ABB ACS6080 User manual

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SYSTEM DRIVES
ACS6080
User manual
OWNING ORGANIZATION
ABB Switzerland Ltd.
DATE
2020-11-18
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS842007 E01
REV.
D
LANG.
en
PAGE
1/220
© Copyright 2018 ABB All rights reserved.

PRODUCT
ACS6080
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS842007 E01
REV.
D
LANG.
en
PAGE
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Legal disclaimer
This document contains information about one or more ABB products and may include a description
of or a reference to one or more standards that are relevant to the ABB products. The presence of
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The buyer acknowledges the proprietary and confidential nature of the information contained in this
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herein shall oblige ABB to furnish any particular information to the buyer.
The information in this document is subject to change without notice and should not be construed
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or consequential damages of any nature or kind whatsoever arising from the use of this document,
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ABB is a registered trademark of ASEA BROWN BOVERI LTD.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2018 ABB
All rights reserved

CONTENTS
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Contents
1. About this manual .............................................................................. 17
1.1. Product overview ................................................................................ 17
1.1.1. Standard applications .............................................................. 17
1.2. Equipment covered by this manual .................................................. 18
1.3. Structure of the user documentation .............................................. 18
1.4. Terms and abbreviations ................................................................... 19
1.5. Related documents ........................................................................... 24
1.6. Target groups and required qualification ...................................... 26
1.6.1. Handling ................................................................................... 26
1.6.2. Mechanical installation ........................................................... 26
1.6.3. Electrical installation .............................................................. 26
1.6.4. Operation ................................................................................. 26
1.6.5. Maintenance ............................................................................. 26
1.7. User’s responsibilities ....................................................................... 27
1.8. Intended use of equipment............................................................... 27
1.9. Quality certificates and applicable standards ................................ 27
1.10. Identifying the delivery ..................................................................... 28
1.11. 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
2.7.2. Safety and protection requirements for the MCB ............... 36
2.8. Maintenance recommendation ......................................................... 37
3. Power electronics and cabinet features ............................................ 39
3.1. Drive system topology ...................................................................... 39
3.1.1. Drive .......................................................................................... 39
3.1.1.1. ACS6080 cabinet units ................................................... 41
3.1.1.2. Final drive configuration ................................................ 41
3.1.2. Motor ......................................................................................... 41
3.2. Standard cabinet units ..................................................................... 42
3.2.1. Active rectifier unit (ARU)/inverter unit (INU) ...................... 42
3.2.2. Line supply unit (LSU) ............................................................. 44
3.2.3. Capacitor bank unit (CBU) ...................................................... 46
3.2.4. Terminal unit (TEU) .................................................................. 47
3.2.5. Control unit (COU) ................................................................... 48
3.2.5.1. Main circuit breaker ....................................................... 49
3.2.5.2. Speed and torque control ............................................. 49
3.2.5.3. Peripheral I/O devices ................................................... 49
3.2.5.4. S500 I/O system ............................................................ 49

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3.2.5.5. Local control panels ....................................................... 50
3.2.6. Water cooling unit (WCU)......................................................... 51
3.2.6.1. Cooling circuit ................................................................ 53
3.2.6.2. External cooling connection ......................................... 53
3.3. Optional cabinet units ...................................................................... 54
3.3.1. Input reactor unit (IRU) ........................................................... 54
3.3.2. Input filter unit (IFU) ............................................................... 55
3.3.3. Voltage limiter unit (VLU) ....................................................... 56
3.3.4. Braking units ............................................................................. 57
3.3.4.1. Braking chopper unit ..................................................... 58
3.3.4.2. Resistor braking unit ..................................................... 59
3.3.5. Excitation unit (EXU) ............................................................... 60
3.3.5.1. DCS880/DCT880 control panel ..................................... 61
3.3.5.2. Output disconnector ...................................................... 61
3.3.6. Customer interface unit (CIU) ................................................ 62
3.3.6.1. Arc detection with Arc Guard (optional) ..................... 63
3.4. Air cooling .......................................................................................... 63
3.4.1. Air-to-air heat exchangers ...................................................... 63
3.4.2. Auxiliary fan units .................................................................... 64
3.5. Cabinet design .................................................................................. 65
3.6. Door locking system ......................................................................... 66
3.7. Arc resistant design ...........................................................................67
3.7.1. Internal arc classification ........................................................ 67
3.8. Busbars and grounding .................................................................... 68
3.8.1. AC busbars ............................................................................... 68
3.8.2. DC busbars ............................................................................... 68
3.8.3. PE busbar ................................................................................. 68
3.8.4. PG busbar ................................................................................. 68
4. Transportation, storage and disposal ............................................... 69
4.1. Safety ................................................................................................ 69
4.2. Transport conditions ........................................................................ 69
4.3. Unpacking and inspection ............................................................... 69
4.4. Identifying transport units .............................................................. 69
4.5. Lifting and transportation .............................................................. 71
4.5.1.1. Lifting recommendations .............................................. 72
4.6. Storage ................................................................................................ 74
4.6.3. Storing and handling of spare parts ....................................75
4.6.3.1. Warranty information ..................................................... 75
4.7. Disposing package materials and components ............................ 76
5. Mechanical installation ...................................................................... 77
5.1. Safety ................................................................................................. 77
5.2. Overview .............................................................................................. 77
5.3. General notes on installation ......................................................... 78
5.3.1. Dimensions and clearances .................................................... 78
5.3.2. Access to the cabinets ............................................................ 78
5.3.3. Cabinet roof ........................................................................... 78
5.3.4. Fire protection ......................................................................... 78
5.3.5. Cable duct material ............................................................... 79
5.3.6. Installation material ................................................................ 79
5.3.7. Tools .......................................................................................... 79

