ABB ACS1000 User manual

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SYSTEM DRIVES
ACS1000 water-cooled
User manual
OWNING ORGANIZATION
ABB Switzerland Ltd.
DATE
2021-11-17
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213400 E01
REV.
J
LANG.
en
PAGE
1/166
© Copyright 2009 ABB All rights reserved.

PRODUCT
ACS1000W
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213400 E01
REV.
J
LANG.
en
PAGE
2/166
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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
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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
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secure connection between the product and the system network and/or any other networks that may be
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consequential damages of any nature or kind whatsoever arising from the use of this document, nor shall
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without the prior written permission from ABB, and the contents thereof must not be disclosed or made
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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.
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Trademarks
ABB is a registered trademark of ASEA BROWN BOVERI LTD.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2009 ABB
All rights reserved

CONTENTS
PRODUCT
ACS1000W
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213400 E01
REV.
J
LANG.
en
PAGE
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Contents
1. About this manual ............................................................................................ 13
1.1. Equipment covered by this manual ................................................................. 13
1.2. Structure of the user documentation ............................................................. 13
1.3. Terms and abbreviations .................................................................................. 14
1.4. Related documents ........................................................................................... 16
1.5. Target groups and required qualification ....................................................... 17
1.5.1. Handling .................................................................................................... 17
1.5.2. Mechanical installation ............................................................................ 17
1.5.3. Electrical installation ...............................................................................17
1.5.4. Operation .................................................................................................. 17
1.5.5. Maintenance ............................................................................................. 18
1.6. User’s responsibilities ...................................................................................... 18
1.7. Intended use of equipment.............................................................................. 18
1.8. Quality certificates and applicable standards ............................................... 19
1.10. Identifying the delivery ..................................................................................... 20
2. Important safety information ........................................................................ 21
2.1. Safety standards ............................................................................................... 21
2.2. Safety messages ............................................................................................... 21
2.3. Product safety labels ........................................................................................ 22
2.4. General safety instructions .............................................................................. 23
2.5. The 7 steps that save lives ............................................................................... 24
2.6. Possible residual risks ...................................................................................... 26
2.7. Main circuit breaker protection device ........................................................... 27
2.7.1. Safety and protection requirements ..................................................... 28
2.7.2. Minimum requirements for MCB and MCB control .............................. 28
2.8. Maintenance recommendation ........................................................................ 29
3. Power electronics and cabinet features .......................................................... 31
3.1. Overview ............................................................................................................. 31
3.2. Main components of the drive system ........................................................... 32
3.3. Power supply configurations ........................................................................... 33
3.3.1. Main power supply configurations ........................................................ 33
3.3.2. Auxiliary power supply configurations ................................................. 34
3.4. Drive topology ................................................................................................... 35
3.4.1. Overview ................................................................................................... 35
3.4.2. Control and terminal compartment ...................................................... 36
3.4.3. DC-link and filter compartment ............................................................. 37
3.4.4. Grounding switch .................................................................................... 38
3.4.5. Filter ..........................................................................................................38
3.4.6. Rectifier and inverter compartment ...................................................... 39
3.4.7. Optional Braking Chopper ..................................................................... 40
3.4.8. Cooling systems ..................................................................................... 44
3.5. Cabinet design ................................................................................................. 44
3.6. Door locking system ......................................................................................... 45
3.6.1. Optional cabinets .................................................................................... 45
3.7. Arc resistant design (optional) ........................................................................ 46

