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

10.4 Removing the CDP control panel 165
10.5 LEDs and switches on circuit boards and I/O devices 166
10.5.1 AMC circuit board 167
10.5.2 S800 I/O bus modem TB820 168
10.5.2.1 Bus modem address 168
10.5.3 S800 I/O modules 169
10.6 Corrective maintenance 169
10.6.1 Safety 171
10.6.2 De-energizing the drive 172
10.6.2.1 Stopping the motor 172
10.6.2.2 De-energizing the drive 172
10.6.3 Opening and closing the doors 174
10.6.4 Grounding switch is not released 176
10.6.5 Emergency release of a door safety switch 177
10.6.5.1 Location of safety switches 177
10.6.5.2 Safety-switch settings 178
10.6.6 Visual checks on the drive 179
10.6.7 Cleaning§ 180
10.6.7.1 Cleaning the drive cabinet 180
10.6.8 Checking wire and cable connections 181
10.6.9 Checking and replacing filter mats 181
10.6.9.1 Location 181
10.6.9.2 Replacing filter mats 181
10.6.10 Replacing a door-mounted fan 182
10.6.11 Replacing a fan of an IP42 roof-mounted cooling unit 183
10.6.11.1 Replacing a fan 183
10.6.12 Replacing a fan of an IP54 roof-mounted cooling unit 184
10.6.12.1 Replacing a fan 184

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Figures
Figure 1-1 Typical delivery 28
Figure 2-1 Product warning label examples
(label placement depends on the drive) 30
Figure 2-2 Drive system overview 35
Figure 3-1 Typical block diagram of the drive 37
Figure 3-2 Switching levels 38
Figure 3-3 Principle of 9-level topology 38
Figure 3-4 IGCT 39
Figure 3-5 Frame sizes 1 – 4 40
Figure 3-6 Primary PCU, 1700 mm 42
Figure 3-7 Primary PCU, 1700 mm: side view left (A) and
side view right (B) 43
Figure 3-8 Primary PCU, 2100 mm 44
Figure 3-9 Primary PCU, 2100 mm: side view left (A) and
side view right (B) 45
Figure 3-10 Secondary PCU, 1700 mm (A) and 2100 mm (B) 46
Figure 3-11 Block diagram of control system 47
Figure 3-12 COU control section 48
Figure 3-13 DTC torque control 50
Figure 3-14 Local control panel 52
Figure 3-15 COU customer interface section 53
Figure 3-16 Motor terminal section of frame size 1 and 2:
bottom entry (A) and top entry (B) 54
Figure 3-17 Motor terminal section of frame size 3 and 4:
bottom entry (A) and top entry (B) 55
Figure 3-18 WCU (1400 mm), frame size 3 56
Figure 3-19 EXU 57

Figure 3-20 EXU control panel 58
Figure 3-21 Location of protection features and lights 59
Figure 3-22 Grounding switch 60
Figure 3-23 Locking bar and white lamp 61
Figure 3-24 Grounding stud 62
Figure 3-25 4-way grounding set 62
Figure 3-26 Connection studs for the 4-way grounding set in
the COU 63
Figure 3-27 Connection studs for the 4-way grounding set in
a PCU 64
Figure 4-1 Lifting bracket on base frame of a drive and
safety hook secured to lifting bracket 68
Figure 4-2 Lift frame and lift spreader 69
Figure 5-1 Floor inclination 75
Figure 5-2 Connection points on side of transport units (PCU
example) 77
Figure 5-3 Applying silicone 78
Figure 5-4 Roof joint 78
Figure 5-5 Lifting a cooling unit (example with IP54 unit) 79
Figure 5-6 Cable duct openings (example with 1700 mm PCU) 81
Figure 5-7 Water inlet / outlet and drain outlet (back view) 83
Figure 5-8 Roof attachment 84
Figure 5-9 Recommended ceiling and wall fixings 85
Figure 5-10 Busbar connections 87
Figure 5-11 AC busbar connection 88
Figure 5-12 PE ground busbar connection 88
Figure 5-13 DC busbar connection 88
Figure 5-14 Heating cable connection 89
Figure 6-1 Grounding the transformer and the drive (in PCU) 93

Figure 6-2 Grounding the drive and the motor (multi-point
bonding) 94
Figure 6-3 Grounding the drive and the motor (single-point
bonding) 95
Figure 6-4 PE ground busbar in COU (back view) 96
Figure 6-5 PE ground busbar in PCU (back view) 96
Figure 6-6 Wiring across shipping splits, frame size 1 (A)
and 2 (B) 99
Figure 6-7 Wiring across shipping splits, frame size 3 and 4 100
Figure 6-8 Cable entry with sealing modules – type 1 101
Figure 6-9 Cable entry frame sizes (top) for type 1 sealing
modules (bottom) 102
Figure 6-10 Cable entry with sealing modules – type 1 103
Figure 6-11 Cable entry with cable gland 103
Figure 6-12 Cable entry with EMC plates 104
Figure 6-13 Preparing power cables for cable glands 106
Figure 6-14 Preparing power cables for sealing modules 107
Figure 6-15 PCU cable terminals, top and bottom entry (back
view) 109
Figure 6-16 COU cable terminals, top and bottom entry (back
view) - frame sizes 1 and 2 (A) and 3 and
4 (B) 110
Figure 6-17 Bolted busbar connection 111
Figure 6-18 Preparing control cables for EMC plates 113
Figure 6-19 Preparing control cables for sealing modules 114
Figure 6-20 Preparing control cables for cable glands 115
Figure 6-21 Cable routing in WCU800 (A) and WCU1400 (B)
cabinets 116
Figure 6-22 Shield grounding clamp 117
Figure 6-23 COU customer interface section 117

