ABB ACS1000 User manual

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SYSTEM DRIVES
ACS1000 air-cooled
User manual
OWNING ORGANIZATION
System Drives, ABB Switzerland Ltd.
DATE
2023-09-13
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213401 E01
REV.
L
LANG.
en
PAGE
1/164
© Copyright 2011 ABB All rights reserved.

PRODUCT
ACS1000A
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213401 E01
REV.
L
LANG.
en
PAGE
2/164
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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
vested in ABB, in particular with regard to any intellectual property rights. Nothing contained herein shall
oblige ABB to furnish any particular information to the buyer.
The information in this document is subject to change without notice and should not be construed as a
binding declaration of ABB. ABB assumes no responsibility for any errors or omissions in this document.
Products described or referenced in this document are designed to be connected with networks and
provide information and data through network interfaces. The products must be connected to a secure
network. It is the sole responsibility of the buyer of the products to provide and continuously ensure a
secure connection between the product and the system network and/or any other networks that may be
connected to the product. ABB is in no event liable for the security of the network used by buyer.
The buyer of the product must establish and maintain appropriate measures, including, but not limited
to, the installation of firewalls, application of authentication measures, encryption of data, installation of
antivirus programs, and so on, to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and/or theft of data or
information. Any liability of ABB in this regard is excluded.
ABB may perform functionality testing on the products and may release updates. However, it is the sole
responsibility of the buyer of the product to ensure that any product updates or other major system
updates (to include but not limited to code changes, configuration file changes, third-party software
updates or patches, hardware change out, and so on) are compatible with the security measures
implemented. The buyer of the product must verify that the system and associated products function as
expected in the environment in which they are deployed. ABB has no obligations in this regard.
In no event shall ABB be liable for any damages inclusive but not limited to indirect, special, incidental or
consequential damages of any nature or kind whatsoever arising from the use of this document, nor shall
ABB be liable for any damages inclusive but not limited to indirect, special, incidental or consequential
damages arising from the use of any software or hardware described in this document.
This document and parts thereof must be kept strictly confidential and must not be reproduced or copied
without the prior written permission from ABB, and the contents thereof must not be disclosed or made
available to any third party nor used for any unauthorized purpose.
The software or hardware described in this document may be furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license.
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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 © 2011 ABB.
All rights reserved.

CONTENTS
PRODUCT
ACS1000A
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS213401 E01
REV.
L
LANG.
en
PAGE
3/164
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CONTENTS
1. About this manual................................................................................................................. 12
1.1. Equipment covered by this manual ............................................................................................. 12
1.2. Structure of the user documentation ......................................................................................... 12
1.3. Terms and abbreviations................................................................................................................13
1.4. Related documents ........................................................................................................................15
1.4.1. Maintenance ..........................................................................................................................15
1.4.2. Technical data .......................................................................................................................15
1.4.3. Schematics.............................................................................................................................15
1.4.4. Specifications and guidelines...........................................................................................15
1.4.5. Serial communication interfaces .....................................................................................15
1.4.6. Encoder...................................................................................................................................15
1.5. Target groups and required qualification..................................................................................16
1.5.1. Handling .................................................................................................................................16
1.5.2. Mechanical installation .......................................................................................................16
1.5.3. Electrical installation ...........................................................................................................16
1.5.4. Operation ...............................................................................................................................16
1.5.5. Maintenance ..........................................................................................................................16
1.6. User’s responsibilities..................................................................................................................... 17
1.7. Intended use of equipment ........................................................................................................... 17
1.8. Quality certificates and applicable standards ..........................................................................18
1.9. Items covered by delivery ...............................................................................................................19
1.10. Identifying the delivery .................................................................................................................. 20
1.11. Document conventions.................................................................................................................. 20
2. Important safety information............................................................................................. 21
2.1. Safety messages and safety signs in this document ............................................................. 21
2.1.1. Safety messages .................................................................................................................. 21
2.1.2. Safety signs............................................................................................................................21
2.2. Product safety labels.......................................................................................................................22
2.3. Electrical safety.................................................................................................................................22
2.3.1. General safety instructions................................................................................................22
2.3.2. The seven steps that save lives.........................................................................................23
2.3.3. Possible residual risks.........................................................................................................25
2.4. Main circuit breaker protection device ...................................................................................... 26
2.4.1. Safety and protection requirements...............................................................................27
2.4.2. Minimum requirements for MCB and MCB control .....................................................27
2.5. Maintenance recommendation.................................................................................................... 28
3. Power electronics and cabinet features ............................................................................29
3.1. Overview ............................................................................................................................................ 29
3.2. Drive topology.................................................................................................................................. 30
3.3. Power supply configurations......................................................................................................... 31
3.3.1. Main power supply configurations..................................................................................31
3.3.2. Auxiliary power supply configurations ...........................................................................32
3.4. Drive topology...................................................................................................................................33
3.4.1. Overview .................................................................................................................................33
3.4.2. Control compartment and terminal compartment.....................................................33
3.4.3. Rectifier and inverter compartment............................................................................... 35
3.4.4. Grounding switch................................................................................................................ 36

