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ABB INDUSTRIAL DRIVES

ACS580MV Hardware manual

(200 kW to 6300 kW, 3.3 kV to 11 kV)
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List of related manuals
Drive hardware manuals and guides Code (English)
ACS580MV hardware manual 2UBB004520
ACS-AP-X assistant control panels user’s manual 3AUA0000085685
ACS580MV Engineering Guideline 2UBB013672
ACS580MV Gravity Center for Packing 2UBB022468
User’s manual Start-up and maintenance PC tool Drive 3AUA0000094606
composer
ACS580MV Preventive Maintenance Schedule 2UBB022658
ACS580MV Synchronized Bypass Unit Hardware Manual 2UBB005655E01
ACS580MV Wiring Diagram of Synchronized Bypass Unit 2UBB005212
ACS580MV Synchronized Bypass unit Engineering Guideline 2UBB005656
ACS580MV Manual Bypass unit Hardware Manual 2UBB005416E01
ACS580MV Manual Bypass unit Engineering Guideline 2UBB005683
ACS580MV Air duct interface Outline Drawing AC Fan Box 2UBB005072
ACS580MV Air duct interface Outline Drawing EC Fan Box 2UBB005074
ACS580MV Base frame & TEU layout design 2UBB020751

Drive firmware manuals and guides

ACS580MV primary control program firmware manual 3BHS811381

Option manuals and guides

Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.

You can find manuals and other product documents in PDF format on the Internet. See
http://www.abb.com/motors&drives. For manuals not available in the Document library, contact
your local ABB representative.
For more information, please refer to ACS580 MV Hardware Manual which can be found by
scanning the QR code below.

APP version (IOS/Android) Web page version

 Hardware manual
ACS580 MV drives
200 kW to 6300 kW
3.3 kV to 11 kV

Table of contents

1. Safety instructions

6. Transportation, storage
and disposal

7. Mechanical installation

8. Electrical Installation

10. Operation

12. Maintenance

 2025 ABB Beijing Drive Systems Company 2UBB004520 Rev L

Ltd, All Rights Reserved. EN
EFFECTIVE: 2025-01-20
 Table of contents 5

Table of contents

1. Table of contents
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
User’s responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Possible residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . 17
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Equipment covered by the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target groups and required qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Relevant chapters of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
User’s responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Intended equipment use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4. Function and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power supply configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Main power supply to multi-winding phase-shifting transformer . . . . . . . . . . . . . 27
Auxiliary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cabinet layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Terminal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transformer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Table of contents

Inverter unit (left-right structure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inverter unit (Top-Down structure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cabinet design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Door locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5. Control system and interfaces

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control unit (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
I/O extension and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Control locations and operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Local operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Local control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Supply OFF/ON pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Alarm and fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emergency off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
I/O interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Customer control and process I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
I/O signal requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Communication interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6. Guidelines for planning the electrical installation

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7. Transportation, storage and disposal

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Unpacking and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Lifting and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General notes on transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Preparing cabinets for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Storage and handling instructions for spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disposal of packaging materials and components . . . . . . . . . . . . . . . . . . . . . . . . . . 60
 Table of contents 7

8. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Overview on installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dimensions, clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Preparing the foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cabinet roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installing fan units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Bolting together the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fixing units to the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Location of tool kit and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Combine cabinet primary cables installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9. Electrical Installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Overview of installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cable requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parallel routing of power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connecting external wiring to the control unit or optional I/O terminal block . . . . 70
Terminal sizes for auxiliary and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Ground cable and cable shield connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Grounding of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cables and PE busbar between integrated transformer and drive . . . . . . . . . . . . . . . 74
Cable entries for external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Power cable entry via holes in cable entry plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Control and auxiliary cable entry with EMC plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installing power and ground cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Preparing the cable entry and the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connecting the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Installing auxiliary, control and serial communication cables . . . . . . . . . . . . . . . . . . . . 84
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Preparing the cable entry and the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Preparing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connecting the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Control and power supply cables for fan units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Sealing holes in entry plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

10. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8 Table of contents

11. Operation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Overview on drive status and sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Status indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Start sequence of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Stop sequence of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Emergency off sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Energizing and starting the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checks before starting the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Starting the drive from remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Starting the drive locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Stopping the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

12. Fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Alarm and fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Diagnosis data and parameter backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

13. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Preparation for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Documentation and reporting of maintenance work . . . . . . . . . . . . . . . . . . . . . . . 108
Required tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Storage and handling of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Software and hardware updates information in MoR . . . . . . . . . . . . . . . . . . . . . . . 108
Shutting down the drive for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
De-energizing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Unlocking and locking the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Connecting a grounding set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Grounding power module enclosure and busbar with grounding hook . . . . . . . . 112
Starting the drive after maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Emergency release of the door safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Safety-switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Visual checks and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replacing the door air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cable connects, bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Spare power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Spare power module reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Software update in spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Auxiliary voltage verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Protective settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
UPS battery refresh charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Testing main power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
 Table of contents 9

Reforming capacitor of power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Replacing roof AC fans* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Required tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Replacing roof EC fans* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Replacing the power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Required manpower and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replacement of a power module frame size R1 - R3 . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replacing the power module fuse R1 - R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Replacement of a power module frame size R4 - R6 . . . . . . . . . . . . . . . . . . . . . . . . . 132
Replacing the power module fuse R4 - R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Replacement of a power module frame size R7 - R9 . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replacing the power module fuse R7 - R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Circuit board replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Control unit (BCU) and memory unit (ZMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Replacing the SD memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
High voltage divider board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
CVMI2 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Control hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Control hub daughter board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Drive seasonal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Shutting down the drive for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Maintain the drive for preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Maintain the drive before restarting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Start the drive following chapter of “Operation” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

14. Technical data

10 Table of contents
 11

Terms and trademarks

Terms
The following table lists the terms and abbreviations you should be familiar with
when using the manual. Some of the terms and abbreviations used in the manual are
unique to ABB and might differ from the normal usage.

Term / Abbreviation Meaning

Control unit used for controlling drives, inverters and converters via fiber
BCU
optic links.

Converter Short form for ACS580MV frequency converter.

Control unit
COU
Short form for control compartment of the drive.

Distributed Drive Control System

DDCS DDCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers.

Drive Short form for ACS580MV frequency converter.

The drive system includes all equipment used to convert electrical into
Drive system
mechanical power to give motion to the machine.

DriveStartup guides step by step through the complete commissioning

DriveStartup
including reporting.

Equipment Frequency converter and related equipment.

Electromagnetic compatibility

EMC All measures to suppress electromagnetic disturbances caused by

different electrical equipment in the same electromagnetic environment,
and to strengthen the immunity of the equipment to such disturbances.

ESD Electrostatic discharge

Ground Earth

The conducting path (e.g. conductor) between the electric equipment (e.g.
To ground frequency converter) and the earth. The electric equipment is connected to
the earth, e.g. by a grounding set or a grounding switch.

Inverter Unit
INU The INU converts the DC voltage to the required AC motor voltage and
frequency.

IGBT Insulated Gate Bipolar Transistor

Line voltage RMS voltage of the main power supply of the drive.

Main Circuit Breaker

MCB The MCB is a major protection device of the drive system and connects /
disconnects the main power supply to the drive. The MCB is controlled
entirely by the drive.

PCB Printed Circuit Board

12

Term / Abbreviation Meaning

Point of Common Coupling. The PCC is the point in the electrical power
supply system where the responsibility of the utility changes to the
industrial customer. The utility is responsible to provide clean voltage and
PCC
current with respect to harmonic distortion up to the PCC. The industrial
customer is responsible not to distort voltage and current by its electrical
systems.

PE Protective Earth

Power Electronic Building Block (semiconductor stack). This is another

PEBB
term for power module.
The power module is a compact assembly of electronic components
Power module including power semiconductors and circuit boards that serves as a
standardized building block for the INU of the drive.

Safeline ABB synonym for uninterruptible power supply.

Terminal Unit
TEU
Short form for terminal compartment of the drive.

Transformer unit
TRU
Short form for transformer compartment of the drive.

Trademarks
Names that are believed to be trademarks of other companies and organizations are
designated as such. The absence or presence of such a designation should however
not be regarded as an offence of the legal status of any trademark. The following
registrations and trademarks are used in this manual:

Term / Abbreviation Meaning

Windows® Registered trademark of Microsoft Corporation

Ethernet® Registered trademark of Xerox Corporation

Profibus® Registered trademark of Profibus International (P.I.)

Modbus® Registered trademark of the Modbus IDA organization

 Safety instructions 13

1
Safety instructions

Contents of this chapter

This chapter contains the safety instructions which you must obey when you install
and operate the drive and do maintenance on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Safety instructions are used to highlight a potential hazard when working on the
equipment. Safety instructions must be strictly followed! Non-compliance can
jeopardize the safety of personnel, the equipment and the environment. The manual
uses these warning symbols:

DANGER indicates a hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

The safety instructions are derived from the following standards:

• ISO 3864-2:2004 (E)
Graphical symbols – Safety colors and safety signs – Part 2: Design principles for
product safety labels
• ANSI Z535.6
American National Standard for Product Safety Information in Product Manuals,
Instructions, and Other Collateral Materials
14 Safety instructions

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

General safety information

To maintain safety and minimize hazards observe the following:
• Before the drive is energized, make sure that:
• all foreign objects are removed from the drive
• all internal and external covers are securely fastened and all doors are closed,
locked and / or bolted
• the manual release of the door safety switches is in the locked position.
• Before starting to work on the drive, make sure that:
• the main and auxiliary power supply to the drive is switched off, locked out,
and tagged out
• the drive is dead
• safety ground connections are in place
• appropriate personal protective equipment is provided and used when
required
• everyone involved is informed.
• When working near the running drive protective earmuffs should be worn.
• Before work is carried out simultaneously on the drive and on other drive system
equipment, make sure that
• the relevant safety codes and standards are observed
• all energy sources of the equipment are turned off
• lock-out and tag-out devices are in place
• barriers and appropriate covers are used on equipment which is still live
• everyone involved is informed.
• In case of fire in the drive room:
• Observe the established rules and regulations for fire protection
• Only firemen with appropriate protective equipment are allowed to enter the
drive room.
• For 13.8kV input voltage, PPE and Safety should be followed “ABB Electrical
Safety Matrix” (SA-S-101-07-01) and defined by each country's HSE department.
 Safety instructions 15

Possible residual risks

The following risks can arise from a drive system and pose a hazard to people. These
risks must therefore be taken into account by the system integrator and / or the
plant owner when assessing the risks of the machinery.
• Electric power equipment generates electro-magnetic fields which can cause a
hazard to people with metal implants and / or a pacemaker.
• Drive system components can move unintentionally when being commissioned,
operated, or serviced due to, for example:
• Operation of the equipment outside the scope of the specifications
• Incorrectly assembled or installed equipment
• Wrongly connected cables
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware.
• Hazardous touch voltages can be present on drive system components caused
by, for example:
• Operation of the equipment outside the scope of the specifications
• External influence on, or damage of the equipment
• Induced voltages by external equipment (e.g. induced voltage from a
spinning rotor)
• Condensation on equipment components, or pollution
• Faulty hardware.
• High temperatures, noise, particles, or gases can be emitted from drive system
components caused by, for example:
• Operation of the equipment outside the scope of the specifications
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware.
• Hazardous substances can be emitted from drive system components due to,
for example:
• Incorrect disposal of components.

Safety labels
Safety labels are attached to the cabinet where necessary to alert personnel of
potential hazards when working on the equipment. The instructions on the safety
16 Safety instructions

labels must always be followed, and the labels must be kept in a perfectly legible
condition.

General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive and do maintenance
work on it:
• If you select an external source for the start command and it is on, the drive will
start immediately after fault reset unless you configure the drive for pulse start.
See the firmware manual.
• When the control location is not set to Local, the stop key on the control panel
will not stop the drive.
 Safety instructions 17

Electrical safety in installation, start-up and

maintenance
 Precautions before electrical work
These warnings are for all personnel who do work on the drive, motor cable or
motor.

DANGER
High voltage!
Before starting to work on the drive, make sure:
• that the main and auxiliary power supply to the drive is switched off, locked out, and
tagged out
• that the drive is dead
• that safety ground connections are in place, ensure that both of the input and
output sides of the drive are grounded by grounding harness
• that personal protective equipment is provided and used when required
• that everyone involved is informed.
Before energizing the drive, make sure:
• that all foreign objects are removed from the drive
• that all internal and external covers are securely fastened and all doors are closed,
locked and / or bolted
• that the release dials of safety switches are in the locked position.

Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur. If you are not a qualified electrician, do not do installation or
maintenance work. Go through these steps before you begin any installation or
maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
• Open the main circuit breaker of the drive.
• Wait until internal circuits are discharged completely and doors are unlocked (15
minutes).
• Open the upstream disconnector to disconnect the supply voltage from the
input busbars.
• Disconnect any external power sources from the control circuits before you
do work on the control cables.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors (e.g. when the
protective plate between COU and TEU is removed).
18 Safety instructions

5. Measure that the installation is de-energized.

• Use only instrumentation (meters, oscilloscopes, etc.) intended for high
voltage measurements.
6. Always discharge equipment and verify that it is neither electrically alive nor
thermally hot.
7. Always install temporary grounding as required by the local regulations.
8. Ask for a permit to work from the person in control of the electrical installation
work.

 Additional instructions and notes

• Do not connect the drive to a voltage higher than what is on the rating plate.
• The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
• If the motor type is a permanent magnet motor, ensure that the motor shaft is
locked and the motor terminals are shorted and grounded by grounding harness
before opening the INU door.
• External wiring can supply dangerous voltages to the terminals of relay outputs.

 Grounding
• Always ground the drive, the motor and adjoining equipment according to the
maintenance instructions in this manual. Assure that the drive is grounded on
both sides, i.e. on supply and motor side. According to IEC 61800-5-1:2016, the
protective earthing must not be disconnected, otherwise the touch current may
exceed 3.5mA. Proper grounding also reduces electromagnetic emission and
interference.
• Make sure that the cross-section of the grounding conductors is sufficient. See
the ACS580MV Engineering Guideline. Obey the local regulations.
 Introduction to the manual 19

2
Introduction to the manual

Contents of this chapter

This manual documents the operation, maintenance and troubleshooting of the
ACS580MV medium voltage drive.
This manual and parts thereof must not be reproduced or copied, or disclosed to
third parties, nor used for any unauthorized purpose without written permission
from ABB Beijing Drive Systems Company Ltd.
The hardware and software described in this manual is provided under a license and
may be used, copied, or disclosed only in accordance with the terms of such license.