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5.3.8. Floor preparation .................................................................... 79
5.3.9. Floor fixation ............................................................................ 79
5.3.10. Raw water circuit ..................................................................... 79
5.4. Aligning transport units ................................................................... 80
5.5. Joining transport units..................................................................... 82
5.6. Joining water pipes ........................................................................... 83
5.6.1. Removing a pipe joint ............................................................. 84
5.7. Joining busbars ............................................................................. 85
5.7.1. DC busbars ............................................................................... 86
5.7.2. Ground busbars ....................................................................... 88
5.7.3. AC busbars between COU/TEU and LSU (5/7/9
MVA) .......................................................................................... 89
5.7.4. AC busbars between COU/TEU and LSU (14 MVA) .............. 90
5.7.5. AC busbars between COU/TEU and ARU/INU ....................... 91
5.7.6. AC busbar joints - without disconnector ............................... 91
5.7.7. AC busbar joints - with motorized disconnector................. 92
5.8. Installing and removing air-to-air heat exchangers ...................... 94
5.8.1. Installing air-to-air heat exchangers ..................................... 94
5.8.1.1. Installation .................................................................... 95
5.8.2. Removing air-to-air heat exchangers .................................... 99
5.8.2.1. Removing an air-to-air heat exchanger ..................... 100
5.8.2.2. Reinstalling an air-to-air heat exchanger ................... 101
5.8.3. Installing the transformers of air-to-air heat
exchangers .............................................................................. 102
5.9. Installing the pressure relief vents ................................................. 103
5.10. Attaching the sealing tapes ............................................................ 105
5.11. Installing the roof joints and the roof attachments .................... 106
5.11.1. Installing roof joints ............................................................... 106
5.11.2. Installing roof attachments................................................... 107
6. Electrical installation ....................................................................... 109
6.1. Safety ............................................................................................... 109
6.2. Cable requirements .......................................................................... 110
6.2.1. Power cables ........................................................................... 110
6.2.2. Auxiliary and control cables ................................................. 110
6.2.3. Synchronization cables .......................................................... 110
6.3. Grounding the drive system ............................................................. 111
6.3.1. Grounding diagrams ............................................................... 111
6.3.2. Ground cable connection ....................................................... 112
6.3.3. Cable shield ground connection ........................................... 112
6.3.4. EXU cabinet ground connections ......................................... 113
6.4. Internal wiring .................................................................................. 113
6.4.1. Optical fiber cables .............................................................. 114
6.4.1.1. Installing the standard optical fibers ......................... 114
6.4.2. Optical fiber cables for the optional Arc Guard
System™ .................................................................................. 115
6.4.2.1. Connecting the detector cables to the arc
monitor device .............................................................. 116
6.5. Cable entry systems .......................................................................... 117
6.5.1. Frames with type 1 sealing modules ..................................... 117
6.5.2. Frame with type 2 sealing modules ...................................... 119
6.5.3. Plates with cable glands ........................................................ 119

