ABB ACS6080 User manual

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SYSTEM DRIVES
ACS6080
User manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DATE
2023-06-14
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS842007 E01
REV.
I
LANG.
en
PAGE
1/211
© Copyright 2018 ABB All rights reserved.

PRODUCT
ACS6080
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS842007 E01
REV.
I
LANG.
en
PAGE
2/211
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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.
—
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 © 2018 ABB.
All rights reserved.

CONTENTS
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CONTENTS
1. About this manual................................................................................................................. 14
1.1. Product overview..............................................................................................................................14
1.1.1. Standard applications.........................................................................................................14
1.2. Equipment covered by this manual .............................................................................................14
1.3. Structure of the user documentation .........................................................................................15
1.4. Terms and abbreviations................................................................................................................15
1.5. Related documents..........................................................................................................................19
1.5.1. Maintenance ..........................................................................................................................19
1.5.2. Technical data ...................................................................................................................... 20
1.5.3. Schematics............................................................................................................................ 20
1.5.4. Specifications and guidelines.......................................................................................... 20
1.5.5. Service.................................................................................................................................... 20
1.5.6. Communication interfaces ................................................................................................ 21
1.5.7. User manuals related to drive units ................................................................................ 21
1.6. Target groups and required qualification.................................................................................. 21
1.6.1. Handling ................................................................................................................................. 21
1.6.2. Mechanical installation ....................................................................................................... 21
1.6.3. Electrical installation ...........................................................................................................22
1.6.4. Operation ...............................................................................................................................22
1.6.5. Maintenance ..........................................................................................................................22
1.7. User’s responsibilities .....................................................................................................................22
1.8. Intended use of equipment ...........................................................................................................22
1.9. Quality certificates and applicable standards ..........................................................................23
1.9.1. Standards...............................................................................................................................23
1.10. Identifying the delivery ...................................................................................................................23
1.11. Tools.................................................................................................................................................... 24
1.12. Document conventions.................................................................................................................. 24
2. Important safety information.............................................................................................25
2.1. Safety messages and safety signs in this document .............................................................25
2.1.1. Safety messages ..................................................................................................................25
2.1.2. Safety signs............................................................................................................................25
2.2. Product safety labels ...................................................................................................................... 26
2.3. Electrical safety................................................................................................................................ 26
2.3.1. General safety instructions............................................................................................... 26
2.3.2. The 7 steps that save lives..................................................................................................27
2.3.3. Possible residual risks........................................................................................................ 29
2.4. Main circuit breaker protection device ...................................................................................... 30
2.4.1. Safety and protection requirements...............................................................................31
2.4.2. Safety and protection requirements for the MCB ....................................................... 31
2.5. Maintenance recommendation.....................................................................................................32
3. Power electronics and cabinet features ............................................................................ 33
3.1. Drive system topology ....................................................................................................................33
3.1.1. Drive.........................................................................................................................................33
3.1.1.1. ACS6080 cabinet units .......................................................................................... 35
3.1.1.2. Final drive configuration ....................................................................................... 35
3.1.2. Motor...................................................................................................................................... 35
3.2. Standard cabinet units .................................................................................................................. 36

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3.2.1. Active rectifier unit (ARU)/inverter unit (INU) .............................................................. 36
3.2.2. Line supply unit (LSU) ........................................................................................................ 38
3.2.3. Capacitor bank unit (CBU) ................................................................................................ 40
3.2.4. Terminal unit (TEU)..............................................................................................................41
3.2.5. Control unit (COU)............................................................................................................... 42
3.2.5.1. Main circuit breaker ................................................................................................ 43
3.2.5.2. Speed and torque control ..................................................................................... 43
3.2.5.3. Peripheral I/O devices............................................................................................ 43
3.2.5.4. Local control panels................................................................................................ 44
3.2.6. Water cooling unit (WCU) .................................................................................................. 45
3.2.6.1. Cooling circuit ...........................................................................................................47
3.2.6.2. External cooling connection..................................................................................47
3.3. Optional cabinet units ................................................................................................................... 48
3.3.1. Input reactor unit (IRU)...................................................................................................... 48
3.3.2. Input filter unit (IFU)........................................................................................................... 49
3.3.3. Voltage limiter unit (VLU) .................................................................................................. 50
3.3.4. Braking units .........................................................................................................................51
3.3.4.1. Braking chopper unit ..............................................................................................52
3.3.4.2. Resistor braking unit.............................................................................................. 53
3.3.5. Excitation unit (EXU)........................................................................................................... 54
3.3.5.1. DCS880/DCT880 control panel........................................................................... 55
3.3.5.2. Output disconnector.............................................................................................. 55
3.3.6. Customer interface unit (CIU).......................................................................................... 56
3.3.6.1. Arc detection with Arc Guard (optional) ............................................................57
3.4. Air cooling...........................................................................................................................................57
3.4.1. Air-to-air heat exchangers .................................................................................................57
3.4.2. Auxiliary fan units................................................................................................................ 58
3.5. Cabinet design ................................................................................................................................. 59
3.6. Door locking system....................................................................................................................... 60
3.7. Arc resistant design ........................................................................................................................ 60
3.7.1. Internal arc classification................................................................................................... 60
3.8. Busbars and grounding ..................................................................................................................61
3.8.1. AC busbars.............................................................................................................................61
3.8.2. DC busbars ............................................................................................................................61
3.8.3. PE busbar ...............................................................................................................................61
3.8.4. PG busbar...............................................................................................................................61
4. Transportation, storage, and disposal ..............................................................................62
4.1. Safety.................................................................................................................................................. 62
4.2. Transport conditions...................................................................................................................... 62
4.3. Unpacking and inspection ............................................................................................................ 62
4.4. Identifying transport units ........................................................................................................... 62
4.4.1. Packing list ............................................................................................................................ 62
4.4.2. Packing label......................................................................................................................... 63
4.5. Lifting and transportation............................................................................................................ 64
4.5.1. Lifting attachment types .................................................................................................. 65
4.5.2. Lifting with lifting plates................................................................................................... 66
4.5.3. Lifting with rotating eyebolts ...........................................................................................67
4.5.4. Reinstalling lifting attachments ...................................................................................... 68
4.5.5. Sling configurations for lift frames and spreader frames........................................ 69
4.6. Storage............................................................................................................................................... 70
4.6.1. Storage conditions ............................................................................................................. 70

