-1
6.3 Cables requirements 6-1
6.4 Ground cable connection and cable shield connections 6-2
6.5 Cabling between drive and transformer 6-3
6.5.1 Drive with integrated transformer 6-3
6.5.2 Drive with non-integrated transformer 6-4
6.6 Cable entries 6-5
6.6.1 Cable entry with sealing modules, type 1 6-5
6.6.2 Cable entry with sealing modules, type 2 6-6
6.6.3 Cable entry with cable glands 6-6
6.6.4 Cable entry with EMC plates 6-6
6.7 Power cables, ground cables, equipotential bonding conductor 6-7
6.7.1 Further information 6-7
6.7.2 Preparing the cable entries and the cables 6-7
6.7.3 Connecting the cables 6-12
6.8 Auxiliary power, control and serial communication cables 6-16
6.8.1 Further information 6-16
6.8.2 Cable entry 6-16
6.8.3 Routing the cables 6-17
6.8.4 Determining the cable length 6-17
6.8.5 Preparing the cable entry 6-17
6.8.6 Connecting the cables 6-18
6.8.7 Final checks 6-20
6.9 Power supply cables for fan units 6-20
6.10 Transformer heating cable 6-21
Chapter 7 - Commissioning 7-1

Table of contents ABB
4 (6) 3BHS221906 ZAB E01 Rev. D 5k A UM
7.1 Required qualification 7-1
7.2 Commissioning procedure 7-1
7.3 Commissioning check list 7-1
7.4 Customer assistance 7-1
7.5 Customer acceptance 7-1
Commissioning check list 1
Mechanical installation 1
Electrical installation 1
Main circuit breaker (MCB) 2
Input transformer (if applicable) 2
Motor 2
Insulation tests 3
Power supply 3
Miscellaneous 3
Chapter 8 - Operation 8-1
8.1 Operating conditions 8-1
8.2 Safety 8-2
8.3 Overview 8-2
8.4 Overview of local operator panel 8-2
8.4.1 Lamp test 8-4
8.5 Status messages 8-4
8.5.1 Overview on status messages 8-4
8.5.2 Start sequence of the drive 8-6
8.5.3 Stop sequence of the drive 8-7
8.5.4 Emergency-off sequence of the drive 8-8
8.6 Starting the drive 8-8
8.6.1 Checks before starting the drive 8-9
8.6.2 Starting the drive from remote 8-9
8.6.3 Starting the drive locally 8-10
8.7 Stopping the drive 8-13
8.8 Emergency-off 8-14
8.8.1 Function 8-14
8.8.2 Initiating an emergency-off 8-14
8.8.3 Starting the drive after an emergency-off 8-15
Chapter 9 - CDP control panel 9-1
9.1 Overview 9-1
9.1.1 Display and keypad 9-1
9.2 CDP control panel functions 9-2

ABB Table of contents
5k A UM 3BHS221906 ZAB E01 Rev. D 5 (6)
9.3 CDP control panel modes 9-2
9.4 Identification mode 9-3
9.5 Actual signals mode 9-4
9.5.1 Overview 9-4
9.5.2 Selecting the actual signals display 9-6
9.5.3 Toggle between actual signals display and fault history 9-6
9.5.4 Displaying three actual signals 9-6
9.5.5 Selecting actual signals 9-7
9.5.6 Displaying a fault and resetting the fault history 9-9
9.5.7 Displaying and resetting an active fault 9-11
9.6 Parameters mode 9-11
9.6.1 Overview 9-11
9.6.2 Selecting and changing parameters 9-13
9.6.3 Enabling / unlocking a parameter lock 9-16
9.7 Functions mode 9-16
9.7.1 Overview 9-16
9.7.2 Adjusting the display contrast 9-17
9.8 Local and remote control 9-19
9.8.1 Local control 9-19
9.8.2 Remote control 9-20
9.8.3 Disabling / enabling local lock function 9-21
9.9 Operational commands 9-22
9.9.1 Setting the direction of rotation 9-22
9.9.2 Entering a reference value 9-23
Chapter 10 - Preventive and corrective maintenance 10-1
10.1 General information 10-1
10.1.1 Required qualification 10-1
10.1.2 Maintenance schedule 10-1
10.1.3 Logbook 10-1
10.1.4 Spare parts 10-1
10.2 Identifying electrical equipment 10-2
10.2.1 Device identification 10-2
10.2.2 Cables and wires 10-2
10.2.3 Understanding wiring diagrams 10-2
10.3 Alarm / fault indications 10-3
10.3.1 Messages 10-3
10.3.2 Error message levels 10-4
10.3.3 Fault handling 10-4
10.3.4 Troubleshooting procedure 10-5
10.4 Removing the CDP control panel 10-6
10.5 LEDs and switches on circuit boards and I/O modules 10-8
10.5.1 AMC circuit board 10-8
10.5.2 S800 I/O - TB820 bus modem 10-9
10.5.3 S800 I/O modules 10-10