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6.5.4. EMC plates with sealing grommets ..................................... 120
6.6. Preparing cable entry systems for TEU, ARU and
EXU cabinets ..................................................................................... 120
6.6.1. TEU cable entry frames with type 1 sealing
modules ................................................................................... 120
6.6.2. ARU cable entry frames with type 1 sealing
modules ................................................................................... 122
6.6.3. EXU cable entry with EMC plate and sealing
grommets ................................................................................ 123
6.7. Power, ground and equipotential bonding conductor cables ... 124
6.7.1. Determining the cable length ............................................... 124
6.7.2. Preparing cables for sealing modules.................................. 125
6.7.3. Preparing cables for cable glands ........................................ 126
6.7.4. Preparing cables for EMC plates .......................................... 126
6.7.5. Connecting the cables ......................................................... 128
6.7.5.1. Checking the cable insulation ..................................... 128
6.7.5.2. EXU cabinet connections ............................................. 128
6.7.5.3. Bolted busbar connections – marine drives .............. 129
6.7.5.4. Bolted busbar connections – non-marine drives ...... 130
6.8. Auxiliary power, control and serial communication cables ......... 131
6.8.1. Determining the cable length ............................................... 131
6.8.2. Preparing cables for sealing modules.................................. 132
6.8.3. Preparing cables for cable glands ........................................ 133
6.8.4. Preparing cables for EMC plates .......................................... 133
6.8.5. Routing cables in a WCU ........................................................ 135
6.8.6. Routing cables in a COU cabinet .......................................... 135
6.8.6.1. Connecting the cables .................................................. 137
6.8.7. Routing cables in an EXU cabinet ......................................... 138
6.8.7.1. Auxiliary power and control cables ............................. 138
6.8.7.2. Optical fiber cables .................................................... 140
6.8.7.3. Routing optical fiber cables in an EXU
cabinet with an ED5V, EB5R, EB5S, EB7P and
EB7Q type DCS880/DCT880 converter ......................140
6.8.7.4. Routing cables in an EXU cabinet with an
ED7Y type DCS880/DCT880 converter ....................... 142
6.9. Heating cable ................................................................................... 144
6.10. Final checks...................................................................................... 144
7. Commissioning................................................................................. 145
7.1. Required qualification ................................................................... 145
7.2. Commissioning procedure ............................................................ 145
7.3. Commissioning checklist ............................................................... 145
7.4. Customer assistance ...................................................................... 145
7.5. Customer acceptance .................................................................... 145
7.6. Commissioning checklists............................................................... 146
7.6.1. Mechanical installation checklist .......................................... 146
7.6.2. Electrical installation checklist .............................................146
7.6.3. Main circuit breaker (MCB) .................................................... 147
7.6.4. Input transformer checklist ................................................... 147
7.6.5. Motor checklist .......................................................................148
7.6.6. Insulation tests checklist .......................................................148
7.6.7. Power checklist .......................................................................148

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7.6.8. Miscellaneous checklist .........................................................148
8. Operation ......................................................................................... 149
8.1. Overview ............................................................................................ 149
8.2. Operating conditions ....................................................................... 149
8.3. Safety ............................................................................................... 149
8.4. Assistant control panels .................................................................. 150
8.4.1. Control panels for drives with an ARU ................................. 151
8.4.1.1. Lamp test ....................................................................... 151
8.4.2. Control panels for drives with an LSU .................................. 152
8.4.2.1. Lamp test ....................................................................... 152
8.5. EXU control panel ............................................................................. 153
8.5.1. Operational settings ............................................................ 153
8.5.2. Resetting alarm and fault messages .................................... 154
8.5.3. Parameter settings ............................................................... 154
8.6. Grounding switch and door locking system ................................. 155
8.6.1. Lamp test ................................................................................ 155
8.6.2. Door locking system ............................................................... 156
8.7. Optional switchgear and controlgear ............................................ 157
8.7.1. DC-link disconnector .............................................................. 157
8.7.2. Output switches ..................................................................... 157
8.7.3. Manual output isolation......................................................... 157
8.8. Status messages .............................................................................. 158
8.8.1. Start sequence of the drive ................................................. 159
8.8.2. Stop sequence of the drive .................................................. 160
8.8.3. Emergency-off sequence ..................................................... 161
8.8.4. Prevention of unexpected startup sequence .................... 161
8.9. Starting the drive ............................................................................. 162
8.9.1. Checks before starting the drive .......................................... 162
8.9.2. Starting the drive remotely ................................................... 163
8.9.3. Starting the drive locally ........................................................ 163
8.10. Stopping the drive ........................................................................... 165
8.10.1. Stopping the drive locally ...................................................... 165
8.10.2. Stopping the drive with the emergency-off function ........ 165
8.10.3. Initiating an emergency-off ................................................. 165
8.10.4. Starting the drive system after an emergency-off ............. 166
8.11. Arc detection with the Arc Guard System™ (optional) ................ 166
8.11.1. Action after the Arc Guard System™ has been
triggered ................................................................................. 167
9. Preventive and corrective maintenance .......................................... 169
9.1. General information ......................................................................... 169
9.1.1. Required qualification ............................................................ 169
9.1.2. Maintenance schedule............................................................ 169
9.1.3. Logbook ................................................................................... 169
9.1.4. Spare parts .............................................................................. 169
9.2. Identifying electrical equipment .................................................... 170
9.2.1. Device designation ................................................................. 170
9.2.2. Cables and wires ..................................................................... 170
9.2.2.1. Understanding wiring diagrams ................................. 170
9.3. Status indicators ............................................................................... 171
9.3.1. Alarm / fault indications ......................................................... 171