CONTENTS
PRODUCT
ACS1000A
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3BHS213401 E01
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3.4.5. Rectifier.................................................................................................................................. 36
3.4.6. Protection IGCTs.................................................................................................................. 36
3.4.7. Inverter ....................................................................................................................................37
3.4.8. Filter.........................................................................................................................................37
3.4.9. Optional Braking Chopper ................................................................................................ 38
3.5. Cooling system..................................................................................................................................41
3.5.1. Fan configurations...............................................................................................................41
3.5.2. Type of fan .............................................................................................................................41
3.5.3. Starting, stopping the cooling system...........................................................................41
3.5.4. AC redundant fans - operating principles..................................................................... 42
3.5.5. EC redundant fans – operating principles.................................................................... 43
3.5.6. Air flow overview (AC and EC fans)................................................................................. 44
3.5.7. Monitoring the air pressure.............................................................................................. 45
3.5.8. Adjustable parameters ...................................................................................................... 45
3.6. Cabinet design................................................................................................................................. 46
3.7. Door locking system....................................................................................................................... 46
3.7.1. Optional cabinets.................................................................................................................47
3.8. Arc resistant design (optional) .....................................................................................................47
3.8.1. Internal arc classification (IAC) .........................................................................................47
3.8.2. Associated protection requirement ................................................................................47
3.9. Space heaters................................................................................................................................... 48
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) ..........................................................................61
5. Transportation, storage and disposal ...............................................................................62
5.1. Safety.................................................................................................................................................. 62
5.2. Transport conditions...................................................................................................................... 62
5.3. Unpacking and inspection ............................................................................................................ 62
5.4. Lifting and transportation ............................................................................................................ 63
5.4.1. Lifting attachment types .................................................................................................. 64
5.4.2. Lifting with the top lifting rails........................................................................................ 65
5.4.3. Lifting with rotating eyebolts (redundant fan unit)....................................................67
5.4.4. Reinstalling lifting attachments .......................................................................................67
5.4.5. Sling configuration for top lifting rails .......................................................................... 68
5.5. Storage............................................................................................................................................... 68
5.5.1. Storage conditions ............................................................................................................. 68
5.5.2. Storing the drive.................................................................................................................. 68
5.5.3. Storage and handling of spare parts............................................................................. 70
5.6. Disposal of packaging materials and components ............................................................... 70
6. Mechanical installation ........................................................................................................ 71
6.1. Safety................................................................................................................................................... 71
6.2. Overview of installation work........................................................................................................ 71
6.3. General notes on installation ........................................................................................................ 71
6.3.1. Dimensions and clearances............................................................................................... 71

