— Contents About this manual Product overview 1.1.1 Standard applications Equipment covered by this manual Structure of the user documentation Terms and abbreviations Trademarks Related documentation Target groups and required qualification 1.7.1 Handling 1.7.2 Mechanical installation 1.7.3 Electrical installation 1.7.4 Operation 1.7.5 Maintenance...
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2.7.2 Safety and protection requirements for the MCB Maintenance recommendation Power electronics and cabinet features Drive system topology 3.1.1 Drive 3.1.1.1 ACS6080 cabinet units 3.1.1.2 Final drive configuration 3.1.2 Motor Standard cabinet units 3.2.1 Active rectifier unit (ARU)/inverter unit (INU) 3.2.2...
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3.3.1 Input reactor unit (IRU) 3.3.2 Input filter unit (IFU) 3.3.3 Voltage limiter unit (VLU) 3.3.4 Braking units 3.3.4.1 Braking chopper unit 3.3.4.2 Resistor braking unit 3.3.5 Excitation unit (EXU) 3.3.5.1 DCS880/DCT880 control panel 3.3.5.2 Output disconnector 3.3.6 Customer interface unit (CIU) 3.3.6.1 Arc detection with Arc Guard (optional) Air cooling...
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Identifying transport units Lifting and transportation 4.5.1.1 Lifting recommendations Storage Storing and handling of spare parts 4.7.1 Warranty information Disposing package materials and components Mechanical installation Safety Overview General notes on installation 5.3.1 Dimensions and clearances 5.3.2 Access to the cabinets 5.3.3 Cabinet roof 5.3.4...
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5.7.2 Ground busbars 5.7.3 AC busbars between COU/TEU and LSU (5/7/9 MVA) 5.7.4 AC busbars between COU/TEU and LSU (14 MVA) 5.7.5 AC busbars between COU/TEU and ARU/INU 5.7.6 AC busbar joints - without disconnector 5.7.7 AC busbar joints - with motorized disconnector Installing and removing air-to-air heat exchangers 5.8.1 Installing air-to-air heat exchangers...
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6.3.3 Cable shield ground connection 6.3.4 EXU cabinet ground connections Internal wiring 6.4.1 Optical fiber cables 6.4.1.1 Installing the standard optical fibers 6.4.2 Optical fiber cables for the optional Arc Guard System™ 6.4.2.1 Connecting the detector cables to the arc monitor device Cable entry systems 6.5.1...
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6.7.5.4 Bolted busbar connections – non-marine drives Auxiliary power, control and serial communication cables 6.8.1 Determining the cable length 6.8.2 Preparing cables for sealing modules 6.8.3 Preparing cables for cable glands 6.8.4 Preparing cables for EMC plates 6.8.5 Routing cables in a WCU 6.8.6 Routing cables in a COU cabinet 6.8.6.1...
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7.6.3 Main circuit breaker (MCB) 7.6.4 Input transformer checklist 7.6.5 Motor checklist 7.6.6 Insulation tests checklist 7.6.7 Power checklist 7.6.8 Miscellaneous checklist Operation Overview Operating conditions Safety Assistant control panels 8.5.1 Control panels for drives with an ARU 8.5.1.1 Lamp test 8.5.2 Control panels for drives with an LSU 8.5.2.1...
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8.9.1 Start sequence of the drive 8.9.2 Stop sequence of the drive 8.9.3 Emergency-off sequence 8.9.4 Prevention of unexpected startup sequence 8.10 Starting the drive 8.10.1 Checks before starting the drive 8.10.2 Starting the drive remotely 8.10.3 Starting the drive locally 8.11 Stopping the drive 8.11.1...
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9.3.2 Error message levels 9.3.2.1 Alarm and fault messages 9.3.2.2 Fault handling 9.3.2.3 Standard troubleshooting procedure 9.3.3 LEDs and switches on PCBs and I/O modules 9.3.3.1 BCU-55 control unit 9.3.3.2 S500 I/O modules 9.3.3.3 Serial communication interfaces 9.3.3.4 LEDs on optional heat exchangers Maintenance tasks 9.4.1 Safety...
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9.4.10.1 Removing a phase module 9.4.10.2 Installing a phase module 9.4.11 Visual checks on the drive 9.4.12 Cleaning 9.4.12.1 Cleaning the drive cabinet 9.4.13 Checking wire and cable connections 9.4.14 Checking and replacing filter mats 9.4.15 Testing and replacing auxiliary fan units 9.4.15.1 Testing auxiliary fan units 9.4.15.2 Replacing auxiliary fan units 9.4.16...
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Location of control panels on master COU (A) and slave COU (B) Figure 3-14 WCU1400 (A) and WCU800 (B) cabinet and system components Figure 3-15 Cooling circuit in an ACS6080 drive Figure 3-16 IRU circuit diagram Figure 3-17 IRU cabinet Figure 3-18...
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EXU H4/T4 frame cabinet (A) and EXU H6 frame cabinet (B) Figure 3-27 CIU cabinet (A) and WCU800 cabinet (B) Figure 3-28 ACS6080 example drive with air-to-air heat exchanger Figure 3-29 Auxiliary fan unit Figure 3-30 Air circulation through ventilation grids in 600 mm...
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Figure 5-8 AC busbar joints between the COU/TEU and LSU (14 MVA). Figure 5-9 Air-to-air heat exchanger (type LT-5-5165-UL) Figure 5-10 Tools for installing an air-to-air heat exchanger Figure 5-11 Correct and incorrect cable installation Figure 5-12 ARU/INU/IFU cable routing Figure 5-13 LSU cable routing Figure 5-14...
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Figure 6-8 Cable tray and cable ducts in an LSU (A = front) Figure 6-9 Cable entry with type 1 sealing modules Figure 6-10 Cable entry frame with type 1 sealing modules Figure 6-11 Cable entry with type 2 sealing modules Figure 6-12 Cable gland Figure 6-13...
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Figure 6-30 Location of top blanking plates of 600 mm COU (A) and 1000 mm COU (B) Figure 6-31 Location of bottom blanking plates of 600 mm COU (A) and 1000 mm COU (B) Figure 6-32 Cable routing in 1000 mm COU (A) and 600 mm COU (B) Figure 6-33 Shield grounding for encoder cable...
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Figure 8-8 Arc Guard System™ in a WCU REB Figure 8-9 HMI panel Figure 9-1 Labels on S500 I/O modules and associated wiring diagram Figure 9-2 Cable and wire designation Figure 9-3 Assistant control panel Figure 9-4 BCU-55 control unit front view (A) and rear view Figure 9-5 S500 I/O modules in a COU Figure 9-6...
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Figure 9-22 Phase module removal Figure 9-23 COU filter Figure 9-24 Accessing the fan units in the WCU roof box Figure 9-25 Air-to-air heat exchanger overview (type LT-5-5165- Figure 9-26 Wire connection points on the circuit board Figure 9-27 DCS880 controller - size H4 Figure 9-28 DCS880 controller - size H6 Figure 9-29...
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Main components in a WCU cabinet Table 3-5 BCU braking power Table 3-6 RBU braking power Table 3-7 ABB arc resistant classes Table 5-1 Installation material for AC busbars (COU/TEU – ARU/INU) Table 5-2 Installation material for roof joints Table 6-1...
