Acs 6000

ABB
ACS 6000
Medium Voltage Drives
3 to 27 MVA
User’s Manual
Document No.: 3BHS212794 ZAB E01 Rev. -
Issued: 03-06-2005
 ABB Switzerland Ltd. All Rights Reserved.

ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

ABB
Table of Contents
General Information
Contact Information
Related Documentation
Quality Certificates and Applicable Standards
Chapter 1 - Safety 1-1
1.1 Intended Audience and Required Qualifications 1-1

1.2 Owner’s Responsibilities 1-1
1.3 Safety Instructions 1-2
1.4 Safety Labels and Signs 1-3
1.5 Danger Zones 1-4
Chapter 2 - Transportation, Storage and Disposal 2-1
2.1 Transportation 2-1

2.1.1 Transport Conditions 2-1
2.1.2 Unpacking and Inspection 2-1
2.1.3 Loading and Unloading 2-1
2.2 Storage 2-4
2.2.1 Storage Conditions 2-4
2.2.2 Storage 2-4
2.3 Storage and Handling Instructions for Spare Parts 2-5
2.4 Disposal of Packaging Materials 2-6
2.5 Disposal of Components 2-6
Chapter 3 - Mechanical Installation 3-1
3.1 Overview 3-1

3.2 Installation Site 3-1
3.2.1 Ambient Conditions 3-1
3.2.2 Dimensions and Clearances 3-2
3.2.3 Foundation, Floor Levelling and Cable Ducts 3-2
3.3 Identifying Converter Units 3-2
3.4 Installing the Converter 3-4
3.4.1 Raw Water Circuit 3-4
3.4.2 Mechanical Door Interlock 3-4
3.4.3 Installation Procedure 3-6
ACS 6000 User’s Manual 3BHS212794 ZAB E01 Rev. - 1 (4)

ABB
3.4.4 Installing Transport Units 3-7
3.4.5 Attaching the Sealing Tape 3-9
3.4.6 Installing Roof Joining Pieces 3-9
3.4.7 Installing Roof Fixings 3-10
3.4.8 Installing Roof-Mounted Heat Exchangers 3-13
3.4.9 Joining Water Pipes 3-14
3.4.10 Joining DC Busbars 3-16
3.4.11 Joining Ground Busbars 3-19
3.4.12 Joining AC Busbars in ARU, INU, IFU 3-20
3.4.13 Joining AC Busbars in LSU 3-23
Chapter 4 - Electrical Installation 4-1
4.1 Overview 4-1

4.2 Cables 4-2
4.3 Internal Wiring 4-3
4.4 Busbars and Ground Connections 4-5
4.5 External Power Cabling 4-8
4.5.1 Connecting Incoming Feeder and Motor Cables 4-8
4.5.2 Connecting Braking Resistor Cables 4-10
4.5.3 Connecting Excitation Cables 4-11
4.6 Connecting Auxiliary Power and Control Cables 4-13
4.6.1 Connecting Auxiliary Power Cable 4-14
4.6.2 Connecting Control Cables in WCU 4-14
4.7 Connecting Cables for Serial Communication
and Encoders 4-17
4.8 Connecting Position Encoder Cables in
Marine Drives 4-25
4.9 Connecting the Heating Cable 4-27
Chapter 5 - Information on Commissioning 5-1
5.1 Customer Assistance and Acceptance 5-1
Chapter 6 - Operation 6-1
Chapter 7 - CDP Control Panel 7-1
7.1 Overview 7-1

7.2 Identification Mode 7-2
7.3 Actual Signal Display Mode 7-3
7.4 Parameter Mode 7-6
7.4.1 Parameter Lock 7-8
2 (4) 3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

ABB
7.5 Function Mode 7-8
7.6 Operational Commands 7-9
7.6.1 Selecting Local/Remote 7-9
7.6.2 Setting the Direction of Rotation 7-10
7.6.3 Entering a Setpoint 7-11
Chapter 8 - Maintenance and Troubleshooting 8-1
8.1 Safety Instructions 8-2

8.2 Specific Maintenance Tasks 8-3
8.2.1 Cleaning 8-3
8.2.2 Checking Wire and Cable Connections 8-3
8.3 Standard Procedure for Troubleshooting 8-4
Appendix A - Water Cooling Unit

Appendix A contains all documentation relevant to the water cooling
system:
• User’s Manual
• Data Sheet
• Flow Diagram
Appendix B - Options
Appendix C - Mechanical Drawings
Appendix D - Electrical Diagrams
Appendix E - Parts List
Appendix F - Test Reports
Appendix G - Signal and Parameter Table

Appendix H is provided to file the Signal and Parameter Table. The table
includes a complete description of all control parameters and their default
setting.
If the Signal and Parameter Table is not included in the Appendix, the
commissioning engineer will hand out a copy to the customer after com-
missioning of the converter has been completed. The Signal and
Parameter Table can also be obtained from ABB. For contact address see
section General Information.

ABB

ABB
General Information
Contact Information
If information is required beyond the instructions in this manual, ABB can

be contacted as follows:
ABB Switzerland Ltd
CH-5300 Turgi, Switzerland
Phone: +41 844 845 845

Fax: +41 58 589 2984
E-mail mvdrives@ch.abb.com
Related Documentation
The following documents can be optained from ABB for supplementary

information.
Document
Title
Number
Power Cable Specification 3BHS125090
Main Circuit Breaker Specification 3BHS125149
LSU Main Transformer Specification 3BHS125150
ARU Main Transformer Specification 3BHS125092
Voltage Transformer Requirement Specification 3BHS125393
Asynchronous Motor Specification 3BHS125088
Synchronous Motor Specification 3BHS125093
Tool Sets for Installation, Commissioning and 3BHS130246

Maintenance
Emergency Off/Stop Modes and Prevention of 3BHS196243

Operation
ACS 6000 Troubleshooting 3BHS204855
ACS 6000 Service and Maintenance Manual 3BHS202077

ABB
Quality Certificates and Applicable Standards
The following certificates and conformity declarations are available with

ABB:
• ISO 9001 / ISO 14001 certificates stating that ABB Switzerland Ltd has
implemented and maintains a management system which fulfills the re-
quirements of the normative standards
• EC Conformity Declaration
• List of standards the converter complies with

ABB
Chapter 1 - Safety
1.1 Intended Audience and Required Qualifications
The user’s manual addresses personnel who are responsible for the
installation, operation and maintenance of the converter. The personnel
must be qualified and fully acquainted with medium voltage equipment.
Installation Personnel The installation personnel are mainly responsible for:

• Preparing the mounting site
• Transporting the converter
• Performing the mechanical and electrical installation
• Preparing the water cooling unit for operation (if present in the
converter)
Operating Personnel The operating personnel include all persons who operate the converter as
required for the application using the control panel(s) of the converter or a
supervisory control system. Operating the converter does not require
special knowledge of converter technology. However, the operator must
know the functions of the control panel.
Maintenance The maintenance personnel are mainly responsible for:

Personnel
• Periodical checks of the converter
• Maintenance tasks
1.2 Owner’s Responsibilities
It is the owners responsibility to ensure that each person involved in the

installation, operation or maintenance of the converter has received the
appropriate training and has thoroughly read and clearly understood the
relevant safety instructions.
The technical specifications and the approved purpose of the converter
must be strictly adhered to.
The owner must ensure that the converter is operated under proper
conditions and in a fully serviceable state. The specified service intervalls
and ambient conditions for the converter must be followed.
Unauthorized modifications and constructional changes of the converter
are not permitted.
ACS 6000 User’s Manual 3BHS212794 ZAB E01 Rev. - 1-1 (4)
Chapter 1 - Safety ABB
1.3 Safety Instructions
Safety instructions are used to highlight a potentially dangerous situation

when working on the converter. Safety instructions must be strictly
followed! Non-compliance can jeopardise the safety of personnel, the
machine and the environment.
DANGER!
Indicates an imminent hazardous situation. If not observed, it will lead to
death or life-threatening injury.
WARNING!
Indicates a potentially dangerous situation. If not observed, it could result
in death or life-threatening injury.
CAUTION!
! Indicates a potentially dangerous situation. If not observed, it could lead to

minor or moderate injury or property damage.
NOTICE!
Indicates important information related to personal safety and protection
of property.
IMPORTANT!
! Emphazises hints and highlights information.
1-2 (4) 3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual
ABB Chapter 1 - Safety
1.4 Safety Labels and Signs
Safety labels are attached to the converter enclosure to alert personnel of

potential hazards when working on the converter. The safety labels must
always be followed and kept in perfectly legible condition.
Depending on the scope of supply, the following additional safety signs are
provided:
Fire fighting:
The sign explains the procedure when fighting fire in electrical equipment.
The sign should be installed well visible near the converter.
Heart pacemaker:
The magnetic field of the converter can influence the functioning of heart
pacemakers. The sign should be installed at the entrance to the drive
room or at a minimum distance of 6 meters (20 ft) from the converter!
High voltage:
The sign should be installed well 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 converter transformer until the
main circuit breaker has been opened and secured and the converter has
been de-energized and grounded.
Chapter 1 - Safety ABB
1.5 Danger Zones
Figure 1-1 indicates the danger zones of the converter.
Danger from auxiliary and control

voltages in water cooling unit!
Danger from auxiliary and control voltages Cooling system may start automati-
in control unit when front door is open! cally when auxiliary voltage is on.
Line Terminal Control Inverter Capacitor Water

Supply Unit Unit Unit Bank Cooling
Unit Unit Unit
High voltage! High voltage!