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9.3.2. Error message levels ...............................................................171
9.3.2.1. Alarm and fault messages ........................................... 172
9.3.2.2. Fault handling ............................................................... 172
9.3.2.3. Standard troubleshooting procedure ......................... 172
9.3.3. LEDs and switches on PCBs and I/O modules .................... 173
9.3.3.1. BCU-55 control unit ...................................................... 173
9.3.3.2. S500 I/O modules ......................................................... 174
9.3.3.3. Serial communication interfaces ................................ 174
9.3.3.4. LEDs on optional heat exchangers ............................. 174
9.4. Maintenance tasks ........................................................................... 175
9.4.1. Safety ................................................................................. 175
9.4.2. De-energizing and grounding the drive ............................... 176
9.4.3. Grounding the drive when the grounding switch is
not released ............................................................................ 179
9.4.4. Unlocking and opening the doors ....................................... 180
9.4.5. Closing and locking the doors .............................................. 182
9.4.6. Testing the white lamp .......................................................... 183
9.4.7. Emergency release of a door safety switch .......................184
9.4.7.1. Location of safety switches ......................................... 184
9.4.7.2. Safety-switch settings ................................................. 185
9.4.7.3. Unlocking a safety switch ............................................ 185
9.4.8. Connecting a grounding set ................................................ 186
9.4.8.1. Drives with LSU ............................................................. 187
9.4.8.2. Drives with ARU ............................................................. 188
9.4.9. Drives with the manual output isolation (optional) ........... 189
9.4.9.1. Removing the busbar connectors ............................. 190
9.4.9.2. Fitting the busbar connectors .................................... 194
9.4.10. Removing and installing a phase module ............................ 195
9.4.10.1. Removing a phase module ........................................... 195
9.4.10.2. Installing a phase module ............................................ 197
9.4.11. Visual checks on the drive ..................................................... 198
9.4.12. Cleaning ................................................................................. 198
9.4.12.1. Cleaning the drive cabinet ........................................... 198
9.4.13. Checking wire and cable connections ................................ 199
9.4.14. Checking and replacing filter mats ...................................... 199
9.4.15. Testing and replacing auxiliary fan units ............................. 201
9.4.15.1. Testing auxiliary fan units ............................................ 201
9.4.15.2. Replacing auxiliary fan units ....................................... 202
9.4.16. Testing and replacing air-to-air heat exchangers.............. 203
9.4.16.1. Testing the fan units ................................................... 204
9.4.16.2. Replacing the complete heat exchanger ................... 205
9.4.16.3. Replacing the circuit board ........................................ 205
9.4.16.4. Replacing internal fan 1 - left side ............................. 207
9.4.16.5. Replacing internal fan 2 - right side .......................... 209
9.4.16.6. Replacing the ambient fans ......................................... 211
9.4.17. Replacing the fan unit in an EXU with a
DCS880 H4/DCT880 T4 unit ................................................. 212
9.4.18. Replacing the fan unit in an EXU with a
DCS880 H6 unit ...................................................................... 215
9.4.19. Replacing the air-to-water heat exchanger of the
EXU ........................................................................................... 217

