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—
SYSTEM DRIVES
ACS5000 water-cooled (generation 2)
User manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DATE
2023-11-22
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
1/186
© Copyright 2009 ABB All rights reserved.

PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
2/186
—
LEGAL DISCLAIMER
This document contains information about one or more ABB products and may include a description of or
a reference to one or more standards that are relevant to the ABB products. The presence of any such
description of a standard or reference to a standard is not a representation that all of the ABB products
referenced in this document include all the features of the described or referenced standard. In order to
determine the specific features included in a particular ABB product, the product specifications for the
particular ABB product apply.
The buyer acknowledges the proprietary and confidential nature of the information contained in this
document and agrees that all rights to and concerning the information contained in this document remain
vested in ABB, in particular with regard to any intellectual property rights. Nothing contained herein shall
oblige ABB to furnish any particular information to the buyer.
The information in this document is subject to change without notice and should not be construed as a
binding declaration of ABB. ABB assumes no responsibility for any errors or omissions in this document.
Products described or referenced in this document are designed to be connected with networks and
provide information and data through network interfaces. The products must be connected to a secure
network. It is the sole responsibility of the buyer of the products to provide and continuously ensure a
secure connection between the product and the system network and/or any other networks that may be
connected to the product. ABB is in no event liable for the security of the network used by buyer.
The buyer of the product must establish and maintain appropriate measures, including, but not limited
to, the installation of firewalls, application of authentication measures, encryption of data, installation of
antivirus programs, and so on, to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and/or theft of data or
information. Any liability of ABB in this regard is excluded.
ABB may perform functionality testing on the products and may release updates. However, it is the sole
responsibility of the buyer of the product to ensure that any product updates or other major system
updates (to include but not limited to code changes, configuration file changes, third-party software
updates or patches, hardware change out, and so on) are compatible with the security measures
implemented. The buyer of the product must verify that the system and associated products function as
expected in the environment in which they are deployed. ABB has no obligations in this regard.
In no event shall ABB be liable for any damages inclusive but not limited to indirect, special, incidental or
consequential damages of any nature or kind whatsoever arising from the use of this document, nor shall
ABB be liable for any damages inclusive but not limited to indirect, special, incidental or consequential
damages arising from the use of any software or hardware described in this document.
This document and parts thereof must be kept strictly confidential and must not be reproduced or copied
without the prior written permission from ABB, and the contents thereof must not be disclosed or made
available to any third party nor used for any unauthorized purpose.
The software or hardware described in this document may be furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license.
—
TRADEMARKS
ABB is a registered trademark of ASEA BROWN BOVERI LTD.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2009 ABB.
All rights reserved.

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
3/186
—
CONTENTS
1. About this manual................................................................................................................. 13
1.1. Equipment covered by this manual ............................................................................................. 13
1.2. Structure of the user documentation ......................................................................................... 13
1.3. Related documents..........................................................................................................................14
1.3.1. Maintenance ..........................................................................................................................14
1.3.2. Technical data .......................................................................................................................14
1.3.3. Schematics.............................................................................................................................14
1.3.4. Specifications and guidelines...........................................................................................14
1.3.5. Manuals...................................................................................................................................14
1.3.7. Serial communications interfaces ...................................................................................15
1.4. Terms and abbreviations................................................................................................................15
1.3.6. I/O interface ..........................................................................................................................15
1.5. Target groups and required qualification.................................................................................. 17
1.5.1. Handling ................................................................................................................................. 17
1.5.2. Mechanical installation ....................................................................................................... 17
1.5.3. Electrical installation ........................................................................................................... 17
1.5.4. Operation ...............................................................................................................................18
1.5.5. Maintenance ..........................................................................................................................18
1.6. User’s responsibilities .....................................................................................................................18
1.7. Intended use of equipment ...........................................................................................................18
1.8. Quality certificates and applicable standards .......................................................................... 19
1.8.1. Standards...............................................................................................................................19
1.9. Items covered by delivery .............................................................................................................. 20
1.9.1. Identifying the delivery ...................................................................................................... 20
1.10. Tools.................................................................................................................................................... 20
1.11. Document conventions................................................................................................................... 21
2. Important safety information............................................................................................. 22
2.1. Safety messages and safety signs in this document .............................................................22
2.1.1. Safety messages ..................................................................................................................22
2.1.2. Safety signs............................................................................................................................22
2.2. Product safety labels .......................................................................................................................23
2.3. Electrical safety................................................................................................................................ 24
2.3.1. General safety instructions............................................................................................... 24
2.3.2. The 7 steps that save lives..................................................................................................25