About this manual Product overview The ACS6080 is a medium voltage drive that can control any type of AC motor, including high-power induction, synchronous, and permanent magnet motors. The ACS6080 covers a power range of 3 - 36 MVA and delivers output frequencies of 0 - 75 Hz in the voltage range up to 3.3 kV.
• Appendix G - Signal and parameter table: includes descriptions of actual signals, control and status words, and control parameters and their default settings. 3BHS842007 E01 REV C ACS6080 USER MANUAL 26/238...
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 1-1 Terms and abbreviations...
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Digital Input Deutsches Institut für Normung Digital Output Drive Synonym for ACS6080 frequency converter Drive Composer Windows application for commissioning and maintaining ABB drives. Drive system The drive system includes all equipment for converting electrical into mechanical power to give motion to the machine.
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3-level voltage source inverter consisting of three identical power modules. I/O device Term ABB’s S500 I/O system. An I/O device consists of a module termination unit (MTU) and one I/O module. I/O module Term of ABB’s S500 I/O system. The I/O module is an active input or output device for digital or analog signals.
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Power Plate Communication Circuit PPCS Power plate communication system PPCS is an acronym for a serial communication protocol designed for data transfer via optical fibers between AMC circuit board and INTerface circuit boards 3BHS842007 E01 REV C ACS6080 USER MANUAL 30/238...
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Rolling Mill Drive Revolutions Per Minute S500 I/O The S500 I/O is a distributed process input output system that can be connected to various process controllers from ABB and other companies. Short-Circuit Synchronous Motor Semi-Redundant Drive Synchronous Serial Interface The SSI is a point-to-point, serial communication interface for digital data transmission between a master (eg, drive) and a slave (eg, sensor).
Registered trademark of Microsoft Corporation Related documentation The following documents are available for supplementary information: Table 1-3 Maintenance Title Document number ACS6080 preventive maintenance schedule 3BHS838899 E01 Table 1-4 Technical data Title Document number Technical data from drive smart (configuration...
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Project-specific Table 1-6 Specifications and guidelines Title Document number Main circuit breaker specification 3BHS125149 E60 ABB MVD ACS Transformer Specification 3BHS356582 E01 ABB MVD ACS Motor Specification 3BHS824803 E01 Technical project Specification Motor 3BHS824804 E01 ABB MVD ACS High Performance...
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[29] PLC Automation: PLCs, Control Panels, 3ADR020077C0204 Engineering Suite AC500, CP600, Automation Builder [30] I/O configuration S500/BCON for ACS6080 3BHS830984 E01 [31] System Assembly and Device Specifications 3ADR010121 for AC500 V2 Products Table 1-9 User manuals related to drive units...
IMPORTANT! Commissioning of the drive must only be performed by qualified and certified ABB personnel. 1.7.1 Handling Personnel must be skilled and experienced in unpacking and transporting heavy equipment.
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.
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 •...
1.13 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 Service Equipment manual.
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. 3BHS842007 E01 REV C ACS6080 USER MANUAL 39/238...
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. 3BHS842007 E01 REV C ACS6080 USER MANUAL 40/238...
7) 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 3BHS842007 E01 REV C ACS6080 USER MANUAL 41/238...
02 IMPORTANT SAFETY INFORMATION 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.
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• 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” 3BHS842007 E01 REV C ACS6080 USER MANUAL 43/238...
• External influence on or damage of the equipment • Wrong parameter settings • Software errors • Faulty hardware 5) Hazardous substances can be emitted from drive system components, eg, due to Incorrect disposal of components 3BHS842007 E01 REV C ACS6080 USER MANUAL 44/238...
• Maximum safety trip time: 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. 3BHS842007 E01 REV C ACS6080 USER MANUAL 46/238...
(4) No hazard to personnel (5) Maximum protection trip time (6) Maximum safety trip time In order to meet the stipulated safety requirements, ABB recommends one of the following: • MCB is equipped with 2 independent opening coils • MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage •...
• Motor 3.1.1 Drive The ACS6080 is a voltage source frequency converter for high-power induction and synchronous motors. The drive features a common DC bus permitting the configuration of single-motor or multi-motor solutions. Figure 3-1 Common DC-bus principle for single motor drive (A) and multi-...
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03 POWER ELECTRONICS AND CABINET FEATURES The ACS6080 has a flexible modular design with standard and optional cabinet units. Each cabinet unit is dedicated to a specific function. Figure 3-2 ACS6080 drive example (1) Active rectifier unit (ARU): (5) Water cooling unit (WCU):...
03 POWER ELECTRONICS AND CABINET FEATURES 3.1.1.1 ACS6080 cabinet units Standard cabinet units Optional cabinet units • Active rectifier unit (ARU) • Input reactor unit (IRU) • Inverter unit (INU) • Input filter unit (IFU) • Line supply unit (LSU) •...
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Clamping circuit Protects the circuit from excessive rises in current with di/dt reactors and freewheeling diodes. Electromagnetic Protects the transformer from excessive compatibility (EMC) filter voltage slopes 3BHS842007 E01 REV C ACS6080 USER MANUAL 52/238...
The LSU allows two-quadrant operation and maintains the power factor at 0.95 in the whole operating range. To achieve 24-pulse rectification or to increase the drive power, units with the same power rating can be operated in parallel. 3BHS842007 E01 REV C ACS6080 USER MANUAL 53/238...
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Define the current rise in the thyristor crowbar. reactors Thyristor crowbar Protection circuit that activates when a short- circuit occurs. By applying protection firing, the thyristor crowbar short-circuits the rectifier to prevent further damage of the drive. 3BHS842007 E01 REV C ACS6080 USER MANUAL 54/238...
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03 POWER ELECTRONICS AND CABINET FEATURES Figure 3-8 LSU (12-pulse) (1) Snubber resistor (4) di/dt limiting reactors (2) Snubber capacitor (5) Diode stacks (3) Rectifier monitoring unit 3BHS842007 E01 REV C ACS6080 USER MANUAL 55/238...
These can only be closed if the DC-link capacitors have been discharged. For more information, see “8.6 EXU control panel” on page 168. Figure 3-9 CBU (1) Grounding switch (2) DC-link capacitor 3BHS842007 E01 REV C ACS6080 USER MANUAL 56/238...
• Optional fieldbus adapters for serial data transfer to a higher-level control system • PC-based service tools comprising: - DriveWare software tools - DriveOPC for data transfer between ABB drives and Windows- based applications. 3BHS842007 E01 REV C ACS6080 USER MANUAL...
Each control unit (COU) is equipped with a local control panel (Fig. 3-13). The control panel serves as the basic user interface for monitoring, control and operation of the drive and setting of parameters. Figure 3-12 Control panel 3BHS842007 E01 REV C ACS6080 USER MANUAL 60/238...
The water cooling units are accessible for maintenance even when the drive is in operation. Note: For more information, see "ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual" (3BHS821937 E01) and "ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual"...