CONTENTS
PRODUCT
ACS1000A
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User manual
DOCUMENT ID.
3BHS213401 E01
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6.3.2. Cabinet roof........................................................................................................................... 71
6.3.3. Fire protection ...................................................................................................................... 71
6.3.4. Cable duct material ............................................................................................................. 71
6.4. Preparing the floor...........................................................................................................................72
6.5. Fixing the cabinet to the floor ......................................................................................................72
6.6. Assembling and installing the air exhaust hood ......................................................................73
6.7. Installing the redundant fan unit..................................................................................................74
7. Electrical installation ...........................................................................................................78
7.1. Safety...................................................................................................................................................78
7.2. Overview of installation work........................................................................................................78
7.3. Cable requirements .........................................................................................................................78
7.3.1. Additional cable requirements for a UL certified drive ..............................................78
7.4. Cable entries......................................................................................................................................79
7.4.1. Cable entry with EMC plates .............................................................................................79
7.4.2. Cable entry with type 1 sealing modules....................................................................... 80
7.4.3. Cable entry with type 2 sealing modules ...................................................................... 80
7.4.4. Cable entry with cable glands...........................................................................................81
7.5. Power cables, ground cables and equipotential bonding conductor ................................81
7.5.1. Preparing the cable entry and the cables ......................................................................81
7.5.2. Connecting the cables ....................................................................................................... 88
7.5.3. Minimum creepage distance between cable and busbar ........................................ 90
7.5.4. Bolted connections..............................................................................................................91
7.6. Auxiliary power, control and serial communication cables .................................................. 92
7.6.1. Preparing the cable entry and the cables ..................................................................... 92
7.6.2. Connecting the cables ....................................................................................................... 96
7.7. Power supply cable for redundant fan unit ...............................................................................97
7.8. Final checks....................................................................................................................................... 98
8. Commissioning .....................................................................................................................99
8.1. Overview ............................................................................................................................................ 99
8.1.1. Required qualification........................................................................................................ 99
8.1.2. Commissioning procedure ............................................................................................... 99
8.1.3. Commissioning checklist .................................................................................................. 99
8.1.4. Customer assistance.......................................................................................................... 99
8.1.5. Customer acceptance ........................................................................................................ 99
8.2. Commissioning checklists .......................................................................................................... 100
8.2.1. Mechanical installation checklist................................................................................... 100
8.2.2. Electrical installation checklist....................................................................................... 100
8.2.3. Main circuit breaker (MCB) checklist............................................................................ 100
8.2.4. Input transformer checklist............................................................................................. 101
8.2.5. Motor checklist ................................................................................................................... 101
8.2.6. Insulation tests checklist.................................................................................................. 101
8.2.7. Power supply checklist...................................................................................................... 101
8.2.8. Miscellaneous checklist .................................................................................................... 101
9. Operation.............................................................................................................................102
9.1. Safety.................................................................................................................................................102
9.2. Overview ...........................................................................................................................................102
9.3. Operating conditions ....................................................................................................................102
9.4. Sound pressure level......................................................................................................................102
9.5. Local operator panel......................................................................................................................103
9.6. Status messages ........................................................................................................................... 104

CONTENTS
PRODUCT
ACS1000A
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User manual
DOCUMENT ID.
3BHS213401 E01
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9.6.1. Start sequence of the drive .............................................................................................105
9.6.2. Stop sequence of the drive............................................................................................. 106
9.6.3. Emergency off sequence of the drive...........................................................................107
9.7. Starting the drive............................................................................................................................107
9.7.1. Checks before starting the drive....................................................................................107
9.7.2. Starting the drive remotely..............................................................................................107
9.7.3. Starting the drive locally.................................................................................................. 108
9.8. Stopping the drive......................................................................................................................... 109
9.9. Emergency-off .................................................................................................................................111
9.9.1. Initiating an emergency-off..............................................................................................111
9.9.2. Starting the drive after an emergency-off................................................................... 112
10. CDP control panel ............................................................................................................... 113
10.1. Overview ........................................................................................................................................... 113
10.2. CDP control panel functions........................................................................................................ 114
10.3. CDP control panel modes............................................................................................................. 114
10.3.1. Identification mode ........................................................................................................... 114
10.3.2. Actual signals mode .......................................................................................................... 115
10.3.3. Parameters mode...............................................................................................................122
10.3.4. Functions mode..................................................................................................................128
10.4. Local and remote control ............................................................................................................. 131
10.4.1. Local control ........................................................................................................................ 131
10.4.2. Remote control ...................................................................................................................132
10.5. Operational commands................................................................................................................133
10.5.1. Setting the direction of rotation ....................................................................................133
10.5.2. Entering a reference value................................................................................................134
11. Preventive and corrective maintenance........................................................................... 136
11.1. General information.......................................................................................................................136
11.1.1. Required qualification.......................................................................................................136
11.1.2. Maintenance schedule ......................................................................................................136
11.1.3. Logbook................................................................................................................................136
11.1.4. Spare parts...........................................................................................................................136
11.2. Identifying electrical equipment ................................................................................................137
11.2.1. Device identification..........................................................................................................137
11.2.2. Cables and wires ................................................................................................................137
11.2.3. Understanding wiring diagrams.................................................................................... 137
11.3. Alarm / fault indications...............................................................................................................138
11.3.1. Messages..............................................................................................................................138
11.3.2. Error message levels..........................................................................................................138
11.3.3. Fault handling .....................................................................................................................138
11.3.4. Standard troubleshooting procedure...........................................................................139
11.4. Removing the CDP control panel............................................................................................... 140
11.5. LEDs and switches on circuit boards........................................................................................ 141
11.5.1. AMC circuit board............................................................................................................... 141
11.5.2. IOEC I/O modules ..............................................................................................................142
11.6. Corrective maintenance................................................................................................................143
11.6.1. Safety.....................................................................................................................................143
11.6.2. De-energizing the drive locally........................................................................................145
11.6.3. Grounding ........................................................................................................................... 146
11.6.4. Grounding switch is not released ..................................................................................147
11.6.5. Checking the release conditions for the grounding switch ................................. 148
11.6.6. Visual checks on the drive............................................................................................... 149