Contact information
Address:
ABB Beijing Drive Systems Company Ltd
No.1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District
Beijing, 100015
Phone +86 10 5821 7788
Fax +86 10 5821 7618
E-mail [email protected]
Web http:// www.abb.com/motors&drives

Equipment covered by the manual

This manual covers a standard drive and provides generic information on the drive.
The manual does not claim to cover all variations and details of the drive, nor to
20 Introduction to the manual

consider all eventualities that may arise during installation, commissioning,

operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and handling,
installation, and operation of the drive are affected by these modifications,
information on these modifications is provided in the appropriate documentation
(e.g. outline drawings, wiring diagrams, technical data, engineering notes).
If information is required beyond the instructions in this manual, refer the matter to
ABB.

Target groups and required qualifications

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

 Handling
The personnel must be skilled and experienced in unpacking and transporting heavy
equipment.

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

 Electrical installation
The personnel must have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment, be experienced with
electrical wiring principles, and know the electrical symbols typically used in wiring
diagrams.

 Operation
The personnel include all persons who operate the drive from the local operating
panel of the drive. The personnel must know the functions of the operating panel, be
adequately trained for the drive, and know the driven process. Special knowledge of
frequency converter technology is not required.
 Introduction to the manual 21

 Maintenance
The personnel include all persons who
• are qualified to carry out preventive and corrective maintenance on drive as
described in this manual
• are thoroughly familiar with the drive
• have a sound knowledge of the relevant electrical codes and specifications
covering low and medium voltage equipment
• are able to assess the hazards associated with the energy sources of the drive
system and act correspondingly
• know the safe shutdown and grounding procedures for the drive system.

Contents of the manual

This manual contains the instructions and information for the basic drive
configuration.

 Relevant chapters of the manual

No. Chapter Handling Installation Operation Maintenance
1 Safety instructions X X X X
2 Introduction X X X X
Function and hardware
3 X X
description
Control system and
4 X X
interfaces
Guidelines for planning the
5 X
electrical installation
Transportation, storage
6 X X
and disposal
7 Mechanical installation X
8 Electrical installation X
9 Installation checklist X
10 Operation X X
11 Fault tracing X
12 Maintenance X
13 Technical data X X

 Related manuals
See List of related manuals on the inside of the front cover.

User’s responsibilities
It is the responsibility of those in charge of the drive to ensure that each person
involved in the handling, installation, operation or maintenance of the drive has
received the appropriate training and has thoroughly read and clearly understood
the instructions in this manual and the relevant safety instructions.
22 Introduction to the manual

Intended equipment use

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

Cyber security disclaimer

This product is designed to be connected to and to communicate information and
data via a network interface. It is Customer's sole responsibility to provide and
continuously ensure a secure connection between the product and Customer
network or any other network (as the case may be). Customer shall establish and
maintain any appropriate measures (such as but not limited to the installation of
firewalls, application of authentication measures, encryption of data, installation of
anti-virus programs, etc) to protect the product, the network, its system and the
interface against any kind of security breaches, unauthorized access, interference,
intrusion, leakage and/or theft of data or information. ABB and its affiliates are not
liable for damages and/or losses related to such security breaches, any
unauthorized access, interference, intrusion, leakage and/or theft of data or
information.

Categorization by frame size and option code

Some instructions, technical data and dimension drawings which concern only
certain frame sizes are marked with the symbol of the frame size (e.g. 6R6, 10R6).
The frame size is not marked on the rating plate. To identify the frame size of your
drive, see the Technical Data.
 Function and hardware description 23

3
Function and hardware
description

Contents of this chapter

This chapter provides information on the power equipment and cabinet design and
briefly describes the operation principle of the drive.

Product overview
The air-cooled ACS580MV is a general purpose frequency converter for the control of
standard induction motors. It is used for a wide variety of applications in different
industries with a voltage of 3.3 kV to 11 kV and a motor shaft power range of 200 kW
to 6300 kW.
The drive is characterized by
• integrated multi-winding input transformer
• modular power electronics
• 18 / 24 / 30 / 36 / 48 / 54 pulse diode rectifier input
• no additional filter requirement
• multi-level output voltage
• motor cables up to 1000 m as standard
• Grid voltage range: 3.3 kV to 13.8 kV
• Motor voltage range: 3.3 kV to 11 kV
24 Function and hardware description

Note: The product design and layout are shown as below pictures. Several typical
drive types are used for demonstrating the product HW configuration in this
document.
For information on the power and voltage range of your drive, see the Technical data
and the Rating plate of the drive. For further information on the general drive
characteristics, refer to the ACS580MV catalogue.
• Typical drive line-up (drive type 10R6)

1 2 3 4 5 4

6
A B

A Drive unit
B Transformer unit (TRU)
1 Local control panel (rear side)
2 Control unit (COU)
3 Inverter unit (INU) with power modules
4 Cooling fans
5 Integrated input transformer
6 Terminal unit (TEU) behind protective plate
 Function and hardware description 25

The dimensions and weight of the cabinet depend on the drive power.
• Typical drive line-up (drive type 4.16 R9)

• Typical drive line-up (drive type 4.16 R6)

For 3.3 kV (Power ≤ 710 kW) and 4.16 kV (Power ≤ 870 kW) only.

A Drive unit
B Transformer unit (TRU)
1 Control unit (COU) and Terminal unit (TEU)
2 Inverter unit (INU) with power modules
3 Integrated input transformer
4 Cooling fans
26 Function and hardware description

Rating plate
The rating plate includes an IEC rating, appropriate markings, a type designation
and a serial number, which allow identification of each unit. The rating plate is
located on the back of the control compartment door. An example label is shown
below.

No. Description
Location of rating
1 1
plate
Type designation,
2 see ACS580MV
catalog.
3 Ratings
Compliance
4
information
5 Serial number

Made in China

Type code ACS580MV-07-0153A-110 2

Serial number 5 2UBA958004052
Year of manufacture 2023
Degree of protection IP42
Design standard IEC 61800, IEC 60146 4
Weight kg 7'200

Number of input phases 1x3

Rated input current A 1 x 146.2
Rated input voltage V 11'000
Rated input frequency Hz 50
Max. permissible short-circuit current kA 31.5

Number of output phases 1x3

Rated output current A 1 x 153 3
Rated output voltage V 11'000
Output voltage range V 0…11'000
Rated output frequency Hz 50
Output frequency range Hz 0…75
Duty cycle A 171.4 (60 s every 600 s)
Motor type Asynchronous machine

1-phase auxiliary power consumption VA 300

3-phase auxiliary power consumption VA 10'400

Cooling method AF (air forced)

Rating plate complies with IEC 60146-1-1
 Function and hardware description 27

Label with MV full typecode for ABB internal use is pasted below the rating plate.

 System overview
Higher level control system

Motor speed (rpm), Motor current

Remote MCB close cmd.
Remote MCB open cmd.

Ready, Running, Fault

Speed reference
Emergency OFF

AO (4-20 mA)
AI (4-20 mA)
Start / Stop
Fieldbus

DO
DI
3ph
3 ph 3.3
6 kVkV
ACAC tokV
or 10 13.8kV
AC AC

MCB

TRU INU

HV switchgear ACS580MV Motor

Auxiliary supplies:
100-240 V AC or 120-370 V DC State: MCB open, MCB closed
(option: 10 Min internal UPS) Command: MCB close, MCB open

Cabinet heater 220-240 V AC

System overview and single line diagram

The ACS580MV drive consists of the following parts:
• integrated input transformer with multiple secondary windings (TRU)
• power modules connected in cascaded h-bridge technology (INU)
• control system based on BCU or UCU control unit.

Power supply configuration

The drive requires two independent power supplies:
• Main MV power supply for the power modules via the integrated input
transformer
• Auxiliary power supply for the control and cooling equipment.
If the drive is equipped with the optional cabinet heaters, an additional AC supply is
required.

 Main power supply to multi-winding phase-shifting transformer

The main power is fed to the drive by the multi-winding phase-shifting transformer
which adapts the line voltage to the required voltage for the power modules. The
input isolation transformer is always part of the drive system.
28 Function and hardware description

The secondary side of the input transformer is a multi-winding configuration that

matches the number of individual power modules :
• 3 x 3 modules (3.3 kV)
• 3 x 4 modules (4.16 kV)
• 3 x 5 modules (6/6.3 kV)
• 3 x 6 modules (6.6 kV)
• 3 x 8 modules (10 kV)
• 3 x 9 modules (10.5/11 kV)

 Auxiliary power supply

The drive needs auxiliary power for:
• the cooling fans
The power is always fed by a three-phase power supply.
• the control hardware
The power is fed by a single-phase power supply.
• the optional cabinet heaters
The power is fed by a single-phase power supply.
The power feed for the auxiliary supply must be protected with a suitable circuit
protection rated for the inrush current. For information on the type dependent
auxiliary power consumption figures, see ACS580MV power supply consumption of
the drive in the ACS580MV Engineering Guideline.
Several auxiliary power supply schemes are available. As a standard, the customer
has to provide the following supplies:

Standard configuration
• External 3 phase supply for fan supply (380 - 425 VAC)
• External single phase supply for control supply (100 - 240 VAC or 120 - 370 VDC)
• With optional cabinet heaters: additional external single phase supply (220 -
240 VAC)
Alternatively:
• External 3 phase supply with PE and neutral line (380 - 425 VAC)
Control auxiliary power is taken from one phase and the neutral line.
• With optional cabinet heaters: additional external single phase supply (220 -
240 VAC)

Alternative configurations
For details on optional alternative supply configurations, see ACS580MV Engineering
Guideline.

Cabinet layouts
This section describes the main design features and introduces the major power
electronics and control components of a typical ACS580MV.
 Function and hardware description 29

 Terminal unit

1 Voltage dividers
2 Motor side terminals
3 Input terminals
4 Cable entry plate
5 Cabinet grounding busbar

Terminal compartment with cover plate removed

The terminal unit (TEU) is located behind the control unit (COU). A bolted protection
plate separates the two compartments.The plate is integrated into the protection
loop to prevent access when the drive is energized.
30 Function and hardware description

The compartment provides the terminals for the feeder and motor cables, and the
ground bus for the termination of the ground cable and the cable screens.
For further information on the cable entry, see
• ACS580MV Base frame & TEU layout design
• Chapter Electrical Installation, Cable entries for external connections.

 Transformer unit
The integrated input transformer is placed on the right side of the drive. It is
delivered as a separate unit (TRU) and joint with the converter unit at the final
installation location.

1 Fan units (Fan+Fanbox)

2 Terminal block for monitoring and fan supply
3 Transformer
Transformer secondary terminals leading to the power
4
modules
5 Transformer primary side power terminals

Transformer unit (drive type 10R6)

The transformer is air-cooled by centrifugal blowers, the number of blowers
depends on the drive size.

 Inverter unit (left-right structure)

The inverter unit (INU) is part of the drive unit, i.e. it is located between the control
unit and the transformer. The INU contains the series connected low voltage power
 Function and hardware description 31

modules (see section Power module) and the associated control equipment (control
hub).

1 Fan unit
2 Control hub
3 Power modules phase A
4 Power modules phase B
5 Power modules phase C

Inverter unit (drive type 11R6)

32 Function and hardware description

 Inverter unit (Top-Down structure)

For 3.3 kV (Power ≤ 710 kW) and 4.16 kV (Power ≤ 870 kW), the Inverter unit and
Transformer unit are combined as one unit. The INU is located on the top and TRU is
on the bottom.

2 3 4 5

1 Fan unit (Fan+Fanbox)

2 Control hub
3 Power modules phase A
4 Power modules phase B
5 Power modules phase C

Inverter unit (drive type 4.16 R6)

 Power module
Three types of power modules are used:
• Power module 0 (frame sizes R1, R2, R3)
• Power module 1 (frame sizes R4, R5, R6)
• Power module 2 (frame sizes R7, R8, R9)
The power modules are mounted on guide rails and bolted to the frame for easy
replacement.
 Function and hardware description 33

For information on the dimensions and the weight, see Technical data.

1 2 3 4

5 2

1 Input cables (3 phases)

2 Power cable terminals
3 Input fuses
4 Fiber optic terminal
5 Output busbar (behind cable
terminals)

Power module 0/1(frame size R1 - R6)

ϭ ϯ ϱ ^ϭ ^ϯ

&ϭ
&Ϯ <ϭ
ϭ

^Ϯ ^ϰ
Ϯ ϰ ϲ
Zϭ

F1, F2 Input fuses

D1 - D6 Diode rectifier bridge
C1 DC circuit capacitor
S1 - S4 Inverter IGBTs
R1 Charging resistor
K1 Bypass relay (optional)

Power module circuit diagram

34 Function and hardware description

Each power module integrates in one single housing a

• 6 pulse diode rectifier bridge
• DC circuit
• inverter IGBTs
• gate driver electronics.
• Bypassing relay as an option, when cell bypass function is ordered.
The active 3-phase unit is designed as a self-commutated, multi-level voltage source
inverter. As a result of the multi-level topology, the drive produces an optimum
number of switching levels - e.g. 21 level for 6 kV, 33 level for 10 kV, phase to phase.
The resulting waveforms permit the use of DOL motors.

1 2

1 Output current
2 Output voltage

Output current and voltage waveforms for 10 kV, 50 Hz

Cell bypass circuit
The cell bypass circuit is installed in power module as an option. It enables the power
module output bypassed in case of such module goes wrong with fault class 2, for
example module over temperature. Bypass is achieved by close the relay and short
the output terminal of power module.
When running with motor, one of power module fails, for example input diode open
circuit, and the failure will be reported to control unit. The control unit will first stop
modulation and then send a command to bypass the module. The relay then closes
and send a status feedback signal to control unit. When the status is confirmed, the
modulation will be restarted. The motor could restart in less than 200ms.
A warning of cell bypassed will be indicated on control panel.
 Function and hardware description 35

When drive running with power module bypassed, it is highly recommended

replacing the failure power module in 12h, to prevent further damage to the system,
such as partial loss of output power, motor speed down, transformer overload, etc.
The max number of bypassing power module allowed is defined as 2 per phase or 4
per drive.
Notice that, in a certain time window there is only 1 module bypassing allowed.
Otherwise, the drive will trip. Means that modules could be bypassed one by one till
max allow number.

Charging circuit
The DC link capacitor is charged via the charging resistor R1 when the MCB is closed
and the drive is connected to the main power supply. Thus, excessive inrush currents
are prevented.
The charging sequence is started by pressing the SUPPLY ON pushbutton on the
control compartment door. After the charging sequence has finished, the charging
resistor is bypassed and the DC link will reach its nominal level. The drive then is in
status Ready run (hot standby).
When the DC link has been charged, it is possible to keep the drive in this state to
facilitate a more rapid start-up procedure.

