Acs 5000

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SYSTEM DRIVES
ACS5000 water-cooled
User manual
5 – 36 MVA, 6 - 6.9 kV
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General information
Copyright
© 2020 ABB. All rights reserved. The information in this manual
is subject to change without notice.
This document and parts thereof must not be reproduced or
copied, or disclosed to third parties, nor used for any
unauthorized purpose without written permission from
ABB Switzerland Ltd., System Drives.
The hardware and software described in this document is
provided under a license and may be used, copied, or
disclosed only in accordance with the terms of such license.
Document owner
ABB Switzerland Ltd.
System Drives
CH-5300 Turgi, Switzerland
Document name
ACS5000 water-cooled user manual
Document number
3BHS799208 E01 Rev E
Release date
17.06.2020
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new.abb.com/drives/medium-voltage-ac-drives
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Contents
1. About this manual 19
1.1 Equipment covered by this manual 19
1.2 Structure of the user documentation 19
1.3 Related documents 20
1.4 Terms and abbreviations 21
1.5 Trademarks 23
1.6 Target groups and required qualification 24
1.6.1 Handling 24
1.6.2 Mechanical installation 24
1.6.3 Electrical installation 24
1.6.4 Operation 24
1.6.5 Maintenance 25
1.7 User’s responsibilities 25
1.8 Intended use of equipment 25
1.9 Cyber security disclaimer 25
1.10 Quality certificates and applicable standards 27
1.11 Items covered by delivery 28
1.11.1 Identifying the delivery 28
1.12 Tools 28
2. Important safety information 29
2.1 Safety standards 29
2.2 Safety messages 29
2.3 Product safety labels 30
2.4 General safety instructions 31
2.5 The 7 steps that save lives 32

2.6 Possible residual risks 34
2.7 Important note - main circuit breaker 35
2.7.1 Safety and protection requirements 36
2.7.3 Maintenance recommendation 36
3. Power electronics and cabinet features 37
3.1 Main features of the drive 37
3.2 Frame sizes 40
3.3 Phase converter unit (PCU) 41
3.3.1 Primary phase converter unit (1700 mm and 2100 mm) 41
3.3.2 Secondary phase converter unit (1700 mm and 2100

mm) 46
3.4 Control unit (COU) 47
3.4.1 Main components 48
3.4.1.1 AMC circuit board 49
3.5 Transformer and motor cable terminals 54
3.5.1 Transformer cable terminals 54
3.5.2 Motor cable terminals 54
3.6 Water cooling unit (WCU) 56
3.7 EXU – Excitation unit (optional) 57
3.8 Door interlocking system 59
3.9 Grounding switches 60
3.9.1 Locking bars 61
3.10 Grounding studs 62
3.10.1 Grounding set 62
3.10.2 Output grounding studs in COU 63
3.10.3 Input grounding studs in a PCU 64
4. Transportation, storage and disposal 65
4.1 Safety 65
4.2 Transport conditions 65
4.3 Unpacking and inspection 65
4.4 Identifying drive units 66
4.4.1 Packing list 66
4.4.2 Packing label 67
4.5 Lifting and transportation 67
4.5.1 Using a crane to lift a transport unit or the drive

by the base frame 68
4.6 Storage 70
4.6.1 Storage conditions 70
4.6.2 Storage 70
4.7 Storage and handling of spare parts 71
4.7.1 Warranty information 71
4.8 Disposal of packaging materials and components 72
5. Mechanical installation 73
5.1 Safety 73
5.2 Overview on installation work 73
5.3 General notes on installation 74
5.4 Dimensions and clearances 74
5.4.1 Rear and top access to the cabinet 74
5.4.2 Cabinet roof 74
5.4.3 Fire protection 74
5.4.4 Cable duct material 74
5.4.5 Installation material 74
5.4.6 Tools 74
5.5 Preparing the installation site 75
5.6 Aligning transport units 75
5.7 Joining transport units 77

5.8 Applying silicone 78
5.9 Installing roof joints 78
5.10 Installing roof-mounted cooling units 79
5.10.1 Lifting a unit with a crane 79
5.10.2 Installing IP42 roof-mounted cooling units 80
5.10.3 Installing IP54 roof-mounted cooling units 82
5.11 Installing roof attachments 84
5.12 Joining water pipes 86
5.12.1 Removing a pipe joint 86
5.13 Joining busbars 87
5.14 Connecting the heating cable 89
5.15 Connecting raw water pipes 90
5.16 Fixing the drive to the floor 90
6. Electrical installation 91
6.1 Safety 91
6.2 Overview 91
6.3 Cable requirements 92
6.3.1 Power cables 92
6.3.2 Auxiliary and control cables 92
6.4 Grounding 93
6.4.1 Grounding the transformer and the drive 93
6.4.2 Grounding the drive and the motor (multi-point bonding) 94
6.4.3 Grounding the drive and the motor (single-point

bonding) 95
6.4.4 Ground cable connection 96
6.5 Internal wiring 97
6.5.1 Optical fibers 98
6.6 Cable entries 101

6.6.1 Cable entry with sealing modules, type 1 101
6.6.2 Cable entry with sealing modules, type 2 103
6.6.3 Cable entry with cable glands 103
6.6.4 Cable entry with EMC plates 104
6.7 Power cables, ground cables, equipotential

bonding conductor 105
6.7.1 Preparing the cable entry and the cables 105
6.7.1.1 Determining the cable length 105
6.7.1.2 Preparing cables for cable entries with cable glands 106
6.7.1.3 Preparing cables for cable entries with sealing modules 107
6.7.2 Connecting the cables 108
6.7.2.1 Checking the cable insulation 108
6.7.2.2 Connecting the cables 109
6.7.2.3 Bolted connections 111
6.8 Auxiliary power cables and control cables 112
6.8.1 Preparing the cable entry and the cables 112
6.8.1.1 Preparing cables for cable entries with sealing modules 114
6.8.1.2 Preparing cables for cable entries with cable glands 115
6.8.2 Connecting the cables 115
6.8.2.1 Connecting auxiliary power cables and space heater

cables in WCU 116
6.8.2.2 Connecting cables in COU 117
7. Commissioning 119
7.1 Required qualification 119
7.2 Commissioning procedure 119
7.3 Commissioning checklist 119
7.4 Customer assistance 119
7.5 Customer acceptance 119

7.6 Commissioning checklists 120
7.6.1 Mechanical installation checklist 120
7.6.2 Electrical installation checklist 120
7.6.3 Door interlocking checklist 121
7.6.4 Main circuit breaker (MCB) 121
7.6.5 Input transformer checklist 121
7.6.6 Motor checklist 122
7.6.7 Insulation tests checklist 122
7.6.8 Power checklist 122
7.6.9 Miscellaneous checklist 122
8. Operation 123
8.1 Operating conditions 123
8.2 Safety 123
8.3 Overview 123
8.4 Local operator panel 123
8.5 Lamp-test function 125
8.6 Status messages 125
8.6.1 Start sequence of the drive 127
8.6.2 Stop sequence of the drive 128
8.6.3 Emergency-off sequence 129
8.7 Starting the drive 129
8.7.1 Checks before starting the drive 130
8.7.2 Starting the drive from remote 130
8.7.3 Starting the drive locally 130
8.8 Stopping the drive 133
8.9 Emergency-off 134
8.9.1 Initiating an emergency off 134

8.9.2 Starting the drive system after an emergency-off 134
8.10 Arc resistant design 136
8.10.1 Internal arc classification (IAC) 136
8.10.2 Arc detection with the Arc Guard System™ 137
8.10.3 Action after the Arc Guard System™ has been triggered 137
8.11 De-energizing and grounding the drive 138
8.12 Opening the doors 138
9. CDP control panel 139
9.1 Overview 139
9.1.1 Display and keypad 139
9.1.2 Functions 140
9.2 Modes 140
9.2.1 Identification mode 140
9.2.2 Actual signals mode 142
9.2.2.1 Overview 142
9.2.2.2 Selecting the actual signals display 143
9.2.2.3 Toggling between actual signals display and fault

memory 144
9.2.2.4 Displaying three actual signals 144
9.2.2.5 Selecting actual signals 144
9.2.2.6 Displaying a fault and resetting the fault memory 146
9.2.2.7 Displaying and resetting an active fault 148
9.2.3 Parameters mode 149
9.2.3.1 Overview 150
9.2.3.2 Changing a parameter setting 151
9.2.3.3 Enabling / unlocking a parameter lock 153
9.2.3.4 User lock 153
9.2.4 Functions mode 154

9.2.4.1 Adjusting the display contrast 154
9.2.5 Local and remote control mode 156
9.2.5.1 Local control 156
9.2.5.2 Disabling / enabling local lock function 156
9.2.5.3 Enabling the local lock 157
9.2.5.4 Remote control 157
9.3 Operational commands 158
9.3.1 Setting the direction of rotation 158
9.3.2 Entering a reference value 159
10. Preventive and corrective maintenance 161
10.1 General information 161
10.1.1 Required qualification 161
10.1.2 Maintenance schedule 161
10.1.3 Logbook 161
10.1.4 Spare parts 161
10.2 Identifying electrical equipment 161
10.2.1 Device designation 161
10.2.2 Cables and wires 162
10.2.3 Understanding wiring diagrams 162
10.3 Alarm / fault indications 163
10.3.1 Messages 163
10.3.2 Error message levels 163
10.3.2.1 Alarm 163
10.3.2.2 Fault 163
10.3.2.3 Alarm / fault messages 164
10.3.3 Fault handling 164
10.3.4 Standard troubleshooting procedure 165

10.4 Removing the CDP control panel 165
10.5 LEDs and switches on circuit boards and I/O devices 166
10.5.1 AMC circuit board 167
10.5.2 S800 I/O bus modem TB820 168
10.5.2.1 Bus modem address 168
10.5.3 S800 I/O modules 169
10.6 Corrective maintenance 169
10.6.1 Safety 171
10.6.2 De-energizing the drive 172
10.6.2.1 Stopping the motor 172
10.6.2.2 De-energizing the drive 172
10.6.3 Opening and closing the doors 174
10.6.4 Grounding switch is not released 176
10.6.5 Emergency release of a door safety switch 177
10.6.5.1 Location of safety switches 177
10.6.5.2 Safety-switch settings 178
10.6.6 Visual checks on the drive 179
10.6.7 Cleaning§ 180
10.6.7.1 Cleaning the drive cabinet 180
10.6.8 Checking wire and cable connections 181
10.6.9 Checking and replacing filter mats 181
10.6.9.1 Location 181
10.6.9.2 Replacing filter mats 181
10.6.10 Replacing a door-mounted fan 182
10.6.11 Replacing a fan of an IP42 roof-mounted cooling unit 183
10.6.11.1 Replacing a fan 183
10.6.12 Replacing a fan of an IP54 roof-mounted cooling unit 184
10.6.12.1 Replacing a fan 184

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Figures
Figure 1-1 Typical delivery 28
Figure 2-1 Product warning label examples

(label placement depends on the drive) 30
Figure 2-2 Drive system overview 35
Figure 3-1 Typical block diagram of the drive 37
Figure 3-2 Switching levels 38
Figure 3-3 Principle of 9-level topology 38
Figure 3-4 IGCT 39
Figure 3-5 Frame sizes 1 – 4 40
Figure 3-6 Primary PCU, 1700 mm 42
Figure 3-7 Primary PCU, 1700 mm: side view left (A) and
side view right (B) 43
Figure 3-8 Primary PCU, 2100 mm 44
Figure 3-9 Primary PCU, 2100 mm: side view left (A) and
side view right (B) 45
Figure 3-10 Secondary PCU, 1700 mm (A) and 2100 mm (B) 46
Figure 3-11 Block diagram of control system 47
Figure 3-12 COU control section 48
Figure 3-13 DTC torque control 50
Figure 3-14 Local control panel 52
Figure 3-15 COU customer interface section 53
Figure 3-16 Motor terminal section of frame size 1 and 2:

bottom entry (A) and top entry (B) 54
Figure 3-17 Motor terminal section of frame size 3 and 4:

bottom entry (A) and top entry (B) 55
Figure 3-18 WCU (1400 mm), frame size 3 56
Figure 3-19 EXU 57

Figure 3-20 EXU control panel 58
Figure 3-21 Location of protection features and lights 59
Figure 3-22 Grounding switch 60
Figure 3-23 Locking bar and white lamp 61
Figure 3-24 Grounding stud 62
Figure 3-25 4-way grounding set 62
Figure 3-26 Connection studs for the 4-way grounding set in

the COU 63
Figure 3-27 Connection studs for the 4-way grounding set in

a PCU 64
Figure 4-1 Lifting bracket on base frame of a drive and

safety hook secured to lifting bracket 68
Figure 4-2 Lift frame and lift spreader 69
Figure 5-1 Floor inclination 75
Figure 5-2 Connection points on side of transport units (PCU

example) 77
Figure 5-3 Applying silicone 78
Figure 5-4 Roof joint 78
Figure 5-5 Lifting a cooling unit (example with IP54 unit) 79
Figure 5-6 Cable duct openings (example with 1700 mm PCU) 81
Figure 5-7 Water inlet / outlet and drain outlet (back view) 83
Figure 5-8 Roof attachment 84
Figure 5-9 Recommended ceiling and wall fixings 85
Figure 5-10 Busbar connections 87
Figure 5-11 AC busbar connection 88
Figure 5-12 PE ground busbar connection 88
Figure 5-13 DC busbar connection 88
Figure 5-14 Heating cable connection 89
Figure 6-1 Grounding the transformer and the drive (in PCU) 93
Figure 6-2 Grounding the drive and the motor (multi-point
bonding) 94
Figure 6-3 Grounding the drive and the motor (single-point

bonding) 95
Figure 6-4 PE ground busbar in COU (back view) 96
Figure 6-5 PE ground busbar in PCU (back view) 96
Figure 6-6 Wiring across shipping splits, frame size 1 (A)

and 2 (B) 99
Figure 6-7 Wiring across shipping splits, frame size 3 and 4 100
Figure 6-8 Cable entry with sealing modules – type 1 101
Figure 6-9 Cable entry frame sizes (top) for type 1 sealing
modules (bottom) 102
Figure 6-10 Cable entry with sealing modules – type 1 103
Figure 6-11 Cable entry with cable gland 103
Figure 6-12 Cable entry with EMC plates 104
Figure 6-13 Preparing power cables for cable glands 106
Figure 6-14 Preparing power cables for sealing modules 107
Figure 6-15 PCU cable terminals, top and bottom entry (back
view) 109
Figure 6-16 COU cable terminals, top and bottom entry (back
view) - frame sizes 1 and 2 (A) and 3 and
4 (B) 110
Figure 6-17 Bolted busbar connection 111
Figure 6-18 Preparing control cables for EMC plates 113
Figure 6-19 Preparing control cables for sealing modules 114
Figure 6-20 Preparing control cables for cable glands 115
Figure 6-21 Cable routing in WCU800 (A) and WCU1400 (B)

cabinets 116
Figure 6-22 Shield grounding clamp 117
Figure 6-23 COU customer interface section 117

Figure 8-1 Local operator panel 124
Figure 8-2 IAC label example 136
Figure 8-3 Arc Guard™ system with HMI panel 137
Figure 8-4 HMI panel 137
Figure 9-1 CDP control panel 139
Figure 9-2 Control panel functions for Actual signals mode 142
Figure 9-3 Control panel functions for Parameters mode 149
Figure 9-4 Control panel functions for Functions mode 154
Figure 10-1 Device identification 162
Figure 10-2 Cable and wire designation 162
Figure 10-3 LEDs of AMC circuit board 167
Figure 10-4 TB820 bus modem 168
Figure 10-5 Example of S800 I/O station 169
Figure 10-6 Location of safety switches 177
Figure 10-7 Safety switch 178
Figure 10-8 Filter mat replacement for PCU (A) and WCU (B) 182
Figure 10-9 Roof-mounted cooling unit (IP42) 183
Figure 10-10 Roof-mounted cooling unit (IP54) 184

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Table
Table 1-1 Maintenance 20
Table 1-2 Technical data 20
Table 1-3 Schematics 20
Table 1-4 Specifications and guidelines 20
Table 1-5 Manuals 20
Table 1-6 I/O interface 21
Table 1-7 Serial communications interfaces 21
Table 1-8 Terms and abbreviations 21
Table 1-9 Trademarks 23
Table 1-10 Standards 27
Table 3-1 Line-up specifications by frame size 40
Table 5-1 Installation material per roof joint 78
Table 5-2 Installation material per IP42 unit 80
Table 5-3 Installation material per IP54 unit 82
Table 6-1 Type 1 sealing modules and cables per frame

opening 102
Table 6-2 Maximum number of type 1 sealing modules per

frame opening 102
Table 6-3 Maximum number of cables per frame opening -

3 core 102
Table 6-4 Maximum number of cables per frame opening -

single core 102
Table 8-1 ABB arc resistant classes 136
Table 10-1 Filter mat specifications 181

1. About this manual
1.1 Equipment covered by this manual

This manual covers standard drive and provides generic information on
the drive. The manual does not claim to cover all variations and details of
the drive, nor to consider all eventualities that may arise during
installation, commissioning, operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and
handling, installation, and operation of the drive are affected by these
modifications, information on these modifications is provided in the
appropriate documentation (such as layout drawings, wiring diagrams,
project-specific data, engineering notes).
If information is required beyond the instructions in this manual, refer the
matter to ABB.
1.2 Structure of the user documentation

The complete set of user documentation of a standard drive consists of
this manual and supplementary documentation that is provided in the
following appendices:
• Appendix A - Additional manuals: provides manuals about additional
equipment delivered with the drive (such as project-specific
options like pulse encoder or fieldbus interfaces), or information on
modifications of the standard drive.
• Appendix B - Technical data: contains the technical data sheets of
the drive.
• Appendix C - Mechanical drawings: provides the outline drawings of
the drive. The drawings are generated according to the customer-
specific project.
• Appendix D - Wiring diagrams contains the circuit diagrams with
information on device identification, cross-reference and device
identification conventions. The diagrams are generated according
to the customer-specific project. “Setting of protective devices” is
generated according to the customer-specific project.
• Appendix E - Parts list: produced for each project and contains all
information to identify a component.
• Appendix F - Test reports and certificates: provides the test reports of
the drive. Quality certificates, and codes and standards the drive
complies with are added if necessary for the project.
• Appendix G - Signal and parameter table: includes descriptions of
actual signals, control and status words, and control parameters
and their default settings.
3BHS799208 E01 REV E ACS5000 WATER-COOLED USER MANUAL 19/186

01 ABOUT THIS MANUAL
1.3 Related documents

The following documents are available for supplementary information:
Table 1-1 Maintenance
Title Document number

[1] ACS5000 preventive maintenance schedule 3BHS855274 E01
[2] Permission for working and permit to work for 3BHS817511 E30
test work at test stations
Table 1-2 Technical data
[3] Technical data from DriveSmart (1)

(1)
Configuration software for medium voltage drives
Table 1-3 Schematics

[4] Layout drawing Project-specific
Table 1-4 Specifications and guidelines

[5] Generic transformer specification 3BHS356582 E01
[6] Generic motor specification 3BHS824803 E01
[7] Main circuit breaker engineering guideline 3BHS125149 E50
[8] ACS5000 power cable specification 3BHS215798 E01
[9] Power cables engineering guideline 3BHS542290 E01
[10] Auxiliary power and control cables guideline 3BHS813742 E01
[11] Customer interface 3BHS347034 E03
Table 1-5 Manuals

[12] ACS5000 Service manual 3BHS264270 E20
[13] Air-cooled excitation units user manual 3BHS252500 E01

Table 1-6 I/O interface
[14] S800 I/O Getting started (1) 3BSE020923
[15] S800 I/O Modules and Termination Units (1) 3BSE020924
(1)
Also available online in the ABB Library (https://library.abb.com)
Table 1-7 Serial communications interfaces

[16] Ethernet - NETA-21 remote monitoring tool 3AUA0000096939
(1)
user manual
[17] Modbus - NMBA-01 installation and 3AFY58919772
(1)
start-up guide
[18] Profibus - NPBA-12 installation and 3BFE64341588
(1)
start-up guide
(1)
Also available online in the ABB Library (https://library.abb.com)
1.4 Terms and abbreviations

The following table lists terms and abbreviations you should be familiar
with when using this user manual. Some of the terms and abbreviations
used in this user manual are unique to ABB and might differ from the
normal usage.
Table 1-8 Terms and abbreviations
Term/Abbreviation Definition
AMC The application and motor controller (AMC) is a digital
signal processor and the heart of the drive
control system.
Converter Short form for ACS5000 frequency converter
COU The control unit (COU) consists of a control section, a
customer interface section and a terminal section.
The control section incorporates the hardware for
control, monitoring and protection functions of the drive
and the communication interface to the door-mounted
CDP control panel.
The COU compartment also incorporates the grounding
frame for cable screens and the ground cable, the
grounding accessories and the motor terminal section.
CVMI Current voltage measurement interface
Drive Synonym for ACS5000 frequency converter

Table 1-8 Terms and abbreviations (continued)
DriveDebug DriveDebug is part of ABB’s DriveWare® software tools for
devices using the DDCS communications protocol.
DriveDebug runs on computers with Microsoft Windows®
operating systems. DriveDebug is a specialist tool used to
diagnose, tune and troubleshoot frequency converters.
DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a
32-bit Microsoft Windows® application for
commissioning and maintaining ABB drives equipped
with optical communication links.
DriveMonitor DriveMonitor is a monitoring and diagnostics system that
allows secure access to the frequency converter via the
Internet from a remote location. DriveMonitor provides
long-term monitoring functions that allow to infer
equipment status and improve equipment performance.
EAF Earth fault monitoring
EMC Electromagnetic compatibility
EOI Electrical-optical interface
Equipment Frequency converter and related equipment
EXU The excitation unit (EXU) is part of the drive when a
synchronous motor has to be supplied with excitation
power.
Ground Earth
To ground To connect the electrical equipment to the earth, eg, by a
grounding set or a grounding switch.
I/O device Term of ABB’s S800 I/O process system. An I/O device
consists of a module termination unit (MTU) and one I/O
module.
I/O module Term of ABB’s S800 I/O process system. The I/O module
is an active input or output device for digital or analog
signals.
I/O station Term of ABB’s S800 I/O process system. The I/O station
typically consists of a bus modem and several input and
output devices.
IGCT Integrated gate-commutated thyristor
IPS Insulated power supply
LED Light emitting diode
LSU Line supply unit (rectifier phase module)
MCB The main circuit breaker (MCB) is a major protection
device of the drive system and connects and / or
disconnects the main power supply to the drive.