Hot equipment inside the Do not attempt to open doors of Do not remove any
converter medium voltage units by force when bolted walls or plates
converter is energized. when converter is ener-
The doors are electromechanically gized or before converter
interlocked. When the light GROUND- is grounded.
ING SWITCH UNLOCKED is on, the
converter can be grounded and then
the doors can be opened.
Illustration shows basic configuration of the converter
Figure 1-1 Danger Zones
ABB
Chapter 2 - Transportation, Storage and Disposal
2.1 Transportation
2.1.1 Transport Conditions

The transport conditions are based on IEC 721-3-2 'Classification of
environmental conditions: Classification of groups of environmental
parameters and their severities; Transportation'.
Classification: 2K4 / 2B1 / 2M1
Transport time: max. 2 month
2.1.2 Unpacking and Inspection

Proceed as follows:
1 Remove all packaging material carefully. Do not use sharp or pointed
tools.
2 Check the converter and accompanying equipment for damage.
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.
2.1.3 Loading and Unloading

Observe the following points when transporting the converter:
CAUTION!
! Do not lift and move the converter or a transport unit using a forklift. The
frame of the cabinets could be damaged. If a crane is not available contact
ABB for instructions on other means of moving. See section General
Information for contact address.
CAUTION!
! Converter components can be damaged during transportation. Therefore,

the converter must be transported in upright position.
Chapter 2 - Transportation, Storage and Disposal ABB
CAUTION!
! When transporting the converter ensure that no dirt enters. Keep doors
closed. Metallic dust in particular may cause damage and lead to
malfunction when the converter is powered up.
CAUTION!
! The roof plates of medium voltage units are equipped with pressure relief
flaps. Do not stand on roof due to danger of collapse.
• See Appendix C - Mechanical Drawings for dimensions and weight

details.
• Material and diameter of the lifting cables must correspond to the
weight of the converter.
• When lifting a converter equipped with a base frame always use the
lifting lugs which are attached to the base frame. The lugs can be
removed after the converter has been installed at its final location.
• Do not pass a lifting cable through the fastening hole of a lug. Use a
safety hook to attach a cable to a lug.
• The lifting cables should be approximately at an angle as indicated in
Figure 2-1 to Figure 2-3.
• Protect the roof edges of the cabinets using appropriate means.
When lifting cabinets with marine-type door handles, use spreader
bars or similar equipment to ensure that the lifting cables do not
damage the door handles and the roof edges (see Figure 2-3). If the
door handles cannot be protected it is recommended to unscrew
them.
• Lift the converter slowly and steadily to the required clearance height
maintaining the converter in upright position.
• Check the horizontal position of the converter. Reposition the cables
if necessary.
• If a door cannot be opened see Chapter 3 - Mechanical Installation,
3.4.2 Mechanical Door Interlock for information on opening.
• If a delivery comprises transport units for several converters see
Chapter 3 - Mechanical Installation, 3.3 Identifying Converter Units,
for information how transport units belonging to a particular converter
are identified.
ABB Chapter 2 - Transportation, Storage and Disposal
Protect
30° edges !
Figure 2-1 Cabinets with Base Frame and without Door Handles
30°
Figure 2-2 Cabinets with Base Frame and Marine-type Door Handles
Cable angle
MAX. indicated on
120° cabinet roof
Figure 2-3 Cabinets without Base Frame
2.2 Storage
2.2.1 Storage Conditions

The minimum requirements for storage are based on IEC 721-3-1
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage'.
Classification: 1K4 / 1Z3 / 1B1 / 1M3
The converter can be stored for up to 1 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.
2.2.2 Storage
If the converter 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 frostproofing, if the converter is to be stored in ambient
temperatures below 0 °C (32 °F).
See Appendix A - Water Cooling Unit for information on frostproofing.
2 Remove the batteries (if applicable).
3 Cover all cable inlets and ventilation slots with an impermeable plastic
or aluminum foil and a wooden panel.
4 Add the desiccant of the appropriate quality: 1 unit desiccant (30g)
absorbs 6 g water vapor. The following quantity is needed when using
a polyethylene foil:
• 10 units/sqm foil
5 Close and lock the doors of the converter.
6 Use polyethylene or equivalent for packaging:
• 0,3g/sqm/24h water vapor diffusion
7 Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly.
Any damages which occur during the storage period should be repaired
immediately.
ABB Chapter 2 - Transportation, Storage and Disposal
2.3 Storage and Handling Instructions for Spare Parts
Inspect 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 to + 55 °C (23 °F to 131 °F)
• 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 to 85 %
If in doubt if the maximum allowed humidity is
exceeded, protect spare parts by an external heater.
• Apply static-sensitive precautions when handling printed circuit
boards. Static electricity can damage these components.
• 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.
2.4 Disposal of Packaging Materials
Dispose of the following materials according to local regulations:

• Wooden frame
• Wooden pallet
• Polyethylene sheet
• Plywood
• Silicagel
2.5 Disposal of Components
At the end of the life time of the converter dispose of the following
components according to local regulations:
• Batteries
• Capacitors
• Printed circuit boards
• Electronic devices
ABB
Chapter 3 - Mechanical Installation
NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
3.1 Overview
The mechanical installation includes the following steps:

• Fitting water pipes
see 3.4.1 Raw Water Circuit
• Installing transport units
see 3.4.4 Installing Transport Units
• Attaching sealing tape
see 3.4.5 Attaching the Sealing Tape
• Installing roof fixings
see 3.4.6 Installing Roof Joining Pieces
• Installing pipe joints
see 3.4.9 Joining Water Pipes
• Installing busbar joining pieces
see 3.4.10 Joining DC Busbars
3.2 Installation Site
3.2.1 Ambient Conditions

Ambient factors such as temperature, relative humidity, air contamination,
shock and vibration must be in compliance with the stated maximum
permissible levels.
• Maximum ambient temperature: see rating plate of converter
• Operation with respect to climatic and environmental conditions is
based on IEC 721-3
Classification: 3K3 / 3B1 / 3C2 / 3S2 / 3M3
If the condition of the installation site is not within the specifications or if
the transportation or the installation require special measures, contact the
ABB service organization.
Chapter 3 - Mechanical Installation ABB
3.2.2 Dimensions and Clearances
The converter must be mounted with adequate free space. The
dimensions of transport units, the overall dimensions of the converter and
the clearances are provided in Appendix C - Mechanical Drawings.
3.2.3 Foundation, Floor Levelling and Cable Ducts

The floor must be of non-flammable material, with smooth and non-
abrasive surface, protected against humidity diffusion, levelled and able to
support the weight of the cabinets (min. 1’000 kg/m2).
The maximum allowable overall unevenness is ≤ 5 mm / 5 m. If the
mounting surface is uneven, the cabinet doors become misaligned and do
not open or close properly.
Cable ducts must be of non-flammable material with non-abrasive
surface.
Suitable fire protection measures must be applied to prevent fire from
spreading into the converter.
All cable entries and exits must be protected to prevent dust, humidity and
animals from entering into the converter.
See Appendix C - Mechanical Drawings for exact dimensions, if holes and
channels for cables and water pipes have to be cut into the floor and
mounting holes have to be drilled.
3.3 Identifying Converter Units
If a delivery comprises transport units for several converters, the transport

units need to be identified and assigned to the converter to which they
belong. For this purpose, the converters have been numbered on the
accompanying papers (e.g. converter 1, converter 2 etc.). The
corresponding information is provided on
• the packing list, attached to the packaging of each transport unit
and
• the packing label on the back wall of each converter unit (ARU, LSU,
CBU etc.). The packing label is only visible after the packaging has
been removed.
Packing List Transport units which belong to a particular converter are identified with
the help of the commodity description on the packing lists. The identical
column of the packing list states the number of the converter to which the
transport unit belongs (see section of packing list in Figure 3-1).
ABB Chapter 3 - Mechanical Installation
the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
shown on this packing list.
ABB item Qty. Unit. Identnumber Commodity description

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

Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zürich/Switzerland
CH-5401 Baden/Schweiz +41 58 589 27 95 755749 abb ch +41 58 589 29 84
Transport units where packing lists

have the same number in this place
belong to one converter
Figure 3-1 Identifying the Converter on the Packing List
Separately delivered crates with accessories such as tools and installation

material are also assigned to a converter by means of the packing list. The
item number in column ’ABB Item / Customer item’ provides the necessary
information (see section of packing list in Figure 3-2).
the nearest Lloyd's agent may be contacted. Please also inform the contact person with ABB Schweiz AG
shown on this packing list.
ABB item Qty. Unit. Identnumber Commodity description

Customer item
001221 1 PC cross wiring

001222 1 PC WCU accessory
001223 1 PC crank for isolator
001500 1 PC 3BHB013202R0001 ACS6000 Max-SL LOSE TEILE konfig.
ABB Switzerland Ltd
Drives
Mailing address: Phone: Telex: Facsimile: Bank Credit Suisse CH-8070 Zürich/Switzerland
CH-5401 Baden/Schweiz +41 58 589 27 95 755749 abb ch +41 58 589 29 84
The number in this place (4th. digit from right) states the converter to which
the accessories belong. In this example they belong to converter 1.
Figure 3-2 Identifying the Converter on the Accessories Packing List
Packing Label The packing labels on the back walls of converter units can also be used
to identify the converter (see Figure 3-3).
ABB Packing Label 0000

Material no 3BHB009964R1500 1 ST
Material Schrank kpl. ARU_INU konfig
Order no/positions 11027727 001241 Project CBA
Material Document
004902892300012004
001241
The number in this place (4th. digit from right)
identifies the converter to which the
transport unit belongs.
Figure 3-3 Identifying the Converter on the Packing Label
3.4 Installing the Converter
3.4.1 Raw Water Circuit

See the following when preparing the connection for the cooling water:
• Rating Plate for information on:
• Type of water cooling unit
• Project specific values of flow rate, pressure range
etc.
• Appendix C - Mechanical Drawings for information on dimensions of
the raw water entry
• Datasheet in Appendix A - Water Cooling Unit for information on:
• Nominal values of flow rate, pressure range etc.
• Industrial cooling water specification
3.4.2 Mechanical Door Interlock

The doors of the medium voltage units (units with names plates: LSU,
ARU, IFU, IRU, CBU, INU, BCU, RBU, VLU, TEU, ISU) are equipped with
a solenoid interlock which ensures that a door cannot be opened when the
converter is energized. The doors can also not be opened, when the
converter is disconnected from the auxiliary power and the solenoid
interlock is in “locked” position. To be able to open the doors for the
installation of the converter, the solenoid interlocks are unlocked before
the converter leaves the factory. If a door cannot be opened, however, the
solenoid interlock must be manually unlocked as described below.
Required Tools • A small cross-slot screwdriver
• Triangular door key
Figure 3-4 Triangular Door Key
Procedure The solenoid interlocks are mounted behind the name plate on the doors
of the medium voltage units (see arrows in Figure 3-5).
Figure 3-5 Location of Name Plates
1 Remove the name plate of the door to be opened and insert the key
through the opening in the door (see Figure 3-6) into the triangular
counterpart of the solenoid interlock (see Figure 3-7).
Figure 3-6 Door Opening
2 Turn the key from the “locked” to the “unlocked” position to release
the interlock (when looking through the opening at an angle the
symbols are visible). The door can now be opened.
Unlocked position
Locked position
Figure 3-7 Manual Release of the Interlock
3 Remount the name plate.
IMPORTANT!
! After the mechanical and electrical installation has been finished, it is the
task of the commissioning engineer to check that the manual release of all
solenoid interlocks is in the “locked” position. Otherwise, the converter
cannot be started up.
3.4.3 Installation Procedure

