ABBMEGADRIVE-LCI water-cooled User manual

LEGAL DISCLAIMER

This document contains information about one or more ABB products and may include a description of or a reference to one 

or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to 

a standard is not a representation that all of the ABB products referenced in this document include all the features of the 

described or referenced standard. In order to determine the specific features included in a particular ABB product, the 

product specifications for the particular ABB product apply.

The buyer acknowledges the proprietary and confidential nature of the information contained in this document and agrees 

that all rights to and concerning the information contained in this document remain vested in ABB, in particular with regard 

to any intellectual property rights. Nothing contained herein shall oblige ABB to furnish any particular information to the 

buyer.

The information in this document is subject to change without notice and should not be construed as a binding declaration 

of ABB. ABB assumes no responsibility for any errors or omissions in this document.

Products described or referenced in this document are designed to be connected with networks and provide information and 

data through network interfaces. The products must be connected to a secure network. It is the sole responsibility of the 

buyer of the products to provide and continuously ensure a secure connection between the product and the system network 

and/or any other networks that may be connected to the product. ABB is in no event liable for the security of the network used 

by buyer.

The buyer of the product must establish and maintain appropriate measures, including, but not limited to, the installation of 

firewalls, application of authentication measures, encryption of data, installation of antivirus programs, and so on, to protect 

these products, the network, its system, and interfaces against security breaches, unauthorized access, interference, 

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buyer of the product to ensure that any product updates or other major system updates (to include but not limited to code 

changes, configuration file changes, third-party software updates or patches, hardware change out, and so on) are 

compatible with the security measures implemented. The buyer of the product must verify that the system and associated 

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In no event shall ABB be liable for any damages inclusive but not limited to indirect, special, incidental or consequential 

damages of any nature or kind whatsoever arising from the use of this document, nor shall ABB be liable for any damages 

inclusive but not limited to indirect, special, incidental or consequential damages arising from the use of any software or 

hardware described in this document.

This document and parts thereof must be kept strictly confidential and must not be reproduced or copied without the prior 

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for any unauthorized purpose.

The software or hardware described in this document may be furnished under a license and may be used, copied, or disclosed 

only in accordance with the terms of such license.

—

TRADEMARKS

ABB is a registered trademark of ASEA BROWN BOVERI LTD. 

All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.

Copyright © 2025 ABB.

All rights reserved.

1. About this manual

1.1. Equipment covered by this 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 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 (eg, layout drawings, wiring diagrams, technical data, 

engineering notes).

If information is required beyond the instructions in this manual, refer the matter to ABB.

1.2. Terms and abbreviations

The following table lists terms and abbreviations you should be familiar with when using this user 

manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might 

differ from the normal usage.

Table 1 – Terms and abbreviations

1.3. Structure of the user documentation

The documentation for a standard drive consists of this document and the following project-specific 

appendices.

NOTE – These appendices are NOT included in this document.

– Appendix A - Technical data contains the technical data sheets of the drive.

– Appendix B - Mechanical drawings provides the outline drawings of the drive. The drawings 

are generated according to the customer-specific project.

– Appendix C - Electrical drawings including parts list contains the circuit diagrams with 

information on device identification, cross-reference and device identification conventions. The 

diagrams are generated according to the customer-specific project. “Setting of protective 

devices” is generated according to the customer-specific project. The parts list is produced for 

each project and contains all information to identify a component.

– Appendix D - Signal and parameter table includes descriptions of actual signals, control and 

status words, and control parameters and their default settings.

– Appendix F - Test reports and certificates provides the test reports of the drive. Quality 

certificates, and codes and standards the drive complies with are added if necessary for the 

project.

– Appendix G - Additional manuals / options provides manuals about additional equipment 

delivered with the drive (such as project-specific options like pulse encoder or fieldbus 

interfaces), or information on modifications of the standard drive.

– Appendix H - Water-cooling unit includes raw-water specification and water cooling unit user 

manual

1.4. Related documents

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

PE Protective Earth

PPE Personal Protective Equipment

1.4.1. Service documents

Title ABB ID

MEGADRIVE-LCI preventive maintenance schedule 3BHS855047 E01

Ethernet - NETA-21 remote monitoring tool user manual 3AUA0000096939

1.4.2. Specifications and guidelines

Title ABB ID

Auxiliary power and control cables guideline 3BHS813742 E01

1.5. 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 equipment. The personnel must carry out the below listed tasks 

in a manner that does not cause physical harm or danger, and to ensure the safe and reliable 

functioning of the drive.