Table 1-8 Terms and abbreviations (continued)
Motor terminal This is the customer terminal for connecting motor
section cables. It is located behind the swing frame of the COU
compartment.
NP Neutral point
OEI Optical-electrical interrupter
PCU A primary phase converter unit (PCU) consists of a
transformer terminal section, a rectifier stack, a DC link
and an inverter stack.
A secondary phase converter unit consists of a DC link and
an inverter stack.
Phase module The phase module is a compact assembly of wired
components including power semiconductors and circuit
boards that serves as a standardized building block for
the inverter and rectifier stack.
PINT Pulse interface
SW Software
S800 I/O The S800 I/O is a distributed process input / output
system that can be connected to various process
controllers from ABB and other companies.
Transformer This is the customer terminal for connecting transformer
terminal section cables. It is located in the back of the PCU compartment.
WCU The water cooling unit (WCU) dissipates heat losses of
the power electronics.
1.5 Trademarks
Names that are believed to be trademarks of other companies and
organizations are designated as such. The absence or presence of such a
designation should however not be regarded as an offense of the legal
status of any trademark. The following registrations and trademarks are
used in this manual:
Table 1-9 Trademarks
Trademark Description
ABB Ability™ Registered trademark of ABB
Arc Guard System™ Registered trademark of ABB
DeviceNet® Registered trademark of the Open DeviceNet Vendor
Association, Inc.
DriveWare® Registered trademark of ABB
Ethernet® Registered trademark of Xerox Corporation
Industrial IT™ Trademark of ABB

Table 1-9 Trademarks
Trademark Description
Modbus® Registered trademark of the Modbus Organization, Inc.
Profibus® Registered trademark of Profibus International (PI)
Windows® Registered trademark of Microsoft Corporation
1.6 Target groups and required qualification

The drive presented in this manual is part of an industrial environment
where voltages are present that contain a potential hazard of electric
shock and / or burn. For this reason, only personnel who have a thorough
knowledge of the drive and the industrial environment and have obtained
the required qualification should handle, install, operate, or maintain
the drive.
The manual addresses personnel who are responsible for unpacking,
transportation, installation, operation and maintenance of the drive. The
personnel must carry out the below listed tasks in a manner that does not
cause physical harm or danger, and ensures the safe and reliable
functioning of the drive.
IMPORTANT! Commissioning of the drive must only be performed by
qualified and certified ABB personnel
1.6.1 Handling
Personnel must be skilled and experienced in unpacking and transporting
heavy equipment.
1.6.2 Mechanical installation

The personnel must be qualified to prepare the installation site according
to the site and equipment requirements and to perform the installation
accordingly.
1.6.3 Electrical installation

Personnel must have a sound knowledge of the relevant electrical codes
and specifications covering low and medium voltage equipment, be
experienced with electrical wiring principles and know the electrical
symbols typically used in wiring diagrams.
1.6.4 Operation
The personnel include all persons who operate the drive from the local
operator panel of the drive. The personnel must know the functions of the
operator panel, be adequately trained for the drive, and know the driven
process. Special knowledge of frequency converter technology is
not required.

1.6.5 Maintenance
The personnel include all persons who
• Are qualified to carry out preventive and corrective maintenance on
drive as described in this manual
• Are thoroughly familiar with the drive
• Have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment
• Are able to assess the hazards associated with the energy sources
of the drive and
act correspondingly
• Know the safe shutdown and grounding procedures for the drive
system
1.7 User’s responsibilities

It is the responsibility of those in charge of the drive to ensure that each
person involved in the installation, operation or maintenance of the drive
has received the appropriate training and has thoroughly read and clearly
understood the instructions in this manual and the relevant safety
instructions.
1.8 Intended use of equipment

Those in charge of the drive must ensure that the drive is only used as
specified in the contractual documents, operated under the conditions
stipulated in the technical specifications and on the rating plate of the
drive, and serviced in the intervals specified by ABB.
Use of the drive outside the scope of the specifications is not permitted.
Intended equipment use also implies that only spare parts recommended
and approved by ABB must be used.
Unauthorized modifications and constructional changes of the drive are
not permitted.
1.9 Cyber security disclaimer

This product is designed to be connected to and to communicate
information and data via a network interface. It is the customer's
sole responsibility to provide and continuously ensure a secure
connection between the product and Customer network or any other
network (as the case may be).

Customer shall establish and maintain any appropriate measures (such as

but not limited to the installation of firewalls, application of
authentication measures, encryption of data, installation of anti-virus
programs, etc) to protect the product, the network, its system and the
interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and/or theft of data
or information.
ABB and its affiliates are not liable for damages and/or losses related to
such security breaches, any unauthorized access, interference, intrusion,
leakage and/or theft of data or information.

1.10 Quality certificates and applicable standards

The following certificates and conformity declarations are available
with ABB:
• ISO 9001 and ISO 14001 certificates stating that ABB Switzerland
Ltd has implemented and maintains a management system which
fulfills the requirements of the normative standards
• EC declaration of conformity
• List of standards the drive complies with
Table 1-10 Standards
Title
[19] ANSI Z535.6 American national standard for product safety information in
product manuals, instructions, and other collateral materials
[20] ISO 3864-2 :2004 (E) - ‘Graphical symbols – Safety colors and safety signs
– Part 2: Design principles for product safety labels’
[21] ISO 7010 :2011 (E) - Graphical symbols - Safety colours and safety signs -
Registered safety sign
[22] EN 50110 European standard code for electrical work safety
[23] ISO 13849-1 Safety of machinery - Safety-related parts of control systems
- Part 1: General principles for design, section 6.2.6 Category 3
[24] IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
[25] IEC 60721-3-2 Classification of environmental conditions: Classification of
groups of environmental parameters and their severities; Transportation
[26] IEC 60721-3-1 Classification of environmental conditions: Classification of
groups of environmental parameters and their severities; Storage
[27] IEC 60721-3-3 Stationary use at weather-protected locations
[28] IEC 62477-2 Safety requirements for power electronic converter systems
and equipment – Part 2: Power electronic converters from 1 000 V AC or 1 500 V
DC up to 36 kV AC or 54 kV DC

1.11 Items covered by delivery

The delivery includes the following items, whereas items 3 – 5 are shipped
in a separate container.
1 2
3 5
Figure 1-1 Typical delivery

(1) Drive (either frame size): Shipped (4) Roof attachments (only for marine
in transport units. Shipping splits drives)
are defined in the customer- (5) Door keys
specific layout drawing.
(2) Rating plate: on the first door
from the left.
(3) Roof joints
1.11.1 Identifying the delivery

The drive and accessories are identified by the type code printed on the
rating label.
The rating label is located on the back of the control compartment door.
The label provides information on the type of drive, the rated voltage, the
frequency and the current of the main and the auxiliary power supply.
1.12 Tools
ABB offers various tool sets containing all necessary tools and equipment
for installation, commissioning and maintenance of the drive. The content
of the tool sets is described in the manual Service equipment.

2. Important safety information
Read this material carefully before working on or around the equipment.
Failure to do so can result in serious Injury or DEATH! Keep for
future reference.
2.1 Safety standards

The following industry standards are observed:
• ANSI Z535.6
• ISO 3864-2
• ISO 7010
• EN 50110
2.2 Safety messages

The following safety messages are provided to help prevent personal
injury and damage to the equipment. The indicated hazard level is based
on the ANSI Z535.6 standard.
This is the safety alert symbol. It is used to alert you to potential physical
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
▲ DANGER
⚠
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
▲ WARNING
⚠
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
⚠ CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury.
▲NOTICE
Is used to address practices not related to physical injury, but which can
result in equipment damage.

02 IMPORTANT SAFETY INFORMATION
2.3 Product safety labels

Safety labels are affixed to the drive components to alert personnel of
potential hazards when working on the equipment. For more information,
see the label placement document for the drive. The instructions on the
safety labels must always be followed and the labels must be kept in a
perfectly legible condition.
1 3
2 4
Figure 2-1 Product warning label examples

(label placement depends on the drive)
(1) Danger label (3) Caution label
(2) Warning label (4) Notice label
Additional safety labels, including the following, might also be provided:
Electricity warning
This sign can also have additional text below it, eg, “High voltage”.
No access for people with active implanted cardiac device

The magnetic field of the drive can influence the functioning of
pacemakers. The pacemaker sign should be installed at the entrance to
the drive room or at a minimum distance of 6 m from the drive to stop
personnel with pacemakers approaching the drive.
Firefighting sign
Outlines the procedure when fighting fire in electrical equipment. The
sign must be installed well visible near the drive.
High voltage sign
Must be installed clearly visible at the main circuit breaker in the
switchgear room. The sign alerts personnel to the high voltage which can
be present on the secondary side of the input transformer until the main
circuit breaker has been opened and secured and the drive has been de-
energized and grounded.

2.4 General safety instructions

1) Minimize hazards
2) Before energizing the drive:

• Remove all foreign objects are from the drive
• Fasten all internal and external covers securely
• Close, lock, and/or bolt all doors
• Move the release dial of the door safety switches into the
locked position
3) Before working on the drive:
• Turn off, lock out, and tag out the main and auxiliary power supplies
to the drive
• De-energize the drive
• Ensure that the safety ground connections are in place
• Ensure that the appropriate personal protective equipment (PPE) is
available and used when required
• Inform the involved personnel about the potential safety hazards
• Wear hearing protection when a drive is running.
4) Before working simultaneously on the drive and on other drive
system equipment:
• Observe the relevant safety codes and standards
• Turn off all energy sources for the equipment
• Ensure that all lockout and tagout devices are in place
• Install barriers around and use appropriate covers on the
equipment that is still energized
• Inform the involved personnel about the potential safety hazards
5) In case of fire in the drive room:
• Observe the established rules and regulations for fire safety
• Only allow firefighters with the appropriate PPE to enter the
drive room

2.5 The 7 steps that save lives

ABB’s 7 steps that save lives concept is a series of actions that must take
place prior to commencing work on or near electrical installations.
1) Prepare for the work: do an on-site risk assessment or job hazard

analysis that considers the limits of approach for shock and arc-flash.
• Be in possession of a clear work order to execute the work.
• When required, the access or work permit is to be obtained by a
person who is authorized for the specific electrical system.
• Engage the person responsible for electrical equipment or system
to review single-line diagrams, schematics, switching plans, etc.
• Ensure the competence of workers.
• Check for proper tools for the job.
• Determine and select the proper arc-rated Personal Protective
Equipment (PPE).
• Decide of the appropriate work methods and initiate the Permit To
Work (PTW) process.
• For an example “Permit to Work”, see "Permission for working and
permit to work for test work at test stations" (3BHS817511 E30)
2) Clearly identify the work location and equipment.

• Use your senses (sight, hearing and smell) to identify
problem areas.
• Define the work area via barriers and barricading and
label equipment.
• Avoid distractions such as talking or texting on the phone.
3a) Disconnect all sources of supply.

• If ABB is responsible for switching and it cannot be done remotely,
then the person performing the switching must be properly trained
and wearing the proper PPE identified in step 1.
• The Person in Charge of Work (PICW) must ensure that switching is
performed in the proper manner by witnessing it from a safe
distance if present on site or by engaging the person responsible
for switching to identify all isolation points.
3b) Secure against reconnection by applying Lockout/Tagout.

• Apply Lockout/Tagout (LOTO) to the energy isolation device and if
multiple energy isolation devices are involved, then Group LOTO
must be implemented with the PICW serving as the
Group LOTO Leader.

4) Verify the absence of operating voltage: always test before you touch!
Only use properly rated and inspected voltage detection devices and
wear proper PPE identified in step 1:
• Test voltage detection device
• Test for voltage
• Test voltage detection device
It is highly important that the voltage detection device is tested on a
known voltage source such as a Proving Unit or by performing an
internal self-test, according to the manufacturer’s instructions,
before and after testing for the absence of operating voltage.
5) Carry out earthing and short-circuiting.

• Close and lock the earthing switch if the electrical equipment is
designed for this purpose or apply portable equipment for earthing
and short-circuiting.
If this is carried out by the customer, then the PICW must ensure
that this equipment is properly earthed as a part of the integration/
verification and during step 7 when the PICW walks the PTW.
6) Protect against adjacent live parts and take special precautions when
close to bare conductors.
• Determine minimum approach distances, apply screening or
shrouding, and when applicable, padlock both cable and
busbar shutters.
• If working within the restricted approach boundary or vicinity zone
where inadvertent movement could cause contact with live parts,
special precautions must be employed, such as the use of the
properly rated insulated gloves and tools.
7) Complete the permit to work and “Walk the Permit”.

• Check isolation points
• Verify that all circuits are isolated and secured
• Ensure all parties are integrated with the Lockout/Tagout
• Check the earths are properly applied
• Answer specific questions from the working group
• Ensure the work can proceed without danger
• Complete and verify the “Permit to Work”

2.6 Possible residual risks

Residual risks must be considered by the drive system integrator and/or
plant owner when assessing the hazards of the equipment to personnel.
The following risks can pose a hazard to drive system personnel:
1) Electric power equipment generates electro-magnetic fields which can

cause a hazard to people with metal implants and / or a pacemaker.
2) Drive system components can move unintentionally when being

commissioned, operated, or serviced due to:
• Operation of the equipment outside the scope of the specifications
• Incorrectly assembled or installed equipment
• Wrongly connected cables
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware
3) Hazardous touch voltages can be present on drive system

components, which can be caused by:
• External influence on, or damage of the equipment
• Induced voltages by external equipment
• Condensation on equipment components, or pollution
• Faulty hardware
4) High temperatures, noise, particles, or gases can be emitted from

drive system components caused by:
• External influence on or damage of the equipment
• Incorrect parameter settings
• Software errors
• Faulty hardware
5) Hazardous substances can be emitted from drive system components

caused by:
• Incorrect disposal of components

2.7 Important note - main circuit breaker

The main circuit breaker (MCB) is a major protection device of the drive. If
a serious fault occurs in the drive, the MCB must disconnect the main
power supply to the drive immediately. The main power supply must be
disconnected without delay on an open or trip command from the drive to
prevent hazard to the personnel and further damage to the equipment.
The MCB is located on the primary side of the converter transformer.
5 6 7 8
Figure 2-2 Drive system overview

(1) Main power supply (6) Protection relay
(2) MCB control interface (7) Converter transformer
(3) Higher-level control system (8) Drive
(4) Local MCB control (9) Motor
(5) MCB
The MCB is defined as a switching device to disconnect the power supply

whenever required by the process or when a fault occurs. Typical devices
used as MCBs are:
• Vacuum circuit breakers
• SF6 circuit breakers
• Fused contactors or motor control centers
A dedicated protection relay is used for:
• Transformer primary cable protection
• Transformer protection (if applicable)
• Transformer secondary cable protection (if applicable)
• Backing up the drive protection
In general, these protective measures are not included in the drive as
provided by ABB.

2.7.1 Safety and protection requirements

For safety and protection reasons, the MCB must meet the stipulated
minimum requirements of the specifications of ABB MV Drives. It is the
system integrator's responsibility to ensure that the minimum
requirements are met. The minimum requirements for the MCB are stated
in this note and in the respective MCB engineering guideline, which are
available for each medium voltage drive from ABB.
The safety requirements for the drive are based on the
following standards:
• ISO 13849-1
• IEC 60204-1
2.7.2 Minimum requirements for MCB and MCB control

• The MCB open and / or trip command has to be wired directly from
the drive to the MCB.
It is not permitted to wire the trip command through any PLC or
DCS system if it is not certified to meet SIL three-level requirements
and to fulfill the timing requirements outlined below.
Opening of the MCB by the drive must be possible at any time. It is
not permitted to interrupt the open and / or trip command, eg, by
a local-remote switch in the MCB.
When the MCB is in service position, the drive must have exclusive
control of closing the MCB. Local closing of the MCB is
not permitted.
• The maximum opening time of the MCB must never exceed the
product- or project-specific maximum time defined in the MCB
specifications. Typical maximum values for the drive are defined
as follows:
- Ma x im um p rotec tion tr ip tim e: 75 ms
The maximum protection trip time is the maximum allowed
breaking time (open and arcing) of the breaking device after the
open command has been initiated to prevent further damage to
the drive, such as diode failures.
- Ma x im um s a fety tr ip tim e: 500 ms
The maximum safety trip time is the maximum allowed time to
ensure safe disconnection of the main power supply to prevent
any hazard to personnel.
Note: For more information on the MCB requirements, control interface
and control philosophy, see "Main circuit breaker engineering guideline"
(3BHS125149 E50).
2.7.3 Maintenance recommendation

The MCB trip circuits should be checked once per year.