CONTENTS
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ACS1000A
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3BHS213401 E01
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11.6.7. Cleaning the drive ............................................................................................................. 149
11.6.8. Checking wire and cable connections ......................................................................... 150
11.6.9. Cleaning and replacing filter mats................................................................................ 150
11.6.10. Inspecting and replacing batteries ...............................................................................153
11.6.11. Replacing the non-redundant fan..................................................................................155
11.6.12. Replacing a redundant fan...............................................................................................158

FIGURES
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ACS1000A
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3BHS213401 E01
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FIGURES
Fig. 1. Delivered items ....................................................................................................... 19
Fig. 2. Product warning label examples (label placement depends on
the drive) .................................................................................................................22
Fig. 3. Drive system overview ........................................................................................... 26
Fig. 4. MCB opening timing diagram .............................................................................. 28
Fig. 5. ACS1000 air-cooled ............................................................................................... 29
Fig. 6. Block diagrams of an ACS1000A with a (A) 12-pulse rectifier and a
drive with a (B) 24-pulse rectifier ........................................................................ 30
Fig. 7. Drive overview with power supplies ..................................................................... 31
Fig. 8. ACS1000 air-cooled topology ................................................................................33
Fig. 9. Control and terminal compartments ................................................................... 34
Fig. 10. Rectifier compartment .......................................................................................... 35
Fig. 11. Grounding switch .................................................................................................. 36
Fig. 12. Three-level voltage source inverter principle ...................................................... 37
Fig. 13. Voltage and current waveforms at drive output ................................................. 37
Fig. 14. ACS1000A with braking chopper (1) .................................................................... 38
Fig. 15. Principle diagram .................................................................................................. 38
Fig. 16. Braking chopper design ........................................................................................ 39
Fig. 17. Operating times of the AC fan units during continuous (A) drive
operation and (B) Intermittent drive operation ..................................................42
Fig. 18. Operating principles of redundant EC fans........................................................ 43
Fig. 19. Air flow: (1) non-redundant fan configuration ................................................... 44
Fig. 20. Air flow: redundant fan configuration ................................................................. 44
Fig. 21. Air pressure switches ............................................................................................ 45
Fig. 22. Door locks ............................................................................................................... 46
Fig. 23. IAC label example .................................................................................................... 47
Fig. 24. Space heaters ......................................................................................................... 48
Fig. 25. Block diagram of control system with (A) customer interface, (B)
control system, and (C) power electronics ......................................................... 49
Fig. 26. Control compartment............................................................................................ 50
Fig. 27. Control compartment – I/O devices ..................................................................... 51
Fig. 28. AMC circuit board ...................................................................................................52
Fig. 29. Direct torque control ............................................................................................. 53
Fig. 30. PID control mode ................................................................................................... 55
Fig. 31. IOEC interfaces overview ...................................................................................... 56
Fig. 32. IOEC module ........................................................................................................... 59
Fig. 33. IOEC module identification .................................................................................. 60
Fig. 34. NTAC-02 pulse encoder interface ......................................................................... 61
Fig. 35. Lifting attachment types ...................................................................................... 64