Discharging the power modules

Discharging is initiated by pressing the SUPPLY OFF pushbutton on the control
compartment door. The energy stored in the DC link is dissipated in the resistors of
the power part of the drive. For safety reasons, the cabinet doors are locked for 15
minutes during the DC link capacitors discharge. After the DC link capacitors have
discharged completely the cabinet doors of the power compartments unlock and
the SUPPLY OFF pushbutton changes to constantly on. The power modules can then
be discharged further of induced energy with the supplied grounding hook (for details
see Shutting down the drive for maintenance).
36 Function and hardware description

 Control unit

1 6
3 8
7

5
12
4
11

9 10

1 Control supply, mini circuit breakers 7 24 VDC power supply for control
2 MCB control relays 8 -24 VDC converter for control
Customer terminal blocks and cable 9 EMC cushions for cable bottom entry
3
duct
10 PE busbar
4 Control unit (BCU)
11 I/O controller
5 Local control equipment (backside)
12 Terminal blocks & fuses
6 Fan supply, breakers

Control compartment with open swing frame

 Function and hardware description 37

1 CVMI2 board

Control compartment with swing frame closed

1 Local control panel and pushbuttons

2 Sealing grommets for cable top entry

Control compartment with front door closed

38 Function and hardware description

Cabinet design
The cabinet has been designed using the MNS cabinet system of ABB. The design
consists of a skeletal frame to which the outer panels are bolted to. Corrosion
resistant materials are used to protect the cabinet from corrosion.

The basic elements of the frame are C-shaped steel profiles with screw holes at a
regular distance of 25 mm. The profiles are anti-corrosion-coated. The outer panels
are bolted to the C-shaped profiles with self-tapping screws. The panels are also
protected by hot-dip zinc-coating.
The outside of the doors and the side panels are painted to enhance the appearance
of the cabinet. The standard color is RAL 7035 and RAL7032.
The cabinet’s inside panels are not painted, because paint tends to reduce the
effectiveness of metallic bonding which is important for successful EMC.

 Protection class
Standard protection class is IP21. IP42 is available as option.
 Function and hardware description 39

Door locking system

All doors and removable cover plates of the drive and the transformer units are
either lockable or bolted. Additionally, the door of the INU is secured with a safety
switch. The safety switch is tied into an interlocking circuit that prevents the door
from being opened as long as the DC link of the drive is charged.
The door of the control compartment (1) is not integrated into the interlocking
circuit and can always be opened. However, the removable cover plates leading to
the terminal compartment are equipped with safety contacts that are tied into the
interlocking circuit. An Emergency off is initiated if one of these contacts is opened.

1 3 4

1 Door of control compartment: lockable

Cover plates to TEU with safety contact: bolted.
2 2 The main power cannot be switched on when the
plate is removed.
Doors of INU compartment: electromechanically
3
locked
4 Doors of transformer unit: bolted

Door locks
40 Function and hardware description

Cooling system
The drive unit and the transformer unit are each equipped with one or several fan
units, depending on the drive type. Optionally, the drive and the integrated
transformer can each be equipped with a redundant fan configuration. This
configuration ensures that the operation of the drive system is not interrupted if a
fan fails.

Fan units on top of transformer unit

 Function
Fan groups
For control reasons, the fan unit(s) of the drive and the integrated transformer
combined together are defined as Fan groups.
• Fan group 1: 1 Fan unit of drive and 1 Fan unit of integrated transformer.
• Fan group 2, Fan group 3, Fan group 4: Fan group number is defined as maximum
number of Fan units of drive or integrated transformer.
The fan units of a Fan group are always switched on and off together.
Note: For 3.3 kV (Power ≤ 710 kW) and 4.16 kV (Power ≤ 870 kW), Fan group 1 is
defined only 1 Fan unit for the drive and integrated transformer.

Starting, stopping
The standard fan unit or fan group 1 is switched on by the control system of the drive
when the charging of the DC link is initiated. When the MCB has opened, the fan
units continue to run for a preset time.
Air flow inside the drive
Drive unit: the fan unit feeds the cooling air to the main power electronic
components and transfers the heat to the outside of the cabinet.
Transformer unit: the fan unit feeds the cooling air to the transformer and transfers
the heat to the outside of the cabinet.
 Function and hardware description 41

The air enters the drive cabinet through the louvered panels at the front, passes the
power modules in the INU compartment, or the transformer in the TRU. The air then
exits through the outlet of the fan unit on the cabinet top.

Air flow through the drive (10R6)

Air flow through the drive (4.16 R6)

When a fan of the drive or a fan of the integrated transformer fails, the control
system of the drive switches on the stand-by fan automatically in case of redundant
fans. The failure of a fan is indicated on the control panel of the drive.

Temperature monitoring
The power modules, the ambient temperature and the transformer are monitored for
overtemperature.
42 Function and hardware description
 Control system and interfaces 43

4
Control system and interfaces

Contents of this chapter

This chapter contains an overview of the control system, the default I/O connection
diagram, descriptions of the terminals and contains references to related manuals
and documentation.

Main components
The control compartment incorporates the hardware for the control, monitoring and
protection functions of the drive, and the communication interfaces to the local
control panel and to the remote control devices. Depending on the control concept
of the drive system, the remote control devices include a higher-level control system
and / or remote operator stations.
44 Control system and interfaces

 Control block diagram

Higher level control system

Customer IO
PC
Drive Tool
ACS-AP-W panel
PC Drive Motor
USB-RS485-WE-1800-BT
Composer protection
relay
AC500-eCo
(IO controller) DDCS NETA-21

PC Drive
Startup
FB FSCA-01 FDCO-02
BIOC-01
BCU ZMU-02

CVMI2

Control hub

PEBB control board HVRB

PEBB control board

PEBB control board IM

PEBB control board

Control system block diagram

The BCU is the major component of the drive control system and performs general
drive, motor control functions.
The main internal control devices and the peripheral input and output interfaces to
the customer communicate with the BCU via optical fibers and hardwired I/Os.
The control hub provides the interfaces between the inverter unit and the control
compartment. This includes the inverter control as well as the monitoring signals
from the inverter cabinet.
DDCS communication channels are used for high speed data transfer via the control
hub to the PEBB control boards inside the power modules.
Internal and external, analog and binary I/O signals are connected to the BCU via an
AC500 I/O controller. The I/O controller and the BCU communicate via a fieldbus
link.
Analog measurement signals (i.e. supply and motor voltages and currents) are
transmitted to the BCU via the CVMI2 board.
For the physical locations of the control components see chapter Function and
hardware description.
 Control system and interfaces 45

Control unit (BCU)

The BCU is a control unit used for controlling drives, inverters and converters via
fiber optic links. The BCU contains integrated branching unit functionality for
collecting and storing real-time data from the converter modules to help fault
tracing and analysis. The data is stored in a SD card (data logger memory).

1
1 Battery slot 2
2 Memory unit
3
3 7-segment display 4
Ethernet ports for control panel
4
& service PC
5
Indication LEDs
• Real time clock battery ok 6
(BATT OK)
5 7
• Internal voltage ok (PWR OK)
• Program fault (FAULT)
8
• Writing to SD card (WRITE)
6 SD card slot
7 Fiber optic connections
3 slots for optional extension
8
and communication modules
9 Hardwired I/Os 9
10 Labels for hardwired I/Os

10

BCU control unit

The BCU has an integrated Ethernet port for PC tool communication and a
removable memory unit. When, for example, a converter is replaced, the parameter
settings can be retained by transferring the memory unit from the defective
converter to the new one.

 I/O extension and fieldbus modules

The BCU has three option slots for I/O extensions and fieldbus adapters. Two are
available for customer use, allowing the use of following fieldbus protocols:
Profibus, Modbus RTU, Modbus TCP, EtherNet/IP, Profinet, and/or analog and
digital I/O extension adapters.
The actual configuration of the I/O extensions and fieldbus adapters can be derived
from the option codes in the ordering code of the drive (for identification refer to
the ACS580MV catalog). Typical configuration includes one I/O extension adapter
plus one fieldbus module, OR, two I/O extension adapters.
For the related manuals refer to the project documentation, containing the relevant
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
46 Control system and interfaces

 Control tasks
The BCU has specific control and closed-loop tasks assigned to it. It processes drive
and status information, performs the speed and torque control tasks, and monitors
the operation of the drive.
All relevant drive variables (e.g. speed, torque, current, voltage) are continuously
monitored by the control system. Pre-programmed protection functions ensure that
these variables remain within certain limits in order to maintain safe operation of
the drive. These internal functions are not programmable by the user.
Optionally, the drive can monitor signals from external equipment. These can be
activated and adjusted with parameters.
Other general control, protection and monitoring tasks regarding the whole drive
include control and monitoring of:
• Main circuit breaker
The main circuit breaker (MCB) is an important switching and protection device
of the drive system. Therefore it must only be controlled by the drive.

• Door locking system

• Cooling fans

Control locations and operating modes

The ACS580MV has two main control locations: external and local. The control
location is selected with the Loc/Rem key on the control panel or in the PC tool.
Refer to ACS580MV primary control program firmware manual.

Local operating elements

The local operating elements are located on the front door of the control
compartment.

 Local control panel

The control panel serves as the basic user interface for operating and monitoring the
drive when the local operating mode has been selected.
The control panel can be attached to or detached from the drive without having to
switch off the auxiliary power supply first.
Using the control panel, it is possible
• to enter start-up data
• to control the drive with a reference value, and start, stop and direction
commands
• to display actual values (3 values can be read simultaneously)
• to display and adjust parameters
• to display information on the most recent fault events
• to display history graphs
• to upload and download complete parameter sets.
 Control system and interfaces 47

The control panel has a status LED that indicates if there are any faults or warnings
present. The table below shows the meaning of the LED indications.
LED status Meaning

Green, continuous Normal operation

Data is transferred between the PC tool and drive through the USB
Green, flickering
connection of the control panel.

Green, flashing Alarm pending

Red Drive in fault state.

For details on use and maintenance of the control panel refer to ACS-AP-X assistant
control panels user’s manual.

1 Control panel
Supply OFF/ON pushbuttons and
2
indication lamps
Alarm (flashing) / Fault (on) indication
3
light
Emergency Reset button (optional for
4
1 SIL3)
5 Emergency off button

Local operating elements

48 Control system and interfaces

 Supply OFF/ON pushbuttons

The SUPPLY OFF pushbutton is used to disconnect the drive from the main power
supply. It is illuminated when the MCB is open and the drive is discharged.
The SUPPLY ON pushbutton is used to connect the drive to the main power supply. It
is illuminated when the MCB is closed.

 Alarm and fault indications

When a failure occurs in the drive or in the equipment monitored by the drive, the
control panel displays a corresponding alarm or fault message and the red
Fault / Alarm button on the control compartment door lights up:
Button / Light Color Status Meaning

Off Normal operation

Fault/Alarm Red Flashing Alarm pending

On Drive in fault state.

 Emergency off
The Emergency off button initiates an immediate stop of the drive.
In the event of an Emergency off, the following happens immediately:
• the pulses of the inverter are blocked
• the MCB is tripped.
• the DC link is discharged.
All auxiliary circuits remain live.

Monitoring
Basic system monitoring is done with the local control panel. For more detailed
diagnosis and signal monitoring the Drive Composer – PC tool is available.

I/O interfaces
 Customer control and process I/Os
This chapter provides an overview of the hardwired I/Os. For details refer to
ACS580MV Engineering Guideline and ACS580MV Catalog.
Please note that this I/O interface only available in standard option, if Synchronized
Bypass or manual bypass selected, please see I/O interface in separated
Synchronized Bypass hardware manual or Manual bypass hardware manual.
 Control system and interfaces 49

Central Controler
Default control connections for the factory macro
XPOW External power input
1 +24VI
24 VDC, 2 A (internally used)
2 GND
XAI Reference voltage and analog inputs
1 +VREF 10 VDC, RL 1…10 kohm
2 -VREF -10 VDC, RL 1…10 kohm
3 AGND Ground
4 AI1+ Speed reference
5 AI1- 0(2)…10 V, R in>200 kohm
6 AI2+ By default not in use.
7 AI2- 0(4)…20 mA, Rin>100 ohm
XAO Analog outputs
1 AO1 Motor speed rpm
2 AGND 0…20 mA, RL<500 ohm
3 AO2 Motor current
4 AGND 0…20 mA, RL<500 ohm
XRO1, XRO2, XRO3 Relay outputs
11 NC Ready
12 COM 250 VAC/30 VDC
13 NO 2A
21 NC Running
22 COM 250 VAC/30 VDC
23 NO 2A
Fault 31 NC Fault (-1)
32 COM 250 VAC/30 VDC
33 NO 2A
XD24 Digital interlock
5 +24 VD +24 V DC 200 mA
6 DICOM Digital input ground
7 +24 VD +24 V DC 200 mA
8 DIOGND Digital input/output ground
XDIO Digital input/outputs
1 DIO1 MCB trip command (internally used)
2 DIO2 MCB status closed (internally used)
XDI Digital inputs
1 DI1 Stop (0) / Start (1)
2 DI2 Forward (0) / Reverse (1)
3 DI3 Reset
4 DI4 Acc/Dec time set 1 (0) / set 2 (1)
5 DI5 Constant speed 1 (1 = On)
6 DI6 By default, not in use
X13 Control panel connection (internally used)
X205 Memory unit connection (internally used)
XETH PC ethernet connection for Drive Composer

Default control connections for the factory macro

50 Control system and interfaces

Customer Interface Terminal Block

X1 Customer Interface Terminal Block
1 floating contacts to customer
MB close cmd
3 making capability: 40 A
5 thermal current: Ith = 6 A @40°C
MB trip/unlock cmd
7 breaking capability:
9 AC-15 50 Hz Ie(240 V)=4 A, Ie(500 V)=2 A
MB open cmd 1
11 DC-13 Ie(24 V)=2.5 A, Ie(110 V)=0.7 A, Ie(240 V)=0.4 A
13 MB open cmd 2 minimum load: 17 V, 5 mA
15 (if MO2) isolation rated voltage 690 VAC
17 Connect contact from customer
MB open status
19 internal supply 24 VDC, 20 mA, max resistance 140 Ÿ
21 Connect contact from customer
MB closed status
23 internal supply 24 VDC, 5mA
25
MB ready status
27
29 Connect contacts from customer
Emergency off 1
31 Max resistance 60 Ÿ.
33 Internal supply, 24 VDC, 25 mA
Emergency off 2
35
37
Remote MB close cmd
39
41
Remote MB open cmd Connect contacts from customer
43 internal supply 24 VDC, 5 mA
45 Process stop/ Switchable
Remote disable local
47 mode
49 RO, NC/NO can be selective, 250 VAC/30 VDC, 2 A
Alarm
51
53
54
55
56 24Vdc 24 VDC for digit input
57
58
59

Customer interface terminal block

 I/O signal requirements

See the Technical data.

 Communication interfaces
See the ACS580MV primary control program firmware manual and the Technical data.
 Guidelines for planning the electrical installation 51

5
Guidelines for planning the
electrical installation

References
For instructions for planning the electrical installation of the drive and for the
technical requirements for the protection and control of the medium voltage supply
see the ACS580MV Engineering Guideline.
For selecting a specific drive type and options refer to ACS580MV Engineering
Guideline.

Limitation of liability
The installation must always be designed and made according to applicable local
laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
52 Guidelines for planning the electrical installation
 Transportation, storage and disposal 53

6
Transportation, storage and
disposal

Contents of this chapter

This chapter provides information and instructions for transportation, storage and
disposal of the drive.