3. Power electronics and cabinet features
3.1 Main features of the drive

The water-cooled ACS5000 is a voltage source frequency converter of the
ACS product range. It is available for up to 36 MVA and for standard
motors with voltages up to 6.9 kV.
The drive features several proven ABB technologies including:
• Multilevel-fuseless voltage source inverter (VSI-MF) design
• Direct torque control (DTC) platform
• IGCT power semiconductors
5 7 8 9
1 12
2 10 11
Figure 3-1 Typical block diagram of the drive

(1) Main power supply (7) 36-pulse rectifier
(2) Auxiliary power supply (8) DC link
(3) I >> Prot (9) 9-level inverter
(4) MCB (10) Control system
(5) Transformer (11) Cooling system
(6) ACS5000 (12) Motor

03 POWER ELECTRONICS AND CABINET FEATURES
VSI-MF
The VSI design employs DC-link capacitors and provides a switched
voltage waveform. As a result of the multilevel topology, the drive
produces an optimum number of switching levels - 9 levels, phase to
phase. The resulting output waveform permits the application of standard
motors without decreasing the reliability and efficiency of the motor.
10000 V 5
5000 V
3
6
- 5000 V
7
8
- 10000 V
9
Figure 3-2 Switching levels
15000 2000
1500
10000
1000
5000
500
1 0 0 2
-500
-5000
-1000
-10000
-1500
-15000 -2000
3
4 5
Figure 3-3 Principle of 9-level topology

(1) Volts (4) Voltage
(2) Amps (5) Current
(3) 50 Hz operation point

IGCT
Integrated gate-commutated thyristors (IGCT) are used as switching
devices in the inverter section of the phase converter units. IGCTs
combine fast switching capabilities with low losses and enable a drive
design with a low parts count.
Figure 3-4 IGCT

Fuseless protection concept
The drive does not require any power fuses. Instead, the IGCTs of the
inverter are used for protection. If an overcurrent occurs, protection firing
is triggered and fault clearing is initialized in less than 25 µs.

3.2 Frame sizes

The drive comes in four frame sizes. Depending on the frame size, the
drive has the following line-up specifications.
Table 3-1 Line-up specifications by frame size
Frame Rating COU Primary Secondary PCU WCU Total

size PCU PCUs width width length
(mm) (mm) (mm)
1 12 MVA 1 3 0 1700 800 7130
2 18 MVA 1 3 0 2100 1400 8930
3 24 MVA 1 3 3 1700 1400 12830
4 36 MVA 1 3 3 2100 1400 15230
Figure 3-5 Frame sizes 1 – 4

3.3 Phase converter unit (PCU)

All frame sizes use three primary phase converter units, each supplying
one motor phase.
In frame size 1 and 2, one primary phase converter unit represents a
complete functional assembly.
In frame size 3 and 4, one primary and one secondary phase converter unit
(connected via DC link) represent a complete functional assembly.
Transformer cable connection

The back left part of the primary phase converter unit contains the
terminals for the transformer cables (Fig. 3-6:1 and Fig. 3-8:1).
Depending on the cable entry ordered, the unit comes with a top or
bottom cable entry.
Note: For information on the dimensions and the busbar arrangement, see
“Appendix C – Mechanical drawings”.
3.3.1 Primary phase converter unit (1700 mm and 2100 mm)

Primary PCU (1700)
Primary phase converter units of 1700 mm are used in frame size 1 and 3.

3
7
4
8
Figure 3-6 Primary PCU, 1700 mm

(1) Grounding switch (5) Roof-mounted cooling unit
(2) Crowbar circuit board or PINT (6) Phase INT circuit board
circuit board (7) PE ground busbar
(3) 2 di/dt chokes and 2 VLSCD (8) Back oscillation damping circuit
circuit boards
(4) DC-link capacitors

B
A 5
6
8
7
1
2 9
4
3
Figure 3-7 Primary PCU, 1700 mm: side view left (A) and side view right (B)
(1) Terminals for transformer cables (6) Water pipe
(2) NP filter unit (7) Invert stack consisting of
diodes sand IGCTs
(3) Rectifier stack consisting of
diodes and thyristors (8) AC busbars for adjacent PCU and
motor phase
(4) DC-link connection
(9) Gate unit
(5) Roof-mounted cooling unit

Primary PCU (2100)

Primary phase converter units of 2100 mm are used in frame size 2 and 4.
2 8
3 9
10
4
5 11
12
6
13
Figure 3-8 Primary PCU, 2100 mm

(1) Roof-mounted cooling unit (8) 2 IPS
(2) EAF circuit board (9) Grounding switch
(3) Pulse transformers for (10) HVD and CVMI circuit board
crowbar thyristors for voltage and
current measurement
(4) PINT circuit board
(11) Clamp resistor
(5) 2 di/dt chokes and 2 VLSCD
circuit boards (12) PE ground busbar
(6) DC-link capacitors (13) Back oscillation damping circuit
(7) Main INT circuit board

A 6
9
10
7
1 4
8
2
5
3
Figure 3-9 Primary PCU, 2100 mm: side view left (A) and side view right (B)
(1) Terminal compartment for (6) Roof-mounted cooling unit
transformer cables (7) Inverter stacks consisting of
(2) VLSCD circuit board diodes and IGCTs
(3) Discharging circuit (8) Gate unit
(4) Rectifier stacks consisting of (9) Water pipe
diodes and thyristors (10) AC busbars for adjacent PCU and
(5) DC-link connection motor phase

3.3.2 Secondary phase converter unit (1700 mm and 2100 mm)

The secondary phase converter unit has the same design as the primary
unit, except that the rectifier stack and the transformer terminal section
are missing.
Secondary PCU
(1700 and 2100)
Secondary phase converter units of 1700 mm are used in frame size 3.
Secondary phase converter units of 2100 mm are used in frame size 4.
A
B
Figure 3-10 Secondary PCU, 1700 mm (A) and 2100 mm (B)

3.4 Control unit (COU)

The control unit incorporates the hardware for the control, monitoring
and protection functions of the drive, and the communication interfaces
to the local control panel and to the remote control devices. Depending on
the control concept of the drive system, the remote control devices
include a higher-level control system and / or remote operator stations.
5
4
11
12
2
6 6 6
13
14
15
6
7
6 11
8 16
8
3
10
Figure 3-11 Block diagram of control system

(1) Customer interface (9) Main INT interface
(2) Control unit (10) Phase INT interface
(3) Inverter (11) s800 I/O process system
(4) DriveMonitor (12) Process I/O
(5) Higher-level control system (13) CDP control panel
(6) DDCS (14) RS485
(7) AMC circuit board (15) PC tools
(8) Fiber-optic (16) Internal I/Os

3.4.1 Main components
13
1
14
2
4 15
5 16
17
6
7
9 8 18
19
10 18
11
12 12 20
Figure 3-12 COU control section

(1) Arc Guard System™ (12) Isolating transformers for
customer UPS – T1011, T1012, and
(2) NETA-21
step-down transformer for
(3) AMC and main INT circuit board internal buffer T1021 (optional)
(4) Terminals for customer UPS and (13) S800 I/O process system
PCU auxiliary power supply – X200,
(14) Customer terminals
X100, X101, X120, X3
(from top to bottom) (15) Thermostat for internal
temperature
(5) Auxiliary relay
(16) EOI circuit board
(6) Safety relay
(17) Thermostat for door-mounted
(7) Motor circuit-breakers
cooling fan
(8) Auxiliary contactors
(18) Miniature circuit breakers
(9) Charging contactor
(19) 230 V socket
(10) Switched-mode power supplies
(20) Transformer for unbuffered
(11) Electrolytic capacitors (optional) auxiliary power supply (T1111)

3.4.1.1 AMC circuit board

The AMC circuit board is the major component of the drive’s control
system and performs general drive, motor control, and closed loop
functions. The main internal control devices and the peripheral input and
output interfaces to the customer communicate with the AMC circuit
board via optical fibers.
The circuit board is fitted with a Motorola DSP processor and features two
PPCS and eight DDCS communication channels. The communication
channels are used for high speed data transfer via the INT circuit boards
to the Phase-INT circuit boards inside the phase modules.
Control tasks
The AMC circuit board has specific control and closed-loop tasks assigned
to it. It processes drive and status information, performs the speed and
torque control tasks, and monitors the operation of the drive.
All relevant drive variables (eg, speed, torque, current, voltage) are
continuously monitored by the control system. Pre-programmed
protection functions ensure that these variables remain within certain
limits in order to maintain safe operation of the drive. These internal
functions are not programmable by the user.
Optionally, the drive can monitor signals from external equipment. These
can be activated and adjusted with “ Parameters”.
Other general control, protection and monitoring tasks regarding the
whole drive include control and monitoring of:
• Main circuit breaker (MCB)
• Grounding switches
• Door interlocking
• Cooling system

Direct torque control

The speed and torque of the motor is controlled by DTC (Direct Torque
Control). The DTC motor control platform is unique to ABB and has been
proven in all variable speed drives of the ACS product range. DTC provides
accurate speed and torque control, and high dynamic speed response.
DTC is implemented on the AMC circuit board of the INU.
1
5 6 8
9
3
7 10
11
12
Figure 3-13 DTC torque control

(1) Torque reference (7) Motor model
(2) Speed reference (8) Switching logic
(3) Actual reference (9) Switch positions
(4) Speed controller (10) Voltage
(5) Torque reference controller (11) Current
(6) Torque-flux comparator (12) Motor
Switching of the semiconductors i is directly controlled in accordance

with the motor core variables flux and torque.
The measured motor currents and DC link voltages are inputs to an
adaptive motor model. The model produces exact values of torque and
flux every 25 microseconds. Motor torque and flux comparators compare
the actual values to reference values which are produced by the torque
and flux reference controllers.
Depending on the outputs from the hysteresis controllers, the switching
logic directly determines the optimum switch positions every 50 ms and
initiates switching whenever required.
Parameters
The control system is configured, customized, and tuned with a set of
application parameters. The application parameters are organized in
functional groups and have factory-set default values.
The default parameter values are adjusted during commissioning to the
specific application of the drive in order to activate the specific control,
monitoring and protection functions for the driven process, and to define
the signals and data transferred between drive and external equipment.

Note: For more information on the parameters for signal allocation, signal
type selection, signal inversion, scaling, and filtering, see “Appendix G –
Signal and parameter table”.
Main circuit breaker
The main circuit breaker (MCB) is an important switching and protection
device of the drive system. Therefore it must only be controlled and
monitored by the drive.
Note: For more information, see:
• "Main circuit breaker engineering guideline" (3BHS125149 E50)
• “2.7 Important note - main circuit breaker”
Peripheral I/O devices
The peripheral input and output devices connected to the AMC circuit
board include:
• “ Local control panel” on page 51
• “ Customer interface” on page 52
• “ S800 I/O system” for parallel signal transfer to external devices
• Fieldbus adapters for serial data transfer to a higher-level
control system
• PC-based service tools comprising:
- Dr ive Wa re ® s of twa re tool s : includes software tools such as
the commissioning and maintenance tools DriveWindow and
DriveDebug, and DriveOPC for data transfer between ABB drives
and Windows®-based applications.
- Dr ive Moni tor (option ): a monitoring and diagnostics tool that
allows access to the drive from any location in the world via a
secure internet connection.
Local control panel
The control panel serves as the basic user interface for monitoring,
control and operation of the drive and setting of parameters.
Note: For more information on local operation and the CDP control panel,
see “8 Operation” on page 123 and “9 CDP control panel” on page 139.

Figure 3-14 Local control panel

(1) Local control panel (2) Local control pushbuttons
Customer interface
The devices present in the customer interface depend on the options
ordered, such as:
• Serial communications interface to a higher-level control system
• The modules of the S800 I/O system for monitoring of external
equipment, such as transformer and motor
• DriveMonitor

4
5
1 6
Figure 3-15 COU customer interface section

(1) Arc Guard System™ (5) Grey encoder (optional)
(2) Remote condition monitoring (6) NTAC-02 pulse encoder (optional)
NETA-21 and fieldbus interface (7) Customer terminals
(4) S800 I/O process system
(customer- specific configuration)
S800 I/O system

The S800 I/O station with digital and analog I/O interfaces transfers
drive-related hardwired signals to the AMC circuit board.
Standard ABB Advant S800 I/O modules interconnect internal and
external digital and analog I/O signals with the control system of the
drive. The I/O station consists of a bus modem serving as an interface to
the AMC circuit board and the I/O modules. Each I/O module is plugged
into a termination unit that is wired to separate terminals to which the
external signals are connected.

3.5 Transformer and motor cable terminals

3.5.1 Transformer cable terminals
Note: For information on the location of the terminals, see Fig. 3-7.
3.5.2 Motor cable terminals

The motor terminals are in the back of the COU compartment. To access
them, open the swing frame of the control unit.
Besides of the busbars for motor cable terminations, this unit also
includes the charging transformer for the DC link, the EMC filter and the
EAF filter.
The layout of the motor terminal section depends on the following:
• Frame size (single or double busbars)
• Cable entry (from top or from bottom of the cabinet)
Note: For information on the dimensions and the busbar arrangement,
see “Appendix C – Mechanical drawings”.
1 2
A B
Figure 3-16 Motor terminal section of frame size 1 and 2: bottom entry (A) and
top entry (B)

A B
Figure 3-17 Motor terminal section of frame size 3 and 4: bottom entry (A) and
top entry (B)

3.6 Water cooling unit (WCU)

Depending on the frame size, the water cooling unit comes as one of the
following two models:
• 800 mm (frame size 1 and 2)
• 1400 mm (frame size 3 and 4)
Fig. 3-18 shows the water cooling unit of frame size 3 (type WCU1400). It
allows you to identify the components of other models as well.
1 2
5
6
7
3
Figure 3-18 WCU (1400 mm), frame size 3

(1) Deaeration valve (5) Ion exchange vessel
(2) Expansion vessels (6) Water-to-water heat exchanger
(3) Water pump 1 (7) Water pump 2
(4) Filter
Note: For more information on the water cooling unit, see

“Appendix A – Additional manuals”.

3.7 EXU – Excitation unit (optional)

The EXU supplies a synchronous motor with excitation power. The EXU is
available for the following excitation methods:
• Brush excitation (DC excitation): Brush excitation uses a DCS800 AC-
to-DC converter (see figure below) which is supplied by the mains.
The converter controls the direct current for generating the
magnetic field. Brushes and slip-rings feed the DC current to the
rotor.
• Brushless excitation (AC excitation): Brushless excitation uses a
three-phase DCS800 AC-power controller (see figure below). The
power controller feeds an exciter which is mounted on the shaft of
the main motor. The rotating armature of the exciter supplies a
rectifier which generates the DC current for producing the
magnetic field in the synchronous motor.
1 3
Figure 3-19 EXU

(1) AC-to-DC converter (3) AC power controller
(2) Output disconnector (option)

DCS800 control panel

The control panel of the DCS800 unit enables the user to control, read the
status messages and set the parameters of the DCS800 unit. The panel
can also be used to copy parameters from one DCS800 unit to
another DCS800.
Figure 3-20 EXU control panel

Note: For more information, see “8 Operation” on page 123.
Reversing switch
The EXU for brushless excitation is equipped with a reversing switch for
changing the sense of rotation. The switch is actuated by the drive.
The switch changes the sense of rotation via the optical communication
link. When the drive is in state ReadyOn or NotReadyOn, the switch
is opened.
Output disconnector
The optional output disconnector (Fig. 3-19: 3) is used to disconnect the
EXU from the motor for maintenance purposes.

3.8 Door interlocking system

The doors of each PCU compartment are secured with an
electromechanical interlocking mechanism to prevent them from being
opened during operation.
The main protection features of the interlocking system are:
• Grounding switches (Fig. 3-22)
• Locking bars (Fig. 3-23)
The interlocking system ensures that you cannot connect the main power
supply to the drive until all doors of PCU compartments are closed and
locked and the grounding switches are in ungrounded position.
The interlocking system also ensures that you cannot open the doors of
PCU compartments until the main power supply is disconnected, the DC-
link capacitors are discharged and the grounding switches are in
grounded position.
The doors of the COU compartment (control unit and motor terminal
section) and the WCU compartment are not integrated into the
interlocking system and can be opened at all time. However, do not open
the swing frame of the control unit while the drive is in operation.
Figure 3-21 Location of protection features and lights

Note: For instructions on how to open and close doors, see “10.6.3
Opening and closing the doors” on page 174.

3.9 Grounding switches

There is one grounding switch (Fig. 3-22: 1) on each primary PCU.
Turning a grounding switch to the grounded position (horizontal) is only
possible once the yellow lamp (Fig. 3-22: 2) lights up. The yellow lamp
indicates that the main power supply is disconnected and the DC link
has discharged.
Figure 3-22 Grounding switch

(1) Grounding switch:
Horizontal position - drive is grounded
Vertical position - drive is not grounded.
(2) Yellow lamp (grounding switch released): Lights up to indicate that you can
turn the grounding switch to the grounded or ungrounded position.

Note: For a detailed grounding diagram, see “Appendix D –

Wiring diagrams”.
3.9.1 Locking bars

There is one locking bar (Fig. 3-23: 3) on each primary and each
secondary PCU.
Sliding a locking bar to the unlocked or locked position is only possible,
once the white lamp (Fig. 3-23: 2) lights up. The white lamp indicates that
the drive is grounded.
In addition, sliding a locking bar to the locked position is only possible,
once all doors of a PCU (2 doors in 1700 mm PCUs, 3 doors in 2100 mm
PCUs) are closed.
Figure 3-23 Locking bar and white lamp
(1) White lamp: Lights up to indicate that the drive is grounded and you can
slide the locking bar to the unlocked or locked position.
(2) Locking bar: Unlocks or locks the door handles of a PCU compartment.

3.10 Grounding studs

The COU and each PCU has grounding studs that are designed for use with
the 4-way grounding set (Fig. 3-25).
Figure 3-24 Grounding stud
3.10.1 Grounding set
▲ DANGER
⚠
Hazardous voltages!
The steps in the “2.5 The 7 steps that save lives” on page 32 must be
completed before you access the grounding studs in the PCU.
1
3
Figure 3-25 4-way grounding set

(1) Enclosure ground clamp (3) Busbar ground clamp
(2) Telescopic insulating pole

3.10.2 Output grounding studs in COU

The converter output grounding studs (Fig. 3-26: 1L1, 1L2, 1L3, and PE) are
behind the swing frame in the COU.
1L3
1L2
1L1
PE
Figure 3-26 Connection studs for the 4-way grounding set in the COU

3.10.3 Input grounding studs in a PCU
▲ DANGER
⚠
Hazardous voltages!
The steps in the “2.5 The 7 steps that save lives” on page 32 must be
completed before you remove the side and back walls from the drive to
access the grounding studs in a PCU.
The converter input grounding studs (Fig. 3-27: 1L1, 1L2, and 1L3; Frame
sizes 3 and 4 also have 2L1, 2L2, and 2L3) and the protective earth
grounding studs (Fig. 3-27: PE) are at the back of each PCU.
2L2 2L3 2L1
1L2
1L3 1L1
PE
Figure 3-27 Connection studs for the 4-way grounding set in a PCU

4. Transportation, storage and disposal
4.1 Safety
The drive must only be handled by personnel who are skilled and
experienced in unpacking and transporting heavy equipment
4.2 Transport conditions

The transport conditions for the drive are based on IEC 60721-3-2.
Classification: 2K12 / 2B1 / 2C2 / 2S5 / 2M4
4.3 Unpacking and inspection

1. Remove all packaging material carefully.
2. Check the drive and accompanying equipment for damages.
3. Compare the complete delivery with the purchase order and the
packing list.
4. If parts are missing or damaged, immediately inform the shipping
company and the ABB service organization.
It is recommended to photograph the damages and send the
photographs to ABB.