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Figures
Figure 2-1 Product warning label examples (label placement depends on
the drive) ......................................................................................................................... 30
Figure 2-2 Drive system overview ................................................................................. 35
Figure 2-3 MCB opening timing diagram .................................................................... 37
Figure 3-1 Common DC-bus principle for single motor drive (A) and
multi-motor drive (B) ..................................................................................................... 39
Figure 3-2 ACS6080 drive example .............................................................................. 40
Figure 3-3 ARU/INU block diagram .............................................................................. 42
Figure 3-4 ARU/INU circuit diagram ............................................................................ 42
Figure 3-5 ARU/INU (A) and phase modules with IGCTs (B) ..................................... 43
Figure 3-6 LSU block diagram ..................................................................................... 44
Figure 3-7 LSU (12-pulse) circuit diagram .................................................................. 44
Figure 3-8 LSU (12-pulse) .............................................................................................. 45
Figure 3-9 CBU ................................................................................................................ 46
Figure 3-10 TEU (1000 mm) ........................................................................................... 47
Figure 3-11 Master COU (1000 mm) and control equipment .....................................48
Figure 3-12 Control panel ................................................................................................50
Figure 3-13 Location of control panels on master COU (A) and
slave COU (B) .................................................................................................................... 50
Figure 3-14 WCU1400 (A) and WCU800 (B) cabinet and system
components ...................................................................................................................... 52
Figure 3-15 Cooling circuit in an ACS6080 drive ......................................................... 53
Figure 3-16 IRU cabinet (A) and circuit diagram (B) ................................................... 54
Figure 3-17 IFU cabinet (A) and circuit diagram (B) ................................................... 55
Figure 3-18 VLU cabinet (A) and circuit diagram (B) .................................................. 56
Figure 3-19 BCU cabinet (A) and circuit diagram (B) ................................................. 58
Figure 3-20 RBU cabinet (A) and circuit diagram (B) ................................................. 59
Figure 3-21 EXU H4/T4 frame cabinet (A) and EXU H6 frame cabinet (B) ............... 60
Figure 3-22 CIU cabinet (A) and WCU800 cabinet (B) ................................................ 62
Figure 3-23 ACS6080 example drive with air-to-air heat exchanger ........................ 63
Figure 3-24 Auxiliary fan unit ..........................................................................................64
Figure 3-25 Air circulation through ventilation grids in 600 mm COU (A),
1000 mm COU (B) and WCU800 (C) ................................................................................ 64
Figure 3-26 Basic cabinet design ................................................................................. 65

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Figure 3-27 IAC label example ......................................................................................... 67
Figure 3-28 Busbars .........................................................................................................68
Figure 4-1 Lifting bracket on base frame of a drive, safety hook
secured to lifting bracket and eye bolt. ....................................................................... 72
Figure 4-2 Lift frame (A) and lift spreader (B) ............................................................ 73
Figure 5-1 Connection point locations on transport units ........................................ 82
Figure 5-2 Minimum distances and locking bolt orientation (A = front) ................... 83
Figure 5-3 Bolted busbar connection .......................................................................... 85
Figure 5-4 Top view of DC busbar configuration 1 .....................................................86
Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B) and 4 (C) ........................ 87
Figure 5-6 Ground busbar joints ..................................................................................88
Figure 5-7 AC busbar joints between the COU/TEU and LSU (5/7/9
MVA). ................................................................................................................................ 89
Figure 5-8 AC busbar joints between the COU/TEU and LSU (14 MVA). ................. 90
Figure 5-9 Air-to-air heat exchanger (type LT-5-5165-UL) ......................................... 94
Figure 5-10 Tools for installing an air-to-air heat exchanger .................................... 94
Figure 5-11 Correct and incorrect cable installation .................................................... 96
Figure 5-12 ARU/INU/IFU cable routing ........................................................................98
Figure 5-13 LSU cable routing.........................................................................................98
Figure 5-14 Air-to-air heat exchangers (type LT-5-5165-UL) ....................................... 99
Figure 5-15 Tools for removing an air-to-air heat exchanger .................................. 100
Figure 5-16 Installation example of transformers in an air-to-air heat
exchanger ........................................................................................................................ 102
Figure 5-17 Connect wires to terminal block ............................................................... 103
Figure 5-18 Pressure relief vents ................................................................................ 103
Figure 5-19 Tools required to fasten the pressure relief vent to the
roof ................................................................................................................................ 104
Figure 5-20 Installation example of pressure relief vents ....................................... 104
Figure 5-21 Attach sealing tape to the joining crossbar (1) ...................................... 105
Figure 5-22 Roof joints (1) ............................................................................................. 106
Figure 5-23 Roof attachment parts ............................................................................ 107
Figure 5-24 Recommended ceiling and wall fixings ................................................. 108
Figure 6-1 Phase module on lift table .......................................................................... 109
Figure 6-2 Grounding the input side (A) and output side (B) of the
drive system ..................................................................................................................... 111
Figure 6-3 System ground connection (1) in a 600 mm TEU ...................................... 112
Figure 6-4 Grounding the EXU ..................................................................................... 113
Figure 6-5 Cable tray and cable ducts in an LSU (A = front) ................................... 114

