ABB ACS5000 User manual

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SYSTEM DRIVES
ACS5000 water-cooled (generation 2)
User manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DATE
2023-11-22
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
1/186
© Copyright 2009 ABB All rights reserved.

PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
2/186
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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 any such
description of a standard or reference to a standard is not a representation that all of the ABB products
referenced in this document include all the features of the described or referenced standard. In order to
determine the specific features included in a particular ABB product, the product specifications for the
particular ABB product apply.
The buyer acknowledges the proprietary and confidential nature of the information contained in this
document and agrees that all rights to and concerning the information contained in this document remain
vested in ABB, in particular with regard to any intellectual property rights. Nothing contained 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 as a
binding declaration of ABB. ABB assumes no responsibility for any errors or omissions in this document.
Products described or referenced in this document are designed to be connected with networks and
provide information and data through network interfaces. The products must be connected to a secure
network. It is the sole responsibility of the buyer of the products to provide and continuously ensure a
secure connection between the product and the system network and/or any other networks that may be
connected to the product. ABB is in no event liable for the security of the network used by buyer.
The buyer of the product must establish and maintain appropriate measures, including, but not limited
to, the installation of firewalls, application of authentication measures, encryption of data, installation of
antivirus programs, and so on, to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and/or theft of data or
information. Any liability of ABB in this regard is excluded.
ABB may perform functionality testing on the products and may release updates. However, it is the sole
responsibility of the buyer of the product to ensure that any product updates or other major system
updates (to include but not limited to code changes, configuration file changes, third-party software
updates or patches, hardware change out, and so on) are compatible with the security measures
implemented. The buyer of the product must verify that the system and associated products function as
expected in the environment in which they are deployed. ABB has no obligations in this regard.
In no event shall ABB be liable for any damages inclusive but not limited to indirect, special, incidental or
consequential damages of any nature or kind whatsoever arising from the use of this document, nor shall
ABB be liable for any damages inclusive but not limited to indirect, special, incidental or consequential
damages arising from the use of any software or hardware described in this document.
This document and parts thereof must be kept strictly confidential and must not be reproduced or copied
without the prior written permission from ABB, and the contents thereof must not be disclosed or made
available to any third party nor used for any unauthorized purpose.
The software or hardware described in this document may be furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license.
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TRADEMARKS
ABB is a registered trademark of ASEA BROWN BOVERI LTD.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2009 ABB.
All rights reserved.

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
3/186
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CONTENTS
1. About this manual................................................................................................................. 13
1.1. Equipment covered by this manual ............................................................................................. 13
1.2. Structure of the user documentation ......................................................................................... 13
1.3. Related documents..........................................................................................................................14
1.3.1. Maintenance ..........................................................................................................................14
1.3.2. Technical data .......................................................................................................................14
1.3.3. Schematics.............................................................................................................................14
1.3.4. Specifications and guidelines...........................................................................................14
1.3.5. Manuals...................................................................................................................................14
1.3.7. Serial communications interfaces ...................................................................................15
1.4. Terms and abbreviations................................................................................................................15
1.3.6. I/O interface ..........................................................................................................................15
1.5. Target groups and required qualification.................................................................................. 17
1.5.1. Handling ................................................................................................................................. 17
1.5.2. Mechanical installation ....................................................................................................... 17
1.5.3. Electrical installation ........................................................................................................... 17
1.5.4. Operation ...............................................................................................................................18
1.5.5. Maintenance ..........................................................................................................................18
1.6. User’s responsibilities.....................................................................................................................18
1.7. Intended use of equipment ...........................................................................................................18
1.8. Quality certificates and applicable standards ..........................................................................19
1.8.1. Standards...............................................................................................................................19
1.9. Items covered by delivery .............................................................................................................. 20
1.9.1. Identifying the delivery ...................................................................................................... 20
1.10. Tools.................................................................................................................................................... 20
1.11. Document conventions................................................................................................................... 21
2. Important safety information............................................................................................. 22
2.1. Safety messages and safety signs in this document .............................................................22
2.1.1. Safety messages ..................................................................................................................22
2.1.2. Safety signs............................................................................................................................22
2.2. Product safety labels.......................................................................................................................23
2.3. Electrical safety................................................................................................................................ 24
2.3.1. General safety instructions............................................................................................... 24
2.3.2. The 7 steps that save lives..................................................................................................25
2.3.3. Possible residual risks.........................................................................................................27
2.4. Main circuit breaker protection device ...................................................................................... 28
2.4.1. Safety and protection requirements.............................................................................. 29
2.4.3. Maintenance recommendation ....................................................................................... 29
3. Power electronics and cabinet features ............................................................................30
3.1. Main features of the drive ............................................................................................................. 30
3.2. Drive frame sizes and configurations .........................................................................................32
3.3. Phase converter unit (PCU)........................................................................................................... 34
3.3.1. Primary phase converter unit (1700 mm and 2100 mm) ........................................... 35
3.3.1.1. Primary PCU (1700 mm) – FS 1 and FS 3............................................................ 35
3.3.1.2. Primary PCU (2100) – FS 2 and FS 4.....................................................................37
3.4. Control unit (COU)...........................................................................................................................40
3.4.1. Main components ................................................................................................................41