04 TRANSPORTATION, STORAGE AND DISPOSAL
4.4 Identifying drive units

A delivery can consist of transport units for several drives. To identify the
transport units and assign them to a particular drive, see the following
accompanying papers for information:
• Packing list, attached to the packaging of each transport unit
• Packing label on the back wall of each drive unit (PCU, COU, WCU).
The packing label is only visible after the packaging has
been removed.
4.4.1 Packing list

The “Commodity description” column of the packing list states the
number of the drive that the transport unit belongs to.
ABB item Qty. Unit. Identnumber Commodity description

Customer item
001201 1 PC Converter 1(1): Transport Unit 1
ABB Switzerland Ltd

Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zurich/Switzerland
CH-5401 Baden/Switzerland +41 58 589 27 95 755749 abb ch +41 58 580 20 84
(1)
All of the transport units for a drive have the same converter number, in this case,
“Converter 1”.
The item number in the “ABB Item / Customer item” column of the packing
list provides information about separately delivered crates with
accessories such as tools and installation material .
ABB item Qty. Unit. Identnumber Commodity description

Customer item
001221(1) 1 PC cross wiring
001222 1 PC WCU accessory

001223 1 PC crank for isolator
001500 1 PC 3BHB013202R0001 ACS6080 Max-SL LOOSE PARTS config.
ABB Switzerland Ltd
Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zurich/Switzerland
CH-5401 Baden/Switzerland +41 58 589 27 95 755749 abb ch +41 58 580 20 84
(1) The third digit from the right identifies the drive that the accessories belong to, ie,
drive 1.

4.4.2 Packing label

The packing labels on the back wall of transport units can also be used for
identification.
ABB Packing Label 0000

Material no 3BHB009964R1500 1 ST
Material Cabinet ARU/INU LSU config.
Order no/positions 11027727 001241(1) Project CBA
Material Document
004902892300012004
(1) The fourth digit from the right identifies the drive that the transport unit belongs
to, ie, drive 1.
4.5 Lifting and transportation

▲NOTICE
Risk of component damage.
Refer to “Appendix C – Mechanical drawings” before transporting the
drive. This appendix provides details on dimensions, weight, and center of
gravity of the drive.
• To prevent distortions, DO NOT lift and move the drive or a
transport unit with a forklift.
• If the transport units are joined but not yet on the base frame,
DO NOT lift and move them with a crane.
Instead, use appropriate transport means, such as heavy load
hydraulics rollers or air cushions. If in doubt, contact ABB for
instructions.
• To prevent damage to drive components, transport and move the
drive or a transport unit only in upright position.
• To prevent dirt from entering the drive, keep the doors of the drive
or a transport unit closed.
Metallic dust in particular can cause damage and failure when the
drive is energized.

4.5.1 Using a crane to lift a transport unit or the drive by the base frame
⚠ CAUTION
Tipping hazard!
• To prevent the drive or transport unit from tipping when following
these instructions, use an extra sling around the cabinet for
stabilization (Fig. 4-2).
▲NOTICE
To prevent deformation of the cabinet:
• Only use a crane to lift single transport units or the drive by the
base frame.
• Always observe the center of gravity!
Refer to Fig. 4-1 and Fig. 4-2 when following these ABB recommendations:
• Use a lift frame or a lift spreader with the crane.
• If a lift frame or lift spreader is not available, make sure that the
slope angle is a maximum of 15° (see Fig. 4-2).
• Use lifting equipment (eg, web slings, chain slings, round slings,
safety hooks, shackles) that corresponds to the weight that is to
be lifted.
• Attach the slings to the lifting brackets at the base frame.
• To prevent the drive or transport unit from crashing if one sling
tears, fasten an extra sling around the cabinet for stabilization.
• Use appropriate safety hooks or shackles to attach a sling.
• Do not pass a sling through the hole of the bracket.
• If the slings are too close to the cabinet, protect the edges and the
door handles or levers.
• Lift the drive or a transport unit slowly and steadily to the required
clearance height, maintaining it in upright position.
• Check the horizontal position and reposition the slings if necessary.
1
2
Figure 4-1 Lifting bracket on base frame of a drive and safety hook secured to
lifting bracket
(1) Lifting bracket (hole ∅42 mm) (2) Safety hook

5
6
7
15° max
5
6
Figure 4-2 Lift frame and lift spreader

(3) Lift frame (7) Safety hook or shackle
(4) Protect the edges (8) Lifting bracket
(5) Protect door handles and levers (9) Slope angle
(6) Extra sling (10) Lift spreader

4.6 Storage
4.6.1 Storage conditions
The minimum requirements for storage are based on IEC 60721-3-1.
Classification: 1K22 / 1B1 / 1C2 / 1S11 / 1M11
The drive can be stored for up to one year in the original packaging as long
as it is not damaged or opened. For information on longer storage
periods, contact the ABB service organization.
4.6.2 Storage
If the drive is taken out of service for a longer time proceed as follows:
1. Drain the cooling circuit completely or add the appropriate amount of
glycol for frost proofing if the drive is to be stored in ambient
temperatures below 0 °C.
Note: For information about draining and frost proofing, see the
manual of the water cooling unit in “Appendix A – Additional manuals”.
2. Cover all cable inlets and ventilation slots with an impermeable
plastic or aluminum foil and a wooden panel.
3. Add a desiccant of the appropriate quality:
• One unit desiccant (30 g) absorbs 6 g water vapor
• When using a polyethylene foil: 10 units/m 2 foil

4. Close and lock the doors of the drive.
5. Use polyethylene or equivalent for packaging:
• 0.3 g/m 2 /24 h water vapor diffusion

6. Attach humidity indicators to the packaging.
NOTICE The storage conditions and the packaging should be checked
regularly. Any damages which occur during the storage period must be
repaired immediately.

4.7 Storage and handling of spare parts

▲NOTICE
Static electricity can damage printed circuit boards.
• Apply static-sensitive precautions when handling spare parts.
4.7.1 Warranty information

IMPORTANT! Check the spare parts immediately after receipt for damages.
Report any damage to the shipping company and the ABB
service organization.
Observe the following to maintain spare parts in good condition and to
keep the warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in antistatic bags or boxes.
• Storage temperature range: -5 °C – + 55 °C
• Storage place requirements:
- Free of vibration and shock.
- Protected against dust, sand, vermin and insects.
- Free of corrosive gases, salt or other impurities that could
damage electronic equipment.
- Dry, no condensation: relative air humidity: 5 – 95%
If in doubt whether the maximum allowed humidity is exceeded,

protect spare parts by an external heater.
• Do not touch a component without wearing a wrist grounding strap.
• Put the component on a grounded working surface protected
against electrostatic discharges.
• Hold the component only at the edge.

4.8 Disposal of packaging materials and components

Dispose of the packaging materials and components at the end of the life
time of the drive according to local regulations.

5. Mechanical installation
5.1 Safety
All installation work must be carried out by qualified personnel according
to the site and equipment requirements and in compliance with
local regulations.
5.2 Overview on installation work

The drive is delivered in transport units that must be joined and fixed to
the floor at the installation site.
The installation includes the following work:
• “5.5 Preparing the installation site” on page 75
• “5.6 Aligning transport units” on page 75
• “5.7 Joining transport units” on page 77
• “5.8 Applying silicone” on page 78
• “5.9 Installing roof joints” on page 78
• “5.10 Installing roof-mounted cooling units” on page 79 (option)
• “5.11 Installing roof attachments” on page 84 (option)
• “5.12 Joining water pipes” on page 86
• “5.13 Joining busbars” on page 87
• “5.14 Connecting the heating cable” on page 89 (option)
• “5.15 Connecting raw water pipes” on page 90
• “5.16 Fixing the drive to the floor” on page 90

05 MECHANICAL INSTALLATION
5.3 General notes on installation

▲NOTICE
Risk of component damage,
Observe the following during installation:
• Ensure that no dirt enters the drive.
Always close the doors when work is discontinued and completely
cover openings. Metallic dust in particular may cause failures when
the drive is powered up and cause damage.
• When joining two transport units, do not damage or dislocate the
EMC sealing strip that is glued onto the outer joining surfaces of
the cabinet frame.
• If the transport units are joined but not yet on the base frame, do
not lift and move them with a crane.
Instead, use appropriate transport means, such as heavy load
hydraulics rollers or air cushions.
5.4 Dimensions and clearances

Note: For information on dimensions, location and size of fixing holes and
clearances, see “Appendix C – Mechanical drawings”.
5.4.1 Rear and top access to the cabinet

Joining the transport units and DC busbars requires rear and top access.
5.4.2 Cabinet roof

The cabinet roof is not designed as a base for foreign devices or cable
ducts. Therefore, do not install any foreign objects on the roof.
5.4.3 Fire protection

To prevent fire from spreading into the drive, apply suitable fire
protection measures.
5.4.4 Cable duct material

Use cable ducts of non-flammable material with non-abrasive surface.
To prevent dust, humidity and animals from entering the drive, protect all
cable entries and exits of cable ducts.
5.4.5 Installation material

Installation material is supplied with the drive in a separate box.
5.4.6 Tools
See “1.12 Tools” on page 28.

5.5 Preparing the installation site

To ensure proper alignment and installation of the drive, prepare the floor
as follows:
• The floor must be able to support the weight of the drive
(min. 1500 kg/m 2 ).
• The overall incline of the floor across 5 m must not exceed 5 mm.
2
1
1 mm 1 5 mm
1 mm
3
5m
Figure 5-1 Floor inclination

(1) Tolerance from mean ground (3) Tolerance for incline: 5 mm incline
± 1 mm on 5 mm length
(2) Surface or floor
The floor must be even.

• Check the evenness and incline of the floor well in advance so that
work for improving the surface is completed before the installation
of the drive.
• Use a spirit level or flooring rule with a vial for checking.
Recommended length: 1 – 2 m.
• If the surface cannot be improved, place shims or leveling plates
under the base frame at appropriate distances (every 1 m)
for adjustment.
• Leveling plates of the following size are recommended:
10 mm x 10 mm
• Drill the fixing holes before moving the drive to the final location.
5.6 Aligning transport units

1. Remove the protective covers from the water pipe ends on
both sides.

2. Check that a pipe joint has been slid on one pipe end of two adjoining
water pipes.
3. Line up the transport units as shown in “Appendix C –

Mechanical drawings”.
The units can be lined up either beginning from the left or the right.
4. Align the transport units.
5. Verify the following alignment parameters:
6. Maximum values for the axial misalignment and the angular
deflection of two adjoining water pipes are not exceeded
Axial misalignment: ± 3 mm
Axial deflection: 5°
7. Screw holes are exactly aligned.

8. Cabinet doors are not misaligned and that there are no gaps between
cabinet walls and cabinet frame
9. Adjoining surfaces of transport units meet perfectly all around
5.7 Joining transport units

Join the transport units with the supplied installation material. The
installation material is mounted at one of the transport units.
Figure 5-2 Connection points on side of transport units (PCU example)

5.8 Applying silicone

Silicone prevents water from entering the gap between two joining roof
plates. Apply silicone where two transport units have been joined
(Fig. 5-3). Gaps within a transport unit are factory-sealed.
Figure 5-3 Applying silicone
5.9 Installing roof joints

Install the roof joints across shipping splits at the following locations:
• Marine drives: at the front of the roof (the back is reserved for roof
attachments, see “5.11 Installing roof attachments” on page 84.)
• Standard drives: at the front and the back of the roof
Note: For the exact number and fitting location of roof joints, see
Table 5-1 Installation material per roof joint
Items Details ID Number

Connecting piece 8 x 80 x 220 mm 3BHB011552R0001
Hex-head bolt M16 x 40 NB 312350P0464
Washer 17x30x3 9ABA450078P0008
Figure 5-4 Roof joint

5.10 Installing roof-mounted cooling units

Note: This section applies only if the units are not preinstalled.
5.10.1 Lifting a unit with a crane
⚠ CAUTION
Heavy objects!
• An IP42 cooling unit weighs 40 kg .
• An IP54 cooling unit weighs 98 kg.
Procedure:
1. Attach appropriate slings and shackles to the lifting brackets of a
cooling unit.
2. Using a crane, lift the cooling units above the cabinet.
Figure 5-5 Lifting a cooling unit (example with IP54 unit)

5.10.2 Installing IP42 roof-mounted cooling units

One by one, install the IP42 roof-mounted cooling units on top of the PCU
compartments that have the designated openings.
Table 5-2 Installation material per IP42 unit
Item Quantity Details

Self-tapping Torx screws 18 M6x16
Washers with sealing 18 6.8x1 (4.8x2.8)
Cable binders
1. Align the unit with the opening (1) in the cabinet roof.
2. Slowly lower the cooling unit onto the cabinet roof.

IMPORTANT! Make sure that the screw holes fit.
3. Screw the cooling unit to the cabinet roof.
4. To get to the cable inside the cabinet, remove the back wall if
necessary to reach them from the back.

5. Route the cables along the pre-installed white cable brackets and
through the designated openings (1) into the front of the cable duct.
Use cable binders to fix the cables to the cable brackets.
Figure 5-6 Cable duct openings (example with 1700 mm PCU)

6. In the cable duct at the front, connect the cables according to
“Appendix D – Wiring diagrams”.

5.10.3 Installing IP54 roof-mounted cooling units

One by one, install the IP54 roof-mounted cooling units on top of the PCU
compartments that have the designated openings.
Table 5-3 Installation material per IP54 unit
Item Quantity Details

Self-tapping Torx screws 22 M6x16
Washers with sealing 22 6.8x1 (4.8x2.8)
Tube spacers 2
1. Align the water inlet / outlet (1), drain outlet (2), and cables (3) of the
unit with the designated openings in the cabinet roof.
2 3
1
2. Slowly lower the cooling unit onto the cabinet.

Make sure that the water inlet / outlet, the drain outlet, the cables and
the screw holes fit.
3. Screw the cooling unit to the cabinet roof.
4. To get to the water inlet / outlet and the drain outlet from inside
the cabinet.
• Try to reach them from underneath the cable duct at the front
• Remove the back wall if necessary to reach them from the back.

5. Connect the tube from the return pipe (Fig. 5-7: 5) to the water outlet
(Fig. 5-7: 1).
The tubes are transparent. The colors used in Fig. 5-7 are for
illustration only.
6. Seen from the back, the water outlet is on the left. Seen from the
front, the water outlet is on the right.
7. Connect the tube from the feed pipe (at bottom of cabinet) to the
water inlet (Fig. 5-7: 2).
8. Seen from the back, the water inlet is on the right. Seen from the
front, the water inlet is on the left.
9. Connect the drain tube to the drain outlet (Fig. 5-7: 3).
The drain tube guides condensation water to the cabinet floor.
1 2
3
4
4
Figure 5-7 Water inlet / outlet and drain outlet (back view)
10. Install the two white spacers (Fig. 5-7: 4) between the inlet and
outlet tube.
11. In the cable duct at the front, connect the cables according to the
Wiring Diagram in “Appendix D – Wiring diagrams”.

5.11 Installing roof attachments

Note: This section applies to marine drives.
To prevent tilting and dampen vibrations, attach the drive to the ceiling or
the back wall of the drive room according to the instructions. For
information on the fitting location, see “Appendix D – Wiring diagrams”.
11
12
10
9
6
5
3
2
1
Figure 5-8 Roof attachment
Item Details ID number

(1) 2 x nuts M12 HZN 452198P1022
(2) 2 x washers 13 / 29 ST / ZN 9ABA450078P0007
(3) 2 x washers 17x30x3 9ABA450078P0008
(4) 2 x hex-head bolts M16x40 NB 312350P0464
(5) 1 x bracket 3BHB035997R0002
(6) 2 x spacers 3BHB032466R0001
(7) 1 x damping pad 3BHB035998R0001
(8) 1 x bracket 3BHB035997R0001
(9) 2 x damping connectors 3BHB033405R0001
(10) 2 x plates 3BHB035999R0001
(11) 2 x washers 13 / 29 ST / ZN 9ABA450078P0007
(12) 2 x hex-head bolts M12x80 NB 312450P8127

1. Assemble the roof attachment.

2. Tighten the bolts firmly.
3. To fix the drive to the ceiling or the back wall, use two suitable struts
per roof attachment (the struts are not part of the scope of delivery).
WARNING! Do not install the struts at a 90° angle to the cabinet
roof (Fig. 5-9).
4. If you fix the drive to the ceiling, use two struts per roof attachment
(1 in Fig. 5-9).
5. If you fix the drive to the back wall, install one strut in a 90° angle to
the drive (2 in Fig. 5-9).
1 2
~45° ~45° 3
~90°
Figure 5-9 Recommended ceiling and wall fixings

(1) Two struts at 45° to ceiling (3) Do not install the struts at a 90°
angle to the cabinet roof
(2) One strut at 90° to wall

5.12 Joining water pipes

1. Mark the length of a pipe joint on one end of a water pipe as a
fitting guide.
2. Slide the pipe joint over the two adjoining pipe ends.
3. Center the pipe joint.
47 mm
4. After adjusting a pipe joint, alternately tighten the bolts lightly.

5. Tighten the bolts to the torque indicated on the pipe joint.
5.12.1 Removing a pipe joint

If you need to remove a pipe joint, proceed as follows:
1. Loosen the bolts alternately but do not remove them completely.
2. Slide the pipe joint to the side.
3. The sealing lip may touch the pipe end.
4. Turn and move the pipe joint smoothly.
5. Clean the pipe joint and treat the bolts with an appropriate lubricant
before refitting.

5.13 Joining busbars

There are three types of busbars that need to be joined:
• AC busbars (Fig. 5-10: 1)
• PE ground busbar (Fig. 5-10: 2)
• DC busbars (Fig. 5-10: 3)
Figure 5-10 Busbar connections

1. Before installing the joining pieces, grease the bolts to maintain the
required contact pressure.
2. Join the busbars.
3. Tighten the bolts to the torque of 40 Nm.

AC busbars
The joining pieces of the AC busbars and related installation material are
mounted at one of the busbar ends in the transport units.
Figure 5-11 AC busbar connection

PE ground busbar
The joining pieces of the PE ground busbar and related installation
material are mounted at one of the busbar ends in the transport units.
Figure 5-12 PE ground busbar connection

DC busbars
The joining pieces of the DC busbars are deposited inside the transport
units. Related installation material is mounted at one of the busbar ends
in the transport units.
Figure 5-13 DC busbar connection

5.14 Connecting the heating cable

This section applies to drives that are delivered in several transport units
and are equipped with a heating cable.
• Connect the heating cables of two adjoining transport units with
each other.
• Fasten the connectors with cable ties.
Figure 5-14 Heating cable connection

5.15 Connecting raw water pipes

Connect the incoming and outgoing raw water pipes to the flanges of the
water cooling unit.
Installation material such as counter flanges, bolts, nuts and seals
are supplied.
Note: For dimensions of the raw water entry and the flanges, see
5.16 Fixing the drive to the floor

The base frame provides holes for fixing the drive to the floor. Floor
fixings are not supplied. Bolts and nuts of size M16 are recommended.

