ABB ACS 6000 User manual

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SYSTEM DRIVES
ACS6000
User manual

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General information
Copyright
© 2020 ABB. All rights reserved. The information in this manual
is subject to change without notice.
This document 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., System Drives.
The hardware and software described in this document is
provided under a license and may be used, copied, or
disclosed only in accordance with the terms of such license.
Document owner
ABB Switzerland Ltd.
System Drives
CH-5300 Turgi, Switzerland
Document name
ACS6000 user manual
Document number
3BHS212794 E01 Rev M
Release date
18.06.2020
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new.abb.com/drives/medium-voltage-ac-drives
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Contents
1. About this manual 27
1.1 Equipment covered by this manual 27
1.2 Structure of the user documentation 27
1.3 Terms and abbreviations 28
1.4 Trademarks 34
1.5 Related documentation 34
1.6 Target groups and required qualification 37
1.6.1 Handling 37
1.6.2 Mechanical installation 37
1.6.3 Electrical installation 37
1.6.4 Operation 37
1.6.5 Maintenance 37
1.7 User’s responsibilities 38
1.8 Intended use of equipment 38
1.9 Cyber security disclaimer 38
1.10 Quality certificates and applicable standards 39
1.11 Identifying the delivery 40
1.12 Tools 40
2. Important safety information 41
2.1 Safety standards 41
2.2 Safety messages 41
2.3 Product safety labels 42
2.4 General safety instructions 43
2.5 The 7 steps that save lives 44
2.6 Possible residual risks 46

2.7 Important note - main circuit breaker 47
2.7.1 Safety and protection requirements 48
2.7.2 Safety and protection requirements for the MCB 48
2.8 Maintenance recommendation 49
3. Power electronics and cabinet features 51
3.1 Drive system topology 51
3.1.1 Drive 51
3.1.1.1 ACS6000 cabinet units 53
3.1.1.2 Final drive configuration 53
3.1.2 Motor 53
3.2 Standard cabinet units 53
3.2.1 Active rectifier unit (ARU)/inverter unit (INU) 53
3.2.2 Line supply unit (LSU) 55
3.2.3 Capacitor bank unit (CBU) 58
3.2.4 Terminal unit (TEU) 59
3.2.5 Control unit (COU) 60
3.2.5.1 COU versions 60
3.2.5.2 Control system configuration 62
3.2.5.3 AMC circuit board 63
3.2.5.4 Main circuit breaker 64
3.2.5.5 Speed and torque control 65
3.2.5.6 Peripheral I/O devices 65
3.2.5.7 Local control panels 66
3.2.5.8 S800 I/O system 66
3.2.6 Water cooling unit (WCU) 67
3.2.6.1 Cooling circuit 70
3.2.6.2 External cooling connection 70

3.3 Optional cabinet units 71
3.3.1 Input reactor unit (IRU) 71
3.3.2 Input filter unit (IFU) 72
3.3.3 Voltage limiter unit (VLU) 73
3.3.4 Braking units 74
3.3.4.1 Braking chopper unit 75
3.3.4.2 Resistor braking unit 76
3.3.5 Excitation unit (EXU) 77
3.3.5.1 DCS800 control panel 78
3.3.5.2 Reversing switch 78
3.3.5.3 Output disconnector 78
3.3.6 Customer interface unit (CIU) 79
3.3.6.1 Arc detection with Arc Guard (optional) 80
3.4 Air cooling 80
3.4.1 Air-to-air heat exchangers 80
3.4.2 Auxiliary fan units 81
3.5 Cabinet design 82
3.6 Door locking system 83
3.7 Arc resistant design 83
3.7.1 Internal arc classification 83
3.8 Busbars and grounding 84
3.8.1 AC busbars 84
3.8.2 DC busbars 85
3.8.3 PE busbar 85
3.8.4 PG busbar 85
4. Transportation, storage and disposal 87
4.1 Safety 87

4.2 Transport conditions 87
4.3 Unpacking and inspection 87
4.4 Identifying transport units 87
4.5 Lifting and transportation 89
4.5.1.1 Lifting recommendations 90
4.6 Storage 92
4.7 Storing and handling of spare parts 93
4.7.1 Warranty information 93
4.8 Disposing package materials and components 94
5. Mechanical installation 95
5.1 Safety 95
5.2 Overview 95
5.3 General notes on installation 96
5.3.1 Dimensions and clearances 96
5.3.2 Access to the cabinets 96
5.3.3 Cabinet roof 96
5.3.4 Fire protection 96
5.3.5 Cable duct material 97
5.3.6 Installation material 97
5.3.7 Tools 97
5.3.8 Floor preparation 97
5.3.9 Floor fixation 97
5.3.10 Raw water circuit 97
5.4 Aligning transport units 98
5.5 Joining transport units 100
5.6 Joining water pipes 101
5.6.1 Removing a pipe joint 102