CONTENTS
PRODUCT
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3.7.1. Internal arc classification .......................................................................46
3.7.2. Power compartment doors ....................................................................46
3.7.3. Associated protection requirement ...................................................... 47
3.8. Space heaters .................................................................................................... 47
4. Control system .................................................................................................49
4.1. Overview ............................................................................................................. 49
4.2. Main components ..............................................................................................50
4.2.1. Local control panel .................................................................................. 51
4.2.2. AMC circuit board .................................................................................... 52
4.3. I/O interfaces .................................................................................................... 56
4.3.1. IOEC I/O modules .................................................................................... 56
4.3.2. Serial communication interface (fieldbus) ........................................... 61
4.3.3. Pulse encoder interface NTAC (option) ................................................. 62
5. Transportation, storage and disposal ............................................................. 63
5.1. Safety ................................................................................................................ 63
5.2. Transport conditions ........................................................................................ 63
5.3. Unpacking and inspection ............................................................................... 63
5.4. Lifting and transportation ............................................................................... 64
5.4.1. General notes on transportation ......................................................... 64
5.4.2. Using a crane ...........................................................................................64
5.5. Storage ............................................................................................................... 67
5.5.1. Storage conditions .................................................................................. 67
5.5.2. Storing the drive ...................................................................................... 67
5.5.3. Storage and handling of spare parts .................................................. 68
5.6. Disposal of packaging materials and components ....................................... 68
6. Mechanical installation .................................................................................... 69
6.1. Safety ................................................................................................................ 69
6.2. Overview of installation work .......................................................................... 69
6.3. General notes on installation ......................................................................... 69
6.3.1. Dimensions and clearances .................................................................... 69
6.3.2. Cabinet roof ............................................................................................. 69
6.3.3. Fire protection ......................................................................................... 70
6.3.4. Cable duct material ................................................................................. 70
6.4. Preparing the floor ............................................................................................ 70
6.5. Fixing the cabinet to the floor ......................................................................... 70
6.6. Installing the cabinet with the second rectifier ............................................ 73
6.7. Installing the redundant fan ............................................................................ 74
6.8. Preparing the water supply connections ........................................................ 75
6.9. Checking the door center posts ...................................................................... 75
7. Electrical installation ....................................................................................... 77
7.1. Safety ................................................................................................................ 77
7.2. Overview of installation work .......................................................................... 77
7.3. Cable requirements ........................................................................................... 77
7.4. Ground cable connection and cable shield connections .............................. 78
7.5. Cable entries ...................................................................................................... 79
7.5.1. Cable entry with EMC plates .................................................................. 79
7.5.2. Cable entry with type 1 sealing modules ............................................. 80
7.5.3. Cable entry with type 2 sealing modules .............................................. 81
7.5.4. Cable entry with cable glands ................................................................ 81

CONTENTS
PRODUCT
ACS1000W
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User manual
DOCUMENT ID.
3BHS213400 E01
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7.6. Power cables, ground cables and equipotential
bonding conductor ........................................................................................... 82
7.6.1. Preparing the cable entry, the cable spacers and
the cables ............................................................................................... 82
7.6.2. Connecting the cables ............................................................................94
7.6.3. Bolted connections .................................................................................94
7.7. Auxiliary power, control and serial communication cables ..........................96
7.7.1. Preparing the cable entry and the cables ............................................. 96
7.7.2. Connecting the cables .......................................................................... 101
7.8. Power supply cable for redundant fan unit .................................................. 102
7.9. Final checks ...................................................................................................... 102
8. Commissioning............................................................................................... 103
8.1. Overview ........................................................................................................... 103
8.1.1. Required qualification ......................................................................... 103
8.1.2. Commissioning procedure ................................................................. 103
8.1.3. Commissioning checklist .................................................................... 103
8.1.4. Customer assistance ........................................................................... 103
8.1.5. Customer acceptance .......................................................................... 103
8.2. Commissioning checklists .............................................................................. 104
8.2.1. Mechanical installation checklist ......................................................... 104
8.2.2. Electrical installation checklist ............................................................ 104
8.2.3. Main circuit breaker (MCB) ................................................................... 105
8.2.4. Input transformer checklist .................................................................. 105
8.2.5. Motor checklist ...................................................................................... 105
8.2.6. Insulation tests checklist ...................................................................... 105
8.2.7. Power supply checklist .......................................................................... 106
8.2.8. Miscellaneous checklist ........................................................................ 106
9. Operation ....................................................................................................... 107
9.1. Safety .............................................................................................................. 107
9.2. Overview ........................................................................................................... 107
9.3. Operating conditions ...................................................................................... 107
9.4. Sound pressure level ....................................................................................... 107
9.5. Local operator panel ....................................................................................... 108
9.6. Status messages ............................................................................................. 109
9.6.1. Start sequence of the drive ................................................................ 110
9.6.2. Stop sequence of the drive .................................................................. 111
9.6.3. Emergency off sequence of the drive ................................................ 112
9.7. Starting the drive ........................................................................................... 112
9.7.1. Checks before starting the drive .......................................................... 112
9.7.2. Starting the drive remotely ................................................................... 113
9.7.3. Starting the drive locally ........................................................................ 113
9.8. Stopping the drive ...........................................................................................115
9.9. Emergency-off ..................................................................................................116
9.9.1. Initiating an emergency-off .................................................................. 116
9.9.2. Starting the drive after an emergency off ........................................... 117
10.CDP control panel........................................................................................... 119
10.1. Overview ............................................................................................................ 119
10.2. CDP control panel functions .......................................................................... 120
10.3. CDP control panel modes ............................................................................... 120
10.3.1. Identification mode ............................................................................... 120