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4.6.2. Storing the drive.................................................................................................................. 70
4.6.3. Storage and handling of spare parts.............................................................................. 71
4.6.3.1. Warranty information.............................................................................................. 71
4.7. Disposing package materials and components ...................................................................... 71
5. Mechanical installation ........................................................................................................ 72
5.1. Safety...................................................................................................................................................72
5.2. Overview .............................................................................................................................................72
5.3. General notes on installation ........................................................................................................72
5.3.1. Dimensions and clearances...............................................................................................72
5.3.2. Access to the cabinets ........................................................................................................72
5.3.3. Cabinet roof...........................................................................................................................73
5.3.4. Fire protection ......................................................................................................................73
5.3.5. Cable duct material .............................................................................................................73
5.3.6. Installation material.............................................................................................................73
5.3.7. Tools ........................................................................................................................................73
5.3.8. Floor preparation .................................................................................................................73
5.3.9. Floor fixation .........................................................................................................................73
5.3.10. Raw water circuit ..................................................................................................................73
5.4. Aligning transport units .................................................................................................................74
5.5. Joining transport units ...................................................................................................................76
5.6. Joining water pipes..........................................................................................................................77
5.6.1. Removing a pipe joint .........................................................................................................79
5.7. Joining busbars ................................................................................................................................79
5.7.1. DC busbars ........................................................................................................................... 80
5.7.2. Ground busbars................................................................................................................... 82
5.7.3. AC busbars between COU/TEU and LSU (5/7/9 MVA).............................................. 83
5.7.4. AC busbars between COU/TEU and LSU (14 MVA)..................................................... 84
5.7.5. AC busbars between COU/TEU and ARU/INU ............................................................ 85
5.7.6. AC busbar joints - without disconnector...................................................................... 85
5.7.7. AC busbar joints - with motorized disconnector........................................................ 86
5.8. Installing and removing air-to-air heat exchangers ............................................................... 88
5.8.1. Installing air-to-air heat exchangers .............................................................................. 88
5.8.1.1. Installation ................................................................................................................ 89
5.8.2. Removing air-to-air heat exchangers............................................................................. 94
5.8.2.1. Removing an air-to-air heat exchanger............................................................. 95
5.8.2.2. Reinstalling an air-to-air heat exchanger.......................................................... 96
5.8.3. Installing the transformers of air-to-air heat exchangers .........................................97
5.9. Installing the pressure relief vents .............................................................................................. 98
5.10. Attaching the sealing tapes........................................................................................................ 100
5.11. Installing the roof joints and the roof attachments.............................................................. 101
5.11.1. Installing roof joints........................................................................................................... 101
5.11.2. Installing roof attachments.............................................................................................102
6. Electrical installation .........................................................................................................104
6.1. Safety................................................................................................................................................ 104
6.2. Cable requirements .......................................................................................................................105
6.2.1. Power cables........................................................................................................................105
6.2.2. Auxiliary and control cables.............................................................................................105
6.2.3. Synchronization cables .....................................................................................................105
6.3. Grounding the drive system ....................................................................................................... 106
6.3.1. Grounding diagrams ........................................................................................................ 106
6.3.2. Ground cable connection .................................................................................................107