Table of contents ABB
6 (6) 3BHS221906 ZAB E01 Rev. D 5k A UM
10.5.4 Serial communication interfaces 10-11
10.6 Corrective maintenance 10-15
10.6.1 Overview on maintenance tasks 10-15
10.6.2 Safety 10-15
10.6.3 De-energizing the drive locally 10-16
10.6.4 Grounding switches are not released 10-18
10.6.5 Connecting a grounding set 10-20
10.6.6 Emergency release of the door safety switch 10-21
10.6.7 Door handles 10-24
10.6.8 Visual checks on the drive 10-24
10.6.9 Cleaning 10-25
10.6.10 Checking wire and cable connections 10-26
10.6.11 Replacing the filter mats 10-27
10.6.12 Replacing a fan 10-29
Terms, trademarks, related documentation 1
Terms and abbreviations 1
Trademarks 3
Related documentation 4

ABB
5k A UM 3BHS221906 ZAB E01 Rev. D 1 (2)
Table of figures
Fig. 1 Delivered items 1-5
Fig. 1-1 Safety labels 1-4
Fig. 2-1 Drive overview 2-2
Fig. 2-2 Overview 2-4
Fig. 2-3 DC link 2-5
Fig. 2-4 Grounding switch 2-6
Fig. 2-5 Grounding the drive 2-7
Fig. 2-6 Terminal compartment 2-9
Fig. 2-7 Control compartment of the transformer 2-12
Fig. 2-8 Door locks 2-13
Fig. 2-9 Air flow through the drive 2-15
Fig. 2-10 Location of air pressure switch in the drive 2-16
Fig. 2-11 Location of air pressure switch in the transformer 2-16
Fig. 3-1 Block diagram of control system 3-1
Fig. 3-2 Control compartment 3-2
Fig. 3-3 Location of AMC circuit board 3-3
Fig. 3-4 DTC torque control 3-5
Fig. 3-5 S800 I/O stations 3-9
Fig. 3-6 Location of fieldbus and pulse encoder interfaces 3-13
Fig. 4-1 Transporting the cabinet by crane 4-3
Fig. 5-1 Anchor bolt 5-2
Fig. 6-1 Grounding the drive system 6-2
Fig. 6-2 Drive with integrated transformer 6-3
Fig. 6-3 Drive with non-integrated transformer 6-4
Fig. 6-4 Preparing power cables for sealing modules 6-8
Fig. 6-5 Preparing power cables for EMC plates 6-10
Fig. 6-6 Preparing power cables for cable glands 6-11
Fig. 6-7 Cable connection and bolt orientation 6-12
Fig. 6-8 Cable connection and bolt orientation 6-13
Fig. 6-9 Cable connection and bolt orientation 6-13
Fig. 6-10 Ground busbar inside drive cabinet 6-14
Fig. 6-11 Ground busbar inside non-integrated transformer 6-14
Fig. 6-12 Bolted busbar connection 6-15
Fig. 6-13 Cable entry for auxiliary and control cables 6-16
Fig. 6-14 Routing control cables 6-17
Fig. 6-15 Terminals inside control compartment 6-18
Fig. 6-16 Encoder module – Shield grounding point 6-19
Fig. 6-17 Control cables – Shield grounding clamps 6-19
Fig. 6-18 Fan – Power supply connector 6-20
Fig. 6-19 Heating cable connection 6-21
Fig. 8-1 Local operator panel 8-4
Fig. 9-1 CDP control panel 9-1
Fig. 10-1 Device identification 10-2
Fig. 10-2 AMC circuit board 10-8