CONTENTS
PRODUCT
ACS5000W gen. 2
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User manual
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3BHS799208 E01
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3.4.2. AMC circuit board................................................................................................................ 42
3.4.2.1. Control tasks ............................................................................................................ 42
3.4.2.2. Direct torque control.............................................................................................. 43
3.4.2.3. Parameters................................................................................................................ 44
3.4.2.4. Main circuit breaker ................................................................................................ 44
3.4.2.5. Peripheral I/O devices............................................................................................ 44
3.4.2.6. Local control panel.................................................................................................. 45
3.4.2.7. Customer interface................................................................................................. 46
3.4.2.8. S800 I/O system...................................................................................................... 46
3.5. Water cooling unit (WCU) ...............................................................................................................47
3.6. Transformer and motor cable terminals................................................................................... 48
3.6.1. Transformer cable terminals............................................................................................ 48
3.6.2. Motor cable terminals ........................................................................................................ 48
3.7. EXU – Excitation unit (optional)................................................................................................... 49
3.7.1. DCS880/DCT880 control panel....................................................................................... 50
3.7.2. Output disconnector.......................................................................................................... 50
3.8. Door interlocking system .............................................................................................................. 50
3.8.1. Grounding switches ............................................................................................................51
3.8.2. Locking bars ..........................................................................................................................52
3.9. Grounding studs...............................................................................................................................52
3.9.1. Grounding set ...................................................................................................................... 53
3.9.2. Output grounding studs in COU..................................................................................... 54
3.9.3. Input grounding studs in a PCU ...................................................................................... 55
4. Transportation, storage, and disposal ..............................................................................56
4.1. Safety.................................................................................................................................................. 56
4.2. Transport conditions...................................................................................................................... 56
4.3. Unpacking and inspection ............................................................................................................ 56
4.4. Identifying drive units .................................................................................................................... 56
4.4.1. Packing list .............................................................................................................................57
4.4.2. Packing label..........................................................................................................................57
4.5. Lifting and transportation ............................................................................................................ 58
4.5.1. Lifting attachment types .................................................................................................. 59
4.5.2. Lifting with lifting plates...................................................................................................60
4.5.3. Lifting with rotating eyebolts ...........................................................................................61
4.5.4. Reinstalling lifting attachments ...................................................................................... 62
4.5.5. Sling configurations for lift frames and spreader frames........................................ 63
4.6. Storage............................................................................................................................................... 64
4.6.1. Storage conditions ............................................................................................................. 64
4.6.2. Storing a drive...................................................................................................................... 64
4.7. Storage and handling of spare parts ......................................................................................... 65
4.7.1. Warranty information ......................................................................................................... 65
4.8. Disposal of packaging materials and components ............................................................... 65
5. Mechanical installation ........................................................................................................66
5.1. Safety.................................................................................................................................................. 66
5.2. Overview of installation work....................................................................................................... 66
5.3. General notes on installation ....................................................................................................... 66
5.4. Dimensions and clearances...........................................................................................................67
5.4.1. Rear and top access to the cabinet .................................................................................67
5.4.2. Cabinet roof...........................................................................................................................67
5.4.3. Fire protection ......................................................................................................................67
5.4.4. Cable duct material .............................................................................................................67

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
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5.4.5. Installation material.............................................................................................................67
5.4.6. Tools ........................................................................................................................................67
5.5. Preparing the installation site...................................................................................................... 68
5.6. Aligning transport units ................................................................................................................ 69
5.7. Joining transport units ................................................................................................................... 71
5.8. Applying silicone...............................................................................................................................72
5.9. Installing roof joints.........................................................................................................................72
5.10. Installing roof-mounted cooling units........................................................................................73
5.10.1. Lifting a cooling unit with a crane ...................................................................................73
5.10.2. Installing IP42 roof-mounted cooling units...................................................................74
5.10.3. Installing IP54 roof-mounted cooling units...................................................................76
5.11. Installing roof attachments on marine drives...........................................................................78
5.12. Joining water pipes.........................................................................................................................80
5.12.1. Removing a pipe joint ........................................................................................................ 80
5.13. Joining busbars ................................................................................................................................81
5.13.1. AC busbars............................................................................................................................ 82
5.13.2. PE ground busbar ............................................................................................................... 82
5.13.3. DC busbars ........................................................................................................................... 83
5.14. Connecting the heating cable ...................................................................................................... 83
5.15. Connecting raw water pipes......................................................................................................... 84
5.16. Fixing the drive to the floor .......................................................................................................... 84
6. Electrical installation ...........................................................................................................85
6.1. Safety.................................................................................................................................................. 85
6.2. Overview ............................................................................................................................................ 85
6.3. Cable requirements ........................................................................................................................ 85
6.3.1. Power cables......................................................................................................................... 85
6.3.2. Auxiliary and control cables.............................................................................................. 85
6.4. Grounding ......................................................................................................................................... 86
6.4.1. Grounding the transformer and an 18-pulse drive..................................................... 86
6.4.2. Grounding the transformer and a 36-pulse drive........................................................87
6.4.3. Grounding the drive and the motor (multi-point bonding)..................................... 88
6.4.4. Grounding the drive and the motor (single-point bonding).................................... 89
6.4.5. Ground cable connection.................................................................................................. 90
6.4.6. EXU cabinet ground connections ....................................................................................91
6.5. Internal wiring ...................................................................................................................................91
6.5.1. Optical fibers........................................................................................................................ 94
6.5.1.1. Optical fibers for internal arc protection.......................................................... 94
6.6. Cable entries..................................................................................................................................... 95
6.6.1. Cable entry with sealing modules, type 1...................................................................... 95
6.6.2. Cable entry with sealing modules, type 2 ......................................................................97
6.6.3. Cable entry with cable glands...........................................................................................97
6.6.4. Cable entry with EMC plates ............................................................................................ 98
6.7. Power cables, ground cables, equipotential bonding conductor....................................... 99
6.7.1. Preparing the cable entry and the cables ..................................................................... 99
6.7.1.1. Determining the cable length .............................................................................. 99
6.7.1.2. Preparing cables for cable entries with cable glands.................................... 99
6.7.1.3. Preparing cables for cable entries with sealing modules ........................... 101
6.7.2. Connecting the cables ......................................................................................................102
6.7.2.1. Checking the cable insulation.............................................................................102
6.7.2.2. Connecting the cables ..........................................................................................102
6.7.2.3. Bolted connections................................................................................................105