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The ion exchange vessel in the water treatment circuit deionizes the coolant of the internal cooling circuit and maintains the conductivity. 3-way valve The three-way valve controls the flow of the external cooling liquid through the water-to-water heat exchanger. 3BHS842007 E01 REV C ACS6080 USER MANUAL 62/238...
• External cooling circuit: transfers the heat losses from the water-to- water heat exchanger to the exterior. The water cooling units are pressurized and not open to atmospheric pressure. Figure 3-15 Cooling circuit in an ACS6080 drive (1) Return pipes (6) Heat exchanger (2) LSU...
ARU and reduces harmonic voltages injected to the supply network. Figure 3-18 IFU circuit diagram (1) TEU (3) ARU (2) IFU Figure 3-19 IFU cabinet (1) Resistor (3) Reactor (2) Capacitor 3BHS842007 E01 REV C ACS6080 USER MANUAL 66/238...
During braking, the energy is dissipated in liquid-cooled resistors. The resistors are controlled by IGCT semiconductors and protected against overload. DC (+) DC (NP) DC (-) Figure 3-20 VLU circuit diagram Figure 3-21 VLU cabinet (1) Air-cooled resistors (2) IGCT 3BHS842007 E01 REV C ACS6080 USER MANUAL 67/238...
03 POWER ELECTRONICS AND CABINET FEATURES 3.3.4 Braking units A braking chopper unit (BCU) and a resistor braking unit (RBU) are available for the ACS6080. Table 3-5 BCU braking power Braking resistor (ohm) Single braking power Double braking power (kW)
The energy generated during braking is dissipated in external water-cooled resistors, which are not part of the drive. DC (+) DC (NP) DC (-) Figure 3-22 BCU circuit diagram (1) Resistor (external) (2) BCU Figure 3-23 BCU cabinet (1) IGCT 3BHS842007 E01 REV C ACS6080 USER MANUAL 69/238...
Resistor braking unit An RBU, with integrated resistors, is used for smaller braking capabilities. DC (+) DC (NP) DC (-) Figure 3-24 RBU circuit diagram Figure 3-25 RBU cabinet (1) IGCT (2) Water-cooled resistor 3BHS842007 E01 REV C ACS6080 USER MANUAL 70/238...
Figure 3-26 EXU H4/T4 frame cabinet (A) and EXU H6 frame cabinet (B) (1) Ground fault detection (5) DCS880/DCT880 H4 unit device (optional) (6) Overvoltage protection (not (2) Fuses shown in A) (3) Control compartment (7) DCS880 H6 unit (4) Fan units 3BHS842007 E01 REV C ACS6080 USER MANUAL 71/238...
DCT880 unit to another DCS880/DCT880. Note: For more information, see “8.6 EXU control panel” on page 168. 3.3.5.2 Output disconnector The optional output disconnector is used to disconnect the EXU from the motor for maintenance purposes. 3BHS842007 E01 REV C ACS6080 USER MANUAL 72/238...
(REB) of the water cooling unit. For more I/O modules, a CIU is required. Figure 3-27 CIU cabinet (A) and WCU800 cabinet (B) (1) CIU (3) WCU800 (2) Roof extension box (REB) 3BHS842007 E01 REV C ACS6080 USER MANUAL 73/238...
“Appendix C – Mechanical drawings”. The number of installed air-to-air heat exchangers and transformers depends on the configuration of the drive. Figure 3-28 ACS6080 example drive with air-to-air heat exchanger (1) Air-to-air heat exchanger (2) Additional transformer 3BHS842007 E01 REV C...
Figure 3-29 Auxiliary fan unit Figure 3-30 Air circulation through ventilation grids in 600 mm COU (A), 1000 mm COU (B) and WCU800 (C) Note: The number of fans varies depending on the cabinet. 3BHS842007 E01 REV C ACS6080 USER MANUAL 75/238...
03 POWER ELECTRONICS AND CABINET FEATURES Cabinet design The cabinet has been designed using the modular cabinet system of ABB and fulls the requirements of international standards. The design consists of a skeletal frame made of galvanized steel where the outer panels made of 1.5 mm thick painted galvanized steel are bolted to.
168. Arc resistant design The optional “Arc Resistant Design” provides the drive with arc fault protection (see Table 3-7) in accordance with IEC 62477-2. Table 3-7 ABB arc resistant classes ABB class Description Class I Protection based on arc prevention (NOT certified according to...
(Associated Protection Requirement) without the need for additional devices. The MCB requirements are described in “2.7 Important note - main circuit breaker” on page 45. Busbars and grounding The ACS6080 drive contains busbars for various types of connections. Figure 3-33 Busbars 3.8.1 AC busbars The incoming feeder and motor cables are connected to their corresponding busbars inside a TEU.
To ensure proper operation, cable shields are connected to the PG ground busbar. The PE and PG busbar connect inside the capacitor bank unit, which has the grounding switch on the front door. The connection is made in the factory. 3BHS842007 E01 REV C ACS6080 USER MANUAL 79/238...
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.
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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.
NOT lift and move them with a crane. - 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.
04 TRANSPORTATION, STORAGE AND DISPOSAL 4.5.1.1 Lifting recommendations 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. • Use lifting equipment (eg, web slings, chain slings, round slings, safety hooks, shackles) that corresponds to the weight that is to be lifted.
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(1) Safety hook (5) Safety hook or shackle (2) Lift frame (6) Lifting bracket (3) Strap (7) Slope angle (maximum 15°) (4) Protect the edges, door handles (8) Lift spreader and levers 3BHS842007 E01 REV C ACS6080 USER MANUAL 85/238...
04 TRANSPORTATION, STORAGE AND DISPOSAL Storage The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. Note: For information on longer storage periods, contact the ABB service organization. 4.6.1 Storage conditions The minimum requirements for storage are based on IEC 60721-3-1.
4.7.1 Warranty information IMPORTANT! Check the spare parts immediately after receipt for damages and 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: •...
Dispose of the packaging materials and components at the end of the life time of the drive according to local regulations. Note: For more information on the disposal of packaging materials and drive components, see the recycling instructions. 3BHS842007 E01 REV C ACS6080 USER MANUAL 88/238...
• Only for optional components - “5.8 Installing and removing air-to-air heat exchangers” on page 106 - “5.9 Installing the pressure relief vents” on page 115 - “5.10 Attaching the sealing tapes” on page 117 3BHS842007 E01 REV C ACS6080 USER MANUAL 89/238...
• DO NOT install any foreign objects on the roof and do not step on roof. 5.3.4 Fire protection ⚠ CAUTION • To prevent fire from spreading into the drive, apply suitable fire protection measures. 3BHS842007 E01 REV C ACS6080 USER MANUAL 90/238...
WCU. Installation material such as counter-flanges, bolts, nuts and seals are supplied. For information on dimensions of the raw water entry and the flanges, see “Appendix C – Mechanical drawings”. 3BHS842007 E01 REV C ACS6080 USER MANUAL 91/238...
2. Check that a pipe joint (1) 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”. Note: The units can be lined-up either beginning from the left or the right. 3BHS842007 E01 REV C ACS6080 USER MANUAL 92/238...
