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

8.9.1 Start sequence of the drive 175
8.9.2 Stop sequence of the drive 176
8.9.3 Emergency-off sequence 177
8.9.4 Prevention of unexpected startup sequence 177
8.10 Starting the drive 178
8.10.1 Checks before starting the drive 178
8.10.2 Starting the drive remotely 178
8.10.3 Starting the drive locally 179
8.11 Stopping the drive 180
8.11.1 Stopping the drive locally 180
8.11.2 Stopping the drive with the emergency-off function 181
8.11.3 Initiating an emergency-off 181
8.11.4 Starting the drive system after an emergency-off 182
8.12 Arc detection with the Arc Guard System™ (optional) 183
8.12.1 Action after the Arc Guard System™ has been triggered 183
9. Preventive and corrective maintenance 185
9.1 General information 185
9.1.1 Required qualification 185
9.1.2 Maintenance schedule 185
9.1.3 Logbook 185
9.1.4 Spare parts 185
9.2 Identifying electrical equipment 186
9.2.1 Device designation 186
9.2.2 Cables and wires 186
9.2.2.1 Understanding wiring diagrams 187
9.3 Status indicators 187
9.3.1 Alarm / fault indications 187

9.3.2 Error message levels 187
9.3.2.1 Alarm and fault messages 188
9.3.2.2 Fault handling 188
9.3.2.3 Standard troubleshooting procedure 189
9.3.3 LEDs and switches on PCBs and I/O modules 189
9.3.3.1 BCU-55 control unit 189
9.3.3.2 S500 I/O modules 191
9.3.3.3 Serial communication interfaces 191
9.3.3.4 LEDs on optional heat exchangers 191
9.4 Maintenance tasks 193
9.4.1 Safety 193
9.4.2 De-energizing and grounding the drive 194
9.4.3 Grounding the drive when the grounding switch is not
released 196
9.4.4 Unlocking and opening the doors 198
9.4.5 Closing and locking the doors 199
9.4.6 Testing the white lamp 200
9.4.7 Emergency release of a door safety switch 202
9.4.7.1 Location of safety switches 202
9.4.7.2 Safety-switch settings 203
9.4.7.3 Unlocking a safety switch 203
9.4.8 Connecting a grounding set 204
9.4.8.1 Drives with LSU 205
9.4.8.2 Drives with ARU 206
9.4.9 Drives with the manual output isolation (optional) 206
9.4.9.1 Removing the busbar connectors 208
9.4.9.2 Fitting the busbar connectors 212
9.4.10 Removing and installing a phase module 213

9.4.10.1 Removing a phase module 213
9.4.10.2 Installing a phase module 215
9.4.11 Visual checks on the drive 216
9.4.12 Cleaning 216
9.4.12.1 Cleaning the drive cabinet 216
9.4.13 Checking wire and cable connections 217
9.4.14 Checking and replacing filter mats 217
9.4.15 Testing and replacing auxiliary fan units 219
9.4.15.1 Testing auxiliary fan units 219
9.4.15.2 Replacing auxiliary fan units 220
9.4.16 Testing and replacing air-to-air heat exchangers 221
9.4.16.1 Testing the fan units 222
9.4.16.2 Replacing the complete heat exchanger 223
9.4.16.3 Replacing the circuit board 223
9.4.16.4 Replacing internal fan 1 - left side 225
9.4.16.5 Replacing internal fan 2 - right side 226
9.4.16.6 Replacing the ambient fans 229
9.4.17 Replacing the fan unit in an EXU with a DCS880
H4/DCT880 T4 unit 230
9.4.18 Replacing the fan unit in an EXU with a DCS880 H6
unit 232
9.4.19 Replacing the air-to-water heat exchanger of the EXU 234