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
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6.8. Auxiliary power cables and control cables.............................................................................. 106
6.8.1. Preparing the cable entry and the cables ................................................................... 106
6.8.1.1. Determining the cable length ............................................................................ 106
6.8.1.2. Routing the cables................................................................................................ 106
6.8.1.3. Preparing cables for EMC plates - only top cable entry .............................. 106
6.8.1.4. Preparing cables for cable entries with sealing modules ...........................107
6.8.1.5. Preparing cables for cable entries with cable glands.................................. 108
6.8.2. Routing and connecting low voltage cables .............................................................. 109
6.8.2.1. WCU - auxiliary power and space heater cable.............................................. 109
6.8.2.2. Connecting cables in COU ....................................................................................111
6.8.3. Routing cables in a stand-alone EXU cabinet............................................................. 113
6.8.3.1. Auxiliary power and control cables.................................................................... 113
6.8.3.2. Optical fiber cables................................................................................................ 114
6.8.3.3. Routing optical fiber cables in an EXU cabinet with an ED5V, EB5R,
EB5S, EB7P, and EB7Q type DCS880/DCT880 converter............................. 114
6.8.3.4. Routing cables in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter................................................................................. 116
7. Commissioning ................................................................................................................... 118
7.1. Required qualification................................................................................................................... 118
7.2. Commissioning procedure .......................................................................................................... 118
7.3. Commissioning checklist ............................................................................................................. 118
7.4. Customer assistance..................................................................................................................... 118
7.5. Customer acceptance ................................................................................................................... 118
7.6. Commissioning checklists ........................................................................................................... 119
7.6.1. Mechanical installation checklist.................................................................................... 119
7.6.2. Electrical installation checklist........................................................................................ 119
7.6.3. Door interlocking checklist ..............................................................................................120
7.6.4. Main circuit breaker (MCB) checklist.............................................................................120
7.6.5. Input transformer checklist.............................................................................................120
7.6.6. Motor checklist ...................................................................................................................120
7.6.7. Insulation tests checklist..................................................................................................120
7.6.8. Power checklist ................................................................................................................... 121
7.6.9. Miscellaneous checklist .................................................................................................... 121
8. Operation............................................................................................................................. 122
8.1. Operating conditions ....................................................................................................................122
8.2. Safety.................................................................................................................................................122
8.3. Overview ........................................................................................................................................... 122
8.4. Local operator panel......................................................................................................................123
8.5. EXU control panel ...........................................................................................................................124
8.5.1. Operational settings .........................................................................................................124
8.5.1.1. Display values..........................................................................................................125
8.5.2. Resetting alarm and fault messages ............................................................................125
8.5.3. Parameter settings ............................................................................................................125
8.6. Lamp-test function........................................................................................................................125
8.7. Status messages ............................................................................................................................125
8.7.1. Start sequence of the drive .............................................................................................127
8.7.2. Stop sequence of the drive..............................................................................................128
8.7.3. Emergency-off sequence .................................................................................................128
8.8. Starting the drive............................................................................................................................129
8.8.1. Checks before starting the drive................................................................................... 130
8.8.2. Starting the drive remotely............................................................................................. 130