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Fig. 5-1) • Cabinet doors are not misaligned and that there are no gaps between cabinet walls and cabinet frame • Adjoining surfaces of transport units meet perfectly all around 3BHS842007 E01 REV C ACS6080 USER MANUAL 93/238...
In such cases, you only need to join the connection points that you can access. Figure 5-1 Connection point locations on transport units (1) Connection point locations (2) M6 x 16 (9ABA450093R0259 SCR-CBS-M6X16-8_8-FLZNNC) 3BHS842007 E01 REV C ACS6080 USER MANUAL 94/238...
Note: The sealing lip can touch the pipe end. 3. Turn and move the pipe joint smoothly. 4. Clean the pipe joint and treat the bolts with an appropriate lubricant before refitting. 3BHS842007 E01 REV C ACS6080 USER MANUAL 96/238...
• Orientate the parts of a joint (plates, bolts, and nuts) as shown. • Use a conical spring washer on each side of a connection. Figure 5-3 Bolted busbar connection (1) Conical spring washer 3BHS842007 E01 REV C ACS6080 USER MANUAL 97/238...
HZN 452198P1022 coated (4) Conical spring 13 x 29 x 3 HAQN400344P0111 washer (5) Busbar with positive potential (6) Busbar with neutral potential (7) Busbar with negative potential (8) Front of cabinet 3BHS842007 E01 REV C ACS6080 USER MANUAL 98/238...
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Figure 5-5 Top view DC busbar configurations 2 (A), 3 (B) and 4 (C) (1) Busbar with negative potential (3) Busbar with positive potential (2) Busbar with neutral potential (4) Front of cabinet 3BHS842007 E01 REV C ACS6080 USER MANUAL 99/238...
3BHB010246R0001/R0051 (2) Hex-head bolt M12 x 40-A2 NB 312350P8119 (3) Hex-head nut M12-A2-70, HZN 452198P1022 coated (4) Conical spring 13 x 29 x 3 HAQN400344P0111 washer (5) Water pipe (6) Cabinet front 3BHS842007 E01 REV C ACS6080 USER MANUAL 100/238...
M12 x 45-A2-70 NB 312450P8120 (6) Hex-head bolt M12 x 50-A2-70 NB 312450P8121 (7) Conical spring DIN6796-13 x 29 x 3 HAQN400344P0111 washer (8) Hex-head nut M12-A2-70 HZN 452198P1022 (9) Flange nut M12-A2 3BHB038117R0001 3BHS842007 E01 REV C ACS6080 USER MANUAL 101/238...
(3) Connection bu bar LSU-TEU 3a 3BHB045558R0001 (4) Hex-head bolt M12 x 45-A2-70 NB 312450P8120 (5) Hex-head bolt M12 x 65-A2-70 NB 312450P8124 (6) Conical spring DIN6796-13x29x3 HAQN400344P0111 washer (7) Hex-head nut DIN934-M12-A2-70 HZN 452198P1022 3BHS842007 E01 REV C ACS6080 USER MANUAL 102/238...
• Height: 316 mm Figure 5-10 Tools for installing an air-to-air heat exchanger (1) Cordless drill (4) M6 x 12 Torx screw (2) Wire cutter (5) Cable tie (3) Torx drill bit 3BHS842007 E01 REV C ACS6080 USER MANUAL 106/238...
• Damage to the heat exchanger Procedure: 1. Before lifting the heat exchanger onto the roof, cut off the cable ties. 2. Loop the cables as illustrated and fasten them to the cable tie mounts (circles). 3BHS842007 E01 REV C ACS6080 USER MANUAL 107/238...
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4. Remove the cover on the roof where the heat exchanger is installed. 5. Lift the heat exchanger above the opening in the roof and orientate the heat exchanger with the LEDs (circle) pointing to the front of the cabinet. 3BHS842007 E01 REV C ACS6080 USER MANUAL 108/238...
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05 MECHANICAL INSTALLATION 6. Route the cables through the designated openings (circle) at the front of the cabinet. 7. While lowering the heat exchanger onto the roof, pull the cables through the openings. 3BHS842007 E01 REV C ACS6080 USER MANUAL 109/238...
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10. In the upper part of the cable duct (1), fasten the cables to the cabinet frame. 15 x 11. In the lower part (2), tie the cables together at regular distances. 3BHS842007 E01 REV C ACS6080 USER MANUAL 110/238...
• Take appropriate measures for removing and installing the heat exchanger safely. Figure 5-14 Air-to-air heat exchangers (type LT-5-5165-UL) Air-to-air heat exchangers must be removed and refitted where two transport units are joined. 3BHS842007 E01 REV C ACS6080 USER MANUAL 111/238...
(2) Wire cutter (4) Cable tie 5.8.2.1 Removing an air-to-air heat exchanger 1. Loosen the 4 self-tapping M6x12 screws (HAQN401205P0257) that fasten the heat exchanger to the roof. 2. Remove the cable ties. 3BHS842007 E01 REV C ACS6080 USER MANUAL 112/238...
4. Fix the cables with cable ties at regular distances of approximately 20 cm. 5. Tighten all screws of the heat exchanger. 6. Fix the cables inside the terminal box with cable ties. 3BHS842007 E01 REV C ACS6080 USER MANUAL 113/238...
(5) 1.5 kVA transformer: ~17 kg (2) Transformer hood (6) 2.8 kVA transformer: ~49 kg (3) 4 x M8x20 (9ABA450093R0310) (7) 3.5 kVA transformer: ~49 kg (4) Transformer connection plate (8) 6 kVA transformer: ~66 kg 3BHS842007 E01 REV C ACS6080 USER MANUAL 114/238...
Pressure relief vents are installed on the roofs of TEUs and COUs. Figure 5-18 Pressure relief vents • Weight: ~26 kg • Length: 840 mm • Width: 520 mm • Height: 210 mm 3BHS842007 E01 REV C ACS6080 USER MANUAL 115/238...
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Figure 5-20 Installation example of pressure relief vents (1) Orientation of baffle blades (3) Pressure relief vents (2) Center of drive 2. Fasten the pressure relief vent to the roof with the supplied screws (Fig. 5-20). 3BHS842007 E01 REV C ACS6080 USER MANUAL 116/238...
2. Cut the sealing tape to the required length. 3. Attach the tape on the whole length of the joining crossbars (1). Figure 5-21 Attach sealing tape to the joining crossbar (1) 4. Reinstall the roof plates. 3BHS842007 E01 REV C ACS6080 USER MANUAL 117/238...
• Install the joints at the front and the back of the roof of two adjoining transport units using the supplied installation material. Note: The joints (1) within a transport unit are factory-installed. Figure 5-22 Roof joints (1) 3BHS842007 E01 REV C ACS6080 USER MANUAL 118/238...
3BHB035997R0001 2 x damping 3BHB033405R0001 connectors (10) 2 x plates 3BHB035999R0001 (11) 2 x washers 13 / 29 ST / ZN 9ABA450078P0007 (12) 2 x hex-head bolts M12 x 80 NB 312450P8127 3BHS842007 E01 REV C ACS6080 USER MANUAL 119/238...
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Figure 5-24 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 3BHS842007 E01 REV C ACS6080 USER MANUAL 120/238...