6. Electrical installation
6.1 Safety
▲ DANGER
⚠
Hazardous voltage!
• Improper work could lead to life-threatening injury or death.
• The electrical installation must be carried out by qualified
personnel according to the site and equipment requirements, and
the relevant electrical codes.
• When the electrical installation is completed, the main and auxiliary
power supply to the drive must not be switched on without the
consent of the
ABB commissioning personnel.
• Take appropriate measures to prevent the main and auxiliary power
supply from being switched on during installation.
6.2 Overview
The installation includes the following items:
• “6.4 Grounding” on page 93
• “6.5 Internal wiring” on page 97
• “6.6 Cable entries” on page 101
• “6.7 Power cables, ground cables, equipotential
bonding conductor” on page 105
• “6.8 Auxiliary power cables and control cables” on page 112

06 ELECTRICAL INSTALLATION
6.3 Cable requirements

6.3.1 Power cables
For information on the requirements for power cables, ground cable and
equipotential bonding conductor, see:
• ACS5000 power cable specification
• Power cables engineering guideline
6.3.2 Auxiliary and control cables
▲NOTICE
Risk of false signals!
• DO NOT lay control cables in parallel to the power supply cables.
• If this cannot be avoided, a minimum distance of 30 cm must be
maintained between control and power supply cables.
• Cross control and power supply cables at an angle of 90°
Note: For information on the requirements for the auxiliary power cable
and the control cables, see “Auxiliary power and control cables guideline”

6.4 Grounding
The cabinet is equipped with ground buses (marked PE, Protective Earth)
for grounding the armor and shields of the cables, and for the connection
of the ground cable.
Note: To identify the ground buses, see “Appendix C –
Mechanical drawings”.
6.4.1 Grounding the transformer and the drive

Fig. 6-1 shows the grounding connections of a drive and an input
transformer in the PCU compartments.
1
+20° -20°
-20° +20° -20°
-20°
0° 0°
3
W V U W V U W V U W V U W V U W V U PE
4
3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1
3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1
PE
2 L3
2 L2
2 L3
2 L3
2 L2
2 L2
1 L3
1 L2
1 L3
1 L3
2 L1
1 L2
1 L2
2 L1
2 L1
1 L1
1 L1
1 L1
Figure 6-1 Grounding the transformer and the drive (in PCU)
(1) Input transformer (5) Cable screen
(2) Drive (6) Cable shield
(3) Grounding network of (7) Equipotential bonding conductor
installation site
(4) Ground cable

6.4.2 Grounding the drive and the motor (multi-point bonding)

Fig. 6-2 shows the multi-point connections to ground a drive and a motor
in the COU compartment.
Note: For more information see the “Power cables engineering
guideline” document.
1L1 1L2 1L3 PE
1 2 3 5
1 2 3
1 2 3 1 2 3
U V W PE
Figure 6-2 Grounding the drive and the motor (multi-point bonding)
(1) Drive (5) Cable screen
(2) Motor (6) Cable shield
(3) Grounding network of (7) Equipotential bonding conductor
installation site
(4) Ground cable

6.4.3 Grounding the drive and the motor (single-point bonding)

Fig. 6-3 shows the single-point bonding connections to ground a drive and
a motor in the COU compartment.
Note: For more information see the “Power cables engineering
guideline” document.
1L1 1L2 1L3 PE
1 2 3 1 2 3
5
1 2 3 1 2 3
U V W PE
Figure 6-3 Grounding the drive and the motor (single-point bonding)
(1) Drive (4) Ground cable
(2) Motor (5) Cable screen
(3) Grounding network of (6) Cable shield
installation site

6.4.4 Ground cable connection

The ground cable enters the COU compartment from the top or from the
bottom. It connects to the PE ground busbar of the adjoining PCU
compartment. The ground busbar spans across the entire length of the
drive (Fig. 6-4, Fig. 6-5). The connection must be in compliance with local
regulations. For project-specific illustrations, see “Appendix D –
Wiring diagrams”.
Figure 6-4 PE ground busbar in COU (back view)

(1) Bottom entry (3) Top entry
(2) PE ground busbar
Figure 6-5 PE ground busbar in PCU (back view)

(1) Bottom entry: frame sizes 1 (3) Top entry: frame sizes 2
and 3 (example) and 4 (example)
(2) PE ground busbar

6.5 Internal wiring

For information on each individual connection, see the Converter
hardware diagram in “Appendix D – Wiring diagrams”.
Internal wiring comprises all cabling and wiring across shipping splits,
and includes:
• Signal cable connection
• Auxiliary power supply cable connection
• Optical fiber connections
• Arc Guard sensor cabling
Make the above mentioned connections through the cable duct in the
upper part of the drive cabinet (Fig. 6-6, Fig. 6-7).
Additionally there is one charging cable to be connected. The charging
cable is located at the bottom of the drive cabinet behind the water pipe.
The cables and wires can be identified by their specific designation. All
cables are prepared for connection and are also marked with the
corresponding terminal designation.

6.5.1 Optical fibers
▲NOTICE
Risk of equipment failure!
Handle optical fibers with care.
• DO NOT touch the ends of the fibers, they are sensitive to dirt.
When unplugging, hold the connector and not the fiber.
• If an optical fiber is damaged or improperly installed, data
transmission can be affected and the equipment can fail.
To prevent such problems, follow the handling and
installation guidelines.
• Observe the maximum long-term tensile load of 1.0 N and the
minimum bend radius of 25 mm.
Optical fibers for internal arc protection
▲NOTICE
Risk of cable damage.
• The optical fiber cables are only available in standard lengths and
cannot be cut or extended.
• The excess cable must be wound up in coils with a diameter of at
least 100 mm.
Each unit with power cable entries and terminals is monitored for arc
faults by the Arc Guard System™ with up to 4 detectors. See the project-
specific “Converter hardware diagram” on page 392 for the exact number
of detectors in each cubicle.
The Arc Guard unit and the HMI panel are in the COU (Fig. 3-15) and the
detectors are pre-installed in the relevant cabinets. The optical fibers,
which are coiled up beside the detectors, must be routed from the
detectors to the Arc Guard unit in the COU.

A B
5 5
Figure 6-6 Wiring across shipping splits, frame size 1 (A) and 2 (B)
(1) Shipping split PCUx1 – PCUx1 (4) Charging cable behind water pipe
(not illustrated), laid on the
(2) Cable ducts on each side of
brackets and connected to
the shipping split for:
the busbar
- Auxiliary power supply cables
- Optical fibers (5) PCUx1
- Signal cables
(3) Connection point for
charging cable

1 1
2 2
PCUx0 PCUx1 PCUx1 PCUx0
3 4 3 4
Figure 6-7 Wiring across shipping splits, frame size 3 and 4

(1) Shipping split (4) Charging cable behind water pipe
(not illustrated), laid on the
(2) Cable ducts on each side of
brackets and connected to
the shipping split for:
the busbar
- Auxiliary power supply cables
- Optical fibers (5) PCUx0
- Signal cables (6) PCUx1
(3) Connection point for
charging cable

6.6 Cable entries

The drive is prepared for top or bottom cable entry with one or a
combination of the following cable entries:
• Cable entry with sealing modules, type 1
• Cable entry with cable glands
Note: For information on the location and the dimensions of the cable
entry, see “Appendix C – Mechanical drawings”.
6.6.1 Cable entry with sealing modules, type 1

• Usage: power cables, ground cables, bonding conductors
• Included in delivery: cable entry frame (Fig. 6-8: 1)
• Not included in delivery: sealing modules (Fig. 6-8: 2),
accessories, tools
2 2
Figure 6-8 Cable entry with sealing modules – type 1

(1) Compression wedge (1) Cable entry frame
(2) Sealing module (RM120)

Frame sizes (FS)
6 A
1 2 5
6 B
3 4
L1 L2
L1 L2
L3 L3 L1
RM120 RM69 RM60
Figure 6-9 Cable entry frame sizes (top) for type 1 sealing modules (bottom)
Table 6-1 Type 1 sealing modules and cables per frame opening
Frame 1 1 2 3 4 5 6A 6B
Location COU PCU PCU PCU PCU EXU SBU SBU
Cable entry FS 2/4/6 FS 2/4/6 FS 1/3/5 - - √ √ √
top
Cable entry FS 2/4/6 FS 2/4 FS 1/3 FS 6 FS 5 √ √ √
bottom
Table 6-2 Maximum number of type 1 sealing modules per frame opening
Frame 1 1 2 3 4 5 6A 6B
RM120 2 2 2 1 1 1 2 1
RM90 - - - - - 2 2 1
RM60 8 8 8 4 4 6 8 4
Table 6-3 Maximum number of cables per frame opening - 3 core
Frame 1 1 2 3 4 5 6A 6B
∅ 68-99 mm 2 2 2 1 1 1 2 1
∅ 48-71 mm - - - - - 2 2 1
Table 6-4 Maximum number of cables per frame opening - single core
Frame 1 1 2 3 4 5 6A 6B
∅ 28-50 mm 8 8 8 4 4 6 8 4

6.6.2 Cable entry with sealing modules, type 2

• Usage: auxiliary power cables and control cables
• Included in delivery: frame (Fig. 6-10: 1)
Figure 6-10 Cable entry with sealing modules – type 1

• Supplier: Roxtec AB (roxtec.com)
• Not included in delivery: EMC sealing inserts (Fig. 6-8: 2), installation
tools, accessories
6.6.3 Cable entry with cable glands

• Usage: power cables, ground cables, bonding conductors, auxiliary
power cables, control cables
• Included in delivery: undrilled plate for cable glands
Figure 6-11 Cable entry with cable gland

• Cable strain reliefs: (C-rails).

• Not included in delivery: cable glands, tools, cable clamps,

accessories
6.6.4 Cable entry with EMC plates

• Usage: power cables, ground cables, bonding conductors, auxiliary
power cables, control cables
• Included in delivery: galvanized plate with EMC mesh (Fig. 6-12: 1) and
sealing grommets (Fig. 6-12: 1)
Ø45 mm
Figure 6-12 Cable entry with EMC plates

6.7 Power cables, ground cables, equipotential

bonding conductor
See Appendix A – Additional manuals for information on:
• Project-specific cable entry
• Distance between point of cable entry and terminals
• Busbar and fastening hole dimensions
• Installation instructions for sealing modules
See Appendix D – Wiring diagrams for information on:
• Designation, cross-reference and device identification conventions
• Transformer cables and motor cables and their
corresponding connections
6.7.1 Preparing the cable entry and the cables
▲NOTICE
Risk of damage or malfunction!
Waste inside the cabinet can cause damage or malfunction.
• If possible, do not cut cables inside the terminal compartment.
• Retrieve any waste which accidentally dropped into the cabinet.
6.7.1.1 Determining the cable length

1. Determine the required length of a cable between the point of entry
and the connection point inside the cabinet.
2. Cut the cable to the required length before connection.

6.7.1.2 Preparing cables for cable entries with cable glands

Prepare cables with an outer cable screen or shield for EMC bonding with
the metal enclosure of the cabinet as illustrated.
1
5
Figure 6-13 Preparing power cables for cable glands

(1) Cable gland (5) Conductor insulation removed to
expose cable shield
(2) Plate
(6) Cable screen extension to be
(3) Heat-shrinkable termination
connected to PE ground busbar
(4) Outer cable sheath
(7) Sheath seal

6.7.1.3 Preparing cables for cable entries with sealing modules

• Prepare cables with an outer cable screen or shield for EMC bonding
with the metal enclosure of the cabinet as illustrated.
1 7
2
8
12
4 9
10
11
Figure 6-14 Preparing power cables for sealing modules

(1) Sealing module (8) Cable sheath removed to expose
cable shield
(2) Frame
(9) Shield extension to be connected
(3) Conductive foil of sealing module
to PG busbar
(4) Cable clamp
(10) Cable screen extension to be
(5) Shrinkable sheath seal connected to the PG busbar
(6) Heat-shrinkable termination (11) Cable lug as specified by the cable
(7) Outer cable sheath supplier and suitable for M12 bolt
(12) Sheath seal
• Install the sealing modules according to the instructions of the

sealing module supplier.

6.7.2 Connecting the cables
⚠ CAUTION
Risk of flashover!
High voltages will be present in the terminal compartment. High voltages
can cause flashover between conductors with different electric potential,
and between a conductor and earth.
Therefore, route and connect the cables in such a way that the following
minimum clearances are maintained:
• 70 mm between cable lugs of conductors with a different potential
• 70 mm between the cable lug of a conductor and the parts with
earth potential
• 30 mm between cables with a different potential
6.7.2.1 Checking the cable insulation

• Measure the insulation of each cable before connection and verify
that the results are within the specification of the cable
manufacturer.
• Leave the conductors unconnected at both ends until the
commissioning personnel has given permission to connect them.

6.7.2.2 Connecting the cables

Connect the cables to their corresponding busbars:
• Transformer cables to the busbars inside the primary
PCU (Fig. 6-15)
• Motor cables to the busbars inside the COU (Fig. 6-16)
• Ground cable to the PE ground busbar
6.7.2.2.1 Transformer cables
2 2 2 2
1 1
3 3 3 3
Figure 6-15 PCU cable terminals, top and bottom entry (back view)
(1) Busbars for transformer cables (3) Bottom cable entry
(2) Top cable entry

6.7.2.2.2 Motor cables
A B
1
2 4
3
6
Figure 6-16 COU cable terminals, top and bottom entry (back view) - frame sizes
1 and 2 (A) and 3 and 4 (B)
(1) Top cable entry (4) Top cable entry

(frame sizes 1 and 2) (frame sizes 3 and 4)
(2) Busbars for motor cables (frame (5) Busbars for motor cables (frame
sizes 1 and 2) sizes 3 and 4)
(3) Bottom cable entry (6) Bottom cable entry
(frame sizes 1 and 2) (frame sizes 3 and 4)

6.7.2.3 Bolted connections

Material requirements
Use stainless steel bolts and nuts with the appropriate steel grade and
property class for the connection (recommended: A2-70 [designation
according to ISO 3506]).
Nuts with bonded coating can be used as an alternative to uncoated
stainless steel nuts.
Connection type
The following connection type is recommended when a cable lug
(Fig. 6-17: 4) is connected to a busbar:
• Spring washer (Fig. 6-17: 1) and flat washer (Fig. 6-17: 2) on each
side of the busbar (Fig. 6-17: 3).
Other washers can be used, provided they maintain the required
contact pressure.
• Use cable lugs suitable for M12 bolts.
1 2 3 4 2 1
Figure 6-17 Bolted busbar connection

Lubrication
• If stainless steel bolts and nuts are used, lubricate the thread and
head contact surface of the bolt using recommended pasts, eg,
Molykote D paste.
If a coated nut (eg, with bonded molybdenum-disulfide [MoS 2 ]
coating) is used, the connection does not have to be lubricated.
Tightening torque
• Tighten bolted connections with bolts of sizes M10 and greater with
the recommended nominal torque for the bolt size used.

6.8 Auxiliary power cables and control cables

See Appendix C – Mechanical drawings for information on:
• Project-specific cable entry
• Dimensions between point of cable entry and terminals
See Appendix D – Wiring diagrams for information on:
• Conventions for cross-references and device identification
• Terminal designations
6.8.1 Preparing the cable entry and the cables
Determining the cable length

1. Determine the required length of a cable between the point of entry
and the connection point inside the cabinet.
2. Cut the cable to the required length before connection.
Routing the cables

• The auxiliary power supply cables enter the WCU compartment.
• The control cables enter the COU compartment.
Preparing cables for EMC plates - only top cable entry

1. Remove the grommets.
2. To ensure proper sealing, cut along the marking that corresponds to
the cable diameter.
3. Slide the grommet onto the cable.
The grommet must fit tightly to prevent water entering the cabinet.
If cables are entered through the cabinet floor, the grommets can be
discarded.
4. If necessary, remove the entry plate and pull the cable through the
entry holes.

5. Remove the cable insulation at the point of entry (Fig. 6-18: 1).
If the outer cable screen is non-conductive, cut open the cable screen
in the middle of the stripped area (Fig. 6-18: 1). To turn the conductive
side inside out, pull the cable screen ends over the cable insulation
(Fig. 6-18: 2). Connect the screens ends with a continuous conducting
foil (Fig. 6-18: 3).
1 3
Figure 6-18 Preparing control cables for EMC plates

6. Pull the cable through the entry plate.
7. To prevent water from entering the cabinet, fit the grommet tightly
and seal any gaps with silicone.
8. If you had removed the entry plate, remount it and fasten it properly.

6.8.1.1 Preparing cables for cable entries with sealing modules

1. Unscrew the frame and remove the sealing modules.
Note: For information on removing and installing the sealing modules
and using the compression wedge, see “Appendix A –
Additional manuals”.
2. Prepare the cables with an outer cable screen for EMC bonding with
the metal enclosure of the cabinet as illustrated.
1
2
3
4
4
Figure 6-19 Preparing control cables for sealing modules

(1) Sealing module (4) Conductor screen extension to be
connected to PE terminal
(2) Conductive foil
(3) Cable sheath removed to expose
cable shield

6.8.1.2 Preparing cables for cable entries with cable glands

Prepare the cables with an outer cable screen for EMC bonding with the
metal enclosure of the cabinet as illustrated.
2 3
Figure 6-20 Preparing control cables for cable glands

(1) Outer cable sheath (4) Plate
(2) Cable gland (5) Conductor screen extension to be
connected to PE terminal
(3) Conductor insulation removed to
expose cable shield
6.8.2 Connecting the cables

• For information on project-specific connections, see “Appendix D –
Wiring diagrams”.
• For information on terminal sizes, see document
“Customer interface”.

6.8.2.1 Connecting auxiliary power cables and space heater cables in WCU
Top cable entry
1. Route the cables through the cable transit into the terminal
compartment (Fig. 6-21: 1) of the WCU.
2. Connect the cables to the relevant terminals.
Bottom entry
1. Route the cables through the floor or the top of the WCU, up the cable
duct (4 in Fig. 6-21) on the right side wall and then into the terminal
compartment (3 in Fig. 6-21) of the WCU.
2. Connect the cable to the bottom of the relevant terminals, according
to the converter wiring diagram.
A B
1
1
Figure 6-21 Cable routing in WCU800 (A) and WCU1400 (B) cabinets
(1) Terminal compartment (3) WCU1400 cable entry bottom
(2) WCU800 cable entry bottom (4) Cable entry top (WCU800 and
WCU1400)

6.8.2.2 Connecting cables in COU

Shielded cables
• If you use twisted pair cables, leave the unshielded cable ends
twisted until they reach the terminals.
• Leave unshielded conductor ends as short as possible.
• Use a shield grounding clamp (Fig. 6-22) to fasten the overall shield
and the individual shields to the ground busbar (Fig. 6-22: 8).
Figure 6-22 Shield grounding clamp
4 5
1 6
Figure 6-23 COU customer interface section

(1) Arc Guard™ (5) Grey encoder (optional)
(2) Remote condition monitoring (6) NTAC-02 pulse encoder (optional)
NETA-21 and fieldbus interface (7) Customer terminals
(4) S800 I/O process system
(customer- specific configuration)

Control power supply

• Connect the cable for the control power to terminal X2
(Fig. 6-23: 11).
Control signals
• Connect the cables to the following terminals:
- X10, X11 (Fig. 6-23: 10)
Main circuit breaker signals and emergency off signals
- X20 – X27 (Fig. 6-23: 7)
Control signals of monitored equipment
Fieldbus interface
• Connect the cable directly to the fieldbus adapter.
Encoder interface
1. Connect the cable directly to the encoder adapter.
2. Connect the overall shield and the individual shields of the encoder
cable to the copper busbar.
IMPORTANT! DO NOT connect the shields directly to the encoder adapter.

7. Commissioning
7.1 Required qualification

Commissioning, parameter adjustments and functional tests must
be carried out only by qualified commissioning personnel that
have been certified by ABB.
7.2 Commissioning procedure

Information on the commissioning procedure and the start
conditions for commissioning can be obtained from ABB.
7.3 Commissioning checklist

In order to ensure uncomplicated and speedy commissioning, it is
important that drive and associated equipment are ready for
commissioning. Reviewing and completing the items in the
commissioning checklist before the commissioning personnel
arrive on site will help to achieve this.
7.4 Customer assistance

During the commissioning period, the customer is requested to
provide qualified personnel for assistance, who are:
• Experienced with medium and low voltage equipment and

with the local safety regulations,
• Familiar with the driven process
• Authorized to operate associated medium and low voltage
equipment (eg, input circuit breaker, other low and medium
voltage switchgear)
• Authorized to operate the driven process for
functional tests
7.5 Customer acceptance

When commissioning has been completed, the commissioning
report is signed by the responsible commissioning personnel and
by the customer as a sign of acceptance. A copy of the report and
a copy of the actual parameter settings are handed out to
the customer.