IMPORTANT! Commissioning of drive equipment must only be performed by qualified and certified 

personnel.

1.5.1. Handling

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

1.5.2. Mechanical installation

The personnel must be qualified to prepare the installation site according to the site and equipment 

requirements and to perform the installation accordingly.

1.5.3. 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.

1.5.4. Operation

The personnel include all persons who operate the equipment 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.

1.5.5. Maintenance

The personnel include all persons who:

– Are qualified to carry out preventive and corrective maintenance on the 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

1.6. Intended use of the equipment

Those in charge of the drive must ensure that the equipment 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.

1.7. Cyber security features

The following sections describe the cyber security features of the drive.

1.7.1. Software security

The cyber security robustness of the drive is achieved with technical solutions (security features on 

the component level) as well as using the following best practices when you integrate the drive into 

your system and when you interact with the drive:

– Isolate drive control network (172.16.0.0) from other networks.

– Restrict drive connections to the interfaces in Table 2.

– Scan USB flash drives for viruses/malware before you connect them to the LCT.

– Route Ethernet-based bus communication (if existing) for the plant control system through a 

protected control network infrastructure that is isolated from the Internet.

– Follow the remote access gateway setup recommendations to establish a network connection 

to the ABB Ability platform.

– Restrict physical access to the drive and control network access to authorized personnel.

– Only allow control network access for drive servicing by qualified personnel.

1.7.2. PEC controller security features

The PEC controller software fulfills the minimum cyber-security requirements by using security 

features of AC 800PEC platform. The following Ethernet ports are open by default to ensure that the 

system operates properly

Table 3 – Open Ethernet ports for PEC controller software

Port Service Usage

22/tcp ssh/sftp Secure communication with AC 800PEC controller

(used by AC 800PEC Tool, LCT, Shell Terminal)

8080 / tcp http-proxy, 

gSOAP soap2.8

SOAP communication with AC 800PEC controller

8081 / tcp blackice-icecap, 

gSOAP soap2.8

SOAP communication with AC 800PEC controller

102 / tcp mms/IEC61850 MMS Server (only running with Industrial IT), IEC61850

123 / udp ntp Network Time Protocol: Synchronize computer clock times in a network 

of computers.

5002 / udp rfe/PEC Scanner For scanning controller over network (used by AC 800PEC Tool)

The AC 800PEC controller is also equipped with a serial port that provides a root shell for a user to 

directly change a password. This port must be secured and only made accessible to authorized 

persons.

IMPORTANT! Connecting the serial port to a remote terminal server to gain access the serial port 

remotely can create security risks. Exposure of the Ethernet ports, serial port or controller password 

to unauthorized persons can create significant security risk.

1.7.3. Control terminal (LCT) security features

The LCT Ethernet interface (AC 800PEC) is used for the internal exchange of drive data. 

The main security features of the LCT are:

– System files are write-protected

A few storage locations for user data and settings do not have write protection. 

– LCT regularly reboots from write-protected system storage to restore the original state and 

configuration of the LCT operating system 

– Unused ports (Ethernet and others) are disabled or blocked.

Ports and services that are required by the system are left open and are described in Table 4.

. Quality certificates and applicable standards

The following certificates and conformity declarations are available with ABB:

– ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and 

maintains a management system that fulfills the requirements of the normative standards

Table 8 – Standards

Standard Title

ANSI Z535.6 American national standard for product safety information in product manuals, instructions, and 

other collateral materials

ISO 3864-2 2004 (E) - Graphical symbols – Safety colors and safety signs – Part 2: Design principles for product 

safety labels

ISO 7010 2011 (E) - Graphical symbols - Safety colours and safety signs - Registered safety sign

EN 50110 European standard code for electrical work safety

ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design, 

section 6.2.6 Category 3

IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements

IEC 60721-3-1 Classification of environmental conditions - Part 3-1: Classification of groups of environmental 

parameters and their severities - Storage

IEC 60721-3-2 Classification of environmental conditions - Part 3-2: Classification of groups of environmental 

parameters and their severities - Transportation and Handling

IEC 60721-3-3 Classification of environmental conditions - Part 3: Classification of groups of environmental 

parameters and their severities - Section 3: Stationary use at weather-protected locations

IEC 62477-2 Safety requirements for power electronic converter systems and equipment - Part 2: Power electronic 

converters from 1 000 V AC or 1 500 V DC up to 36 kV AC or 54 kV DC

2.3. Electrical safety

The following electrical safety instructions are based on EN 50110.