• 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. • To prevent main and auxiliary power supply being switched on during installation, take appropriate measures.
"Auxiliary power and control cables guideline" (3BHS813742 E01). 6.2.3 Synchronization cables Synchronization cables are used in drives with an ARU. A shielded, 3-phase cable without neutral wire is required for the supply voltage of the synchronization transformer. 3BHS842007 E01 REV C ACS6080 USER MANUAL 122/238...
Cable shields are connected to the separate PG ground busbar. The connection between the PE and PG ground busbars inside the CBU is made in the factory. The CBU has a grounding switch on the door. 3BHS842007 E01 REV C ACS6080 USER MANUAL 124/238...
All necessary data for each individual connection are specified on the “Converter hardware diagram” and the Wiring list in “Appendix D – Wiring diagrams”. The data provide information on: • Cable identification • Cable type • Cross-sectional area • Location of terminals 3BHS842007 E01 REV C ACS6080 USER MANUAL 125/238...
RBU, BCU and VLU, make sure that the cables are at a minimum distance of 5 mm from the closest metal part. 3. Connect all cables and wires according to the “Converter Hardware” diagram. 3BHS842007 E01 REV C ACS6080 USER MANUAL 126/238...
• Arc Guard unit TVOC-2 with HMI panel • Optical fiber detectors The detectors are pre-installed in the relevant cabinets with the corresponding optical fibers coiled up beside the detectors (Fig. 6-7). 3BHS842007 E01 REV C ACS6080 USER MANUAL 127/238...
2. Lay the cables into their designated trays and cable ducts as illustrated in Fig. 6-8. 3. Connect the cables to the arc monitor located in the REB according to the drawings. 3BHS842007 E01 REV C ACS6080 USER MANUAL 128/238...
(2) Sealing module (RM120) Usage • Power cables • Ground cables • Equipotential bonding conductors Included in delivery • Cable entry frame Not included in • Sealing modules delivery • Accessories • Tools 3BHS842007 E01 REV C ACS6080 USER MANUAL 129/238...
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Maximum number Maximum number of cables/ entry of sealing openings frame modules/openings RM12 Single- Three- Single- core core core Ø28 - 50 Ø68 - 99 Ø48 - 71 1000 mm 600 mm 3BHS842007 E01 REV C ACS6080 USER MANUAL 130/238...
Usage • Power cables, ground cables, bonding conductors • Auxiliary power cables, control cables Included in delivery • Undrilled gland plate Not included in • Cable glands delivery • Tools • Accessories 3BHS842007 E01 REV C ACS6080 USER MANUAL 131/238...
• Sealing grommets Preparing cable entry systems for TEU, ARU and EXU cabinets This section describes how to prepare cable entry systems for the following cabinets: • TEU • ARU • EXU 3BHS842007 E01 REV C ACS6080 USER MANUAL 132/238...
Figure 6-14 TEU 1000 mm cabinet (A = back) with top (1) and bottom (2) cable entries (1) Top cable entry frame (4) Compression wedge (2) Bottom cable entry (5) RM90 sealing module with 3-core cable (3) High-voltage busbars 3BHS842007 E01 REV C ACS6080 USER MANUAL 133/238...
(4) 1/2” wrench (2) Remove these bolts (5) 17 mm and 19 mm (3) Bottom bracket 4. After you have routed the cables, install the busbars in the reverse order of removal. 3BHS842007 E01 REV C ACS6080 USER MANUAL 134/238...
EXU with a DCS880 H4/DCT880 T4 unit” on page 230. 4. Unplug the fan power supply cables and the tube from the air pressure switch. Figure 6-17 EXU cabinet (1) Front cover (2) Pull relief 3BHS842007 E01 REV C ACS6080 USER MANUAL 135/238...
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. 3BHS842007 E01 REV C ACS6080 USER MANUAL 136/238...
(6) Heat shrinkable termination cable supplier and suitable for M12 bolt (7) Outer cable sheath (12) Sheath seal 2. Install the sealing modules according to the instructions of the sealing module supplier. 3BHS842007 E01 REV C ACS6080 USER MANUAL 137/238...
This section describes how to prepare standard cables for EMC plates as well as cables for an EXU. 1. Remove the grommets from the entry plate. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter. 3BHS842007 E01 REV C ACS6080 USER MANUAL 138/238...
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(2) EMC sleeve (7) Conductor insulation removed to expose cable shield (3) Cable tie (8) Cable screen extension to connect (4) Heat-shrinkable termination to the PE busbar (5) Outer cable sheath (9) Cable clamp 3BHS842007 E01 REV C ACS6080 USER MANUAL 139/238...
2. Fasten the cables to the strain relief rails with suitable cable clamps. Figure 6-21 Cable connections in an EXU cabinet (1) Cable clamp (3) Strain relief rail (2) Cable lugs on each side of busbar 3BHS842007 E01 REV C ACS6080 USER MANUAL 140/238...
] coating) is used, the connection does not need to be lubricated. 6.7.5.4.4 Tightening torque ABB recommends a tightening torque of 40 Nm for M12 bolts. For other sizes, follow the manufacturer’s recommendations. 3BHS842007 E01 REV C ACS6080 USER MANUAL...
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. 3BHS842007 E01 REV C ACS6080 USER MANUAL 143/238...
Note: If cables are routed through the cabinet floor, the grommets can be discarded. 4. If necessary, remove the entry plate and pull the cable through the entry holes. 3BHS842007 E01 REV C ACS6080 USER MANUAL 145/238...
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3. Connect the screens ends with a continuous conducting foil (3 in Fig. 6-28). Figure 6-28 Preparing the screens of control cables for EMC plates (1) Cable screen (3) Conductive foil (2) Cable screen ends 3BHS842007 E01 REV C ACS6080 USER MANUAL 146/238...
The serial communications and encoder cables are connected inside a COU. Top and bottom cable entries are covered with blanking plates. Materials for cable fitting, EMC requirements and sealing are not supplied. 3BHS842007 E01 REV C ACS6080 USER MANUAL 147/238...
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1000 mm COU (B) (1) Bottom blanking plate (2) Front 2. Prepare the length of cable that passes through the cable entry according to “6.8.3 Preparing cables for cable glands” on page 145. 3BHS842007 E01 REV C ACS6080 USER MANUAL 148/238...
• Leave unshielded conductor ends as short as possible (not longer than 50 mm). Cable shields • Connect the shield of serial communications cables to the fieldbus adapter. 3BHS842007 E01 REV C ACS6080 USER MANUAL 149/238...
145 • Cable entries with cable glands: “6.8.3 Preparing cables for cable glands” on page 145. Note: Materials for cable fitting, EMC requirements and sealing are not supplied for undrilled plates. 3BHS842007 E01 REV C ACS6080 USER MANUAL 150/238...
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(4) Terminal strip for auxiliary power (8) Optical fibers to DCS880 H6 and control cables converter (5) Auxiliary supply cable 4. Connect the cables to the terminals inside the terminal compartment of the cabinet. 3BHS842007 E01 REV C ACS6080 USER MANUAL 151/238...