Depending on the configuration, the converter is delivered in one unit or in
several transport units, which are joined and fixed to the floor at the
installation site. See Appendix C - Mechanical Drawings to identify the
units and their position in the lign-up. Transport units must be ligned up as
shown on the Layout Drawing. The units can be ligned up either beginning
from the left or the right.
Parts needed for the installation (bolts, washers, joining pieces etc.) are
supplied with the converter in a separate box.
Observe the following points when installing the converter:
1 Drill the floor fixing holes before moving the converter unit(s) to the
final location.
2 Be careful when moving the converter unit(s).
See Chapter 2 - Transportation, Storage and Disposal, 2.1 Transpor-
tation for information to be observed.
CAUTION!
! When installing the converter ensure that no dirt enters. Always close the
doors when work is discontinued and completely cover openings. Metallic
dust in particular may cause malfunction when the converter is powered
up and cause damage.
CAUTION!
! The roof plates of medium voltage units are equipped with pressure relief
flaps. Do not stand on roof due to danger of collapse.
NOTICE!
When joining two cabinets do not damage or dislocate the EMC sealing
strip which is glued onto the outer joining surface of the cabinet frame.
NOTICE!
Do not weld cabinets without base frame to the floor. The corrosion
protection will become ineffective.
NOTICE!
The roof plates of the cabinets are not designed as a mounting base for
foreign devices, cable ducts etc. Therefore, it is not permitted to install any
foreign devices on the cabinet roofs.
3.4.4 Installing Transport Units

Proceed as follows:
1 Carefully lift the first transport unit to its installation position.
2 If the transport unit has water pipes, remove the protective covers
from each water pipe end.
3 Align the transport unit and fix it to the floor.
• Floor fixings are not part of the delivery.
Recommended size of bolts and nuts: M12.
4 Before aligning the following transport units make sure that:
• the protective covers are removed from the water
pipe ends on both sides
• the water pipe joints are in place.
The pipe joints have been slid onto the water pipes in
the factory.
IMPORTANT!
! When aligning a transport unit make sure that two joining water pipes have
a linear misalignment of a maximum of +/- 3 mm (see Figure 3-8).
Figure 3-8 Aligning a Water Pipe
5 Join the transport units using the supplied M6 screws, item 1 in Table
3-1. Number and position of connecting points are illustrated in Figure
3-9.
Cabinet connecting points
Front of cabinet
Figure 3-9 Cabinet Connecting Points
6 Connect the wiring ducts using the supplied M6 screws and nuts,
washers and spring washers, items 1, 2, 3 and 4 in Table 3-1.
Connecting points
Figure 3-10 Connecting Points of Wiring Duct
Table 3-1 Installation Material
Item Type Ident. Number Use
1 Hexagon head screw M6x20 Connection of transport

3BHE004520R0003
unit
2 Hexagon head bolt M6x20 NB312350P0260 Connection of wiring duct
3 Washer A 6.4/12.5 NB335050P0607 Connection of wiring duct
4 Spring washer NB335805P0509 Connection of wiring duct
5 Hexagon head nut M6 A2-70 HZN452198P0016 Connection of wiring duct
3.4.5 Attaching the Sealing Tape
IMPORTANT!
! This section is applicable for marine converters and converters with

insulation protection IP 54.
The self-adhesive sealing tape (supplied with the converter) prevents

water from entering into the gap between two joining roof plates. The tape
has to be installed where two transport units have been joined. Gaps
within a transport unit have been sealed with a tape in the factory already.
Proceed as follows:
1 Remove the roof plates of two joining transport units.
2 Cut the sealing tape to the required length.
3 Attach the tape on the whole length of the joining crossbars (see
Figure 3-11).
4 Remount the roof plates again.
Sealing Tape
Figure 3-11 Attaching the Sealing Tape
3.4.6 Installing Roof Joining Pieces

The joining pieces are mounted at the front and the back (see Figure 3-12)
of the roof and connect two joining transport units. The joining pieces
within a transport unit have been mounted in the factory already.
Joining pieces
Figure 3-12 Roof Joining Pieces
Item Type Ident. Number
Joining piece 8x80x220 mm 3BHB011552R0001
Bolt M16x45 NB312350R0465
Washer A17/30 NB335050R0611
3.4.7 Installing Roof Fixings
IMPORTANT!
! This section is only applicable for marine drives.
Roof Attachments To prevent tilting, the cabinets are fixed to the ceiling or the back wall of
the drive room by means of roof attachments which also serve as vibration
dampers. All parts of a complete roof attachment assembly are listed in
Table 3-3.
See Appendix C - Mechanical Drawings for
• number and location of roof attachments
• hole center distances and dimensions.
1 Steel bracket, roofside 120x80x8 mm, L=120 mm

3BHB11553R0001
with 14 mm mounting holes
2 Steel bracket, wallside 120x80x8 mm, L=120 mm

3BHB11553R0002
with 30 mm mounting holes
3 Rubber pad 80x220 mm 3BHB12579R0001
4 2 Sleeves - 3BHB012580R0001
Table 3-3 Installation Material (Continued)
5 2 Bolts M12x80 NB312450P8127
6 2 Washers 13x45x4 3BHL001710P0001
7 2 Nuts M12 3BHB011779R0002
8 2 Washers A13/24 NB335050P0610
Normally, roofside steel brackets (item 1 in Table 3-3) within a transport

unit have been mounted in the factory already (see Figure 3-13). If the
brackets are not mounted for transport reasons (e.g. between transport
units) they are part of the separate installation material delivered with the
converter.
The steel brackets can be distinguished by their mounting holes:
• The roofside brackets have holes with a diameter of 14 mm (see
Figure 3-13).
• The wallside brackets have holes with a diameter of 30 mm (see
Figure 3-14).
1 4 mm
factory mounted
within a transport
unit
Figure 3-13 Roofside Steel Bracket
Before starting assembling have all parts of a roof attachment ready at

hand.
A roof attachment can be assembled by one person but depending on the
site conditions the assistance of a second person is helpful.
Proceed as follows:
1 Check that the roofside steel brackets have been mounted according
to Appendix C - Mechanical Drawings.
2 Align the rubber pad and the wallside steel bracket with the roofside
steel bracket (see Figure 3-14).
3 Insert one of the sleeves into a mounting hole until the sleeve is flush
with the surface of the second bracket.
4 Join the parts with one set of the supplied bolts, nuts and washers,
with the nut on the roofside bracket and the bolt on the wallside
bracket (see Figure 3-15). Tighten the bolted connection by hand.
5 Insert the second sleeve and join the parts with the remaining bolt, nut
and washers. Tighten the bolted connection by hand.
6 Finally, tighten the bolted connections until the rubber of the sleeves
starts to bulge (see Figure 3-15).
To be mounted on site:
2nd steel bracket
Rubber pad
30 m m Sleeve
Figure 3-14 Installing the Roof Attachments
Nut Bolt
Figure 3-15 Roof Attachment Assembled
7 Fix the cabinets to the ceiling or the back wall with suitable struts. The
struts are not part of the delivery.
When fixing the cabinets to the ceiling, it is recommended to use two
struts per roof attachment as illustrated in Figure 3-16 a.
Struts connecting the cabinet to the wall should be mounted in a 90°
angle to the converter as illustrated in Figure 3-16 b.
IMPORTANT!
! When fixing the struts to the ceiling, do not mount the struts in a 90° angle
to the cabinet roof as illustrated in Figure 3-16 c.
45° 45°
90°
a Recommended! b Recommended! c Not recommended!
Figure 3-16 Recommended Ceiling and Wall Fixings
3.4.8 Installing Roof-Mounted Heat Exchangers

See Appendix C - Mechanical Drawings for number and location of the
heat exchangers and overall height of the converter.
Proceed as follows:
1 If present, remove the cover from the mounting frame.
2 Place the heat exchanger on the mounting frame and align the screw
holes on the underside of the heat exchanger with the screw holes of
the mounting frame (one screw hole in each corner, see Figure 3-17).
3 Fasten the heat exchanger to the frame using the supplied screws
and washers.
4 Plug the power leads into the connectors on the roof (see Figure 3-
18) and fasten the coupling rings.
Fixing points are in

all four corners of the
support frame
Figure 3-17 Heat Exchanger Fixing Points
Figure 3-18 Heat Exchanger Electric Connections
3.4.9 Joining Water Pipes

The pipe joints connecting the water pipes of two joining transport units
have been slid onto the water pipes in the factory with the bolts showing
in the direction where they can be reached best with a wrench. On the
installation site, they have to be slid over two joining pipe ends, centered,
adjusted and fastened after the cabinets have been aligned.
Proceed as follows:
1 Connect the pipe ends by sliding the pipe joint over the two joining
pipe ends.
2 Center the pipe joint.
Mark the length of a pipe joint on one end of a water pipe as a fitting
guide (see Figure 3-19).
Figure 3-19 Marker for Centering a Pipe Joint
Slide the pipe joint over two pipe ends as shown in Figure 3-20.
47
mm
Figure 3-20 Centering a Pipe Joint
3 Adjust the pipe joint.
IMPORTANT!
! When adjusting a pipe joint make sure that the locking part of the pipe joint
is at a minimum distance of 55 mm from a DC busbar.
Front of cabinet
5 5 min
mm .
Locking part of
pipe joint
m
55 min.
m
Figure 3-21 Adjusting Pipe Joints
4 After adjusting a pipe joint, alternately tighten the bolts only lightly.
5 Tighten the bolts with a torque wrench to the final torque rate
indicated on the pipe joints outer surface.
Torque rate
Figure 3-22 Torque Rate
IMPORTANT!
! Do not tighten bolts above indicated torque rate.
6 If a pipe joint has to be removed, proceed as follows:

• Loosen bolts alternately but do not remove them
completely.
• Slide pipe joint to the side.
IMPORTANT!
! Sealing lip may touch pipe end. Turn and move pipe joint smoothly.
• Clean pipe joint and treat bolts with an appropriate

lubricant before refitting.
3.4.10 Joining DC Busbars

DC busbars must be connected with joining pieces between two transport
units. Busbar joining pieces within a transport unit have already been
mounted in the factory. The DC busbars are reached best from behind and
from the top.
Remove top plates and rear walls if necessary.
IMPORTANT!
! All joining pieces and bolts must be orientated exactly as shown in Figure
3-23 to Figure 3-26 to maintain the required distance between busbars of
different polarity.
When fitting the joining pieces make sure that the bolt head is on the
busbar side and the nut is on the side of the joining piece.
IMPORTANT!
! Tightening torque for bolted busbar connections: 30 Nm.

