ABB ACS6080 User manual

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SYSTEM DRIVES
ACS6080
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
ACS6080 user manual
Document number
3BHS842007 E01 Rev C
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 25
1.1 Product overview 25
1.1.1 Standard applications 25
1.2 Equipment covered by this manual 25
1.3 Structure of the user documentation 26
1.4 Terms and abbreviations 27
1.5 Trademarks 32
1.6 Related documentation 32
1.7 Target groups and required qualification 35
1.7.1 Handling 35
1.7.2 Mechanical installation 35
1.7.3 Electrical installation 35
1.7.4 Operation 35
1.7.5 Maintenance 35
1.8 User’s responsibilities 36
1.9 Intended use of equipment 36
1.10 Cyber security disclaimer 36
1.11 Quality certificates and applicable standards 37
1.12 Identifying the delivery 38
1.13 Tools 38
2. Important safety information 39
2.1 Safety standards 39
2.2 Safety messages 39
2.3 Product safety labels 40
2.4 General safety instructions 41

2.5 The 7 steps that save lives 42
2.6 Possible residual risks 44
2.7 Important note - main circuit breaker 45
2.7.1 Safety and protection requirements 46
2.7.2 Safety and protection requirements for the MCB 46
2.8 Maintenance recommendation 47
3. Power electronics and cabinet features 49
3.1 Drive system topology 49
3.1.1 Drive 49
3.1.1.1 ACS6080 cabinet units 51
3.1.1.2 Final drive configuration 51
3.1.2 Motor 51
3.2 Standard cabinet units 51
3.2.1 Active rectifier unit (ARU)/inverter unit (INU) 51
3.2.2 Line supply unit (LSU) 53
3.2.3 Capacitor bank unit (CBU) 56
3.2.4 Terminal unit (TEU) 57
3.2.5 Control unit (COU) 58
3.2.5.1 Main circuit breaker 59
3.2.5.2 Speed and torque control 59
3.2.5.3 Peripheral I/O devices 59
3.2.5.4 S500 I/O system 60
3.2.5.5 Local control panels 60
3.2.6 Water cooling unit (WCU) 61
3.2.6.1 Cooling circuit 64
3.2.6.2 External cooling connection 64
3.3 Optional cabinet units 65

3.3.1 Input reactor unit (IRU) 65
3.3.2 Input filter unit (IFU) 66
3.3.3 Voltage limiter unit (VLU) 67
3.3.4 Braking units 68
3.3.4.1 Braking chopper unit 69
3.3.4.2 Resistor braking unit 70
3.3.5 Excitation unit (EXU) 71
3.3.5.1 DCS880/DCT880 control panel 72
3.3.5.2 Output disconnector 72
3.3.6 Customer interface unit (CIU) 73
3.3.6.1 Arc detection with Arc Guard (optional) 74
3.4 Air cooling 74
3.4.1 Air-to-air heat exchangers 74
3.4.2 Auxiliary fan units 75
3.5 Cabinet design 76
3.6 Door locking system 77
3.7 Arc resistant design 77
3.7.1 Internal arc classification 77
3.8 Busbars and grounding 78
3.8.1 AC busbars 78
3.8.2 DC busbars 79
3.8.3 PE busbar 79
3.8.4 PG busbar 79
4. Transportation, storage and disposal 81
4.1 Safety 81
4.2 Transport conditions 81
4.3 Unpacking and inspection 81

4.4 Identifying transport units 81
4.5 Lifting and transportation 83
4.5.1.1 Lifting recommendations 84
4.6 Storage 86
4.7 Storing and handling of spare parts 87
4.7.1 Warranty information 87
4.8 Disposing package materials and components 88
5. Mechanical installation 89
5.1 Safety 89
5.2 Overview 89
5.3 General notes on installation 90
5.3.1 Dimensions and clearances 90
5.3.2 Access to the cabinets 90
5.3.3 Cabinet roof 90
5.3.4 Fire protection 90
5.3.5 Cable duct material 91
5.3.6 Installation material 91
5.3.7 Tools 91
5.3.8 Floor preparation 91
5.3.9 Floor fixation 91
5.3.10 Raw water circuit 91
5.4 Aligning transport units 92
5.5 Joining transport units 94
5.6 Joining water pipes 95
5.6.1 Removing a pipe joint 96
5.7 Joining busbars 97
5.7.1 DC busbars 98