• When using cable ties, be careful not to deform the optical fibers and do not use a cable tie gun. • When connecting or unplugging an optical fiber, hold it at the connector and not at the fiber. 3BHS842007 E01 REV C ACS6080 USER MANUAL 152/238...
4. Gently press down the latch tab with the tip of the screwdriver and pull the corner of the cover forward and repeat for the other side. 5. Slide the removable cover up and then remove the cover. 3BHS842007 E01 REV C ACS6080 USER MANUAL 153/238...
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(6) Terminal for optical fibers behind cover (3) Cable enters through the floor (7) Optical fibers to DCS880/DCT880 (4) Terminal strip for auxiliary power converter and control cables 8. Reattach the front cover of the DCS880/DCT880. 3BHS842007 E01 REV C ACS6080 USER MANUAL 154/238...
2. Connect the two optical fibers to the receptacles of slot 1 according to the terminal numbers printed on the marker sleeves. Figure 6-39 1 Control unit SDCS-CON-H01 (1) Slot 1 (FDCO-01 module (2) Control panel 3BHS842007 E01 REV C ACS6080 USER MANUAL 155/238...
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(6) Terminal for optical fibers behind cover (3) Cable enters through the floor (7) Optical fibers to DCS880/ (4) Terminal strip for auxiliary power DCT880 D4 converter and control cables 4. Reattach the DCS880/DCT880 cover. 3BHS842007 E01 REV C ACS6080 USER MANUAL 156/238...
2. Connect the heating cables of two adjoining transport units with each other. 3. Fasten the connectors with cable ties. Figure 6-41 Heating cable connection (1) Heating cable plug (2) Cable tie 3BHS842007 E01 REV C ACS6080 USER MANUAL 157/238...
• Check that the entry plates are properly fastened. • If EMC entry plates with grommets are used, check that the grommets fit tightly (arrows) to prevent water entering the cabinet. - If necessary, seal gaps with silicone. 3BHS842007 E01 REV C ACS6080 USER MANUAL 158/238...
ABB. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB. Commissioning checklist In order to ensure uncomplicated and speedy commissioning, it is important that drive and associated equipment are ready for commissioning.
□ 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).
Pay attention to MCB opening time and installation of undervoltage coil or second opening coil 7.6.4 Input transformer checklist □ Grounding is completed □ 2) Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are ready. □ 3) Protection devices are tested and in operation. 3BHS842007 E01 REV C ACS6080 USER MANUAL 161/238...
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 3BHS842007 E01 REV C ACS6080 USER MANUAL 162/238...
Operation Overview This chapter describes how to operate an ACS6080 drive from an assistant control panel on a control unit of the drive, ie, local operation. Figure 8-1 Assistant control panel Note: Control of the drive via a PLC or higher-level control system is not described in this chapter.
Local control panels Assistant control panels Each control unit (COU) on the ACS6080 drive has at least one assistant control panel (ACP) to ensure easy and intuitive operation throughout your entire installation. For instructions on how to use the assistant control panel, see the "ACX-AP-x Assistant control panels user manual"...
The control panels for the ARU and motor 1 are on the door of control unit COU1 (A in Fig. 8-3). The location of additional control panels depends on the configuration of the drive (B in Fig. 8-3). 3BHS842007 E01 REV C ACS6080 USER MANUAL 165/238...
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(12) Main power supply on (22) Starts and stops the INU/ (13) Charges the DC link additional motor, eg, motor 2 (14) Closes the main circuit breaker (23) Displays the status messages of the INU 3BHS842007 E01 REV C ACS6080 USER MANUAL 166/238...
(11) Closes the main circuit breaker additional motor, eg, motor 2 (12) Emergency off reset push button (20) Displays the status messages of the INU (13) Resets the emergency-off relay in the drive control system 3BHS842007 E01 REV C ACS6080 USER MANUAL 167/238...
Remote operation is indicated with the letters REM in the top left corner of the display. The actual values shown on the display can be freely selected. The following default values are shown on the display when the panel is in local mode: 3BHS842007 E01 REV C ACS6080 USER MANUAL 168/238...
• DO NOT change any parameter if the meaning of the parameter and the effects of the change are not fully understood. The parameters are set as required for operation and verified during commissioning and must not be changed afterwards. 3BHS842007 E01 REV C ACS6080 USER MANUAL 169/238...
DC-link voltage is below 50 V(DC). When the grounding switch is in position grounded, the door safety switches of the medium voltage units are released and the doors can be opened. 3BHS842007 E01 REV C ACS6080 USER MANUAL 170/238...
Figure 8-7 Location on the safety switches The safety switches are part of an interlocking circuit that prevents the doors being opened as long as the DC link is charged. The interlocking circuit ensures that the: 3BHS842007 E01 REV C ACS6080 USER MANUAL 171/238...
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DC-link capacitors have been discharged, and the grounding switch is in position grounded. The locking bar locks and unlocks the locking mechanism of the door of a medium voltage unit. 3BHS842007 E01 REV C ACS6080 USER MANUAL 172/238...
Note: For more information, see “9.4.9 Drives with the manual output isolation (optional)” on page 206. 3BHS842007 E01 REV C ACS6080 USER MANUAL 173/238...
“Ready run” 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 “Ready ref” again. 3BHS842007 E01 REV C ACS6080 USER MANUAL 174/238...
• Only in drives with an ARU 7) Ready run • INU starts magnetizing (only in drives with an ARU) • INU starts to modulate 8) Start command 9) Ready ref 10) Operation 3BHS842007 E01 REV C ACS6080 USER MANUAL 175/238...
• Only in drives with an ARU 8) Ready to switch on • Drive is grounded • Doors in medium voltage units are released for opening • Auxiliary power supply switched off 9) Not ready to switch on 3BHS842007 E01 REV C ACS6080 USER MANUAL 176/238...
• Doors are closed and locked or bolted. 8.10.2 Starting the drive remotely When the drive system is operated from a higher-level control system or an operator control desk, follow the instructions in the applicable manuals. 3BHS842007 E01 REV C ACS6080 USER MANUAL 178/238...
• If a fault cannot be reset, the responsible personnel must rectify it. • (Drives with an ARU) When faults are present and the drive is ready, the INU is “Ready to switch on”. 3BHS842007 E01 REV C ACS6080 USER MANUAL 179/238...
The drive is now in stopping mode. 2. When the motor has reached zero speed, the drive is “Ready run”. As long as the MCB has not been opened, you can restart the motor at any time. 3BHS842007 E01 REV C ACS6080 USER MANUAL 180/238...
When an emergency-off is initiated during operation, the following sequence of events occurs: 1) MCB opens 2) Drive system coasts down 3) DC-link of the drive discharges 4) EMERGENCY-OFF RESET button flashes 5) SUPPLY OFF push button flashes 3BHS842007 E01 REV C ACS6080 USER MANUAL 181/238...
• After resetting, the status message of the drive changes to “Ready to switch on”. 3. The main power supply can be connected to the drive again and the drive system can be started up. 3BHS842007 E01 REV C ACS6080 USER MANUAL 182/238...
Arc detection with the Arc Guard System™ (optional) The optional Arc Guard System™ detects fast arc faults in the terminal sections of an ACS6080 drive. When the Arc Guard System detects an arc fault the drive performs protection firing and immediately opens the main circuit breaker.