Safety
The drive must only be handled by personnel who are skilled and experienced in
unpacking and transporting heavy equipment.
All work must be carried out by qualified personnel according to the site and
equipment requirements and in compliance with the local regulations.

Transport conditions
The transport conditions for the drive are based on IEC 60721-3-2 'Classification of
environmental conditions: Classification of groups of environmental parameters and
their severities; Transportation'.
Parameter Limits

2K12 (Climatic conditions), 2C2 (Chemical gases), 2B1 (Biological conditions), 2S5 (Solid particles),
2M4 (Vibration and shock)
Low air temperature - 45 °C
High air temperature 70 °C
Relative humidity 5 to 95 %, no condensation
54 Transportation, storage and disposal

Unpacking and inspection

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

Lifting and transportation

It is recommended to have the following information at hand before transporting
the cabinet:
• Chapter Technical data provides details on dimensions, weight, and of center of
gravity of the cabinet.
• Chapter Maintenance provides instructions if the door of the INU compartment
cannot be opened.

 General notes on transportation

• Drive components can be damaged during transportation. Therefore, transport
the cabinet in an upright position.
• Transport separated units only!
• Keep the doors closed to prevent dirt from entering. Metallic dust in particular
can cause damage and failure when the drive is energized.

 Dimensions and weights

• Choose the load capacity according to the following table?for center of gravity
see the ACS580MV Gravity Center for Packing.

Drive unit Transformer unit

Type
Height Depth Width Weight Height Depth Width Weight
(mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg)

3.3R4 2821 1198 2530 3010

3.3R5 2821 1198 2530 3280

3.3R6 2821 1198 2530 3550 Transformaer unit intigrated

4.16R4 2821 1198 2530 3360 with Drive unit

4.16R5 2821 1198 2530 3620

4.16R6 2821 1198 2530 4100

3.3R7 2571 1398 2215 1480 2571 1398 2415 3300

3.3R8 2571 1398 2215 1525 2571 1398 2415 3900

3.3R9 2571 1398 2215 1615 2571 1398 2615 4660

 Transportation, storage and disposal 55

Drive unit Transformer unit

Type
Height Depth Width Weight Height Depth Width Weight
(mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg)

4.16R7 2571 1398 2215 1630 2571 1398 2415 3730

4.16R8 2571 1398 2215 1690 2571 1398 2415 4330

4.16R9 2571 1398 2215 1810 2571 1398 2615 5260

6/6.3R1 2571 1198 1815 1100 2571 1198 2215 1800

6/6.3R2 2571 1198 1815 1150 2571 1198 2215 1950

6/6.3R3 2571 1198 1815 1200 2571 1198 2215 2300

6/6.3R4 2571 1198 1815 1300 2571 1198 2215 2700

6/6.3R5 2571 1198 1815 1300 2571 1198 2215 3300

6/6.3R6 2571 1198 1815 1350 2571 1198 2415 3650

6/6.3R7 2571 1398 3015 2300 2571 1398 2615 4800

6/6.3R8 2571 1398 3015 2450 2571 1398 2615 6350

6/6.3R9 2571 1398 3015 2600 2571 1398 3215 7700

6.6R1 2571 1198 1815 1150 2571 1198 2215 1850

6.6R2 2571 1198 1815 1200 2571 1198 2215 2100

6.6R3 2571 1198 1815 1250 2571 1198 2215 2450

6.6R4 2571 1198 1815 1350 2571 1198 2215 2950

6.6R5 2571 1198 1815 1400 2571 1198 2215 3400

6.6R6 2571 1198 1815 1450 2571 1198 2415 4150

6.6R7 2571 1398 3415 2800 2571 1398 2615 5000

6.6R8 2571 1398 3415 2900 2571 1398 2815 6600

6.6R9 2571 1398 3415 3200 2571 1398 3215 8150

10R1 2571 1198 1815 1200 2571 1198 2215 2100

10R2 2571 1198 1815 1250 2571 1198 2215 2450

10R3 A/B/C 2571 1198 1815 1300 2571 1198 2215 2800

10R3D 2571 1198 1815 1350 2571 1198 2215 3050

10R4 2571 1198 2215 1550 2571 1198 2215 3550

10R5 2571 1198 2215 1600 2571 1198 2415 4300

10R6 2571 1198 2215 1650 2571 1198 2415 4950

10R7 2571 1398 3815 3400 2571 1398 2815 6700

10R8 2571 1398 3815 3500 2571 1398 3215 8800

10R9 2571 1398 3815 3800 2871 1398 3215 10800

10.5/11 R1 2571 1198 1815 1250 2571 1198 2215 2250

10.5/11 R2 2571 1198 1815 1300 2571 1198 2215 2700

10.5/11 R3 2571 1198 1815 1350 2571 1198 2215 3050

56 Transportation, storage and disposal

Drive unit Transformer unit

Type
Height Depth Width Weight Height Depth Width Weight
(mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg)

10.5/11 R4 2571 1198 2215 1600 2571 1198 2415 4000

10.5/11 R5 2571 1198 2215 1650 2571 1198 2415 4350

10.5/11 R6 2571 1198 2215 1700 2571 1198 2415 5500

10.5/11 R7 2571 1398 4615 4000 2571 1398 2815 7200

10.5/11 R8 2571 1398 4615 4200 2571 1398 3215 9200

10.5/11 R9 2571 1398 4615 4500 2871 1398 3215 11600

 Using a crane
• Use lifting equipment (e.g, web slings, chain slings, round slings, safety hooks,
shackles) that corresponds to the weight of the cabinet.
• Use a metal beam through the holes in the base frame.
• Use appropriate safety hooks or shackles to attach a sling.
• Do not pass a sling through the fastening hole.
• Verify that the slope angle (1 in figure below) corresponds to the weight of the
cabinet.
 Transportation, storage and disposal 57

• Observe the center of gravity (see the ACS580MV Gravity Center for Packing).
• Lift the cabinet slowly and steadily to the required clearance height maintaining
the cabinet in upright position.
• Check the horizontal position of the cabinet. Reposition the slings, if necessary.
58 Transportation, storage and disposal

 Using a forklift
• Only transport the cabinet with the long side facing the driving direction.

• Use forks with sufficient length to ensure stable transportation and to prevent
tipping.
The forks must be at least as long as the cabinet.
• Insert the fork fully into the cabinet’s forklift pockets.

Storage
 Storage conditions
The minimum requirements for storage are based on IEC 60721-3-1 'Classification of
environmental conditions: Classification of groups of environmental parameters and
their severities; Storage'.
Parameter Limits

1K22 (Climatic conditions), 1C2 (Chemical gases), 1B1 (Biological conditions), 1S11 (Solid particles),
1M11 (Vibration and shock).
Low air temperature - 25 °C
High air temperature 55 °C
Relative humidity 5 to 95 %, no condensation

Cabinets can be stored for up to one year in the original packaging as long as they
are not damaged or opened. For information on longer storage periods, contact the
ABB service organization.

 Preparing cabinets for storage

If the drive is taken out of service for a longer time proceed as follows:
 Transportation, storage and disposal 59

1. Cover all cable inlets and ventilation slots with an impermeable plastic or
aluminum foil and a wooden panel.
2. Add a desiccant of the appropriate quality:
• 1 unit desiccant (30 g) absorbs 6 g water vapor.
The following quantity is needed when using a polyethylene foil:
• 10 units/m2 foil
3. Close and lock the doors of the cabinet.
4. Use polyethylene or equivalent for packaging:
• 0,3 g/m2/24 h water vapor diffusion
5. Attach humidity indicators to the packaging.
Check the storage conditions and the packaging regularly. Immediately repair any
damages that occur during the storage period.

 Storage and handling instructions for spare parts

Electronic devices (e.g, circuit boards, power modules) are sensitive to electrostatic
discharge (ESD). ESD can damage these devices.
Apply ESD handling precautions before handling these devices.
Check the spare parts immediately after receipt for damages. Report any damage to
the shipping company and the ABB service organization.
Observe the following to maintain spare parts in good condition and to keep the
warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in anti-static 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 95%, no condensation
If in doubt whether the maximum allowed humidity is exceeded, protect the
spare parts by an external heater.
• Ground yourself with a wrist strap before touching a component.
• Put the component on a grounded working surface protected against
electrostatic discharges.
• Hold the component only at the edge.
• Reforming capacitors of the power modules:
Power modules that are used as spare parts must be installed and operated in a
drive every 2 years in order to reform the capacitors and thus reduce the risk of a
60 Transportation, storage and disposal

potential hazard. For detailed information, go to section Reforming capacitor of

power modules.

 Disposal of packaging materials and components

Dispose of the packaging materials and the drive components at the end of the life
time of the drive according to the international and local regulations.
The main parts of the drive can be recycled to preserve natural resources and energy.
Product components and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious
metals can be recycled. Plastics, rubber, cardboard and other packaging material can
be used in energy recovery. Printed circuit boards and capacitors need selective
treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are
marked with an appropriate identification code.
Contact your local ABB distributor for further information on environmental aspects
and recycling instructions for professional recyclers.
 Mechanical installation 61

7
Mechanical installation

Contents of this chapter

This chapter describes the mechanical installation procedure of the drive.

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

Examining the installation site

Examine the installation site (see the ACS580MV Engineering Guideline ):
• The installation site is sufficiently ventilated or cooled to transfer away the drive
losses. 1)
• The ambient conditions of the drive meet the specifications. 1)
• The wall behind the unit is of non-flammable material.
• There is enough free space above the drive to enable cooling air flow, service and
maintenance. See the ACS580MV Base frame & TEU layout design.
• The floor that the unit is installed on is of non-flammable material, as smooth as
possible, and strong enough to support the weight of the unit. Check the floor
flatness with a spirit level. The maximum allowed deviation from the surface level
is 5 mm in every 5 meters. Level the installation site, if necessary, as the cabinet
is not equipped with adjustable feet.
1) The heat losses and ambient conditions are specified in the ACS580MV Engineering
Guideline.
62 Mechanical installation

Necessary tools
The tools required for moving the unit to its final position, fastening it to the floor
and wall and tightening the connections are listed below:
• crane, fork-lift (check load capacity!), iron bar, jack and rollers
• Pozidrive and Torx (2.5…6 mm) screwdrivers
• torque wrench
• set of wrenches or sockets

Overview on installation work

The installation includes the following work:
• Preparing the foundation
• Moving the converter and transformer units to their final location
• Aligning and bolting together the units
• Fixing base frames to the floor

General notes on installation

Foreign matter and particularly metallic dust can cause failure and damage when the
drive is energized.
Ensure that foreign matter cannot enter the cabinet:
• Close the doors and cover openings completely when work is discontinued.
• Retrieve any foreign matter which accidentally dropped into the cabinet.

 Dimensions, clearances
See Outline drawing for information on:
• Cabinet dimensions
• Clearances to be observed
• Mounting hole sizes

 Preparing the foundation

The floor must be of non-flammable material, with a smooth and non-abrasive
surface, protected against humidity diffusion, leveled and able to support the weight
of the cabinet.
The maximum recommended allowable overall unevenness is £ 5 mm per 5 m.

 Cable ducts
Cable ducts should be of non-flammable material with a non-abrasive surface.
All cable entries and exits should be protected to prevent dust, humidity and animals
entering the drive.
 Mechanical installation 63

 Fire protection
Suitable fire protection measures should be applied to prevent fire spreading into the
drive.

 Cabinet roof
The cabinet roof is not designed as a mounting base for foreign devices, cable ducts
and
so on. Therefore, it is not permitted to install any foreign device on the roof.

 Installing fan units

AC fans are already mounted when delivered from works.

EC fans need to be installed with fan box in the field.
• For information on the number of fan units to be installed, see ACS580MV
Outline Drawing.
Recognize fan
The fan can be match to its mounting position by recognize below labels:

1 Fan type and position label 3 Sn labels include CON/TRU Sn number (For EC Fan)

2 Fan position label 4 Sn labels include CON/TRU Sn number

64 Mechanical installation

Installation (without air channel)

1. Lift the fan unit onto the cabinet roof by means of a forklift or a crane (if using a
crane, empty the lifting eyes in the fan roof).

• ~70 kg for EC500 fan units

• ~90 kg for EC560 fan units

NOTICE
The mounting position can be identified by the cutouts in the drive roof.

2. Use the supplied screws to fasten the fan units to the cabinet roof.
For information on the electrical installation, see Control and power supply cables for
fan units.
For 3.3 kV (Power ≤ 710 kW) and 4.16 kV (Power ≤ 870 kW), EC fans need to be
installed with fan box and air channel in the field.
 Mechanical installation 65

Installation (with air channel)

1. Install air channel on the drive roof.
- ~40 kg for air channel

2. Lift fan unit onto the air channel.

 Bolting together the units

Required bolts are attached to the drive unit side wall adjoining the transformer
unit. Align the units. Then bolt the units together using the 12 hexagonal bolts with
5N·M(see figure below).

 Fixing units to the floor

Floor fixings are not supplied. 16 anchor bolts as illustrated (B in figure below), or
screws, nuts and washers of size M16 are recommended (diameter of holes in base
frame: 18 mm).
66 Mechanical installation

Fixing the base to the floor

Location of tool kit and accessories

1. COU Key
Key for control unit fix on the door of COU.
2. Combination screws
Screws for combining converter and transformer are fixed on the door of control
unit.
3. Tool Kit
You can find the tool kit by open the door of control unit. It is on the bottom of
the cabinet.

Open the box, you can find all the tools and accessories for future use. A
description of all the items in the kit is delivered alongside. Please pay attention
to the screw driver which is used for open the transformer cabinet is in this box,
 Mechanical installation 67

it should be kept by authorized person, actions without authorization are

dangerous.
4. Absorbing material in cabinet - Desiccant
Place Desiccant in the cabinet, one bag for per door, position them on the
bottom plate uniformly distributed.
Notice: Take out from the cabinet in time after unpacking. To prevent other
violations.

COU INU TRU

Combine cabinet primary cables installation

Step 1: Take down the 3x primary cables fixing on the INU side plate. Unfold the
phase A, B and C power cables from bottom to top and should not cross each
other.Disassemble the insulation covers from the front primary terminals. Connect
the cables to the corresponding terminals of the transformer with 40N.
68 Mechanical installation

Step 2: Remove the cable tie bag from the cabinet frame. Fixing phase A cable on the
black support block which have installed on the frame with cable ties.

The fixing order should be from right to left as shown in the following figure.

Step 3: Fixing phase B cable on the black support block which have installed on the
frame with cable ties. The fixing order should be from right to left as shown in the
following figure.

Step 4: Fixing phase C cable on the black support block which have installed on the
frame with cable ties. The fixing order should be from right to left as shown in the
following figure.
 Mechanical installation 69

Step 5: Mount back the insulation cover after the cable connection confirmed.