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Figure 6-6 Arc Guard System™ in an optional roof extension box (REB) .................115
Figure 6-7 Location of Arc Guard sensors in a TEU ....................................................116
Figure 6-8 Cable tray and cable ducts in an LSU (A = front) ....................................116
Figure 6-9 Cable entry with type 1 sealing modules ................................................. 117
Figure 6-10 Cable entry frame with type 1 sealing modules ................................... 118
Figure 6-11 Cable entry with type 2 sealing modules ................................................ 119
Figure 6-12 Cable gland ..................................................................................................119
Figure 6-13 Cable entry with EMC plates ................................................................... 120
Figure 6-14 TEU 1000 mm cabinet (A = back) with top (1) and bottom
(2) cable entries ............................................................................................................. 121
Figure 6-15 Short busbar removal in ARU .................................................................. 122
Figure 6-16 EXU with top cable entry (A) and EXU with bottom
cable entry (B) ................................................................................................................ 123
Figure 6-17 EXU cabinet ............................................................................................... 123
Figure 6-18 Preparing power cables for sealing modules ....................................... 125
Figure 6-19 Prepare power cables for cable glands ................................................. 126
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 ............................................................................................. 127
Figure 6-21 Cable connections in an EXU cabinet .................................................... 128
Figure 6-22 Minimum distance between bolted joints of different phases
in an EXU ....................................................................................................................... 129
Figure 6-23 Bolted busbar connection - marine drives ........................................... 129
Figure 6-24 Bolted busbar connection - non-marine drive ..................................... 130
Figure 6-25 Cable entry with sealing modules ........................................................... 132
Figure 6-26 Preparing control cables for sealing modules ..................................... 132
Figure 6-27 Preparing auxiliary control cables for cable glands ............................ 133
Figure 6-28 Preparing the screens of control cables for EMC plates .................... 134
Figure 6-29 Preparing control cables for EMC plates .............................................. 135
Figure 6-30 Location of top blanking plates of 600 mm COU (A) and
1000 mm COU (B) ......................................................................................................... 136
Figure 6-31 Location of bottom blanking plates of 600 mm COU (A) and
1000 mm COU (B) ......................................................................................................... 136
Figure 6-32 Cable routing in 1000 mm COU (A) and 600 mm COU (B) .................... 137
Figure 6-33 Shield grounding for encoder cable ...................................................... 138
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 (B) ............................................ 139