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6. Reset the fault on Arc Guard HMI panel. 7. Acknowledge the firing through with parameter 16.26 on the control panel (only when fault was understood and corrected). 8. Restart the drive. 3BHS842007 E01 REV C ACS6080 USER MANUAL 184/238...
ABB service organization. 9.1.2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule, on time and at the stated intervals in the "ACS6080 preventive maintenance schedule" (3BHS838899 E01). 9.1.3 Logbook...
Cables and wires in the drive are equipped with marker sleeves that carry the same identifying number as on the wiring diagrams. Figure 9-2 Cable and wire designation (1) Wire number (2) Terminal number 3BHS842007 E01 REV C ACS6080 USER MANUAL 186/238...
An alarm cannot be reset manually. The alarm message is deleted from the display as soon as the alarm condition has been corrected. 3BHS842007 E01 REV C ACS6080 USER MANUAL 187/238...
Date and time stamps facilitate fault tracing, especially when a fault leads to several subsequent faults. Note: For more information on alarms and faults, see “Appendix G – Signal and parameter table”. 3BHS842007 E01 REV C ACS6080 USER MANUAL 188/238...
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: •...
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V24T V24R V25T V25R V26T V26R STATUS: A B C D E F G H I J K L Figure 9-4 BCU-55 control unit front view (A) and rear view (B) (1) LEDs 3BHS842007 E01 REV C ACS6080 USER MANUAL 190/238...
(3AUA0000031044). 9.3.3.4 LEDs on optional heat exchangers Two LEDs on the front of the heat exchanger indicate the status of the unit. Alarm signals are also shown on the control panel. 3BHS842007 E01 REV C ACS6080 USER MANUAL 191/238...
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(1) Red LED off (A) and Green LED on (3) Red LED off (A) and Green LED (B): Heat exchanger is healthy off (B): Auxiliary voltage is missing (2) Red LED on (A) and Green LED off (B): Alarm conditions 3BHS842007 E01 REV C ACS6080 USER MANUAL 192/238...
During operation, the capacitor voltage is 300 V (DC) over ground. • Wait 5 minutes for the capacitors to discharge. • Before touching a capacitor, verify that the capacitors are discharged. 3BHS842007 E01 REV C ACS6080 USER MANUAL 193/238...
The motor stops according to the preset stop function. When the motor has reached zero speed, the drive is in “Ready run. 3. Press the SUPPLY OFF push button to disconnect the drive from the main power supply. 3BHS842007 E01 REV C ACS6080 USER MANUAL 194/238...
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Ungrounded position 6. If the yellow lamp GROUNDING SWITCH UNLOCKED is on, keep the yellow lamp cap pressed while you turn the grounding switch to the grounded position. 3BHS842007 E01 REV C ACS6080 USER MANUAL 195/238...
The lamp-test circuit and the grounding circuit are independent of each other. From the lamp not lighting up, it cannot be concluded that the discharging circuit and / or the grounding circuit are not working. 3BHS842007 E01 REV C ACS6080 USER MANUAL 196/238...
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• Converter hardware diagram • Wiring diagram of COU1 For information on the wiring of the discharging circuit and/or the grounding circuit, see: • Wiring diagram of COU1 • Wiring diagram of CBU. 3BHS842007 E01 REV C ACS6080 USER MANUAL 197/238...
(1) White lamp (2) Yellow lamp 2. Slide the locking bar from the locked (1) to the unlocked (2) position. • Door hinged on the left: • Door hinged on the right: 3BHS842007 E01 REV C ACS6080 USER MANUAL 198/238...
2. To lock the door, bring the door handle in line with the door plate (1) and press the handle down (2) until it clicks in. 3. Slide the locking bar from the unlocked (1) to the locked (2) position. • Door hinged on the left: 3BHS842007 E01 REV C ACS6080 USER MANUAL 199/238...
• If the LED is lit, the drive control system receives the feedback signal "grounding switch is closed", but the control system has not released the doors. • If the LED is not lit, the feedback signal is missing. 3BHS842007 E01 REV C ACS6080 USER MANUAL 200/238...
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• Converter hardware diagram • Wiring diagram of COU1 For information on the wiring of the discharging circuit and / or the grounding circuit, see: • Wiring diagram of COU1 • Wiring diagram of CBU 3BHS842007 E01 REV C ACS6080 USER MANUAL 201/238...
Figure 9-11 Safety switch on an ARU/INU cabinet door (1) Screw cap on door (4) Unlocked position (2) Safety switch location (5) Locked position (behind door) (6) Release dial (3) Safety switch 3BHS842007 E01 REV C ACS6080 USER MANUAL 202/238...
2. Loosen the locking screw (1) until the release dial can be turned. 3. Turn the release dial from the locked to the unlocked position. 5 mm You can now actuate the locking bar and open the doors. 3BHS842007 E01 REV C ACS6080 USER MANUAL 203/238...
(3) Telescopic insulating pole (2) Enclosure ground clamp Depending on the type of line-side rectifier, continue with: • “9.4.8.1 Drives with LSU” on page 205 • “9.4.8.2 Drives with ARU” on page 206 3BHS842007 E01 REV C ACS6080 USER MANUAL 204/238...
• Busbar connectors in TEU1 and COU1 - Busbar connectors for INU1 are located in TEU1. - Busbar connectors for INU2 are located in the terminal compartment inside COU1. • Lever for removing and fitting the busbar connectors 3BHS842007 E01 REV C ACS6080 USER MANUAL 206/238...
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(10) Motor (4) CBU1 (11) Busbar connectors (3 x) in TEU (5) BCU1 (12) Busbar connectors (3 x) in COU1 (6) INU2 (13) Lever for removing and fitting the busbar connections (7) COU1 3BHS842007 E01 REV C ACS6080 USER MANUAL 207/238...
• Follow local safety procedures Figure 9-17 Tools for removing the busbar connectors (1) Orientation of lever for removing (3) Four-way grounding set (4x) busbar connectors (2) Orientation of lever for fitting the busbar connectors 3BHS842007 E01 REV C ACS6080 USER MANUAL 208/238...
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• Busbars in the INU (3 in Fig. 9-19) LSU1 TEU1 INU1 INU2 COU1 LSU2 Figure 9-18 Overview of grounding the drive - INU1 is shut down (A) and INU2 is shut down (B). Numbers indicate the connection sequence. 3BHS842007 E01 REV C ACS6080 USER MANUAL 209/238...
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Figure 9-19 Connect the grounding sets in COU1 (A and C), TEU1 (B), INU1 (D) and INU2 (E) (1) Busbars for secondary (4) PE transformer windings (5) Ground ball stud (2) Busbars for motor cables (3) INU busbars 3BHS842007 E01 REV C ACS6080 USER MANUAL 210/238...
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7. Check that tools and foreign objects are not left inside the cabinets. 8. Close and lock the doors. 9. Check that the power operating mode (POM) of the drive corresponds to the busbar connectors fitted. 3BHS842007 E01 REV C ACS6080 USER MANUAL 211/238...