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Figures
Figure 2-1 Product warning label examples
(label placement depends on the drive) 40
Figure 2-2 Drive system overview 45
Figure 2-3 MCB opening timing diagram 47
Figure 3-1 Common DC-bus principle for single motor drive
(A) and multi-motor drive (B) 49
Figure 3-2 ACS6080 drive example 50
Figure 3-3 ARU/INU block diagram 52
Figure 3-4 ARU/INU circuit diagram 52
Figure 3-5 ARU/INU (A) and phase modules with IGCTs (B) 53
Figure 3-6 LSU block diagram 54
Figure 3-7 LSU (12-pulse) circuit diagram 54
Figure 3-8 LSU (12-pulse) 55
Figure 3-9 CBU 56
Figure 3-10 TEU (1000 mm) 57
Figure 3-11 Master COU (1000 mm) and control equipment 58
Figure 3-12 Control panel 60
Figure 3-13 Location of control panels on master COU (A)
and slave COU (B) 61
Figure 3-14 WCU1400 (A) and WCU800 (B) cabinet and system
components 63
Figure 3-15 Cooling circuit in an ACS6080 drive 64
Figure 3-16 IRU circuit diagram 65
Figure 3-17 IRU cabinet 65
Figure 3-18 IFU circuit diagram 66
Figure 3-19 IFU cabinet 66

Figure 3-20 VLU circuit diagram 67
Figure 3-21 VLU cabinet 67
Figure 3-22 BCU circuit diagram 69
Figure 3-23 BCU cabinet 69
Figure 3-24 RBU circuit diagram 70
Figure 3-25 RBU cabinet 70
Figure 3-26 EXU H4/T4 frame cabinet (A) and EXU H6 frame
cabinet (B) 71
Figure 3-27 CIU cabinet (A) and WCU800 cabinet (B) 73
Figure 3-28 ACS6080 example drive with air-to-air heat exchanger 74
Figure 3-29 Auxiliary fan unit 75
Figure 3-30 Air circulation through ventilation grids in 600 mm
COU (A), 1000 mm COU (B) and WCU800 (C) 75
Figure 3-31 Basic cabinet design 76
Figure 3-32 IAC label example 78
Figure 3-33 Busbars 78
Figure 4-1 Lifting bracket (1) on base frame of a drive,
safety hook (2) secured to lifting bracket and eye
bolt (3). 84
Figure 4-2 Lift frame (A) and lift spreader (B) 85
Figure 5-1 Connection point locations on transport units 94
Figure 5-2 Minimum distances and locking bolt orientation (A
= front) 95
Figure 5-3 Bolted busbar connection 97
Figure 5-4 Top view of DC busbar configuration 1 98
Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B)
and 4 (C) 99
Figure 5-6 Ground busbar joints 100
Figure 5-7 AC busbar joints between the COU/TEU and LSU
(5/7/9 MVA). 101

Figure 5-8 AC busbar joints between the COU/TEU and LSU
(14 MVA). 102
Figure 5-9 Air-to-air heat exchanger (type LT-5-5165-UL) 106
Figure 5-10 Tools for installing an air-to-air heat exchanger 106
Figure 5-11 Correct and incorrect cable installation 108
Figure 5-12 ARU/INU/IFU cable routing 110
Figure 5-13 LSU cable routing 110
Figure 5-14 Air-to-air heat exchangers (type LT-5-5165-UL) 111
Figure 5-15 Tools for removing an air-to-air heat exchanger 112
Figure 5-16 Installation example of transformers in an air-to-air
heat exchanger 114
Figure 5-17 Connect wires to terminal block 115
Figure 5-18 Pressure relief vents 115
Figure 5-19 Tools required to fasten the pressure relief vent
to the roof 116
Figure 5-20 Installation example of pressure relief vents 116
Figure 5-21 Attach sealing tape to the joining crossbar (1) 117
Figure 5-22 Roof joints (1) 118
Figure 5-23 Roof attachment parts 119
Figure 5-24 Recommended ceiling and wall fixings 120
Figure 6-1 Phase module on lift table 121
Figure 6-2 Grounding the input side (A) and output side (B)
of the drive system 123
Figure 6-3 System ground connection (1) in a 600 mm TEU 124
Figure 6-4 Grounding the EXU 125
Figure 6-5 Cable tray and cable ducts in an LSU (A =
front) 126
Figure 6-6 Arc Guard System™ in an optional roof extension
box (REB) 127
Figure 6-7 Location of Arc Guard sensors in a TEU 128