The bolts must be greased to maintain the required contact pressure.
Use the items listed inTable 3-4 when joining the busbars.
Hexagon head bolt M12x35 NB 312350P8118
Strain washer GZN 490084P0111
Hexagon head nut M6 A2-70 HZN 452198P0022
Joining piece 3BHB009410R0001
Grease GJN598105P0153
Top of cabinet Strain washer on each side Front of cabinet

of a connection!
Joining piece
- +
NP
Figure 3-23 Busbar Configuration 1, Polarity and Bolt Orientation

of a connection!
Joining piece
+ - - +
NP NP

of a connection!
Joining piece
- + + - - +
NP NP NP
Top of cabinet Front of cabinet

Strain washer on each side
Joining piece of a connection!
+ - - + + - - +
NP NP NP NP
3.4.11 Joining Ground Busbars

Ground busbars must be connected with joining pieces between two
transport units. Busbar joining pieces within a transport unit have already
been mounted in the factory.
IMPORTANT!

Mount the joining pieces for safety ground busbar (PE) and power ground
busbar (PG) as shown in Figure 3-27 using the items listed inTable 3-5.
Joining piece 3BHB009221R0001
PG busbar
Strain washer on each side

of a connection!
Pipe joint
Connecting piece
PE busbar
Front of cabinet
Figure 3-27 Connecting Ground Busbars
3.4.12 Joining AC Busbars in ARU, INU, IFU
If a Terminal Unit (TEU) is joined to an Activer Rectiver Unit (ARU), an
Inverter Unit (INU) or an Input Filter Unit (IFU) the AC busbars in these
cabinets must be connected to the corresponding busbars in the TEU.
The busbar joining pieces between two transport units have oblong holes
for fine adjustment.
IMPORTANT!

Connecting Points on Figure 3-28 shows the connecting points of AC busbars of ARU, INU and
the Right of TEU IFU when located on the right of a terminal unit.
Connecting points
for phase L3 of IFU
Front of TEU cabinet
Connecting points for

phase L3 of ARU/INU/IFU
L3
L2
phase L2 of ARU/INU

L1 phase L1 of ARU/INU/IFU
Figure 3-28 Connecting Points of AC Busbars in ARU, INU, IFU
Connecting Points on Figure 3-29 shows the connecting points of AC busbars of ARU, INU and
the Left of TEU IFU when located on the left of a terminal unit.
L3
L2
L1
Connecting points for ARU/INU
Connecting points for IFU
Phase L1
Phase L2
Phase L3
Figure 3-29 Connecting Points of AC Busbars in ARU, INU, IFU
3.4.13 Joining AC Busbars in LSU

If a Line Supply Unit (LSU) is joined to a Terminal Unit (TEU), the AC
busbars in this cabinet must be connected to the corresponding busbars
in the TEU.
IMPORTANT!

Item Type Ident. Number Remarks
Hexagon head bolt M12x50 NB 312450P8121 single busbars
Hexagon head bolt M12x80 NB 312450P8127 double busbars
Connecting Points on Figure 3-30 shows the connecting points of AC busbars of LSU when
the Right of TEU located on the right of a terminal unit.
Connecting points
Figure 3-30 Connecting Points of AC Busbars in LSU
Single busbars in Double busbars in

7 and 9 MVA units 14 MVA units
require M12x40 bolts require M12x40 bolts
Figure 3-31 Busbar Arrangements in LSU
ABB
Chapter 4 - Electrical Installation
NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
Power must not be applied to the drive system without the consent of the
ABB commissioning staff.
DANGER!
Hazardous voltage!
To ensure safety, the converter must be installed in accordance with the
instructions in this manual. Improper work can lead to life-threatening
injury or death.Take appropriate measures to prevent that mains and
auxiliary power can be switched on.
4.1 Overview
The electrical installation includes the following steps:

• Internal wiring
see section 4.3 Internal Wiring
• Ground cable
see section 4.4 Busbars and Ground Connections
• Power cables
see section 4.5 External Power Cabling
• Auxiliary voltage and control cables
see section 4.6 Connecting Auxiliary Power and Control Cables
• Serial communications and encoder cables
see sections:
4.7 Connecting Cables for Serial Communication and Encoders
4.8 Connecting Position Encoder Cables in Marine Drives
• Heating cables
see section 4.9 Connecting the Heating Cable
Understanding Designation, cross-reference and device-identification conventions are

Electrical Drawings defined on the diagrams in Appendix D - Electrical Diagrams.
Abbreviations Control Unit (COU) and Terminal Unit (TEU) exist in a version for 3 and 5
MVA converters and a version for converters with a power rating of 7MVA
Chapter 4 - Electrical Installation ABB
and above. Both versions have a different physical layout and can be
present in a drive line-up. To distinguish the cabinets, the following
abbreviations are used:
• COU Type 1 and TEU Type 1 for 3 and 5 MVA converters
• COU Type 2 and TEU Type 2 for power ratings of 7 MVA and above.
Tools ABB offers various tool sets which contain all necessary tools and
equipment for installation, commissioning and maintenance of the
converter. The content of the tool sets is described in manual Tool Sets for
Installation, Commissioning and Maintenance.
4.2 Cables
Power Cables See the Power Cable Specification for information on suitable power
cables (incoming feeder cables, motor cables, braking resistor cables) or
contact ABB.
Auxiliary Power Cable A 3-phase cable is required for the auxiliary power supply. A neutral
connector is not required. Type and rating is to be selected according to
local regulations.
Control Cables Control cables should be provided in accordance with Table 4-1. Either
single or multiple twisted pair cables may be used.
Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm (12 in) must be
maintained between control and power cables. Control and power cables
should be crossed at an angle of 90°.
Table 4-1 Control Cable Requirements
Signal Type General Cable Type Cross-Section
Analog In 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Analog Out 0.5 to 2.5 mm2 /

AWG 20 to AWG 12
Digital In 0.5 to 2.5 mm2 /

AWG 20 to AWG 12
Digital Out 0.5 to 2.5 mm2 /

AWG 20 to AWG 12
Speed Encoder Twisted pair cable with overall shield 0.5 mm2
and separately shielded pairs 4 x (2+1)
Position Encoder Twisted pair cable with overall shield 0.5 mm2
and separately shielded pairs 4 x (2+1
Synchronization Synchronization cables are used in ACS 6000 configurations with ARU. A
Cables 3-phase shielded cable without neutral wire is required for the voltage
ABB Chapter 4 - Electrical Installation
supply of the synchronization transformer. For information on ratings

contact ABB.
4.3 Internal Wiring
Cables for internal wiring are prepared inside the cabinets. All necessary
data for each individual connection, i.e.
• Cable numbers
• Cable type
• Cross-section
• Location of terminals
are specified on the Converter Hardware Diagram in Appendix D -
Electrical Diagrams.
The cables have been connected on one side or they have been rolled up
and delivered as loose items.
All cables to be connected can be identified by their specific number.
Individual strands or wires have been marked with the designation of the
terminal they have to be connected to.
Proceed as follows:
1 Pull all cables through the cable duct located at the top of the
cabinets. Cut-outs in the ducts provide entry into the cabinets.
Cable duct
Figure 4-1 Location of Cable Duct
2 Lay the cables and wires in their designated trays and cable ducts as
shown in Figure 4-2.
Front of cabinet
Cable trays A for:

- Auxiliary supply
- Control cables
Cable duct B for:

Fiber optic cables
Mounting rail C for:

IGCT power supply cable of
- Discharging Unit (DIU)
- Ristor Braking Unit (RBU)
- Voltage Limiting Unit (VLU)
Figure 4-2 Cable Duct Sections
IMPORTANT!
! When fastening IGCT power supply cables on mounting rail C (see Figure
4-2) make sure that the cables are at a minimum distance of 5 mm from
the nearest metall part.
3 Connect all cables and wires according to the Converter Hardware

Diagram in Appendix D - Electrical Diagrams.
IMPORTANT!
! Handle fiber optic cables with care. Do not touch the ends of the fibers,
they are extremely sensitive to dirt. When unplugging a fiber optic cable,
always hold it at the connector not at the fiber.
Observe the maximum long-term tensile load of 1.0 N and the minimum
bend radius of 25 mm.
4.4 Busbars and Ground Connections
Cable entry from top
LSU TEU INU CBU WCU EXU (CIU)
DC (-)
DC (NP)
DC (+)
1L1
1L2
1L3
L3
L2
L1
2L3
2L2
2L1
PG
PE
Cable entry from bottom PG to PE connection in CBU

