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
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The buyer acknowledges the proprietary and confidential nature of the information contained in this
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The information in this document is subject to change without notice and should not be construed
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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