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6.3.3. Cable shield ground connection ....................................................................................107
6.3.4. EXU cabinet ground connections ................................................................................. 108
6.4. Internal wiring ................................................................................................................................ 109
6.4.1. Optical fiber cables........................................................................................................... 109
6.4.1.1. Installing the standard optical fibers............................................................... 109
6.4.2. Optical fiber cables for the optional Arc Guard System™ ....................................... 110
6.4.2.1. Connecting the detector cables to the arc monitor device .........................111
6.5. Cable entry systems ...................................................................................................................... 112
6.5.1. Frames with type 1 sealing modules............................................................................. 113
6.5.2. Frame with type 2 sealing modules............................................................................... 115
6.5.3. Plates with cable glands................................................................................................... 115
6.5.4. EMC plates with sealing grommets .............................................................................. 116
6.6. Preparing cable entry systems for TEU, ARU and EXU cabinets .........................................117
6.6.1. TEU cable entry frames with type 1 sealing modules................................................117
6.6.2. ARU cable entry frames with type 1 sealing modules............................................... 118
6.6.3. EXU cable entry with EMC plate and sealing grommets ......................................... 119
6.7. Power, ground and equipotential bonding conductor cables............................................120
6.7.1. Determining the cable length .........................................................................................120
6.7.2. Preparing cables for sealing modules .......................................................................... 121
6.7.3. Preparing cables for cable glands .................................................................................122
6.7.4. Preparing cables for EMC plates....................................................................................123
6.7.5. Connecting the cables ......................................................................................................124
6.7.5.1. Checking the cable insulation.............................................................................125
6.7.5.2. EXU cabinet connections .....................................................................................125
6.7.5.3. Bolted busbar connections – marine drives ...................................................126
6.7.5.4. Bolted busbar connections in non-marine drives .........................................126
6.8. Auxiliary power, control and serial communication cables .................................................127
6.8.1. Determining the cable length ......................................................................................... 127
6.8.2. Preparing cables for sealing modules ..........................................................................128
6.8.3. Preparing cables for cable glands .................................................................................129
6.8.4. Preparing cables for EMC plates................................................................................... 130
6.8.5. Routing cables in a WCU.................................................................................................. 130
6.8.6. Routing cables in a COU cabinet.................................................................................... 131
6.8.6.1. Connecting the cables ..........................................................................................132
6.8.7. Routing cables in an EXU cabinet ..................................................................................133
6.8.7.1. Auxiliary power and control cables....................................................................133
6.8.7.2. Optical fiber cables................................................................................................135
6.8.7.3. Routing optical fiber cables in an EXU cabinet with an ED5V, EB5R,
EB5S, EB7P and EB7Q type DCS880/DCT880 converter .............................135
6.8.7.4. Routing cables in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter.................................................................................137
6.9. Connecting the heating cable .....................................................................................................138
6.10. Final checks......................................................................................................................................139
7. Commissioning ...................................................................................................................140
7.1. Required qualification.................................................................................................................. 140
7.2. Commissioning procedure ......................................................................................................... 140
7.3. Commissioning checklist ............................................................................................................ 140
7.4. Customer assistance.................................................................................................................... 140
7.5. Customer acceptance .................................................................................................................. 140
7.6. Commissioning checklists ........................................................................................................... 141
7.6.1. Mechanical installation checklist.................................................................................... 141

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7.6.2. Electrical installation checklist........................................................................................ 141
7.6.3. Main circuit breaker (MCB) checklist.............................................................................142
7.6.4. Input transformer checklist.............................................................................................142
7.6.5. Motor checklist ...................................................................................................................142
7.6.6. Insulation tests checklist..................................................................................................142
7.6.7. Power checklist ...................................................................................................................143
7.6.8. Water Cooling unit checklist............................................................................................143
7.6.9. Miscellaneous checklist ....................................................................................................143
8. Operation.............................................................................................................................144
8.1. Overview .......................................................................................................................................... 144
8.2. Operating conditions ................................................................................................................... 144
8.3. Safety................................................................................................................................................ 144
8.4. Control panels .................................................................................................................................145
8.4.1. Navigating the home view .............................................................................................. 146
8.4.2. Control panels for drives with an ARU ..........................................................................147
8.4.3. Control panels for drives with an LSU.......................................................................... 148
8.4.4. EXU control panel .............................................................................................................. 149
8.4.4.1. Operational settings ............................................................................................ 149
8.4.4.2. Resetting alarm and fault messages ............................................................... 150
8.4.4.3. Parameter settings ............................................................................................... 150
8.5. Lamp test ........................................................................................................................................ 150
8.6. Grounding switch and door locking system ........................................................................... 151
8.6.1. Lamp test ............................................................................................................................. 151
8.6.2. Door locking system..........................................................................................................152
8.7. Optional switchgear and controlgear.......................................................................................153
8.7.1. DC-link disconnector.........................................................................................................153
8.7.2. Output switches.................................................................................................................153
8.7.3. Manual output isolation ...................................................................................................153
8.8. Status messages ............................................................................................................................154
8.8.1. Start sequence of the drive .............................................................................................155
8.8.2. Stop sequence of the drive..............................................................................................156
8.8.3. Emergency-off sequence .................................................................................................156
8.8.4. Prevention of unexpected startup sequence..............................................................157
8.9. Starting the drive............................................................................................................................157
8.9.1. Checks before starting the drive....................................................................................158
8.9.2. Starting the drive remotely..............................................................................................158
8.9.3. Starting the drive locally...................................................................................................158
8.10. Stopping the drive..........................................................................................................................159
8.10.1. Stopping the drive locally.................................................................................................159
8.10.2. Stopping the drive in an emergency .............................................................................159
8.10.2.1. Starting the drive system after an emergency-off....................................... 160
8.11. Arc detection with the Arc Guard System™ (optional) ........................................................ 160
8.11.1. Action after the Arc Guard System™ has been triggered........................................ 161
9. Preventive and corrective maintenance........................................................................... 162
9.1. General information.......................................................................................................................162
9.1.1. Required qualification.......................................................................................................162
9.1.2. Maintenance schedule ......................................................................................................162
9.1.3. Logbook................................................................................................................................162
9.1.4. Spare parts...........................................................................................................................162
9.2. Identifying electrical equipment ................................................................................................163
9.2.1. Device designation ............................................................................................................163