Step 6: Adjusting the cable position. The 3x primary cables should keep at least 5 mm
distance with each other and keep at least 20 mm distance with metal cabinet.
70 Mechanical installation
 Electrical Installation 69

8
Electrical Installation

Contents of this chapter

This chapter gives instructions on the installation of the power cables and wiring of
control and auxiliary power.

Safety
WARNING Hazardous voltage!
Improper work could lead to life-threatening injury or death.
The electrical installation must be carried out by qualified personnel according to
the site and equipment requirements, and the relevant electrical codes.
When the electrical installation is completed, the main and auxiliary power supply
to the drive must not be switched on without the consent of the ABB
commissioning personnel.
Take appropriate measures to prevent main and auxiliary power supply from
being switched on during installation.

Overview of installation work

The electrical installation includes the following wire and cable connections:
• Cables between integrated transformer and drive
• Power cables, ground cables
• Auxiliary power, control and serial communication cables
• Power supply and signal cables for fans in transformer unit
70 Electrical Installation

Cable requirements
For information on the requirements for power cables and the ground cable see the
ACS580MV Engineering Guideline.
For information on the requirements for the auxiliary power cable and the control
cables, see Auxiliary power and control cables guideline.

Parallel routing of power cables

Cables between drive and motor can be laid in parallel. The number of cables laid in
parallel is limited by the number of entry holes of the entry plate.
For information on the supply voltages, see Rating label of the drive.

Connecting external wiring to the control unit or

optional I/O terminal block
Leave the other ends of the control cable shields unconnected or ground them
indirectly via a high-frequency capacitor with a few nanofarads. The shield can also
be grounded directly at both ends if they are in the same ground line with no
significant voltage drops between the end points.
Note: Keep any signal wire pairs twisted as close to the terminals as possible.
Twisting the wire with its return wire reduces disturbances caused by inductive
coupling.
Ground the pair-cable shields the grounding clamp. Do not connect shields of
different cables to the same grounding clamp.
 Electrical Installation 71

Terminal sizes for auxiliary and control connections

Customer I/O terminal
Terminal Wire cross-section (mm2)
X1:1
X1:3
X1:5
X1:7
1.5...2.5 mm2
X1:9
2 mm2 recommonded
X1:11
X1:13
X1:15
X1:17
X1:19
X1:21
X1:23
X1:25
X1:27
X1:29
X1:31
X1:33 0.2...2.5 mm2
2 recommonded
X1:35 0.75 mm
X1:37
X1:39
X1:41
X1:43
X1:45
X1:47
X1:49
X1:51
X1:52
X1:53
X1:54 0.75...2.5 mm2
X1:55 2 mm2 recommonded
X1:56
X1:57
X1:58
X1:59
X1:60
X1:61
X1:62 0.2...2.5 mm2
X1:63 0.75 mm2 recommonded
X1:64
X1:65
X1:66
X1:67
X1:68

Customer supply connection terminals

Terminal Wire cross-section (mm2)
X4:N 2.5…4 mm2
X4:PE 4 mm2 recommonded
X5:N 0.75…4 mm2
X5:PE 2.5 mm2 recommonded
X6 (X18) 6…35 mm2
2 recommonded
X6 (X18) 25 mm
72 Electrical Installation

Auxiliary power supply interface

Terminal Wire cross-section (mm2)
16…35 mm2
F8(Q8): 1, 3, 5
25 mm2recommonded
6…25 mm2
F7(Q7): 1, 3, 5
10 mm2recommonded
Q4051(Q14): 1, 3 2.5…25 mm2
Q4052(Q15): 1, 3 4 mm2 recommonded
0.75…25 mm2
Q4061(Q16): 1, 3
2.5 mm2 recommonded

Ground cable and cable shield connections

The cabinet is equipped with ground buses (marked PE, Protective Earth) for
grounding the armor and shields of the cables, and for the connection of the ground
cable.
To identify the ground buses, see ACS580MV Wiring Diagram.

 Grounding of the drive system

Grounding of the drive system must be in line with the ACS580MV Engineering
Guideline.
 Electrical Installation 73

4 4

1
1
2
2
4

4
5

6 5

7
8 6

7
5
8
3
4

3
4

1 Input transformer (TRU)

2 Drive
3 Motor
4 Earth electrode
5 Ground cable
6 Cable screen
7 Cable shield
8 Equipotential bonding conductor

Grounding drive system and integrated transformer

74 Electrical Installation

Cables and PE busbar between integrated transformer

and drive

2 1

1 Transformer unit
2 Drive unit
3 Control cable lead-through
4 PE busbar

Drive with integrated transformer

Cables and PE busbar between drive and integrated transformer includes the
following connections:
• Transformer primary and secondary cables
• Temperature sensor cables
• Three-phase power supply cable to each of the transformer fan units
• PE Busbar to connect INU and TRU.
or
Auxiliary supply from internal main transformer (option)
• Heating cable (option)
The cables are identified by their specific number and are labeled with the
designation of the terminal where they are connected to.
The terminals for the primary and the secondary cables are located on the side wall of
the drive cabinet. The transformer terminals are accessible through the left side door
of the transformer unit. The cables must be mounted to the transformer terminals as
shown in the figure below.
 Electrical Installation 75

2 2 2 4

1 3 3 3 2

6 3
5

1 Bolt
2 Dished washers (4 pcs. per terminal)
3 Flat washers (4 pcs. per terminal)
4 Nuts (2 pcs. per terminal)
5 Cable shoes
6 Support plate

Transformer terminal connections

The supply cables for the fan units of the transformer and the control cables are
routed through the cable lead-through in the side wall.

NOTICE
The required tightening torque for the internal transformer terminal connections
is 15Nm (M8 bolt), 30Nm (M10 bolt). Use a torque wrench.

The PE busbar is connected with INU and TRU PE busbars through the side wall.

PE busbar connection
76 Electrical Installation

For further information on locating the temperature sensor cables, auxiliary power
supply cables and the optional heating cable, see ACS580MV Wiring Diagram.

Cable entries for external connections

Power cable terminals are located in the terminal compartment behind the control
compartment. They can be accessed after removing the metal cover (tripping loop
terminals -XS1 on the cover must be opened first).
The drive is prepared for top or bottom cable entry with one or a combination of the
following cable entries:
• Metal plate hole cable entry for power cables, ground cables
• Cable entry with EMC plates, EMC cushions and sealing grommets for auxiliary
and control cables

For detailed information e.g. location and dimensions, see ACS580MV Base frame &
TEU layout design.

 Power cable entry via holes in cable entry plate

Power cable entry can be from bottom or top.

1 3

1 Power cable entry plate (in TEU)

2 Auxiliary and control cable entry (in COU)
3 Sealing compound

Galvanized plate for cable entry.

Plate mounted on top. See Sealing holes in entry plates for more information.

 Control and auxiliary cable entry with EMC plates

Cable entry can be from bottom or top.
• Galvanized plate (1 in figure below) with EMC cushions (2, 3, 4) and sealing
grommets (5). See ACS580MV Base frame & TEU layout design for details and for
the possible mounting variants.
 Electrical Installation 77

2
4

1 Lead through plate

1 2 Bracket
3 Bracket
4 EMC cushions
5
5 Sealing grommets
6 Opening in cable entry plate

Material for cable entry with EMC plate (bottom mounted)

The EMC cushions (1 in figure below) are mounted on the underside of the EMC plate
when entering cables from top. They are mounted on top of the EMC plate when
entering cables from underneath.

EMC cushion
See Preparing the cables for more information.
78 Electrical Installation

Installing power and ground cables

 Further information
See ACS580MV Base frame & TEU layout design for information on:
• Project-specific cable entry
• Distance between the point of cable entry and the termination bars
• Busbar and fastening hole dimensions
• Busbar designations
See ACS580MV Wiring Diagram for information on:
• Conventions for cross-references and device identification

 Preparing the cable entry and the cables

NOTICE
Risk of damage or malfunction!
Waste inside the cabinet can cause damage or malfunction.
If possible, do not cut cables inside the terminal compartment. Retrieve any waste
which accidentally dropped into the cabinet.

Determining the cable length

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

Preparing cables for entry plates

• Prepare the cable termination as illustrated in the figure below.
 Electrical Installation 79

1 Outer cable sheath

4 2 Entry plate
Conductor screen extension to be connected
3
to PE ground busbar.
4 Heat-shrinkable termination
5 Sealing compound

Power cable termination

80 Electrical Installation

 Connecting the cables

NOTICE Risk of flash-over
High voltages will be present in the terminal compartment. High voltages can
cause flash-over between the electric potential of different conductors, and the
electric potential of a conductor and earth.
Therefore, a minimum clearance of 59.5 mm must be maintained between a
conductor and earth, and 90 mm between a conductor and the terminals of any
other conductor.

1 High voltage resistor board

2 Motor side terminals
3 Input terminals
4 Cable entry plate
5 Cabinet PE busbar

Terminal compartment with cover plate removed, view from front

 Electrical Installation 81

Side view: Power cable entry from top ( (1) screen extensions to ground )
82 Electrical Installation

Side view: Power cable entry from bottom ( (1) screen extensions to ground )
Checking the cable insulation
• Check the insulation of each cable before connection and verify that the results
are within the specification of the cable manufacturer.
• Leave the cables unconnected at both ends until the commissioning personnel
has given permission to connect them.

Connections
Connect the cables to their corresponding busbars:
• Feeder cables to busbars U1, V1, W1
• Motor cables to busbars U2, V2, W2
• Screen ends of all conductors and the shields of all cables to the PE ground
busbar
• Ground cable to the PE ground busbar
 Electrical Installation 83

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

1 2 3 2 1

5 6

1 Spring washer (2 pcs. per terminal)

2 Flat washers (2 pcs. per terminal)
3 Busbar
4 Cable lug
5 M12 bolt
6 M12 nut

• Use cable lugs suitable for M12 bolts. The required tightening torque is 40 Nm.
Lubrication
• If stainless steel bolts and nuts are used, lubricate the thread and head contact
surface of the bolt using recommended pasts, e.g. Molykote D paste.
Note: If a coated nut (e.g. with bonded molybdenum-disulfide [MoS2] coating) is
used, the connection does not have to be lubricated.
Tightening torque
• Tighten bolted connections with bolts of sizes M10 and greater with the
recommended nominal torque for the bolt size used.
84 Electrical Installation

Installing auxiliary, control and serial communication

cables
 Further information
See ACS580MV Base frame & TEU layout design for information on:
• Project-specific cable entry
• Dimensions between point of cable entry and terminals
See ACS580MV Wiring Diagram for information on:
• Conventions for cross-references and device identification
• Terminal designations

 Preparing the cable entry and the cables

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

Routing the cables

• Route the cables as illustrated through the provided cable duct to the customer
terminals or fieldbus modules in the control compartment.

Duct for auxiliary and control cables [40x60]mm

 Electrical Installation 85

 Preparing the cables

1. Remove the grommets.
2. To ensure proper sealing, cut along the marking that
corresponds to the cable diameter. Slide the grommet
onto the cable. The grommet must fit tightly to prevent
water from entering the cabinet.
3. If necessary, remove the entry plate and pull the cables
through the entry holes.
4. Loosen the screws of the EMC cushion brackets and push
the cushions apart (arrow).

5. Remove the cable insulation at the point of entry (1).

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

1
3

6. Pull the cables through the EMC cushions.

7. Push the cushions together so they fit tightly around the bare screen and tighten
the screws.
86 Electrical Installation

 Connecting the cables

• Connect the cables for digital and analog input and output signals to the
corresponding terminals / modules.
• If a twisted pair cable is used, leave the unshielded cable ends twisted until they
reach the terminals.
• Leave unshielded conductor ends as short as possible (not longer than 50 mm).
• Connect the shield of serial communications cables to the PE busbar located
near the fieldbus adapter.

 Control and power supply cables for fan units

1. Route the control and power supply cables through one of the cable entries
located in the floor of the fan unit. Choose either the front or the rear cable entry,
according to the position of the fan cable connector.
2. Connect each cable to the appropriate connector.

1
2

1 Front cable entry

2 Rear cable entry
3 Fan cable connectors

For information on connection details, see ACS580MV Wiring Diagram.

NOTICE
The control and power supply cables are already prepared in the factory for
connection.
 Electrical Installation 87

Note: For 3.3 kV (Power ≤ 710 kW) and 4.16 kV (Power ≤ 870 kW), control and power
supply cables connection with fan units and air channel.

Sealing holes in entry plates

Sealing the gap between cable and entry plate are necessary. Recommend two
component sealants.

Final checks
Check that the entry plates are properly fastened and cable entries are correctly
sealed.
88 Electrical Installation
 Installation checklist 89

9
Installation checklist

Contents of this chapter

This chapter contains an installation checklist which you must complete before
commissioning can take place.

Safety
DANGER
High voltage!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.
Before starting to work on the drive, make sure:
• that the main and auxiliary power supply to the drive is switched off, locked
out, and tagged out
• that the drive is dead
• that safety ground connections are in place
• that personal protective equipment is provided and used when required
• that everyone involved is informed.
Before energizing the drive, make sure:
• that all foreign objects are removed from the drive
• that all internal and external covers are securely fastened and all doors are
closed, locked and / or bolted
• that the release dials of safety switches are in the locked position.
90 Installation checklist

WARNING! Obey the instructions in chapter Safety instructions. If you ignore

them, injury or death, or damage to the equipment can occur.

NOTICE! The field engineer should confirm that the power cables are
connected to the correct bus bars before switching on the main power. Once
the main power direct reach the output bus bars by wrong connections, the
power modules would be irreversible damaged.

Checklist
Do the steps in section Precautions before electrical work on page 17 before you start
the work. Go through the checklist together with another person.

Mechanical installation
1. The infrastructure of the electric room is finished and the installation site is sufficiently
ventilated or cooled and dehumidification to ensure the converter can running at the
appropriate temperature and humidity.

2. The wall behind the unit is of non-flammable material. Please take the photo and send
back.

3. There is enough free space above the drive to enable cooling air flow, service and
maintenance. See layout drawing. Please take the photo and send back.

4. Ambient operating conditions meet the specifications given in chapter Technical data

5. Drive installed according to the instructions in this manual (Chapters Mechanical

installation and Electrical Installation)

6. Drive securely fastened to the floor

7. INU cabinet and transformer cabinet have finished combination.

8. The floor that the unit is installed on is of non-flammable material, as smooth as possible,
and strong enough to support the weight of the unit. Check the floor flatness with a spirit
level. The maximum allowed deviation from the surface level is 5 mm in every 3 meters.
Level the installation site, if necessary, as the cabinet is not equipped with adjustable
feet.