Figure 6-8 Cable tray and cable ducts in an LSU (A =
front) 128
Figure 6-9 Cable entry with type 1 sealing modules 129
Figure 6-10 Cable entry frame with type 1 sealing modules 130
Figure 6-11 Cable entry with type 2 sealing modules 131
Figure 6-12 Cable gland 131
Figure 6-13 Cable entry with EMC plates 132
Figure 6-14 TEU 1000 mm cabinet (A = back) with top (1)
and bottom (2) cable entries 133
Figure 6-15 Short busbar removal in ARU 134
Figure 6-16 EXU with top cable entry (A) and EXU with
bottom cable entry (B) 135
Figure 6-17 EXU cabinet 135
Figure 6-18 Preparing power cables for sealing modules 137
Figure 6-19 Prepare power cables for cable glands 138
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 139
Figure 6-21 Cable connections in an EXU cabinet 140
Figure 6-22 Minimum distance between bolted joints of different
phases in an EXU 141
Figure 6-23 Bolted busbar connection - marine drives 141
Figure 6-24 Bolted busbar connection - non-marine drive 142
Figure 6-25 Cable entry with sealing modules 144
Figure 6-26 Preparing control cables for sealing modules 144
Figure 6-27 Preparing auxiliary control cables for cable glands 145
Figure 6-28 Preparing the screens of control cables for EMC
plates 146
Figure 6-29 Preparing control cables for EMC plates 147

Figure 6-30 Location of top blanking plates of 600 mm COU
(A) and 1000 mm COU (B) 148
Figure 6-31 Location of bottom blanking plates of 600 mm
COU (A) and 1000 mm COU (B) 148
Figure 6-32 Cable routing in 1000 mm COU (A) and 600 mm
COU (B) 149
Figure 6-33 Shield grounding for encoder cable 150
Figure 6-34 Cable routing examples in an EXU cabinet with
an ED5V, EB5R, EB5S, EB7P or EB7Q type
DCS880/DCT880 converter (A) and in an EXU
cabinet with an ED7Y type DCS880 converter 151
Figure 6-35 DCS880/DCT880 H4 converter (ED5V, EB5R, EB5S,
EB7P and EB7Q types) 153
Figure 6-36 1 Control unit SDCS-CON-H01 154
Figure 6-37 Cable routing example in an EXU cabinet with an
ED5V, EB5R, EB5S, EB7P and EB7Q type DCS880/
DCT880 converter 154
Figure 6-38 DCS880/DCT880 converter (ED7Y) 155
Figure 6-39 1 Control unit SDCS-CON-H01 155
Figure 6-40 Cable routing example in an EXU cabinet with an
ED7Y type DCS880/DCT880 converter 156
Figure 6-41 Heating cable connection 157
Figure 8-1 Assistant control panel 163
Figure 8-2 Assistant control panel front and back 164
Figure 8-3 Master control panel on COU1 (A) and slave
control panel (B) for a drive with an ARU 166
Figure 8-4 Master control panel on COU1 (A) and slave
control panel (B) for a drive with an LSU 167
Figure 8-5 DCS880 control panel 168
Figure 8-6 CBU grounding switch in ungrounded (A) and
grounded (B) 170
Figure 8-7 Location on the safety switches 171

Figure 8-8 Arc Guard System™ in a WCU REB 183
Figure 8-9 HMI panel 183
Figure 9-1 Labels on S500 I/O modules and associated wiring
diagram 186
Figure 9-2 Cable and wire designation 186
Figure 9-3 Assistant control panel 190
Figure 9-4 BCU-55 control unit front view (A) and rear view
(B) 190
Figure 9-5 S500 I/O modules in a COU 191
Figure 9-6 Status LEDs on optional air-to-air heat exchangers 192
Figure 9-7 Grounding switch ungrounded 195
Figure 9-8 Grounding switch grounded 196
Figure 9-9 Grounding switch grounded 198
Figure 9-10 Testing the white lamp 200
Figure 9-11 Safety switch on an ARU/INU cabinet door 202
Figure 9-12 Safety switch settings 203
Figure 9-13 Four-way grounding set 204
Figure 9-14 TEU ground ball stud locations 205
Figure 9-15 ARU/INU ground ball stud locations 206
Figure 9-16 Manual output isolation overview 207
Figure 9-17 Tools for removing the busbar connectors 208
Figure 9-18 Overview of grounding the drive - INU1 is shut
down (A) and INU2 is
shut down (B). Numbers indicate the connection
sequence. 209
Figure 9-19 Connect the grounding sets in COU1 (A and C),
TEU1 (B), INU1 (D) and INU2 (E) 210
Figure 9-20 Busbar connector removal sequence in TEU1 or
COU1 211
Figure 9-21 Fitting sequence for busbar connectors 212