07 COMMISSIONING
7.6 Commissioning checklists

This checklist is designed to help you prepare the drive and associated
equipment for commissioning.
7.6.1 Mechanical installation checklist
1) Drive is aligned according to drive layout drawing (if delivered in
several transport units) and installed according to the
□
instructions in this user manual (3BHS799208 E01 Rev E).
2) Silicon sealant is applied across roof plate gaps.
□
3) Roof joints are installed.
□
4) Pipe joints are orientated and torqued correctly.
□
5) Roof attachments are installed (if applicable).
□
6) Busbars are installed and torqued correctly.
□
7) Raw water piping is completed and pipes are flanged to the
drive (if applicable).
□
8) Raw water supply is ready.
□
9) Visual inspection:
□
• No badly affixed or damaged components
• No foreign objects left in the cabinet
• No dirt, dust or moisture in the cabinet
7.6.2 Electrical installation checklist

1) Types and cross sections of control cables suitable for the signal
type and signal level.
□
2) Types and cross sections of power cables selected according to
the ABB power cable specification.
□
3) Pulse encoder cable shields are connected to the shield earthing
point and not connected directly to the pulse encoder interface
□
(applies only to drives with pulse encoder interface).
4) Cable entries prepared according to the instructions in the user
manual (3BHS799208 E01 Rev E).
□
5) Control cable screens and conductors are connected as
instructed in the user manual, labeled appropriately, and the
□
customer side connections are completed.
6) Heating cables (if supplied) connected
□

07 COMMISSIONING
7.6.2 Electrical installation checklist (continued)

7) Wiring across shipping splits is completed according to the
instructions in the user manual (3BHS799208 E01 Rev E).
□
8) Ground cable of the drive is securely connected at both ends.
□
9) Cable armor and screens of power supply cables are connected
to PE ground busbar.
□
10) The transformer and motor cables are installed but the
conductors not connected at both ends (cables and drive must
□
be insulation resistance tested (Megger test)
before connection).
7.6.3 Door interlocking checklist

1) The release dial of the safety switches in the locked position.
□
7.6.4 Main circuit breaker (MCB)
1) MCB selected as per “Main circuit breaker specification” (1) □

2) High-voltage power connections completed
□
3) MCB is ready to be tested with drive
□
4) MCB protection relay settings are tested
□
5) Protection devices (eg, door locks) are tested and in operation.
□
6) Local operation of MCB is disabled.
□
7) Emergency-off loop is tested.
□
(1)
Pay attention to MCB opening time and installation of undervoltage coil or second
opening coil
7.6.5 Input transformer checklist

1) Grounding is completed
□
2) Transformer auxiliaries (eg, dehydrating breathers, cooling,
protection devices) are ready.
□
3) Protection devices are tested and in operation.
□

07 COMMISSIONING
7.6.6 Motor checklist

1) Motor is installed, aligned and alignment protocol available.
□
2) Motor is not coupled to driven load.
□
3) Grounding is completed
□
4) Motor auxiliaries (eg, bearing lubrication) are ready
□
5) Control and monitoring signals are connected.
□
7.6.7 Insulation tests checklist
1) Insulation of the cables to input transformer, from input
transformer to drive and from drive to motor is tested, and
□
measured values within required limits.
2) Test report is available
□
If the commissioning personnel carry out the test, an additional
day per drive-motor combination must be reserved. After the
test, the mains cables can be connected, except at the drive end.
Test must comply with the specification.
7.6.8 Power checklist

1) Medium voltage available for startup of drive.
□
2) Low voltage is available for startup of drive.
□
7.6.9 Miscellaneous checklist
1) Sufficient number and correct type of spare parts available
□
2) Sufficient quantity of deionized water according is available.
(see “Appendix C – Mechanical drawings”).
□
3) Air conditioning of drive room ready for load run of drive
□
4) Optional equipment (eg, chiller) ready
□

8. Operation
8.1 Operating conditions

The operating conditions for the drive are according to IEC 60721-3-3.
Classification: 3K22 / 3B1 / 3S6 / 3M11
8.2 Safety
The drive system must only be operated by qualified and authorized
personnel, ie, personnel who are familiar with the operation of the drive
system and the hazards involved.
8.3 Overview
This chapter outlines the local operation of the drive.
Control of the drive via a PLC or higher-level control system is not
described in this chapter. If the drive is controlled from remote, see the
applicable manuals for information.
The status messages and parameter settings used in this chapter are
typical examples to illustrate the related instructions and display
functions and may therefore differ from the actual status messages and
parameter settings in the drive.
8.4 Local operator panel

The operator panel on the control compartment enables the operator to
control the drive without restrictions, provided that all requirements for
normal operation are met. The functions of the local operator
panel include:
• Connecting and disconnecting the main power supply
• Setting the reference value
• Starting and stopping the drive system
• Displaying: Actual values, status messages and alarm and
fault messages
• Viewing and setting parameters
• Resetting alarm and fault messages
• Activating the emergency-off
• Testing lights and illuminated pushbuttons

08 OPERATION
2 4
3 5
Figure 8-1 Local operator panel

(1) CDP control panel (4) Alarm fault lamp
(2) Main power supply off (5) Emergency-off reset pushbutton
(3) Main power supply on (6) Emergency-off
latching pushbutton
CDP control panel

• Starts / stops drive and motor
• Displays status messages
• Displays alarm and fault messages of the drive and monitored
foreign equipment
• Resets alarm and fault messages
Note: For more information, see “9 CDP control panel” on page 139.
Main power supply off
• Illuminated pushbutton opens the main circuit breaker
Main power supply on
• Illuminated pushbutton charges the DC link and closes the main
circuit breaker

08 OPERATION
Alarm fault lamp

• Flashing light: alarm
• Permanent light: fault
Emergency-off reset pushbutton
• Resets the emergency-off relay in the drive control system
• Flashes when the auxiliary voltage is switched on, or when an
emergency-off switch is pressed
Emergency-off latching pushbutton
• Prevents starting when pressed at standstill of the drive
• Main circuit breaker opens and DC link discharges when pressed
during operation of the drive
8.5 Lamp-test function

The lights and illuminated pushbuttons on the control compartment can
be tested with the lamp-test function.
The lamp test is activated via the CDP control panel by setting control
parameter 16.7 to LAMP TEST. The lamp-test function resets itself after a
set time.
8.6 Status messages

The following section lists the status messages of the main operating
states that the drive passes through when:
• Drive is put into operation (see “8.6.1 Start sequence of the drive”
on page 127)
• Drive is stopped (see “8.6.2 Stop sequence of the drive”
on page 128)
• Fault condition has occurred
The status messages are sent to the higher-level control system and are
displayed on the CDP control panel of the drive.
Note: For information on other status messages (eg, fault status
messages), see the status words in “Appendix G – Signal and
parameter table”.

08 OPERATION
NotReadyOn
The DC link cannot be charged and the drive cannot be connected
to the main power supply, ie, the main circuit breaker cannot be
closed. The status message is displayed, eg, when the doors of
medium voltage compartments are still open, the grounding
switch of the drive is in the grounded position, or the motor
starter of the fan unit is switched off.
ReadyOn
The drive is healthy and ready for the ON command. The ON
command initiates charging of the DC link capacitors and the
closing of the main circuit breaker of the drive. Depending on the
control location, the command can either be sent from the higher-
level control system to the drive or be initiated by pressing the
SUPPLY ON pushbutton on the control compartment door.
Charging
The status message ReadyOn changes to Charging when the DC
link capacitors of the drive are being charged.
ReadyRun
The drive is energized and ready for operation. As soon as the start
command is initiated, the motor is magnetized and the drive
starts to modulate.
ReadyRef
The drive is running and operating according to the set speed or
torque reference value. When in remote control mode, the
reference value is set at the higher-level control system. When in
local control mode, the value is entered into the
CDP control panel.
Stopping
The drive has received a stop command and that a ramp or coast
stop has been initiated. The stopping mode depends on the
parameter setting. The status message changes to ReadyRun
when the zero speed threshold is reached.
When a start command is given while the drive is stopping, the
drive resumes operation and the status message changes to
ReadyRef again.
Tripped
A fault condition has occurred that requires a shutdown of the
drive. The status message always alternates with the specific fault
message. The type of shutdown depends on the fault class the
fault condition is assigned to in the drive software.

08 OPERATION
8.6.1 Start sequence of the drive
1) NotReadyOn
2) ReadyOn
• Auxiliary power supply on
• PCU doors closed and locked
• Drive not grounded
• No emergency-off
• No fault
• WCU ready
3) On command
4) Charging
• DC link charges
• MCB closes
• Cooling system switches on
5) ReadyRun
6) Start Command
• Inverter starts to modulate
7) ReadyRef
8) Operation

08 OPERATION
8.6.2 Stop sequence of the drive
1) Operation
2) ReadyRef
3) Stop command
4) Stopping
• Speed ramps down
• Inverter stops modulating
5) ReadyRun
6) Off command
• MCB opens
• DC link discharges
• Cooling system switches off after a delay
7) ReadyOn
• Ground drive
• PCU doors are released for opening
• Switch off auxiliary power supply
8) NotReadyOn

08 OPERATION
8.6.3 Emergency-off sequence
1) Operation
2) ReadyRef
3) Emergency-off command
• MCB opens
• Inverter stop modulating
• Speed coasts down
4) NotReadyOn
8.7 Starting the drive

▲ DANGER
⚠
Hazardous voltages!
• To prevent unintentional contact with energized components, all
covers must be screwed in place.
• The release dial of the door safety switches must be in the locked
position to prevent the doors of the medium voltage compartments
from being opened unintentionally during operation.
⚠ CAUTION
Cooling system starts automatically!
The cooling system can start automatically as soon as the auxiliary
voltage has been switched on.
▲NOTICE
When you start the drive system locally for the first time after
commissioning, have the following documents at hand:
• “Appendix D – Wiring diagrams” to identify the circuit breakers to
be switched on
• “Appendix A – Additional manuals”, manual of the water cooling unit
to check that the water cooling unit is ready for operation
• “9 CDP control panel” on page 139” for information on functions
and features of the CDP control panel

08 OPERATION
8.7.1 Checks before starting the drive

When the drive is put into service after it has been commissioned, or after
it has been taken out of service for a longer period, check the drive
according to the following list:
• Check that tools and foreign objects are not left inside the cabinet.
• Check that all auxiliary power supplies from external sources are
switched on.
• Check that all internal circuit breakers of the drive are closed.
• Check that all covers are fitted.
• Check that all locking screws are removed from the locking bars on
the inside of the doors of medium voltage compartments.
• Check that the doors are closed and locked or bolted.
• Check that the grounding switch is in position not grounded.
• Check that the MCB is in operating position.
• Check that there is no run interlock active.
8.7.2 Starting the drive from remote

When the drive system is operated from a higher-level control system or
an operator control desk, follow the instructions in the
applicable manuals.
8.7.3 Starting the drive locally

1. Set the CDP control panel to local control mode.
LOC RESET REF
REM
2. If the EMERGENCY-OFF RESET pushbutton is flashing, press the

pushbutton to cancel flashing.
Each time the auxiliary voltage is switched off and on again, the
emergency-off safety relay of the drive is actuated and lets the
EMERGENCY-OFF RESET pushbutton flash.
The pushbutton also flashes if the EMERGENCY-OFF pushbutton on
the control compartment door, or any other emergency-off switch
linked to the drive, is pressed. If the pushbutton continuous flashing,
verify that there is no emergency-off command active.
Note: For more information, see “8.9 Emergency-off” on page 134.
3. Check that no alarm or fault messages are displayed on the CDP
control panel.
When a fault message is displayed on the CDP control panel, reset
the fault.
LOC RESET REF
REM

08 OPERATION
If a fault cannot be reset, it must be rectified by the

responsible personnel.
When no alarms and faults are present and the drive is ready, the CDP
control panel displays ReadyOn.
1 L -> 0.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
4. Press the SUPPLY ON pushbutton on the control compartment door

to charge the DC link. The pushbutton flashes during charging.
The status line of the CDP control panel alternates between Charging
and AuxiliaryOn.
Alternating display message:

1 L -> 0.0 rpm
StateINU Charging • Charging
MOTOR SP 0.00 rpm
POWER 0.0 kW • AuxiliaryOn
After charging has been finished, the following takes place:

• The main circuit breaker closes automatically.
• The SUPPLY ON pushbutton lights up permanently.
1 L -> 0.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
5. Enter the reference value.

Note: For more information, see “9.3.2 Entering a reference value”
on page 159.
1 L -> [600.0 rpm] 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

08 OPERATION
6. To start the motor, press the START key.
LOC RESET REF
REM
After the motor has been magnetized, the motor speed ramps up to
the reference value.
While the motor is accelerating, the run status message in the display
blinks. When the motor speed has reached the reference value, the run
status message lights up permanently.
The display shows ReadyRef to indicate that the drive system
is operating.
1 L -> 600.0 rpm I

StateINU ReadyRef
MOTOR SP 0.00 rpm
POWER 1000.0 kW

08 OPERATION
8.8 Stopping the drive

• To stop the motor, press the STOP key.
I 0
The motor stops according to the preset stop function. While the
motor stops, the status line of the display shows ReadyRef and the run
status message blinks.
1 L -> 600.0 rpm I

StateINU ReadyRef
MOTOR SP 300.00 rpm
POWER 20.0 kW
As long as the stop sequence is in progress, you can always restart the
drive by pressing the START key.
LOC RESET REF
REM
Just before the motor comes to a standstill, the status line shortly
displays Stopping.
1 L -> 600.0 rpm 0

StateINU Stopping
MOTOR SP 0.00 rpm
POWER 0.0 kW
When the motor has reached zero speed, the status line
displays ReadyRun.
1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
As long as the MCB has not been opened, you can restart the motor at
any time.

08 OPERATION
8.9 Emergency-off
⚠ CAUTION
Pressing the EMERGENCY-OFF pushbutton DOES NOT disconnect the
auxiliary power supply from the drive.
The drive is equipped with a hardwired emergency-off circuit. When an

emergency situation occurs during operation, this safety feature ensures
that the drive system can be disconnected without delay from the main
power supply. When the EMERGENCY-OFF pushbutton has been pressed
while the drive is at standstill, the main power supply cannot be connected
to the drive, hence the drive cannot be started up.
The EMERGENCY-OFF pushbutton of the drive is part of the local operator
panel (Fig. 8-1) and features a latching switch action.
8.9.1 Initiating an emergency off

To initiate an emergency stop, press the EMERGENCY-OFF pushbutton on
the door of the control compartment, or, if present, an external
EMERGENCY-OFF pushbutton that is linked to the emergency-off circuit.
When an emergency-off is initiated during operation, the following
takes place:
• Main circuit breaker opens
• Drive coasts down
• DC link of the drive discharges
• Status line indication of the CDP control panel alternates between
EmergencyOff and NotReadyOn.

1 L -> 600.0 rpm
StateINU EmergeOff • EmergeOff
MOTOR SP 0.00 rpm
POWER 0.0 kW • NotReadyOn
• EMERGENCY-OFF RESET pushbutton flashes.

• SUPPLY OFF pushbutton flashes.
8.9.2 Starting the drive system after an emergency-off

1. To start up the drive system after an emergency-off, unlatch the
EMERGENCY-OFF pushbutton.
The EMERGENCY-OFF pushbutton returns to its initial position when
turned into the direction indicated by the arrows on the pushbutton.
2. To reset the emergency-off safety relay of the drive, press
EMERGENCY-OFF RESET button.

08 OPERATION
After resetting, the drive status message changes to ReadyOn.
1 L -> 0.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
The main power supply can be connected to the drive, and the drive
can be started again.

08 OPERATION
8.10 Arc resistant design

The arc resistant design provides the drive with ABB class IV arc fault
protection (see Table 8-1) in accordance with IEC 62477-2.
Table 8-1 ABB arc resistant classes
ABB class Description

Class I Protection based on arc prevention (NOT certified according to
IEC 62477-2 )
Class II Protection based on arc resistant cabinet structure (1)
Class III Protection based on external arc fault limitation and elimination.
HV fuses are applied externally to limit the arc fault current (1)
Class IV Fast arc detection and elimination (1)
(1) IAC certified by 3rd body according to IEC 62477-2
8.10.1 Internal arc classification (IAC)

The arc fault rating, which is based on arc fault tests, is on the label
underneath the drive rating plate of the drive.
Internal Arc Classification (IAC)

ABB Class IV
IAC F L R T B Iඉ tඉ APR SC
IEC 62477-2 2b 2b 2b 1 1 9.5 kA 0.5 s Yes No

Distance [m] 0.3 0.3 0.3 - -
3BHB049908R5409
Figure 8-2 IAC label example

IMPORTANT! The Main Circuit Breaker (MCB) for the drive fulfills the APR
(Associated Protection Requirement) without the need for additional
devices. The MCB requirements are described in “2.7 Important note -
main circuit breaker” on page 35.

08 OPERATION
8.10.2 Arc detection with the Arc Guard System™

The Arc Guard System™ detects fast arc faults in the terminal sections of
the drive. When the Arc Guard System detects an arc fault the drive
performs protection firing and immediately opens the main circuit
breaker. The Arc Guard monitor and HMI panel are located in the
COU (Fig. 3-12).
Figure 8-3 Arc Guard™ system with HMI panel

The Arc Guard System™ consists of the following:
• Arc Guard unit TVOC-2 with HMI panel
• Optical fiber detector
8.10.3 Action after the Arc Guard System™ has been triggered
1. De-energize and ground the drive according to “10.6.2 De-energizing
the drive” on page 172.
2. Search for the location where the arc has been detected.
3. Check the Arc Guard HMI panel messages and use the
circuit diagrams.
Figure 8-4 HMI panel

4. Open the power units and localize the defect.
5. Repair the defect or contact support line if needed.
6. Reset the fault on Arc Guard HMI panel.
7. Acknowledge the firing through with parameter 16.26 on the CDP
control panel (only when fault was understood and corrected).
8. Restart the drive.

08 OPERATION
8.11 De-energizing and grounding the drive

See “10.6.2 De-energizing the drive” on page 172.
8.12 Opening the doors

See “10.6.3 Opening and closing the doors” on page 174.

9. CDP control panel
9.1 Overview
The panel messages and parameter settings in the following sections are
typical examples and might differ from the actual ones.
9.1.1 Display and keypad
2 1 L -> 1242.0 rpm

StateINU ReadyOn
3 MOTOR SP 1242 rpm
POWER 86.0 kW
11
6 12
7 13
8 14
9
15
10
Figure 9-1 CDP control panel

(1) Display (8) Reset key
(2) Status line (9) Forward key
(3) Actual signal names and values (10) Backward key
(4) Keypad (11) Slow navigation key for selecting
signals or fault messages
(5) Mode selection keys
(12) Enter key, terminates a procedure
(6) Fast navigation key for selecting
the actual signals display or the (13) Reference key
fault memory display (14) Start key
(7) Local / remote selection key (15) Stop key

09 CDP CONTROL PANEL
9.1.2 Functions
The CDP control panel serves as the basic user interface for operating and
monitoring the drive when the local operating mode has been selected.
The CDP control panel can be attached to or detached from the drive
without having to switch off the auxiliary power supply first.
Using the CDP control panel, it is possible to:
• Enter startup data
• Enter reference values
• Enter start, stop and direction commands
• Display actual values (three values can be read simultaneously)
• Display and adjust parameters
• Display information on the most recent 64 fault events
9.2 Modes
The CDP control panel provides the following modes:
• “9.2.1 Identification mode” on page 140
• “9.2.2 Actual signals mode” on page 142
• “9.2.3 Parameters mode” on page 149
• “9.2.4 Functions mode” on page 154
• Drive mode (not used)
9.2.1 Identification mode

The identification mode informs the user about the CDP control panel
version and the ID number of the drive. The information appears on
the display
• when the power supply is switched on, or
• when the CDP control panel is connected to the drive and the
auxiliary voltage has been switched on already.
When the CDP control panel is initialized, the display changes as follows:
CDP312 PANEL V5.30
...........
After 2-3 seconds the display shows the drive name (1, 2), the application
software in use (3), and the drive identification (4) is displayed.

1 ACS6000 xxxx
2 <Device Name>
3 LXHH44xx
4 ID-NUMBER 1
After another few seconds.
1 L -> 0.0 rpm

StateINU InitSeq....
MOTOR SP 0.00 rpm
POWER 0.0 kW
After another few seconds, the display changes to the actual signals
display. The status line of the display alternates between DCGndNOpen
and NotReadyOn.