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ACS5000W gen. 2
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8.8.3. Starting the drive locally.................................................................................................. 130
8.9. Stopping the drive..........................................................................................................................132
8.9.1. Stopping the drive in an emergency .............................................................................133
8.9.2. Starting the drive system after an emergency-off....................................................134
8.10. Arc resistant design.......................................................................................................................135
8.10.1. Internal arc classification (IAC) .......................................................................................135
8.10.2. Arc detection with the Arc Guard System™ ................................................................136
8.10.3. Action after the Arc Guard System™ has been triggered........................................136
8.11. De-energizing and grounding the drive ...................................................................................137
8.12. Opening the doors......................................................................................................................... 137
9. CDP control panel ............................................................................................................... 138
9.1. Overview ...........................................................................................................................................138
9.1.1. Display and keypad ............................................................................................................138
9.1.2. Functions..............................................................................................................................139
9.2. Modes................................................................................................................................................139
9.2.1. Identification mode ...........................................................................................................139
9.2.2. Actual signals mode .......................................................................................................... 141
9.2.2.1. Overview ................................................................................................................... 141
9.2.2.2. Selecting the actual signals display ..................................................................142
9.2.2.3. Toggling between actual signals display and fault memory ......................143
9.2.2.4. Displaying three actual signals...........................................................................143
9.2.2.5. Selecting actual signals........................................................................................143
9.2.2.6. Displaying a fault and resetting the fault memory .......................................145
9.2.2.7. Displaying and resetting an active fault.......................................................... 146
9.2.3. Parameters mode...............................................................................................................147
9.2.3.1. Overview .................................................................................................................. 149
9.2.3.2. Changing a parameter setting .......................................................................... 150
9.2.3.3. Enabling / unlocking a parameter lock ............................................................152
9.2.3.4. User lock...................................................................................................................152
9.2.4. Functions mode..................................................................................................................153
9.2.4.1. Adjusting the display contrast............................................................................153
9.2.5. Local and remote control mode .....................................................................................155
9.2.5.1. Local control ............................................................................................................155
9.2.5.2. Disabling / enabling local lock function...........................................................155
9.2.5.3. Enabling the local lock ..........................................................................................156
9.2.5.4. Remote control .......................................................................................................156
9.3. Operational commands................................................................................................................157
9.3.1. Setting the direction of rotation ....................................................................................157
9.3.2. Entering a reference value................................................................................................157
10. Preventive and corrective maintenance........................................................................... 159
10.1. General information.......................................................................................................................159
10.1.1. Required qualification.......................................................................................................159
10.1.2. Maintenance schedule ......................................................................................................159
10.1.3. Logbook................................................................................................................................159
10.1.4. Spare parts...........................................................................................................................159
10.2. Identifying electrical equipment ................................................................................................159
10.2.1. Device designation ............................................................................................................159
10.2.2. Cables and wires ............................................................................................................... 160
10.2.3. Understanding wiring diagrams................................................................................... 160
10.3. Alarm / fault indications.............................................................................................................. 160
10.3.1. Messages.............................................................................................................................. 161

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ACS5000W gen. 2
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3BHS799208 E01
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10.3.2. Error message levels.......................................................................................................... 161
10.3.2.1. Alarm ......................................................................................................................... 161
10.3.2.2. Fault........................................................................................................................... 161
10.3.2.3. Alarm / fault messages ........................................................................................162
10.3.3. Fault handling .....................................................................................................................162
10.3.4. Standard troubleshooting procedure...........................................................................163
10.4. Removing the CDP control panel................................................................................................164
10.4.1. Communication with AMC circuit board......................................................................164
10.5. LEDs and switches on circuit boards and I/O devices .........................................................165
10.5.1. AMC circuit board...............................................................................................................165
10.5.2. S800 I/O bus modem TB820 ..........................................................................................166
10.5.2.1. Bus modem address .............................................................................................166
10.5.3. S800 I/O modules.............................................................................................................. 167
10.6. Corrective maintenance................................................................................................................168
10.6.1. Safety.....................................................................................................................................168
10.6.2. De-energizing the drive ....................................................................................................169
10.6.2.1. Stopping the motor...............................................................................................169
10.6.2.2. De-energizing the drive ........................................................................................169
10.6.3. Opening and closing the doors.......................................................................................171
10.6.3.1. Releasing the doors................................................................................................171
10.6.3.2. Opening the doors................................................................................................. 172
10.6.3.3. Closing and locking the doors............................................................................ 172
10.6.4. Grounding the drive when the grounding switch is not released......................... 173
10.6.5. Emergency release of a door safety switch ................................................................ 174
10.6.5.1. Location of safety switches................................................................................. 174
10.6.5.2. Safety-switch settings.......................................................................................... 175
10.6.6. Visual checks on the drive................................................................................................176
10.6.7. Cleaning ................................................................................................................................ 176
10.6.7.1. Cleaning the drive cabinet ................................................................................... 176
10.6.8. Checking wire and cable connections .......................................................................... 177
10.6.9. Checking and replacing filter mats................................................................................ 177
10.6.9.1. Replacing filter mats .............................................................................................178
10.6.10. Replacing a fan in an IP42 roof-mounted cooling unit............................................ 180
10.6.11. Replacing a fan in an IP54 roof-mounted cooling unit............................................. 181
10.6.12. Replacing a fan in an EXU with a DCS880 H4/DCT880 T4 controller...................182
10.6.13. Replacing a fan in an EXU with a DCS880 H6 unit.................................................... 184