9. Fan units installed with correct poison and type.

 Installation checklist 91

10. Visual inspection:

no badly affixed or damaged components
no foreign objects inside cabinet
no dirt, dust and humidity inside cabinet

Electrical installation
1. Types and cross-sections of control cables suitable for the signal type and signal level

2. Types and cross-sections of power cables selected according to the ACS580MV

Engineering Guideline

3. Pulse encoder cable screens connected to screen grounding point and not connected
directly to the pulse encoder interface (only applicable for drives with pulse encoder
interface)

4. Internal cabling to integrated transformer (power, auxiliary, control and heater cables)
made according to the instructions in this manual (Chapter Electrical Installation)

5. Cable entry made according to the instructions in this manual (Chapter Electrical
Installation)

6. All control cable screens and conductors are connected according to the instructions in
this manual (Chapter Electrical Installation), appropriately labeled, and the customer-
side connections are completed

7. Heating cable (if supplied) installed according to the instructions in this manual (Chapter
Electrical Installation)

8. Ground cable of drive securely connected at both ends

9. Input and motor cables not connected at both ends (cables must be meggered before
connection, drive optional - recommended in case of long storage time, humid
environment or visible transportation damages)

Door interlocking
1. Door locks tested and in operation

2. The manual release of the door safety switch(es) is in the locked position.

Main circuit breaker (MCB)

1. Type of MCB selected as per ACS580MV Engineering Guideline
92 Installation checklist

2. High voltage connections completed

3. MCB ready to be tested with drive

4. MCB interposing relay settings tested

5. Local close order is disabled, and the connection to switch or button is canceled.

6. The wiring of the control & signal cables connecting with the converter is finished.

7. Safety devices checked and in operation

8. The user manual and technical specification is available.

9. Withstand voltage test of the MCB have been done according to Manufacture`s
specifications. The official test report must be available.

Motor
1. Motor installed, aligned and alignment protocol available

2. Motor decoupled from driven load

3. Ground connection completed

4. Customer side motor protection set and ready (e.g. winding temperature, vibration)

5. Motor auxiliaries (e.g. bearing lubrication, heater cooling) ready

6. The user manual and technical specification is available.

Power cables
1. All cable screens are connected. Please take the photo and send back.
 Installation checklist 93

2. Grounding cables of transformer, converter and motor are connected and tighten.

3. Types and cross sections of power cables are selected according to the “ABB power cable
specification”. Type of cable .

4. Transformer and motor cables are not fastened at both ends (cables and converter must
be meggered before connection).

Insulation tests
1. All power cables to drive, and from drive to motor are meggered, and measured values are
within the required limits.

2. Test report of the megger test available

Note: If the test is carried out by the commissioning engineer of the drive, an additional
day per drive motor combination needs to be reserved. After the test, the feeder cables
can be connected, except at the drive end. The test must comply with the specification.

3. Optional insulation tests of the drive are completed and documented. Insulation tests of
the drive recommended in case: long storage time (>4 months), humid environment or
visible damages due to transportation/installation.

Power supply
1. Medium voltage available for start-up of drive

2. Low voltage auxiliary power available for start-up of drive

Miscellaneous
1. Sufficient number and correct type of spare parts available

2. Cooling of drive room ready for load run of drive

3. Optional equipment ready

4. Drive room properly dust filtered (dust filters at air inlet), see ACS580MV
Engineering Guideline
94 Installation checklist
 Operation 95

10
Operation

Contents of this chapter

This chapter contains the start-up procedure of the drive. The default device
designations (if any) are given in brackets after the name, for example “main switch-
disconnector (Q1)”. The same device designations are also used in the ACS580MV
Wiring Diagram typically.

Operating conditions
The operating conditions for the drive are according to IEC 60721-3-3 ’Stationary use
at weather-protected locations’ (unless indicated otherwise).For details see
Technical data.

Safety
The drive must only be operated by qualified and authorized personnel, i.e.
personnel who are familiar with the operation of the drive and the hazards involved.

Overview
The chapter outlines the local operation of the drive. For additional details on using
the local control panel see User’s Manual “ACS-AP-X assistant control panels user’s
manual ”.
Control of the drive via a PLC or a higher-level control system is not described in this
chapter. If the drive is controlled from remote, see the appropriate manuals for
information.
The panel messages and parameter settings used in this chapter are typical
examples to illustrate the related instructions and display functions and may
therefore differ from the actual messages and parameter settings in the drive.
96 Operation

Overview on drive status and sequences

The following section lists the main operating states of the drive and the related
indications on the local control panel when the drive is put into operation (see Start
sequence of the drive), when it is stopped (see Stop sequence of the drive), or when a
fault condition has occurred.
For information on other status messages, such as fault status messages in
particular, see the ACS580MV primary control program firmware manual.

 Status indications
The drive status is indicated with a status icon on the control panel.
Status icon Animation Drive status

- Stopped

- Stopped, start inhibited

Blinking Stopped, start command given but start inhibited

Blinking Faulted

Flashing Running, at reference, but the reference value is 0

Rotating Running, not at reference

Rotating Running, at reference

 Operation 97

 Start sequence of the drive

Drive not ready

Conditions for start:
Auxiliary supply on
TEU protective plate mounted
&
TRU / INU door closed and locked
No emergency off active
No fault active

Drive ready on

SUPPLY ON command

MCB closes
DC link charges
Fans switch on

Drive ready run

Enter setpoint
Start command

INU starts modulation

Drive running

Operation
98 Operation

 Stop sequence of the drive

Operation

Drive running

Stop command

Speed ramps down

INU stops modulation

Drive ready run

SUPPLY OFF command

MCB opens
DC link discharges (15 Min)
Fan switches off
after a delay

Drive ready on
Actions:

TRU / INU door released for opening

Switch off auxiliary supply

Drive not ready

 Operation 99

 Emergency off sequence

Operation

Drive running

Emergency off command

Motor is stopped
by coasting

MCB opens
INU stops modulation

Drive not ready

100 Operation

Energizing and starting the drive

It is recommended to have the following documents at hand when starting the drive
locally for the first time after commissioning:
• ACS580MV Wiring Diagram to identify the circuit breakers
• User’s Manual “ACS-AP-X assistant control panels user’s manual ”.

 Checks before starting the drive

DANGER
Hazardous voltages!
All covers must be screwed in place to prevent unintentional contact with
energized components.
The manual release of the door safety switches must be in the locked position. The
locked position prevents doors of medium voltage compartments being opened
unintentionally during operation.

When the drive is put into service after it has been commissioned, or after it has
been taken out of service for maintenance or troubleshooting, check the drive
according to the following list:
• Check that no tools and foreign objects are left inside the cabinets.
• Check that all auxiliary power supplies from external sources are switched on.
• Check that all internal circuit breakers of the drive are closed.
• Check that all grounding devices are removed
• Check that all covers are mounted and the doors are closed, locked and / or
bolted.
• Check that the MCB is in operating position.
• Check that there is no run interlock active.

 Starting the drive from remote

When the drive is operated from remote through a higher-level control system or an
operator control desk, follow the instructions in the appropriate manuals.
 Operation 101

 Starting the drive locally

1. Enable the local control mode of the control panel by pressing the Loc/Rem key
(1).

The drive is in state Stopped and the display shows .

2. Press the SUPPLY ON pushbutton to connect the drive to the main power supply.
The following takes place:
• The MCB closes.
• The DC link charges.
While the DC link charges, the SUPPLY ON pushbutton flashes. As soon as the DC
link is charged, the SUPPLY ON pushbutton changes to a permanent light.

3. Enter the setpoint. See “ACS-AP-X assistant control panels user’s manual ”.
4. Press the Start key (2) to start the motor.
After the motor has been magnetized, the motor speed ramps up to the
setpoint.
102 Operation

While the motor is accelerating, the run status indication on the display blinks.
When the motor speed has reached the setpoint, the run status indication lights
up permanently.

Stopping the drive

This section describes how to stop the drive using the local operator panel of the
drive. If the drive is remotely-controlled, follow the established shutdown
procedures.
For details on using the local control panel see “ACS-AP-X assistant control panels
user’s manual ”.
1. Enable the local control mode of the control panel by pressing the Loc/Rem key
(1).

1
 Operation 103

2. Press the Stop key (2).

The motor stops according to the preset stop function and the drive stops
modulating. When the motor has reached zero speed, the drive is in state
Stopped and the display shows .

DANGER
Hazardous voltages!
The ACS580MV is not de-energized in the state Stopped. Before doors are opened
/ removed or work is begun on the drive, the system must first be de-energized
(see Chapter Maintenance, Shutting down the drive for maintenance).
104 Operation
 Fault tracing 105

11
Fault tracing

Contents of this chapter

This chapter describes the fault tracing possibilities of the drive.

Alarm and fault indications

When a failure occurs in the drive or in the equipment monitored by the drive, the
control panel displays a corresponding alarm or fault message and the red
Fault / Alarm button on the control compartment door lights up:
• Alarm: flashing light
• Fault: permanent light

Button / Light Fault/Alarm

Color Red

Off

Status Flashing

on

Normal operation

Meaning Alarm pending

Drive in fault state

106 Fault tracing

Warning and fault messages

In case of an alarm or fault refer to the ACS580MV primary control program firmware
manual for the descriptions, causes and remedies of the drive control program
warning and fault messages.

 Diagnosis data and parameter backup

See User’s manual “Start-up and maintenance PC tool Drive composer”
 Maintenance 107

12
Maintenance

Contents of this chapter

This chapter contains instructions for preventive maintenance and component
replacements and the Maintenance schedule with recommended maintenance
intervals.

Safety
DANGER
High voltage!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.
Before starting to work on the drive, make sure:
• that the main and auxiliary power supply to the drive is switched off, locked
out, and tagged out
• that the drive is dead
• that safety ground connections are in place
• that personal protective equipment is provided and used when required
• that everyone involved is informed.
Before energizing the drive, make sure:
• that all foreign objects are removed from the drive
• that all internal and external covers are securely fastened and all doors are
closed, locked and / or bolted
• that the release dials of safety switches are in the locked position.
108 Maintenance

NOTICE
Foreign matter and particularly metallic dust can cause failure and damage when
the drive is energized.
Ensure that foreign matter cannot enter the cabinet:
• Close the doors and cover openings completely when the work is
discontinued.
• Retrieve any foreign matter accidentally dropped into the cabinet.

NOTICE
All maintenance tasks that are listed in the maintenance schedule, but are not
described in detail in this manual, may only be carried out by ABB.
Call ABB service if such a task is due.

Preparation for maintenance work

 Documentation and reporting of maintenance work
It is recommended to record all troubleshooting and maintenance work in a logbook
including:
• Date and time
• Detailed description

 Required tools and equipment

Standard set of tools. If special tools are needed for a maintenance task, a specific
list is provided.
Use only instrumentation (e.g. meters, oscilloscopes, etc.) intended for high voltage
measurements (that is, isolation is provided inside the instrument, not provided by
isolating the chassis ground of the instrument). Never defeat the instrument's
grounding.

 Storage and handling of spare parts

To ensure safe and reliable operation, it is important to use only spare parts
recommended and approved by ABB.
For information on types and identification codes, see the spare part kits or contact
ABB service organization.

 Software and hardware updates information in MoR

Check preventive updates information in MoR, prepare appropriate documentation
and required material.
For information which is beyond of update instruction, contact ABB service
organization.
 Maintenance 109

Shutting down the drive for maintenance

See Chapter Operation, Stopping the drive for instructions on de-energizing the drive
using the local operator panel of the drive. If the drive is remotely-controlled, follow
the established shutdown procedures.
For details on using the local control panel, see User’s Manual “ACS-AP-X assistant
control panels user’s manual ”.

DANGER
Hazardous voltages!
For work in the medium voltage circuit of the drive the connection of grounding
equipment at the appropriate locations is a must. The grounding equipment
ensures that hazardous voltages cannot be fed into the drive neither from the
main power supply nor the motor.

 De-energizing the drive

1. Stop the drive following the instructions in Chapter Operation, Stopping the drive.
2. Set the local control panel to local control mode by pressing the Loc/Rem key (1)

3. Press the SUPPLY OFF pushbutton to disconnect the drive from the main power
supply. The following takes place:
• The MCB opens.
• The DC link discharges.
While the DC link discharges, the SUPPLY OFF pushbutton flashes.
110 Maintenance

• Wait 15 minutes until the DC link capacitors have discharged completely (the
delay time is triggered when the main power feeder is disconnected).
After the DC link capacitors have discharged completely, the cabinet doors of
the power compartments unlock, the SUPPLY OFF pushbutton changes to a
permanent light and the status line displays .

4. Rack-out, lock-out, ground and tag-out the main power feeder.

5. Switch off and lock-out all auxiliary voltages from external sources.
6. Verify that the drive system is de-energized.
7. To connect a grounding set, continue with Connecting a grounding set on page
111.
8. To open the door of the medium voltage compartment, continue with Unlocking
and locking the doors on page 110.
Tip: To open the power compartment doors, auxiliary voltage is required.
9. Before start working in the power compartment, the power modules must be
individually grounded by touching them with the grounding stick. See Grounding
power module enclosure and busbar with grounding hook on page 112.

 Unlocking and locking the doors

The door is secured by a safety switch and the control compartment door has
pivoted door handles and locks with triangular inserts. Open the door with the
supplied key.

1. To release the door handle, insert and turn the key to the right. The door handle
will pop out.
2. To open the door, turn the door handle
• to the right, if the door is hinged on the right,
• to the left, if the door is hinged on the left.
3. To lock the door, bring the door handle in line with the door plate and press the
handle down until it clicks in.
4. Before manually release the door lock, make sure that the lock handle is back to
the original position (in vertical direction).
 Maintenance 111

 Connecting a grounding set

Before starting to work on the drive, you must ground the three input and three
output terminals in the terminal unit (TEU). Always ground the drive on both sides,
i.e. on supply and motor side. Grounding on motor side is needed to avoid induced
voltage from a spinning rotor.
For this purpose, two grounding harnesses are needed. They can be ordered
separately as an optional grounding harness set (consisting of two grounding
harnesses plus a telescopic insulating pole) for the 3-phase power input.
Notice: To adapt grounding harness ordered from ABB, ball type grounding studs
are provided as option.

1 Telescopic insulating pole

2 Enclosure ground clamp
3 Busbar ground clamp

Example for grounding harness

1. Open the COU door.
2. Connect the enclosure grounding clamp (item 2 in the figure above) to the
cabinet’s PE busbar.
3. Remove the protective plate between COU and TEU.
112 Maintenance

4
5

1 High voltage resistor board

2 Motor side terminals
3 Input terminals
4 Cable entry plate
5 Cabinet PE busbar

Terminal compartment with cover plate removed

4. Use the telescopic insulating pole to connect the busbar grounding clamps to
the busbars in the Terminal Unit, and to tighten each connection.

 Grounding power module enclosure and busbar with grounding

hook
Since the power modules are on a floating potential, make sure there is no residual
voltages on the module terminals before starting work on the modules.

Required tools
• Voltmeter or multimeter with impedance of >=10 Mohm (not part of supply)
• Voltage divider probe (not part of supply)
• Grounding hook (part of supply)
 Maintenance 113

The grounding hook is attached to the left side wall inside the COU cabinet. The
other end of the PE cable is fixed to the PE busbar (see the figure below). The
length of the PE cable is 4.5 m or 6 m, depending on the drive type.