Figure 8-1 Local operator panel 124
Figure 8-2 IAC label example 136
Figure 8-3 Arc Guard™ system with HMI panel 137
Figure 8-4 HMI panel 137
Figure 9-1 CDP control panel 139
Figure 9-2 Control panel functions for Actual signals mode 142
Figure 9-3 Control panel functions for Parameters mode 149
Figure 9-4 Control panel functions for Functions mode 154
Figure 10-1 Device identification 162
Figure 10-2 Cable and wire designation 162
Figure 10-3 LEDs of AMC circuit board 167
Figure 10-4 TB820 bus modem 168
Figure 10-5 Example of S800 I/O station 169
Figure 10-6 Location of safety switches 177
Figure 10-7 Safety switch 178
Figure 10-8 Filter mat replacement for PCU (A) and WCU (B) 182
Figure 10-9 Roof-mounted cooling unit (IP42) 183
Figure 10-10 Roof-mounted cooling unit (IP54) 184

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Table
Table 1-1 Maintenance 20
Table 1-2 Technical data 20
Table 1-3 Schematics 20
Table 1-4 Specifications and guidelines 20
Table 1-5 Manuals 20
Table 1-6 I/O interface 21
Table 1-7 Serial communications interfaces 21
Table 1-8 Terms and abbreviations 21
Table 1-9 Trademarks 23
Table 1-10 Standards 27
Table 3-1 Line-up specifications by frame size 40
Table 5-1 Installation material per roof joint 78
Table 5-2 Installation material per IP42 unit 80
Table 5-3 Installation material per IP54 unit 82
Table 6-1 Type 1 sealing modules and cables per frame
opening 102
Table 6-2 Maximum number of type 1 sealing modules per
frame opening 102
Table 6-3 Maximum number of cables per frame opening -
3 core 102
Table 6-4 Maximum number of cables per frame opening -
single core 102
Table 8-1 ABB arc resistant classes 136
Table 10-1 Filter mat specifications 181

3BHS799208 E01 REV E ACS5000 WATER-COOLED USER MANUAL 19/186
1. About this manual
1.1 Equipment covered by this 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 (such as layout drawings, wiring diagrams,
project-specific data, engineering notes).
If information is required beyond the instructions in this manual, refer the
matter to ABB.
1.2 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: provides manuals about additional
equipment delivered with the drive (such as project-specific
options like pulse encoder or fieldbus interfaces), or information on
modifications of the standard drive.
• Appendix B - Technical data: contains the technical data sheets of
the drive.
• Appendix C - Mechanical drawings: provides the outline drawings of
the drive. The drawings are generated according to the customer-
specific project.
• Appendix D - Wiring diagrams contains the circuit diagrams with
information on device identification, cross-reference and device
identification conventions. The diagrams are generated according
to the customer-specific project. “Setting of protective devices” is
generated according to the customer-specific project.
• Appendix E - Parts list: produced for each project and contains all
information to identify a component.
• Appendix F - Test reports and certificates: provides the test reports of
the drive. Quality certificates, and codes and standards the drive
complies with are added if necessary for the project.
• Appendix G - Signal and parameter table: includes descriptions of
actual signals, control and status words, and control parameters
and their default settings.

01 ABOUT THIS MANUAL
3BHS799208 E01 REV E ACS5000 WATER-COOLED USER MANUAL 20/186
1.3 Related documents
The following documents are available for supplementary information:
Table 1-1 Maintenance
Title Document number
[1] ACS5000 preventive maintenance schedule 3BHS855274 E01
[2] Permission for working and permit to work for
test work at test stations
3BHS817511 E30
Table 1-2 Technical data
Title Document number
[3] Technical data from DriveSmart(1)
(1) Configuration software for medium voltage drives
Table 1-3 Schematics
Title Document number
[4] Layout drawing Project-specific
Table 1-4 Specifications and guidelines
Title Document number
[5] Generic transformer specification 3BHS356582 E01
[6] Generic motor specification 3BHS824803 E01
[7] Main circuit breaker engineering guideline 3BHS125149 E50
[8] ACS5000 power cable specification 3BHS215798 E01
[9] Power cables engineering guideline 3BHS542290 E01
[10] Auxiliary power and control cables guideline 3BHS813742 E01
[11] Customer interface 3BHS347034 E03
Table 1-5 Manuals
Title Document number
[12] ACS5000 Service manual 3BHS264270 E20
[13] Air-cooled excitation units user manual 3BHS252500 E01