FIGURES
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ACS5000W gen. 2
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FIGURES
Fig. 1. Typical delivery....................................................................................................... 20
Fig. 2. Product warning label examples (label placement depends on
the drive) .................................................................................................................23
Fig. 3. Drive system overview ........................................................................................... 28
Fig. 4. Typical block diagram of the drive ...................................................................... 30
Fig. 5. Switching levels ...................................................................................................... 31
Fig. 6. Principle of 9-level topology .................................................................................. 31
Fig. 7. IGCT .......................................................................................................................... 31
Fig. 8. Typical drive configurations for FS 1, FS 2, FS 3, and FS 4 ................................33
Fig. 9. Primary PCU, 1700 mm .......................................................................................... 35
Fig. 10. Primary PCU, 1700 mm: (A) side view left and (B) side view right ................... 36
Fig. 11. Primary PCU, 2100 mm ........................................................................................... 37
Fig. 12. Primary PCU, 2100 mm: (A) side view left and (B) side view right ................... 38
Fig. 13. (A) Secondary PCU, 1700 mm and (B) secondary PCU 2100 mm ...................... 39
Fig. 14. Block diagram of control system ......................................................................... 40
Fig. 15. COU control section ............................................................................................... 41
Fig. 16. ................................................................................................................................. 43
Fig. 17. DTC torque control ................................................................................................ 43
Fig. 18. Local control panel ................................................................................................ 45
Fig. 19. COU customer interface section .......................................................................... 46
Fig. 20. (A) WCU800 and (B) WCU1400 cooling system components (low
voltage control compartment not visible) ........................................................... 47
Fig. 21. (A) EXU H4/T4 frame cabinet and (B) EXU H6 frame cabinet .......................... 49
Fig. 22. Location of protection features and lamps (FS 2 drive example) .................... 50
Fig. 23. Grounding switch ................................................................................................... 51
Fig. 24. Locking bar positions ............................................................................................52
Fig. 25. Grounding stud ....................................................................................................... 52
Fig. 26. 4-way grounding set.............................................................................................. 53
Fig. 27. Location of PE busbar and grounding studs (1L1, 1L2, and 1L3) in
COU, FS 1 and FS 2 ................................................................................................. 54
Fig. 28. Location of PE busbar and grounding studs (1L1, 1L2, 1L3, 2L1, 2L2,
and 2L3) in COU, frame sizes 3 and 4 .................................................................. 54
Fig. 29. Location of PE busbar and grounding studs (1L1, 1L2, and 1L3) in
an 6-pulse PCU ........................................................................................................55
Fig. 30. Location of PE busbar and grounding studs (1L1, 1L2, 1L3, 2L1, 2L2,
and 2L3) in a 12-pulse PCU ....................................................................................55
Fig. 31. Lifting attachment types ...................................................................................... 59
Fig. 32. Torque wrench socket for rotating eyebolt (not included in delivery) ............ 62
Fig. 33. Sling configuration for (A) lift frame and (B) spreader frame ......................... 63

FIGURES
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ACS5000W gen. 2
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Fig. 34. Floor inclination ..................................................................................................... 68
Fig. 35. Connection points on side of transport units (PCU example) .......................... 71
Fig. 36. Base frame connection points .............................................................................. 71
Fig. 37. Applying silicone ..................................................................................................... 72
Fig. 38. Roof joint .................................................................................................................72
Fig. 39. Lifting a cooling unit (example with IP54 unit) ................................................... 73
Fig. 40. Lifting an IP42 cooling unit ................................................................................... 74
Fig. 41. Cable duct openings (example with 1700 mm PCU) ........................................... 75
Fig. 42. Lifting an IP54 cooling unit .................................................................................. 76
Fig. 43. Water tube connections (back view) .................................................................... 77
Fig. 44. Roof attachment .................................................................................................... 78
Fig. 45. Recommended ceiling and wall fixings ............................................................... 79
Fig. 46. Busbar connections ................................................................................................ 81
Fig. 47. AC busbar connection ........................................................................................... 82
Fig. 48. PE ground busbar connection .............................................................................. 82
Fig. 49. DC busbar connection ........................................................................................... 83
Fig. 50. Heating cable connection ..................................................................................... 83
Fig. 51. Grounding the transformer and an 18-pulse drive (in PCU) ............................. 86
Fig. 52. Grounding the transformer and a 36-pulse drive (in PCU) ................................ 87
Fig. 53. Grounding the drive and the motor (multi-point bonding) .............................. 88
Fig. 54. Grounding the drive and the motor (single-point bonding) ............................ 89
Fig. 55. PE ground busbars in a (A and B) COU, (C) PCU FS1, and (D)
PCU FS 2 ................................................................................................................. 90
Fig. 56. Grounding the EXU ................................................................................................. 91
Fig. 57. Wiring across shipping splits, (A) FS 1 and (B) FS 2 .......................................... 92
Fig. 58. Wiring across shipping splits, FS 3 and FS 4 ..................................................... 93
Fig. 59. Cable entry with sealing modules – type 1 ......................................................... 95
Fig. 60. Cable entry frame sizes (top) for type 1 sealing modules (bottom) ............... 96
Fig. 61. Cable entry with sealing modules – type 2 ..........................................................97
Fig. 62. Cable entry with cable gland ................................................................................. 97
Fig. 63. Cable strain reliefs, C-rails .................................................................................... 97
Fig. 64. Cable entry with EMC plates ................................................................................ 98
Fig. 65. Preparing power cables for cable glands ......................................................... 100
Fig. 66. Preparing power cables for sealing modules .................................................... 101
Fig. 67. PCU 12-pulse top and bottom entry (back view) .............................................. 103
Fig. 68. PCU 6-pulse top and bottom entry (back view) ................................................ 103
Fig. 69. COU cable terminals, top and bottom entry (back view) - (A) FS 1
and FS 2, and (B) FS 3 and FS 4 .......................................................................... 104
Fig. 70. Bolted busbar connection ................................................................................... 105
Fig. 71. Preparing control cables for sealing modules .................................................. 107
Fig. 72. Preparing control cables for cable glands ......................................................... 108

