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