CONTENTS
PRODUCT
ACS1000W
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DOCUMENT ID.
3BHS213400 E01
REV.
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10.3.2. Actual signals mode ............................................................................... 121
10.3.3. Parameters mode ................................................................................ 128
10.3.4. Functions mode ..................................................................................... 134
10.4. Local and remote control ............................................................................... 136
10.4.1. Local control ........................................................................................... 136
10.4.2. Remote control ...................................................................................... 137
10.5. Operational commands .................................................................................. 138
10.5.1. Setting the direction of rotation ......................................................... 138
10.5.2. Entering a reference value .................................................................... 139
11. Preventive and corrective maintenance ........................................................ 141
11.1. General information ........................................................................................ 141
11.1.1. Required qualification ........................................................................... 141
11.1.2. Maintenance schedule........................................................................... 141
11.1.3. Logbook .................................................................................................. 141
11.1.4. Spare parts ............................................................................................. 141
11.2. Identifying electrical equipment ................................................................... 142
11.2.1. Device identification ............................................................................. 142
11.2.2. Cables and wires .................................................................................... 142
11.2.3. Understanding wiring diagrams .......................................................... 142
11.3. Alarm / fault indications ................................................................................ 143
11.3.1. Messages ................................................................................................ 143
11.3.2. Error message levels ............................................................................. 143
11.3.3. Fault handling ........................................................................................ 144
11.3.4. Standard troubleshooting procedure ................................................. 145
11.4. Removing the CDP control panel ................................................................... 146
11.5. LEDs and switches on circuit boards............................................................ 147
11.5.1. AMC circuit board .................................................................................. 147
11.5.2. IOEC I/O modules .................................................................................. 148
11.6. Corrective maintenance .................................................................................. 149
11.6.1. Safety ................................................................................................. 149
11.6.2. De-energizing the drive locally ............................................................. 150
11.6.3. Grounding ............................................................................................... 152
11.6.4. Grounding switch is not released ...................................................... 153
11.6.5. Checking the release conditions for the grounding
switch .................................................................................................... 154
11.6.6. Visual checks on the drive .................................................................... 155
11.6.7. Cleaning the drive ................................................................................ 156
11.6.8. Checking wire and cable connections ............................................... 157
11.6.9. Cleaning and replacing filter mats ...................................................... 157
11.6.10. Inspecting and replacing batteries ..................................................... 159
11.6.11. Replacing the fan inside the water-cooling unit ...............................161
11.6.12. Replacing the redundant fan unit ...................................................... 163

FIGURES
PRODUCT
ACS1000W
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User manual
DOCUMENT ID.
3BHS213400 E01
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Figures
Figure 1-1 Delivered items ............................................................................................. 20
Figure 2-1 Product warning label examples
(label placement depends on the drive) ........................................................................ 22
Figure 2-2 Drive system overview ................................................................................... 27
Figure 2-3 MCB opening timing diagram .................................................................... 29
Figure 3-1 ACS1000 water-cooled................................................................................... 31
Figure 3-2 Block diagrams of an ACS1000W with a 12-pulse rectifier (A)
and a drive with a 24-pulse rectifier (B) ...................................................................... 32
Figure 3-3 Drive overview with power supplies .......................................................... 33
Figure 3-4 ACS1000W ..................................................................................................... 35
Figure 3-5 Control and terminal compartment ........................................................... 36
Figure 3-6 DC link and filter compartment ................................................................. 37
Figure 3-7 Grounding switch ......................................................................................... 38
Figure 3-8 Voltage and current waveforms at drive output ........................................ 38
Figure 3-9 Rectifier and inverter compartment .......................................................... 39
Figure 3-10 Three-level voltage source inverter principle .......................................... 40
Figure 3-11 ACS1000W water-cooled with braking chopper (1) ................................. 40
Figure 3-12 Principle diagram ....................................................................................... 41
Figure 3-13 Braking chopper design ............................................................................ 42
Figure 3-14 Door locks ................................................................................................... 45
Figure 3-15 IAC label example ......................................................................................... 46
Figure 3-16 Door bolts ..................................................................................................... 46
Figure 3-17 Optional space heaters .............................................................................. 47
Figure 4-1 Block diagram of control system with customer interface (A),
control system (B) and power electronics (C) .............................................................49
Figure 4-2 Control compartment ..................................................................................50
Figure 4-3 Control compartment – I/O devices .......................................................... 51
Figure 4-4 AMC circuit board ........................................................................................ 52
Figure 4-5 Direct torque control ................................................................................... 53
Figure 4-6 PID control mode ......................................................................................... 55
Figure 4-7 IOEC interfaces overview ............................................................................ 56
Figure 4-8 IOEC module ................................................................................................ 59
Figure 4-9 IOEC module identification ....................................................................... 60
Figure 4-10 NTAC-02 pulse encoder interface ............................................................. 62