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Fig. 73. Cable routing options to WCU800 control compartment ................................ 109
Fig. 74. Top and bottom cable routing in (A and B) WCU800 and (C and
D) WCU1400 cabinets ........................................................................................... 110
Fig. 75. Shield grounding clamp ........................................................................................ 111
Fig. 76. COU customer interface section .......................................................................... 111
Fig. 77. Cable routing in COU cabinet .............................................................................. 112
Fig. 78. Cable routing examples in an (A) EXU cabinet with an ED5V, EB5R,
EB5S, EB7P or EB7Q type DCS880/DCT880 converter and in an (B)
EXU cabinet with an ED7Y type DCS880 converter .......................................... 113
Fig. 79. DCS880/DCT880 H4 converter (ED5V, EB5R, EB5S, EB7P and
EB7Q types) ........................................................................................................... 114
Fig. 81. Cable routing example in an EXU cabinet with an ED5V, EB5R,
EB5S, EB7P and EB7Q type DCS880/DCT880 converter .................................. 115
Fig. 80. 1 Control unit SDCS-CON-H01 ............................................................................. 115
Fig. 82. DCS880/DCT880 converter (ED7Y) ..................................................................... 116
Fig. 83. 1 Control unit SDCS-CON-H01 ............................................................................. 116
Fig. 84. Cable routing example in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter .................................................................................. 117
Fig. 85. Local operator panel ............................................................................................ 123
Fig. 86. EXU control panel front and back ....................................................................... 124
Fig. 87. Detail of local control panel ................................................................................ 134
Fig. 88. IAC label example .................................................................................................. 135
Fig. 89. Arc Guard™ system with HMI panel .................................................................... 136
Fig. 90. HMI panel ...............................................................................................................136
Fig. 91. CDP control panel ................................................................................................. 138
Fig. 92. Control panel functions for Actual signals mode ............................................. 141
Fig. 93. Control panel functions for Parameters mode .................................................148
Fig. 94. Control panel functions for Functions mode .................................................... 153
Fig. 95. Device identification ............................................................................................ 159
Fig. 96. Cable and wire designation ................................................................................. 160
Fig. 97. LEDs of AMC circuit board ................................................................................... 165
Fig. 98. TB820 bus modem ................................................................................................ 166
Fig. 99. Example of S800 I/O station ............................................................................... 167
Fig. 100. Location of safety switches ................................................................................ 174
Fig. 101. Safety switch ......................................................................................................... 175
Fig. 102. Roof-mounted cooling unit (IP42) ..................................................................... 180
Fig. 103. Roof-mounted cooling unit (IP54) ...................................................................... 181
Fig. 104. DCS880 controller - size H4................................................................................. 182
Fig. 105. DCS880 controller - size H6 ................................................................................. 184

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—
TABLES
Table 1 Line-up specifications by frame size..........................................................................................32
Table 2 PCU rectifier types ......................................................................................................................... 34
Table 3 Lifting attachment specifications ............................................................................................. 62
Table 4 Installation material per roof joint..............................................................................................72
Table 5 Installation material per IP42 unit...............................................................................................74
Table 6 Installation material per IP54 unit...............................................................................................76
Table 7 Type 1 sealing modules and cables per frame opening....................................................... 96
Table 8 Maximum number of type 1 sealing modules per frame opening .................................... 96
Table 9 Maximum number of cables per frame opening – 3 core.................................................... 96
Table 10 Maximum number of cables per frame opening – single core........................................... 96
Table 11 ABB arc resistant classes.............................................................................................................135
Table 12 Filter mat specifications.............................................................................................................. 177

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1. About this manual
1.1. Equipment covered by this manual
This manual covers standard drive and provides generic information on the drive. The manual
does not claim to cover all variations and details of the drive, nor to consider all eventualities
that may arise during installation, commissioning, operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and handling, installation, and
operation of the drive are affected by these modifications, information on these modifications
is provided in the appropriate documentation (such as layout drawings, wiring diagrams,
project-specific data, engineering notes).
If information is required beyond the instructions in this manual, refer the matter to ABB.
1.2. Structure of the user documentation
The 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 like pulse encoder or fieldbus interfaces), or
information on modifications of the standard drive.
–Appendix B – Technical data contains the technical data sheets of the drive.
–Appendix C – Mechanical drawings provides the outline drawings of the drive. The drawings
are generated according to the customer-specific project.
–Appendix D – Wiring diagrams contains the circuit diagrams with information on device
identification, cross-reference and device identification conventions. The diagrams are
generated according to the customer-specific project. “Setting of protective devices” is
generated according to the customer-specific project.
–Appendix E – Parts list produced for each project and contains all information to identify a
component.
–Appendix F – Test reports and certificates provides the test reports of the drive. Quality
certificates, and codes and standards the drive complies with are added if necessary for the
project.
–Appendix G – Signal and parameter table includes descriptions of actual signals, control
and status words, and control parameters and their default settings.

