ABB ACS5000 User manual

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SYSTEM DRIVES
ACS5000 water-cooled
User manual
5 – 36 MVA, 6 - 6.9 kV

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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
ACS5000 water-cooled user manual
Document number
3BHS799208 E01 Rev E
Release date
17.06.2020
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new.abb.com/drives/medium-voltage-ac-drives
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Contents
1. About this manual 19
1.1 Equipment covered by this manual 19
1.2 Structure of the user documentation 19
1.3 Related documents 20
1.4 Terms and abbreviations 21
1.5 Trademarks 23
1.6 Target groups and required qualification 24
1.6.1 Handling 24
1.6.2 Mechanical installation 24
1.6.3 Electrical installation 24
1.6.4 Operation 24
1.6.5 Maintenance 25
1.7 User’s responsibilities 25
1.8 Intended use of equipment 25
1.9 Cyber security disclaimer 25
1.10 Quality certificates and applicable standards 27
1.11 Items covered by delivery 28
1.11.1 Identifying the delivery 28
1.12 Tools 28
2. Important safety information 29
2.1 Safety standards 29
2.2 Safety messages 29
2.3 Product safety labels 30
2.4 General safety instructions 31
2.5 The 7 steps that save lives 32

2.6 Possible residual risks 34
2.7 Important note - main circuit breaker 35
2.7.1 Safety and protection requirements 36
2.7.3 Maintenance recommendation 36
3. Power electronics and cabinet features 37
3.1 Main features of the drive 37
3.2 Frame sizes 40
3.3 Phase converter unit (PCU) 41
3.3.1 Primary phase converter unit (1700 mm and 2100 mm) 41
3.3.2 Secondary phase converter unit (1700 mm and 2100
mm) 46
3.4 Control unit (COU) 47
3.4.1 Main components 48
3.4.1.1 AMC circuit board 49
3.5 Transformer and motor cable terminals 54
3.5.1 Transformer cable terminals 54
3.5.2 Motor cable terminals 54
3.6 Water cooling unit (WCU) 56
3.7 EXU – Excitation unit (optional) 57
3.8 Door interlocking system 59
3.9 Grounding switches 60
3.9.1 Locking bars 61
3.10 Grounding studs 62
3.10.1 Grounding set 62
3.10.2 Output grounding studs in COU 63
3.10.3 Input grounding studs in a PCU 64
4. Transportation, storage and disposal 65
4.1 Safety 65

4.2 Transport conditions 65
4.3 Unpacking and inspection 65
4.4 Identifying drive units 66
4.4.1 Packing list 66
4.4.2 Packing label 67
4.5 Lifting and transportation 67
4.5.1 Using a crane to lift a transport unit or the drive
by the base frame 68
4.6 Storage 70
4.6.1 Storage conditions 70
4.6.2 Storage 70
4.7 Storage and handling of spare parts 71
4.7.1 Warranty information 71
4.8 Disposal of packaging materials and components 72
5. Mechanical installation 73
5.1 Safety 73
5.2 Overview on installation work 73
5.3 General notes on installation 74
5.4 Dimensions and clearances 74
5.4.1 Rear and top access to the cabinet 74
5.4.2 Cabinet roof 74
5.4.3 Fire protection 74
5.4.4 Cable duct material 74
5.4.5 Installation material 74
5.4.6 Tools 74
5.5 Preparing the installation site 75
5.6 Aligning transport units 75
5.7 Joining transport units 77

5.8 Applying silicone 78
5.9 Installing roof joints 78
5.10 Installing roof-mounted cooling units 79
5.10.1 Lifting a unit with a crane 79
5.10.2 Installing IP42 roof-mounted cooling units 80
5.10.3 Installing IP54 roof-mounted cooling units 82
5.11 Installing roof attachments 84
5.12 Joining water pipes 86
5.12.1 Removing a pipe joint 86
5.13 Joining busbars 87
5.14 Connecting the heating cable 89
5.15 Connecting raw water pipes 90
5.16 Fixing the drive to the floor 90
6. Electrical installation 91
6.1 Safety 91
6.2 Overview 91
6.3 Cable requirements 92
6.3.1 Power cables 92
6.3.2 Auxiliary and control cables 92
6.4 Grounding 93
6.4.1 Grounding the transformer and the drive 93
6.4.2 Grounding the drive and the motor (multi-point bonding) 94
6.4.3 Grounding the drive and the motor (single-point
bonding) 95
6.4.4 Ground cable connection 96
6.5 Internal wiring 97
6.5.1 Optical fibers 98
6.6 Cable entries 101