2.3.3. Possible residual risks.........................................................................................................27
2.4. Main circuit breaker protection device ...................................................................................... 28
2.4.1. Safety and protection requirements.............................................................................. 29
2.4.3. Maintenance recommendation ....................................................................................... 29
3. Power electronics and cabinet features ............................................................................30
3.1. Main features of the drive ............................................................................................................. 30
3.2. Drive frame sizes and configurations .........................................................................................32
3.3. Phase converter unit (PCU) ........................................................................................................... 34
3.3.1. Primary phase converter unit (1700 mm and 2100 mm) ........................................... 35
3.3.1.1. Primary PCU (1700 mm) – FS 1 and FS 3............................................................ 35
3.3.1.2. Primary PCU (2100) – FS 2 and FS 4.....................................................................37
3.4. Control unit (COU)........................................................................................................................... 40
3.4.1. Main components ................................................................................................................41

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
4/186
3.4.2. AMC circuit board................................................................................................................ 42
3.4.2.1. Control tasks ............................................................................................................ 42
3.4.2.2. Direct torque control.............................................................................................. 43
3.4.2.3. Parameters................................................................................................................ 44
3.4.2.4. Main circuit breaker ................................................................................................ 44
3.4.2.5. Peripheral I/O devices............................................................................................ 44
3.4.2.6. Local control panel.................................................................................................. 45
3.4.2.7. Customer interface................................................................................................. 46
3.4.2.8. S800 I/O system...................................................................................................... 46
3.5. Water cooling unit (WCU) ...............................................................................................................47
3.6. Transformer and motor cable terminals................................................................................... 48
3.6.1. Transformer cable terminals............................................................................................ 48
3.6.2. Motor cable terminals........................................................................................................ 48
3.7. EXU – Excitation unit (optional)................................................................................................... 49
3.7.1. DCS880/DCT880 control panel....................................................................................... 50
3.7.2. Output disconnector.......................................................................................................... 50
3.8. Door interlocking system .............................................................................................................. 50
3.8.1. Grounding switches ............................................................................................................51
3.8.2. Locking bars ..........................................................................................................................52
3.9. Grounding studs...............................................................................................................................52
3.9.1. Grounding set ...................................................................................................................... 53
3.9.2. Output grounding studs in COU..................................................................................... 54
3.9.3. Input grounding studs in a PCU ...................................................................................... 55
4. Transportation, storage, and disposal ..............................................................................56
4.1. Safety.................................................................................................................................................. 56
4.2. Transport conditions...................................................................................................................... 56
4.3. Unpacking and inspection ............................................................................................................ 56
4.4. Identifying drive units .................................................................................................................... 56
4.4.1. Packing list .............................................................................................................................57
4.4.2. Packing label..........................................................................................................................57
4.5. Lifting and transportation............................................................................................................ 58
4.5.1. Lifting attachment types .................................................................................................. 59
4.5.2. Lifting with lifting plates................................................................................................... 60
4.5.3. Lifting with rotating eyebolts ...........................................................................................61
4.5.4. Reinstalling lifting attachments ...................................................................................... 62
4.5.5. Sling configurations for lift frames and spreader frames........................................ 63
4.6. Storage............................................................................................................................................... 64
4.6.1. Storage conditions ............................................................................................................. 64
4.6.2. Storing a drive...................................................................................................................... 64
4.7. Storage and handling of spare parts ......................................................................................... 65
4.7.1. Warranty information ......................................................................................................... 65
4.8. Disposal of packaging materials and components ............................................................... 65
5. Mechanical installation ........................................................................................................66
5.1. Safety.................................................................................................................................................. 66
5.2. Overview of installation work....................................................................................................... 66
5.3. General notes on installation ....................................................................................................... 66
5.4. Dimensions and clearances...........................................................................................................67
5.4.1. Rear and top access to the cabinet .................................................................................67
5.4.2. Cabinet roof...........................................................................................................................67
5.4.3. Fire protection ......................................................................................................................67
5.4.4. Cable duct material .............................................................................................................67

CONTENTS
PRODUCT
ACS5000W gen. 2
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS799208 E01
REV.