5.7.2 Ground busbars 100
5.7.3 AC busbars between COU/TEU and LSU (5/7/9 MVA) 101
5.7.4 AC busbars between COU/TEU and LSU (14 MVA) 102
5.7.5 AC busbars between COU/TEU and ARU/INU 103
5.7.6 AC busbar joints - without disconnector 103
5.7.7 AC busbar joints - with motorized disconnector 104
5.8 Installing and removing air-to-air heat exchangers 106
5.8.1 Installing air-to-air heat exchangers 106
5.8.1.1 Installation 107
5.8.2 Removing air-to-air heat exchangers 111
5.8.2.1 Removing an air-to-air heat exchanger 112
5.8.2.2 Reinstalling an air-to-air heat exchanger 113
5.8.3 Installing the transformers of air-to-air heat exchangers 114
5.9 Installing the pressure relief vents 115
5.10 Attaching the sealing tapes 117
5.11 Installing the roof joints and the roof attachments 118
5.11.1 Installing roof joints 118
5.11.2 Installing roof attachments 119
6. Electrical installation 121
6.1 Safety 121
6.2 Cable requirements 122
6.2.1 Power cables 122
6.2.2 Auxiliary and control cables 122
6.2.3 Synchronization cables 122
6.3 Grounding the drive system 123
6.3.1 Grounding diagrams 123
6.3.2 Ground cable connection 124

6.3.3 Cable shield ground connection 124
6.3.4 EXU cabinet ground connections 125
6.4 Internal wiring 125
6.4.1 Optical fiber cables 126
6.4.1.1 Installing the standard optical fibers 126
6.4.2 Optical fiber cables for the optional Arc Guard
System™ 127
6.4.2.1 Connecting the detector cables to the arc monitor
device 128
6.5 Cable entry systems 129
6.5.1 Frames with type 1 sealing modules 129
6.5.2 Frame with type 2 sealing modules 131
6.5.3 Plates with cable glands 131
6.5.4 EMC plates with sealing grommets 132
6.6 Preparing cable entry systems for TEU, ARU and
EXU cabinets 132
6.6.1 TEU cable entry frames with type 1 sealing modules 133
6.6.2 ARU cable entry frames with type 1 sealing modules 134
6.6.3 EXU cable entry with EMC plate and sealing grommets 135
6.7 Power, ground and equipotential bonding conductor cables§ 136
6.7.1 Determining the cable length 136
6.7.2 Preparing cables for sealing modules 137
6.7.3 Preparing cables for cable glands 138
6.7.4 Preparing cables for EMC plates 138
6.7.5 Connecting the cables 140
6.7.5.1 Checking the cable insulation 140
6.7.5.2 EXU cabinet connections 140
6.7.5.3 Bolted busbar connections – marine drives 141

6.7.5.4 Bolted busbar connections – non-marine drives 142
6.8 Auxiliary power, control and serial communication cables 143
6.8.1 Determining the cable length 143
6.8.2 Preparing cables for sealing modules 144
6.8.3 Preparing cables for cable glands 145
6.8.4 Preparing cables for EMC plates 145
6.8.5 Routing cables in a WCU 147
6.8.6 Routing cables in a COU cabinet 147
6.8.6.1 Connecting the cables 149
6.8.7 Routing cables in an EXU cabinet 150
6.8.7.1 Auxiliary power and control cables 150
6.8.7.2 Optical fiber cables 152
6.8.7.3 Routing optical fiber cables in an EXU cabinet with
an ED5V, EB5R, EB5S, EB7P and EB7Q type DCS880/
DCT880 converter 153
6.8.7.4 Routing cables in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter 155
6.9 Heating cable 157
6.10 Final checks 158
7. Commissioning 159
7.1 Required qualification 159
7.2 Commissioning procedure 159
7.3 Commissioning checklist 159
7.4 Customer assistance 159
7.5 Customer acceptance 159
7.6 Commissioning checklists 160
7.6.1 Mechanical installation checklist 160
7.6.2 Electrical installation checklist 160

7.6.3 Main circuit breaker (MCB) 161
7.6.4 Input transformer checklist 161
7.6.5 Motor checklist 162
7.6.6 Insulation tests checklist 162
7.6.7 Power checklist 162
7.6.8 Miscellaneous checklist 162
8. Operation 163
8.1 Overview 163
8.2 Operating conditions 163
8.3 Safety 163
8.5 Assistant control panels 164
8.5.1 Control panels for drives with an ARU 165
8.5.1.1 Lamp test 167
8.5.2 Control panels for drives with an LSU 167
8.5.2.1 Lamp test 168
8.6 EXU control panel 168
8.6.1 Operational settings 168
8.6.2 Resetting alarm and fault messages 169
8.6.3 Parameter settings 169
8.7 Grounding switch and door locking system 170
8.7.1 Lamp test 171
8.7.2 Door locking system 171
8.8 Optional switchgear and controlgear 173
8.8.1 DC-link disconnector 173
8.8.2 Output switches 173
8.8.3 Manual output isolation 173
8.9 Status messages 174