ABB ACS1000i air-cooled User manual

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MED I UM VO LTAGE AC DR IV E S
ACS1000i air-cooled
User manual

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ACS1000i air-cooled
The flexibility you require.
The reliability you expect.
Document name
ACS1000i air-cooled user manual
Document owner
ABB Switzerland Ltd.
Medium voltage AC drives
Document number
3BHS206977 E01 Rev H
Number of pages
174
Release date
2020-03-18
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new.abb.com/drives/medium-voltage-ac-drives

Contents
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ACS1000i air-cooled
User manual

01 About this manual 5
02 Important safety information 17
03 Power electronics and cabinet features 29
04 Control system 57
05 Transportation, storage and disposal 71
06 Mechanical installation 79
07 Electrical installation 89
08 Commissioning 105
09 Operation 111
10 CDP control panel 125
11 Preventive and corrective maintenance 149

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01
About this manual 01
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5 - 16

1.1 Copyright notice 7
1.2 Equipment covered by this manual 7
1.3 Structure of the user documentation 7
1.4 Terms and abbreviations 8
1.5 Trademarks 9
1.6 Related documentation 9
1.7 Target groups and required qualification 10
1.7.1 Handling 11
1.7.2 Mechanical installation 11
1.7.3 Electrical installation 11
1.7.4 Operation 11
1.7.5 Maintenance 11
1.8 User’s responsibilities 11
1.9 Intended use of equipment 12
1.10 Cyber security disclaimer 12
1.11 Quality certificates and applicable standards 13
1.12 Items covered by delivery 14
1.13 Identifying the delivery 15

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1.1 Copyright notice
The information in this manual is subject to change without notice.
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 Switzerland Ltd.,
Medium Voltage Drives.
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.
1.2 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.
1.3 Structure of the user documentation
The complete set of user documentation of a standard drive consists of this manual and
supplementary documentation that is provided in the following appendices:
- Appendix A - Additional manuals
Appendix A provides manuals about additional equipment delivered with the drive (such as
project-specific options such as pulse encoder or fieldbus interfaces), or information on
modifications of the standard drive.
- Appendix B - Technical data
Appendix B contains the technical data sheets of the drive.
- Appendix C - Mechanical drawings
Appendix C provides the outline drawings of the drive. The drawings are generated
according to the customer-specific project.
- Appendix D - Wiring diagrams
• Appendix D 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.
- Appendix E - Parts list
The parts list is produced for each project and contains all information to
identify a component.
- Appendix F - Test reports and certificates
Appendix F provides the test reports of the drive. Quality certificates, and codes and
standards the drive complies with are added if necessary for the project.

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- Appendix G - Signal and parameter table
The Signal and parameter table includes descriptions of actual signals, control and status
words, and control parameters and their default settings.
1.4 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.
Term/Abbreviation Definition
AMC circuit board Application and Motor Controller
The digital signal processor is the heart of the control system of the drive.
Cluster A cluster is a synonym for a group of hardware modules of the drive
control system.
DDCS Distributed drive control system
DDCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers.
Drive Short form for ACS1000i drive
Drive system The drive system includes all equipment used to convert electrical into
mechanical power to give motion to the machine.
DriveBus Communication link dedicated for ABB drives
DriveDebug DriveDebug is part of ABB’s DriveWare® software tools for drives using the
DDCS communications protocol. DriveDebug runs on computers with
Windows® operating systems. DriveDebug is a specialist’s tool used to
diagnose, tune and troubleshoot ABB drives.
DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows®
application for commissioning and maintaining ABB drives equipped with
optical communication links.
Equipment Frequency converter and related equipment
EMC Electromagnetic compatibility
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.
Ground Earth
To ground The conducting path (eg, conductor) between the electric equipment (eg,
frequency converter) and the earth. The electric equipment is connected to the
earth, eg, by a grounding set or a grounding switch.
INU Inverter unit of the drive. The INU converts the DC voltage to the required AC
motor voltage and frequency.
IOEC module The IOEC module is an active input and output device for digital and
analog signals.
Line voltage RMS voltage of the main power supply of the drive
MCB Main circuit breaker
The MCB is a major protection device of the drive and is the main connection
and disconnection point between the main power supply and the drive.
Molykote Brand name for lubricants
PCB Printed circuit board