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9.2.2. Cables and wires ................................................................................................................163
9.2.2.1. Understanding wiring diagrams........................................................................163
9.3. Status indicators ............................................................................................................................164
9.3.1. Alarm / fault indications...................................................................................................164
9.3.2. Error message levels..........................................................................................................164
9.3.2.1. Alarm and fault messages ...................................................................................165
9.3.2.2. Fault handling .........................................................................................................165
9.3.2.3. Standard troubleshooting procedure...............................................................165
9.3.3. LEDs and switches on PCBs and I/O modules...........................................................166
9.3.3.1. UCU-26 control unit ...............................................................................................166
9.3.3.2. S500 I/O modules..................................................................................................167
9.3.3.3. Serial communication interfaces .......................................................................167
9.3.3.4. LEDs on optional heat exchangers....................................................................168
9.4. Maintenance tasks .........................................................................................................................169
9.4.1. Safety.....................................................................................................................................169
9.4.2. De-energizing and grounding the drive .......................................................................169
9.4.3. Grounding the drive when the grounding switch is not released..........................171
9.4.4. Unlocking and opening the doors ................................................................................. 172
9.4.5. Closing and locking the doors ........................................................................................ 173
9.4.6. Testing the white lamp ..................................................................................................... 174
9.4.7. Emergency release of a door safety switch ................................................................ 174
9.4.7.1. Location of safety switches................................................................................. 174
9.4.7.2. Safety-switch settings.......................................................................................... 175
9.4.7.3. Unlocking a safety switch .................................................................................... 176
9.4.8. Connecting a grounding set............................................................................................ 177
9.4.8.1. Drives with an LSU................................................................................................. 178
9.4.8.2. Drives with an ARU................................................................................................. 179
9.4.9. Drives with the manual output isolation (optional) ................................................. 180
9.4.9.1. Removing the busbar connectors ..................................................................... 181
9.4.9.2. Fitting the busbar connectors............................................................................185
9.4.10. Removing and installing a phase module................................................................... 186
9.4.10.1. Removing a phase module ................................................................................. 186
9.4.10.2. Installing a phase module................................................................................... 188
9.4.11. Visual checks on the drive............................................................................................... 189
9.4.12. Cleaning............................................................................................................................... 189
9.4.12.1. Cleaning the drive cabinet.................................................................................. 189
9.4.13. Checking wire and cable connections ......................................................................... 190
9.4.14. Checking and replacing filter mats............................................................................... 190
9.4.14.1. Replacing a filter mat............................................................................................ 191
9.4.15. Testing and replacing auxiliary fan units ..................................................................... 191
9.4.15.1. Testing auxiliary fan units....................................................................................192
9.4.15.2. Replacing auxiliary fan units................................................................................193
9.4.16. Testing and replacing air-to-air heat exchangers......................................................194
9.4.16.1. Testing the fan units .............................................................................................195
9.4.16.2. Replacing the complete heat exchanger..........................................................196
9.4.16.3. Replacing the circuit board .................................................................................196
9.4.16.4. Replacing internal fan 1 - left side......................................................................198
9.4.16.5. Replacing internal fan 2 - right side..................................................................200
9.4.16.6. Replacing the ambient fans................................................................................ 203
9.4.17. Replacing the fan unit in an EXU with a DCS880 H4/DCT880 T4 unit................204
9.4.18. Replacing the fan unit in an EXU with a DCS880 H6 unit .......................................206
9.4.19. Replacing the air-to-water heat exchanger of the EXU...........................................209

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FIGURES
Fig. 1. Product warning label examples (label placement depends on the
drive) ........................................................................................................................26
Fig. 2. Drive system overview ........................................................................................... 30
Fig. 3. MCB opening timing diagram ............................................................................... 31
Fig. 4. Common DC-bus principle for (A) single motor drive and (B)
multi-motor drive ................................................................................................... 33
Fig. 5. ACS6080 drive example ........................................................................................ 34
Fig. 6. ARU/INU block diagram ........................................................................................ 36
Fig. 7. ARU/INU circuit diagram ...................................................................................... 36
Fig. 8. (A) ARU/INU and (B) phase module with IGCTs .................................................. 37
Fig. 9. LSU block diagram ................................................................................................ 38
Fig. 10. LSU (12-pulse) circuit diagram ............................................................................. 38
Fig. 11. LSU (12-pulse) ........................................................................................................ 39
Fig. 12. CBU .......................................................................................................................... 40
Fig. 13. TEU (1000 mm) ....................................................................................................... 41
Fig. 14. Master COU (1000 mm) and control equipment ................................................ 42
Fig. 15. Location of (1) control panels on master (A) COU and (B)
follower COU .......................................................................................................... 44
Fig. 16. (A) WCU1400 and (B) WCU800 cabinet and system components .................... 46
Fig. 17. Cooling circuit in an ACS6080 drive ..................................................................... 47
Fig. 18. (A) IRU cabinet and (B) circuit diagram .............................................................. 48
Fig. 19. (A) IFU cabinet and (B) circuit diagram .............................................................. 49
Fig. 20. (A) VLU cabinet and (B) circuit diagram ............................................................. 50
Fig. 21. (A) BCU cabinet and (B) circuit diagram .............................................................. 52
Fig. 22. (A) RBU cabinet and (B) circuit diagram ............................................................. 53
Fig. 23. (A) EXU H4/T4 frame cabinet and (B) EXU H6 frame cabinet .......................... 54
Fig. 24. (A) CIU cabinet and (B) WCU800 cabinet ............................................................ 56
Fig. 25. ACS6080 example drive with air-to-air heat exchanger ..................................... 57
Fig. 26. Auxiliary fan unit .................................................................................................... 58
Fig. 27. Air circulation through ventilation grids in (A) 600 mm COU, (B)
1000 mm COU, and (C) WCU800 .......................................................................... 58
Fig. 28. Basic cabinet design ............................................................................................. 59
Fig. 29. IAC label example ................................................................................................... 60
Fig. 30. Busbars .................................................................................................................... 61
Fig. 31. Lifting attachment types ...................................................................................... 65
Fig. 32. Torque wrench socket for rotating eyebolt (not included in delivery) ............ 68
Fig. 33. (A) Lift frame and (B) lift spreader ...................................................................... 69
Fig. 34. Connection point locations on transport units ................................................. 76
Fig. 35. Minimum distances and locking bolt orientation (A = front) ........................... 78