2.3.1. General safety instructions

1) Minimize hazards

2) Before energizing the drive:

• Remove all foreign objects are from the drive

• Fasten all internal and external covers securely

• Close, lock, and/or bolt all doors

• Move the release dial of the door safety switches into the locked position

3) Before working on the drive:

• Turn off, lock out, and tag out the main and auxiliary power supplies to the drive 

• De-energize the drive

• Ensure that the safety ground connections are in place

• Ensure that the appropriate personal protective equipment (PPE) is available and used when 

required

• Inform the involved personnel about the potential safety hazards

• Wear hearing protection when a drive is running.

4) Before working simultaneously on the drive and on other drive system equipment:

• Observe the relevant safety codes and standards

• Turn off all energy sources for the equipment

• Ensure that all lockout and tagout devices are in place

• Install barriers around and use appropriate covers on the equipment that is still energized

• Inform the involved personnel about the potential safety hazards

5) In case of fire in the drive room:

• Observe the established rules and regulations for fire safety

• Only allow firefighters with the appropriate PPE to enter the drive room

2.3.2. The 7 steps that save lives

ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing 

work on or near electrical installations.

1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the 

limits of approach for shock and arc-flash.

• Be in possession of a clear work order to execute the work.

• When required, the access or work permit is to be obtained by a person who is authorized for 

the specific electrical system.

• Engage the person responsible for electrical equipment or system to review single-line 

diagrams, schematics, switching plans, etc.

• Ensure the competence of workers.

• Check for proper tools for the job.

• Determine and select the proper arc-rated Personal Protective Equipment (PPE).

• Decide of the appropriate work methods and initiate the Permit To Work (PTW) process.

2) Clearly identify the work location and equipment.

• Use your senses (sight, hearing and smell) to identify problem areas.

• Define the work area via barriers and barricading and label equipment.

• Avoid distractions such as talking or texting on the phone.

3) Disconnect all sources of supply and secure against reconnection by applying 

Lockout/Tagout.

• If ABB is responsible for switching and it cannot be done remotely, then the person 

performing the switching must be properly trained and wearing the proper PPE identified in 

step 1.

• The Person in Charge of Work (PICW) must ensure that switching is performed in the proper 

manner by witnessing it from a safe distance if present on site or by engaging the person 

responsible for switching to identify all isolation points.

• Apply Lockout/Tagout (LOTO) to the energy isolation device and if multiple energy isolation 

devices are involved, then Group LOTO must be implemented with the PICW serving as the 

Group LOTO Leader.

4) Verify the absence of operating voltage: always test before you touch!

Only use properly rated and inspected voltage detection devices and wear proper PPE identified 

in step 1:

• Test voltage detection device

• Test for voltage

• Test voltage detection device

It is highly important that the voltage detection device is tested on a known voltage source such 

as a Proving Unit or by performing an internal self-test, according to the manufacturer’s 

instructions, before and after testing for the absence of operating voltage.

5) Carry out earthing and short-circuiting.

• Close and lock the earthing switch if the electrical equipment is designed for this purpose or 

apply portable equipment for earthing and short-circuiting.

If this is carried out by the customer, then the PICW must ensure that this equipment is properly 

earthed as a part of the integration/verification and during step 7 when the PICW walks the 

PTW.

6) Protect against adjacent live parts and take special precautions when close to bare 

conductors.

• Determine minimum approach distances, apply screening or shrouding, and when 

applicable, padlock both cable and busbar shutters.

• If working within the restricted approach boundary or vicinity zone where inadvertent 

movement could cause contact with live parts, special precautions must be employed, such 

as the use of the properly rated insulated gloves and tools.

7) Complete the permit to work and “Walk the Permit”.

• Check isolation points

• Verify that all circuits are isolated and secured

• Ensure all parties are integrated with the Lockout/Tagout

• Check the earths are properly applied

• Answer specific questions from the working group

• Ensure the work can proceed without danger

• Complete and verify the “Permit to Work