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