1 Grounding hook
2 Grounding cable connected to PE busbar

Grounding hook in stowed position

Procedure:
1. Please make sure that the three input and three output terminals in the terminal
unit (TEU) are grounded. Always ground the drive on both sides.
2. Open the INU door.
3. Connect the voltage divider probe to the volt-/multimeter and select the
appropriate metering range (see the instruction manuals of the devices).
4. Connect the grounding clip of the voltage divider probe to the cabinet (PE
busbar, see the instruction manual of the probe).
5. Touch all the input and output terminals of each power module with the contact
electrode of the probe and check that the voltage is below 50 V.
6. Touch all the input and output terminals of each power module with the contact
tip of the grounding hook.
7. Hang the grounding hook to the terminal of the power module to be serviced
and leave it there until work on the module is finished.
8. Make sure again that all power module terminal voltages are below 50 V. Use a
multimeter and measure the voltage between the grounded power terminal and
all other power module terminals before working on the power module.
114 Maintenance

Starting the drive after maintenance

See Chapter Operation, Energizing and starting the drive for instructions on energizing
the drive using the local operator panel of the drive. If the drive is remotely-
controlled, follow the established start-up procedures.

Emergency release of the door safety switch

DANGER
Hazardous voltages!
Touching energized components can be fatal.
Before you unlock the safety switch, verify that the drive is de-energized.
Do not unlock the safety switch permanently.

The door of the INU compartment is secured by a safety switch (item 1 in figure
below).

Location of door safety switch

The safety switch is tied into the door interlocking circuit of the drive and the
interlocks from the main circuit breaker of the drive. The interlocking system
ensures that:
• the main power can only be connected to the drive if the door is securely closed
and the safety switch is in the locked position.
• the door can only be opened if the main circuit breaker is open and the DC link is
discharged.
Also, the door of the INU compartment can not be opened
• if the drive is disconnected from the auxiliary power
• if the safety switch of the door is in the locked position.
If the auxiliary voltage is switched off and the door is locked but cannot be opened,
check the position of the release dial of the safety switch. If the release dial is in the
locked position, unlock the safety switch as described in Safety-switch settings on
page 115.
 Maintenance 115

 Safety-switch settings
There’re two kinds of safety switches as follows,

Safety-switch setting 1

3 2 1

1 Release dial
Unlocked position
2 The unlocked position enables opening the door of a medium
voltage unit whether the auxiliary voltage is switched on or off.
Locked position
Locked is the normal operating setting. To open the door of a
3
medium voltage unit, the DC link must be discharged and the
auxiliary voltage must be switched on.

Unlocking
1. To access the release dial of the safety switch, remove the cap in the top right
corner of the INU compartment door.
2. Turn the release dial from the locked to the unlocked position.

1
PZ0

3. When the door is open, turn the release dial to the locked position.
4. Insert the cap again.

Safety-switch setting 2

2 1 3 1 Release dial
Unlocked position
2 The unlocked position enables opening the door of a medium voltage
unit whether the auxiliary voltage is switched on or off.
Locked position

3 Locked is the normal operating setting. To open the door of a medium

voltage unit, the DC link must be discharged and the auxiliary voltage
must be switched on.

Unlocking
1. To access the release dial of the safety switch, remove the cap in the top right
corner of the INU compartment door.
2. Screw out the locking screw (1) until the release dial can be turned.
116 Maintenance

1
PZ0

3. Turn the release dial from the locked to the unlocked position.

5 mm

4. When the door is open, turn the release dial to the locked position and screw in
the locking screw.
5. Insert the cap again.

Visual checks and cleaning

WARNING! Obey the instruction in chapter Safety instructions. If you ignore
them, injury or death, or damage to the equipment can occur.

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance on page 109 before you start the work.
2. Check the drive and its immediate vicinity visually at the intervals stated in the
maintenance schedule and pay attention to the following items:
• Air temperature and humidity inside the drive room
• Permitted range of ambient air temperature and humidity of the drive
• Dust built-up inside the drive room and inside the drive
• Signs for overheated components, wires, cables or busbars, for example,
connections of transformer primary side
• Corrosion on circuit boards, connectors or busbars
3. When cleaning the drive, mind the following:
• Do not use alcohol or solvents
• To prevent dirt or dust from falling into surrounding equipment and
assemblies, cover them before you start cleaning
• To clean components that are sensitive to electrostatic discharge, take
electrostatic-sensitive precautions and use suitable tools. For example, to
 Maintenance 117

clean circuit boards, use a soft antistatic brush or an antistatic vacuum

cleaner with a soft nozzle
• To remove dirt or dust from insensitive surfaces, use compressed air, a
vacuum cleaner or a lint-free cloth
• To remove water and oily or greasy deposits from assemblies, components,
busbars and such, use water- and oil-absorbing microfibers.
4. Check the air inlet filters of the cabinet. Clean when necessary.
5. When necessary, replace components, wires, or busbars with overheating or
corrosion.

Replacing the door air filters

Inspect filter mat condition, replace if necessary. Replace filter mat regularly
according to PM schedule. see ACS580MV Preventive Maintenance Schedule. ABB
also provide air filter cassette as option for higher level protection.
Note: It is not allowed to replace air filter during drive operation !

1 Filter

1. Unscrew and remove the fixed part of ventilation cover.

2. Lift the grating and pull it away from the door.

3. Remove the air filter.

4. Place the new filter into the grating.

5. Reinstall the filter and grating in reverse order.

118 Maintenance

Cable connects, bolted connections

1. Inspect power cables and earthing cables, including earthing in doors:
• Insolate with different voltage potential.
• Appropriate fastening of cables and wires and connections of cable shields
and screens.
• Integrity of cable insulation. The outer cable sheath must not be damaged.
2. Inspect control cables:
• Check the connections of control cable and relays.
• If necessary, tighten the screws.
• Replace damaged or wobbling connectors.
3. Inspect bolted connections:
Pay more attention to following current-carrying connections:
• Terminals of mains and motor cables.
• Terminals of transformer primary and secondary side.
• Busbar fastening bolts in the INU (on and between PEBBs).
• Ground busbar joints.
Check bolted connections are tightened with the nominal torque for the bolt size
used:

Bolt
Bolt type Tightening torque (Nm)
size
M3 Copper 0.8
Steel/ Stainless steel 2
M4
Copper 1.2
Steel/ Stainless steel 3
M5
Copper 2
Steel/ Stainless steel 5.5
M6
Copper 3
Steel/ Stainless steel 10 (aluminum busbar)/ 15(copper busbar)
M8
Copper 6
Steel/ Stainless steel 20 (aluminum busbar)/ 30(copper busbar)
M10
Copper 10
Steel/ Stainless steel 30 (aluminum busbar)/ 40(copper busbar)
M12
Copper 15.5
Steel/ Stainless steel 90 (aluminum busbar)/ 120(copper busbar)
M16
Copper 30
 Maintenance 119

Steel/ Stainless steel 120 (aluminum busbar)/ 160(copper busbar)

M20
Copper 52

If a bolted connection must be renewed, see section Electrical Installation for bolt
selection and connection method.

NOTICE! Inappropriate connection method could lead to overheating or mechanical

damage.

Spare parts
 Spare power module
The spare power modules are distinguished as standard module (without bypass
function) and cell bypass module. Mixed use on one converter is not allowed.
The part numbers are different,
• 2UBAXXXXXXR000X - standard module
• 2UBAXXXXXXR010X - cell bypass module

 Spare power module reforming

Reform DC-link capacitors in spare power modules If the stock age more than 1 year,
following chapter Reforming capacitor of power modules.

 Software update in spare parts

Software in below spare parts should be checked and updated to same software
version as drive:
• BCU
• Control panel
• CVMI board
• IO controller
• Control hub
• HMI panel

Auxiliary voltage verification

 Protective settings
Check the settings of protective devices by following document Settings of
protective devices which attached in ACS580MV ROUTINE TEST REPORT
[2UBB011997 E01] or contact ABB service organization for this information.

 Voltage measurement

WARNING! Obey the instruction in chapter Safety instructions. If you ignore

them, injury or death, or damage to the equipment can occur.
120 Maintenance

NOTICE! This test is only possible to preform after energizing and starting the drive,
please follow instructions in section Starting the drive after maintenance.

Check the configuration of drive and measure following voltage level:

1. External 3 phase supply for fan supply
• 380...415 VAC (for AC fans)
• 380...480 VAC (for EC fans)
2. External single phase supply for control supply
• 100...240 VAC or 90...350 VDC
3. 24VDC distribution
• 23.0...25.0 VDC
4. External single phase supply for cabinet heater power supply
• 220...240 VAC
5. External single phase supply for motor space heater power supply
• 220...240 VAC

UPS battery refresh charge

If the drive is equipped with the optional UPS battery, refresh charge required.
When it is unavoidable to store the battery for 3 months or longer, periodically
recharge the battery fully with auxiliary power on at the intervals recommended in
the table below depending on ambient temperature. Avoid storing the battery for
more than 12 months.
Storage temperature Interval of auxiliary charge (refresh charge)
Below 20°C 12 months
20°C to 30°C 9 months
30°C to 40°C 6 months

Note:
1. Please follow ACS580MV Preventive Maintenance Schedule for maintain and
replace.
2. To obtain maximum life, batteries should never be stored in discharged status.
 Maintenance 121

Testing main power supply circuit

The main power supply circuit must be tested regularly according to the preventive
maintenance interval table. The tests consist of the actuation and checking of
proper
reaction of
• Safety circuit
• MCB door button (Main power supply OFF and ON)
• Control panel button
• Customer specific devices

 Safety circuit
Local/remote emergency off circuit is main safety circuit of ACS580MV.

WARNING! Obey the instruction in chapter Safety instructions. If you ignore

them, injury or death, or damage to the equipment can occur.

NOTICE! This test is only possible to preform after energizing and starting the drive,
please follow instructions in section Starting the drive after maintenance.

1. Start the drive.

2. Initiates an immediate stop by pushing local emergency off button, following
happens immediately:
• The pulses of the inverter are blocked
• The MCB is tripped
• The DC link is discharged
• All auxiliary circuits remain live
3. Reset emergency by:
• Pulling out emergency off push button;
• Pressing Emergency Reset button (optional for SIL3)
4. Repeat step 1 to 4 to test remote emergency off circuit.
5. There should be no component failure or system level shut down during the test.

Capacitors
The power module contains electrolytic capacitors. Their performance and lifetime
are influenced by various factors, including the operating temperature, humidity,
applied voltage, and the duration of the reforming process. The reforming times
provided in this chapter are recommended values based on standard conditions.
However, under specific operating environments or application scenarios, it may
be necessary to adjust the intervals and duration of the reforming process.
In order to ensure reliable drive operation, replace the power modules according to
the maintenance interval table.
122 Maintenance

 Reforming capacitor of power modules

The DC link capacitors in power modules need to be reformed in case the drive or
spare power module has been nonoperational for more than one year.
1. Check storage time of drive and spare power module:
• Check the event log by local control panel or PC tool Drive composer, find the
time of latest event “Drive charged”, it’s the most recent charging date of
drive
• For the first time to reform spare power module, find its serial number,
which defines week of manufacture. For example, 2UBA916040009
- 2UBA9: Fixed value
- 16: Year of manufacture (2016)
- 04: Week of manufacture (4th week)
- 0009: Running number
• It’s highly recommended to record reforming date for future maintenance
2. Reforming capacitors in power modules if the storage time more than 1 year but
less than 2 years:
• Charging the drive by following section Energizing and starting the drive in
chapter Operation.
• The power modules will be powered on and reformed
• Do not load the drive while reforming is ongoing, keep this hot standby
status for certain time as below figure requires:

• Discharging the drive

• The spare power modules can also be reformed in drive, install spare power
modules by following section Replacing the power modules, repeat upper
reforming process
3. Reforming capacitors in power modules if the storage time more than 2 years:
 Maintenance 123

Contact the ABB service organization, skilled personnel and specific equipment are
needed.

Replacing roof AC fans*

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off the motor starter of the fan unit to isolate the fan unit from the
auxiliary power supply. To identify the motor starter, see ACS580MV Wiring
Diagram.
3. Remove the hex-head combination screws (M6x16) that attach the top cover to
the fan box. Lift the top cover and pull it away from the fan box.

M6X16 combi screw



4. Disconnect the connector and make sure that the supply connector is detached
from the support beam.

5. Remove the four hex-head combination screws (M6x16) that attach the support
beam to the side plate of fan box frame.

NOTICE
For some types of fan boxes two additional hex-head combination screws must be
removed.
124 Maintenance

6. Fix the lifting eyes to the support beam. Attach lifting gear, appropriate for the
weight of the impeller, to the lifting eyes. Lift off the support beam and the
impeller attached to it.

4ͲM6X16 
Bracket
combi screw

7. Remove the hex-head screws which attach the support beam to the impeller.

NOTICE
Type and quantity of the hex-head screws depend on the impeller model.

8. Disconnect the power cable from the connector on the support beam.

M10X25 combi screw



9. Mount the new impeller to the support beam.

10. Connect the wires of the fan motor cable to the terminal block according to the
electrical drawings.
11. Proceed in reverse order as previously described to reinstall the impeller with the
support beam.
12. Check by hand for proper fan rotation before energizing the drive.
 Maintenance 125

13. When the work is completed the drive can be started up again. See section
Energizing and starting the drive in chapter Operation.
14. Check visually the direction of fan rotation when starting the drive. The correct
rotation direction please refer to arrow direction posted on fan box.
* Depends on site situation, ACS580MV fan box can be mounted backward, the
screw positions are compatible between fan box and cabinet top plate. The
procedure can refer to instruction above. For details of the AC fan box outline
information, see ACS580MV Air duct interface Outline Drawing of AC Fan Box.

 Required tools and equipment

• Screwdriver for M6 and M10 screw
• Lifting eye: M8, 2 pieces

2x

The fans can be lifted by crane or by hand.

126 Maintenance

Replacing roof EC fans*

 Procedure
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off the motor starter of the fan unit to isolate the fan unit from the
auxiliary power supply. To identify the motor starter, see ACS580MV Wiring
Diagram.
3. Remove the hex-head combination screws that attach the top cover to the fan
box. Lift the top cover and pull it away from the fan box.

M6X12 combi screw



4. Disconnect the control and power supply cables of the fan.

5. Remove the fastening screws from the support plate and the duct ring.
 Maintenance 127

6. Using the lifting eyes in the fan housing cover and a lifting gear, lift off the
support plate with the fan attached to it.

6ͲM6X16combi screw

Bracket 

7. Unscrew the support plate from the fan.

NOTICE
Type and quantity of the hex-head screws depend on the impeller model.

M8/10X25 
128 Maintenance

8. Replace the fan and re-assemble in reverse order of removal.

* depends on site situation, ACS580MV fan box can be mounted backward, the screw
positions are compatible between fan box and cabinet top plate. The procedure can
refer to instruction above. For details of the EC fan box outline see ACS580MV Air
duct interface Outline Drawing of EC Fan Box.
 Maintenance 129

Replacing the power modules

WARNING! Obey the instructions in chapter Safety instructions. If you ignore

them, injury or death, or damage to the equipment can occur.