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Fig. 36. Bolted busbar connection .................................................................................... 79
Fig. 37. Top view of DC busbar configuration 1 ............................................................... 80
Fig. 38. Top view (A) DC busbar configuration 2, (B) configuration 3, and
(C) configuration 4 ................................................................................................. 81
Fig. 39. Ground busbar joints ............................................................................................ 82
Fig. 40. AC busbar joints between the COU/TEU and LSU (5/7/9 MVA) ....................... 83
Fig. 41. AC busbar joints between the COU/TEU and LSU (14 MVA). ............................ 84
Fig. 42. Air-to-air heat exchanger (type LT-5-5165-UL) ................................................... 88
Fig. 43. Tools for installing an air-to-air heat exchanger ............................................... 88
Fig. 44. Correct and incorrect cable installation ............................................................. 90
Fig. 45. M8 rotating eyebolt and heat exchanger with mounted rotating
eyebolts ................................................................................................................... 91
Fig. 46. ARU/INU/IFU cable routing .................................................................................. 92
Fig. 47. LSU cable routing .................................................................................................. 92
Fig. 48. Air-to-air heat exchangers (type LT-5-5165-UL) ................................................. 94
Fig. 49. Tools for removing an air-to-air heat exchanger ............................................... 94
Fig. 50. Installation example of transformers in an air-to-air heat exchanger ............. 97
Fig. 51. Connect wires to terminal block .......................................................................... 98
Fig. 52. Pressure relief vents .............................................................................................. 98
Fig. 54. Installation example of pressure relief vents ..................................................... 99
Fig. 53. Tools required to fasten the pressure relief vent to the roof ........................... 99
Fig. 55. Attach sealing tape to the joining crossbar (1) ................................................ 100
Fig. 56. Roof joints (1) ........................................................................................................ 101
Fig. 57. Roof attachment parts ......................................................................................... 102
Fig. 58. Recommended ceiling and wall fixings .............................................................. 103
Fig. 59. Phase module on lift table ................................................................................... 104
Fig. 60. Grounding the (A) input side and (B) output side of the drive
system ....................................................................................................................106
Fig. 61. System (1) ground connection in a 600 mm TEU .............................................. 107
Fig. 62. Grounding the EXU ............................................................................................... 108
Fig. 63. Cable tray and cable ducts in an LSU (A = front) .............................................. 109
Fig. 64. Arc Guard System™ in an optional roof extension box (REB) .......................... 110
Fig. 65. Location of Arc Guard sensors in a TEU .............................................................. 111
Fig. 66. Cable tray and cable ducts in an LSU (A = front) ............................................... 111
Fig. 67. Cable entry with type 1 sealing modules ........................................................... 113
Fig. 68. Cable entry frame with type 1 sealing modules ................................................ 114
Fig. 69. Cable entry with sealing modules – type 2 ........................................................ 115
Fig. 70. Cable gland ............................................................................................................ 115
Fig. 71. Cable entry with EMC plates ............................................................................... 116
Fig. 72. TEU 1000 mm cabinet (A = back) with (1) top and (2) bottom
cable entries ........................................................................................................... 117