Connecting point of system ground
Figure 4-3 Principal Busbar Arrangements
AC Busbars Incoming feeder and motor cables are connected to their corresponding
busbars inside a TEU. In multi-motor converters, several TEUs are part of
the drive line-up. See the Converter Hardware Diagram in Appendix D -
Electrical Diagrams to assign incoming feeder and motor cables to their
corresponding TEU.
The incoming busbars are interconnected with the line rectifier unit (ARU
or LSU) and the outgoing busbars with the motor inverter(s) (INU). The
busbars can be identified by their phase designations.
DC Busbars The DC busbars connect the line rectifiers (ARU or LSU) with motor
inverter(s) (INU) and CBU. In multi-motor configurations up to four DC
busbar arrangements can be installed (see Chapter 3 - Mechanical
Installation, 3.4.10 Joining DC Busbars). The busbars are mounted in the
upper part of the converter and are marked with DC (+), DC (-) and DC
(NP).
Protective Earth It is important that the converter is properly grounded to maintain safety
and to ensure smooth functioning of the equipment. For this reason, the
converter’s ground cable must be securely tied to the grounding system of
the installation site (system ground).
The converter is equipped with a continuous ground busbar (marked PE,
Protective Earth) which is installed in the bottom area of the cabinets (see
Figure 4-3).
The ground cable is tied to a connecting bar which is accessible from the
front of the cabinets (see Figure 4-5 to Figure 4-6).
IMPORTANT!
! The ground cable must be connected to the ground busbar of the

converter at only one point: at the busbar inside the TEU closest to the
CBU. See Converter Hardware Diagram in Appendix D - Electrical
Diagrams for project-specific illustration.
The connection must be in compliance with local regulations.
Connection details:
• Thickness of connecting bar: 5 mm
• Diameter of provided fixing hole for the ground cable: 13 mm.
• Recommended minimum cross section of the ground cable:
150 mm2.
Connecting bar
for
grounding cable
Note: If cable enters from the

top, the connecting bar is
mounted below the roof
Figure 4-4 Bottom Connecting Point of System Ground in TEU Type 1
Connecting point
for
ground cable
Figure 4-5 Bottom Connecting Point of System Ground in TEU Type 2
Connecting point
for
grounding cable
Figure 4-6 Top Connecting Point of System Ground in TEU Type 2
Power Ground Cable shields must be connected to the converter to ensure proper
operation. A separate busbar (Power Ground, PG) is installed for this
purpose. The busbars of “power ground” and “protective earth” are
connected with each other inside the CBU which has the grounding switch
mounted on the front door. The connection has been made in the factory
already.
See Power Cable Specification, section 1.3 Installation Requirements for
a principal illustration on cable shield grounding.
4.5 External Power Cabling
The following sections

• 4.5.1 Connecting Incoming Feeder and Motor Cables
• 4.5.2 Connecting Braking Resistor Cables
describe cable entry using EMC ROX modules. These modules are not in
ABB’s scope of supply.
Information on EMC ROX modules can be optained from www.roxtec.com
and from the Power Cable Specification.
See the Layout Drawing in Appendix C - Mechanical Drawings for the
dimensions of the EMC ROX frame(s).
If EMC ROX modules are not used, cable transits in accordance with local
regulations must be installed.
4.5.1 Connecting Incoming Feeder and Motor Cables

The incoming feeder and motor cables are connected inside a TEU. If
several TEUs are part of the converter, see Appendix D - Electrical
Diagrams to assign incoming feeder and motor cables to their
corresponding TEU.
Cable entry can either be from the top or from the bottom. Project specific
cable entry is illustrated on the Layout Drawing in Appendix C -
Mechanical Drawings.
NOTICE!
Do not cut cables inside the terminal unit. Make sure that waste from cable
cutting and stripping cannot enter the converter. Any waste which
accidentally dropped into the converter must be retrieved. The waste
could cause damage or malfunction.
1 Enter a cable into the respective terminal unit to measure the

conductor length.
Mark the required conductor length and withdraw the cable. Cut it to
the correct length, strip the conductor ends and mount the cable lugs
suitable for M12 bolts. Cables must be terminated with lugs according
to the specification of the cable manufacturer.
See Appendix C - Mechanical Drawings for hole sizes of cable termi-
nation bar inside the TEU.
2 Cable armor must be in contact with the EMC ROX module as shown
in Figure 4-7 (see also Power Cable Specification). If non-armored
cables are used, the cable shield must be in contact with the EMC
ROX module.
3 Pull the conductors into the cabinet and install the EMC ROX
modules.
EMC ROX module
Strip this part of

the cable jacket
Entry plate
Figure 4-7 Cable Entry for Power Cables with EMC ROX Modules
4 Check the insulation of each cable before connection and verify that
the results are within the specification of the cable manufacturer.
5 Connect the phase conductors to the corresponding busbars. See the
specification of the manufacturer of the cable lugs for tightening
torques.
CAUTION!
! High voltages will be present in the terminal unit. High voltages can cause
flashover between the potential of a phase conductor and ground.
A minimum clearance of 55 mm must be maintained between each cable
and the terminals of any other phase.
6 Connect the shield ends of all conductors to the power ground busbar
(PG).
7 Enter the ground cable into the cabinet through the entry plate and
fasten it to the PE ground busbar.
8 Connect the armor of all cables to the power ground busbar (PG).
9 Mount top plates and rear walls of all cabinets and fasten them with
the supplied screws.
IMPORTANT!
! All provided screws must be mounted and tightened to achieve best EMC.
10 Cover all remaining cable entry openings.
4.5.2 Connecting Braking Resistor Cables
IMPORTANT!
! This section is only applicable for converters with a Braking Chopper Unit
(BCU).
The braking resistor cables are connected inside a BCU.

Cable entry can either be from the top or from the bottom. Project specific
cable entry is illustrated on the Layout Drawing in Appendix C -
Mechanical Drawings.
NOTICE!
Do not cut cables inside the terminal unit. Make sure that waste from cable
cutting and stripping cannot enter the converter. Any waste which
accidentally dropped into the converter must be retrieved. The waste
could cause damage or malfunction.
Proceed as follows:
1 Enter a cable into the cabinet to measure the conductor length.
Mark the required conductor length and withdraw the cable. Cut it to
the correct length, strip the conductor ends and mount the cable lugs
suitable for M12 bolts. Cables must be terminated with lugs according
to the specification of the cable manufacturer.
2 Cable armor must be in contact with the EMC ROX module as shown
in Figure 4-7 (see also Power Cable Specification). If non-armored
cables are used, the cable shield must be in contact with the EMC
ROX module.
3 Pull the conductors into the cabinet and install the EMC ROX module.
4 Check the insulation of each cable before connection and verify that
the results are within the specification of the cable manufacturer.
5 Connect the phase conductors to the corresponding busbars. See the
specification of the manufacturer of the cable lugs for tightening
torques.
CAUTION!
! High voltages will be present in the terminal unit. High voltages can cause
flashover between the potential of a phase conductor and ground.
A minimum clearance of 55 mm must be maintained between each cable
and the terminals of any other phase.
6 Connect the shield ends of all conductors to the power ground busbar
(PG) (see Figure 4-8).
7 Connect the armor of all cables to the power ground busbar (PG).
Connecting point of
cable shield
Cable entry
Figure 4-8 BCU Bottom Cable Entry
4.5.3 Connecting Excitation Cables
IMPORTANT!
! This section is only applicable for converters with synchronous motors.
Information on cable connection can be found on the Converter Hardware

The incoming feeder and motor cables can be entered either from the top
or from the bottom of a cabinet. Project specific cable entry is illustrated
on the Layout Drawing in Appendix C - Mechanical Drawings.
Proceed as follows:
1 Enter the conductors through the EMC sleeves of the entry plate as
shown in Figure 4-9:
• Strip the cable insulation at the point of entry. Tighten
the EMC sleeve on the stripped part of the cable with
cable ties.
• If necessary, remove the entry plate and slide it onto
the cable. Fasten the entry plate, after the ground
connections have been made.
• Remove the rubber grommets from the entry plate
and cut them to adequate cable diameter (Figure 4-
10). To ensure proper sealing, cut along the diameter
marking that corresponds to the cable diameter. Slide
the grommet onto the cable (Figure 4-9). The
grommet must fit tight to prevent water from entering
the cabinet. If necessary, seal the junctions with
silicone rubber.
Outer sheath
1st. insulated conductor
2nd. insulated conductor

Mounting bracket
3rd. insulated conductor
Strip conductor
Rubber grommet insulation to
expose shield
Entry plate
EMC sleeve
3rd. insulated conductor
Strip conductor
insulation to
2nd. insulated conductor
expose shield
1st. insulated conductor
Mounting bracket
Outer sheath
Top entry Bottom entry

Figure 4-9 Principle Cable Entry into EXU
A B C
Figure 4-10 Cutting Rubber Grommets to Size
2 Connect the supply cables and motor cables to their corresponding

busbars.
3 Connect the end of the cable shields to PE.
4.6 Connecting Auxiliary Power and Control Cables
The auxiliary power cable and the control cables are connected inside the
Water Cooling Unit (WCU).
Information on cable connection can be found on the Converter Hardware
The cables can be entered either from the top or from the bottom of the
WCU. Project specific cable entry is illustrated on the Layout Drawing in
Appendix C - Mechanical Drawings.
It is recommended to properly determine the required length of a cable
between the point of entry and the connection point inside a cabinet and
to cut the cable to the required length before connection to avoid excess
cable to be stored in the cable ducts.
The following section describes cable entry using EMC ROX modules
(type CS-EMV). These modules are not in ABB’s scope of supply.
Information on EMC ROX modules can be optained from
www.roxtec.com.
See the Layout Drawing in Appendix C - Mechanical Drawings for the
dimensions of the EMC ROX frame(s).
If EMC ROX modules are not used, cable transits in accordance with local
regulations must be installed.
Cable transit inside cabinet
EMC ROX-Module
Remove outer
sheath in this area
Figure 4-11 Cable Transit inside Cabinet
4.6.1 Connecting Auxiliary Power Cable
Proceed as follows:
1 Enter the auxiliary power cable into the WCU.
2 Connect the cable according to the Converter Hardware Diagram in
Appendix D - Electrical Diagrams.
• Shielded cables: Remove the outer cable sheath in
the area of the cable transit. The conductive parts of
the EMC ROX module must be in contact with the
cable shield (see Figure 4-11). The cable shield is
connected to PE.
4.6.2 Connecting Control Cables in WCU
Top Cable Entry Proceed as follows:

1 Enter the control cables into the WCU through the entry plate (see
Figure 4-12).
• Remove the rubber grommets from the entry plate
and cut them to adequate diameter for the auxiliary
power cable. To ensure proper sealing, cut along the
diameter marking that corresponds to the cable
diameter (see Figure 4-10). Slide the grommet onto
the cable. The grommet must fit tight to prevent water
from entering the cabinet. If necessary, seal the
junctions with silicone rubber.
Top entry plate
Cable transit
Cable routing
Figure 4-12 WCU Top Cable Entry
2 Pull the cables through the cable transit (see Figure 4-14).
• Shielded cables are prepared as illustrated in Figure
4-11. Remove the cable insulation in the area of the
cable transit to bring the conductive parts of the EMC
ROX module in contact with the cable shield.
3 Connect the end of the cable shield to PE.
4 Connect the cables to the terminals below the cable transit according
to the Converter Hardware Diagram in Appendix D - Electrical
Diagrams.
Bottom Cable Entry Proceed as follows:

1 Remove the cover (if present) of the cable entry. The cover can either
be discarted or used as an entry plate.
Bottom entry plate
Figure 4-13 WCU Types 29, 50 Bottom Cable Entry
2 Enter the cables through the floor and run them up the side wall as
illustrated in Figure 4-14.
3 Fix the cables to the C-rails on the side of the cabinet.
• The cables can be fixed using a screw base with a
cable tie or cable clamps.
4 Pull the cables through the cable transit (see Figure 4-14).
• Shielded cables are prepared as illustrated in Figure
4-11. Remove the cable insulation in the area of the
cable transit to bring the conductive parts of the EMC
ROX module in contact with the cable shield.
5 Connect the end of the cable shield to PE.
Cable transit
Cable routing
C-rail
Bottom cable entry
Walls removed for illustration purposes
Figure 4-14 WCU Bottom Cable Entry - Cable Routing
6 Connect the cables to the terminals below the cable transit according
to the Converter Hardware Diagram in Appendix D - Electrical
Diagrams.
4.7 Connecting Cables for Serial Communication and Encoders
The serial communications and encoder cables are entered into a COU
either from the top or from the bottom.
Information on cable termination can be found on the Converter Hardware
Top and bottom cable entry are covered by plates. Holes for cable glands
have to be drilled on site.
It is recommended to properly determine the required length of a cable
between the point of entry and the connection point inside a cabinet and
to cut the cable to the required length before connection to avoid excess
cable to be stored in the cable ducts.
Top Cable Entry When cables are entered through the roof, EMC cable glands have to be
used. These cable glands are not part of the delivery.
Top entry plate
Figure 4-15 Top Cable Entry
Proceed as follows:
1 Remove the entry plate and drill a hole adequate for the diameter of
the cable gland.
2 Cut off the cable sheath on the length of cable between the cable
gland and the connection point.
Prepare the cable in the area of the cable gland according to Figure
4-16.
Overall cable shield

in contact with cable
gland
Point of entry
Entry plate
Figure 4-16 Cable Entry with EMC Cable Gland
3 Pull the cable through the cable gland, attach the cable gland to the
entry plate and fasten the entry plate to the roof.
4 Lay the cable along cable tray A (see Figure 4-17).
Cable routing
Front of cabinet
Cable trays A for control cables
Figure 4-17 Control Cable Trays
5 At the end of cable tray A run the cable down into the cable duct to its
destination inside the COU (see Figure 4-18 regarding COU type 1 or
Figure 4-19 regarding COU type 2).
Routing control cable

from cable tray A to
cable duct
Figure 4-18 Front View of COU Type 1

from cable tray A to
cable duct
Figure 4-19 Front View of COU Type 2
6 See the Converter Hardware Diagram in Appendix D - Electrical

Diagrams to identify the device terminals where the conductors are
connected.
If twisted pair cable is used, leave the unshielded cable ends twisted
up to the device terminals.
Connect the cable shields as described in section Bottom Cable
Entry.
Bottom Cable Entry If control cables are entered through the bottom, rubber grommets must
be used to seal the entry plate. The rubber grommets are not part of the
delivery.
Proceed as follows:
1 Remove the entry plate and drill a hole adequate for the diameter of
the rubber grommet.
2 Enter the cable through the bottom entry plate. Depending on the
type of COU, run the cable to the duct on the right (see Figure 4-20
regarding COU type 1) or to the duct on the left (see Figure 4-21,
Figure 4-22 and Figure 4-23 regarding COU type 2).
Entry plate
Cable routing
Figure 4-20 Bottom Cable Entry in COU Type 1
Entry plate
Cable routing
Figure 4-21 Bottom Cable Entry COU Type 2
Inside a COU type 2 without cable duct, fasten the cable to the water
pipe with suitable cable ties.
Entry plate
Routing cable
along water pipe
Figure 4-22 Bottom Cable Entry COU Type 2
3 Run the cable up the cable duct and lead the cable through the cable
transit.
Cable transit through the frame is the same for both types of COU.
Figure 4-24 illustrates cable transit through the frame inside a COU
type 2.
• Cut the rubber grommet(s) to the correct size.
• Remove the cable shield in the area of the grounding
bracket.
• Ground the overall cable shield.
• Fix the cable to the side wall.
Front
Cable routing
Side wall removed for

illustration purposes
Figure 4-23 Cable Routing in COU Type 1
Front Control cable fixing
Cable transit
Grounding brackets
for overall cable shield
Cable duct
Figure 4-24 Cable Transit
4 Run the cable along the horizontal cable duct and down through the
vertical duct to its destination inside the COU (see Figure 4-25
regarding COU type 1 and Figure 4-26 regarding COU type 2).

through cable duct
to
encoder or
fieldbus Interface
Rubber grommets
Figure 4-25 Routing Control Cable in COU Type 1

through cable duct
to
encoder or fieldbus
interface
Rubber grommets
Figure 4-26 Routing Control Cable in COU Type 2
5 See Converter Hardware Diagram in Appendix D - Electrical

Diagrams to identify the device terminals where the conductors are
connected.
If twisted pair cable is used, leave the unshielded cable ends twisted
up to the device terminals.
Connect the cable shields as described in section Bottom Cable
Entry, page 4-20.
Grounding Cable
Shields
IMPORTANT!
! The individual shields and the overall shield of encoder cables must not
be connected to the terminals of the encoder adapter but to the separate
shield grounding point next to it (see Figure 4-27).
The unshielded cable ends must be as short as possible. The shield ends
which are fixed to the grounding clamp must be not longer than 50 mm.
The shields of serial communications cables, however, are terminated at
the fieldbus adapter as shown on the Converter Hardware Diagram in
Gray encoder interface

Shield grounding point for
gray encoder interface
Pulse encoder interface
Shield grounding point for

pulse encoder interface
Figure 4-27 Shield Grounding Points
A shield grounding point consists of a slotted mounting bracket which has

been mounted in the factory and an grounding clamp.
Depending on the layout of the COU, the shield grounding points can be
mounted at a different place than shown in Figure 4-27.
Instead of the brackets, slots can have been cut into the back wall of the
COU swing frame for fixing the grounding clamps.
Three grounding clamps of different sizes (see Figure 4-28) are supplied
for each connection to accommodate encoder cables of different diameter.
The clamps are tied to each mounting bracket.
SK 10
SK 9
SK 8
Figure 4-28 Shield Grounding Clamps
4.8 Connecting Position Encoder Cables in Marine Drives
IMPORTANT!
! This section is only applicable for marine converters used for azipod
propulsion.
In applications for azipod propulsion, fibre-optic cables are used for signal
transmission between position encoder(s) and the associated receiver(s)
in the converter. The number of the pulse encoders and the location of the
receiver(s) in the converter depends on the application. The receiver(s)
can either be installed in the Water Cooling Unit (WCU) or a Control Unit
(COU). See Converter Hardware Diagram in Appendix D - Electrical
Diagrams for project specific details.
NOTICE!
If a fiber-optic cable is damaged or improperly installed, data transmission
can be affected and the equipment can mulfunction. To prevent such
problems always follow the handling and installation guidelines.
Handling and • Lay the fiber-optic cables in a steel or plastic conduit to protect the
Installation Guidelines cables against damages. The conduit shall only be used for encoder
cables.
• The conduit starts at the Azipod Information Unit (AIU) and ends
inside the converter.
On the AIU side, the conduit starts at the rubber cable penetrations
through which the fiber-optic cable is entered into the cabinet.
On the converter side, the conduit enters through the entry plate with
about 10 to 20 mm of conduit extending from the entry plate.
• Cover the cable end with a cap to protect the tip of the fiber against
scratches before pulling the cable through the conduit.
• Do not exceed the maximum tensile load and the minimum bend
radius of the cable. See cable specification for information.
• When using cable ties be careful not to deform the fiber-optic cable.
Do not use tie guns.
• Connect/unplug a fiber-optic cable by holding the connector and not
the fiber.
Routing Cables Proceed as follows when routing cables through the Water Cooling Unit
through WCU (WCU):
1 Route the cables through the WCU as desribed in section 4.6.2
Connecting Control Cables in WCU.
2 After the cables have been pulled through the cable transit inside the
WCU run the cables through the WCU as indicated with the dashed
line in Figure 4-29.
3 Connect the cable to the receiving connector of the receiver (see
Figure 4-29).
The supplied connectors must be used if the cable has not been
equipped with connectors.
Redundant cables should be stored appropriately for later use.
Cable transit
Receiving connector
Installation location of receiver can be different
Figure 4-29 Pulse Encoder Receiver
Routing Cables When routing cables through a COU proceed as illustrated in section 4.7
through COU Connecting Cables for Serial Communication and Encoders.
4.9 Connecting the Heating Cable
When the converter has been ordered with a heating cable, the heating
cable has been readily installed along the bottom water pipe (see Figure
4-30).
The following connections have to be made:
• The power supply according to the Converter Hardware Diagram in
• The heating cables of two adjoining transport units have to be
connected with each other.
Figure 4-30 Heating Cable
Figure 4-31 Heating Cable Connector
ABB
Chapter 5 - Information on Commissioning
5.1 Customer Assistance and Acceptance
Commissioning, parameter adjustments and functional tests are to be

carried out by certified commissioning personnel. Information on the
commissioning procedure and conditions for the commissioning to start
can be obtained from ABB. For address see section General Information.
During the commissioning period, the customer is requested to provide
qualified personnel for assistance, who are
• familiar with medium and low voltage equipment and with local safety
regulations,
• familiar with the driven process,
• authorized to operate associated medium and low voltage equipment
(MCB, other MV and LV switchgear etc.),
• authorized to operate the driven process for functional tests.
When commissioning is completed, the commissioning report is signed by
the responsable commissioning engineer 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.
Chapter 5 - Information on Commissioning ABB
ABB
Chapter 6 - Operation
The instruction manual applicable for the converter is filed at the end of the
manual.
Chapter 6 - Operation ABB
ABB
Chapter 7 - CDP Control Panel
7.1 Overview
The CDP control panel is the basic user interface for operating, controlling
and monitoring the converter.
The panel messages and parameter settings used in this chapter are
typical examples to illustrate the related instructions and display functions.
They may differ from the actual messages and parameter settings in your
converter.
1 L -> 1242,0 rpm I