6.6.1 Cable entry with sealing modules, type 1 101
6.6.2 Cable entry with sealing modules, type 2 103
6.6.3 Cable entry with cable glands 103
6.6.4 Cable entry with EMC plates 104
6.7 Power cables, ground cables, equipotential
bonding conductor 105
6.7.1 Preparing the cable entry and the cables 105
6.7.1.1 Determining the cable length 105
6.7.1.2 Preparing cables for cable entries with cable glands 106
6.7.1.3 Preparing cables for cable entries with sealing modules 107
6.7.2 Connecting the cables 108
6.7.2.1 Checking the cable insulation 108
6.7.2.2 Connecting the cables 109
6.7.2.3 Bolted connections 111
6.8 Auxiliary power cables and control cables 112
6.8.1 Preparing the cable entry and the cables 112
6.8.1.1 Preparing cables for cable entries with sealing modules 114
6.8.1.2 Preparing cables for cable entries with cable glands 115
6.8.2 Connecting the cables 115
6.8.2.1 Connecting auxiliary power cables and space heater
cables in WCU 116
6.8.2.2 Connecting cables in COU 117
7. Commissioning 119
7.1 Required qualification 119
7.2 Commissioning procedure 119
7.3 Commissioning checklist 119
7.4 Customer assistance 119
7.5 Customer acceptance 119

7.6 Commissioning checklists 120
7.6.1 Mechanical installation checklist 120
7.6.2 Electrical installation checklist 120
7.6.3 Door interlocking checklist 121
7.6.4 Main circuit breaker (MCB) 121
7.6.5 Input transformer checklist 121
7.6.6 Motor checklist 122
7.6.7 Insulation tests checklist 122
7.6.8 Power checklist 122
7.6.9 Miscellaneous checklist 122
8. Operation 123
8.1 Operating conditions 123
8.2 Safety 123
8.3 Overview 123
8.4 Local operator panel 123
8.5 Lamp-test function 125
8.6 Status messages 125
8.6.1 Start sequence of the drive 127
8.6.2 Stop sequence of the drive 128
8.6.3 Emergency-off sequence 129
8.7 Starting the drive 129
8.7.1 Checks before starting the drive 130
8.7.2 Starting the drive from remote 130
8.7.3 Starting the drive locally 130
8.8 Stopping the drive 133
8.9 Emergency-off 134
8.9.1 Initiating an emergency off 134

8.9.2 Starting the drive system after an emergency-off 134
8.10 Arc resistant design 136
8.10.1 Internal arc classification (IAC) 136
8.10.2 Arc detection with the Arc Guard System™ 137
8.10.3 Action after the Arc Guard System™ has been triggered 137
8.11 De-energizing and grounding the drive 138
8.12 Opening the doors 138
9. CDP control panel 139
9.1 Overview 139
9.1.1 Display and keypad 139
9.1.2 Functions 140
9.2 Modes 140
9.2.1 Identification mode 140
9.2.2 Actual signals mode 142
9.2.2.1 Overview 142
9.2.2.2 Selecting the actual signals display 143
9.2.2.3 Toggling between actual signals display and fault
memory 144
9.2.2.4 Displaying three actual signals 144
9.2.2.5 Selecting actual signals 144
9.2.2.6 Displaying a fault and resetting the fault memory 146
9.2.2.7 Displaying and resetting an active fault 148
9.2.3 Parameters mode 149
9.2.3.1 Overview 150
9.2.3.2 Changing a parameter setting 151
9.2.3.3 Enabling / unlocking a parameter lock 153
9.2.3.4 User lock 153
9.2.4 Functions mode 154

9.2.4.1 Adjusting the display contrast 154
9.2.5 Local and remote control mode 156
9.2.5.1 Local control 156
9.2.5.2 Disabling / enabling local lock function 156
9.2.5.3 Enabling the local lock 157
9.2.5.4 Remote control 157
9.3 Operational commands 158
9.3.1 Setting the direction of rotation 158
9.3.2 Entering a reference value 159
10. Preventive and corrective maintenance 161
10.1 General information 161
10.1.1 Required qualification 161
10.1.2 Maintenance schedule 161
10.1.3 Logbook 161
10.1.4 Spare parts 161
10.2 Identifying electrical equipment 161
10.2.1 Device designation 161
10.2.2 Cables and wires 162
10.2.3 Understanding wiring diagrams 162
10.3 Alarm / fault indications 163
10.3.1 Messages 163
10.3.2 Error message levels 163
10.3.2.1 Alarm 163
10.3.2.2 Fault 163
10.3.2.3 Alarm / fault messages 164
10.3.3 Fault handling 164
10.3.4 Standard troubleshooting procedure 165