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Fig. 73. Short busbar removal in ARU .............................................................................. 118
Fig. 74. (A) EXU with top cable entry and (B) EXU with bottom cable entry ............... 119
Fig. 75. EXU cabinet ........................................................................................................... 119
Fig. 76. Preparing power cables for sealing modules .................................................... 121
Fig. 77. Prepare power cables for cable glands .............................................................. 122
Fig. 78. Preparing cables for EMC plates: (A) cables with an outer screen
or shield, (B) cables without an outer screen or shield or (C)
cables in an EXU cabinet ..................................................................................... 124
Fig. 79. EXU cable connections ......................................................................................... 125
Fig. 80. Bolted busbar connection - marine drives ........................................................ 126
Fig. 81. Bolted busbar connection - non-marine drive .................................................. 126
Fig. 82. Cable entry with sealing modules ...................................................................... 128
Fig. 83. Preparing control cables for sealing modules .................................................. 128
Fig. 84. Preparing auxiliary control cables for cable glands ......................................... 129
Fig. 85. Preparing control cables for EMC plates ........................................................... 130
Fig. 86. Blanking plates on 600 mm COU and 1000 mm COU ....................................... 131
Fig. 87. Cable routing in (A) 1000 mm COU and (B) 600 mm COU ............................... 132
Fig. 88. Shield grounding for encoder cable ................................................................... 133
Fig. 89. Cable routing examples in an EXU cabinet with an (A) ED5V, EB5R,
EB5S, EB7P or EB7Q type DCS880/DCT880 converter and in an (B)
EXU cabinet with an ED7Y type DCS880 converter .......................................... 134
Fig. 90. DCS880/DCT880 H4 converter (ED5V, EB5R, EB5S, EB7P and
EB7Q types) ........................................................................................................... 135
Fig. 91. 1 Control unit SDCS-CON-H01 ............................................................................. 136
Fig. 92. Cable routing example in an EXU cabinet with an ED5V, EB5R,
EB5S, EB7P and EB7Q type DCS880/DCT880 converter .................................. 136
Fig. 93. DCS880/DCT880 converter (ED7Y) ..................................................................... 137
Fig. 94. 1 Control unit SDCS-CON-H01 ............................................................................. 137
Fig. 95. Cable routing example in an EXU cabinet with an ED7Y type
DCS880/DCT880 converter ................................................................................. 138
Fig. 96. Assistant control panel ........................................................................................ 144
Fig. 97. Assistant control panel front and back .............................................................. 145
Fig. 98. Master control panel on (A) COU1 and (B) slave control panel for a
drive with an ARU ................................................................................................. 147
Fig. 99. (A) Master control panel on COU1 and (B) slave control panel for a
drive with an LSU ..................................................................................................148
Fig. 100. DCS880 control panel........................................................................................... 149
Fig. 101. CBU grounding switch in (A) ungrounded and (B) grounded
positions ................................................................................................................ 151
Fig. 102. Safety switches ..................................................................................................... 152
Fig. 103. Arc Guard System™ in a WCU REB ...................................................................... 160
Fig. 104. HMI panel ............................................................................................................... 161
Fig. 105. Labels on S500 I/O modules and associated wiring diagram ........................ 163

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Fig. 106. Cable and wire designation ................................................................................. 163
Fig. 107. (A) Assistant control panel and UCU-26: (B) top (C) front and (D)
rear .........................................................................................................................166
Fig. 108. S500 I/O modules in a COU ................................................................................. 167
Fig. 109. Status LEDs on optional air-to-air heat exchangers ........................................ 168
Fig. 110. Safety switch on an ARU/INU cabinet door....................................................... 175
Fig. 111. Safety switch settings ......................................................................................... 175
Fig. 112. Four-way grounding set ....................................................................................... 177
Fig. 113. TEU ground ball stud locations ........................................................................... 178
Fig. 114. ARU/INU ground ball stud locations .................................................................. 179
Fig. 115. Manual output isolation overview ..................................................................... 180
Fig. 116. Tools for removing the busbar connectors ....................................................... 181
Fig. 117. Overview of grounding the drive – (A) INU1 is shut down, and (B)
INU2 is shut down. Numbers indicate the connection sequence. .................. 182
Fig. 118. Connect the grounding sets in (A and C) COU1, (B) TEU1, (D) INU1,
and (E) INU2 .......................................................................................................... 183
Fig. 119. Busbar connector removal sequence in TEU1 or COU1 .................................... 184
Fig. 120. Fitting sequence for busbar connectors ........................................................... 185
Fig. 121. Phase module removal ......................................................................................... 187
Fig. 122. COU filter ............................................................................................................... 190
Fig. 123. Accessing the fan units in the WCU roof box .................................................... 193
Fig. 124. Air-to-air heat exchanger overview (type LT-5-5165-UL) .................................. 194
Fig. 125. Wire connection points on the circuit board ..................................................... 197
Fig. 126. DCS880 controller - size H4 ................................................................................ 204
Fig. 127. DCS880 controller - size H6................................................................................ 206
Fig. 128. Air-to-water heat connections ........................................................................... 209
Fig. 129. Lift heat exchanger out of EXU cabinet ............................................................. 210

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—
TABLES
Table 1 Main components in an ARU/INU cabinet................................................................................37
Table 2 Main components in a 12-pulse LSU cabinet .......................................................................... 39
Table 3 Main components in a CBU cabinet .......................................................................................... 40
Table 4 Main components in a WCU cabinet ......................................................................................... 45
Table 5 BCU braking power.........................................................................................................................51
Table 6 RBU braking power .........................................................................................................................51
Table 7 ABB arc resistant classes.............................................................................................................. 60
Table 8 Lifting attachment specifications ............................................................................................. 68
Table 9 Installation material for AC busbars (COU/TEU – ARU/INU).............................................. 85
Table 10 Installation material for roof joints........................................................................................... 101
Table 11 Cable entry frames for type 1 sealing modules ..................................................................... 114
Table 12 Medium voltage units with safety switches and locking bars ..........................................152
Table 13 Filter mat specifications............................................................................................................. 190
Table 14 Air-to-air heat exchanger specifications .................................................................................194