MotCurr 76.00 A Alphanumeric display
MotSpeed 1242.0 rpm (4 lines x 20 characters)
Torque 86.00 %
Mode selection buttons
Selection and changing buttons Enter button
Reset button Setpoint setting button
Local, remote button Start button
Forward, reverse buttons Stop button
Figure 7-1 CDP Control Panel
Chapter 7 - CDP Control Panel ABB
Keypad Modes The CDP control panel provides the following modes:
• Identification mode
• Actual Signal Display mode, selected by the ACT button
• Parameter mode, selected by the PAR button
• Function mode, selected by the FUNC button
• Drive Selection mode, selected by the DRIVE button.
7.2 Identification Mode
After the converter has been energized or after the panel has been
connected to the converter for which the auxiliary voltage has been
switched on already, the identification display appears showing the panel
version and then the ID-number of the converter. When the control panel
is being initialized the display changes as follows:
CDP312 PANEL V5.30
........
After 2-3 seconds:
ACS 6000 xxxx

< Device Name >
ID-NUMBER 1
After another few seconds, the display changes to the Actual Signal
Display mode.
1 L -> 0.0 rpm 0

Status... Earth Iso clos
MotorSpeed 0.00 rpm
Power 0.0 %
ABB Chapter 7 - CDP Control Panel
7.3 Actual Signal Display Mode
Two displays can be selected in the Actual Signal Display mode:

• Actual Signal Display
• Fault History Display.
The Actual Signal Display appears first when the Actual Signal Display
mode has been selected. However, when the converter is in a fault
condition, the Fault Display will be shown instead.
The Actual Signal Display is used to monitor the converter without
interfering the operation of the converter. Three selectable actual values
are shown continuously on the display.
The panel will automatically return to the Actual Signal Display mode
from other modes within one minute when no buttons are pressed
(exceptions: Status Display and Common Reference Display when in
Drive Selection mode and Fault Display mode).
A complete list of selectable actual signals can be found in the Signal and
Parameter Table.
The fault memory includes information on the 64 most recent fault events
that occurred in the converter. The name of the fault and the actual time
are displayed. The procedure for selecting and clearing the fault history is
described in Table 7-3.
When a fault or warning is generated in the converter, the message will be
displayed immediately, except when in Drive Selection mode.
Changing from the Fault Display mode to other display modes is possible
without resetting the fault first. When no buttons are pressed, the fault or
warning text is displayed as long as the fault is pending.
The Actual Signal Display mode is selected by pressing the ACT button.
1 L -> 600.0 rpm 0

ACT Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %
When in Actual Signal Display mode, the fast UP/DOWN buttons allow
to toggle between Actual Signal Display and Fault History Display.
1 L -> 600.0 rpm 0

1 LAST FAULT
Overspeed
001231 12:30:02.3256
Table 7-1 Displaying three Actual Signals
Button to be
Step Function Display
pressed
1. to display the full name of HOLD

the three actual signals 1 L -> 600.0 rpm 1
ACT
DriveStatusWord
MotorSpeed
Power
2. to return to the Actual RELEASE

Signal Display mode 1 L -> 600.0 rpm 1
ACT
DriveStatus Running
MotorSpeed 600.00 rpm
Power 75.0 %
Table 7-2 Selecting Actual Signals
Button to be
pressed
1. to enter the Actual

ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
2. to select a row where the

actual signal is to be 1 L -> 600.0 rpm 0
displayed (a blinking Status ReadyOn
cursor indicates the MotorSpeed 0.00 rpm
selected row) Power 0.0 %
3. to enter the actual signal

selection function 1 L -> 600.0 rpm 0
1 Actual Signals
ENTER
13 Power
0.0 %
4. to select a parameter
group 1 L -> 600.0 rpm 0
2 Actual Signals
01 Excitation Cur
Table 7-2 Selecting Actual Signals (Continued)
Button to be
pressed
5. to select an actual signal

1 L -> 600.0 rpm 0
1 Actual Signals
09 NP Voltage
0.0 V
6.a to accept the selection

and to return to the 1 L -> 600.0 rpm 0
Actual Signal Display Status ReadyOn
ENTER
mode MotorSpeed 0.00 rpm
NP Voltage 0.0 V
6.b to cancel the selection

and keep the original ACT PAR 1 L -> 600.0 rpm 0
selection, press any of Status ReadyOn
the mode buttons MotorSpeed 0.00 rpm
FUNC DRIVE Power 0.0 %
the selected keypad
mode is entered
Table 7-3 Displaying a Fault and Resetting Fault History
Button to be
pressed
1. to enter the Actual

ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
2. to enter the Fault

History Display 1 L -> 600.0 rpm 0
1 Last Fault
+ Panel Lost
Power 0.0 %
3. to select the previous

(UP) or next fault 1 L -> 600.0 rpm 0
(DOWN) 2 Last Fault
Speed Ref Lost
980224 10:45:32.0705
to clear the fault history 1 L -> 600.0 rpm 0

RESET 1 Last Fault
the fault history is empty
H Min S
Table 7-3 Displaying a Fault and Resetting Fault History (Continued)
Button to be
pressed
4. to return to the Actual

Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
Table 7-4 Displaying and Resetting an Active Fault
Button to be
pressed
1. to display an active fault

1 L -> 600.0 rpm 0
ACT
ACS 1000
*** Fault ***
Panel Lost
2. to reset the fault

1 L -> 600.0 rpm 0
RESET
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
7.4 Parameter Mode
NOTICE!
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. Running the drive system with incorrect data can
result in improper operation, reduction of control accuracy and damage of
equipment.
Parameters allow the converter to be configured and set-up specifically for

an application (see also Signal and Parameter Table).
Parameters are organized in functional groups. All control functions are
represented by a parameter group and can be activated and set-up
individually.
Selecting Parameters The Parameter mode is used to check and change parameters. When this
mode is entered for the first time after the auxiliary voltage of the converter
has been switched on, the display will show the first parameter of
parameter group 11. The next time, the Parameter mode is entered, the
previously selected parameter is shown.
Some parameter values cannot be changed while the converter is running.

If tried, the following warning will be displayed:
** Warning **
Write Access Denied
Parameter Setting
Not Possible
Table 7-5 Selecting a Parameter and Changing the Value
Button to be
pressed
1. to enter the Parameter

mode 1 L -> 600.0 rpm 0
PAR
75 OPTION MODULES
01 IOEC3 OptionBoard
YES
2. to select a different
group 1 L -> 600.0 rpm 0
75 OPTION MODULES
YES
3. to select a parameter
1 L -> 600.0 rpm 0
75 OPTION MODULES
NO
4. to enter the parameter

setting function 1 L -> 600.0 rpm 0
75 OPTION MODULES
ENTER
[NO]
5. to change the parameter

value 1 L -> 600.0 rpm 0
(slow change for 75 OPTION MODULES
numbers and text) 02 IOEC4 OptionBoard
(fast change for numbers [YES]
only)

Actual Signal Display 75 OPTION MODULES
ENTER
mode 02 IOEC4 OptionBoard
YES
Table 7-5 Selecting a Parameter and Changing the Value (Continued)
Button to be
pressed
6.b to cancel the setting and

keep the original ACT PAR
1 L -> 600.0 rpm 0
selection, press any of 75 OPTION MODULES
the mode buttons 02 IOEC4 OptionBoard
FUNC DRIVE NO
the selected keypad
mode is entered
7.4.1 Parameter Lock

Unwanted parameter entry can be prevented by activating the Parameter
Lock function which is part of group 16 SYSTEM CTR INPUTS.
The Parameter Lock is activated by setting parameters 16.02 and 16.03
accordingly. The user pass code can be changed by setting parameters
16.04 and 16.05. For more details see Signal and Parameter Table.
To activate the Parameter Lock:
1 Select parameter 16.02 PARAMETER LOCK
2 Set parameter 16.02 to LOCKED
3 Save the setting and exit the Parameter mode
To open the Parameter Lock:
1 Select parameter 16.03 PASS CODE
2 Set the correct pass code. If not known see Signal and Parameter
Table for details.
3 Save the setting and exit the Parameter mode.
7.5 Function Mode
Setting the Display The Function mode is used to set the contrast of the display.
Contrast
Table 7-6 Setting the Contrast of the Panel Display
Button to be
pressed
1. to enter the Function

mode 1 L -> 0.0 rpm 0
FUNC
UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
Table 7-6 Setting the Contrast of the Panel Display (Continued)
Button to be
pressed
2. to select a function (a
blinking cursor indicates 1 L -> 0.0 rpm 0
the selected function) UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
3. to enter the contrast

setting function 1 L -> 0.0 rpm 0
CONTRAST [4]
ENTER
4. to set the contrast

1 L -> 0.0 rpm 0
CONTRAST [6]

Actual Signal Display UPLOAD <= <=
ENTER
mode DOWNLOAD => =>
CONTRAST 6
5.b to cancel the setting

and keep the original ACT PAR
1 L -> 0.0 rpm 0
selection, press any of UPLOAD <= <=
the mode buttons DOWNLOAD => =>
FUNC DRIVE CONTRAST 4
the selected keypad
mode is entered
7.6 Operational Commands
7.6.1 Selecting Local/Remote

LOC
Local control mode is selected by pressing the REM button of the control
panel.
Local Control When the panel is switched to LOCAL, operation via the pushbuttons on
the front door of the COU and the CDP control panel is possible. Control
commands from remote have no effect. LOCAL can only be selected
when the converter has been stopped and no remote run command is
active. Switching from LOCAL to REMOTE while the converter is running
stops the converter.
Remote Control When the panel is switched to REMOTE, the pushbuttons on the front
door of the control unit and the operational buttons of the control panel are
disabled. Operational commands and reference value from a remote
control station are transmitted via fieldbus or remote I/O to the converter.
Switching from REMOTE to LOCAL while the converter is running is not
possible.
Table 7-7 Selecting Local/Remote
Button to be
pressed
1. to select LOCAL control

1 ->L 550.0 rpm 1
LOC
(the local control location Status Running
is indicated by the letter L) REM MotorSpeed 0.00 rpm
Power 0.0 %
2. to select REMOTE control