1 L -> 0.0 rpm
StateINU DCGndNopen • DCGndNopen
MOTOR SP 0.00 rpm

9.2.2 Actual signals mode
1 1 L -> 600.0 rpm

StateINU InitSeq....
2 MOTOR SP 0.00 rpm
POWER 0.0 kW
4 6
Figure 9-2 Control panel functions for Actual signals mode

(1) Display (5) Slow navigation key for selecting
signals or fault messages
(2) Actual signal names and values
(6) Enter key for confirming the
(3) Selection key for actual
selection
signals mode
(4) Fast navigation key for selecting
the actual signals display or the
fault memory display
9.2.2.1 Overview
Two displays can be selected in the actual signals mode:
• Actual signals display
• Fault memory display
The actual signals display appears first when entering the actual signals
mode. However, when the drive is in a fault condition, the fault memory
display appears instead.
The actual signals display is used to monitor the drive without interfering
with its operation. It continuously displays three selectable actual values.

If no key is actuated within one minute (an exception from this is the fault
memory display), the CDP control panel automatically returns to the
actual signals display from other modes.
Actual values
For the complete list of selectable actual signals, see
“Appendix G – Signal and parameter table”.
The actual values are organized in groups.
Group Description
Group 01 Measured or calculated motor values
Group 02 Measured or calculated drive values
Group 03 Reference values
Group 04 Status signals of S800 I/O system
Group 05 Communication link and MCB status signals
Group 06 Software version, drive and motor nominal values
Group 07 Control words
Group 08 Status words
Group 09 Fault and alarm words
Fault memory
The fault memory display provides information on the 64 most recent
fault events that occurred in the drive. It displays the name of the fault
and the time it occurred. For instructions on how to display and reset the
fault memory, see “9.2.2.7 Displaying and resetting an active fault”
on page 148.
When the drive generates a fault or alarm, the corresponding message
displays immediately.
Changing from the fault memory display to other modes is possible
without resetting the fault first. If no key is actuated, the fault or alarm
message displays as long as the fault is active.
9.2.2.2 Selecting the actual signals display

To select the actual signals display, press the ACT key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0

9.2.2.3 Toggling between actual signals display and fault memory

To toggle between actual signals display and fault history display, press a
fast navigation key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

1 LAST FAULT
ENTER
+Overspeed
070730 12:30:02.3256
LOC RESET REF
REM
I 0
9.2.2.4 Displaying three actual signals

1. To display the full name of three actual signals, press and hold the
ACT key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU
ENTER
MOTOR SPEED
POWER
LOC RESET REF
REM
I 0
2. To return to the actual signals display, release the ACT key.
9.2.2.5 Selecting actual signals

1. To select the actual signals display, press the ACT key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0

2. To select a line where the actual signal is to be displayed, press the

slow navigation keys. A blinking cursor indicates the selected line.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0
3. To enter the actual signals selection function, press the ENTER key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

1 ACTUAL SIGNALS
ENTER
15 POWER
0.0 kW
LOC RESET REF
REM
I 0
4. To select a parameter group, press a fast navigation keys.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

1 ACTUAL SIGNALS
ENTER
01 DC VOLTAGE
1000 V
LOC RESET REF
REM
I 0
5. To select an actual signal, press a slow navigation keys.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

2 ACTUAL SIGNALS
ENTER
05 NP VOLTAGE
1000 V
LOC RESET REF
REM
I 0

6. To confirm the selection and to return to the actual signals display,

press the ENTER key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
NP VOLT 0V
LOC RESET REF
REM
I 0
7. To cancel the selection and keep the original selection, press any of
the mode selection keys. The selected keypad mode is entered.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0
9.2.2.6 Displaying a fault and resetting the fault memory

1. To open the actual signals display, press the ACT key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0
2. To change to the fault memory display, press a fast navigation key.

ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

1 LAST FAULT
ENTER
+ PANEL LOST
070730 12:30:02.3256
LOC RESET REF
REM
I 0
3. To display a specific fault, press the slow navigation keys. The up key
selects the previous, the down key the next fault.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

2 LAST FAULT
ENTER
+ AMC: Fault Class 1
9H 38 MIN 48 s
LOC RESET REF
REM
I 0
4. To clear the fault memory, press the RESET key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

1 LAST FAULT
ENTER
H MIN S
LOC RESET REF
REM
I 0
5. To return to the actual signals display, press a fast navigation key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0

9.2.2.7 Displaying and resetting an active fault

1. To display an active fault, press the ACT key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

ACS5000
ENTER
*** FAULT ***
MCB CloseControl
LOC RESET REF
REM
I 0
2. To reset the fault, press the RESET key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0

9.2.3 Parameters mode
▲NOTICE
Running the drive system with incorrect data can result in improper
operation, reduction of control accuracy and damage of equipment.
• Parameters must only be set by qualified personnel.
• DO NOT change any parameter, if the meaning of the parameter and
the effects of the change are not fully understood.
1 1 L -> 600.0 rpm

2 77 SYSTEM CONFIG
3 01 INU IdentifySel
4 INU1 (MASTER)
6 8
Figure 9-3 Control panel functions for Parameters mode

(1) Status line (6) Fast navigation key for selecting a
parameter group (and a parameter
(2) Group number and name
value)
(3) Parameter number and name
(7) Slow navigation key for selecting a
(4) Parameter value parameter (and a parameter value)
(5) Selection key for (8) Enter key for confirming
parameters mode the selection

9.2.3.1 Overview
If the parameter lock is disabled or unlocked (see “9.2.3.3 Enabling /
unlocking a parameter lock” on page 153) the parameters mode allows
entering the parameter settings for the required drive configuration
depending on the application.
The parameters are organized in functional groups, so called
parameter groups.
Group Description Paramet Description

er
Group 07 Control words 21.01 Start function
Group 08 Status words 21.02 Start function
Group 09 Fault and alarm words 21.03 Off1 stop mode
Group 11 Start, stop, direction or 21.04 Process stop selection
MCB control
Group 12 Reference selection 21.05 Process stop signal
Group 16 System control inputs 21.06 Process stop MCB control
Group 17 DC link control 21.07 Process stop mode
Group 18 Utility .
Group 19 Data storage .
Group 20 Limits .
Group 21 Start / stop / process stop 21.17 MCB closing time limit
Group 22 Ramp functions .
Group 23 Speed reference 21.19 MCB available signal
Note: For details about the parameters, their settings and functions, see
“Appendix G – Signal and parameter table”.
When entering the parameters mode for the first time after the auxiliary
supply voltage of the drive has been switched on, the CDP control panel
displays the first parameter of parameter group 11. The next time the
parameters mode is entered, the previously selected parameter displays.
Some parameter settings cannot be changed while the drive is running. If
tried, the following warning displays.
** WARNING **
WRITE ACCESS DENIED
PARAMETER SETTING
NOT POSSIBLE

9.2.3.2 Changing a parameter setting

1. To enter the parameters mode, press the PAR key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

77 SYSTEM CONFIG
ENTER
01 INU IdentifySel
INU1 (MASTER)
LOC RESET REF
REM
I 0
2. To select a different group, press a fast navigation key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
06 C3P1/AI820 Module
DISABLED
LOC RESET REF
REM
I 0
3. To select a parameter, press a slow navigation key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
DISABLED
LOC RESET REF
REM
I 0
4. To enter the parameter setting function, press the ENTER key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
[DISABLED]
LOC RESET REF
REM
I 0

5. To change the parameter value, press

6. the slow navigation keys for numbers and text,
7. the fast navigation keys for numbers only.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
[DI810 24VDC]
LOC RESET REF
REM
I 0
8. To confirm the setting and to return to the actual signals display,

ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
DI810 24 VDC
LOC RESET REF
REM
I 0
9. To cancel the setting and keep the original setting, press any of the
mode selection keys. The selected keypad mode is entered.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

75 OPTION MODULES
ENTER
DISABLED
LOC RESET REF
REM
I 0

9.2.3.3 Enabling / unlocking a parameter lock

Unwanted parameter settings can be prevented by activating the
parameter lock function.
The corresponding parameters are 16.02 PARAMETER LOCK and 16.03
PASSCODE and belong to parameter group 16 SYSTEM CTRL INPUTS.
9.2.3.3.1 Enabling the parameter lock
1. Select parameter 16.02.

2. Set parameter 16.02 to 1 (LOCKED).
3. Confirm the setting and exit the parameters mode.
9.2.3.3.2 Unlocking the parameter lock
1. Select parameter 16.03.

2. Set the correct pass code.
3. Confirm the setting and exit the parameters mode.
Note: For more information, see “Appendix G – Signal and
parameter table”.
9.2.3.4 User lock
▲NOTICE
ABB is not be liable for damages or losses caused by the failure to
activate the user lock with a new pass code.
For more information, see “1.9 Cyber security disclaimer” on page 25.
For better cyber security, it is highly recommended that you set a master
pass code for the control panel to prevent the parameter values from
being changed.
• To activate the user lock for the first time, enter the default pass
code, 358, into 16.02 Passcode. This will make parameters
16.24…16.25 changeable. Then enter the old pass code to 16.24
OldUserPasscode and change user pass code in
16.25 NewUserPasscode. In 16.02 Parameter Lock, the user lock
functionality can now be enabled.
• To reopen the lock, enter your pass code into 16.03 Passcode. This
will again make parameters 16.24 and 16.25 visible.

9.2.4 Functions mode

The functions mode is used for adjusting the display contrast.
1 1 L -> 0.0 rpm

UPLOAD <= <=
2 DOWNLOAD => =>
CONTRAST 4
4 5
Figure 9-4 Control panel functions for Functions mode

(1) Status line (4) Slow navigation key for selecting a
line (and adjusting the contrast)
(2) Selectable functions
(5) Enter key for confirming
(3) Selection key for functions mode
the selection
9.2.4.1 Adjusting the display contrast

1. To enter the functions mode, press the FUNC key.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

UPLOAD <= <=
ENTER
DOWNLOAD => =>
CONTRAST 4
LOC RESET REF
REM
I 0

2. To select the contrast adjustment function, press the slow navigation

keys until the blinking cursor reaches the CONTRAST line.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

UPLOAD <= <=
ENTER
DOWNLOAD => =>
CONTRAST 4
LOC RESET REF
REM
I 0
3. Press the ENTER key.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

CONTRAST [4]
ENTER
LOC RESET REF
REM
I 0
4. To change the contrast, press the slow navigation keys.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

CONTRAST [6]
ENTER
LOC RESET REF
REM
I 0
5. To confirm the setting and to return to the actual signals display,

ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

UPLOAD <= <=
ENTER
DOWNLOAD => =>
CONTRAST 6
LOC RESET REF
REM
I 0

6. To cancel the setting and keep the original setting, press any of the
mode selection keys. The selected keypad mode is entered.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm

UPLOAD <= <=
ENTER
DOWNLOAD => =>
CONTRAST 6
LOC RESET REF
REM
I 0
9.2.5 Local and remote control mode

The local-remote feature of the CDP control panel allows selecting the
control location of the drive. Possible are:
• Local control (L)
• Remote control (R)
Note: In this context, remote control is not necessarily equivalent to
higher-level control. For more information, see “9.2.5.4 Remote
control” on page 157.
9.2.5.1 Local control

In local control mode, full operational control of the drive is enabled from
the local operator panel. Commands from remote have no effect.
• To enter the local control mode, press the LOC-REM key.
Local control is indicated by the letter L.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm 0

StateINU ReadyRun
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0
9.2.5.2 Disabling / enabling local lock function

Accidental switching from remote control to local control can be
prevented with the local lock function.
The corresponding parameter is 16.04 LOCAL LOCK and belongs to the
parameter group 16 SYSTEM CTRL INPUTS.

9.2.5.3 Enabling the local lock

• To enable the local lock, set parameter 16.04 to 2 (LOCKED).
With this parameter setting, local control (including the LOC-REM key)
is disabled.
If the CDP control panel or a DriveWindow PC is in local control mode
at the time that the local lock is enabled, they remain in local control
mode until they are switched to remote control mode. This means that
the CDP control panel displays the letter L until you press the
LOC-REM key.
9.2.5.3.1 Disabling the local lock

• To disable the local lock, set parameter 16.04 to 1 (OPEN).
With this parameter setting, switching between remote and local
control is enabled.
9.2.5.4 Remote control

In remote control mode, operational commands or reference values
usually come from a higher-level control system via fieldbus or
remote I/O.
However, with the following parameter settings it is possible to start and
stop the drive, to set the direction of rotation, and to enter reference
values from the CDP control panel.
• 11.01 EXT1 START/STOP/DIR = 10 (KEYPAD) or
12.03 EXT REF1 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 1 (EXT1)
• 11.02 EXT2 START/STOP/DIR 10 (KEYPAD) or
12.06 EXT REF2 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 2 (EXT2)
• To enter the remote control mode, press the LOC-REM key.
- A blank space indicates full remote control from a higher-level
control system.
- The letter R indicates partial remote control (some commands
are enabled locally).
ACT PAR FUNC DRIVE
1 600.0 rpm 0
StateINU ReadyRun
ENTER
MOTOR SP 0.00 rpm
POWER 0.0 kW
LOC RESET REF
REM
I 0

1R 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
Note: To prevent accidental switching from remote control to local

control, see “9.2.5.2 Disabling / enabling local lock function” on page 156.
9.3 Operational commands

For instructions on how to start and stop the drive system from the CDP
control panel, see “8.7 Starting the drive” on page 129 and “8.8 Stopping
9.3.1 Setting the direction of rotation

Setting the direction of rotation from the CDP control panel is possible in:
• Local control mode (L)
• Remote control mode (R)
The arrow on the display indicates the direction of rotation:
• When the motor is running, the arrow indicates the actual direction.
• When the motor is not running, the arrow indicates the preselected
direction.
To set the direction of rotation, press the forward or backward key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0

ACT PAR FUNC DRIVE
1 L <- 600.0 rpm

StateINU ReadyOn
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0
If you change the direction while the motor is running, the motor
automatically ramps down to zero speed and reaccelerates in the
opposite direction to the preset speed. The arrow changes at zero speed.
9.3.2 Entering a reference value

Entering a reference value from the CDP control panel is possible in:
• Local control mode (L)
• Remote control mode (R)
1. Press a mode selection key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm 0

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0
2. To enter the reference value input mode, press the REF key.
ACT PAR FUNC DRIVE
1 L -> [600.0 rpm] 0

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0

3. To enter / change the reference value, press the corresponding fast

or slow navigation key.
ACT PAR FUNC DRIVE
1 L -> [550.0 rpm] 0

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0
4. To exit the mode, press a mode selection key.
ACT PAR FUNC DRIVE
1 L -> 550.0 rpm 0

StateINU ReadyRun
ENTER
MOTOR SP 600.00 rpm
POWER 75.0 kW
LOC RESET REF
REM
I 0

10. Preventive and corrective maintenance
10.1 General information

During the warranty period of the drive, any maintenance must be carried
out exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by certified personnel.
10.1.1 Required qualification

To maintain safe and reliable operation of the drive, ABB recommends
taking out a service contract with the ABB service organization.
10.1.2 Maintenance schedule

Carry out all maintenance tasks according to the maintenance schedule,
on time and at the stated intervals in the "ACS5000 preventive
maintenance schedule" (3BHS855274 E01).
10.1.3 Logbook
It is recommended to record all troubleshooting and maintenance work in
a logbook including:
• Date and time
• Detailed description
10.1.4 Spare parts

To ensure safe and reliable operation, use only spare parts recommended
and approved by ABB.
Note: For information on types and identification codes, see “Appendix E
– Parts list”.
10.2 Identifying electrical equipment

10.2.1 Device designation
To facilitate the identification in wiring diagrams and parts lists, all
devices are labeled in accordance with IEC 81346-1.

10 PREVENTIVE AND CORRECTIVE MAINTENANCE
-A2501
Figure 10-1 Device identification
10.2.2 Cables and wires

Cables and wires in the drive are equipped with marker sleeves that carry
the same identifying number as on the wiring diagrams.
Figure 10-2 Cable and wire designation

(1) Terminal number (2) Wire number
10.2.3 Understanding wiring diagrams

For information on item designation and cross-reference conventions, see
“Appendix D – Wiring diagrams”.

10.3 Alarm / fault indications

When a failure occurs in the drive or in the equipment monitored by the
drive (eg, main circuit breaker, transformer, cooling system), the CDP
control panel displays a corresponding alarm or fault message.
10.3.1 Messages
The type of light emitted by the alarm / fault lamp on the control
compartment door depends on the type of message:
• Flashing light: alarm
• Light remains on: fault
SUPPLY
OFF ON
1 L -> 600.0 rpm

ACS5000
** FAULT **
CW1 NoWtrPumpOn
ALARM EMERGENCY OFF

FAULT RESET
EMERGENCY OFF
The message can be saved and viewed in the fault history of the drive
when a PC with DriveWindow, DriveDebug or DriveMonitor is connected to
the drive. The fault history can also be called up on the CDP control panel.
10.3.2 Error message levels

• Two error message levels are used in the drive:
• Alarm: does not shut down the drive
• Fault: shuts down the drive
10.3.2.1 Alarm
An alarm does not shut down the drive. If the condition causing the alarm
is not corrected, a persisting alarm can often lead to a fault. An alarm
cannot be reset manually. The alarm message is deleted from the display
as soon as the alarm condition has been corrected.
10.3.2.2 Fault
A fault shuts down the drive. The type of shutdown depends on the origin
of the fault.

Depending on the type of fault, the drive opens the main circuit breaker
(MCB) or keeps it closed:
• Class 1 faults (FC 1) open the MCB.
• Class 2 faults (FC 2) do not open the MCB.
Since the MCB is controlled and monitored entirely by the drive, no
external opening command must be given to the MCB when a fault
condition occurs.
A fault condition must be corrected and the fault be manually reset before
the drive can be started again.
10.3.2.3 Alarm / fault messages

When an alarm or a fault occurs, a specific message is saved in the fault
history of the drive. Information on the 64 most recent fault and alarm
events are saved.
10.3.3 Fault handling

The faults are entered into the fault buffer as they occur and are
numbered:
• The last fault entered has number 1.
• The first fault entered has the highest number.
Information of the fault classification (eg, FC 1 or FC 2) is also saved when
the first fault of the fault class is active. Date and time stamps facilitate
fault tracing, especially when a fault leads to several subsequent faults.
Example:
1) +Fault AMC: Fault Class 2 2008-01-08 16:58:24.3770

2) +Fault PPCS Communication 2008-01-08 16:58:24.3760
3) +Fault AMC: Fault Class 1 2008-01-08 16:56:02.1170
4) +Fault DC Undervoltage 2008-01-08 16:56:02.1170
In the above example:

4. +Fault DC Undervoltage is the reason for the failure of the drive
system as it occurred first.
3. +Fault AMC: Fault Class 1 classifies the fault.
2. +Fault PPCS Communication represents a subsequent fault that
occurred 2 min. 22 s than the first fault.
. +Fault AMC: Fault Class 2 classifies the fault.
Note: For more information on alarms and faults, see “Appendix G - Signal
and parameter table”.

10.3.4 Standard troubleshooting procedure

If a fault shuts down the drive, proceed as follows:
1) DO NOT switch off the auxiliary supply voltage or try to reset a
fault message before all information at the time of the
occurrence of the fault condition has been saved.
2) Select the fault history display on the CDP control panel, but do
not clear the buffer now!
For more information, see “9 CDP control panel” on page 139.
3) Identify the fault and make a logbook entry.
4) Save the content of the data logger when a PC is available that

has the DriveWindow or DriveDebug tool installed.
The data logger provides information (eg, waveforms of
voltage, current, torque) for efficient troubleshooting.
5) Contact ABB service if a fault cannot be rectified.
When calling ABB service, it is recommended to have the
following data available at the time when the fault occurred:
• Operating, ambient and load conditions
• Unusual events
6) After the fault has been rectified, start the drive as described
in “8 Operation” on page 123.
10.4 Removing the CDP control panel

When the CDP control panel must be removed from its mounting cradle,
follow the instructions below.
1. When the panel is removed while the drive is in operation, check the
setting of parameter 31.01 PANEL LOSS SUPERVISION first.
If the parameter is set to NOT USED, the panel can be removed without
interrupting drive operation.
Note: For more information on parameter settings, see “Appendix G –
Signal and parameter table”.