J
LANG.
en
PAGE
5/186
5.4.5. Installation material.............................................................................................................67
5.4.6. Tools ........................................................................................................................................67
5.5. Preparing the installation site...................................................................................................... 68
5.6. Aligning transport units ................................................................................................................ 69
5.7. Joining transport units ................................................................................................................... 71
5.8. Applying silicone...............................................................................................................................72
5.9. Installing roof joints.........................................................................................................................72
5.10. Installing roof-mounted cooling units........................................................................................73
5.10.1. Lifting a cooling unit with a crane ...................................................................................73
5.10.2. Installing IP42 roof-mounted cooling units...................................................................74
5.10.3. Installing IP54 roof-mounted cooling units...................................................................76
5.11. Installing roof attachments on marine drives...........................................................................78
5.12. Joining water pipes......................................................................................................................... 80
5.12.1. Removing a pipe joint ........................................................................................................ 80
5.13. Joining busbars ................................................................................................................................81
5.13.1. AC busbars............................................................................................................................ 82
5.13.2. PE ground busbar ............................................................................................................... 82
5.13.3. DC busbars ........................................................................................................................... 83
5.14. Connecting the heating cable ...................................................................................................... 83
5.15. Connecting raw water pipes......................................................................................................... 84
5.16. Fixing the drive to the floor .......................................................................................................... 84
6. Electrical installation ...........................................................................................................85
6.1. Safety.................................................................................................................................................. 85
6.2. Overview ............................................................................................................................................ 85
6.3. Cable requirements ........................................................................................................................ 85
6.3.1. Power cables......................................................................................................................... 85
6.3.2. Auxiliary and control cables.............................................................................................. 85
6.4. Grounding ......................................................................................................................................... 86
6.4.1. Grounding the transformer and an 18-pulse drive..................................................... 86
6.4.2. Grounding the transformer and a 36-pulse drive........................................................87
6.4.3. Grounding the drive and the motor (multi-point bonding)..................................... 88
6.4.4. Grounding the drive and the motor (single-point bonding).................................... 89
6.4.5. Ground cable connection.................................................................................................. 90
6.4.6. EXU cabinet ground connections ....................................................................................91
6.5. Internal wiring ...................................................................................................................................91
6.5.1. Optical fibers........................................................................................................................ 94
6.5.1.1. Optical fibers for internal arc protection.......................................................... 94
6.6. Cable entries..................................................................................................................................... 95
6.6.1. Cable entry with sealing modules, type 1...................................................................... 95
6.6.2. Cable entry with sealing modules, type 2 ......................................................................97
6.6.3. Cable entry with cable glands...........................................................................................97
6.6.4. Cable entry with EMC plates ............................................................................................ 98
6.7. Power cables, ground cables, equipotential bonding conductor....................................... 99
6.7.1. Preparing the cable entry and the cables ..................................................................... 99
6.7.1.1. Determining the cable length .............................................................................. 99
6.7.1.2. Preparing cables for cable entries with cable glands.................................... 99
6.7.1.3. Preparing cables for cable entries with sealing modules ........................... 101
6.7.2. Connecting the cables ......................................................................................................102
6.7.2.1. Checking the cable insulation.............................................................................102
6.7.2.2. Connecting the cables ..........................................................................................102
6.7.2.3. Bolted connections................................................................................................105
剩余185页未读,继续阅读
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