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1. About this manual
1.1. Product overview
The ACS6080 is a medium voltage drive that can control any type of AC motor, including high-
power induction, synchronous, and permanent magnet motors.
The ACS6080 covers a power range of 3 – 36 MVA and delivers output frequencies of 0 – 75 Hz
in the voltage range up to 3.3 kV.
Modular drive configuration
The ACS6080 has a modular design based on standardized units, each of which are dedicated
to a specific function. The units are combined according to the required output power, motor
configuration and process needs.
1.1.1. Standard applications
Typical fields of applications for the ACS6080 include:
1.2. Equipment covered by this manual
This manual covers standard drive and provides generic information on the drive. The manual
does not claim to cover all variations and details of the drive, nor to consider all eventualities
that may arise during installation, commissioning, operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and handling, installation, and
operation of the drive are affected by these modifications, information on these modifications
is provided in the appropriate documentation (such as layout drawings, wiring diagrams,
project-specific data, engineering notes).
If information is required beyond the instructions in this manual, refer the matter to ABB.
– Marine
• Main propulsion systems
• Thruster drives
– Oil and gas
• Compressors
• Pumps
• Extruders
– Metals and mining
• Rolling mills
• Mine hoists
• Conveyors
• Crushers and mills
– General industry
• Variable speed fans and pumps
• Pump storage plant drives
• Test stand

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1.3. Structure of the user documentation
The documentation for a standard drive consists of this document and the following project-
specific appendices.
NOTE – These appendices are NOT included in this document.
–Appendix A - Additional manuals provides manuals about additional equipment delivered
with the drive (such as project-specific options such as pulse encoder or fieldbus
interfaces), or information on modifications of the standard drive.
–Appendix B - Technical data contains the technical data sheets of the drive.
–Appendix C - Mechanical drawings provides the outline drawings of the drive. The drawings
are generated according to the customer-specific project.
–Appendix D - Wiring diagrams contains the circuit diagrams with information on device
identification, cross-reference and device identification conventions. The diagrams are
generated according to the customer-specific project.
NOTE – “Setting of protective devices” is generated according to the customer-specific
project.
–Appendix E - Parts list is produced for each project and contains all information to identify
a component.
–Appendix F - Test reports and certificates provides the test reports of the drive. Quality
certificates, and codes and standards the drive complies with are added if necessary for the
project.
–Appendix G - Signal and parameter table includes descriptions of actual signals, control
and status words, and control parameters and their default settings.
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.
Term Definition
AC Alternating current
ACS6080 ACS6080 medium voltage AC drive
AI Analog input
ANSI American National Standards Institute
AO Analog Output
APU Auxiliary Pump Unit
ARU
Active Rectifier Unit
The ARU rectifies the voltage of the supply network to the DC voltage and
maintains the DC-link voltage at a constant level irrespective of changes in the
supply network. The unit is designed as a self-commutated, 3-level voltage source
inverter consisting of three identical phase modules. The unit allows
regenerative braking.
ASE Anti Saturation Equipment

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Azipod® ABB’s electric propulsion system for ships
BCON Application and motor controller
BCU Braking Chopper Unit
CBU Capacitor Bank Unit
CCB Converter Control Board
Control panel Serves as the basic user interface for operating and monitoring the drive when the
local operating mode has been selected, also known as assistant control panel.
CHU Charging Unit
CIT Conductivity Transmitter
CIU Customer Interface Unit
Converter Short form for ACS6080 frequency converter
COU
Control Unit
The COU consists of a control compartment and a customer interface
compartment. The control compartment incorporates the hardware for control,
monitoring and protection functions of the drive and the communication interface
to the door-mounted control panel.
CW1 Control water system 1
CW2 Control water system 2
CVMI Current and Voltage Measuring Interface
DBC Drive Backup Control
DC Direct Current
DC_NP DC Neutral Point. Neutral point of the DC link of the drive
DCS Acronym for the AC-to-DC converter or the three-phase AC power controller of an
excitation unit
DDCS Distributed drive control system. DDCS is an acronym for a serial communications
protocol designed for data transfer via optical fibers.
DI Digital Input
DIN Deutsches Institut für Normung (German Institute for Standardization)
DO Digital Output
Drive Synonym for ACS6080 frequency converter
Drive Composer Windows application for commissioning and maintaining ABB drives.
Drive system The drive system includes all equipment for converting electrical into mechanical
power to give motion to the machine.
DTL Direct-to-line
EAF Earth Fault monitoring device
ECB Excitation Circuit Breaker
EIC Excitation Input Contactor
EMC Electromagnetic Compatibility
EOB Excitation Output Breaker
Term Definition

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Equipment Frequency converter and related equipment
EXU Excitation Unit
The EXU supplies excitation power to a synchronous motor.
FBA Fieldbus Adapter
FCB Function Chart Builder
FCI Fieldbus Communication Interface
FFU Fin Fan Unit
FIR filter Fast Impulse Response filter
FIS Flow meter
FT
Firing Through
Synonym for protective firing. Meaning: simultaneous gating of the power
semiconductors of the inverter unit to effectively protect the semiconductors
against overvoltage and overcurrent.
FSCD Fast Short-Circuit Detection
Ground (noun) Earth
ground (verb)
The conducting path (eg, conductor) between the electric equipment (eg,
frequency converter) and the earth. The electric equipment is connected to the
earth, eg, by a grounding set or a grounding switch.
GCT Gate-Commutated Thyristor
GTO Gate Turn-Off thyristor
HVD High Voltage Divider
I/O Input / Output
IEC International Electrotechnical Commission
IFU Input Filter Unit
IGBT Insulated-Gate Bipolar Transistor
IGCT Integrated Gate-Commutated Thyristor
ISU Isolation Unit
IM Induction Motor
INT Interface circuit board
INU
Inverter Unit
The INU converts the three DC voltages to the required AC motor voltage. The unit
is designed as a self-commutated, 3-level voltage source inverter consisting of
three identical power modules.
I/O device Term ABB’s S500 I/O system. An I/O device consists of a module termination unit
(MTU) and one I/O module.
I/O module Term of ABB’s S500 I/O system. The I/O module is an active input or output device
for digital or analog signals.
I/O station Term of ABB’s S500 I/O system. The I/O station typically consists of a bus modem
and several input and output devices.
IOI Inverter Output Isolator
The IOI is a switching device that disconnects the inverter from the motor.
Term Definition