Table of figures ABB
2 (2) 3BHS221906 ZAB E01 Rev. D 5k A UM
Fig. 10-3 TB820 bus modem 10-9
Fig. 10-4 Example of S800 I/O station 10-10
Fig. 10-5Ethernet interface 10-12
Fig. 10-6Modbus interface 10-13
Fig. 10-7Profibus interface 10-14
Fig. 10-8Four-way grounding set (option) 10-20
Fig. 10-9Location of the door safety switch 10-22
Fig. 10-10Pivoted door handle 10-24
Fig. 10-11Fan – Exploded view 10-29

ABB
5k A UM 3BHS221906 ZAB E01 Rev. D 1 (2)
List of tables
Tab. 3-1 Fieldbus adapters 3-11

List of tables ABB
2 (2) 3BHS221906 ZAB E01 Rev. D 5k A UM

ABB
5k A UM 3BHS221906 ZAB E01 Rev. D 1 (8)
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 China Ltd
Medium Voltage Drives
Document
identification
3BHS221906 ZAB E01
Revision index D
Issue date 31.05.2018
Contact information
Address ABB Beijing Drives System Company Limited
No.1, Block D, A-10 Jiuxianqiao Beilu
100015, Chaoyang District, Beijing, PRC
Phone [phone]
E-mail [e-mail]
Equipment covered by the manual
This manual covers standard drive and provides generic information on
the drive. The manual does not claim to cover all variations and details of
the drive, nor to consider all eventualities that may arise during installation,
commissioning, operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and
handling, installation, and operation of the drive are affected by these
modifications, information on these modifications is provided in the
appropriate documentation (eg, layout drawings, wiring diagrams,
technical data, engineering notes).

General information on manual and equipment ABB
2 (8) 3BHS221906 ZAB E01 Rev. D 5k A UM
If information is required beyond the instructions in this manual, refer the
matter to ABB.
Structure of the user documentation
The complete set of user documentation of a standard drive consists of
this manual and supplementary documentation that is provided in the
following appendices:
■Appendix A - Additional manuals
The appendix provides manuals about additional equipment deliv-
ered with the drive (eg, project specific options such as pulse encoder
or fieldbus interfaces), or information on modifications of the standard
drive.
■Appendix B - Technical data
The appendix contains the technical data sheets of the drive.
■Appendix C - Mechanical drawings
The appendix provides the outline drawing(s) of the drive. The draw-
ings are generated according to the customer-specific project.
■Appendix D - Wiring diagrams
The appendix contains the circuit diagrams with information on cross-
reference and device-identification conventions. The diagrams are
generated according to the customer-specific project.
■Appendix E - Parts list
The parts list 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 drive. Quality certifi-
cates, and codes and standards the drive complies with are added if
required for the project.
■Appendix G - Signal and parameter table
The Signal and parameter table includes descriptions of actual
signals, control and status words, and control parameters and their
default settings.

ABB General information on manual and equipment
5k A UM 3BHS221906 ZAB E01 Rev. D 3 (8)
Target groups and required qualifications
The drive presented in this manual is part of an industrial environment
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 drive and the industrial environment and have obtained
the required qualification must handle, install, operate, or maintain the
drive.
The manual addresses personnel who are responsible for unpacking,
transportation, installation, operation and maintenance of the drive. 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 drive.
Handling The personnel must be skilled and experienced in unpacking and
transporting heavy equipment.
Mechanical installation The personnel must be qualified to prepare the installation site according
to the site and equipment requirements and to perform the installation
accordingly.
Electrical installation The personnel must have a sound knowledge of the relevant electrical
codes and specifications covering low and medium voltage equipment,
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 drive from the local
operating panel of the drive. The personnel must know the functions of the
operating panel, be adequately trained for the drive, and know the driven
process. Special knowledge of frequency converter technology is not
required.
Maintenance The personnel include all persons who
■are qualified to carry out preventive and corrective maintenance on
drive as described in this manual,
■are thoroughly familiar with the drive,
■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 drive system and act correspondingly,
■know the safe shutdown and grounding procedures for the drive
system.
Commissioning of the drive must only be performed by qualified and
certified ABB personnel.