1 -> 550.0 rpm 1
LOC
(the remote control Status Running
location is indicated by a REM MotorSpeed 0.00 rpm
blank) Power 0.0 %
7.6.2 Setting the Direction of Rotation

The direction of rotation is selected on the control panel using the
button for forward direction and the button to reverse the direction.
Both buttons can be used when the control panel is in LOCAL mode.
An arrow on the display indicates the direction:
• When the motor is running, the arrow indicates the actual sense of
rotation.
• When the motor is not running, the arrow indicates the preselected
sense of rotation.
In the example below, reverse direction is shown.
1 L <- 600.0 rpm 1

Status Running
Power 40.0 %
When the direction of rotation is changed while the motor is running, the
speed will automatically ramp to zero and the motor will accelerate in
opposite direction to the preset speed. The direction of the arrow on the
display changes to the new direction when the motor has reached zero
speed.
7.6.3 Entering a Setpoint

The setpoint can be changed via the control panel at any time, when set
to LOCAL.
Table 7-8 Entering a Setpoint
Button to be
pressed
1. to enter a keypad mode

displaying the status ACT PAR 1 L -> 600.0 rpm 1
row, press a mode Status Running
button FUNC MotorSpeed 600.00 rpm
Power 50.0 %
2. to enter the Setpoint

Setting function 1 L -> [ 600.0 rpm] 1
REF
Status Running
Power 50.0 %
3. to change the setpoint

1 L -> [ 550.0 rpm] 1
(slow change) Status Running
(fast change) Power 50.0 %
4. to exit the Setpoint

Setting mode, press any ACT PAR 1 L -> 550.0 rpm 1
of the mode buttons Status Running
the selected keypad FUNC DRIVE Power 50.0 %
mode is entered
ABB
Chapter 8 - Maintenance and Troubleshooting
Maintenance and parts replacement on the converter must only be carried

out by qualified personnel in compliance with local regulations.
It is strongly recommended to carry out all maintenance work according to
the maintenance schedule at the end of this chapter and the applicable
service instructions, on time and at the stated intervals.
During the warranty period, any repair work must be carried out
exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by qualified personnel.
ABB offers maintenance and service training courses. Customer staff
having successfully attended such courses, will be certified to do
maintenance and repair work on the converter. To maintain safe and
reliable operation of the converter, ABB recommends taking out a service
contract with the ABB service organization. For more information contact
the ABB service organization. For contact address see section General
Information.
All maintenance activity should be recorded in the maintenance log book
including:
• Date and time of the maintenance work
• Description of the maintenance work
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water before and after the maintenance
routine
Supplementary information on maintenance and troubleshooting can be
obtained from the following manuals:
• Service and Maintenance Manual with instructions on checking and
replacing semiconductors, changing phase modules and replacing
components
• Operation and Maintenance Manual for Water Cooling Systems in
Appendix A - Water Cooling Unit (only in case of water-cooled
converters)
• Signal and Parameter Table
• Troubleshooting Manual. The document supplements the Signal and
Parameter Table and provides explanations of alarm and fault
messages, associated parameters and I/Os and hints for rectification.
Chapter 8 - Maintenance and Troubleshooting ABB
8.1 Safety Instructions
DANGER!
Hazardous voltage!
Do not try to gain access to the converter transformer, the medium voltage
units of the converter nor the motor as long as the drive system is
energized and not grounded.
DANGER!
Voltages from external control circuits may be present inside the
converter, even if mains and auxiliary power are shut off. Take appropriate
measures before working on the converter: de-energize and disconnect all
external devices!
DANGER!
The driven machine can cause the motor to rotate! Always disconnect,
short-circuit or block the motor before work is started.
NOTICE!
Before power is applied to the converter, check that:
• Mains and motor connections are ok
• Auxiliary power and control cable connections are ok
• No tools or other foreign objects are left in the cabinet
• All doors of the power units are properly closed
NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage is switched on.
ABB Chapter 8 - Maintenance and Troubleshooting
8.2 Specific Maintenance Tasks
8.2.1 Cleaning
Dust on electrical components and wiring can cause malfunction and
damage the components.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Carefully clean compartment floors with the vacuum cleaner fitted
with a soft nozzle to prevent component damage.
3 When finished, restart the drive system as described in Chapter 6 -
Operation.
8.2.2 Checking Wire and Cable Connections

Vibration can loosen electrical connections and cause occasional
malfunction or equipment failure. Dust and moisture can build up in loose
connections and cause loss of low-level signals.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Check all power and control cable connections and tighten them if
necessary. Check that all plugs and connectors are tight.
IMPORTANT!
! Capacitor bushings will be damaged when excessive force is applied. Do

not exceed the maximum tightening torque when tightening the capacitor
terminals. The tightening torque values are printed on a label which is
attached on the capacitor. If not otherwise specified, the maximum torque
must not exceed 20 Nm.
3 When finished, restart the drive system as described in Chapter 6 -

Operation.
Chapter 8 - Maintenance and Troubleshooting ABB
8.3 Standard Procedure for Troubleshooting
Proceed as follows:
1 Do not switch off the auxiliary voltage or try to reset a fault message
before all essential information at the time of the occurance of the
fault condition has been saved.
2 Call up the Fault History Display on the CDP control panel. See
Chapter 7 - CDP Control Panel for further information.
Do not clear the fault buffer now!
3 Identify the fault and make a logbook entry.
4 Save the content of the data logger, when a PC is available which has
the DriveWindow or DriveDebug tool installed.
The data logger provides useful information (e.g. waveforms of
voltage, current, torque etc.) for efficient troubleshooting.
5 Try to rectify the fault following the Troubleshooting Manual.
6 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
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water
After the fault has been rectified, start the converter as described in
Chapter 6 - Operation.
ABB
Maintenance Schedule
Years from start-up

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Start-up P
Cooling
Air Filters R R R R R R R R R R R R R R R R R R R R
Cooling fan (if installed) I I I R I I I R I I I R I I I R I I I R
De-ionizer and mech. filters I R I R I R I R I R I R I R I R I R I R
Cooling pump seals I I I R I - I I I R I - I I I R I - I I
Cooling pumps I I I I I R I I I I I R I I I I I R I I
Heat exchanger I I I I I I I I I I I I I I I I I I I I
Aux Cooling fan (if installed) I I I R I I I R I I I R I I I R I I I R
Aging
Battery of UPS (if installed) I R I R I R I R I R I R I R I R I R I R
Connections and Surroundings
Cable and DC Bus connection

I I I I I I I I I I I I I I I I I I I I
torques
Dustiness, corrosion and
I I I I I I I I I I I I I I I I I I I I
temperature
Improvements
SW / HW upgrade I I I I I I I I I I I I I I I I I I I I
Based on product notes I I I I I I I I I I I I I I I I I I I I
Measurements
Basic measurements with aux.

supply voltage / control of P P P P P P P P P P P P P P P P P P P P
protection settings
Optical connected boards with
I I I I I I I P I P I R I I I I I I I I
transmitter
Fiber optic cables I I I I I I I I I P I R I I I I I I I I
Clamp capacitors I I I I I I I P I I I P I I I P I I I P
Snubber capacitors I I I I I I I P I I I P I I I P I I I P
DC capacitors (CBU) I I I I I I I P I I I P I I I P I I I P
Spare Parts
Spare Parts I I I I I I I I I I I I I I I I I I I I
Legend:
Replacement of component R
Inspection (visual inspection, correction and replacement if needed) I
Performance of on-site work (commissioning, tests, measurements, etc.) P
ACS 6000 User's Manual 3BHS212795 ZAB E01 Rev. - 1 (2)

ABB
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Document No.: 3BHS212794 ZAB E01 Rev. -

 ABB Switzerland Ltd. All Rights Reserved.

3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

Chapter 1 - Safety 1-1

1.1 Intended Audience and Required Qualifications 1-1

Chapter 2 - Transportation, Storage and Disposal 2-1

2.1 Transportation 2-1

Chapter 3 - Mechanical Installation 3-1

3.1 Overview 3-1

ACS 6000 User’s Manual 3BHS212794 ZAB E01 Rev. - 1 (4)

Chapter 4 - Electrical Installation 4-1

4.1 Overview 4-1

Chapter 5 - Information on Commissioning 5-1

5.1 Customer Assistance and Acceptance 5-1

Chapter 6 - Operation 6-1

Chapter 7 - CDP Control Panel 7-1

7.1 Overview 7-1

2 (4) 3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

Chapter 8 - Maintenance and Troubleshooting 8-1

8.1 Safety Instructions 8-2

Appendix A - Water Cooling Unit

Appendix C - Mechanical Drawings

Appendix D - Electrical Diagrams

Appendix E - Parts List

Appendix F - Test Reports

Appendix G - Signal and Parameter Table

ACS 6000 User’s Manual 3BHS212794 ZAB E01 Rev. - 3 (4)

4 (4) 3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

If information is required beyond the instructions in this manual, ABB can

Phone: +41 844 845 845

The following documents can be optained from ABB for supplementary

Power Cable Specification 3BHS125090

Main Circuit Breaker Specification 3BHS125149

LSU Main Transformer Specification 3BHS125150

ARU Main Transformer Specification 3BHS125092

Voltage Transformer Requirement Specification 3BHS125393

Asynchronous Motor Specification 3BHS125088

Synchronous Motor Specification 3BHS125093

Tool Sets for Installation, Commissioning and 3BHS130246

Emergency Off/Stop Modes and Prevention of 3BHS196243

ACS 6000 Troubleshooting 3BHS204855

ACS 6000 Service and Maintenance Manual 3BHS202077

ACS 6000 User’s Manual 3BHS212794 ZAB E01 Rev. - 1 (2)

Quality Certificates and Applicable Standards

The following certificates and conformity declarations are available with

2 (2) 3BHS212794 ZAB E01 Rev. - ACS 6000 User’s Manual

1.1 Intended Audience and Required Qualifications

Installation Personnel The installation personnel are mainly responsible for:

Maintenance The maintenance personnel are mainly responsible for:

1.2 Owner’s Responsibilities

It is the owners responsibility to ensure that each person involved in the

1.3 Safety Instructions

Safety instructions are used to highlight a potentially dangerous situation

! Indicates a potentially dangerous situation. If not observed, it could lead to

! Emphazises hints and highlights information.

1.4 Safety Labels and Signs