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Figure 5-1 Transporting the cabinet by crane - standard case ................................. 65
Figure 5-2 Transporting the cabinet by crane - marine/offshore case ..................... 66
Figure 6-1 Leveling the drive ........................................................................................... 71
Figure 6-2 Location of screw holes in a standard cabinet base and
anchor bolt example ........................................................................................................ 71
Figure 6-3 Shipping braces ............................................................................................. 72
Figure 6-4 Installing the cabinet with the second rectifier cabinet .......................... 73
Figure 6-5 Installing the redundant fan ....................................................................... 74
Figure 6-6 Door center posts (1) .................................................................................... 75
Figure 7-1 Grounding the drive system ........................................................................ 78
Figure 7-2 EMC plate example ...................................................................................... 79
Figure 7-3 EMC cushion .................................................................................................. 80
Figure 7-4 Type 1 sealing modules example .............................................................. 80
Figure 7-5 Type 2 sealing modules example ............................................................... 81
Figure 7-6 Cable entry with cable glands ...................................................................... 81
Figure 7-7 Busbars for 12- pulse drive (B) and 24-pulse drive (A and B) .................. 83
Figure 7-8 Cable spacer (A) and cable spacer with cables attached with
cable ties (B) ...................................................................................................................84
Figure 7-9 Example of busbars with cable spacers - cable entry top ...................... 85
Figure 7-10 Cable entry top for motor-side and line-side - cable entry
(A) and cable routing (B) ............................................................................................... 86
Figure 7-11 Cable entry bottom for motor-side and line-side - cable
entry (A) and cable routing (B) ..................................................................................... 87
Figure 7-12 Additional cable routing options - cable entry top for motor-
side and cable entry bottom for line-side (A) and cable entry top line-
side and cable entry bottom motor-side (B) ..............................................................88
Figure 7-13 Preparing cables for EMC plates: (A) cables with an outer
screen or shield, (B) cables without an outer screen or shield ................................. 91
Figure 7-14 Preparing power cables for sealing modules ......................................... 92
Figure 7-15 Preparing power cables for cable glands ................................................ 93
Figure 7-16 Bolted busbar connections ....................................................................... 95
Figure 7-17 Cable entry from top (A), from bottom (B) ...............................................96
Figure 7-18 Preparing control cables for EMC plates................................................... 97
Figure 7-19 Frame with sealing modules ..................................................................... 98
Figure 7-20 Preparing control cables for sealing modules .......................................99
Figure 7-21 Preparing control cables for cable glands ............................................ 100
Figure 7-22 Shield grounding point for encoder cable .............................................. 101
Figure 7-23 Redundant fan - terminal box ................................................................... 102

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Figure 9-1 Local operator panel .................................................................................... 108
Figure 10-1 CDP control panel ......................................................................................119
Figure 10-2 Control panel - Actual signals mode ...................................................... 123
Figure 10-3 Control panel - Parameters mode .......................................................... 130
Figure 10-4 Control panel - Functions mode ............................................................. 134
Figure 11-1 Device identification .................................................................................. 142
Figure 11-2 AMC circuit board ..................................................................................... 147
Figure 11-3 IOEC module ............................................................................................. 148
Figure 11-4 Location of I/O modules and fuses ....................................................... 153
Figure 11-5 Cleaning and replacing filter mats ......................................................... 158
Figure 11-6 Control compartment – battery location ............................................... 159
Figure 11-7 Control compartment - replacing the batteries ..................................... 160
Figure 11-8 Water cooling unit – Replacing the internal fan .....................................161
Figure 11-9 Water cooling unit – replacing the internal fan ..................................... 162
Figure 11-10 Water cooling unit – replacing the redundant fan – bottom
view (A) ............................................................................................................................ 163