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Figure 6-35 DCS880/DCT880 H4 converter (ED5V, EB5R, EB5S, EB7P and
EB7Q types) ................................................................................................................... 140
Figure 6-36 1 Control unit SDCS-CON-H01 ................................................................ 141
Figure 6-37 Cable routing example in an EXU cabinet with an ED5V,
EB5R, EB5S, EB7P and EB7Q type DCS880/DCT880 converter ................................. 141
Figure 6-38 DCS880/DCT880 converter (ED7Y) ....................................................... 142
Figure 6-39 1 Control unit SDCS-CON-H01 ................................................................ 142
Figure 6-40 Cable routing example in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter ......................................................................................... 143
Figure 6-41 Heating cable connection ....................................................................... 144
Figure 8-1 Assistant control panel ............................................................................... 149
Figure 8-2 Assistant control panel front and back ................................................... 150
Figure 8-3 Master control panel on COU1 (A) and slave control panel (B)
for a drive with an ARU .................................................................................................151
Figure 8-4 Master control panel on COU1 (A) and slave control panel (B)
for a drive with an LSU ................................................................................................ 152
Figure 8-5 DCS880 control panel ................................................................................. 153
Figure 8-6 CBU grounding switch in ungrounded (A) and grounded (B) ................ 155
Figure 8-7 Safety switches ............................................................................................ 156
Figure 8-8 Arc Guard System™ in a WCU REB ........................................................... 166
Figure 8-9 HMI panel ..................................................................................................... 167
Figure 9-1 Labels on S500 I/O modules and associated wiring diagram ............... 170
Figure 9-2 Cable and wire designation ...................................................................... 170
Figure 9-3 Assistant control panel (A) and BCU-55 control unit: front
view (A) and rear view (B) ............................................................................................ 173
Figure 9-4 S500 I/O modules in a COU ........................................................................174
Figure 9-5 Status LEDs on optional air-to-air heat exchangers ..............................174
Figure 9-6 Grounding switch ungrounded ................................................................. 177
Figure 9-7 Grounding switch grounded .................................................................... 178
Figure 9-8 Grounding switch grounded .................................................................... 180
Figure 9-9 Testing the white lamp ............................................................................. 183
Figure 9-10 Safety switch on an ARU/INU cabinet door .......................................... 184
Figure 9-11 Safety switch settings ............................................................................. 185
Figure 9-12 Four-way grounding set .......................................................................... 186
Figure 9-13 TEU ground ball stud locations .............................................................. 187
Figure 9-14 ARU/INU ground ball stud locations ..................................................... 188
Figure 9-15 Manual output isolation overview .......................................................... 189
Figure 9-16 Tools for removing the busbar connectors .......................................... 190

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Figure 9-17 Overview of grounding the drive - INU1 is shut down (A)
and INU2 is shut down (B). Numbers indicate the connection sequence. ...............191
Figure 9-18 Connect the grounding sets in COU1 (A and C), TEU1 (B),
INU1 (D) and INU2 (E) ................................................................................................... 192
Figure 9-19 Busbar connector removal sequence in TEU1 or COU1.......................... 193
Figure 9-20 Fitting sequence for busbar connectors ................................................ 194
Figure 9-21 Phase module removal ............................................................................. 196
Figure 9-22 COU filter ................................................................................................. 200
Figure 9-23 Accessing the fan units in the WCU roof box ......................................... 202
Figure 9-24 Air-to-air heat exchanger overview (type LT-5-5165-UL) .................... 203
Figure 9-25 Wire connection points on the circuit board ....................................... 206
Figure 9-26 DCS880 controller - size H4 ..................................................................... 212
Figure 9-27 DCS880 controller - size H6 ...................................................................... 215
Figure 9-28 Air-to-water heat connections ................................................................ 217
Figure 9-29 Lift heat exchanger out of EXU cabinet .................................................. 218

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—
Tables
Table 1-1 Terms and abbreviations .........................................................................................................19
Table 1-2 Maintenance............................................................................................................................... 24
Table 1-3 Technical data............................................................................................................................ 24
Table 1-4 Schematics................................................................................................................................. 24
Table 1-5 Specifications and guidelines ............................................................................................... 24
Table 1-6 Service ......................................................................................................................................... 25
Table 1-7 Communication interfaces ..................................................................................................... 25
Table 1-8 User manuals related to drive units..................................................................................... 25
Table 1-9 Standards that are referred to in this document..............................................................27
Table 3-1 Main components in an ARU/INU cabinet ......................................................................... 43
Table 3-2 Main components in a 12-pulse LSU cabinet .................................................................... 45
Table 3-3 Main components in a CBU cabinet ....................................................................................46
Table 3-4 Main components in a WCU cabinet ....................................................................................51
Table 3-5 BCU braking power.................................................................................................................. 57
Table 3-6 RBU braking power.................................................................................................................. 57
Table 3-7 ABB arc resistant classes........................................................................................................ 67
Table 5-1 Installation material for AC busbars (COU/TEU – ARU/INU) .........................................91
Table 5-2 Installation material for roof joints.................................................................................... 106
Table 6-1 Cable entry frames for type 1 sealing modules ...............................................................118
Table 8-1 Medium voltage units with safety switches and locking bars.................................... 156
Table 9-1 Filter mat specifications....................................................................................................... 199
Table 9-2 Air-to-air heat exchanger specifications..........................................................................203