General information on manual and equipment ABB
4 (8) 3BHS221906 ZAB E01 Rev. D 5k A UM
Responsibilities of the user
It is the responsibility of those in charge of the drive to ensure that each
person involved in the installation, operation or maintenance of the drive
has received the appropriate training and has thoroughly read and clearly
understood the instructions in this manual and the relevant safety
instructions.
Intended use of equipment
Those in charge of the drive must ensure that the drive is only used as
specified in the contractual documents, operated under the conditions
stipulated in the technical specifications and on the rating plate of the
drive, and serviced in the intervals as specified by ABB.
Use of the drive 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 drive are
not permitted.
Cyber security disclaimer
This product is designed to be connected to and to communicate
information and data via a network interface. It is Customer's sole
responsibility to provide and continuously ensure a secure connection
between the product and Customer network or any other network (as the
case may be).
Customer shall establish and maintain any appropriate measures (such as
but not limited to the installation of firewalls, application of authentication
measures, encryption of data, installation of anti-virus programs, etc) to
protect the product, the network, its system and the interface against any
kind of security breaches, unauthorized access, interference, intrusion,
leakage and/or theft of data or information.
ABB and its affiliates are not liable for damages and/or losses related to
such security breaches, any unauthorized access, interference, intrusion,
leakage and/or theft of data or information.
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 that fulfills
the requirements of the normative standards
■EC declaration of conformity
■List of the standards the drive complies with

ABB General information on manual and equipment
5k A UM 3BHS221906 ZAB E01 Rev. D 5 (8)
Items covered by delivery
Fig. 1 Delivered items
1
33
4
5
6
■Drive (1) and transformer (2)
The transformer is either an integrated or a non-
integrated type.
The cabinets are either shipped in seafreight or
airfreight packaging.
■Fans (3)
The fans are shipped in a separate container. The
number of fans depends on the cooling configuration
ordered.
■Grounding switch lever (4)
■Triangular nut driver (5)
■Door keys (6)
Delivery typically comprises the following items:
2

General information on manual and equipment ABB
6 (8) 3BHS221906 ZAB E01 Rev. D 5k A UM
Identifying the delivery
The drive and accessories are identified by the type code printed on the
rating plate.
The label provides information on the type of drive, the rated voltage, the
frequency and the current of the main and the auxiliary power supply.
Identifying transport 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 (eg, drive 1, drive 2). 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 transport unit. The packing
label is only visible after the packaging has been removed.
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.
Fig. 2 Identifying the drive on the packing list
Separately delivered crates or boxes 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.
ABB item
Customer item
Qty. Unit. Identnumber Commodity description
001201 1 PC Converter 1: Transport Unit 1
ABB Switzerland Ltd
Drives
shown on this packing list.
the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
Mailing address:
CH-5401 Baden/Schweiz
Phone:
[phone]
Telex:
755749 abb ch
Facsimile:
[phone]
Bank Credit Suisse CH-8070 Z黵ich/Switzerland
Transport units where packing lists
belong to one drive
have the same number in this place

ABB General information on manual and equipment
5k A UM 3BHS221906 ZAB E01 Rev. D 7 (8)
Fig. 3 Identifying the drive on the accessories packing list
Packing label The packing labels on the back walls of a transport unit can also be used
to identify the drive to which the transport unit belongs (Fig. 4).
Fig. 4 Identifying the drive on the packing label
ABB item
Customer item
Qty. Unit. Identnumber Commodity description
001221 1 PC cross wiring
001222 1 WCU accessoryPC
001223 1 PC crank for isolator
001500 1 ACS5000 Max-SL LOSE TEILE konfig.PC 3BHB013202R0001
ABB Switzerland Ltd
Drives
shown on this packing list.
the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
Mailing address:
CH-5401 Baden/Schweiz
Phone:
[phone]
Telex:
755749 abb ch
Facsimile:
[phone]
Bank Credit Suisse CH-8070 Z黵ich/Switzerland
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.
ABB
Material no
Order no/positions
Material Document
Packing Label
3BHB009964R1500
Schrank kpl. LSU konfig
1 ST
11027727 001241 Project CBA
Material
004902892300012004
0000
The number in this place (4th digit from right)
001241
identifies the drive to which the
transport unit belongs.

General information on manual and equipment ABB
8 (8) 3BHS221906 ZAB E01 Rev. D 5k A UM
Writing conventions
The following icons and text conventions are used in the manual.
Meaning of icons
Illustrates an illuminated lamp or pushbutton.
Illustrates a button or key to be pressed.
Indicates an alternating display message.
Refers to further information in a separate document.
Text conventions
■marks items in a list.
• marks steps of a procedure when there is no specified sequence.
1marks steps of a procedure to be followed in the specified sequence
(eg, 1, 2, 3).
1 used in figure legends to identify the item in an illustration.
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.
Gray-shaded areas highlight text.