6. Close and lock the doors. 7. Check that the power operating mode (POM) of the drive corresponds to the busbar connectors fitted. 8. Start the drive according to the established procedures. 3BHS842007 E01 REV C ACS6080 USER MANUAL 212/238...
Note: To disconnect the water hose, pull the locking sleeve of the coupling towards the front of the cabinet (arrow). 2. Cut off the cable ties (1) and disconnect the optical fibers and the power supply leads (2). 3BHS842007 E01 REV C ACS6080 USER MANUAL 213/238...
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6. Pull the phase module onto the table. CAUTIONA phase module weighs approximately 190 kg. When pulling out the phase module, make sure that the disconnected water hoses, optical fibers and power supply leads are out of the way. 3BHS842007 E01 REV C ACS6080 USER MANUAL 214/238...
NOTICE DO NOT mix up the cables. The identification on the label must correspond to its counterpart on the phase module. Verify the correct connection with the corresponding wiring diagram. 10. Fasten the cables with cable ties. 3BHS842007 E01 REV C ACS6080 USER MANUAL 215/238...
9.4.11 Visual checks on the drive Check the drive and its immediate vicinity visually at the intervals stated in "ACS6080 preventive maintenance schedule" (3BHS838899 E01) and pay attention to the following items: • Humidity inside the drive • Permitted range of ambient air temperature and humidity of the drive •...
• Check that all plugs and connectors are tight. 9.4.14 Checking and replacing filter mats • Inspection intervals: See the "ACS6080 preventive maintenance schedule" (3BHS838899 E01). • Service during operation: possible. • Filter mat class: G3 (EN779) • Location: installed behind the ventilation grids of control and water cooling units if the drive is prepared for protection class IP 54.
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3. Slide the cover up and pull it out of the slots. 4. Turn the cover over and remove the filter mat. 5. Insert the new filter mat and reinstall the ventilation grid. 3BHS842007 E01 REV C ACS6080 USER MANUAL 218/238...
09 PREVENTIVE AND CORRECTIVE MAINTENANCE Testing and replacing auxiliary fan units 9.4.15 • Inspection intervals: see the "ACS6080 preventive maintenance schedule" (3BHS838899 E01). • Service during operation: possible • Location:• installed behind the doors of the following cabinets: - COU cabinet (2 fan units)
Figure 9-24 Accessing the fan units in the WCU roof box 3. Disconnect the wires (1) and unscrew (2) the fan units. 4. Remove the fan unit. 5. Reinstall the new one in reverse order of removal. 3BHS842007 E01 REV C ACS6080 USER MANUAL 220/238...
09 PREVENTIVE AND CORRECTIVE MAINTENANCE 9.4.16 Testing and replacing air-to-air heat exchangers • Inspection intervals: see the "ACS6080 preventive maintenance schedule" (3BHS838899 E01). • Service during operation: not possible Figure 9-25 Air-to-air heat exchanger overview (type LT-5-5165-UL) (1) Ambient fan 2...
(arrow). 4. Check that the fans run smoothly and if a fan is defective, replace the complete fan unit. 5. Adjust the setting of the thermostat to its original value. 3BHS842007 E01 REV C ACS6080 USER MANUAL 222/238...
For information on replacing the complete heat exchanger, see “Mechanical installation” on page 56. 9.4.16.3 Replacing the circuit board 1. Unscrew the front and top cover. 2. Disconnect the ground wire from the front cover (arrow). 3BHS842007 E01 REV C ACS6080 USER MANUAL 223/238...
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4x J9 4x fan power supply 1x J4 2x J6 3x J8 4x J10 4x fan alarm signals 1x J22 2x J23 3x J24 4x J25 LEDs Red J18 Green J19 Alarm 1 3BHS842007 E01 REV C ACS6080 USER MANUAL 224/238...
9.4.16.4 Replacing internal fan 1 - left side Procedure 1. Unscrew the front top cover. 2. Unplug the plug-in connectors (arrows) and unscrew the screws (1, 2, 3 and 4) which fix the fan mounting bracket to the housing. 3BHS842007 E01 REV C ACS6080 USER MANUAL 225/238...
3. Remove the fan from the housing and unscrew the fan from the mounting bracket. 4. Replace the fan and reassemble the unit in reverse order of removal. 9.4.16.5 Replacing internal fan 2 - right side 3BHS842007 E01 REV C ACS6080 USER MANUAL 226/238...
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09 PREVENTIVE AND CORRECTIVE MAINTENANCE Procedure 1. Unscrew the front top cover. 2. Remove the front cover and disconnect the ground wire (arrow). 3BHS842007 E01 REV C ACS6080 USER MANUAL 227/238...
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5. Disconnect the ground wire (1), cut off the cable tie (2), unplug the plug-in connectors (arrows), and unscrew the screws (3, 4, 5 and 6) fixing the fan mounting bracket to the housing. 3BHS842007 E01 REV C ACS6080 USER MANUAL 228/238...
7. Replace the fan and reassemble the unit in reverse order of removal. 9.4.16.6 Replacing the ambient fans 1. Unscrew the rear cover. 2. Lift the hinged cover up a little and disconnect the ground wire (arrow). 3BHS842007 E01 REV C ACS6080 USER MANUAL 229/238...
1. Switch off the miniature circuit breaker of the fan unit. Note: To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 2. Remove the 6 screws from the fan cover and then remove the fan cover. 3BHS842007 E01 REV C ACS6080 USER MANUAL 230/238...
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4. Remove the 4 fastening screws from the outside panel of the fan unit. 5. Pull the fan unit out of the cabinet. CAUTION! To prevent the fan from falling onto you, put a support (ie, a box) underneath. 3BHS842007 E01 REV C ACS6080 USER MANUAL 231/238...
Figure 9-28 DCS880 controller - size H6 Procedure 1. Switch off the miniature circuit breaker of the fan unit. Note: To identify the miniature circuit breaker, see “Appendix D – Wiring diagrams”. 3BHS842007 E01 REV C ACS6080 USER MANUAL 232/238...
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2. Remove the 6 screws from the fan cover and then remove the fan cover. 3. Unplug the fan cables. 4. Remove the 4 fastening screws from the outside panel of the fan unit. 3BHS842007 E01 REV C ACS6080 USER MANUAL 233/238...
2. Close valves V30 and V31 in the water-cooling unit. 3. Disconnect the hose from valve V30 to drain the WCU. NOTICE Expect approximately 5 liters of water. 4. Unscrew the top plate. 3BHS842007 E01 REV C ACS6080 USER MANUAL 234/238...
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6. Lift the heat exchanger out of the cabinet. CAUTIONThe heat exchanger weighs approximately 16 kg and requires a minimum overhead clearance of 85 cm. Figure 9-30 Lift heat exchanger out of EXU cabinet 3BHS842007 E01 REV C ACS6080 USER MANUAL 235/238...
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Note: For information on adding water to the cooling system, see the manual for the "ACS5000, ACS6000 and ACS6080 water cooling unit WCU800 user manual" (3BHS821937 E01) and "ACS5000, ACS6000 and ACS6080 water cooling unit WCU1400 user manual" (3BHS835714 E01).