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1.5 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 offense of the legal status of any trademark. The following registrations and
trademarks are used in this manual:
1.6 Related documentation
Table 1-1: Maintenance
PCC 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 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
PPCS Power plate communication system
PPCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers between AMC circuit board and INTerface circuit
boards.
RTD Resistance temperature detector or device
The RTD is a temperature sensor where the change in electrical resistance is
used to measure the temperature.
Safeline ABB synonym for uninterruptable power supply
Supervisory signal Indicates the operating condition of a circuit or device.
SW Software
TC Short form for terminal compartment of the drive
UPS Uninterruptible power supply
Zero speed threshold Used in the manual to indicate that the drive has reached the value “zero speed”
that is set in a parameter. The value can be set in the range of 0 and maximum
speed (the unit for the speed is rpm).
Term/Abbreviation Definition
Trademark Definition
Windows® Registered trademark of Microsoft Corporation
Industrial IT™ Trademark of ABB
DriveWare® Registered trademark of ABB
Ethernet® Registered trademark of Xerox Corporation
Profibus® Registered trademark of Profibus International (P.I.)
Modbus® Registered trademark of the Modbus IDA organization
Molykote® Registered trademark of Molykote
Reference
number
Document Document number
[1] ACS1000 preventive maintenance schedule 3BHS855276

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Table 1-2: Technical data
Table 1-3: Schematics
Table 1-4: Specifications and guidelines
Table 1-5: Serial communication interfaces
Table 1-6: Encoder
1.7 Target groups and required qualification
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 should handle, install, operate, or maintain the drive.
Reference
number
Document Document number
[2] Technical data from DriveSmart(1) (configuration software for medium
voltage drives)
(1) Configuration software for medium voltage drives
Reference
number
Document Document number
[3] Layout drawing Project-specific
Reference
number
Document Document number
[4] Retrofit guideline 3BHS301179 E01
[5] Input circuit breaker engineering guideline 3BHS104785 E01
[6] Induction motor specification 3BHS260163 E01
[7] Power cable specification 3BHS189994 E01
[8] Power cables engineering guideline 3BHS542290 E01
[9] Auxiliary power and control cables guideline 3BHS813742 E01
[10] Mechanical interlock 3BHS261596 E01
[11] Transformer protection relay settings application settings 3BHS217968 E01
Reference
number
Document Document number
[12] Ethernet - NETA-21 remote monitoring tool user manual 3AUA0000096939
[13] Modbus - NMBA-01 installation and start-up guide 3AFY58919772
[14] Profibus - NPBA-12 installation and start-up guide 3BFE64341588
[15] DeviceNet - NDNA-02 installation and start-up guide 3AFY58919829
Reference
number
Document Document number
[16] Installation and Start-up Guide for the Pulse Encoder Module NTAC-0x 3AFY58919730

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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 ensures the safe and
reliable functioning of the drive.
1.7.1 Handling
The personnel must be skilled and experienced in unpacking and transporting
heavy equipment.
1.7.2 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.
1.7.3 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.
1.7.4 Operation
The personnel include all persons who operate the drive from the local operator panel of the
drive. The personnel must know the functions of the operator panel, be adequately trained for
the drive, and know the driven process. Special knowledge of frequency converter technology
is not required.
1.7.5 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 and
act correspondingly
- Know the safe shutdown and grounding procedures for the drive system
1.8 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.
Commissioning of the drive must only be performed by qualified and certified
ABB personnel.

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1.9 Intended use of equipment
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 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.
1.10 Cyber security disclaimer
This product is designed to be connected to and to communicate information and
data via a network interface. It is the 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.