2. To remove the panel, proceed as illustrated.

IMPORTANT! When the CDP control panel has been removed during
operation, the drive can only be stopped by pressing the emergency-
off pushbutton.
1 2 3
LEDs
The green LED (4) signals that the control voltage has been switched on.
Communication with AMC circuit board
The CDP control panel (1) is connected to the AMC circuit board (2) via an
RS485 interface.
ACT PAR FUNC DRIVE

2
ENTER
LOC RESET REF
REM
I 0
10.5 LEDs and switches on circuit boards and I/O devices

The following section provides an overview of the meaning of LEDs and
switches of the main circuit boards and I/O modules. The LEDs presented
in the following section can be checked easily while the auxiliary voltage
is switched on without having to remove covers first. The LEDs provide
information on the status of the devices and can be used for
diagnostic purposes.

10.5.1 AMC circuit board
F R
M P
T1 T2
S3 S1
S2 S0
Figure 10-3 LEDs of AMC circuit board
LED Color Description Status when Status when

software software
has loaded has not loaded
Booting ON Booting ON
F Red Fault ON OFF ON ON
R Green Run OFF OFF OFF OFF
M Green ON OFF ON ON
P Green Supply OK ON ON ON ON
T1 Yellow Receiving data on Flashing ON / OFF Flashing ON / OFF
DDCS channel 0
T2 Yellow Receiving data on Flashing ON / OFF Flashing ON / OFF
DDCS channel 3
S3 Yellow OFF OFF OFF OFF
S1 Yellow Flashing OFF Flashing OFF

10.5.2 S800 I/O bus modem TB820
Figure 10-4 TB820 bus modem
LED Color Indication

F Red Fault in module
R Green Device in operation
P Green Power supply is healthy
Rx1 Yellow Traffic on optical module bus
Rx2 Yellow Traffic on optical module bus
ERx Yellow Traffic on electrical module bus
10.5.2.1 Bus modem address

The TB820 bus modem has a unique cluster address that identifies the
module in the software and links it to a parameter.
The address is set with the rotary switch on the module (Fig. 10-4: 1). The
factory-set value must not be changed.

10.5.3 S800 I/O modules

LEDs on I/O modules having the same meaning on all types of I/O modules
are always at the same position. The LEDs are always at the topmost
position on each module (Fig. 10-5: 1) and are identified as follows:
• F: fault
• R: run
• W: warning
• O or OSP (only output modules)
1 1 1 1
Figure 10-5 Example of S800 I/O station
LED Color Indication

F Red Indicates failure
R Green Device is operating normally
W Yellow External fault or minor fault in the module
O Yellow Indicates an active signal
OSP Yellow Indicates an active signal
(Output Set as Predetermined)
Note: For more information, see the following manuals:

• S800 I/O - General information and installation, user’s guide
• S800 I/O - Modules and termination unit, user’s guide
10.6 Corrective maintenance

Overview on maintenance tasks:
• “10.6.6 Visual checks on the drive” on page 179

• “10.6.7 Cleaning§” on page 180

• “10.6.8 Checking wire and cable connections” on page 181
• “10.6.9 Checking and replacing filter mats” on page 181
• “10.6.10 Replacing a door-mounted fan” on page 182
• “10.6.11 Replacing a fan of an IP42 roof-mounted cooling unit”
on page 183 (optional)
• “10.6.12 Replacing a fan of an IP54 roof-mounted cooling unit”
on page 184 (optional)

10.6.1 Safety
▲ DANGER
⚠
Hazardous voltages!
Before starting to work on the drive, make sure:
• Main and auxiliary power supply to the drive are switched off,
locked out, and tagged out,
• Drive is de-energized
• Grounding connections are in place
• Personal protective equipment is provided and used when required
• Everyone involved is informed
Before energizing the drive again, make sure:
• All foreign objects are removed from the drive
• All internal and external covers are securely fastened and all doors
are closed, locked and / or secured (locking bar in locked position)
• Release dials of safety switches are in locked position
• When maintenance on the drive is carried out, such as changing of
semiconductors, grounding equipment must be connected at the
appropriate locations.
The grounding equipment ensures that hazardous voltages cannot
be fed into the drive, from the main power supply or the motor.
▲ WARNING
⚠
Hazardous DC voltage!
Depending on the type of auxiliary supply, the drive can be equipped with
buffer capacitors inside the control unit. During operation, the capacitor
voltage is 300 V (DC).
• Wait 5 minutes for the capacitors to discharge.
• Before touching a capacitor, verify that the capacitors
are discharged.
▲NOTICE
Foreign matter and particularly metallic dust can cause failure and
damage when the drive is energized!
Ensure that foreign matter cannot enter the cabinet:
• Close the doors and cover openings completely when work is
discontinued.
• Retrieve any foreign matter which accidentally dropped into the
cabinet.

10.6.2 De-energizing the drive

The following section describes how to de-energize the drive using the
local operator panel of the drive. If the drive is controlled from remote,
follow the established shutdown procedures.
Note: For instructions on how to use the CDP control panel, see “9 CDP
control panel” on page 139.
10.6.2.1 Stopping the motor

1. Enable the local control mode of the CDP control panel.
LOC RESET REF
REM
2. To stop the motor, press the STOP key.
I 0
When the motor has reached zero speed, the display shows ReadyRun.
1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
10.6.2.2 De-energizing the drive

1. To disconnect the drive from the main power supply, press the
SUPPLY OFF pushbutton. The following takes place:
2. Main circuit breaker (MCB) opens
3. DC link discharges
While the DC link discharges, the CDP control panel shows
the following:
1 L -> 600.0 rpm Alternating display message:

StateINU OffSeqOn
• OffSeqOn
MOTOR SP 0.00 rpm
POWER 0.0 kW • Discharging
• AuxiliaryOn

When the DC link has discharged completely, the status line displays
ReadyOn and the SUPPLY OFF pushbutton changes to a
permanent light.
1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
4. Rack-out, lock-out, ground and tag-out the main circuit breaker.

5. Wait until the yellow lamp GROUNDING SWITCH UNLOCKED lights up.
Because cooling of the drive continues for a preset time after
switching off the main power supply, the yellow lamp lights up with
a delay.
If the lamp does not light up and there is a reason to believe that the
grounding circuit is malfunctioning.
Note: For more information, “10.4 Removing the CDP control panel”
on page 165.
6. Once the yellow lamp GROUNDING SWITCH UNLOCKED is lit, turn the
grounding switch to the grounded position.
7. When the grounding switch is in the grounded position, the status
line alternates between DCGnd NOpen, NotReadyOn, StateINU
NotRdy.
1 L -> 600.0 rpm Alternating display message:

StateINU DCGnd NOpen
• DCGnd Nopen
MOTOR SP 0.00 rpm
8. If necessary, open the doors of medium voltage compartments

according to “10.6.3 Opening and closing the doors” on page 174
9. Switch off and lock-out all auxiliary supply voltages from
external sources.
The drive is now de-energized, and safe access is possible.

10.6.3 Opening and closing the doors

Releasing the doors
(1) White lamp: Lights up to indicate (3) Locking bar: Releases or blocks
that the drive is grounded and you the door handles of a
can slide the locking bar to the PCU compartment.
unlocked / locked position. (4) Grounding switch: in horizontal
(2) Yellow lamp: Lights up when the position, the drive is grounded. In
grounding switch has vertical position, the drive is not
been released. You can then turn grounded.
the grounding switch to the
grounded or ungrounded position.
1. To test the yellow lamp, press its pushbutton.

If the lamp does not light up, see “10.4 Removing the CDP control
panel” on page 165.
2. If the drive is in operation, stop the drive according to “8.8 Stopping
3. To discharge the DC link of the drive, press the SUPPLY OFF
pushbutton on the local control panel.
The yellow lamp lights up when the DC link is discharged.
If the yellow lamp does not light up, see “10.4 Removing the CDP
control panel” on page 165.
4. Once the yellow lamp lights up, turn the grounding switch to the
grounded position.
The white lamp lights up to indicate that the drive is grounded.

5. Once the white lamp lights up, slide the locking bar from the locked
(1) to the unlocked (2) position.
1 2
Opening the doors
1. To release the door handle, insert and turn the key to the right.
The door handle pops out.
2. To open the door, turn the door handle:
3. To the right if the door is hinged on the right
4. To the left if the door is hinged on the left.
Closing and locking the doors

Once maintenance of medium voltage compartments is complete,
proceed as follows:
1. To close a door, bring the door handle in line with the door plate and
press the handle down until it clicks in.
2. Before actuating the locking bars, make sure that the drive is
supplied with auxiliary voltage.
3. To lock a door, slide the locking bar from the unlocked (1) to the
locked (2) position.

1 2
A limit switch monitors the locked position of the locking bars. If any
door of a medium voltage compartment is not locked properly, you
cannot start the drive.
10.6.4 Grounding switch is not released

When the DC link of the drive has been discharged, the lamp GROUNDING
SWITCH UNLOCKED lights up to indicate that the grounding switch is
released and can be turned to the grounded position.
IMPORTANT! Do not use force for turning the grounding switch in
any direction. The handle and / or the switch could get damaged.
If the lamp does not light up, proceed as follows:
1) Verify that the main circuit breaker (MCB) is in the open position.
2) Check the drive status on the CDP control panel.
The drive status should be ReadyOn, indicating that the DC link has
discharged and the MCB has opened.
3) Check the actual value of the DC-link voltage on the CDP
control panel.
The actual value (parameter 2.30 DC Volt 1-3 MaxVal) must be
< 50 V (discharged).
4) Check if there are any alarm and fault messages on the display.
If there are alarms / faults, contact the ABB service organization

10.6.5 Emergency release of a door safety switch
▲ DANGER
⚠
Hazardous voltages!
Touching energized components can be fatal.
• Before you unlock a safety switch, de-energize and ground the drive
according to“10.6.2 De-energizing the drive” on page 172.
• Do not unlock the safety switches permanently.
10.6.5.1 Location of safety switches

Each primary and each secondary PCU is equipped with a safety switch.
The safety switches block and release the locking bars, depending on
whether or not the drive is discharged and grounded. This prevents doors
from being opened unintentionally during operation.
In 1700 mm PCUs, the safety switches are on the back of the left door.
In 2100 mm PCUs, the safety switches are on the back of the middle door.
A screw cap on the front of the door marks the exact position.
Figure 10-6 Location of safety switches

(1) Safety switch

For the safety switches to work and to be able to open the doors, auxiliary
power supply is required.
If the auxiliary power supply is unavailable and the doors are closed, you
can only open them by unlocking the safety switch manually.
10.6.5.2 Safety-switch settings
1
2 3
Figure 10-7 Safety switch

(1) Release dial (3) Locked position: Normal
operating setting
(2) Unlocked position: enables
To open the door of a medium
opening the door of a medium
voltage unit, the DC link must be
voltage unit whether the auxiliary
discharged and the auxiliary
voltage is switched on or off.
voltage must be switched on.
Unlocking
1. To access the release dial (2), remove the screw cap (1) from the door.
2. Turn out the locking screw (1) until the release dial can be turned.
PZ0 1

3. Turn the release dial from the locked to the unlocked position.
You can now actuate the locking bar and open the doors.
5 mm 1
4. When the door is open, turn the release dial to the locked position
and screw in the locking screw.
5. Screw in the locking screw again.

6. Refit the screw cap.
10.6.6 Visual checks on the drive

Check the drive and its immediate vicinity visually at the intervals stated
on the maintenance schedule and pay attention to the following items:
• Humidity inside the drive
• Permitted range of ambient air temperature and humidity of
the drive
• Dust built-up inside the drive
• Appropriate fastening of cables and wires and connections of cable
shields and screens
• Integrity of cable insulation
• Signs for overheated components, wires, cables or busbars
• Corrosion on electronic circuit boards, connectors or busbars
• Correct type of signal and power supply cables
Note: For information, see the applicable cable specifications.

10.6.7 Cleaning§
▲NOTICE
Risk of component damage!
Dust and moisture on electrical components and wiring can cause failure
and damage the components as well as the loss of low-level signals on
loose connections.
• Check the cabinet regularly for signs of dust and humidity and clean
if necessary.
• Use appropriate and recommended cleansing agents.
• DO NOT use alcohol and solvents that can damage the components.
10.6.7.1 Cleaning the drive cabinet

When cleaning the drive cabinet, keep the following in mind:
• To prevent dirt falling into equipment, cover the equipment.
• The drive contains components which are sensitive to electrostatic
discharge. Therefore, take electrostatic-sensitive precautions and
use suitable tools.
• Clean circuit boards with special care. To prevent the components
being damaged, use antistatic brushes and a vacuum cleaner with a
soft nozzle.
• Remove dust on assemblies and busbars inside the cabinet with a
vacuum cleaner and lint-free cleaning cloths.
• Remove water, oily or greasy deposits on assemblies, components
and busbars with water- and oil-absorbing microfibers such as
"3M Scotch Brite".
• Use a nylon brush or a vacuum cleaner for removing dust or deposits
from recesses.
• Clean the outside of the cabinet with a vacuum cleaner and
cleaning cloths.

10.6.8 Checking wire and cable connections
▲NOTICE
Risk of component damage!
Vibration can loosen electrical connections and cause equipment failure!
Excessive force damages the capacitor bushings!
• Tighten to the torque value on the label attached to the capacitor.
IMPORTANT! DO NOT exceed 20 Nm if the tightening torque value is
not specified.
• Check all power and control cable connections and tighten them
if necessary.
• Check that all plugs and connectors are tight.
10.6.9 Checking and replacing filter mats

For the filter mat replacement interval, see the "ACS5000 preventive
maintenance schedule" (3BHS855274 E01).
10.6.9.1 Location
Drives with IP54 cabinet, have filter mats in the following
compartment doors:
• Water cooling unit (WCU)
Drives with IP42 cabinet, have filter mats in the following
compartment doors:
• Phase converter unit (PCU)
• Water cooling unit (WCU)
Note: When replacing a filter mat, see “Appendix D – Wiring diagrams” for
information on the protection switch of the cooling fan
10.6.9.2 Replacing filter mats

IMPORTANT! Use only filter mats of the same filter class and size as the
original filter mat for replacement.
Table 10-1 Filter mat specifications
Item Description
Filter class G3 (EN779)
Thickness ∼ 10 mm
Dimensions WCU: 125 x 250 mm
PCU: 600 x 652 mm
Although checking and replacing the filter mats of the WCU compartment
is possible during operation of the drive, it is easier to do it when the drive
is shut down. The fans behind the air outlet panels may start
automatically when the temperature rises to a certain level.

Replacing both types of WCU filter mats

1. Switch off the protection switch of the cooling fan according to
“Appendix D – Wiring diagrams” in order to prevent the cooling fans
from starting automatically.
2. Remove the air outlet panel (Fig. 10-8:1).
3. Roll down the filter mat (Fig. 10-82) beginning at the top.
4. Insert a new filter mat.
5. Reattach the air outlet panel.
B
2
1 1
Figure 10-8 Filter mat replacement for PCU (A) and WCU (B)
10.6.10 Replacing a door-mounted fan

The WCU compartment has door-mounted fans.
Note: For replacement instructions, see “Assembly instructions for fan and
filter units” in “Appendix A – Additional manuals”.

10.6.11 Replacing a fan of an IP42 roof-mounted cooling unit
▲ WARNING
⚠
Hazardous voltage!
• Before starting any work on the fans, de-energize the cooling unit.
The roof-mounted cooling unit as used with IP42 cabinets consists of

three fans. One fan is redundant and takes over when one of the other
fans fails.
If one fan fails, the red indicator lights up and replacement is required.
10.6.11.1 Replacing a fan

For replacement instructions, see the Instruction manual in
“Appendix A – Additional manuals”
1 2 3
1. Control access panel 3. Location of fans (below cover)

2. Indicator lights
Figure 10-9 Roof-mounted cooling unit (IP42)
• Dimensions: (L x W x H): 1550 x 550 x 230 mm
• Weight: 40 kg

10.6.12 Replacing a fan of an IP54 roof-mounted cooling unit
▲ WARNING
⚠
Hazardous voltage!
• Before starting any work on the fans, de-energize the cooling unit.
The roof-mounted cooling unit as used with IP54 cabinets consists of an

air-to-water heat exchanger and four fans. One fan is redundant and takes
over when one of the other fans fails.
If one fan fails, the red indicator lights up and replacement is required.
10.6.12.1 Replacing a fan

For replacement instructions, see the instruction manual in
“Appendix A – Additional manuals”.
1 2 3 4 5
Figure 10-10 Roof-mounted cooling unit (IP54)

(1) Control access panel (4) Location of fans (below cover)
(2) Air-bleed access plate (5) Lifting eye (one in each corner)
(3) Indicator lights
• Dimensions: (L x W x H): 1550 x 975 x 386 mm

• Weight: 98 kg

/186
—
ABB Switzerland Ltd.
CH-5300 Turgi
Switzerland
new.a b b .com /d r ive s/ me d ium -v ol ta g e -a c- d riv es
3BHS799208 E01 Rev E 17.06.2020
—
© Copyright 2020 ABB. All rights reserved.
The information in this document is subject to change without notice.

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1.1 Equipment covered by this manual 19

1.2 Structure of the user documentation 19

1.3 Related documents 20

1.4 Terms and abbreviations 21

1.6 Target groups and required qualification 24

1.6.2 Mechanical installation 24

1.6.3 Electrical installation 24

1.7 User’s responsibilities 25

1.8 Intended use of equipment 25

1.9 Cyber security disclaimer 25

1.10 Quality certificates and applicable standards 27

1.11 Items covered by delivery 28

1.11.1 Identifying the delivery 28

2. Important safety information 29

2.1 Safety standards 29

2.2 Safety messages 29

2.3 Product safety labels 30

2.4 General safety instructions 31

2.5 The 7 steps that save lives 32

2.7 Important note - main circuit breaker 35

2.7.1 Safety and protection requirements 36

2.7.3 Maintenance recommendation 36

3. Power electronics and cabinet features 37

3.1 Main features of the drive 37

3.2 Frame sizes 40

3.3 Phase converter unit (PCU) 41

3.3.1 Primary phase converter unit (1700 mm and 2100 mm) 41

3.3.2 Secondary phase converter unit (1700 mm and 2100

3.4 Control unit (COU) 47

3.4.1 Main components 48

3.4.1.1 AMC circuit board 49

3.5 Transformer and motor cable terminals 54

3.5.1 Transformer cable terminals 54

3.5.2 Motor cable terminals 54

3.6 Water cooling unit (WCU) 56

3.7 EXU – Excitation unit (optional) 57

3.8 Door interlocking system 59

3.9 Grounding switches 60

3.9.1 Locking bars 61

3.10 Grounding studs 62

3.10.1 Grounding set 62

3.10.2 Output grounding studs in COU 63

3.10.3 Input grounding studs in a PCU 64

4. Transportation, storage and disposal 65

4.3 Unpacking and inspection 65

4.4 Identifying drive units 66

4.4.1 Packing list 66

4.4.2 Packing label 67

4.5 Lifting and transportation 67

4.5.1 Using a crane to lift a transport unit or the drive

4.6.1 Storage conditions 70

4.7 Storage and handling of spare parts 71

4.7.1 Warranty information 71

4.8 Disposal of packaging materials and components 72

5.2 Overview on installation work 73

5.3 General notes on installation 74