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1. About this manual
1.1. Product overview
The ACS6080 is a medium voltage drive that can control any type of AC motor,
including high-power induction, synchronous, and permanent magnet motors.
The ACS6080 covers a power range of 3 - 36 MVA and delivers output frequencies
of 0 - 75 Hz in the voltage range up to 3.3 kV.
Modular drive configuration
The ACS6080 has a modular design based on standardized units, each of which are
dedicated to a specific function. The units are combined according to the required
output power, motor configuration and process needs.
1.1.1. Standard applications
Typical fields of applications for the ACS6080 include:
– Marine
• Main propulsion systems
• Thruster drives
– Oil and gas
• Compressors
• Pumps
• Extruders
– Metals and mining
• Rolling mills
• Mine hoists
• Conveyors
• Crushers and mills
– General industry
• Variable speed fans and pumps
• Pump storage plant drives
• Test stand

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1.2. 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.
1.3. Structure of the user documentation
The documentation for a standard drive consists of this document and the
following project-specific appendices.
NOTE – These appendices are NOT included in this document.
–Appendix A - Additional manuals provides manuals about additional equipment
delivered with the drive (such as project-specific options such as 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.
NOTE – “Setting of protective devices” is generated according to the
customer-specific project.
–Appendix E - Parts list is 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.

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1.4. Terms and abbreviations
The following table lists terms and abbreviations you should be familiar with when
using this user manual. Some of the terms and abbreviations used in this user
manual are unique to ABB and might differ from the normal usage.
Table 1-1 Terms and abbreviations
Term/
Abbreviation
Definition
AC Alternating current
ACS6080 ACS6080 medium voltage AC drive
AI Analog input
ANSI American National Standards Institute
AO Analog Output
APU Auxiliary Pump Unit
ARU Active Rectifier Unit
The ARU rectifies the voltage of the supply network to the DC voltage
and maintains the DC-link voltage at a constant level irrespective of
changes in the supply network. The unit is designed as a self-
commutated, 3-level voltage source inverter consisting of three
identical phase modules. The unit allows regenerative braking.
ASE Anti Saturation Equipment
Azipod® ABB’s electric propulsion system for ships
BCON Application and motor controller
BCU Braking Chopper Unit
BCU-55 Main Control Board box built
CBU Capacitor Bank Unit
CCB Converter Control Board
Control panel Serves as the basic user interface for operating and monitoring the
drive when the local operating mode has been selected, also known as
assistant control panel.
CHU Charging Unit
CIT Conductivity Transmitter
CIU Customer Interface Unit
Converter Short form for ACS6080 frequency converter
COU Control Unit
The COU consists of a control compartment and a customer interface
compartment. The control compartment incorporates the hardware for
control, monitoring and protection functions of the drive and the
communication interface to the door-mounted control panel.
CW1 Control water system 1
CW2 Control water system 2

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CVMI Current and Voltage Measuring Interface
DBC Drive Backup Control
DC Direct Current
DC_NP DC Neutral Point. Neutral point of the DC link of the drive
DCS Acronym for the AC-to-DC converter or the three-phase AC power
controller of an excitation unit
DDCS Distributed drive control system. DDCS is an acronym for a serial
communications protocol designed for data transfer via optical fibers.
DI Digital Input
DIN Deutsches Institut für Normung
DO Digital Output
Drive Synonym for ACS6080 frequency converter
Drive Composer Windows application for commissioning and maintaining ABB drives.
Drive system The drive system includes all equipment for converting electrical into
mechanical power to give motion to the machine.
DTL Direct-to-line
EAF Earth Fault monitoring device
ECB Excitation Circuit Breaker
EIC Excitation Input Contactor
EMC Electromagnetic Compatibility
EOB Excitation Output Breaker
Equipment Frequency converter and related equipment
EXU Excitation Unit
The EXU supplies excitation power to a synchronous motor.
FBA Fieldbus Adapter
FCB Function Chart Builder
FCI Fieldbus Communication Interface
FFU Fin Fan Unit
FIR filter Fast Impulse Response filter
FIS Flow meter
FT Firing Through
Synonym for protective firing. Meaning: simultaneous gating of the
power semiconductors of the inverter unit to effectively protect the
semiconductors against overvoltage and overcurrent.
FSCD Fast Short-Circuit Detection
Ground (noun) Earth
Table 1-1 Terms and abbreviations (continued)
Term/
Abbreviation
Definition