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

8.6 Grounding switch and door locking system 180
8.6.1 Lamp test 181
8.6.2 Door locking system 181
8.7 Optional switchgear and controlgear 183
8.7.1 DC-link disconnector 183
8.7.2 Output switches 183
8.7.3 Manual output isolation 183
8.8 Status messages 184
8.8.1 Start sequence of the drive 186
8.8.2 Stop sequence of the drive 187
8.8.3 Emergency-off sequence 188
8.8.4 Prevention of unexpected startup sequence 188
8.9 Starting the drive 189
8.9.1 Checks before starting the drive 189
8.9.2 Starting the drive remotely 190
8.9.3 Starting the drive locally 190
8.10 Stopping the drive 193
8.10.1 Stopping the drive locally 193
8.10.2 Stopping the drive with the emergency-off function 195
8.10.3 Initiating an emergency-off 195
8.10.4 Starting the drive system after an emergency-off 196
8.11 Arc detection with the Arc Guard System™ (optional) 197
8.11.1 Action after the Arc Guard System™ has been triggered 197
9. CDP control panel 199
9.1 Overview 199
9.1.1 Display and keypad 199
9.1.2 Functions 200

9.2 Modes 200
9.2.1 Identification mode 200
9.2.2 Actual signals mode 202
9.2.2.1 Overview 202
9.2.2.2 Selecting the actual signals display 203
9.2.2.3 Toggling between actual signals display and fault
memory 204
9.2.2.4 Displaying three actual signals 204
9.2.2.5 Selecting actual signals 204
9.2.2.6 Displaying a fault and resetting the fault memory 206
9.2.2.7 Displaying and resetting an active fault 208
9.2.3 Parameters mode 209
9.2.3.1 Overview 210
9.2.3.2 Changing a parameter setting 211
9.2.3.3 Enabling / unlocking a parameter lock 213
9.2.3.4 User lock 213
9.2.4 Functions mode 214
9.2.4.1 Adjusting the display contrast 214
9.2.5 Local and remote control mode 216
9.2.5.1 Local control 216
9.2.5.2 Disabling / enabling local lock function 216
9.2.5.3 Enabling the local lock 217
9.2.5.4 Remote control 217
9.3 Operational commands 218
9.3.1 Setting the direction of rotation 218
9.3.2 Entering a reference value 219
10. Preventive and corrective maintenance 221
10.1 General information 221

10.1.1 Required qualification 221
10.1.2 Maintenance schedule 221
10.1.3 Logbook 221
10.1.4 Spare parts 221
10.2 Identifying electrical equipment 222
10.2.1 Device designation 222
10.2.2 Cables and wires 222
10.2.2.1 Understanding wiring diagrams 223
10.3 Status indicators 223
10.3.1 Alarm / fault indications 223
10.3.2 Error message levels 223
10.3.2.1 Alarm and fault messages 224
10.3.2.2 Fault handling 224
10.3.2.3 Standard troubleshooting procedure 225
10.3.3 LEDs and switches on circuit boards and I/O devices 225
10.3.3.1 AMC circuit board 226
10.3.3.2 S800 I/O bus modem TB820 227
10.3.3.3 S800 I/O modules 227
10.3.3.4 Serial communication interfaces 228
10.3.3.5 LEDs on optional heat exchangers 229
10.4 Maintenance tasks 230
10.4.1 Safety 230
10.4.2 De-energizing and grounding the drive 231
10.4.3 Grounding the drive when the grounding switch is not
released 234
10.4.4 Unlocking and opening the doors 236
10.4.5 Closing and locking the doors 237
10.4.6 Testing the white lamp 238

10.4.7 Emergency release of a door safety switch 240
10.4.7.1 Location of safety switches 240
10.4.7.2 Safety-switch settings 241
10.4.7.3 Unlocking a safety switch 241
10.4.8 Connecting a grounding set 242
10.4.8.1 Drives with LSU 243
10.4.8.2 Drives with ARU 244
10.4.9 Drives with the manual output isolation (optional) 244
10.4.9.1 Removing the busbar connectors 247
10.4.9.2 Fitting the busbar connectors 251
10.4.10 Removing and installing a phase module 253
10.4.10.1 Removing a phase module 253
10.4.10.2 Installing a phase module 255
10.4.11 Visual checks on the drive 256
10.4.12 Cleaning 256
10.4.12.1 Cleaning the drive cabinet 256
10.4.13 Checking wire and cable connections 257
10.4.14 Checking and replacing filter mats 257
10.4.15 Testing and replacing auxiliary fan units 259
10.4.15.1 Testing auxiliary fan units 259
10.4.15.2 Replacing auxiliary fan units 260
10.4.16 Testing and replacing air-to-air heat exchangers 261
10.4.16.1 Testing the fan units 262
10.4.16.2 Replacing the complete heat exchanger 263
10.4.16.3 Replacing the circuit board 263
10.4.16.4 Replacing internal fan 1 - left side 265
10.4.16.5 Replacing internal fan 2 - right side 266

10.4.16.6 Replacing the ambient fans 269
10.4.17 Replacing the fan unit in an EXU with a DCS800 D4
size controller 270
10.4.18 Replacing the fan unit in an EXU with DCS800 size
D5 controller 272
10.4.19 Replacing the air-to-water heat exchanger of the EXU 274