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1.3. Related documents
The following ABB documents are available for supplementary information:
1.3.1. Maintenance
Title ABB ID
ACS5000 preventive maintenance schedule 3BHS855274 E01
1.3.2. Technical data
Title ABB ID
Technical data from DriveSmart
Configuration software for medium voltage drives
1.3.3. Schematics
Title ABB ID
Layout drawing Project-specific
1.3.4. Specifications and guidelines
Title ABB ID
Generic transformer specification 3BHS356582 E01
Generic motor specification 3BHS824803 E01
Main circuit breaker engineering guideline 3BHS125149 E50
ACS5000 power cable specification 3BHS215798 E01
Synchronized bypass unit engineering guideline 3BHS400185 E01
Power cables engineering guideline 3BHS542290 E01
Auxiliary power and control cables guideline 3BHS813742 E01
Customer interface 3BHS347034 E03
1.3.5. Manuals
Title ABB ID
ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual 3BHS821937 E01
ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual 3BHS835714 E01

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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.
1.3.6. I/O interface
Title ABB ID
S800 I/O Getting started
Available: https://library.abb.com
3BSE020923
S800 I/O Modules and Termination Units
Available: https://library.abb.com
3BSE020924
1.3.7. Serial communications interfaces
Title ABB ID
ACX-AP-x Assistant control panels user manual 3AUA0000085685
Ethernet - NETA-21 remote monitoring tool user manual
Available: https://library.abb.com
3AUA0000096939
Modbus - NMBA-01 installation and start-up guide
Available: https://library.abb.com
3AFY58919772
Profibus - NPBA-12 installation and start-up guide
Available: https://library.abb.com
3BFE64341588
Term Definition
AMC The application and motor controller (AMC) is a digital signal processor and the
heart of the drive control system.
Converter Short form for ACS5000 frequency converter
COU
The control unit (COU) consists of a control section, a customer interface section
and a terminal section.
The control section incorporates the hardware for control, monitoring and
protection functions of the drive and the communication interface to the door-
mounted CDP control panel.
The COU compartment also incorporates the grounding frame for cable screens
and the ground cable, the grounding accessories and the motor terminal section.
CVMI Current voltage measurement interface
DDCS Distributed drive control system. DDCS is an acronym for a serial communications
protocol designed for data transfer via optical fibers.
Drive Synonym for ACS5000 frequency converter
DriveDebug
DriveDebug is part of ABB’s DriveWare® software tools for devices using the DDCS
communications protocol. DriveDebug runs on computers with Microsoft
Windows® operating systems. DriveDebug is a specialist tool used to diagnose,
tune and troubleshoot frequency converters.

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DriveWindow
DriveWindow is a DriveWare® product. DriveWindow is a 32-bit Microsoft
Windows® application for commissioning and maintaining ABB drives equipped
with optical communication links.
DriveMonitor
DriveMonitor is a monitoring and diagnostics system that allows secure access to
the frequency converter via the Internet from a remote location. DriveMonitor
provides long-term monitoring functions that allow to infer equipment status
and improve equipment performance.
EAF Earth fault monitoring
EMC Electromagnetic compatibility
EOI Electrical-optical interface
Equipment Frequency converter and related equipment
EXU The excitation unit (EXU) is part of the drive when a synchronous motor has to be
supplied with excitation power.
FS Frame sizes 1 to 4 give the different power ranges. The higher the frame size, the
greater the output power capability.
Ground Earth
To ground To connect the electrical equipment to the earth, eg, by a grounding set or a
grounding switch.
I/O device Term of ABB’s S800 I/O process system. An I/O device consists of a module
termination unit (MTU) and one I/O module.
I/O module Term of ABB’s S800 I/O process system. The I/O module is an active input or
output device for digital or analog signals.
I/O station Term of ABB’s S800 I/O process system. The I/O station typically consists of a bus
modem and several input and output devices.
IGCT Integrated gate-commutated thyristor
IPS Insulated power supply
LED Light emitting diode
LSU Line supply unit (rectifier phase module)
MCB The main circuit breaker (MCB) is a major protection device of the drive system
and connects and / or disconnects the main power supply to the drive.
Motor terminal
section
This is the customer terminal for connecting motor cables. It is located behind the
swing frame of the COU compartment.
NETA-21 Monitoring and diagnostics tool that allows access to the drive from any location
in the world via a secure Internet connection.
NP Neutral point
OEI Optical-electrical interrupter
PCU
A primary phase converter unit (PCU) consists of a transformer terminal section,
a rectifier stack, a DC link and an inverter stack.
A secondary phase converter unit consists of a DC link and an inverter stack.
Phase module
The phase module is a compact assembly of wired components including power
semiconductors and circuit boards that serves as a standardized building block
for the inverter and rectifier stack.
Term Definition