 Required manpower and tools

Two persons are required for replacing a power module.
The following tools are needed:
• Screwdrivers: M6, M8, M10, M12
• Torque wrench with extension bar

 Replacement of a power module frame size R1 - R3

The replacement procedure is basically the same for power modules of R1-R3. The
main difference is the weight of the module types. Replacement power modules
must always be of the same type.
130 Maintenance

Dismounting
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Disconnect the fiber optic links from the power module.
5. Loosen and detach the three power cables and the two busbars behind the
cables.

3 2
4

1 Busbar connections
2 Power cable terminals
3 Fixation screws
4 Terminals for fiber optic cables

6. Loosen and detach the one fixation screws in the front of power module.
 Maintenance 131

7. Slide out the power module by hand

• Weight of power
module: max.
12 kg.

Obey local
regulations when
lifting the power
modules.

Mounting
1. Install the new module in reverse order of removal.
2. Switch on all miniature circuit breakers in the control compartment.
3. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

Converter module testing and repair

Testing and repair of a defective power module is done at ABB works. Send the
module in for repair.

Replacing the power module fuse R1 - R3

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Loosen the 2 mounting screws of the fuse to be replaced.
5. Pull out the fuse.
6. Install the replacement fuse in reverse order of removal.
7. Reinstall the power module in reverse order of removal.
8. Switch on all miniature circuit breakers in the control compartment.
9. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.
132 Maintenance

Replacing power module fuse on a module of frame size R1 - R3

 Replacement of a power module frame size R4 - R6

The replacement procedure is basically the same for power modules of frame size
R1-R3. The main difference is the weight of the module types. Replacement power
modules must always be of the same type.
 Maintenance 133

Dismounting
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Disconnect the fiber optic links from the power module.
5. Loosen and detach the three power cables and the two busbars behind the
cables.

2
4
3 3

1 Busbar connections
2 Power cable terminals
3 Fixation screws
4 Terminals for fiber optic cables

6. Loosen and detach the two fixation screws in the front of power module.
7. Slide out the power module by hand
134 Maintenance

• Weight of power
module: max.
21 kg.

Obey local
regulations when
lifting the power
modules.

Mounting
1. Install the new module in reverse order of removal.
2. Switch on all miniature circuit breakers in the control compartment.
3. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

Converter module testing and repair

Testing and repair of a defective power module is done at ABB works. Send the
module in for repair.
 Maintenance 135

Replacing the power module fuse R4 - R6

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Loosen the 2 mounting screws of the fuse to be replaced.
5. Pull out the fuse.
6. Install the replacement fuse in reverse order of removal.
7. Reinstall the power module in reverse order of removal.
8. Switch on all miniature circuit breakers in the control compartment.
9. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

Replacing power module fuse on a module of frame size R4 - R6

136 Maintenance

 Replacement of a power module frame size R7 - R9

The replacement procedure is basically as for power module of frame size R4-R6.
The main difference is the weight of the module types. Replacement power modules
must
always be of the same type.
Tools and accessories

1 Hoisting gear
2 Hoist
3 Lifting belt

Dismounting
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Attach the hoist to the front base beam of the cabinet.
 Maintenance 137

1 Hoist
2 screw M8X20

5. Disconnect the fiber optic links from the power module.

138 Maintenance

6. Loosen and detach the three power cables and the two busbars in front of the power
module.

4
1

1 Busbar connections
2 Power cable terminals
3 Fixation screws
4 Terminals for fiber optic cables

7. Loosen and detach the three fixation screws (M6X16) that attach the power
module to the front lock.
8. Slide out the power module by hand until stopped by the front lock.

9. Lift the blocking bar of the front lock and pull out the power module until the front
lock
 Maintenance 139

stops it again.

10. Connect the second lifting belts to the lifting eyes provided on the power
module.
140 Maintenance

11. Lift again the blocking bar of the front lock, pull the power module completely out
of the support module beam and lower it.
 Maintenance 141

WARNING! Weight of power module: max. 65 kg. Obey local regulations when
lifting the power modules.

Mounting
1. Loosen and detach the two combination screws (M6X16) from the front lifting bar
that attach the power module to be replaced.
142 Maintenance

2. fix the adapt plate to the new power module with two combination screws
(M6X16), but don’t fix tightly.

1
2

1 Busbar connections
2 Power cable terminals
3 Fixation screws
4 Terminals for fiber optic cables

3. Install the new module in reverse order of removal.

 Maintenance 143

4. Adjust the metal plate to alien the middle three holes with lock holes, fix the
connection with five combination screws (M6X16).

5. Switch on all miniature circuit breakers in the control compartment.

6. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive
144 Maintenance

Replacing the power module fuse R7 - R9

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Ground the power modules according to Grounding power module enclosure and
busbar with grounding hook on page 112.
4. Loosen the 2 mounting screws of the fuse to be replaced.
5. Pull out the fuse.
6. Install the replacement fuse in reverse order of removal.
7. Reinstall the power module in reverse order of removal.
8. Switch on all miniature circuit breakers in the control compartment.
9. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

Replacing power module fuse on a module of frame size R7 – R9

Replacing the control panel battery

The battery is housed on the rear of the control panel. Replace with a new battery.
Dispose the old battery according to local disposal rules or applicable laws.
For details refer to the ACS-AP-X assistant control panels user’s manual.
 Maintenance 145

Circuit board replacements

NOTICE
Electrostatic discharge (ESD) can damage electronic boards and components.
Do not touch printed circuit boards or other sensitive components without
applying static-sensitive handling precautions!
Do not touch the components without wearing ESD protection device.
Put the board or component on a grounded working surface protected against
electrostatic discharges.
Hold a board only at the edge.
Handle a faulty board as carefully as a new one.

NOTICE
Any electrical board replacement must be done after power is off. Only qualified
electricians are allowed to carry out electrical parts replacement.

 Control unit (BCU) and memory unit (ZMU)

To locate the BCU see figure Control compartment with open swing frame on page 36.
Procedure:
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Unplug all connectors on the BCU.
4. Loosen the end brackets of BCU.
146 Maintenance

5. Keep the top of the BCU (looking to the back in cabinet) in place and twist the
bottom (looking towards you) to pull it out of the mounting rail.

View from bottom of cabinet

When a BCU is replaced, the parameter settings can be retained by transferring the
memory unit (ZMU) from the defective BCU to the new BCU. The ZMU is located on
the control unit, see B in figure Replacement of BCU components below.

NOTICE
In case of a defective ZMU, the drive needs to be re-parametrized. Please contact
ABB service.
 Maintenance 147

6. Remove the ZMU: undo the fastening screw and pull out the memory unit.

1 Real-time clock battery

2 Fastening screws for ZMU

3 Fastening screw for SD card

4 Indication LEDs

Replacement of BCU components

7. Insert the new ZMU and fasten the screw.
8. Install the new BCU in reverse order of removal.
9. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.
After power-up, the BCU scans the memory unit. If a different control program or
different parameter settings are detected, they are copied to the BCU. This can
take several minutes.
10. Contact ABB service as soon as possible to obtain a new license before the trial
mode expires.

NOTICE
After a BCU or memory replacement, the license might not match the new hardware.
The drive can be operated with full functionality in trial mode for 30 days. If the drive is
not relicensed within this period, it will stop working after the trial period is over.
148 Maintenance

 Replacing the SD memory card

The SD card is used to record fault information for analysis. It can be removed while
the drive is running. Please note that if the SW version is lower than MHDRE 3.12.0.5,
there is a low probability that drive reports fault while inserting SD card back to the
slot. The fault can be reset by rebooting BCON.
SD/SDHC flash memory type: maximum supported size 4 GB, CLASS 4, 6, 10.
To replace the SD memory card:
1. Check the SW version and make sure it is MHDRE 3.12.0.5 or higher.
2. Check that the yellow LED is off (see D in the Replacement of BCU components
figure above).
Do not remove the SD card while the yellow LED is lit, which indicates that
writing to the SD card is in progress.
3. Undo the fastening screw of the clip covering the memory card and press the
card to remove it. For the card location, see C in the figure Replacement of BCU
components above.
4. Insert the new card in reverse order.

 Replacing the real-time clock battery

The real-time clock battery must be replaced if the “BATT” LED is not illuminated
when the control unit is powered (see D in the Replacement of BCU components figure
Replacement of BCU components above).
Real-time clock battery type: BR2032:
• Temperature range -30...+80 °C (-22...176 °F)
• Voltage 3 V
• Nominal capacity approx. 200 mAh
• To be replaced every 5 years
Procedure:
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Undo the fastening screw and remove the battery (see A in figure Replacement of
BCU components above).
4. Insert the new battery according to the figure Replacement of BCU components.
5. Set the real-time clock.
6. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.
7. Dispose the old battery according to local disposal rules and applicable laws.

 High voltage divider board

To locate the high voltage divider board, see figure Terminal compartment with cover
plate removed on page 29.
Procedure:
 Maintenance 149

1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Loosen the cable connection at the board to be removed.
4. Hold the divider board and remove the two fixation screws.
5. Install the replacement divider board in reverse order of removal.
6. When the work is completed, the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

 CVMI2 board
To locate the CVMI2 board, see figure Control compartment with swing frame closed on
page 37.
Procedure:
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Unplug the fiber optic link (A1, A8), the power supply connector (X201) and the
signal connectors (X203, X204, X205, X206, X207,).
4. Loosen the 4 fixation screws and remove the board.
5. Install new CVMI2 board reconnect in reverse order of removal.
6. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.
150 Maintenance

 Control hub
To locate the control hub see figure Inverter unit (drive type 11R6) on page 31.
Procedure:
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Unplug all fiber optic links on the daughter boards and fiber optic links Y1,Y2,
power supply connector (X1), signal connectors (X2) and the pressure tube.
4. Hold the control hub, loosen the 8 fixing screws on the mounting plate and
remove the module.

5. Install the new control hub in reverse order.

6. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

 Control hub daughter board

The control hub daughter boards are mounted in slots on the control hub board.
1. Stop, de-energize and ground the drive following the steps in section Shutting
down the drive for maintenance before you start the work.
2. Switch off all miniature circuit breakers in the control compartment.
3. Unplug all fiber optic links on daughter boards.
4. Loosen the screws of the retainer and remove it.
 Maintenance 151

5. Pick the daughter board to be replaced and withdraw.

6. Install the new daughter board in reverse order.
7. When the work is completed the drive can be started up again. See Chapter
Operation, Energizing and starting the drive.

Maintenance schedule
The recommended intervals for maintenance and component replacement are based
on the normal operating conditions of the drive. The drive should be checked at least
every two years by qualified personnel whose recommendations should be followed.
Depending on the actual condition of the drive, the maintenance work can be carried
out before or after the recommended interval.
For detailed inspect and replacement time interval, see ACS580MV Preventive
Maintenance Schedule.

Drive seasonal operation

This chapter contains instruction for drive special preventive maintenance when
drives standby more than 2 months. The objective is to avoid malfunction or damage
components when the drives restart up after a long time storage, further to improve
operating efficiency and extending the life of the drives. The example practice is
heating application which drives only operate in winter days.
 Shutting down the drive for maintenance

See chapter Maintenance, shutting down for maintenance for instructions. Follow
the established shutdown procedure by using local operator panel of the drive.

 Maintain the drive for preservation

During standby, it is important to make the drive protected from harsh ambient
conditons of dust, temperature and himidity. Keep the temperature in E-house be
relative stable in the range of 0°C to 50°C, and relative humidity be lower than 70%.
Recommended maintenance soultions.
• Prefered solution: put silica gel bags (type of desiccant) inside the cabinets.
Silica gel bags should not be in direct contact with metal parts because they can
cause corrosion after saturation. The required bag quantity can be calculated
based on protection capacity and cabinet dimension. Close all the doors and
cover the drive with plastic film and seal it by tape as tight as possble. That will
provide protection against dust, salty air or pest during storage.
ABB offered desiccant is 3ABD00005991 (500g/bag). Refer to the minimum
desiccant quantity based on door width.
Distribution Minimum desiccant quantity
1xDoor width 600mm 1x500g
2xDoor width: 800mm 3x500g
• Alternative solution: cover and seal cabinet inlet/outlet and fan box with plastic
or waterproof clothes. That will alleviate the impact from dust, salty air or pest
during storage.
152 Maintenance

 Maintain the drive before restarting up

The maintenance actions can be done by end users to to avoid potential malfuction
or damage components when drive restarting up. Following the chapter of
Mainteance schedule (Years from start-up) to do the recommended maintenance
and component replacement. It is mandatory to complete the checklist before
restarting up can take place.
Visual inspection and take maintenance actions if need
1 No dust in E-house

2 Cleaning heatsinks with an ESD vacuum cleaner. It is prohibted to replace PEBBs or open
PEBBs. If really needed, contact ABB.
3 Air inlet and outlet are clean

4 All air filter mats are clean. Otherwise, replace with new ones from ABB. It is prohibited to wash
the filter mats because the tissue structure will be destroyed
5 No dust and corrosion in cabinet

6 No tools and foreign objects are left inside the cabinets. Don’t forget move out the desiccants
in the cabinets.
7 No condensing in cabinet
Cable and connector
1 Fully inspect tighteness of terminals, connectors connection and visual damage of cables.
All power cables to drive, and from drive to motor are meggered, and measured values are within
2
the required limits.
Spare parts
1 Sufficient number and correct type of spare parts available.
For power modules, need to check their age. If stock age is more than 1year, the DC capacitors
2
need to be reformed later.
Power supply
1 All auxiliary power supplies from external sources are switched on.
2 All internal circuit breakers of the drive are closed.
3 All grounding devices are removed.
4 All covers are mounted and the doors are closed, locked and / or bolted.
5 There is no run interlock active.
6 MCB is in operating position.

 Start the drive following chapter of “Operation”

Attention:
• It is not allowed to start the drive if there is any condensing in drives. Make sure
to heat and remove the condense and moisture in drives before drives are ready
to SUPPLY ON.
• Reform DC-link capacitors in Power modules and spare power modules If the
stock age more than 1 year following section Reforming capacitor of power
modules.
ABB provide standard drive startup service package. 400-810-8885
 Technical data 153

13
Technical data

For the technical specifications of the drive, e.g. ratings sizes and technical
requirements see the following documents:
For technical data, drive types and options refer to ACS580MV Catalog.
For mechanical layout, dimensions and required free space see ACS580MV Base
frame & TEU layout design.
For motor and cable selection and for the technical requirements for the protection
and control of the medium voltage supply refer to ACS580MV Engineering Guideline.
The list of available general documents is provided in List of related manuals on the
inside of the front cover of this manual.
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to abb.com/searchchannels.

Product training
For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Navigate to 
new.abb.com/drives/manuals-feedback-form.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at
abb.com/drives/documents.
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2UBB004520 Rev L (EN) 2025-01-20

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