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Figures
Figure 2-1 Product warning label examples
(label placement depends on the drive) 42
Figure 2-2 Drive system overview 47
Figure 2-3 MCB opening timing diagram 49
Figure 3-1 Common DC-bus principle for single motor drive
(A) and multi-motor drive (B) 51
Figure 3-2 ACS6000 drive example 52
Figure 3-3 ARU/INU block diagram 54
Figure 3-4 ARU/INU circuit diagram 54
Figure 3-5 ARU/INU (A) and phase modules with IGCTs (B) 55
Figure 3-6 LSU block diagram 56
Figure 3-7 LSU (12-pulse) circuit diagram 56
Figure 3-8 LSU (12-pulse) 57
Figure 3-9 CBU 58
Figure 3-10 TEU (1000 mm) 59
Figure 3-11 Control units: 1000 mm COU (A) and 600 mm
COU (B) 61
Figure 3-12 Block diagram of control system 62
Figure 3-13 Examples of AMC circuit boards in 1000 mm
COU (A) and 600 mm COU (B) 63
Figure 3-14 AMC circuit board example 64
Figure 3-15 DTC control platform 65
Figure 3-16 Local control panels on 1000 mm COU (A) and
600 mm COU (B) 66
Figure 3-17 Typical S800 I/O station 67
Figure 3-18 WCU1400 (A) and WCU800 (B) cabinet and system
components 69

Figure 3-19 Cooling circuit in an ACS6000 drive 70
Figure 3-20 IRU circuit diagram 71
Figure 3-21 IRU cabinet 71
Figure 3-22 IFU circuit diagram 72
Figure 3-23 IFU cabinet 72
Figure 3-24 VLU circuit diagram 73
Figure 3-25 VLU cabinet 73
Figure 3-26 BCU circuit diagram 75
Figure 3-27 BCU cabinet 75
Figure 3-28 RBU circuit diagram 76
Figure 3-29 RBU cabinet 76
Figure 3-30 EXU D4 frame cabinet (A) and EXU D5 frame
cabinet (B) 77
Figure 3-31 CIU cabinet (A) and WCU800 cabinet (B) 79
Figure 3-32 ACS6000 example drive with air-to-air heat exchanger 80
Figure 3-33 Auxiliary fan unit 81
Figure 3-34 Air circulation through ventilation grids in 600 mm
COU (A), 1000 mm COU (B) and WCU800 (C) 81
Figure 3-35 Basic cabinet design 82
Figure 3-36 IAC label example 84
Figure 3-37 Busbars 84
Figure 4-1 Lifting bracket (1) on base frame of a drive,
safety hook (2) secured to lifting bracket and eye
bolt (3). 90
Figure 4-2 Lift frame (A) and lift spreader (B) 91
Figure 5-1 Connection point locations on transport units 100
Figure 5-2 Minimum distances and locking bolt orientation (A
= front) 101
Figure 5-3 Bolted busbar connection 103

Figure 5-4 Top view of DC busbar configuration 1 104
Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B)
and 4 (C) 105
Figure 5-6 Ground busbar joints 106
Figure 5-7 AC busbar joints between the COU/TEU and LSU
(5/7/9 MVA). 107
Figure 5-8 AC busbar joints between the COU/TEU and LSU
(14 MVA). 108
Figure 5-9 Air-to-air heat exchanger (type LT-5-5165-UL) 112
Figure 5-10 Tools for installing an air-to-air heat exchanger 112
Figure 5-11 Correct and incorrect cable installation 114
Figure 5-12 ARU/INU/IFU cable routing 116
Figure 5-13 LSU cable routing 116
Figure 5-14 Air-to-air heat exchangers (type LT-5-5165-UL) 117
Figure 5-15 Tools for removing an air-to-air heat exchanger 118
Figure 5-16 Installation example of transformers in an air-to-air
heat exchanger 120
Figure 5-17 Connect wires to terminal block 121
Figure 5-18 Pressure relief vents 121
Figure 5-19 Tools required to fasten the pressure relief vent
to the roof 122
Figure 5-20 Installation example of pressure relief vents 122
Figure 5-21 Attach sealing tape to the joining crossbar (1) 123
Figure 5-22 Roof joints (1) 124
Figure 5-23 Roof attachment parts 125
Figure 5-24 Recommended ceiling and wall fixings 126
Figure 6-1 Phase module on lift table 127
Figure 6-2 Grounding the input side (A) and output side (B)
of the drive system 129
Figure 6-3 System ground connection (1) in a 600 mm TEU 130

Figure 6-4 Grounding the EXU 131
Figure 6-5 Cable tray and cable ducts in an LSU (A =
front) 132
Figure 6-6 Arc Guard System™ in an optional roof extension
box (REB) 133
Figure 6-7 Location of Arc Guard sensors in a TEU 134
Figure 6-8 Cable tray and cable ducts in an LSU (A =
front) 134
Figure 6-9 Cable entry with type 1 sealing modules 135
Figure 6-10 Cable entry frame with type 1 sealing modules 136
Figure 6-11 Cable entry with type 2 sealing modules 137
Figure 6-12 Cable gland 137
Figure 6-13 Cable entry with EMC plates 138
Figure 6-14 TEU 1000 mm cabinet (A = back) with top (1)
and bottom (2) cable entries 139
Figure 6-15 Short busbar removal in ARU 140
Figure 6-16 EXU with top cable entry (A) and EXU with
bottom cable entry (B) 141
Figure 6-17 EXU cabinet 141
Figure 6-18 Preparing power cables for sealing modules 143
Figure 6-19 Prepare power cables for cable glands 144
Figure 6-20 Preparing cables for EMC plates: (A) cables with
an outer screen or shield, (B) cables without an
outer screen or shield or (C) cables in an
EXU cabinet 145
Figure 6-21 Cable connections in an EXU cabinet 146
Figure 6-22 Minimum distance between bolted joints of different
phases in an EXU 147
Figure 6-23 Bolted busbar connection - marine drives 147
Figure 6-24 Bolted busbar connection - non-marine drive 148
Figure 6-25 Cable entry with sealing modules 150