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1.5. Target groups and required qualification
The drive presented in this manual is part of an industrial environment where voltages are
present that contain a potential hazard of electric shock and / or burn. For this reason, only
personnel who have a thorough knowledge of the drive and the industrial environment and have
obtained the required qualification should handle, install, operate, or maintain the drive.
The manual addresses personnel who are responsible for unpacking, transportation,
installation, operation and maintenance of the drive. The personnel must carry out the below
listed tasks in a manner that does not cause physical harm or danger, and ensures the safe and
reliable functioning of the drive.
IMPORTANT! Commissioning of the drive must only be performed by qualified and certified
ABB personnel
1.5.1. Handling
Personnel must be skilled and experienced in unpacking and transporting heavy equipment.
1.5.2. Mechanical installation
The personnel must be qualified to prepare the installation site according to the site and
equipment requirements and to perform the installation accordingly.
1.5.3. Electrical installation
Personnel must have a sound knowledge of the relevant electrical codes and specifications
covering low and medium voltage equipment, be experienced with electrical wiring principles
and know the electrical symbols typically used in wiring diagrams.
PICW Person in charge of work
PINT Pulse interface
PPE Personal protective equipment
PTW Permit to work
S800 I/O The S800 I/O is a distributed process input / output system that can be
connected to various process controllers from ABB and other companies.
SBU
The synchronized bypass unit (SBU) is a control cabinet that provides control to
the startup motor and then synchronizes the motor to the supply network to start
direct-on-line operation (and vice versa)
SW Software
Transformer
terminal section
This is the customer terminal for connecting transformer cables. It is located in
the back of the PCU compartment.
WCU The water cooling unit (WCU) dissipates heat losses of the power electronics.
Term Definition

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1.5.4. Operation
The personnel include all persons who operate the drive from the local operator panel of the
drive. The personnel must know the functions of the operator panel, be adequately trained for
the drive, and know the driven process. Special knowledge of frequency converter technology is
not required.
1.5.5. Maintenance
The personnel include all persons who
– Are qualified to carry out preventive and corrective maintenance on drive as described in this
manual
– Are thoroughly familiar with the drive
– Have a sound knowledge of the relevant electrical codes and specifications covering low and
medium voltage equipment
– Are able to assess the hazards associated with the energy sources of the drive and act
correspondingly
– Know the safe shutdown and grounding procedures for the drive system
1.6. User’s responsibilities
It is the responsibility of those in charge of the drive to ensure that each person involved in the
installation, operation or maintenance of the drive has received the appropriate training and
has thoroughly read and clearly understood the instructions in this manual and the relevant
safety instructions.
1.7. Intended use of equipment
Those in charge of the drive must ensure that the drive is only used as specified in the
contractual documents, operated under the conditions stipulated in the technical
specifications and on the rating plate of the drive, and serviced in the intervals specified by ABB.
Use of the drive outside the scope of the specifications is not permitted.
Intended equipment use also implies that only spare parts recommended and approved by ABB
must be used.
Unauthorized modifications and constructional changes of the drive are not permitted.

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1.8. Quality certificates and applicable standards
The following certificates and conformity declarations are available with ABB:
– ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and
maintains a management system which fulfills the requirements of the normative standards
– EC declaration of conformity
– List of standards the drive complies with (see “Appendix F – Test reports and certificates”)
1.8.1. Standards
Standard Title
ANSI Z535.6 American national standard for product safety information in product manuals,
instructions, and other collateral materials
ISO 3864-2 2004 (E) - ‘Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels’
ISO 7010 2011 (E) - Graphical symbols - Safety colors and safety signs - Registered safety sign
EN 50110 European standard code for electrical work safety
ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design, section 6.2.6 Category 3
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
IEC 60721-3-2 Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Transportation
IEC 60721-3-1 Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage
IEC 60721-3-3 Stationary use at weather-protected locations
IEC 62477-2 Safety requirements for power electronic converter systems and equipment – Part 2:
Power electronic converters from 1 000 V AC or 1 500 V DC up to 36 kV AC or 54 kV DC

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1.9. Items covered by delivery
The delivery includes the following items, whereas items 3 to 5 are shipped in a separate
container.
Fig. 1. Typical delivery
1.9.1. Identifying the delivery
The drive and accessories are identified by the type code printed on the rating label.
The rating label is located on the back of the control compartment door.
The label provides information on the type of drive, the rated voltage, the frequency and the
current of the main and the auxiliary power supply.
1.10. Tools
ABB offers various tool sets containing all necessary tools and equipment for installation,
commissioning and maintenance of the drive. The content of the tool sets is described in the
manual Service equipment.
Key: Explanation
(1) Drive (frame size 1 shown) Shipped in transport units – shipping splits are defined in the
customer-specific layout drawing
(2) Rating plate On the first door from the left
(3) Roof attachments Only for marine drives
(4) Door keys
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4