FIGURES
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ACS1000A
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3BHS213401 E01
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Fig. 36. Top lifting rails with (1) recommended lifting points ....................................... 65
Fig. 37. Mounting bolts and washers for top rail ............................................................ 66
Fig. 38. Sling configuration - standard case with top lifting rails ................................ 68
Fig. 39. Leveling the drive .................................................................................................... 72
Fig. 40. Fixing the cabinet to the floor .............................................................................. 73
Fig. 41. Assembling and installing the air exhaust hood ................................................. 73
Fig. 42. Redundant fan unit – Removing lifting rails (1) and fan access
cover (2) ...................................................................................................................74
Fig. 43. Redundant fan unit – Installation ......................................................................... 75
Fig. 44. Recommended sequence for attaching the sound absorbing panels
on the right side of the fan unit ........................................................................... 76
Fig. 45. Recommended sequence for attaching the sound absorbing panels
on the left side of the fan unit .............................................................................. 77
Fig. 46. EMC plate example ................................................................................................ 79
Fig. 47. EMC cushion ........................................................................................................... 79
Fig. 48. Type 1 sealing modules (example) ....................................................................... 80
Fig. 49. Type 2 sealing modules example ......................................................................... 80
Fig. 50. Cable entry with cable glands ............................................................................... 81
Fig. 51. Cable termination bar (A) top and (B) bottom cable entry; busbar
thickness is 5 mm ...................................................................................................82
Fig. 52. Preparing cables for EMC plates: (A) cables with an outer screen
or shield, (B) cables without an outer screen or shield .................................... 85
Fig. 53. Preparing power cables for sealing modules ..................................................... 86
Fig. 54. Preparing power cables for cable glands ............................................................ 87
Fig. 55. Power cable terminals in (A and C) 12-pulse ACS1000A and (B and
D) 24-pulse ACS1000A ........................................................................................... 89
Fig. 56. Grounding the drive system ................................................................................. 90
Fig. 57. Bolted busbar connections ................................................................................... 91
Fig. 58. Cable entry from (A) top and from (B) bottom .................................................. 92
Fig. 59. Frame with sealing modules ................................................................................ 94
Fig. 60. Preparing control cables for sealing modules ................................................... 95
Fig. 61. Preparing control cables for cable glands .......................................................... 95
Fig. 62. Shield grounding point for encoder cable .......................................................... 96
Fig. 63. Routing, connecting the cable of the redundant fan unit ................................. 97
Fig. 64. Local operator panel ............................................................................................ 103
Fig. 65. CDP control panel ................................................................................................. 113
Fig. 66. Control panel - Actual signals mode ................................................................... 117
Fig. 67. Control panel - Parameters mode ....................................................................... 124
Fig. 68. Control panel - Functions mode ......................................................................... 128
Fig. 69. Device identification ............................................................................................ 137
Fig. 70. AMC circuit board ................................................................................................. 141
Fig. 71. IOEC module .......................................................................................................... 142

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ACS1000A
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Fig. 72. Location of I/O modules and fuses .................................................................... 147
Fig. 73. Filter panel (1) and filter mat (2) on rectifier and inverter
compartment ........................................................................................................ 152
Fig. 74. Control compartment – battery location ........................................................... 153
Fig. 75. Control compartment - replacing the batteries................................................ 154
Fig. 76. Fan location, dimensions and weight ................................................................ 155
Fig. 77. Fan - tools and devices ........................................................................................ 155
Fig. 78. Replacing the non-redundant fan ....................................................................... 156
Fig. 79. Installing the non-redundant fan ........................................................................ 157
Fig. 80. Redundant fans – location, dimensions, and weight ....................................... 158
Fig. 81. Redundant fans - tools and devices ................................................................... 159
Fig. 82. Redundant fan unit – removing the panels ........................................................160
Fig. 83. Redundant fan unit – Unplugging the power supply cable ............................. 160
Fig. 84. Redundant fan unit – removing the fixing bolts ............................................... 161
Fig. 85. Redundant fan unit – using a crane .................................................................... 162
Fig. 86. Redundant fan unit – using a platform .............................................................. 162