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IP Ingress Protection
The IP code specifies the degree of protection provided by an enclosure.
IPS Isolated Power Supply
Line voltage RMS voltage of the main power supply of the drive
LSU
Line Supply Unit
The LSU rectifies the AC line voltage and supplies the electrical energy to the DC
link capacitors.
MCB
Main Circuit Breaker
The MCB is a major protection device of the drive and the main connection and
disconnection point between the main power supply and the drive.
MP3CModel predictive pulse pattern control
MSM Main State Machine
MVD Medium Voltage Drive
NBIO Fast I/O module
NDBU-95 DDCS branching unit
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
The term refers to the neutral point of the DC link
NTAC Pulse encoder interface module
PAI Pulse Amplifier Interface board
PCB Printed Circuit Board
PE Protective Earth
Ground bus for the connection of the ground cable
PFF Power Feed Forward
PF Power Failure
PG Power Ground
Ground bus for the connection of cable shields
Phase module
The phase module is a compact assembly of wired components including the
power semiconductors that serves as a standardized building block for the ARU,
LSU and INU of the drive.
POM Power Operation Mode
PPCC Power Plate Communication Circuit
PPCS
Power plate communication system
PPCS is an acronym for a serial communication protocol designed for data transfer
via optical fibers between AMC circuit board and INTerface circuit boards
PUB PPCS unit for branching software running on an INT circuit board that is used for
data branching
PUPA Pulse pattern
PWM Pulse width modulation
RAL German color standard
Term Definition

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1.5. Related documents
The following documents are available for supplementary information:
RBU Resistor Braking Unit
RDC Redundant Drive Control
RDI Redundant Drive Interface
RDR Receive Data Register
RMD Rolling Mill Drive
RPM Revolutions Per Minute
S500 I/O The S500 I/O is a distributed process input output system that can be connected
to various process controllers from ABB and other companies.
SC Short-Circuit
SM Synchronous Motor
SRD Semi-Redundant Drive
SSI
Synchronous Serial Interface
The SSI is a point-to-point, serial communication interface for digital data
transmission between a master (eg, drive) and a slave (eg, sensor).
TEU
Terminal Unit
The TEU provides the terminals for the transformer and motor cables, the ground
frame for the cable screens and the ground cable, and the grounding accessories.
THD Total Harmonic Distortion
TT Temperature Transmitter
UCU-26 Control unit that controls converters via fiber optic links and electrical interfaces.
UNICOS Operating system
UPS Uninterruptible Power Supply
USB Universal Serial Bus
VLSCD Voltage Limiting Short Circuit Detection
VLU Voltage Limiter Unit
VSD Variable Speed Drive
VSI Voltage Source Inverter
WCU Water Cooling Unit
The WCU dissipates the heat from the power electronics components of the drive.
Zero speed
threshold
Used in the manual to indicate that the drive has reached the value “zero speed”
that is set in a parameter. The value can be set in the range of 0 and maximum
speed (the unit for the speed is rpm).
1.5.1. Maintenance
Title ABB ID
ACS6080 preventive maintenance schedule 3BHS838899 E01
Term Definition

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1.5.2. Technical data
Title ABB ID
Technical data from drive smart (configuration software for medium voltage
drives)
Air-cooled excitation units, brush brushless excitation technical data 3BHS262785 E01
1.5.3. Schematics
Title ABB ID
Layout drawing Project-specific
1.5.4. Specifications and guidelines
Title ABB ID
Main circuit breaker specification 3BHS125149 E60
ABB MVD ACS Transformer Specification 3BHS356582 E01
ABB MVD ACS Motor Specification 3BHS824803 E01
Technical project Specification Motor 3BHS824804 E01
ABB MVD ACS High Performance Motor Specification 3BHS824805 E01
Power cable specification 3BHS125090 E01
Power cables engineering guideline 3BHS542290 E01
Auxiliary power and control cables guideline 3BHS813742 E01
Voltage transformer requirement specification 3BHS125393 E01
Emergency-off and stop modes and prevention of operation 3BHS196243 E01
Recycling instructions 3BHS122085 E01
Environmental information, material declaration 3BHS360175 E01
Roxtec CF16EMC installation instructions 3BHS820829 E01
ACS6000/ACS6080 label placement 3BHS544773 E01
Painting specification for ACS1000, ACS2000, ACS5000 and
ACS6000/ACS6080
3BHS104301 E01
Wiring and Busbar Specification 3BHS205465 E01
Application note - Air gap torque pulsation limits 3BHS210587 E01
1.5.5. Service
Title ABB ID
Service equipment 3BHS264536 E01