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1.11 Quality certificates and applicable standards
The following certificates and conformity declarations are available with ABB:
- ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and
maintains a management system which fulfills the requirements of the
normative standards
- EC declaration of conformity
- List of standards the drive complies with
Table 1-7: Standards
Reference
number
Title
[17] ANSI Z535.6 American national standard for product safety information in product manuals,
instructions, and other collateral materials
[18] ISO 3864-2:2004 (E) - Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
[19] ISO 7010:2011 (E) - Graphical symbols - Safety colours and safety signs - Registered safety sign
[20] EN 50110 European standard code for electrical work safety
[21] ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design, section 6.2.6 Category 3
[22] IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
[23] IEC 60721-3-1 Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage
[24] IEC 60721-3-2 Classification of environmental conditions - Part 3-2: Classification of groups of
environmental parameters and their severities - Transportation and Handling
[25] 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 location
[26] 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

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1.12 Items covered by delivery
Delivery typically comprises the following items:
- Drive that is shipped in sea freight or airfreight packaging.
- Optional components and cabinets
- Set of door keys attached to lifting rail (1 in Fig. 1-1)
- Set of door keys inside the drive
- Rating label (2 in Fig. 1-1)
- Box with USB stick (3 in Fig. 1-1), which contains the user manual and related documents.
- Strain relief rails
- Air exhaust hood
- Redundant fan unit (option)
- Set of bolts, nuts and washers
Figure 1-1: Delivered items
Note: For a complete list of the items in the delivery, see the shipping note.
(1) Drive: shipped in sea freight or air freight
packaging
(2) Cable entry box
(3) Fans: shipped in a separate container.
The number of fans depends on the cooling
configuration ordered.
(4) Input disconnector lever: only supplied if drive is
equipped with an integrated input disconnector
(5) Rating plate
(6) Door keys
(7) Box with USB stick: Contains the user manual and
related documents.
1
233
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5
6
7

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1.13 Identifying the delivery
The drive and accessories are identified by the type code printed on the rating label.
The label provides information on the type of drive, the rated voltage, the frequency and the
current of the main and the auxiliary power supply.

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02
Important safety
information 02
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17 - 28

2.1 Overview 19
2.1.1 Safety standards 19
2.2 Safety messages 19
2.3 Damage prevention information 19
2.4 Product safety labels 20
2.5 General safety instructions 21
2.6 The 7 steps that save lives 22
2.7 Possible residual risks 24
2.8 Important note - main circuit breaker 25
2.8.1 Safety and protection requirements 26
2.8.2 Minimum requirements for MCB and MCB
control 26
2.8.3 Maintenance recommendation 27

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2.1 Overview
Read this material before working on or around the equipment. Failure
to do so can result in injury or death!
2.1.1 Safety standards
The following industry standards are observed:
- "ANSI Z535.6 American national standard for product safety information in product
manuals, instructions, and other collateral materials" [17]
- "ISO 3864-2:2004 (E) - Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels" [18]
- "ISO 7010:2011 (E) - Graphical symbols - Safety colours and safety signs - Registered
safety sign" [19]
- "EN 50110 European standard code for electrical work safety" [20]
2.2 Safety messages
The following safety messages are provided to help prevent personal injury and damage to the
equipment. The indicated hazard level is based on the ANSI Z535.6 standard.
▲ DANGER ⚠
▲ WARNING ⚠
CAUTION
⚠
2.3 Damage prevention information
NOTICE
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.
NOTICE: is used to address practices not related to physical injury, but which can
result in equipment damage.

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2.4 Product safety labels
Safety labels are affixed to the drive components to alert personnel of potential hazards when
working on the equipment. For more information, see the label placement document for
the drive.
The instructions on the safety labels must always be followed and the labels must be kept in a
perfectly legible condition.
Figure 2-1: Product warning label examples (label placement depends on the drive)
Additional safety labels, including the following, might also be provided:
(1) Danger label
(2) Caution label
(3) Warning label
(4) Notice label
Electricity hazard
This sign can also have additional text below it, eg, “High voltage”
Hot surface
Crushing of hands
No access for people with active implanted cardiac device
The magnetic field of the drive can influence the functioning of pacemakers. The
pacemaker sign should be installed at the entrance to the drive room or at a
minimum distance of 6 m from the drive to stop personnel with pacemakers
approaching the drive.
Firefighting sign
Outlines the procedure when fighting fire in electrical equipment. The sign must
be installed well visible near the drive.
High voltage sign
Must be installed clearly visible at the main circuit breaker in the switchgear room.
The sign alerts personnel to the high voltage which can be present on the
secondary side of the input transformer until the main circuit breaker has been
opened and secured and the drive has been de-energized and grounded.
1
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3
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