5.7 Joining busbars 103
5.7.1 DC busbars 104
5.7.2 Ground busbars 106
5.7.3 AC busbars between COU/TEU and LSU (5/7/9 MVA) 107
5.7.4 AC busbars between COU/TEU and LSU (14 MVA) 108
5.7.5 AC busbars between COU/TEU and ARU/INU 109
5.7.6 AC busbar joints - without disconnector 109
5.7.7 AC busbar joints - with motorized disconnector 110
5.8 Installing and removing air-to-air heat exchangers 112
5.8.1 Installing air-to-air heat exchangers 112
5.8.1.1 Installation 113
5.8.2 Removing air-to-air heat exchangers 117
5.8.2.1 Removing an air-to-air heat exchanger 118
5.8.2.2 Reinstalling an air-to-air heat exchanger 119
5.8.3 Installing the transformers of air-to-air heat exchangers 120
5.9 Installing the pressure relief vents 121
5.10 Attaching the sealing tapes 123
5.11 Installing the roof joints and the roof attachments 124
5.11.1 Installing roof joints 124
5.11.2 Installing roof attachments 125
6. Electrical installation 127
6.1 Safety 127
6.2 Cable requirements 128
6.2.1 Power cables 128
6.2.2 Auxiliary and control cables 128
6.2.3 Synchronization cables 128
6.3 Grounding the drive system 129

6.3.1 Grounding diagrams 129
6.3.2 Ground cable connection 130
6.3.3 Cable shield ground connection 130
6.3.4 EXU cabinet ground connections 131
6.4 Internal wiring 131
6.4.1 Optical fiber cables 132
6.4.1.1 Installing the standard optical fibers 132
6.4.2 Optical fiber cables for the optional Arc Guard
System™ 133
6.4.2.1 Connecting the detector cables to the arc monitor
device 134
6.5 Cable entry systems 135
6.5.1 Frames with type 1 sealing modules 135
6.5.2 Frame with type 2 sealing modules 137
6.5.3 Plates with cable glands 137
6.5.4 EMC plates with sealing grommets 138
6.6 Preparing cable entry systems for TEU, ARU and
EXU cabinets 138
6.6.1 TEU cable entry frames with type 1 sealing modules 139
6.6.2 ARU cable entry frames with type 1 sealing modules 140
6.6.3 EXU cable entry with EMC plate and sealing grommets 141
6.7 Power, ground and equipotential bonding conductor cables§ 142
6.7.1 Determining the cable length 142
6.7.2 Preparing cables for sealing modules 143
6.7.3 Preparing cables for cable glands 144
6.7.4 Preparing cables for EMC plates 144
6.7.5 Connecting the cables 146
6.7.5.1 Checking the cable insulation 146

6.7.5.2 EXU cabinet connections 146
6.7.5.3 Bolted busbar connections – marine drives 147
6.7.5.4 Bolted busbar connections – non-marine drives 148
6.8 Auxiliary power, control and serial communication cables 149
6.8.1 Determining the cable length 149
6.8.2 Preparing cables for sealing modules 150
6.8.3 Preparing cables for cable glands 151
6.8.4 Preparing cables for EMC plates 151
6.8.5 Routing cables in a WCU 153
6.8.6 Routing cables in a COU cabinet 153
6.8.6.1 Top cable entry 154
6.8.6.2 Bottom cable entry 155
6.8.6.3 Connecting the cables 156
6.8.7 Routing cables in an EXU cabinet 157
6.8.7.1 Auxiliary power and control cables 157
6.8.7.2 Optical fiber cables 159
6.8.7.3 Routing optical fiber cables in an EXU cabinet with
an ED5V, EB5R, EB5S, EB7P or EB7Q type DCS800
converter 160
6.8.7.4 Routing cables in an EXU cabinet with an ED7Y type
DCS800 converter 162
6.8.8 Routing Azipod® encoder cables 164
6.8.8.1 Handling and installation 164
6.8.8.2 Routing cables through the REB (WCU) 165
6.9 Heating cable 166
6.10 Final checks 167
7. Commissioning 169
7.1 Required qualification 169

7.2 Commissioning procedure 169
7.3 Commissioning checklist 169
7.4 Customer assistance 169
7.5 Customer acceptance 169
7.6 Commissioning checklists 170
7.6.1 Mechanical installation checklist 170
7.6.2 Electrical installation checklist 170
7.6.3 Main circuit breaker (MCB) 171
7.6.4 Input transformer checklist 171
7.6.5 Motor checklist 172
7.6.6 Insulation tests checklist 172
7.6.7 Power checklist 172
7.6.8 Miscellaneous checklist 172
8. Operation 173
8.1 Overview 173
8.2 Operating conditions 173
8.3 Safety 173
8.4.1 ARU control panel 174
8.4.2 INU control panels 175
8.4.2.1 Lamp test 176
8.4.3 Semi-redundant drive control panel (drive backup control) 176
8.4.3.1 Operating modes 177
8.4.3.2 Semi-redundant drive control panel 177
8.5 EXU control panel 178
8.5.1 Operational settings 179
8.5.2 Resetting alarm and fault messages 179
8.5.3 Parameter settings 179